1996 TOYOTA T100 check 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 SR07Q−01
R12180
R12181
SST
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
SR−47
1996 TOYOTA T100 (RM449U)
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:
0.25 N·m (2.5 kgf·cm, 2.2 in.·lbf) or less
2. REMOVE VANE PUMP PULLEY
Using SST to stop the pulley rotating, remove the pulley set nut.
SST 09960−10010 (09962−01000, 09963−01000)
3. REMOVE OIL RESERVOIR
(a) Remove the 3 bolts and oil reservoir.
(b) Remove the O−ring from the oil reservoir.
4. REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND SPRING
Remove the O−ring from the union.
5. REMOVE BRACKET
Remove the 2 bolts.
6. REMOVE REAR HOUSING
(a) Remove the 2 bolts.
(b) Remove the 2 O−rings from the housing.
7. REMOVE WAVE WASHER
8. REMOVE SIDE PLATE
9. REMOVE GASKET
10. REMOVE CAM RING, VANE PLATES AND VANE
PUMP ROTOR
(a) Remove the 10 plates.
NOTICE:
Take care not to drop the plate.
(b) Using a screwdriver, remove the snap ring from the vane
pump shaft.
11. REMOVE VANE PUMP SHAFT
12. REMOVE STRAIGHT PINS
Remove the 2 pins from the front housing.

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R15220
Vane PumpFront Housing
Shaft
Bushing
Z06061
Thickness
Length Height
R10282Feeler Gauge
SR−48
− STEERINGPOWER STEERING VANE PUMP (5VZ−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 caliper gauge, measure the oil clear-
ance.
Standard clearance:
0.003 − 0.005 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.07 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.)

Downloaded from www.Manualslib.com manuals search engine R13897Inscribed Mark
R12184
R07591
Compressed Air
R12185Inscribed Mark
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
SR−49
1996 TOYOTA T100 (RM449U)
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)
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 holes.
If necessary, replace the valve with one having the same letter
as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F

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R10072
Dial Indicator
R14216
SSTOil Seal SST
Bearing
W03367
SST
SST
Oil Seal
SST
R14218
SST
SST
Bearing
Oil Seal
SST
Z14493Bearing SR−60
− STEERINGPOWER STEERING GEAR (2WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT STEERING RACK
(a) Using a dial indicator, check the rack for runout and for
teeth wear or damage.
Maximum runout: 0.03 (0.0012 in.)
(b) Check the back surface for wear or damage.
2. IF NECESSARY, REPLACE OIL SEAL AND BEARING
(a) Using SST, tap out the oil seal and bearing from the con-
trol valve housing.
SST 09950−60010 (09951−00250),
09950−70010 (09951−07150)
(b) Coat a new oil seal lip with power steering fluid.
(c) Using SST, press in the oil seal.
SST 09950−60010 (09951−00180, 09951−00320,
09952−06010), 09950−70010 (09951−07200)
NOTICE:
Make sure to install the oil seal facing the correct direction.
(d) Using SST, press in a new bearing.
SST 09950−60010 (09951−00180, 09951−00340,
09952−06010), 09950−70010 (09951−07200)
3. IF NECESSARY, REPLACE 2 BEARINGS
(a) Using a brass bar, drive out the bearing from the rack
housing.

Downloaded from www.Manualslib.com manuals search engine R13021
Vinyl Tape
R15248
Wire
SST
Cylinder End
Stopper
R04609
SST
R13031
Vinyl Tape
W03369
SST
Oil Seal
− STEERINGPOWER STEERING GEAR (2WD)
SR−65
1996 TOYOTA T100 (RM449U)
4. INSTALL RACK BUSHING AND CYLINDER END
STOPPER
(a) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(b) Coat a new O−ring with power steering fluid and install it
to the bushing.
(c) Push in the bushing.
NOTICE:
Make sure to install the bushing facing the correct direc-
tion.
(d) Push in the cylinder end stopper until the wire installation
hole appears.
5. INSTALL WIRE
(a) Insert a new wire end into the hole of the rack housing.
(b) Using SST, turn the cylinder end stopper clockwise until
the wire end disappears.
SST 09631−10021
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631−12071
(b) Apply 53.3 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the ser-
rated part of the valve shaft.
(c) Install the valve assembly into the control valve housing.
NOTICE:
Be careful not to damage the teflon rings and oil seal.
8. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) Using SST, press in the oil seal.
SST 09612−22011
NOTICE:
Make sure to install the oil seal facing the correct direction.

Downloaded from www.Manualslib.com manuals search engine R14224
Fulcrum
Length
SST
Hexagon Wrench
R14225
SST
Z14297
SST
Length Fulcrum
R04619
− STEERINGPOWER STEERING GEAR (2WD)
SR−69
1996 TOYOTA T100 (RM449U)
(j) Apply sealant to 2 or 3 threads of the rack guide spring
cap lock nut.
Sealant: Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(k) Using a hexagon wrench (21 mm) to hold the rack guide
spring cap, and using SST, install and torque the lock nut.
SST 09922−10010
Torque: 51 N·m (521 kgf·cm, 38 ft·lbf)
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(l) Repeat (h)
15. CHECK TOTAL PRELOAD
(a) Using SST and a torque wrench, check the total preload.
SST 09616−00010
Preload (turning):
0.5 − 1.4 N·m (5 − 14 kgf·cm, 4.3 − 12.2 in.·lbf)
HINT:
The total preload must be within the specification throughout
the full stroke of the steering rack.
If it is not within specification, adjust the total preload again.
(b) Remove the RH and LH rack ends.
16. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner to hold the steering rack steady, and us-
ing SST, torque the rack end.
SST 09922−10010
Torque: 61 N·m (618 kgf·cm, 45 ft·lbf)
NOTICE:
Use SST 09922−10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Using a brass bar and hammer, stake the washer.
NOTICE:
Avoid any impact to the rack.