power steering TOYOTA TERCEL 1996 Service Owner's Manual

SR1EZ-01
Z13631
Thickness
Height
Length
R10282
Feeler Gauge
R13897Inscribed Mark
- STEERINGPOWER STEERING VANE PUMP
SR-27
1996 TERCEL (RM440U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.01 - 0.03 mm (0.0004 - 0.0012 in.)
Maximum clearance: 0.07 mm (0.0028 in.)
If it is more than the 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: 8.0 mm (0.315 in.)
Minimum thickness: 1.77 mm (0.0697 in.)
Minimum length: 14.97 mm (0.5894 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.03 mm (0.0012 in.)
If it is more than the maximum, replace the plate and/or rotor
with the one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None

Z13632
R07591
Compressed Air
SR-28
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
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.)
None44345-1201014.996 - 14.998
(0.59039 - 0.59047)
144345-1202014.994 - 14.996
(0.59032 - 0.59032)
244345-1203014.992 - 14.994
(0.59024 - 0.59032)
344345-1204014.990 - 14.992
(0.59016 - 0.59024)
444345-1205014.988 - 14.990
(0.59008 - 0.59016)
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 392 - 490 kPa (4 - 5 kgf/cm
2, 57 - 71 psi)
of compressed air into the opposite side hole, and confirm
that air does not come out from the end holes.
If necessary, replace the valve with the one having the same let-
ter as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F

R08702
Calipers
- STEERINGPOWER STEERING VANE PUMP
SR-29
1996 TERCEL (RM440U)
4. INSPECT COMPRESSION SPRING
Using calipers, measure the free length of the spring.
Minimum length: 36 - 38 mm (1.42 - 1.49 in.)
If it is not within the specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
NOTICE:
Place the shop rag, as shown, 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), press in the oil seal.
NOTICE:
Make sure you install the oil seal facing the correct direc-
tion.

SR1F0-01
Z13635
Mark
R11542
Vinyl Tape
SR-30
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID
(See page SR-22)
2. INSTALL LONGER STRAIGHT PIN
Using a plastic hammer, tap in a new pin to the front housing.
NOTICE:
Be careful not to damage the pin.
3. INSTALL SIDE FRONT PLATE AND VANE PUMP RO-
TOR
(a) Coat 2 new O-rings with power steering fluid, and install
them to the plate.
(b) Install the plate to the vane pump shaft.
NOTICE:
Make sure you install the plate facing the correct direction.
(c) Install the rotor to the pump shaft with the inscribed mark
on the rotor facing outward.
(d) Using snap ring pliers, install a new snap ring to the vane
pump shaft.
(e) Install a new shorter straight pin to the plate.
NOTICE:
Be careful not to damage the pin.
4. INSTALL VANE PUMP SHAFT WITH VANE PUMP RO-
TOR ANd SIDE FRONT PLATE
(a) To prevent oil seal lip damage, wind vinyl tape on the
pump shaft.
(b) Align the hole of the front plate and longer straight pin.
(c) Tap in the pump shaft with a plastic hammer.
NOTICE:
Be careful not to damage the oil seal and O-rings.
5. INSTALL CAM RING
Align the holes of the ring and straight pins, and install the ring
with the inscribed mark facing outward.

R11071
Round End
R12361
R12362
- STEERINGPOWER STEERING VANE PUMP
SR-31
1996 TERCEL (RM440U)
6. INSTALL VANE PLATES
Install the 10 plates with the round end facing outward.
7. INSTALL SIDE REAR PLATe
(a) Coat a new O-ring with power steering fluid, and install
it to the plate.
(b) Align the holes of the plate and straight pins.
8. INSTALL WAVE WASHER
Install the washer so that its protrusions fit into the slots in the
side rear plate.
9. INSTALL REAR HOUSING
(a) Coat a new O-ring with power steering fluid and install it
to the rear housing.
(b) Install the rear housing and use a press to push down on
the wave washer hard enough to compress it.
NOTICE:

Do not apply too much pressure.

Be careful not to damage the O-ring.
10. INSTALL SPRING, FLOW CONTROL VALVE AND
PRESSURE PORT UNION
(a) Install the valve facing the correct direction.
(See page SR-22)
(b) Coat a new O-ring with power steering fluid, and install
it to the union.
(c) Torque the union.
Torque: 69 N´m (700 kgf´cm, 51 ft´lbf)
11. INSTALL SUCTION PORT UNION
(a) Coat a new O-ring with power steering fluid, and install
it to the union.
(b) Torque the 2 bolts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

SR-32
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
12. INSTALL VANE PUMP PULLEY
(a) Install the woodruff key to the vane pump shaft.
(b) Using SST to stop the pulley rotating, torque the pulley set
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-25)

SR0KQ-03
- STEERINGPOWER STEERING VANE PUMP
SR-33
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL PS VANE PUMP ASSEMBLY
Temporarily tighten the 2 bolts (A and B).
2. INSTALL DRIVE BELT
(a) Adjust drive belt tension (See page SR-3).
(b) Torque the A bolt.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(c) Torque the B bolt.
Torque: 39 N´m (400 kgf´cm, 30 ft´lbf)
3. CONNECT PRESSURE FEED TUBE
Torque the union bolt over a new gasket.
Torque: 54 N´m (550 kgf´cm, 40 ft´lbf)
4. CONNECT RETURN HOSE
5. BLEED POWER STEERING SYSTEM
(See page SR-5)

SR0KX-04
SR-46
- STEERINGPOWER STEERING GEAR
966 Author
: Date
:
1996 TERCEL (RM440U)
POWER STEERING GEAR
COMPONENTS

- STEERINGPOWER STEERING GEAR
SR-47
967 Author
: Date
:
1996 TERCEL (RM440U)

Union Seat SR-48
- STEERINGPOWER STEERING GEAR
968 Author
: Date
:
1996 TERCEL (RM440U)