1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine SR07L−02
R15214
Front HousingVane Pump
Shaft
Bushing
Z06061
Thickness
Height
Length
R10282
R13897Inscribed Mark
SR−38
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1996 TOYOTA T100 (RM449U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. CHECK OIL CLEARANCE BETWEEN VANE PUMP
SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clear-
ance.
Standard Clearance:
0.03 − 0.05 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.007 mm (0.0028 in.)
If it is more than 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: 8.6 mm (0.339 in.)
Minimum thickness: 1.397 mm (0.05500 in.)
Minimum length: 14.991 mm (0.59020 in.)
(b) Using a feeler gauge, measure the clearance between
the rotor groove and plate.
Maximum clearance: 0.035 mm (0.00138 in.)
If it is more than maximum, replace the plate and/or rotor with
one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None
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.)
None44345−2601014.999 − 15.001
(0.59051 − 0.59059)
144345−2602014.997 − 14.999
(0.59043 − 0.59051)
244345−2603014.995 − 14.997
(0.59035 − 0.59043)
344345−2604014.993 − 14.995
(0.59027 − 0.59035)
444345−2605014.991 − 14.993
(0.59020 − 0.59027)

Downloaded from www.Manualslib.com manuals search engine Z14294
R09063
Compressed Air
R09064
Inscribed
Mark
R08702
Calipers
Z14483
SST
Oil Seal
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−39
1996 TOYOTA T100 (RM449U)
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 compressed air 392 −
490 kPa (4 − 5 kgf/cm
2, 57 − 71 psi) into the opposite side,
and confirm that air does not come out from the end hole.
If necessary, replace the valve with one having the same letter
on the front housing.
Inscribed mark: A, B, C, D, E or F
4. INSPECT SPRING
Using calipers, measure the free length of the spring.
Minimum free length: 32.3 mm(1.272 in.)
If it is not within the specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, tap out the oil seal from the front housing.
SST 09631−10030
NOTICE:
Be careful not to damage the bushing of the front housing.
(b) Coat a new oil seal lip with power steering fluid.

Downloaded from www.Manualslib.com manuals search engine F14896
R13869
Press
Bearing
REMOVE INSTALL SR−40
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1996 TOYOTA T100 (RM449U)
(c) Using a socket wrench (24 mm), press in the oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.
6. IF NECESSARY, REPLACE BEARING
(a) Press out the bearing from the vane pump shaft.
(b) Using a snap ring expander, remove the snap ring from
the shaft.
NOTICE:
Be careful not to damage the shaft.
(c) Using a snap ring expander, install a new snap ring to the
shaft.
NOTICE:
Be careful not to damage the shaft.
(d) Coat a new bearing with power steering fluid.
(e) Press in the bearing to the shaft.

Downloaded from www.Manualslib.com manuals search engine SR07M−01
Z14487
SST
Vinyl
Tape Bearing
Oil Seal
Z14920
Inscribed Mark
R09070
R09072
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−41
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID
(See page SR−34)
2. INSTALL VANE PUMP SHAFT WITH BEARING
(a) Wind vinyl tape on the serrated part of the vane pump
shaft.
(b) Using SST, press in the shaft with the bearing.
SST 09608−04031
NOTICE:
Be careful not to damage the oil seal.
(c) Using snap ring pliers, install a new snap ring to the front
housing.
3. INSTALL STRAIGHT PINS
Using a plastic hammer, tap in 2 new pins to the front housing.
NOTICE:
Be careful not to damage the pins.
4. INSTALL CAM RING
Install the ring with the inscribed mark facing outward.
5. INSTALL VANE PUMP ROTOR
(a) Install the rotor with the inscribed mark facing outward.
(b) Install a new snap ring to the vane pump shaft.
6. INSTALL VANE PLATES AND GASKET
(a) Install the 10 plates with the round end facing outward.
(b) Install a new gasket on the front housing.
NOTICE:
Be careful the direction of the gasket.
7. INSTALL SIDE PLATE
Align the holes of the side plate and straight pins, and install the
plate.
8. INSTALL WAVE WASHER
Install the wave washer so that its protrusions fit into the slots
in the side plate.
9. INSTALL REAR HOUSING
(a) Coat 2 new O−rings with power steering fluid and install
them to the housing.
(b) Torque the 2 bolts.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine R09251
SST SR−42
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1996 TOYOTA T100 (RM449U)
10. INSTALL SPRING, FLOW CONTROL VALVE AND
PRESSURE PORT UNION
(a) Install the valve facing the correct direction.
(See page SR−34)
(b) Coat a new O−ring with power steering fluid and install it
to the union.
(c) Torque the union.
Torque: 83 N·m (850 kgf·cm, 61 ft·lbf)
11. INSTALL OIL RESERVOIR
(a) Coat a new O−ring with power steering fluid and install it
to the oil reservoir.
(b) Install the oil reservoir with the 3 bolts.
Torque:
Front side bolt: 13 N·m (130 kgf·cm, 9 ft·lbf)
Rear side bolts: 24 N·m (240 kgf·cm, 17 ft·lbf)
12. INSTALL VANE PUMP PULLEY
Using SST to stop the pulley rotating, torque the 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−37)

Downloaded from www.Manualslib.com manuals search engine SR07N−01
R12952
Stopper
R09245
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−43
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS VANE PUMP ASSEMBLY
Torque the 2 pump assembly set bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
2. CONNECT RETURN HOSE
3. CONNECT PRESSURE FEED TUBE
Torque the union bolt with a new gasket on each side of the
tube.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
HINT:
Make sure the stopper of the tube is touching the PS pump body
as shown, then torque the union bolt.
4. INSTALL DRIVE BELT
(a) Tighten the belt adjusting bolt, adjust drive belt tension.
(See page SR−3)
(b) Torque the power steering idle pulley set nut.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
5. BLEED POWER STEERING SYSTEM
(See page SR−4)

Downloaded from www.Manualslib.com manuals search engine F14897
SR07O−02
SR−44
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
1718 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING VANE PUMP (5VZ−FE)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Z18936
Pressure Port Union
Flow Control ValveOil Reservoir
Rear Housing
Front Housing
BracketSpring
 O−Ring
 Gasket
Vane Pump
Rotor Vane Pump Shaft
Vane Pump Pulley
Wave Washer
Side Plate
Cam Ring x10
Vane Plate
Non−reusable part  O−Ring O−Ring

Power steering fluid Straight Pin
 Oil Seal
 Snap Ring
43 (440, 32)
13 (130, 9)
24 (240, 17)
24 (240, 17)
83 (850, 62)
43 (440, 32)
: Specified torque
N·m (kgf·cm, ft·lbf)
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
SR−45
1719 Author: Date:
1996 TOYOTA T100 (RM449U)