TOYOTA LAND CRUISER 1996 J80 Workshop Manual

SR−20
−
STEERING TILT STEERING COLUMN
1996 LAND CRUISER (RM451U)
11. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and main shaft as-
sembly.
(b) Torque the wheel set nut. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(c) Connect the connector.
12. INSTALL STEERING WHEEL PAD
NOTICE:
Make sure the wheel pad is installed to the specified
torque. If the wheel pad has been dropped, or there are
cracks, dents or other defects in the case or connector, re-
place the wheel pad with a new one. When installing the
wheel pad, take care that the wirings do not interfere with
other parts and are not pinched between other parts.
(a) Connect the airbag connector.
(b) Install the wheel pad after confirming that the circumfer-
ence groove of the torx screws is caught on the screw
case.
(c) Using a torx socket wrench, torque the 2 screws. Torque: 9.0 N·m (90 kgf·cm, 78 in.·lbf)
(d) Install the steering wheel lower No.2 and No.3 cover.
13. CHECK STEERING WHEEL CENTER POINT
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SR16F−01
−
STEERING POWER STEERING VANE PUMP
SR−21
1072
Author: Date:
1996 LAND CRUISER (RM451U)
POWER STEERING VANE PUMP
COMPONENTS
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SR−22
−
STEERING POWER STEERING VANE PUMP
1073
Author: Date:
1996 LAND CRUISER (RM451U)
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SR16G−01
R13336
−
STEERING POWER STEERING VANE PUMP
SR−23
1996 LAND CRUISER (RM451U)
REMOVAL
1. DISCONNECT RETURN HOSE
2. DISCONNECT PRESSURE FEED TUBE
Remove the union bolt and 2 gaskets.
3. REMOVE PS VANE PUMP ASSEMBLY
(a) Remove the 2 nuts.
(b) Remove the O−ring from the vane pump assembly.
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SR16H−01
R08084
R08066
Soft Jaws
R13187
Press
SST
SST
R08067
Screwdriver
SR−24
−
STEERING POWER STEERING VANE PUMP
1996 LAND CRUISER (RM451U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE POWER STEERING VANE PUMP ROTAT-
ING TORQUE
(a) Check that the pump rotates smoothly without abnormal noise.
(b) Using a torque wrench, check the pump rotating torque. Rotation torque:
0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
2. REMOVE SUCTION PORT UNION
(a) Remove the bolt.
(b) Remove the O−ring from the union.
3. REMOVE VANE PUMP DRIVE GEAR
(a) Using soft jaws on a vise, clamp the gear in the vise.
NOTICE:
Be careful not to damage the gear.
(b) Remove the gear set nut.
(c) Using SST, press out the gear.
SST 09527−10011
NOTICE:
Be careful not to damage the gear. To avoid dropping the
PS pump assembly, support the pump assembly with your
hand.
(d) Remove the woodruff key from the vane pump shaft.
4. REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND SPRING
Remove the O−ring from the union.
5. REMOVE REAR HOUSING AND WAVE WASHER
(a) Using 2 screwdrivers, remove the snap ring.
NOTICE:
Take care not to damage the housing.
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R11234
Rear Housing
Brass Bar
R11235
Rear Housing Wood Block
R08075
Extension Bar
R08074
−
STEERING POWER STEERING VANE PUMP
SR−25
1996 LAND CRUISER (RM451U)
(b) Using a brass bar and hammer, tap the housing so that
the spring force of the wave washer pushes the housing
forward.
(c) Gently tap the PS pump assembly on a wood block and remove the housing and washer.
(d) Remove the O−ring from the housing.
6. REMOVE SIDE REAR PLATE
(a) Gently tap the PS pump assembly on a wood block and remove the plate.
(b) Remove the O−ring from the plate.
7. REMOVE CAM RING, VANE PUMP ROTOR AND 10 VANE PLATES
NOTICE:
Be careful not to scratch the cam ring, rotor or vane plates.
8. REMOVE SHORTER STRAIGHT PIN
Remove the pin from the side front plate.
9. REMOVE VANE PUMP SHAFT WITH BEARING
(a) Using snap ring pliers, remove the snap ring.
(b) Using an extension bar and hammer, tap out the shaft
with the bearing.
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R11233
Side Front
PlateSST
SR−26
−
STEERING POWER STEERING VANE PUMP
1996 LAND CRUISER (RM451U)
10. REMOVE SIDE FRONT PLATE
(a) Using SST, tap out the plate from the front housing.
SST 09631−10030
NOTICE:
Be careful not to damage the front housing.
(b) Remove the 2 O−rings from the plate.
11. REMOVE LONGER STRAIGHT PIN
Using pliers, remove the pin from the front housing.
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SR16I−02
R15644
Vane Pump ShaftFront
Housing Bushing
Micrometer
Caliper
Gauge
N00372
Height Thickness
Length
R10282
Feeler Gauge
R15645Inscribed Mark
−
STEERING POWER STEERING VANE PUMP
SR−27
1996 LAND CRUISER (RM451U)
INSPECTION
1. CHECK OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and caliper gauge, measure the oil clear-
ance. Standard clearance:
0.03 − 0.05 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than maximum, replace the front housing and vane
pump shaft.
2. INSPECT V ANE PUMP ROTOR AND 10 VANE PLATES
(a) Using a micrometer, measure the height, thickness and length of the plate.
Minimum height: 8.6 mm (0.339 in.)
Minimum thickness: 1.397 mm (0.0550 in.)
Minimum length: 14.991 mm (0.5902 in.)
(b) Using a feeler gauge, measure the clearance between the rotor groove and plate.
Maximum clearance: 0.033 mm (0.0013 in.)
If more than maximum, replace the plate and/or rotor with one
having the mark equivalent to the mark stamped on the cam
ring. Inscribed mark
Vane pump rotor: 1, 2, or None
Cam ring: 2, 3, or 4
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V08067
Rotor
markCam ring
mark Vane plate part
number Vane plate length
mm (in.)
14.995 − 14.997
(0.59035 − 0.59043)
44345
−60030
2
None
1 3 44345
−60040 14.993
− 14.995
(0.59027 − 0.59035)
14.991 − 14.993
(0.59020 − 0.59027)
44345
−60050
4
2
R08078
SR3776
Compressed Air
R08702
SR−28
−
STEERING POWER STEERING VANE PUMP
1996 LAND CRUISER (RM451U)
HINT:
There are 3 vane plate lengths for the following rotor and cam
ring marks.
3. INSPECT FLOW CONTROL VALVE
(a) Coat the valve with power steering fluid and check that it
falls smoothly into the valve hole by its own weight.
(b) Check the valve for leakage. Close one of the holes and apply 392 − 490 kPa (4 − 5 kgf/cm
2, 57 − 71 psi) of com-
pressed air into the opposite side, and confirm that air
does not come out from the end holes.
Inscribed mark:
A, B, C, D, E or F
4. INSPECT SPRING
Using calipers, measure the free length of the spring. Minimum free length: 35 − 37 mm (1.38 − 1.46 in.)
If it is not within the specification, replace the spring.
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SR4528
Tape
Screwdriver
R13761REMOVEINSTALL
Press
Bearing
R08077
Press
SST Oil Seal
W03071
Socket
Wrench
Press
A
A 3.4 mm
(+ 3mm)
−
STEERING POWER STEERING VANE PUMP
SR−29
1996 LAND CRUISER (RM451U)
5. IF NECESSARY, REPLACE BEARING
(a) Using 2 screwdrivers, remove the snap ring from the vane
pump shaft.
NOTICE:
To prevent vane pump shaft damage, wind tape on the
shaft.
(b) Using a press, press out the bearing.
(c) Coat a new bearing with power steering fluid.
(d) Using a press, press in the bearing.
NOTICE:
Be careful not to damage the shaft.
(e) Install a new snap ring to the shaft.
6. IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal from
the front housing.
NOTICE:
Be careful not to damage the housing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using a socket wrench (23 mm), press in the oil seal as shown in the illustration.
NOTICE:
Make sure you install the oil seal facing the correct
direction.
Be careful not to damage the front housing.
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