1996 TOYOTA RAV4 torque

SR0FX−03
R10967
R10992
SST
R10968
SR−34
− STEERINGPOWER STEERING VANE PUMP
1996 RAV4 (RM447U)
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 PUMP FRONT BRACKET AND PUMP
BRACKET
Remove the 2 bolts.
3. REMOVE VANE PUMP PULLEY
(a) Using SST to stop the pulley rotating, remove the pulley
set nut.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the woodruff key from the vane pump shaft.
4. REMOVE AIR CONTROL VALVE
Remove the union seat.
5. REMOVE PRESSURE FEED NO.2 TUBE
Remove the union bolt and 2 gaskets.
6. REMOVE SUCTION PORT UNION
(a) Remove the union set bolt.
(b) Remove the O−ring from the union.
7. REMOVE PRESSURE PORT UNION
Remove the O−ring from the union.
8. REMOVE FLOW CONTROL VALVE AND SPRING
9. REMOVE FLOW CONTROL SPRING SEAT
(a) Using snap ring pliers, remove the snap ring.
(b) Install the 2 or 3 threads of a bolt (6 mm normal diameter,
1.0 mm pitch, 50 mm length).
Reference
Bolt: 91651−60650
(c) Using pliers, remove the spring seat from the front hous-
ing.
(d) Remove the O−ring from the flow control spring seat.

R10995
2.5°
R10992
SST
− STEERINGPOWER STEERING VANE PUMP
SR−41
1996 RAV4 (RM447U)
(d) Using snap ring pliers, install a new snap ring.
12. INSTALL SPRING AND FLOW CONTROL VALVE
Install the valve facing the correct direction
(See page SR−31).
13. INSTALL PRESSURE PORT UNION
(a) Coat a new O−ring with power steering fluid and install it
to the union.
(b) Torque the union.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
14. INSTALL SUCTION PORT UNION
(a) Coat a new O−ring with power steering fluid and install it
to the union.
(b) Install the O−ring to the union.
(c) Install the union with the bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
15. INSTALL PRESSURE FEED NO.2 TUBE
Torque the union bolt with a new gasket on each side of the
tube.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
HINT:
Pressure feed No.2 tube installation angle is 2.5°.
16. INSTALL AIR CONTROL VALVE
(a) Install a new union seat.
(b) Torque the valve.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
17. INSTALL VANE PUMP PULLEY
(a) Install the woodruff key to the vane pump shaft.
(b) Using SST to stop the pulley rotating, torque the nut.
SST 09960−10010
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
18. INSTALL PUMP BRACKET AND PUMP FRONT
BRACKET
Temporarily tighten the 2 bolts.
19. MEASURE PS VANE PUMP ROTATING TORQUE
(See page SR−34)

SR0G0−03
W01943
Stopper
Pressure Feed
Tube
R10966
W01119
SST
Fulcrum Length
R10981
SR−42
− STEERINGPOWER STEERING VANE PUMP
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL PRESSURE FEED TUBE
Torque the union bolt over a new gasket.
Torque: 52 N·m (525 kgf·cm, 38 ft·lbf)
HINT:
Make sure the tube is touching the stopper of the pressure feed
No.2 tube, as shown, then torque the union bolt.
2. INSTALL PS VANE PUMP ASSEMBLY WITH PUMP
BRACKET
Torque the 3 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
3. CONNECT PRESSURE FEED TUBE
Using SST, connect the tube.
SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.)
This torque value is effective in case that SST is parallel
to a torque wrench.
4. INSTALL DRIVE BELT
(a) Adjust drive belt tension (See page SR−3)
(b) Torque the 3 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
5. CONNECT RETURN HOSE
6. CONNECT 2 VACUUM HOSES
7. CONNECT 2 TUBE CLAMPS
Torque the bolt.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
8. INSTALL FRONT SUSPENSION CROSSMEMBER AS-
SEMBLY (See page SA−42)
9. TORQUE 2 PS GEAR ASSEMBLY SET BOLTS AND
NUTS
Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf)
10. CONNECT RH AND LH LOWER SUSPENSION ARMS
(See page SA−42)
11. INSTALL STABILIZER BAR WITH LINK
(See page SA−42)

− STEERINGPOWER STEERING VANE PUMP
SR−43
1996 RAV4 (RM447U)
12. INSTALL FRONT EXHAUST PIPE
(a) Torque the 2 bolts with a new gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(b) Torque 3 new nuts with a new gasket.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
13. INSTALL RH AND LH ENGINE UNDER COVERS
Tighten the 13 bolts.
14. BLEED POWER STEERING SYSTEM
(See page SR−4)

SR0G1−03
Z19807
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
 GasketTube ClampReturn Tube
No.2 Intermediate
Shaft Pressure Feed Tube
Stabilizer Bar with Link
Front Suspension
Crossmember
Assembly
Front Exhaust Pipe
13 (130, 9)
13 (130, 9)
113 (1, 150, 83)
29 (300, 22)
29 (300, 22)
44 (450, 32)
*36 (365, 26)
62 (630, 46)

62 (630, 46)
 Gasket
Clamp
(A/T)
48 (490, 35)
PS Gear Assembly
Bracket
Bushing
Bracket
Bushing
49 (500, 36)
35 (360, 26)
113 (1, 150, 83)

 Cotter Pin
127 (1, 300, 94)
206 (2, 100, 152)
137 (1, 400, 101)
8.3 (84, 73 in.·lbf)
112 (1, 140, 82)
127 (1, 300, 94)
206 (2, 100, 152)x7 Engine Under CoverN·m (kgf·cm, ft·lbf) : Specified torque
* For use with SST  Non−reusable partx6
127 (1, 300, 94)
137 (1, 400, 101)
137 (1, 400, 101)
W01195
49 (500, 36)
3 Door vehicle 64 (650, 47)
5 Door vehicle 113 (1,150, 83)
SR−44
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)
POWER STEERING GEAR
COMPONENTS

F00871
29 (300, 22)
*23 (234, 17)
 Gasket
29 (300, 22)
*23 (234, 17)
44 (450, 32)
*32 (330, 24)
Union Bolt
 Snap Ring
 Oil Seal Turn Pressure TubeDust Cover
Rack GuideControl Valve
Assembly
 Rack Guide
Spring Cap
Lock Nut  Bearing
 Lock Nut  Gasket
 Oil Seal Teflon Ring
 Bearing Union Seat Bushing
 Precoated part
Molybdenum disulfide lithium base greaseRack Guide Seat Rack Guide
Spring Cap
 Rack Housing Cap
N·m (kgf·cm, ft·lbf) : Specified torque
* For use with SST  Non−reusable part
Power steering fluid
29 (300, 22)
69 (700, 51)
12 (125, 9)
29 (300, 22)
Rack Housing
Conical Spring Washer
Rack Guide Spring
− STEERINGPOWER STEERING GEAR
SR−45
1996 RAV4 (RM447U)

W01239
 Snap Ring
 Oil Seal Tie Rod End
Lock Nut
Rack Boot
Clip
Cylinder End Stopper
Rack Housing  Clamp
 Oil Seal  O−Ring  Teflon RingSteering RackRack End
 Claw Washer
Rack Housing
No.1 BracketGrommet
Lock Nut
Molybdenum disulfide lithium base grease
N·m (kgf·cm, ft·lbf) : Specified torque
* For use with SST  Non−reusable part
Power steering fluid


56 (570, 41)
61 (620, 45)
56 (570, 41)
83 (850, 61)
*60 (615, 44)
83 (850, 61)
*60 (612, 44)
Rack End
Claw Washer
Clamp
Rack BootClip
Tie Rod End SR−46
− STEERINGPOWER STEERING GEAR
1996 RAV4 (RM447U)

W01262
SST
W01263
SST
Spacer
Lock NutBC
A
W04192
12°
Hexagon Wrench
W01265
SST
− STEERINGPOWER STEERING GEAR
SR−57
1996 RAV4 (RM447U)
12. INSTALL LOCK NUT
(a) Using SST to stop the control valve shaft rotating, torque
a new nut.
SST 09616−00010
Torque: 12 N·m (125 kgf·cm, 9 ft·lbf)
(b) Turn C of SST to obtain dimension A, then set SST, as
shown.
SST 09613−12020
Dimension A: 16.5 − 17.0 mm (0.65 − 0.67 in.)
(c) Stake the nut by turning B of SST until it touches the
spacer of SST.
13. INSTALL RACK HOUSING CAP
(a) Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Torque the cap.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
14. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK
GUIDE SPRING AND RACK GUIDE SPRING CAP
(a) Install the seat to the guide.
(b) Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Temporarily install the cap.
15. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (21 mm), torque the rack guide
spring cap.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Using a hexagon wrench (21 mm), return the cap 12°.
(d) Using SST, turn the control valve shaft right and left 1 or
2 times.
SST 09616−00010
(e) Using a hexagon wrench (21 mm), loosen the cap until the
rack guide spring is not functioning.