TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine F14897
SR07O−02
SR−44
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
1718 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING VANE PUMP (5VZ−FE)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Z18936
Pressure Port Union
Flow Control ValveOil Reservoir
Rear Housing
Front Housing
BracketSpring
 O−Ring
 Gasket
Vane Pump
Rotor Vane Pump Shaft
Vane Pump Pulley
Wave Washer
Side Plate
Cam Ring x10
Vane Plate
Non−reusable part  O−Ring O−Ring

Power steering fluid Straight Pin
 Oil Seal
 Snap Ring
43 (440, 32)
13 (130, 9)
24 (240, 17)
24 (240, 17)
83 (850, 62)
43 (440, 32)
: Specified torque
N·m (kgf·cm, ft·lbf)
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
SR−45
1719 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine SR07P−01
R12179
Return
HosePressure
Feed Tube
R12066
A
B
C SR−46
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY
Remove the 5 bolts.
2. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
3. DISCONNECT PRESSURE FEED TUBE
(a) Disconnect the connector from the oil pressure switch.
(b) Remove the oil pressure switch from the pressure feed
tube.
(c) Remove the union bolt and 2 gaskets, and disconnect the
tube from the PS vane pump assembly.
4. REMOVE DRIVE BELT
(a) Loosen the bolt A and nut B.
(b) Loosen the bolt C.
5. REMOVE PS VANE PUMP ASSEMBLY
Remove the bolt A and nut B.

Downloaded from www.Manualslib.com manuals search engine SR07Q−01
R12180
R12181
SST
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
SR−47
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 BRACKET
Remove the 2 bolts.
6. REMOVE REAR HOUSING
(a) Remove the 2 bolts.
(b) Remove the 2 O−rings from the housing.
7. REMOVE WAVE WASHER
8. REMOVE SIDE PLATE
9. REMOVE GASKET
10. 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.
11. REMOVE VANE PUMP SHAFT
12. REMOVE STRAIGHT PINS
Remove the 2 pins from the front housing.

Downloaded from www.Manualslib.com manuals search engine SR07R−03
R15220
Vane PumpFront Housing
Shaft
Bushing
Z06061
Thickness
Length Height
R10282Feeler Gauge
SR−48
− STEERINGPOWER STEERING VANE PUMP (5VZ−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 caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.003 − 0.005 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 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.)

Downloaded from www.Manualslib.com manuals search engine R13897Inscribed Mark
R12184
R07591
Compressed Air
R12185Inscribed Mark
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
SR−49
1996 TOYOTA T100 (RM449U)
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)
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 holes.
If necessary, replace the valve with one having the same letter
as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F

Downloaded from www.Manualslib.com manuals search engine R08702
Calipers
R12186
Vinyl Tape
R12187Oil SealSocket
Wrench SR−50
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
1996 TOYOTA T100 (RM449U)
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 a screwdriver with vinyl tape wound around its tip,
remove the oil seal.
NOTICE:
Be careful not to damage the bushing of the front housing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using a socket wrench (24 mm) and a hammer, tap in the
oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.

Downloaded from www.Manualslib.com manuals search engine SR07S−01
R12188Inscribed Mark
R12189Inscribed Mark
R12190
Round End
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
SR−51
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID
(See page SR−44)
2. INSTALL STRAIGHT PINS
Using a plastic hammer, tap in 2 new pins to the front housing.
NOTICE:
Be careful not to damage the pins.
3. INSTALL VANE PUMP SHAFT
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
Install the 10 plates with the round end facing outward.

Downloaded from www.Manualslib.com manuals search engine R12191
R12193
R12181
SST SR−52
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
1996 TOYOTA T100 (RM449U)
7. INSTALL GASKET
Install a new gasket on the front housing.
NOTICE:
Be careful the direction of the gasket.
8. INSTALL SIDE PLATE
Align the 2 straight pins and holes of the plate.
9. INSTALL WAVE WASHER
Install the washer so that its protrusions fit into the slots in the
side plate.
10. 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)
11. INSTALL SPRING, FLOW CONTROL VALVE AND
PRESSURE PORT UNION
(a) Install the valve facing the correct direction.
(See page SR−44)
(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, 62 ft·lbf)
12. INSTALL BRACKET
Torque the 2 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
13. 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)
14. 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)
15. MEASURE PS VANE PUMP ROTATING TORQUE
(See page SR−47)

Downloaded from www.Manualslib.com manuals search engine SR07T−01
R12066
A
B
C
R12951Stopper
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
SR−53
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS VANE PUMP ASSEMBLY
Temporarily tighten the bolt A and nut B.
2. INSTALL DRIVE BELT
(a) Tighten the bolt C, adjust drive belt tension.
(See page SR−3)
(b) Torque the bolt A and nut B.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
3. CONNECT PRESSURE FEED TUBE
(a) 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.
(b) Install the oil pressure switch.
(c) Connect the connector.
4. CONNECT RETURN HOSE
5. INSTALL AIR CLEANER ASSEMBLY
Install the 5 bolts.
6. BLEED POWER STEERING SYSTEM
(See page SR−4)