P/S Pump Disassembly And Assembly: Assembly

WARNING: This page is about a different car, the 2008 Suzuki Grand Vitara, 2007 Suzuki Grand Vitara, and 2006 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

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 99000-25010SUZUKI Super Grease A

Fig 1: Applying Grease To Oil Seal
Courtesy of SUZUKI OF AMERICA CORP.
Apply power steering fluid to O-rings (1) and fit them to pump body.

Fig 2: Identifying Power Steering Fluid To O-Ring
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
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 up.
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 & 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 by facing the side with a mark (2) toward the pump cover.

Fig 5: Identifying 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 Vanes & 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 (2.8 kg-m, 20.5 lb-ft)

Fig 9: Identifying 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 (2.8 kg-m, 20.5 lb-ft)

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

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

Fig 11: Tightening Plug
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 (1)
Courtesy of SUZUKI OF AMERICA CORP.
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: 12 N.m (1.2 kg-m, 9.0 lb-ft)

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