Opel Frontera UBS. Manual - part 77

POWER STEERING  2A – 29

DISASSEMBLY

Preparation:
Clean oil pump with solvent (plug the discharge and
suction port, to prevent the entry of solvent). Be careful
not to expose the oil seal of shaft assembly to solvent.

1. Bolt

2. Pipe, Suction

3. O-ring

4. Connector

5. O-ring

6. Valve Assembly

7. Retaining Ring

8. Filter

9. Spring

10. Pressure switch

11. Retaining Ring

12. Shaft Assembly

13. Bearing

14. Shaft

15. Retaining Ring

16. Oil Seal

CAUTION:
When removing the oil seal, be careful not to damage the
housing.

17. Bolt

18. Rear Housing Assembly and Pump Cartridge

19. Gasket

20. O-ring

21. O-ring

22. Front Housing

23. Pressure Plate

24. Rotor and Vane

25. Cam

26. Pin

27. Rear Housing

INSPECTION AND REPAIR

Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.

Rotor

Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly.
When part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

2A – 30 POWER STEERING

Vane

Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip in contact with the
cam should be free from wear and distortion).
When part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

Cam

The inner face of the arm should have a uniform contact
pattern without a sign of step wear.
When part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

Side plate

The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger nail.
The parts with minor scores may be reused after lapping
the face.

Valve

The sliding face of the valve must be free from burrs and
damage.
The parts with minor scores may be reused after
smoothing with emery cloth (#800 or finer).

Shaft

Oil seal sliding faces must be free from a step wear which
can be felt by the finger nail.
Bushing face must be free from damage and wear.

O-ring, oil seal, retaining ring

Be sure to discard used parts, and always use new parts
for installation. Prior to installation, lubricate all seals and
rings with power steering fluid.

REASSEMBLY

27. Rear Housing

26. Pin

25. Cam

24. Rotor and Vane

1. Install the rotor with its punch mark facing the front

housing.

2. Install the vanes with curved face in contact with

the inner wall of the cam.

POWER STEERING  2A – 31

23. Pressure Plate

CAUTION:
When installing side plate, be careful not to damage its
inner surface. Damaged side plate may cause poor pump
performance, pump seizure or oil leakage.

22. Front Housing
21. O-ring
20. O-ring

Be sure to discard used O-rings, and always use new
parts for installation.

19. Gasket

Be sure to discard used parts, and always use new
parts for installation.

18. Rear Housing Assembly and Pump Cartridge
17. Bolt

Rear Housing Bolt Torque

N·m (kg·m/lb·ft)

17.6 (1.8 / 12.8)

16. Oil Seal

Be sure to discard used parts, and always use new
parts for installation.

CAUTION:
When installing the oil seal, be careful not to damage the
oil seal contacting surface of the housing.

15. Retaining Ring
14. Shaft
13. Bearing
12. Shaft Assembly
11. Retaining Ring
10. Pressure switch

Pressure Switch Torque

N·m (kg·m/lb·ft)

20 (2.0 / 14)

9.

Spring

8.

Filter

7.

Retaining Ring

6.

Valve

5.

O-ring
Be sure to discard used parts, and always use new
parts for installation.

4.

Connector

Connector Torque

N·m (kg·m/lb·ft)

74 (7.5 / 54)

3.

O-ring
Be sure to discard used parts, and always use new
parts for installation.

2.

Pipe, Suction

1.

Bolt

Suction Pipe Bolt Torque

N·m (kg·m/lb·ft)

15.7 (1.6 / 11.5)

2A – 32 POWER STEERING

POWER STEERING PUMP (4JG2 Engine Model)

Disassembly Steps

1.

Bolt

2.

Pipe, suction

3.

O-ring

4.

O-ring

5.

O-ring

6.

Connector

7.

O-ring

8.

Valve

9.

Retaining ring

10.

Filter

11.

Spring

12.

Retaining ring

13.

Shaft assembly

14.

Bearing

15.

Shaft

16.

Retaining ring

17.

Oil seal

18.

Bolt

19.

Rear housing assembly and pump
cartridge

20.

Gasket

21.

O-ring

22.

O-ring

23.

Front housing

24.

Pressure plate

25.

Rotor and vane

26.

Cam

27.

Pin

28.

Rear housing

Reassembly Steps

28.

Rear housing

27.

Pin

26.

Cam

25.

Rotor and vane

24.

Pressure plate

23.

Front housing

22.

O-ring

21.

O-ring

20.

Gasket

19.

Rear housing assembly and pump
cartridge

18.

Bolt

17.

Oil seal

16.

Retaining ring

15.

Shaft

14.

Bearing

13.

Shaft assembly

12.

Retaining ring

11.

Spring

10.

Filter

9.

Retaining ring

8.

Valve

7.

O-ring

6.

Connector

5.

O-ring

4.

O-ring

3.

O-ring

2.

Pipe, suction

1.

Bolt