Volvo of America Corporation
Contents
1. Drive out punch set in lock nut using punch and Ch Clear keyway 4 mm chisel Keyway must be totally clear r w 27 Using 2 spanner wrench remove lock nut from power piston assembly Slide off brass collar Pull out tube seal Remove split tube by pushing with finger from inside and prying with screw driver Wash all components in solvent All seal rings and 0 ring should be replaced If you must re use wash in water soluble solution Solvent will damage seals Should Be Replaced Inspect valve housing for indication of wear burrs grooves or severe scoring Inspect gear housing for indication of wear burrs grooves or severe scoring i d i i Remove nut 27 Remove collar 24 23 Remove seal and tube 41 42 24 INSPECTION Wash parts replace all seals 25 Inspect valve housing 56 26 Inspect housing 4 27 f e Power piston brass cover must slide freely and W easily in housing bore and must be free of severe scoring Check all sealing surfaces and threads for pres sure and return lines A y 1 Check needle bearings Replace if damaged If bearings are replaced races must also be re placed Remove races using tool SVO 1819 Install using tools SVO 2995 and SVO 1801 Check piston worm gear and sector shaft for eveness severe scoring sealing surface damage or spline damage Check threads and2. disassemble it Hold valve by side drilling Do not mar machined surfaces Clean and replace any damaged part Assemble valve immediately Number of washers Assemble valve 4 regulates spring pressure and therefore max 27 pump output EP WN e Sa 99 j Thoroughly clean all parts Replace all seals Clean parts 100 ASSEMBLY OF P S PUMP Make sure all parts are well cleaned and lightly coated with ATF All sealing components should be replaced Coat parts with ATF 101 Press bearing into housing Use tool SVO 2996 Install bearing Be certain bearing is fully seated Brg should be 9 37 mm or 1 45 from end of housing 102 Apply grease to seal and install in housing using Install seal tool SVO 2997 8 Install bottom o ring in groove in housing Install shaft with previously fitted bearing into housing by tapping with fiber hammer Be cer tain bearing is fully seated Next install brg retaining circlip Place small o ring in groove on inner plate Install plate over shaft in housing Locating pin should go in deeper indentation in plate O ring faces down Be sure plate is fully seated by tapping with fiber hammer Install intermediate piece with locating pin in small hole and arrow up Install rotor with splines up and fine polishing down Insert 10 blades into rotor rounded edges out Install o ring 12 104 Install shaft beari
3. A a i Mc A a A a munum Lem emm A A mm mee HA A ue _ ee ee EN E eme m A gt ee OOS SS e m 7 me a Femme Sege 4 K a pe CL o ES E Ek ACT Mee QUICK TEST TROUBLESHOOTING ADJUSTMENTS REBUILD it y o ci Ea Me Produced By Volvo of America Corporation NATIONAL SERVICE SCHOOL Power Industrial Park Rockleigh N J 07647 For Additional Copies Volvo Dealership Personnel Contact Service Representative or Distributor Service Manager Others Write address above Cost 1 00 each prepaid Must order 10 or more This book cannot be cited for warranty claims Copyright Volvo of America Corporation 1973 MAINTENANCE 8 QUICK TESTS Before rebuilding either power steering component you B Quick Test for Proper Operation should always do the following 1 Road Test car a Is power assist present b Is power assist smooth not erratic A Normal maintenance c Is power steering free from noise 1 Check fluid level in reservoir Fluid should be Y 2 Visual inspection for leaks inch above full mark when engine has been brought a Check hoses and connections to normal operating temperature and then shut off b Check components NOTE Only use Type A or Dexron automatic trans 3 Check front end components for damage and mission fluid alignment 2 Check belt tension with Kent Moor
4. be used Do not exchange with other needle bearings Install sector shaft cover by turning adjusting screw counter clockwise using 5 mm allen wrench Do not turn cover because sealing surfaces will be damaged and bearings may fall into unit 4 aia KA h 7 lt L _ E l a a j j Install 4 bolts with washers in sector shaft cover Tighten to 22 ft Ibs Install rubber cover over control spindle splines on valve housing Remove tape from sector shaft splines Turn in put shaft lock to lock to determine if turn of sector shaft is available either side of center Align marks according to figure If neither of the above is possible realign gears Assemble adjuster screw 11 12 13 Install bearings and o ring 14 15 16 Install cover 16 Bolt down cover 19 20 67 Install rubber cover 51 68 Remove tape and align marks Using 5 mm allen wrench turn adjusting screw clockwise until pressure is felt Tighten adjusting screw locknut to 18 ft Ibs Adjust pressure point 24 and lock 70 Using spring gauge check torque required to Check torque turn input shaft Torque when shaft is in center should be 9 13 Ibs more than at either end of sector shaft travel Maximum torque 40 Ibs 71 After installing unit in car check function Test unit according to instructions in factory service manual section 6 page 32 72 1801
5. Circlip O ring de 23 24 25 26 27 Spring Plug Packing Rotor Spring Control valve Please send in this card when you complete a Power Steering Job Date done Check sections you used CI Quick Tests CO Troubleshooting O In Car Adjustments CJ In Car Pressure Testing O Box Disassembly Box Inspection Box Reassembly Pump Disassembly Pump Inspection Pump Reassembly opoo Circle any section above that gave you trouble or had errors May we contact you L Yes L No Please Print Name Company Address City State Zip Phone Area Code Number ORDER BLANK Do you want more books like this one Cost 1 00 each Check must come with order Quantity Rear axle Overdrive _ Power steering York A C compressor rebuild Please Print Mame Company Address City State Zip Phone Area Code Number FIRST CLASS PERMIT No 25 NORTHVALE NEW JERSEY BUSINESS REPLY MAIL No Postage Stamp Necessary if Mailed in The U S Postage Will be Paid by VOLVO OF AMERICA CORPORATION Service Department Rockleigh New Jersey 07647 PS V A C National Service School ee eee P c o Mail in your envelope to VOLVO OF AMERICA CORPORATION National Service School V A C Service Rockleigh N J 07647 Fold on Line Your comments and questions are invited If you wish to be contacted put your
6. connections for damage on gear housing valve housing and adjusting screw Check caged ball bearing caged needle bearing axial needle bearing ball bearings and sleeve 1 ai i Check piston fit 24 28 Check hose connections 56 29 Check needle bearings Ia 30 Check parts for damage 22 68 10 31 Check all threads 11 6 4 32 Check all bearings 58 60 43 59 34 ASSEMBLY OF STEERING BOX Make certain all parts are absolutely clean Lightly coat parts with ATF type A or dexron Clean and oil parts Replace all seals and gaskets replace seals 35 Install caged needle bearing and sleeve on con Install bearing and trol spindle No clearance should be noted but ae 1 sleeve should turn easily Bearings available in r four sizes to adjust clearance ERN gt A Put valve housing in vise large opening up Place qd A peda caged ball bearing inside seated on bearing race 37 Assemble seals and install worm gear 68 Assemble three o rings and 3 plastic seals on valve assembly Install assembly in housing splined shaft first 38 Install bearing and washer 35 36 Put axial needle bearing and thrust washer on worm Put cover on worm gear Use appropriate bolts to hold cover to housing Tighten bolts to 25 ft Ib Adjust preload by selecting proper thrust washer 6 sizes are avai
7. engine for 10 sec Stop engine turn wheels lock to lock until all oil Drain system has run out Wash component before removal 6 Put box in vise and remove nut 17 Remove unit from vehicle and place in vise Hold adjusting screw with 5 mm allen wrench Re move locknut using 17 mm box wrench Remove bolts 19 Remove four bolts from top cover using 4 m Y socket Turn adjusting screw clockwise with 5 mm allen Remove cover by wrench This will force top cover up and off Do turning screw not turn top cover since that will damage sealing 16 surface 4 Remove needle bearings from top cover Also Remove bearings and remove large o ring o ring 5 Remove circlip screw and washer 11 12 13 Using circlip pliers remove circlip from tension adjusting screw Remove screw and washer BANNNNDNIDID1II Remove shaft Align sector shaft teeth in center of opening 3 P A 10 Using fiber hammer remove sector shaft from housing by lightly tapping end Remove bearings 3 7 Use magnet on 6 handle to remove upper and lower sector shaft needle bearings Remove rubber cover and bolts 50 51 52 Remove rubber cover from input shaft With Y box wrench remove four bolts from valve housing A a mgmgg wm vi ee e AE le geg mmm WEE Carefully remove valve housing Be certain to leave cover 30 in place as it is a ball b
8. from housing 1 small o ring from bottom plate Remove 2 o rings 12 13 A TS Using tool SVO 2996 tap needle bearing and seal out of housing from outside Remove bearing and seal 8 9 89 i del dl a Ai y Check that there are no scratches on shaft from INSPECTION OF COMPONENTS needle bearings Check threads and splines for P S PUMP damages Check shaft 4 90 If sealed ball bearing is damaged it can be re Replace bearing only placed First remove circlip if bad 6 91 Place shaft in vise Do not tighten vise Then tap Remove bearing shaft out of bearing Replace with new bearing 6 Check needle bearing and seal Replace if Check bearing and 62 necessary seal 8 9 93 Inspect plates for wear and scoring V Check plates 14 18 94 Check rotor assembly for evidence of damage rotor blades and intermediate piece Blades should slide freely in rotor Pieces are replaced as a complete set Check rotor plate and blades 15 16 25 Check valve 27 Check that pressure regulator valve slides freely in its bore 96 Check that valve has the same tolerance code as housing Number stamped on lip of housing 1 or 2 agrees with marking stamped into side of valve 1 or 2 or Compare markings 97 Take apart valve if necessary 27 If you suspect there is a problem with valve then
9. 2013 T d Set 2864 2865 2866 2990 2995 2996 2997 When ordering add 999 before numbers shown here SVO 999 See over for illustration and list of special tools and hand tools LIST OF SPECIAL TOOLS AND LIST OF HAND TOOLS SPECIAL TOOLS SVO 999 1801 2010 Inner Sector Shaft Seal Installer 1801 2995 Outer Sector Shaft Bearing Race Puller 1821 Inner Sector Shaft Bearing Race Puller 2060 In Car Power Steering Box Seal Puller Recommend Dealer Purchase 2279 Power Steering Pump Pulley Remover 2303 Drift For Removal Of Power Steering Pump Plates 2481 Sleeve Installer 2863 Steering Box Input Shaft Seal Installer Recommend For Dealer Purchase 2864 Pressure Gauge 2865 amp 2866 Gauge Adapting Nipples 5007 For 164 1973 2996 Pump Housing Bearing And Seal Installer And Remover 4028 Outer Sector Shaft Seal Installer HAND TOOLS 5mm Allen O Ring Tool 2 Medium Screwdrivers Amm Chisel specially made Spring Gauge Magnet On 6 Handle Teflon Tape Marking Paint Vaseline 1 2 Open 7 8 Open 1 1 16 Open 17mm Open Long Nose Pliers Channel Lock Circlip Pliers Slip Joint Pliers Copper Jaws Automatic Trans Fluid A or Dextron 1 Vise Brass Jaws 1 2 Socket 3 8 Drive Spanner Punch Foot Pound Torque Wrench POWER STEERING SPECIAL TOOLS 1801 2481 2013 2860 pa aa 2864 2865 2866 2990 2995 2996 When ordering add 9
10. 99 before numbers shown here SVO 999 4028 DONA Na MN Circlip Lower sealing ring Needle bearing Housing Packing Plug Needle bearing Washer Upper sealing ring Steering shaft Adjuster screw Adjuster washer Circlip Needle bearing Illustration A Steering gear disassembled 15 O ring 29 O ring 16 Cover 30 Cover 17 Locknut 31 O ring 18 Bleeder screw 32 Shims 19 Bolt 33 O ring 20 Washer 34 Packing 21 Plug 35 Bearing washer 22 Piston 36 Needle bearing 23 Pin 37 O ring 24 Sleeve 38 Packing 25 Piston ring 39 O ring 26 O ring 40 O ring 27 Ring nut 41 Packing 28 O ring 42 Pipe halves RALBSR 43 Ball 44 Bolt 45 Lock washer 46 Retainer 47 48 49 50 Washer Spring Washer Bolt 51 Bolt Circlip Sealing ring Washer Valve housing Rubber cover Guide pin only early prod Bearing ring Ball bearing Bearing sleeve Needle bearing Packing O ring Packing O ring Packing 67 O ring 68 Worm KRSSSSSSSS Follow draining procedure and remove unit from car See service manual section 6 page 31 Remove bracket and pulley from P S pump Be careful not to lose woodruff key Use box wrench puller SVO 2279 Remove shaft bearing retaining circlip using circlip pliers DISASSEMBLY OF P S PUMP Drain and remove system Remove bracket amp pul
11. ar Any other corrective measures must be per formed after removing components from vehicle 1 TIGHTEN ALL BOLTS ON STEERING COMPONENTS 2 CHECK HOSES AND REPLACE IF NECESSARY 3 CHECK FLUID LEVEL AND BELT TENSION 4 CHECK OIL LEVEL SHOULD BE 5 10mm 4 ABOVE LEVEL MARK 5 BLEED SYSTEM a Jack up front end Check oil reservoir level Should be 5 10mm ABOVE level mark b Start engine Oil level should go to level mark Add oil if it goes below mark c Turn wheel with engine running lock to lock as long as air bubbles appear in the reservoir Add oil to keep at mark d Stop engine Oil level should rise 5 10mm 4 If car is still stiff or heavy rapid turns check pump number below 6 ADJUST SECTOR SHAFT PRESSURE POINT shown in photo 2 a Jack up front end of car b Remove pitman arm lock nut c Using 9992849 remove pitman arm d Place steering box in middle position by counting number of turns lock to lock Using 17mm wrench loosen adjusting screw lock nut cb f Using 5mm allen wrench turn adjusting screw clockwise until slight resistance is felt when turning steering wheel left or right of center g Tighten lock nut h Check adjustment by turning steering wheel several times from lock to lock Slight resistance should be felt when passing center position i Set front wheels straight forward and steering wheel in center position Fit pitman arm and tighten nut to 17 20 kmp
12. e Belt tension 4 Check tires rims and other related items gauge New belt 100 Ibs Used belt 75 lbs Center 5 Pressure test for proper operation See pages IV and deflection should be 5mm Ae inch V in this book Also refer to 140 series Service Manual 1973 Section 6 Page 32 A A Special Note There are occasions where customers blame power steering when in fact the front end is out or bent or tires are soft or rims are damaged Don t be fooled DO THE QUICK TEST ABOVE AND YOU LL HAVE TIME For OTHER THINGS TABLE OF CONTENTS PAGE ii Do Maintenance and Quick Tests iv Troubleshooting v In Car Adjustments vii In Car Pressure Testing viii Introduction to Rebuild Section 1 Box Disassembly Steering Gear 9 Box Inspection 12 Box Reassembly Steering Gear Parts also special tools and hand tools Fold out Sheet after page 24 25 Pump Disassembly 31 Pump Inspection 35 Pump Reassembly Pump Parts Fold out Sheet after page 40 TROUBLESHOOTING STEERING PROBLEMS numbers in refer to fold out parts drawings CAR WANDERS 1 Check all steering components in QUICK TESTS 2 Check oil level and bleed Number 4 and 5 in IN CAR ADJUSTMENTS PULLS TO ONE SIDE 1 Check front end tires rims brakes and frame 2 Check all steering components in QUICK TESTS STEERING STIFF RIGHT AND LEFT 1 Caster out ball joints jammed check front end 2 Check oil level and bleed Number 4 and 5 i
13. earing re tainer Remove housing 56 10 Pull out piston and Pull out valve assembly with cover and piston Do not screw assembly out worm 22 30 68 11 Turn housing over Remove seal retaining circlip Remove seal with circlip pliers Remove seal using tool 54 SVO 2996 Take care not to damage sealing surface Place piston and valve assembly in vise splines up Be sure to use copper jaws Remove caged ball bearing Remove bearing Note copper jaws 59 13 Using two medium screw drivers carefully pry up Remove sleeve sleeve Do not score steering spindle or damage 60 roller bearing assembly under collar 14 Remove caged needle bearings from control Si Remove bearings spindle pn 61 Remove three plastic seals and three o rings from valve assembly Remove seals and O rings 62 67 16 Screw out valve assembly 68 Screw out valve assembly Hold cover in place until worm gear is removed Caution Do not remove torsion shaft or valves Complete assem bly replaced if defective Disassemble cover 32 36 Remove all seal rings and o rings from cover Re move axial needle bearings thrust washer and shims Remove o ring and seal 25 26 Using o ring tool remove seal and o ring from piston 19 Remove piston from vise and pour out ball bear ings Do not lose or damage any of the 23 bearings Remove ball bearings 20
14. his booklet d Pressure still low Rebuild or replace pump STEERING BOX TEST FOR 140 SERIES ONLY a With pressure gauge hooked up do the pump test number 5 above a b b Put a 6mm 0 240 shim on each stop bolt limiting the full steering lock Leave gauge operating valve open Turn steer ing wheel to lock with force of about 100N 22 Ib and keep force on for 5 seconds while reading gauge Do other direction If same pressures as pump test steering gear is OK c If pressure lower than pump test check for external leaks Do b above again with 1mm 0 040 shims No power steering should be present d Adjust unloading valve 6 which should cancel power steering about 3 before normal lock Check this by test b and c above Only the left turn position can be adjusted Re lease lock nut 5 at front of steering gear housing Screw out valve delays 6 the cancel of PS in makes cancel earlier e Rebuild or replace box 10 STEERING BOX TEST FOR 164 SERIES Turn to lock for 5 seconds and read off pressure If lower than pump rebuild or replace steering gear 164 2865 1972 or earlier EAM or p unscrew connection box Install seal ring in valve housing sealing lip Install seal facing in Use tool SVO 2863 54 ae fold out er si pictur DISASSEMBLY OF P S BOX Jack up car Remove drain plug Remove cover from reservoir Start and run
15. lable 075 094 inch 1 9 2 4 mm Preload 3 7 to 6 4 Ibs using spring gauge When proper preload is established disassemble housing and cover Assemble cover 30 6 small o rings 2 large o rings 1 medium o ring 2 small plastic seals 1 large plastic seal shims thrust washer axial needle bearing Coat mating surface of cover which contacts worm gear With marking paint Place worm gear and cover together Check for proper mating of surfaces by rotating with slight pressure If contact is poor replace seal with larger size 071 1 8 mm disassemble and clean Install cover 30 Bolt cover to housing Check torque 41 Remove cover and housing 30 56 42 Assemble cover 28 38 43 Coat with marking paint 30 68 44 Check contact if poor replace seal 45 Assemble cover with thrust washer determined by photo 41 Coat cover gasket with ATF Put cover on worm gear and bolt to valve housing with 25 ft Ibs torque Using spring gauge check pre load 10 15 Ibs Adjust by installing addition al shims Disassemble Reassemble cover and s gear Check torque 30 56 68 Put piston in vise copper jaws 22 24 Put power piston in vise bore to the side ball bearing feed hole facing up Partially install brass sleeve Use copper jaws Insert worm gear in power piston until gear appears in middle of first feed hole Feed 16 balls while rotating shaft cou
16. ley 74 Remove circlip No 5 75 A ir re Using 1 open end wrench remove plug for Remove plug pressure regulator valve 23 76 Remove spring amp valve 26 27 Using long nose pliers remove spring and pressure regulator valve 77 Remove circlip 20 Using pliers remove large circlip for rear cover 78 Remove cover 19 Remove large rear cover by holding pump with cover facing down and tapping with fiber ham mer Remove small spring 79 Remove o ring Using o ring tool remove first o ring 21 Remove plate Using long nose pliers remove first plate Slight 18 force is necessary since plate is sealed by second o ring AD 31 Using o ring tool remove second o ring Remove o ring 17 82 Remove rotor 25 eg Using long nose pliers carefully lift rotor from pump 83 Remove blades After removing rotor some blades may remain in 15 housing Be certain to remove all 10 Remove plate Remove intermediate piece by pulling and using 16 slight rocking motion 85 Remove shaft Using fiber hammer carefully tap shaft and bear 4 6 ing out of housing from inside 86 Remove plate Remove pump from vise place on bench large 14 opening down Using tool SVO 2303 carefully tap third plate down Tool will fit thru hole in bearing but not in plate 87 Remove 2 o rings using o ring tool 1 large o ring
17. n IN CAR ADJUSTMENTS 3 Check filter and clean channel of reservoir d Check pump Number 8 in IN CAR ADJUSTMENTS Check and clean control valve 27 Number 8c in IN CAR ADJUSTMENTS 5 Rebuild or replace steering box STEERING HEAVY ONE DIRECTION ONLY Rebuild or replace steering gear the steering box HEAVY WITH RAPID STEERING WHEEL TURNS 1 Check power steering belt 2 Check oil then bleed Number 4 and 5 in IN CAR ADJUSTMENTS 3 Check Pump Number 8 in IN CAR ADJUSTMENTS Check iv 7 E 4 a pi q and clean control valve 27 4 Rebuild or replace pump ENGINE STALLS AT IDLE IN LOCK POSITION check pump and steering box Number 8 and 9 in IN CAR ADJUSTMENTS FRONT WHEEL SHIMMY 1 Check all steering components as in quick tests Also check wheel bearings 2 Check oil level then bleed Number 4 and 5 in IN CAR ADJUSTMENTS SHOCKS AND JARRING IN STEERING WHEEL 1 Check oil level then bleed Number 4 and 5 in IN CAR ADJUSTMENTS 2 Adjust sector shaft pressure point Number 6 in IN CAR ADJUSTMENTS 3 Replace or rebuild steering box STEERING CONTINUES TO TURN WITHOUT ASSISTANCE Steering valve needs adjustment 9 Rebuild or replace steering box NOISE FROM PUMP Check oil level and bleed Number 4 and 5 in IN CAR ADJUST MENTS IN CAR ADJUSTMENTS numbers in refer to fold out parts drawings These are the only adjustments and repairs that can be done with the unit in c
18. ng 4 6 105 Install o ring 13 14 Install plate 14 4 ag 107 Install plate 16 y S 108 gt SV e Install rotor and blades 15 25 109 Install second o ring in groove in housing Install o ring 17 110 Install last plate in housing flange down centering pin in larger indentation Be certain plate is fully seated and not cocked Install plate 18 111 Install top o ring in groove in housing Install o ring 21 112 Install small spring and fit cover to housing Install spring and cover 19 22 113 Install large circlip by holding cover down with Install circlip c clamp or handle of hammer 20 114 Install valve 27 Install pressure regulator valve using care not to 7 damage machined surfaces Install spring gasket and plug Use 15 open end wrench Install hose adaptor nipple mounting bracket woodruff key and pulley A ee Sr n lt Install spring gasket and plug 23 24 26 116 Install nipple bracket and pulley 2 3 4 5 6 d Nut Washer Key Shaft Circlip Bearing Circlip Illustration B Power pump disassembled 8 y 10 11 12 13 14 Sealing ring Meedle bearing Housing Pin O ring O ring Inner plate Blade Intermediate piece O ring Outer plate Cover
19. nter clockwise Balls should appear in second hole Do not cock Insert ball bearings worm Put remaining 7 ball bearings in split tube using vaseline Put two halves of tube together and Install ball bearings Put tube in gear place in gear 22 42 49 Check torque required to turn worm gear in Check torque piston 5 10 Ibs using spring gauge If reading is incorrect replace all 23 balls 5 sizes are available When reading is correct carefully disassemble and store balls 50 Assemble gear cover nut and sleeve with seal 68 30 27 24 Place o ring and plastic seal on brass sleeve Put preassembled cover locknut and sleeve on worm gear 51 Put worm gear in piston and insert 23 ball bear ings according to previous method Install seal Assemble gear and power piston with for split tube Seat brass sleeve Make sure all ball bearings teeth are exposed on gear 68 30 27 24 22 52 Do not screw out worm gear as bearings will fall Do not screw out into piston Distance from bottom of gear to worm gear bottom of cover should not exceed 6 inches WARNING 53 Secure locknut by setting with punch Tighten lock nut 27 Install seal in Put steering box in vise positioned as it would be in car Install spacer on top of needle bearing P S housing race Using tools SVO 2010 and SVO 1801 In 8 9 stall seal with lip up 55 Install complete p
20. or 125 145 ft Ibs j Make sure alignment of pitman arm is correct e 7 REPLACEMENT OF CONTROL SPINDLE SEAT 54 ON STEERING BOX shown in 1973 Service Manual 140 series page 6 33 fig 6 71 6 72 a Dismantle steering shaft flange by removing two nuts and bolts Move steering shaft to one side b Mark location of flange on spindle remove clamping bolt and remove flange c Remove rubber cover and circlip from shaft d Carefully apply tool 9992860 to sealing ring Tighten screw fully turn tool backwards and forwards e Fill space in new seal ring lips with multipurpose grease Fit ring on to tool 9992863 with help of loose guide Remove Guide and fit ring into box f Fit circlip and cover g Refit flange according to marks Distance between housing and lower flange 5 7mm or 20 28 h Assemble steering shaft i Check oil level and bleed number 4 above 8 PUMP TEST check belt condition and tension first a Hook up pressure gauge SVO 2864 as shown below b At engine idle engine warm close operating lever on pres sure gauge briefly 10 seconds max Pressure should read 67 Kp Cm 953 psi for all models 140 test at pump 2865 2866 5007 and remove sealing ring If ring sticks in circlip groove care vi In car Pressure Testing see items 8 and 9 on page vi Vil c If pressure low remove pump control valve and clean See steps 76 77 96 97 98 99 115 116 in t
21. ower piston cover and valve y Install piston in assembly in P S housing Teeth should be ex y housing posed in top opening 4 22 30 68 56 Install seal ring in valve housing sealing lip facing Install seal in Use tool SVO 2863 54 57 a 2 o a A Using tool SVO 2863 install valve housing over control spindle taking care not to damage splines Install 4 bolts and tighten to 25 ft Ibs Install valve housing S 58 Using circlip pliers install seal retaining circlip deiere Align teeth of power piston in sector shaft Align teeth opening The space between the second and third teeth should be in center of opening L a Ai j Install lower seal ring using tools SVO 1801 and SVO 2995 Install seal 2 Install needle bearings 3 7 Using vaseline install needle bearings for sector shaft Tape splines and install shaft 10 Put tape on splines of sector shaft to prevent damage to seal Carefully install sector shaft It maybe necessary to turn input shaft back and forth slightly in order to fully seat shaft Do not turn too far or misalignment may occur Assemble tension adjuster screw with washer and circlip Washer is available in different thick nesses to adjust clearance There should be no play when installed but should still turn freely Install needle bearings and o ring in sector shaft cover CAUTION Only sector shaft bearings can
22. phone number here Area Number
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