TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine R14723
PS Vane Pump Assembly
Vacuum Hose
Return Hose
Union Bolt Pressure Feed Tube  Gasket Belt Adjusting Bolt
Drive Belt
Power Steering
Idle Pulley
 Non−reusable part 39 (400, 29)
: Specified torque
N·m (kgf·cm, ft·lbf)
47 (475, 34)
39 (400, 29)
SR07I−01
SR−34
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1708 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING VANE PUMP (3RZ−FE)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Z18935
Vane Pump Pulley Snap RingOil Reservoir
Spring
Front Housing
Flow Control Valve
Pressure Port
Union Vane Pump Shaft
Wave Washer
Rear Housing  Bearing
 Snap Ring Oil Seal O−Ring  O−Ring Gasket
 Straight Pin
Side Plate
Cam Ring
Vane Plate
Non−reusable part
Power Steering fluid O−Ring

Vane Pump Rotor
43 (440, 32)
13 (130, 9)
24 (240, 17)
83 (850, 61)
24 (240, 17)
: Specified torque
N·m (kgf·cm, ft·lbf)
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−35
1709 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine SR07J−01
R09245
R13844
SR−36
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE DRIVE BELT
(a) Loosen the power steering idle pulley set bolt.
(b) Loosen the belt adjusting bolt.
2. DISCONNECT PRESSURE FEED TUBE
Using a spanner (24 mm) to hold the pressure port union, re-
move the union bolt and the 2 gaskets.
3. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
4. REMOVE PS VANE PUMP ASSEMBLY
Remove the 2 pump assembly set bolts.

Downloaded from www.Manualslib.com manuals search engine SR07K−01
R12065
R09248
SST
Z14482
Vinyl Tape
Oil Seal
Bearing
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−37
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.25 N·m (2.5 kgf·cm, 2.2 in.·lbf) or less
2. REMOVE VANE PUMP PULLEY
Using SST to stop the pulley rotating, remove the pulley set nut.
SST 09960−10010 (09962−01000, 09963−01000)
3. REMOVE OIL RESERVOIR
(a) Remove the 3 bolts and oil reservoir.
(b) Remove the O−ring from the oil reservoir.
4. REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND SPRING
Remove the O−ring from the union.
5. REMOVE REAR HOUSING
(a) Remove the 2 bolts and rear housing.
(b) Remove the 2 O−rings from the housing.
6. REMOVE WAVE WASHER
7. REMOVE SIDE PLATE
8. REMOVE CAM RING, VANE PLATES AND VANE
PUMP ROTOR
(a) Remove the 10 plates.
NOTICE:
Take care not to drop the plate.
(b) Using a screwdriver, remove the snap ring from the vane
pump shaft.
9. REMOVE STRAIGHT PINS
Remove the 2 pins from the front housing.
10. REMOVE GASKET
11. REMOVE VANE PUMP SHAFT WITH BEARING
(a) Using snap ring pliers, remove the snap ring from the front
housing.
(b) Wind vinyl tape on the serrated part of the vane pump
shaft.
(c) Using a press, press out the shaft with the bearing.
NOTICE:
Be careful not to damage the oil seal lip.

Downloaded from www.Manualslib.com manuals search engine SR07L−02
R15214
Front HousingVane Pump
Shaft
Bushing
Z06061
Thickness
Height
Length
R10282
R13897Inscribed Mark
SR−38
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1996 TOYOTA T100 (RM449U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. CHECK OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clear-
ance.
Standard Clearance:
0.03 − 0.05 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.007 mm (0.0028 in.)
If it is more than maximum, replace the front housing and vane
pump shaft.
2. INSPECT VANE PUMP ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and
length of the 10 plates.
Minimum height: 8.6 mm (0.339 in.)
Minimum thickness: 1.397 mm (0.05500 in.)
Minimum length: 14.991 mm (0.59020 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.035 mm (0.00138 in.)
If it is more than maximum, replace the plate and/or rotor with
one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None
HINT:
There are 5 vane plate lengths with the following rotor and cam
ring marks:
Rotor and
cam ring markVane plate
part numberVane plate length mm
(in.)
None44345−2601014.999 − 15.001
(0.59051 − 0.59059)
144345−2602014.997 − 14.999
(0.59043 − 0.59051)
244345−2603014.995 − 14.997
(0.59035 − 0.59043)
344345−2604014.993 − 14.995
(0.59027 − 0.59035)
444345−2605014.991 − 14.993
(0.59020 − 0.59027)

Downloaded from www.Manualslib.com manuals search engine Z14294
R09063
Compressed Air
R09064
Inscribed
Mark
R08702
Calipers
Z14483
SST
Oil Seal
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−39
1996 TOYOTA T100 (RM449U)
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 flow control valve for leakage.
Close one of the holes and apply compressed air 392 −
490 kPa (4 − 5 kgf/cm
2, 57 − 71 psi) into the opposite side,
and confirm that air does not come out from the end hole.
If necessary, replace the valve with one having the same letter
on the front housing.
Inscribed mark: A, B, C, D, E or F
4. INSPECT SPRING
Using calipers, measure the free length of the spring.
Minimum free length: 32.3 mm(1.272 in.)
If it is not within the specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, tap out the oil seal from the front housing.
SST 09631−10030
NOTICE:
Be careful not to damage the bushing of the front housing.
(b) Coat a new oil seal lip with power steering fluid.

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R13869
Press
Bearing
REMOVE INSTALL SR−40
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1996 TOYOTA T100 (RM449U)
(c) Using a socket wrench (24 mm), press in the oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.
6. IF NECESSARY, REPLACE BEARING
(a) Press out the bearing from the vane pump shaft.
(b) Using a snap ring expander, remove the snap ring from
the shaft.
NOTICE:
Be careful not to damage the shaft.
(c) Using a snap ring expander, install a new snap ring to the
shaft.
NOTICE:
Be careful not to damage the shaft.
(d) Coat a new bearing with power steering fluid.
(e) Press in the bearing to the shaft.

Downloaded from www.Manualslib.com manuals search engine SR07M−01
Z14487
SST
Vinyl
Tape Bearing
Oil Seal
Z14920
Inscribed Mark
R09070
R09072
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−41
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID
(See page SR−34)
2. INSTALL VANE PUMP SHAFT WITH BEARING
(a) Wind vinyl tape on the serrated part of the vane pump
shaft.
(b) Using SST, press in the shaft with the bearing.
SST 09608−04031
NOTICE:
Be careful not to damage the oil seal.
(c) Using snap ring pliers, install a new snap ring to the front
housing.
3. INSTALL STRAIGHT PINS
Using a plastic hammer, tap in 2 new pins to the front housing.
NOTICE:
Be careful not to damage the pins.
4. INSTALL CAM RING
Install the ring with the inscribed mark facing outward.
5. INSTALL VANE PUMP ROTOR
(a) Install the rotor with the inscribed mark facing outward.
(b) Install a new snap ring to the vane pump shaft.
6. INSTALL VANE PLATES AND GASKET
(a) Install the 10 plates with the round end facing outward.
(b) Install a new gasket on the front housing.
NOTICE:
Be careful the direction of the gasket.
7. INSTALL SIDE PLATE
Align the holes of the side plate and straight pins, and install the
plate.
8. INSTALL WAVE WASHER
Install the wave washer so that its protrusions fit into the slots
in the side plate.
9. INSTALL REAR HOUSING
(a) Coat 2 new O−rings with power steering fluid and install
them to the housing.
(b) Torque the 2 bolts.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine R09251
SST SR−42
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1996 TOYOTA T100 (RM449U)
10. INSTALL SPRING, FLOW CONTROL VALVE AND
PRESSURE PORT UNION
(a) Install the valve facing the correct direction.
(See page SR−34)
(b) Coat a new O−ring with power steering fluid and install it
to the union.
(c) Torque the union.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
11. INSTALL OIL RESERVOIR
(a) Coat a new O−ring with power steering fluid and install it
to the oil reservoir.
(b) Install the oil reservoir with the 3 bolts.
Torque:
Front side bolt: 13 N·m (130 kgf·cm, 9 ft·lbf)
Rear side bolts: 24 N·m (240 kgf·cm, 17 ft·lbf)
12. INSTALL VANE PUMP PULLEY
Using SST to stop the pulley rotating, torque the nut.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
13. MEASURE PS VANE PUMP ROTATING TORQUE
(See page SR−37)

Downloaded from www.Manualslib.com manuals search engine SR07N−01
R12952
Stopper
R09245
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−43
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS VANE PUMP ASSEMBLY
Torque the 2 pump assembly set bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
2. CONNECT RETURN HOSE
3. CONNECT PRESSURE FEED TUBE
Torque the union bolt with a new gasket on each side of the
tube.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
HINT:
Make sure the stopper of the tube is touching the PS pump body
as shown, then torque the union bolt.
4. INSTALL DRIVE BELT
(a) Tighten the belt adjusting bolt, adjust drive belt tension.
(See page SR−3)
(b) Torque the power steering idle pulley set nut.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
5. BLEED POWER STEERING SYSTEM
(See page SR−4)