Vane Pump ASSY: Overhaul

HINT:

COMPONENTS: See VANE PUMP ASSY

NOTE:

When using a vise, do not overtighten.
When installing, coat the parts indicated by the arrows with power steering fluid (See VANE PUMP ASSY ).

DRAIN POWER STEERING FLUID
REMOVE ENGINE UNDER COVER
1. Remove the 16 screws and engine under cover.
REMOVE ENGINE UNDER COVER REAR RH
1. Remove the 2 bolts and engine under cover rear RH.
REMOVE AIR CLEANER INLET NO.1
1. Remove the bolt and air cleaner inlet No. 1.
REMOVE AIR CLEANER ASSY
1. Disconnect the MAF meter connector.
2. Remove the clamp.
3. Remove the 3 bolts and air cleaner assembly.
REMOVE FAN AND GENERATOR V BELT
1. Loosen the fan and generator V belt tension by turning the fan and generator V belt tensioner counterclockwise, and remove the fan and generator V belt belt.
  
  Fig 1: Removing Fan And Generator V Belt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VANE PUMP ASSY
1. Remove the return hose, 2 vacuum hoses and 3 clips.
2. Remove the pressure feed hose union bolt, pressure feed tube and gasket.
3. Remove the 2 bolts, nut and vane pump assembly.
MEASURE PS VANE PUMP ROTATION TORQUE
1. Check that the pump rotates smoothly without abnormal noise.
2. 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
  
  Fig 2: Measuring PS Vane Pump Rotating Torque
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VANE PUMP PULLEY
1. Using SST to stop the pulley rotating, remove the pulley set nut.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Fig 3: Removing Vane Pump Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CONTROL VALVE ASSY
1. Remove the air control valve assy.
2. If necessary, replace union seat.
  1. Using a screw extractor, remove the union seat.
    
    Fig 4: Removing Air Control Valve Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Using an extension bar and a hammer, tap in a new union seat.
  NOTE: Before installing the union seat, remove dust sticking to the vane pump housing sub-assy front.
  
  Fig 5: Installing New Union Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER STEERING SUCTION PORT UNION
1. Remove the 2 bolts and power steering suction port union.
2. Remove the O-ring from the power steering suction port union.
REMOVE POWER STEERING SOLENOID VALVE ASSY
1. Using SST, remove the power steering solenoid valve assy.
  SST 09922-10010
  
  NOTE: Use SST 09922-10010 in the direction shown in the illustration.
  
  Fig 6: Removing Power Steering Solenoid Valve Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using snap ring pliers, remove the snap ring from the vane pump housing sub-assy front.
3. Temporarily install a bolt to the flow control spring seat and pull it out together with the flow control spring seat.
  HINT:
  
  Use a bolt with diameter 6 mm (0.24 in.) and pitch 1.0 mm (0.039 in.).
4. Remove the O-ring from the flow control spring seat.
  
  Fig 7: Removing Flow Control Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VANE PUMP SHAFT
1. Using snap ring pliers, remove the snap ring from the vane pump housing sub-assy front.
2. Temporarily install a appropriate plate washer and the pulley set nut to the vane pump shaft.
3. Using SST, pull out the vane pump shaft.
  SST 09910-00015 (09911-00011, 09912-00010)
4. Using snap ring pliers, remove the snap ring from the vane pump shaft.
  
  Fig 8: Removing Vane Pump Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VANE PUMP BRACKET REAR
1. Remove the 4 bolts and vane pump bracket rear.
2. Remove the O-ring from the vane pump bracket rear.
3. Remove wave washer.
4. Using an extension bar and a press, press out the vane pump side plate front, vane pump cam ring, vane pump rotor, vane pump plates and vane pump side plate rear as an assembly.
5. Using pliers, remove the long cam ring straight pin from the vane pump housing sub-assy front.
6. Remove the O-ring from the vane pump side plate rear.
  NOTE: Take care not to drop the vane plate.
  
  Fig 9: Removing Vane Pump Front Side Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the vane pump rotor and the 10 vane pump plates from the vane pump cam ring.
8. Remove the 10 vane pump plates from the vane pump rotor.
9. Remove the short cam ring straight pin from the vane pump side plate front.
10. Remove the 2 O-rings from the vane pump side plate front.
REMOVE VANE PUMP HOUSING OIL SEAL
1. Using SST, tap out the oil seal.
  SST 09631-10030
  
  NOTE: Be careful not to damage the vane pump housing sub-assy front.
  
  Fig 10: Removing Vane Pump Housing Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OIL CLEARANCE
1. Using a micrometer and caliper gauge, measure the oil clearance.
Standard clearance:

0.03 - 0.045 mm (0.0012 - 0.0018 in.)

Maximum clearance: 0.07 mm (0.028 in.)

If it is more than the maximum, replace the vane pump housing sub-assy front and vane pump shaft.

Fig 11: Inspecting Oil Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT VANE PUMP ROTOR AND VANE PLATES
1. Using a micrometer, measure the height, thickness and length of the 10 vane pump plates.
  Minimum height: 8.1 mm (0.318 in.)
  
  Minimum thickness: 1.797 mm (0.0707 in.)
  
  Minimum length: 14.988 mm (0.5901 in.)
  
  Fig 12: Identifying Vane Pump Plate
  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: 0.028 mm (0.0011 in.)
  
  Fig 13: Measuring Clearance Between Vane Pump Rotor Groove And Vane Pump Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FLOW CONTROL VALVE
1. Coat the flow control valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight.
  
  Fig 14: Inspecting Flow Control Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the flow control valve for leakage. Close one of the holes and apply 392 - 490 kPa (4 - 5 kgf/cm² , 57 - 71 psi) of compressed air into the opposite side hole, and confirm that air does not come out from the end holes.
  
  Fig 15: Checking Flow Control Valve Leakage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FLOW CONTROL VALVE COMPRESSION SPRING
1. Using calipers, measure the free length of the spring.
Minimum free length: 36.9 mm (1.45 in.)

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

Fig 16: Measuring Spring Free Length
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VANE PUMP HOUSING OIL SEAL
1. Coat a new oil seal lip with power steering fluid.
2. Using SST and a press, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00300, 09952-06010), 09950-70010 (09951-07100)

NOTE: Make sure that the oil seal is installed facing in the correct direction.

Fig 17: Installing Oil Seal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VANE PUMP SHAFT
1. Using snap ring pliers, install a new snap ring to the vane pump shaft.
2. Coat the vane pump shaft with power steering fluid.
3. Using SST, press in the vane pump shaft with the bearing.
  SST 09238-47012
4. Using snap ring pliers, install a new snap ring to the vane pump housing sub-assy front.
  
  Fig 18: Installing Vane Pump Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VANE PUMP BRACKET REAR
1. Coat a new long cam ring straight pin with power steering fluid and install it to the vane pump housing sub-assy front.
  NOTE: Be careful not to damage the cam ring straight pin.
2. Coat 2 new O-rings with power steering fluid and install them to the vane pump side plate front.
3. Coat the vane pump side plate front with power steering fluid.
  
  Fig 19: Installing Vane Pump Front Side Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, press in the vane pump side plate front.
  SST 09238-47012
  NOTE:
  - Make sure that the vane pump side front plate is installed facing in the correct direction.
  - Be careful not to damage the O-ring.
  HINT:
  
  Align the wide hole of the vane pump side plate front and longer straight pin.
5. Coat a new short cam ring straight pin with power steering fluid and install it to the vane pump side plate front.
  NOTE: Be careful not to damage the cam ring straight pin.
6. Coat the vane pump cam ring with power steering fluid.
7. Align the wide hole of the vane pump cam ring and long cam ring straight pin, and install the vane pump cam ring with the inscribed mark facing outward.
8. Coat the vane pump rotor with power steering fluid.
9. Install the vane pump rotor with the inscribed mark facing outward.
  
  Fig 20: Installing Vane Pump Rotor With Inscribed Mark Facing Outward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Coat the 10 vane pump plates with power steering fluid.
11. Install the 10 vane pump prates with the round end facing outward.
  
  Fig 21: Installing Vane Pump Plates With Round End Facing Outward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Coat a new O-ring with power steering fluid and install it to the vane pump side plate rear.
13. Coat the vane pump side plate rear with power steering fluid.
14. Using a press, press in the vane pump side plate rear.
  NOTE: Be careful not to damage the O-ring.
  
  HINT:
  
  Align the wide hole of the vane pump side plate rear and long cam ring straight pin.
  
  Fig 22: Aligning Wide Hole Of Vane Pump Rear Side Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Install the wave washer so that is protrusions fit into the slots in the vane pump side plate rear.
16. Coat a new O-ring with power steering fluid and install it to the vane pump bracket rear.
17. Install the vane pump bracket rear to the front housing with the 4 bolts.
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
  
  Fig 23: Installing Wave Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER STEERING SOLENOID VALVE ASSY
1. Coat a new O-ring with power steering fluid and install it to the flow control spring seat.
2. Install the flow control spring seat with the bolt hole facing outward.
3. Using snap ring pliers, install a new snap ring.
4. Coat the flow control valve compression spring with power steering fluid and install it to the vane pump housing sub-assy front.
5. Install the flow control valve facing assy the correct direction (See VANE PUMP ASSY ).
6. Coat the power steering solenoid valve assy with power steering fluid.
  
  Fig 24: Installing Power Steering Solenoid Valve Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using SST, install the power steering solenoid valve assy.
SST 09922-10010

Torque: 51 N.m (520 kgf.cm, 38 ft.lbf)

NOTE: Use SST 09922-10010 in the direction shown in the illustration.

HINT:

Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
INSTALL POWER STEERING SUCTION PORT UNION
1. Coat a new O-ring with power steering fluid and install it to the suction port union.
2. Install the power steering suction port union to the vane pump assembly with the 2 bolts.
Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)
INSTALL AIR CONTROL VALVE ASSY
Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)
INSTALL VANE PUMP PULLEY
1. Using SST to stop the vane pump pulley rotating, torque the pulley set nut.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)
  
  Fig 25: Installing Vane Pump Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
MEASURE PS VANE PUMP ROTATION TORQUE
1. Check that the pump rotates smoothly without abnormal noise.
2. Using a torque wrench, check the pump rotating torque.
  
  Fig 26: Measuring Power Steering Vane Pump Rotating Torque
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Rotating torque:

0.25 N.m (2.5 kgf.cm, 2.2 in.lbf) or less
INSTALL VANE PUMP ASSY
1. Install the power steering vane pump assembly with the nut.
  Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)
2. Install the 2 bolts.
  Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
3. Install the pressure feed tube and a new gasket with the pressure feed hose union bolt.
  HINT:
  
  Make sure the stopper of the pressure feed tube touches the power steering vane pump body as shown in the illustration, then torque the union bolt.
  
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
4. Connect the return hose with the clip.
5. Connect the 2 vacuum hoses with the 2 clips.
  
  Fig 27: Locating Pressure Feed Tube Stopper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FAN AND GENERATOR V BELT
1. Loosen the fan and generator V belt tension by turning the fan and generator V belt tensioner counterclockwise, and install the belt.
INSTALL AIR CLEANER ASSY
1. Install the air cleaner assy with the 3 bolts.
2. Install the clamp.
3. Connect the MAF meter connector.
  
  Fig 28: Installing Fan And Generator V Belt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER INLET NO. 1
1. Install the air cleaner inlet No. 1 with the bolt.
INSTALL ENGINE UNDER COVER REAR RH
1. Install the engine under cover rear RH with the 2 bolts.
INSTALL ENGINE UNDER COVER
1. Install the engine under cover with the 16 bolts.
BLEED POWER STEERING FLUID
INSPECT FLUID LEAK
DRIVE TEST