1996 TOYOTA TERCEL power steering fluid

SR0KM-03
SR-24
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
2. DISCONNECT PRESSURE FEED TUBE
Remove the union bolt and gasket.
3. REMOVE DRIVE BELT
Loosen the 2 pump assembly set bolts.
4. REMOVE PS VANE PUMP ASSEMBLY
Remove the 2 pump assembly set bolts.

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)

SR0L0-02
R10072
Dial Indicator
R11358
Cylinder Gauge
Micrometer
Bushing
R11357
BushingSST Steel
Plate
R11359
Brass Bar
Oil Seal
- STEERINGPOWER STEERING GEAR
SR-53
1996 TERCEL (RM440U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
Using a dial indicator, check the rack for runout and teeth wear
and damage.
Maximum runout: 0.30 mm (0.0118 in.)
2. MEASURE OIL CLEARANCE BETWEEN CONTROL
VALVE ASSEMBLY AND BUSHING
Using a micrometer and a cylinder gauge, measure the oil clear-
ance.
Standard clearance:
0.050 - 0.083 mm (0.00197 - 0.00327 in.)
Maximum clearance: 0.125 mm (0.00492 in.)
3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL
(a) Using SST and 2 steel plates, remove the bushing from
the rack housing.
SST 09612-65014 (09612-01030)
NOTICE:

As shown, from the opposite side of SST confirm that
its claw is firmly caught on the bushing.

Be careful not to damage the rack housing.
(b) Using a brass bar and a hammer, remove the oil seal from
the rack housing.
NOTICE:
Be careful not to damage the rack housing.
(c) Coat a new oil seal lip with power steering fluid.
(d) Using a socket wrench (24 mm), extension bar and ham-
mer, press in the oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.

R10955
R06172
Z06082
Z01716
SR-54
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
(e) Using a socket wrench (24 mm) and a extension bar, care-
fully press in a new bushing to a depth of 73 mm (2.87 in.).
NOTICE:
If the bushing is pushed in too far, it will cause deformation
of the rack housing. If it is not pushed in far enough, it will
interfere with the control valve assembly. Therefore, al-
ways use a press and install the bushing to the proper
depth. Then, install the control valve assembly and ensure
that it rotates smoothly.
4. IF NECESSARY, REPLACE TEFLON RING AND
O-RING
(a) Using a screwdriver, remove the teflon ring and O-ring
from the steering rack.
NOTICE:
Be careful not to damage the groove for the teflon ring.
(b) Coat a new O-ring with power steering fluid and install it.
(c) Expand a new teflon ring with your fingers.
NOTICE:
Be careful not to overexpand the ring.
(d) Coat the ring with power steering fluid.
(e) Install the ring to the steering rack and settle it down with
your fingers.
5. IF NECESSARY, REPLACE TEFLON RINGS
(a) Using a screwdriver, remove the 4 rings from the control
valve assembly.
NOTICE:
Be careful not to damage the grooves for the ring.
(b) Expand 4 new teflon rings with your fingers.
NOTICE:
Be careful not to overexpand the ring.

F05317
SST
- STEERINGPOWER STEERING GEAR
SR-55
1996 TERCEL (RM440U)
(c) Coat the rings with power steering fluid and install them
to the control valve, and settle them down with your fin-
gers.
(d) Carefully slide the tapered end of SST over the rings until
the rings fit to the control valve assembly.
SST 09631-20081
NOTICE:
Be careful not to damage the rings.