TOYOTA TERCEL 1996 Service Repair Manual

SR0KL-03
SR-22
- STEERINGPOWER STEERING VANE PUMP
942 Author
: Date
:
1996 TERCEL (RM440U)
POWER STEERING VANE PUMP
COMPONENTS

- STEERINGPOWER STEERING VANE PUMP
SR-23
943 Author
: Date
:
1996 TERCEL (RM440U)

SR0KM-03
SR-24
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
2. DISCONNECT PRESSURE FEED TUBE
Remove the union bolt and gasket.
3. REMOVE DRIVE BELT
Loosen the 2 pump assembly set bolts.
4. REMOVE PS VANE PUMP ASSEMBLY
Remove the 2 pump assembly set bolts.

SR1EY-01
SST
Z13628
- STEERINGPOWER STEERING VANE PUMP
SR-25
1996 TERCEL (RM440U)
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:
0.3 N´m (2.8 kgf´cm, 2.4 in.´lbf) or less
2. REMOVE VANE PUMP PULLEY
Using SST, stop the pulley rotating and remove the nut.
SST 09960-10010 (09962-01000, 09963-01000)
3. REMOVE SUCTION PORT UNION
(a) Remove the 2 bolts.
(b) Remove the O-ring from the union.
4. REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND COMPRESSION SPRING
Remove the O-ring from the union.
5. REMOVE REAR HOUSING AND WAVE WASHER
(a) Using 2 screwdrivers, remove the snap ring.
NOTICE:
Be careful not to damage the front and rear housing.
(b) Wind vinyl tape on the pump shaft.
(c) Using a plastic hammer, tap the pump shaft end.
6. REMOVE SIDE REAR PLATE
Remove the O-ring from the rear plate.
7. REMOVE CAM RING, 10 VANE PLATES
NOTICE:
Be careful not to drop the plate.
8. REMOVE VANE PUMP SHAFT WITH VANE PUMP RO-
TOR AND SIDE FRONT PLATE
9. REMOVE LOWER STRAIGHT PINS

SR-26
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
Using pliers, remove the pin from the front housing.
10. REMOVE ROTOR AND SIDE FRONT PLATE
(a) Using snap ring pliers, remove the snap ring from the
vane pump shaft.
(b) Remove the 2 O-rings and shorter straight pin from the
plate.

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)