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Home >> Suzuki >> 2001 >> Vitara JS, 4D Utility, Automatic >> Repair and Diagnosis >> Steering >> Power Steering >> Power Assisted Steering System >> Repair Instructions >> Power Steering Pump Disassembly & Assembly >> Assembly

Power Steering Pump Disassembly & Assembly: Assembly

  1. 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 99000-25010

    Fig 1: Identifying Lubrication Points
    G01380916Courtesy of SUZUKI OF AMERICA CORP.
  2. Apply power steering fluid to O-rings (1) and fit them to pump body.
    Fig 2: Identifying O-Rings
    G01380917Courtesy of SUZUKI OF AMERICA CORP.
  3. 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
    G01380918Courtesy of SUZUKI OF AMERICA CORP.
  4. Apply power steering fluid to sliding surface of rotor (1).
  5. Install rotor (1) to shaft, directing dot (3) marked side of rotor facing up.
  6. 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: Installing Rotor To Shaft & Identifying Marked Side Of Rotor
    G01380919Courtesy of SUZUKI OF AMERICA CORP.
  7. Apply power steering fluid to sliding surface of cam ring (1).
  8. Install cam ring (1) to pump body. The tapered end of cam ring (1) should face the side plate (2).
    Fig 5: Identifying Cam Ring To Pump Body Installation Position
    G01380920Courtesy of SUZUKI OF AMERICA CORP.
  9. Apply power steering fluid to each vane (2).
  10. Install vanes (2) (10 pieces) to rotor (1).
    Fig 6: Lubricating & Installing Vanes
    G01380921Courtesy of SUZUKI OF AMERICA CORP.
  11. Apply power steering fluid to O-ring (1).
  12. Install O-ring (1) to pump body.
    Fig 7: Lubricating & Installing O-Ring To Pump Body
    G01380922Courtesy of SUZUKI OF AMERICA CORP.
  13. Apply power steering fluid to sliding surface of pump cover and rotor.
  14. Match the dowel pins (1) to the holes of the cover plate (2) as shown in illustration and install pump cover to pump body.
    Fig 8: Matching Dowel Pins To Holes Of The Cover Plate
    G01380923Courtesy of SUZUKI OF AMERICA CORP.
  15. 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):  23 N.m (2.3 kg-m, 17.0 lb-ft)

    Fig 9: Identifying P/S Pump Cover Bolts
    G01380924Courtesy of SUZUKI OF AMERICA CORP.
  16. Apply power steering fluid to O-ring of pressure switch.
  17. Install pressure switch (1) to pump body.

    Tightening torque 

    Pressure switch (b):  28 N.m (2.8 kg-m, 20.5 lb-ft)

    Fig 10: Identifying Pressure Switch
    G01380925Courtesy of SUZUKI OF AMERICA CORP.
  18. Apply power steering fluid to relief valve (flow control valve).
  19. Install relief valve (flow control valve) to pump body.
  20. Install flow control spring.
  21. Apply power steering fluid to O-rings of plug.
  22. Install O-rings to plug.
  23. Tighten plug to specified torque.

    Tightening torque 

    Plug (a):  60 N.m (6.0 kg-m, 43.5 lb-ft)

    Fig 11: Tightening Plug To Specified Torque
    G01380926Courtesy of SUZUKI OF AMERICA CORP.
  24. Apply power steering fluid to O-ring (2) of suction connector (1).
  25. Install O-ring (2) to suction connector (1).
    Fig 12: Identifying O-Ring & Suction Connector
    G01380927Courtesy of SUZUKI OF AMERICA CORP.
  26. Install suction connector (1) to pump body as shown in the figure. Tighten suction connector (1) bolts to specified torque.

    Tightening torque 

    Suction connector bolt (a):  10 N.m (1.0 kg-m, 7.5 lb-ft)

    Fig 13: Installing Suction Pipe
    G01380928Courtesy of SUZUKI OF AMERICA CORP.
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