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Exploded View: Disassembly

NOTE: Refer to the EXPLODED VIEW  as needed during the following procedure.
  1. Drain the fluid from the pump (see FLUID REPLACEMENT ).
  2. Remove the power steering pump (see PUMP REPLACEMENT ).
  3. Hold the power steering pump (A) in a vise with soft jaws (B), hold the pulley (C) with the special tool (D), and remove the pulley nut (E) and pulley. Be careful not to damage the pump housing with the jaws of the vise.
    Fig 1: Disassembling Pump
    G03678914Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Remove the inlet joint and O-ring.
  5. Remove the pressure control valve cap, O-ring, valve spring, and pressure control valve.
  6. Remove the pump housing cap, O-ring, and pump preload spring.
  7. Remove the pump cover and pump cover seals.
  8. Pull out the roll pin.
  9. Remove the outer case, cam ring, rotor, vanes, and side plate.
  10. Remove the rubber seal and slipper seal from the outer case.
  11. Remove the O-rings from the bottom of the housing.
  12. Remove the 40 mm internal snap ring, then remove the pump driveshaft by tapping the shaft end with the plastic hammer.
  13. Remove the seal from the pump housing.

    Inspection 

  14. Check the pressure control valve for wear, burrs, and other damage to the edges of the grooves in the valve.
    Fig 2: Identifying Pressure Control Valve
    G03678915Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. Inspect the bore of the pressure control valve on the pump housing for scratches and wear.
  16. Slip the pressure control valve (A) back in the pump housing, and check that it moves in and out smoothly. If OK, go to step  17; if not, replace the pump as an assembly. The pressure control valve is not available separately.
    Fig 3: Checking Pressure Control Valve Movements
    G03678916Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Attach a hose (A) to the end of the pressure control valve (B) as shown. Then submerge the pressure control valve in a container of power steering fluid or solvent (C), and blow in the hose.
    • If air bubbles leak through the valve at less than 98 kPa (1.0 kgf/cm2 , 14.2 psi), replace the pump as an assembly. The pressure control valve is not available separately.
    • If the pressure control valve is OK, set it aside for reassembly later.
    Fig 4: Attaching Hose To End Of Pressure Control Valve
    G03678917Courtesy of AMERICAN HONDA MOTOR CO., INC.
  18. Inspect the ball bearing by rotating the outer race slowly. If you feel any play (axial or radial) or roughness, remove the faulty ball bearing (A), and install a new one (B).
    Fig 5: Removing And Installing Ball Bearing
    G03678918Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. Inspect each part shown with an asterisk in the Exploded View; if any of them are worn or damaged, replace the pump as an assembly.

    Reassembly 

  20. Install the new pump seal (A) (with its grooved side facing in) into the pump housing (B) by hand first, then drive it in using the special tools, and the seal is fully seated in the pump housing. Do not apply more than 1,370 N (140 kgf, 308 lbf) of pressure.
    Fig 6: Installing New Pump Seal Into Pump Housing
    G03678919Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Position the pump driveshaft (A) in the pump housing, then press it in with the appropriate size socket wrench (B) as shown.
    Fig 7: Positioning Pump Driveshaft In Pump Housing
    G03678920Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Install the 40 mm internal snap ring (C) with its radius edge facing out.
  23. Coat the new 23.8 mm O-ring (A) with power steering fluid, then position it on the bottom (B) of the pump housing.
    Fig 8: Positioning O-Ring On Bottom Of Pump Housing
    G03678921Courtesy of AMERICAN HONDA MOTOR CO., INC.
  24. Coat the new cover seals (A) and (B), and new 13.0 mm O-ring ('06 model only) (C) with power steering fluid, then position them into the grooves on the cover (D).
    NOTE: For '06 model, be careful not to exchange the 13.0 mm O-ring and the inlet joint O-ring because they are same sizes.
    Fig 9: Positioning Cover Seals And O-Ring Into Grooves On Cover
    G03678922Courtesy of AMERICAN HONDA MOTOR CO., INC.
  25. Install the outer case (A) by aligning the slot (B) inside the outer case with the cover roll pin hole (C). Be sure that the slit (D) on the outer case is in the direction shown.
    Fig 10: Installing Outer Case By Aligning Slot Inside Outer Case
    G03678923Courtesy of AMERICAN HONDA MOTOR CO., INC.
  26. Apply power steering fluid to the rubber seal (E) (black), and install it in the slot (F) of the outer case.
  27. Apply power steering fluid to the slipper seal (G) (white), and install it on top of the rubber seal you just installed.
  28. Install the cam ring (A) by aligning the slot (B) with the slot (C) in the outer case.
    Fig 11: Installing Cam Ring By Aligning Slot With Slot In Outer Case
    G03678924Courtesy of AMERICAN HONDA MOTOR CO., INC.
  29. Insert the roll pin (D) into the slots between the cam ring and outer case, then push the roll pin into the set hole (E).
  30. Install the rotor (A) in the cam ring (B).
    Fig 12: Installing Rotor In Cam Ring
    G03678925Courtesy of AMERICAN HONDA MOTOR CO., INC.
  31. Set the 11 vanes (C) in the grooves in the rotor. Make sure that the round ends (D) of the vanes are in contact with the sliding surface of the cam ring.
  32. Place the side plate (A) on the cam ring, and align the roll pin set hole (B) with the roll pin (C).
    Fig 13: Aligning Roll Pin Set Hole With Roll Pin
    G03678926Courtesy of AMERICAN HONDA MOTOR CO., INC.
  33. Coat the new O-ring (D) with power steering fluid, then position it into the groove on the side plate.
  34. Install the pump housing (A) over the cover assembly (B).
    Fig 14: Installing Pump Housing Over Cover Assembly
    G03678927Courtesy of AMERICAN HONDA MOTOR CO., INC.
  35. Align the bolt holes in the cover (A) with the threaded holes in the pump housing. Install the flange bolts loosely first, then torque the flange bolts in a criss-cross pattern in two or more steps.
    Fig 15: Installing Flange Bolts And Torque Specifications
    G03678928Courtesy of AMERICAN HONDA MOTOR CO., INC.
  36. Push in the cam ring (A) from the pump housing cap hole (B) with a flat-tip screwdriver to make sure the cam ring is fully seated against the outer case.
    Fig 16: Pushing In Cam Ring From Pump Housing Cap Hole
    G03678929Courtesy of AMERICAN HONDA MOTOR CO., INC.
  37. Install the pump preload spring (A) in the pump housing.
    Fig 17: Installing Pump Preload Spring In Pump Housing And Torque Specifications
    G03678930Courtesy of AMERICAN HONDA MOTOR CO., INC.
  38. Coat the new 12.7 mm O-ring (B) with power steering fluid, and install it on the pump housing cap (C).
  39. Install the pump housing cap on the pump housing, and tighten it to the specified torque.
  40. Install the pressure control valve spring (A) in the pump housing.
    Fig 18: Installing Pressure Control Valve Spring In Pump Housing And Torque Specifications
    G03678931Courtesy of AMERICAN HONDA MOTOR CO., INC.
  41. Coat the pressure control valve (B) with power steering fluid, and install it in the pump housing.
  42. Coat the new 16.7 mm O-ring (C) with power steering fluid, and install it on the pressure control valve cap (D).
  43. Install the pressure control valve cap on the pump housing, and tighten it to the specified torque.
  44. Coat the new O-ring (A) with power steering fluid, and install it on the inlet joint (B).
    Fig 19: Installing New O-Ring On Inlet Joint And Torque Specifications
    G03678932Courtesy of AMERICAN HONDA MOTOR CO., INC.
  45. Install the inlet joint on the pump housing.
  46. Install the pulley (A), then loosely install the pulley nut (B). Hold the power steering pump in a vise with soft jaws (C). Be careful not to damage the pump housing with the jaws of the vise.
    Fig 20: Assembling Power Steering Pump And Torque Specifications
    G03678933Courtesy of AMERICAN HONDA MOTOR CO., INC.
  47. Hold the pulley with the special tool, and tighten the pulley nut to the specified torque.
  48. Check that the pump turns smoothly by turning the pulley by band. If it turns hard, loosen the four flange bolts on the cover, then retighten them as in step  35. Turn the pump again by hand.
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