TOYOTA RAV4 1996 Service Repair Manual

To install, reverse removal procedure. After installation, place front wheels in straight-ahead position. Center
steering wheel spiral cable, then install steering wheel and pad. Check front wheel alignment.
Removal (Tundra)
1. Place front wheels in straight-ahead position. Remove steering wheel and pad. Disconnect both tie rod
ends. Disconnect lower steering column shaft from steering gear. Remove clamp plate bolt and remove
clamp plate.
2. Disconnect pressure and return lines from steering gear. Remove power rack and pinion assembly
mounting bolts and nuts. Remove power rack and pinion assembly.
Installation
To install, reverse removal procedure. After installation, place front wheels in straight-ahead position. Center
steering wheel spiral cable, then install steering wheel and pad. Check front wheel alignment.
Removal (4Runner)
1. Place front wheels in straight-ahead position. Remove steering wheel and pad. Remove engine under
cover.
2. Remove stabilizer bar. Disconnect both tie rod ends. Disconnect lower steering column shaft from
steering gear. Disconnect pressure and return lines from steering gear.
3. Remove power rack and pinion assembly mounting bolts and nuts. Remove power rack and pinion
assembly.
Installation
To install, reverse removal procedure. After installation, place front wheels in straight-ahead position. Center
steering wheel spiral cable, then install steering wheel and pad. Check front wheel alignment.
OVERHAUL
POWER STEERING PUMP
Disassembly (RAV4)
1. Mount pump assembly in soft-jaw vise. Ensure pump rotates smoothly. Using a torque wrench, check
pump rotating torque. Rotating torque should be 2.4 INCH lbs. (.3 N.m) or less. Remove front bracket
and pump bracket.
2. While holding pulley, remove pulley nut. Remove pulley and Woodruff key from pump shaft. Remove air
control valve. See Fig. 3
. Remove pressure feed No. 2 tube.
3. Remove union bolt and "O" ring from suction (return) port. Remove "O" ring from pressure port. Remove
flow control valve and spring. See Fig. 3
.
4. Remove flow control valve seat snap ring. Install a 6 x 1 x 50 mm bolt about 2-3 threads into seat. Pull
sprin
g seat from housing. Remove "O" ring.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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5. Remove rear housing snap ring. Wrap tape on serrated part of pump shaft. Using soft-face hammer, tap
out rear housing, washer and side rear plate. Remove "O" rings.
6. Remove cam ring and 10 vane plates. See Fig. 3
. Remove pump shaft with rotor and side front plate.
7. Remove snap ring from pump shaft. Remove 2 "O" rings from plate. Remove rotor and side front plate
from pump shaft. Remove short straight pin from side front plate and long straight pin from front
housing.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Fig. 3: Exploded View Of Power Steering Pump (RAV4)

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection
1. Using micrometer, measure diameter of pump shaft. Using calipers, measure diameter or pump housing
shaft bushing. Determine amount of clearance. Clearance should be .0012-.0020" (.030-.050 mm).
Clearance should not exceed .0028" (.071 mm). If clearance exceeds maximum specification, replace
front housing and pump shaft.
2. Using micrometer, measure height, thickness and length of 10 vane plates. See VANE PLATE
SPECIFICATIONS table. Use feeler gauge to measure clearance between rotor groove and plate.
Maximum clearance is .0012" (.030 mm). If clearance exceeds maximum, replace plate and/or rotor with
one having same mark stamp of "1", "2", "3", "4" or no marking.
3. Coat flow control valve with power steering fluid and check that it falls smoothly into valve hole on its
own weight.
4. Check flow control valve for leakage by closing one hose and applying 57-71 psi (4-5 kg/cm2) air
pressure to opposite hole. Air should NOT come out hole on end of valve. If valve does not respond as
indicated, replace valve with one having same letter mark as on front housing and/or on valve.
5. Using calipers, measure free length of flow control valve spring. Minimum free length is 1.42" (36.0
mm). If not within specification, replace spring.
6. If necessary, replace oil seal. Coat NEW seal lip with power steering fluid and carefully press NEW oil
seal into position. Ensure seal is in same direction as removed.
VANE PLATE SPECIFICATIONS
Reassembly
1. Coat all internal components with power steering fluid. Install long straight pin into front housing and
short straight pin into side front plate.
2. Install 2 NEW "O" rings to side front plate. Coat "O" rings with power steering fluid. Install front plate to
pump shaft. Install rotor to pump shaft with mark facing outward. Install NEW snap ring to pump shaft.
3. Align hole of plate and longer straight pin, and tap shaft into place with soft-face hammer. Use care not to
damage oil seal and "O" rings. Align holes of cam ring and 2 straight pins, and install cam ring with mark
facing outward. Install 10 vane plates, with round end facing outward.
4. Coat a NEW "O" ring with power steering fluid. Install "O" ring to side rear plate. Align holes on plate
and 2 straight pins, and install plate. Install wave washer so protrusions fit into slots in side rear plate.
ApplicationIn. (mm)
RAV4
Height.319 (8.1)
Length.59008 (14.988)
Thickness.0707 (1.796)
Land Cruiser, Sienna, Tacoma, Tundra & 4Runner
Height.339 (8.6)
Length.5902 (14.991)
Thickness.0550 (1.397)

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1999-2000 STEERING Power Rack & Pinion - Trucks
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5. Coat a NEW "O" ring with power steering fluid. Install "O" ring into pump rear housing. Using soft-face
hammer, tap rear housing to front housing. Install NEW snap ring.
6. Coat a NEW "O" ring with power steering fluid. Install "O" ring to flow control spring seat. Using same
bolt for removal, thread into spring seat a small amount. Install spring seat to front housing. Remove bolt.
Install NEW snap ring.
7. Install flow control spring and valve. Ensure valve is facing correct direction. Coat a NEW "O" ring with
power steering fluid. Install "O" ring to pressure port union. Tighten union to specification. See
TORQUE SPECIFICATIONS
.
8. Coat a NEW "O" ring with power steering fluid. Install "O" ring to suction (return) port union. Install
union with bolt, and tighten to specification. See TORQUE SPECIFICATIONS
. Install pressure feed
No. 2 tube.
9. Tighten pressure feed line union bolt, with NEW gasket on each side of line. Tighten to specification. See
TORQUE SPECIFICATIONS
. Pressure feed line installation angle is 2.5 degrees from straight-up
position.
10. Install NEW union seat for air control valve. Install and tighten valve to specification. See TORQUE
SPECIFICATIONS .
11. Install Woodruff key to pump shaft. Position and hold pulley while installing and tightening pulley nut.
See TORQUE SPECIFICATIONS
.
12. Install pump brackets. Measure pump rotating torque. Using a torque wrench, check pump rotating
torque. Rotating torque should be 2.4 INCH lbs. (.3 N.m) or less.
Disassembly (Sienna)
1. Mount pump assembly in soft-jaw vise. Ensure pump rotates smoothly. Using a torque wrench, check
pump rotating torque. Rotating torque should be 2.4 INCH lbs. (.3 N.m) or less.
2. While holding pulley, remove pulley nut. Remove pulley from pump shaft. Remove front and rear
mounting brackets.
3. Remove union bolt and "O" ring from suction (return) port. Remove "O" ring from pressure port. Remove
flow control valve and spring. See Fig. 4
.
4. Remove rear housing bolts and 2 "O" rings. Remove wave washer, side plate and gasket.
5. Remove cam ring and 10 vane plates. See Fig. 4
. Remove snap ring and remove pump rotor. Remove
pump shaft. Remove 2 straight pins from front housing.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Sunday, November 22, 2009 10:35:46 AMPage 12 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Exploded View Of Power Steering Pump (Sienna)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Sunday, November 22, 2009 10:35:46 AMPage 13 © 2005 Mitchell Repair Information Company, LLC.

1. Using micrometer, measure diameter of pump shaft. Using calipers, measure diameter or pump housing
shaft bushing. Determine amount of clearance. Clearance should be .0012-.0020" (.030-.050 mm).
Clearance should not exceed .0028" (.071 mm). If clearance exceeds maximum specification, replace
front housing and pump shaft.
2. Using micrometer, measure height, thickness and length of 10 vane plates. See VANE PLATE
SPECIFICATIONS table. Use feeler gauge to measure clearance between rotor groove and plate.
Maximum clearance is .0014" (.035 mm). If clearance exceeds maximum, replace plate and/or rotor with
one having same mark stamp of "1", "2", "3", "4" or no marking.
3. Coat flow control valve with power steering fluid and check that it falls smoothly into valve hole on its
own weight.
4. Check flow control valve for leakage by closing one hole and applying 57-71 psi (4-5 kg/cm2) air
pressure to opposite hole. Air should NOT come out hole on end of valve. If valve does not respond as
indicated, replace valve with one having same letter mark as on front housing and/or on valve.
5. Using calipers, measure free length of flow control valve spring. Minimum free length is 1.272" (32.3
mm). If not within specification, replace spring.
6. If necessary, remove oil seal from housing. Coat NEW seal lip with power steering fluid and carefully
press NEW oil seal into position. Ensure seal is in same direction as removed.
Reassembly
1. Coat all internal components with power steering fluid. Install pump shaft. Install 2 NEW straight pins
into front housing.
2. Align holes of cam ring and 2 straight pins, and install cam ring with mark facing outward. Install pump
rotor with mark facing outward. Install NEW snap ring on pump shaft. Install 10 vane plates, with round
end facing outward.
3. Install a NEW gasket on housing. Install side plate. Install wave washer so protrusions fit into slots in side
plate.
4. Coat 2 NEW "O" rings with power steering fluid. Install "O" rings into pump rear housing. Install rear
housing and tighten bolts to specification. See TORQUE SPECIFICATIONS
.
5. Install flow control spring and valve. Ensure valve is facing correct direction. Coat a NEW "O" ring with
power steering fluid. Install "O" ring to pressure port union. Tighten union to specification. See
TORQUE SPECIFICATIONS
.
6. Coat a NEW "O" ring with power steering fluid. Install "O" ring to suction (return) port union. Tighten
union bolt to specification. See TORQUE SPECIFICATIONS
.
7. Install pump brackets. Position and hold pump pulley and install nut. Tighten nut to specification. See
TORQUE SPECIFICATIONS
. Measure pump rotating torque. Using a torque wrench, check pump
rotating torque. Rotating torque should be 2.4 INCH lbs. (.3 N.m) or less.
Disassembly (Tacoma & 4Runner 4-Cylinder)
1. Mount pump assembly in soft-jaw vise. Ensure pump rotates smoothly. Using a torque wrench, check
pump rotating torque. Rotating torque should be 2.4 INCH lbs. (.3 N.m) or less.
2. While holding pulley, remove pulley nut. Remove pulley from pump shaft. Remove fluid reservoir.
Remove and discard "O" ring.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
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Sunday, November 22, 2009 10:35:46 AMPage 14 © 2005 Mitchell Repair Information Company, LLC.

3. Remove union bolt and "O" ring from pressure port. Remove flow control valve and spring. See Fig. 5 .
Remove pump bracket.
4. Remove rear housing bolts and 2 "O" rings. Remove wave washer, side plate and gasket.
5. Remove cam ring and 10 vane plates. See Fig. 5
. Remove snap ring and pump rotor. Remove pump
shaft. Remove 2 strai
ght pins from front housing.

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:46 AMPage 15 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Exploded View Of Power Steering Pump (Tacoma & 4Runner 4-Cylinder)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:46 AMPage 16 © 2005 Mitchell Repair Information Company, LLC.

1. Using micrometer, measure diameter of pump shaft. Using calipers, measure diameter or pump housing
shaft bushing. Determine amount of clearance. Clearance should be .0012-.0020" (.030-.050 mm).
Clearance should not exceed .0028" (.071 mm). If clearance exceeds maximum specification, replace
front housing and pump shaft.
2. Using micrometer, measure height, thickness and length of 10 vane plates. See VANE PLATE
SPECIFICATIONS table. Use feeler gauge to measure clearance between rotor groove and plate.
Maximum clearance is .0014" (.035 mm). If clearance exceeds maximum, replace plate and/or rotor with
one having same mark stamp of "1", "2", "3", "4" or no marking.
3. Coat flow control valve with power steering fluid, and check that it falls smoothly into valve hole on its
own weight.
4. Check flow control valve for leakage by closing one hose and applying 57-71 psi (4-5 kg/cm2) air
pressure to opposite hole. Air should NOT come out hole on end of valve. If valve does not respond as
indicated, replace valve with one having same letter mark as on front housing and/or on valve.
5. Using calipers, measure free length of flow control valve spring. Minimum free length is 1.307" (33.2
mm). If not within specification, replace spring.
6. If necessary, replace oil seal in front housing. Coat NEW seal lip with power steering fluid and carefully
press NEW oil seal into position. Ensure seal is in same direction as removed.
7. If necessary, replace pump shaft bearing. Press old bearing off of shaft. Remove snap ring. Install NEW
snap ring. Coat NEW bearing with power steering fluid. Press bearing onto shaft.
Reassembly
1. Coat all internal components with power steering fluid. Cover serrated part of shaft with vinyl tape. Press
pump shaft with bearing into housing. Install NEW snap ring in front housing. Install 2 NEW straight
pins into front housing.
2. Align holes of cam ring and 2 straight pins, and install cam ring with mark facing outward. Install pump
rotor with mark facing outward. Install NEW snap ring on pump shaft. Install 10 vane plates, with round
end facing outward.
3. Install a NEW gasket on front housing. Install side plate, aligning holes with straight pins. Install wave
washer so protrusions fit into slots in side plate.
4. Coat 2 NEW "O" rings with power steering fluid. Install "O" rings into pump rear housing. Install rear
housing and tighten bolts to specification. See TORQUE SPECIFICATIONS
.
5. Install flow control spring and valve. Ensure valve is facing correct direction. Coat a NEW "O" ring with
power steering fluid. Install "O" ring to pressure port union. Tighten union to specification. See
TORQUE SPECIFICATIONS
.
6. Install fluid reservoir with NEW "O" ring. Tighten bolts to specification. See TORQUE
SPECIFICATIONS .
7. Position and hold pump pulley, and install nut. Tighten nut to specification. See TORQUE
SPECIFICATIONS . Measure pump rotating torque. Using a torque wrench, check pump rotating
torque. Rotating torque should be 2.4 INCH lbs. (.3 N.m) or less.
Disassembly (Land Cruiser, Tacoma & 4Runner V6 & Tundra V6 & V8)
1. Mount pump assembly in soft-jaw vise. Ensure pump rotates smoothly. Using a torque wrench, check

1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
Microsoft
Sunday, November 22, 2009 10:35:47 AMPage 17 © 2005 Mitchell Repair Information Company, LLC.