MAZDA Air Pump: Overhaul: Disassembly

NOTE: Mazda recommends the use of Air Pump Service Tool Kit (49 6500 005).

To replace relief valve, remove valve with suitable puller. When installing, position new relief valve on pump housing and hold relief valve replacer on the relief valve. Tap with hammer until valve is seated.
Mount pump in suitable holding fixture.
CAUTION: Do not mount pump housing in vise.

With pulley side down, drive out dowels toward pulley. Remove housing cover attaching bolts, and cover by tapping lightly with plastic hammer.

Fig 1: Air Injection Pump (Exploded View)
Courtesy of MAZDA MOTORS CORP.

Fig 2: Relief Valve Removal
Courtesy of MAZDA MOTORS CORP.
Using a suitable tool to hold pulley, remove rotor ring screws. Remove rear rotor ring and bearing assembly, remove rear carbon seal. Remove vane assembly. Remove carbon shoes and springs.
To replace bearing in rotor ring, position rotor ring on press with bearing part number facing upward. Using suitable tool press out bearing.

Fig 3: Rear Rotor Ring Removal
Courtesy of MAZDA MOTORS CORP.
To replace pulley, straighten lock washer tab. Remove lock nut. Using suitable puller remove pulley.
NOTE: Lock nut is left hand thread.

NOTE: Father disassembly of rotor from pump housing is not recommended. If any component of rotor housing requires replacement, entire housing must be replaced.