P/S Pump Disassembly and Assembly: Assembly

Apply grease to oil seal (1) lip and apply power steering fluid to sliding surface of the shaft (2) then insert pulley's shaft (2) from oil seal side of the pump body.
"A": Grease 99000-25011 (SUZUKI Super Grease A)

Fig 1: Inserting Pulley's Shaft From Oil Seal Side Of Pump Body
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to O-rings (1) and fit them to pump body.

Fig 2: Applying Power Steering Fluid To O-Rings
Courtesy of SUZUKI OF AMERICA CORP.
Install side plate (1) to pump body.
NOTE: Carefully align the dowel pins on the side plate (1) at bolt hole (2) as shown in the figure.

Fig 3: Aligning Dowel Pins On Side Plate Bolt Hole
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to sliding surface of rotor (1).
Install rotor (1) to shaft, directing dot (3) marked side of rotor facing down.
Install new snap ring (2) to shaft, then make sure to fit snap into shaft groove securely.
NOTE: Never reuse the removed snap ring (2).

Fig 4: Identifying Rotor And Snap Ring
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to sliding surface of cam ring (1).
Install cam ring (1) to pump body.
NOTE: Install the cam ring (1) by facing the stepped side (2) toward the pump body.

Fig 5: Installing Cam Ring To Pump Body
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to each vane (2).
Install vanes (2) (10 pieces) to rotor (1).

Fig 6: Identifying Vane And Rotor
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to O-ring (1).
Install O-ring (1) to pump body.

Fig 7: Identifying O-Ring
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to sliding surface of pump cover and rotor.
Match the dowel pins (1) to the holes of the pump cover (2) as shown and install pump cover to pump body.

Fig 8: Matching Dowel Pins To Holes Of Pump Cover
Courtesy of SUZUKI OF AMERICA CORP.
Gradually tighten pump cover (1) bolts to specified torque.
NOTE: After installing pump cover (1), check to make sure that shaft can be turned by hand.

Tightening torque

P/S pump cover bolt (a): 28 N.m (2.9 kg-m, 21.0 lbf-ft)

Fig 9: Tightening Pump Cover Bolts
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to O-rings of pressure switch.
Install O-rings (2) to pressure switch.
Install pressure switch (1) to pump body.
Tightening torque

Pressure switch (a): 28 N.m (2.9 kg-m, 21.0 lbf-ft)

Fig 10: Identifying Pressure Switch O-Ring
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to flow control valve (relief valve).
Install flow control valve (relief valve) to pump body.
Install flow control valve spring.
Apply power steering fluid to O-rings of plug.
Install O-rings to plug.
Tighten plug to specified torque.
Tightening torque

Plug (a): 59 N.m (6.0 kg-m, 43.5 lbf-ft)

Fig 11: Tightening Plug To Specified Torque
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to O-ring (2) of suction connector (1).
Install O-ring (2) to suction connector (1).

Fig 12: Installing O-Ring To Suction Connector
Courtesy of SUZUKI OF AMERICA CORP.
Install suction connector (1) to pump body as shown in figure.
Tighten suction connector bolt to specified torque.

Tightening torque

Suction connector bolt (a): 12 N.m (1.2 kg-m, 9.0 lbf-ft)

Fig 13: Identifying Suction Connector
Courtesy of SUZUKI OF AMERICA CORP.