Contents: Installation ⬇ Tightening torques ⬇
Important: When replacing the receiver, it is necessary to strictly monitor cleanliness. Thoroughly clean the space between the return line connection on the receiver and the pressure line connection on the pump unit; however, you cannot use aggressive cleaning agents for this purpose, such as, for example,. gasoline, solvents, etc. The removed parts should be placed on a clean surface and covered. If the repair is not to be carried out immediately, it is necessary to carefully cover the exposed parts. Do not use lint-producing cloths. Remove parts from packaging only immediately before installation. Use only spare parts packed in their original packaging. The sealant must not come into contact with the mating surfaces of the receiver and the power steering pump unit. When replacing the receiver, it is necessary to ensure that the body "1" of the pump unit is not subjected to tensile, compressive or impact loads. Damage to the pump unit housing may lead to damage to the pump or the seal between the J500 power steering control unit and the pump unit.
Remove the power steering pump unit. After the working fluid for hydraulic systems has been sucked out, only a residual amount of working fluid remains in the pump unit. Close the pressure line connection on the pump unit. Remove the mounting bracket from the pump unit according to the pump unit assembly diagram. Clamp the pump unit in a vice with protective jaws.
Important: The pump unit may only be clamped by the "J500" power steering control unit. Under no circumstances should it be clamped by the "2" pump unit housing. The "2" pump unit housing must not come into contact with either the vise jaws or the workbench. Failure to comply with the above instructions would result in permanent damage to the pump unit.
After loosening the clamp, remove it in an upward direction.
Caution: Use protective gloves when heating and removing the receiver.
Heat the lower part of receiver "2" evenly around the entire perimeter with a hot air gun.
Caution: The receiver must not be heated to temperatures exceeding 80°C.
Remove receiver "2" from pump unit "3".
Installation
Important: The mating surface on the pump unit for the sealing ring and receiver must not be oily. When installing the receiver on the pump unit, neither sliding aids nor lubricants must be used. The sealant must not come into contact with the mating surfaces of the receiver and the power steering pump unit.
Clamp the pump unit in a vice with protective jaws.
Important: The pump unit may only be clamped by the "J500" power steering control unit, position "1." Under no circumstances should it be clamped by the pump unit housing "2." The pump unit housing "2" must not come into contact with either the vise jaws or the workbench. Failure to comply with the above instructions would result in permanent damage to the pump unit. Install a new sealing ring onto the sealing surface of the pump unit.
Ensure that the sealing ring is installed correctly.
Caution: Use protective gloves when heating and installing the receiver.
Heat the bottom of the new receiver evenly around the entire perimeter with a hot air gun. Place receiver -1 on pump unit "2".
The receiver should be oriented so that the return line connection "arrow A" is located above the pressure line screw connection "arrow B." Receiver "1" should be installed so that it rests against the pump unit "2" itself. When installing the receiver, tap evenly with a rubber mallet around the entire perimeter of receiver "1"; do not tap on the filler neck. Make sure that the receiver does not jam. Secure the receiver to the pump unit with a new clamp. Tighten the clamp screw to the specified tightening torque. Close the return line connection on the receiver. After filling the receiver approximately 1/4 full with hydraulic fluid, check the tightness of the connection between the receiver and the pump unit. In case of leakage, eliminate the cause. Empty the receiver. Due to warranty conditions, it is necessary to clearly mark the replacement of the receiver. In the designated area (see picture) apply eg. with permanent colored varnish, a strip of approx. 15 x 30 mm "2".
The mark should be located on both receiver "1" and clamp "3" and on the pump unit "4". Install the mounting bracket on the pump unit according to the pump unit assembly diagram. Open the return line connection on the receiver and the pressure line connection on the pump unit. Build in a pumping unit.
Tightening torques
| Clamp on the receiver of the pump unit | 3 Nm |
| Mounting bracket on the TRW pump unit | 7 Nm |