Vane Pump Assembly: Overhaul

1. Remove the clip and disconnect the oil reservoir to pump hose No. 1.
   NOTE: Take care not to spill fluid on the V belt.

1. Disconnect the connector.
2. Remove the oil power steering pressure switch from the union bolt.
   NOTE: Be careful not to drop the oil power steering pressure switch.

   If the oil power steering pressure switch is dropped or strongly damaged, replace it with a new one.

1. Using a 22 mm spanner to hold the pressure port union, remove the union bolt and gasket.
   Fig 1: Disconnecting Pressure Feed Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Loosen the 2 bolts and remove the vane pump V belt.

1. Remove the 2 bolts and vane pump assembly.
   Fig 2: Remove Vane Pump V Belt

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1. Using SST, stop the vane pump pulley rotation and loosen the nut.

   SST 09960-10010 (09962-01000, 09963-01000)

2. Remove the nut and vane pump pulley from the vane pump shaft.

Fig 3: Removing Vane Pump Pulley

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and power steering suction port union.
2. Remove the O-ring from the power steering suction port union.

1. Remove the pressure port union.
2. Remove the O-ring from the pressure port union.

1. Remove the 2 bolts and pump bracket rear from the vane pump assembly.

1. Remove the 2 bolts, 2 nuts and pump bracket rear from the vane pump assembly.

1. Remove the 4 bolts and vane pump housing rear from the vane pump housing front.
2. Remove the gasket.
3. Remove the 2 O-rings from the vane pump housing rear.

1. Remove the wave washer from the side plate rear.
2. Remove the side plate rear.

1. Remove the 10 vane pump plates from the vane pump rotor.
2. Using a screwdriver, remove the vane pump shaft snap ring from the vane pump shaft.
3. Remove the vane pump rotor.

Fig 4: Removing Vane Pump Rotor

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1. Remove the bolt and pump bracket front from the pump housing front.

1. Using SST and a hammer, tap out the vane pump housing oil seal from the vane pump housing front.

   SST 09631-10030

   NOTE: Be careful not to damage the bushing of the vane pump housing front.
   Fig 5: Removing Vane Pump Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a micrometer and a caliper gauge, measure the oil clearance.
   1. Standard Clearance:  0.027-0.054 mm (0.0011-0.0021 in.)
   2. Maximum Clearance:  0.07 mm (0.0028 in.)

   If it is more than the maximum, replace the vane pump assembly.

   Fig 6: Inspecting Oil Clearance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a micrometer, measure the height, thickness and length of the vane pump plates.

   Minimum Height:  8.6 mm (0.339 in.)

   Minimum Thickness:  1.397 mm (0.0550 in.)

   Minimum Length:  14.991 mm (0.5902 in.)

   Fig 7: Inspecting Vane Pump Rotor & Vane Plates

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane pump plate.

   Maximum Clearance:  0.03 mm (0.0012 in.)

   If it is more than the maximum, replace the vane pump assembly.

   Fig 8: Measuring Clearance Using A Feeler Gauge

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight.
   Fig 9: Inspect Flow Control Valve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392-490 kPa (4-5 kgf/cm² , 57-71 psi) into the opposite side hole, and confirm that air does not come out from the end holes.

   If necessary, replace the vane pump assembly.

   Fig 10: Checking Flow Control Valve For Leakage

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using vernier calipers, measure the free length of the flow control valve compression spring.

   Minimum Free Length:  32.24 mm (1.269 in.)

   If it is not within the specification, replace the vane pump assembly.

   Fig 11: Inspecting Flow Control Valve Compression Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage, replace the vane pump assembly.

1. Coat a new vane pump housing oil seal lip with power steering fluid.
2. Using SST and a press, install a new vane pump housing oil seal.

   SST 09950-60010 (09951-00330), 09950-70010 (09951-07100)

   NOTE: Make sure that the vane pump housing oil seal is installed facing the correct direction.
   Fig 12: Installing Vane Pump Housing Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the pump bracket front with the bolt.

   Torque: 

   1. Type "A" Vane Pump:  43 N.m (438 kgf.cm, 32 ft.lbf)
   2. Type "B" Vane Pump:  44 N.m (449 kgf.cm, 32 ft.lbf)

1. Coat inside bushing surface of the pump housing front with power steering fluid.
2. Gradually insert the vane pump shaft from the pulley side.
   NOTE: Do not damage the vane pump housing oil seal lip in the vane pump housing front.
   Fig 13: Locating Power Fluid

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat inside bushing surface of the pump housing front with power steering fluid.
2. Gradually insert the vane pump shaft from the pulley side.
   NOTE: Do not damage the vane pump housing oil seal lip in the vane pump housing front.
   Fig 14: Locating Power Steering Fluid

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the vane pump rotor.
2. Using a snap ring expander, install a new vane pump shaft snap ring to the vane pump shaft.

Fig 15: Installing Vane Pump Rotor

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1. Align the holes of the vane pump cam ring with 2 straight pins, and install the vane pump cam ring with inscribed mark facing outward.
   Fig 16: Installing Vane Pump Cam Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Coat 10 vane pump plates with power steering fluid.
3. Install the vane pump plates with the round end facing outward.
4. Install a new gasket.

Fig 17: Installing Vane Pump Plates

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Coat a new O-ring with power steering fluid and install it to the side plate rear.
2. Align the groove of the cam ring with that of the side plate, install the side plate rear.
   Fig 18: Installing Vane Pump Side Plate Rear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the wave washer so that its protrusions fit into the slots in the side plate rear.

Fig 19: Installing Wave Washer

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1. Coat a new O-ring with power steering fluid and install it to the vane pump housing rear.
2. Install the pump housing rear with the 4 bolts.

   Torque:  24 N.m (245 kgf.cm, 18 ft.lbf)

1. Check that the vane pump rotates smoothly without abnormal noise.
2. Temporarily install the pulley set nut.
3. Using a torque wrench, check the vane pump rotating torque.

   Rotating Torque:  0.27 N.m (2.8 kgf.cm, 2.4 in.lbf) or less

Fig 20: Measuring Power Steering Vane Pump Rotation Torque (Type "A")

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check that the vane pump rotates smoothly without abnormal noise.
2. Temporarily install the service bolt.

   Recommended Service Bolt: 

   1. Thread Diameter:  10 mm (0.39 in.)
   2. Thread Pitch:  1.25 mm (0.0492 in.)
   3. Bolt Length:  50 mm (1.97 in.)

3. Using a torque wrench, check the vane pump rotating torque.

   Rotating Torque:  0.27 N.m (2.8 kgf.cm, 2.4 in.lbf) or less

   Fig 21: Measuring Power Steering Vane Pump Rotation Torque (Type "B")

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the pump bracket rear with the 2 bolts.

   Torque:  43 N.m (438 kgf.cm, 32 ft.lbf)

1. Install the pump bracket rear with the 2 bolts and 2 nuts.

   Torque:  44 N.m (449 kgf.cm, 32 ft.lbf)

1. Coat the flow control valve compression spring with power steering fluid and install it.

1. Coat the flow control valve with power steering fluid.
2. Install the flow control valve.

1. Coat a new O-ring with power steering fluid and install it to the pressure port union.
2. Install the pressure port union.

   Torque:  83 N.m (846 kgf.cm, 61 ft.lbf)

1. Coat a new O-ring with power steering fluid and install it to the power steering suction port union.
2. Install the power steering suction port union with the bolt.

   Torque:  13 N.m (133 kgf.cm, 10 ft.lbf)

1. Install the vane pump pulley to the vane pump shaft.
2. Using SST, stop the vane pump pulley rotation and install the nut.

   SST 09960-10010 (09962-01000, 09963-01000)

   Torque:  44 N.m (449 kgf.cm, 32 ft.lbf)

Fig 22: Installing Vane Pump Pulley (Type "A")

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the vane pump assembly with the 2 ("A" and "B") bolts.

1. Install the vane pump V belt and adjust the V belt tension. See SERPENTINE BELT ROUTING & ALIGNMENT .
2. Torque the bolt "A".

   Torque:  43 N.m (438 kgf.cm, 32 ft.lbf)

3. Torque the bolt "B".

   Torque:  43 N.m (438 kgf.cm. 32 ft.lbf)

Fig 23: Installing Vane Pump Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a 22 mm spanner to hold the pressure port union, connect the pressure feed tube assembly with the union bolt and a new gasket.

   Torque:  51.5 N.m (525 kgf.cm, 38 ft.lbf)

   NOTE: Make sure the stopper of the pressure feed tube touches the front bracket as shown in the illustration, then install the union bolt.
   Fig 24: Connecting Pressure Feed Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the power steering oil pressure switch to the union bolt.

   Torque:  21 N.m (214 kgf.cm, 15 ft.lbf)

   NOTE: Be careful not to allow oil from being attached to the connector.
2. Connect the connector.

1. Connect the oil reservoir to pump hose No. 1.
2. Install the clip.

Torque:  103 N.m (1,050 kgf.cm, 76 ft.lbf)