1996 TOYOTA TERCEL Service Repair Manual

SR1F0-01
Z13635
Mark
R11542
Vinyl Tape
SR-30
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID
(See page SR-22)
2. INSTALL LONGER STRAIGHT PIN
Using a plastic hammer, tap in a new pin to the front housing.
NOTICE:
Be careful not to damage the pin.
3. INSTALL SIDE FRONT PLATE AND VANE PUMP RO-
TOR
(a) Coat 2 new O-rings with power steering fluid, and install
them to the plate.
(b) Install the plate to the vane pump shaft.
NOTICE:
Make sure you install the plate facing the correct direction.
(c) Install the rotor to the pump shaft with the inscribed mark
on the rotor facing outward.
(d) Using snap ring pliers, install a new snap ring to the vane
pump shaft.
(e) Install a new shorter straight pin to the plate.
NOTICE:
Be careful not to damage the pin.
4. INSTALL VANE PUMP SHAFT WITH VANE PUMP RO-
TOR ANd SIDE FRONT PLATE
(a) To prevent oil seal lip damage, wind vinyl tape on the
pump shaft.
(b) Align the hole of the front plate and longer straight pin.
(c) Tap in the pump shaft with a plastic hammer.
NOTICE:
Be careful not to damage the oil seal and O-rings.
5. INSTALL CAM RING
Align the holes of the ring and straight pins, and install the ring
with the inscribed mark facing outward.

R11071
Round End
R12361
R12362
- STEERINGPOWER STEERING VANE PUMP
SR-31
1996 TERCEL (RM440U)
6. INSTALL VANE PLATES
Install the 10 plates with the round end facing outward.
7. INSTALL SIDE REAR PLATe
(a) Coat a new O-ring with power steering fluid, and install
it to the plate.
(b) Align the holes of the plate and straight pins.
8. INSTALL WAVE WASHER
Install the washer so that its protrusions fit into the slots in the
side rear plate.
9. INSTALL REAR HOUSING
(a) Coat a new O-ring with power steering fluid and install it
to the rear housing.
(b) Install the rear housing and use a press to push down on
the wave washer hard enough to compress it.
NOTICE:

Do not apply too much pressure.

Be careful not to damage the O-ring.
10. INSTALL SPRING, FLOW CONTROL VALVE AND
PRESSURE PORT UNION
(a) Install the valve facing the correct direction.
(See page SR-22)
(b) Coat a new O-ring with power steering fluid, and install
it to the union.
(c) Torque the union.
Torque: 69 N´m (700 kgf´cm, 51 ft´lbf)
11. INSTALL SUCTION PORT UNION
(a) Coat a new O-ring with power steering fluid, and install
it to the union.
(b) Torque the 2 bolts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

SR-32
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
12. INSTALL VANE PUMP PULLEY
(a) Install the woodruff key to the vane pump shaft.
(b) Using SST to stop the pulley rotating, torque the pulley set
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-25)

SR0KQ-03
- STEERINGPOWER STEERING VANE PUMP
SR-33
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL PS VANE PUMP ASSEMBLY
Temporarily tighten the 2 bolts (A and B).
2. INSTALL DRIVE BELT
(a) Adjust drive belt tension (See page SR-3).
(b) Torque the A bolt.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(c) Torque the B bolt.
Torque: 39 N´m (400 kgf´cm, 30 ft´lbf)
3. CONNECT PRESSURE FEED TUBE
Torque the union bolt over a new gasket.
Torque: 54 N´m (550 kgf´cm, 40 ft´lbf)
4. CONNECT RETURN HOSE
5. BLEED POWER STEERING SYSTEM
(See page SR-5)

SR0KR-02
R12816
Column Hole Cover
Sliding Yoke
Manual Steering
Gear Assembly
 Cotter Pin Grommet
Bracket
 Non-reusable part Cotter Pin
BracketGrommet SR-34
- STEERINGMANUAL STEERING GEAR
954 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL STEERING GEAR
COMPONENTS

Z19009
 Non-reusable part

Precoated part
Molybdenum disulfide lithium base grease Tie Rod End
Lock Nut
Rack End
 Claw Washer
Steering Rack Rack Housing  Bushing Clip
Clamp Rack Boot
Pinion Bearing Adjusting
Screw Lock Nut

Rack Guide Spring Cap

Rack Guide Spring
Cap Lock Nut
Rack Guide Rack Guide Spring  Oil Seal

Pinion Bearing Adjusting Screw
 Bearing
Steering Pinion
 Bearing
Clamp
Rack Boot
Clip
 Claw Washer
Rack End
Lock Nut
Tie Rod End
- STEERINGMANUAL STEERING GEAR
SR-35
955 Author
: Date
:
1996 TERCEL (RM440U)

SR0KS-01
SR-36
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD
(See page SR-13)
3. REMOVE STEERING WHEEL
(See page SR-13)
4. DISCONNECT RH AND LH TIE ROD ENDS
(See page SA-10)
5. REMOVE COLUMN HOLE COVER
Remove the 4 nuts.
6. DISCONNECT SLIDING YOKE
(See page SR-13)
7. REMOVE 2 BRACKETS AND GROMMETS
Remove the 2 bolts and nuts.
8. REMOVE MANUAL STEERING GEAR ASSEMBLY
Remove the gear assembly from the LH side of the vehicle.

SR0KT-01
N00249
SST
N00250
Matchmarks
N00251
R12034
SST
R12035
SST
- STEERINGMANUAL STEERING GEAR
SR-37
1996 TERCEL (RM440U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE MANUAL STEERING GEAR IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612-00012
2. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS
Place matchmarks on the tie rod end and rack end.
3. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Remove the clamp screw from the boot.
NOTICE:

Be careful not to damage the boot.

Mark the RH and LH boots.
4. REMOVE RH AND LH RACK ENDS AND CLAW
WASHERS
(a) Using a screwdriver and hammer, unstake the washer.
NOTICE:
Avoid any impact on the steering rack.
(b) Using a spanner, hold the steering rack steadily and using
SST, remove the rack end.
SST 09922-10010
NOTICE:

Use SST 09922-10010 in the direction shown in the il-
lustration.

Mark the RH and LH rack ends.
5. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
6. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE
SPRING AND RACK GUIDE
Using a hexagon wrench (19 mm), remove the cap.