1996 TOYOTA TERCEL steering

Z13632
R07591
Compressed Air
SR-28
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
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.)
None44345-1201014.996 - 14.998
(0.59039 - 0.59047)
144345-1202014.994 - 14.996
(0.59032 - 0.59032)
244345-1203014.992 - 14.994
(0.59024 - 0.59032)
344345-1204014.990 - 14.992
(0.59016 - 0.59024)
444345-1205014.988 - 14.990
(0.59008 - 0.59016)
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 392 - 490 kPa (4 - 5 kgf/cm
2, 57 - 71 psi)
of compressed air into the opposite side hole, and confirm
that air does not come out from the end holes.
If necessary, replace the valve with the one having the same let-
ter as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F

R08702
Calipers
- STEERINGPOWER STEERING VANE PUMP
SR-29
1996 TERCEL (RM440U)
4. INSPECT COMPRESSION SPRING
Using calipers, measure the free length of the spring.
Minimum length: 36 - 38 mm (1.42 - 1.49 in.)
If it is not within the specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
NOTICE:
Place the shop rag, as shown, be careful not to damage the
bushing of the front housing.
(b) Coat a new oil seal lip with power steering fluid.
(c) Using a socket wrench (24 mm), press in the oil seal.
NOTICE:
Make sure you install the oil seal facing the correct direc-
tion.

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)