Vane Pump ASSY: Overhaul

1. Remove the 2 bolts and the air cleaner inlet No.1.

1. Loosen the throttle body side clamp.
2. Disconnect the intake air connector pipe from the throttle body.

1. Disconnect the air flow meter connector from the air cleaner assy.
2. Remove the 2 bolts and air cleaner assy with the intake air connector pipe.
   Fig 1: Removing Fan And Generator V Belt

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1. Put a wrench on the drive belt tensioner set bolt.
2. Turn the drive belt tensioner set bolt counterclockwise and hold it.
   NOTE:

   • The drive belt tensioner set bolt is a left-hand screw.
   • The drive belt tensioner set bolt comes loose when turning it clockwise.
3. Remove the fan and generator V belt.
4. Release the drive belt tensioner.

1. Using pliers, disengage the vane pump side hose clip and slide it.
2. Disconnect the oil reservoir to vane pump hose from the vane pump.

1. Remove the 3 bolts and 3 clamps.
2. Disconnect the vacuum hoses from the vacuum switch.
3. Using pliers, disengage the vacuum hose clips and slide them to disconnect the vacuum hoses.
4. Put a wrench on the pressure feed tube hose side to hold it.
5. Put SST on the flare nut as shown in the illustration on the left.

   SST 09023-12700

6. Joint a spinner handle to the SST.

   HINT:

   Use an extension bar or universal joint according to the situation.

7. Loosen and disconnect the pressure feed tube.
   Fig 2: Attaching SST

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1. Remove the nut and 2 bolts.
2. Remove the vane pump assy with the pressure feed tube assy.

1. Remove the union bolt and gasket.
2. Remove the pressure feed tube assy from the vane pump assy.

1. Remove the 3 bolts and the vane pump bracket from the vane pump assy.

1. Using SST, hold the vane pump assy in a vice.

   SST 09630-00014 (09631-00132)

   HINT:

   Detach SST according to the situation.

   Fig 3: Holding Vane Pump Assy In Vice

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1. Remove the bolt and the suction port union from the vane pump housing front.
2. Using a small screwdriver, remove the O-ring from the suction port union.
   NOTE: Be careful not to damage the suction port union.

1. Using a socket wrench (27 mm), remove the pressure port union.
2. Using a small screwdriver, remove the O-ring from the pressure port union.
   NOTE: Be careful not to damage the pressure port union.
3. Remove the flow control valve and spring.
   Fig 4: Removing Flow Control Valve

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1. Remove the 4 bolts and the vane pump housing rear from the vane pump housing front.
2. Remove the O-ring from the vane pump housing rear.
   Fig 5: Removing Bolts Vane Pump Housing

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1. Using 2 small screwdrivers, remove the snap ring from the w/pulley shaft sub-assy.
2. Remove the w/pulley shaft sub-assy from the vane pump housing front.

Fig 6: Removing Snap Ring From W/Pulley Shaft Sub-Assy

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1. Remove the 10 vane pump plates.
2. Remove the vane pump rotor.

1. Remove the vane pump side plate front from the vane pump housing front.
2. Remove the O-ring from the vane pump side plate front.
   Fig 7: Removing Vane Pump Side Plate Front

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3. Remove the O-ring from the vane pump housing front.
   Fig 8: Removing O-Ring From Vane Pump Housing Front

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1. Using a screwdriver and shop rag, remove the vane pump housing oil seal from the vane pump housing front.

Fig 9: Removing Vane Pump Housing Oil Seal

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1. Using a micrometer and a vernier calipers, measure the oil clearance.

   Standard clearance: Less than 0.07 mm (0.0028 in.) 

   If the bushing or shaft is damaged, replace the vane pump assy. If the oil clearance exceeds the standard, replace the vane pump assy.

   Fig 10: Measuring Oil Clearance

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1. Using a micrometer, measure the thickness of the vane pump plates.

   Standard thickness: 

   1.405 to 1.411 mm (0.05531 to 0.05555 in.) 

   If the thickness is less than the standard, replace the vane pump assy.

   Fig 11: Measuring Thickness Of Vane Pump Plates

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2. Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and the vane pump plate.

   Standard clearance: Less than 0.03 mm (0.0012 in.) 

   If the clearance exceeds the standard, replace the vane pump assy.

   Fig 12: Measuring Clearance Between Side Face Of Vane Pump Rotor Groove And Vane Pump Plate

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1. Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole under its own weight.

   If it is not smooth, replace the vane pump assy.

   Fig 13: Inspecting Flow Control Valve

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2. Check the flow control valve for leakage. Close hole 'a', apply compressed air into hole 'b', and confirm that air does not come out from holes 'c' and 'd'.

   If air leaks from holes 'c' and 'd', replace the vane pump assy.

   Fig 14: Checking Flow Control Valve For Leakage

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1. Using vernier calipers, measure the free length of the compression spring.

   Minimum free length: 30.3 mm (1.193 in.) 

   If the free length is less than the minimum, replace the vane pump assy.

   Fig 15: Measuring Free Length Of Compression Spring

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If the union seat in the pressure port union is severely damaged, it may cause fluid leakage. In that case, replace the vane pump assy.

Fig 16: Installing Vane Pump Housing Oil Seal

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1. Apply power steering fluid to the new vane pump housing oil seal lip.
2. Using SST and a press, install the vane pump housing oil seal.

   SST 09950-60010 (09951-00280), 09950-70010 (09950-07100)

1. Coat the bushing surface of the vane pump housing front with power steering fluid.
2. Gradually insert the w/pulley shaft sub-assy.

HINT:

Wrap the shaft surface with vinyl tape before inserting.

Fig 17: Applying Vinyl Tape On Pulley Shaft

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1. Coat a new O-ring (bigger one) with power steering fluid and install it to the vane pump housing front.
   Fig 18: Installing O-Ring

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2. Coat a new O-ring (smaller one) with power steering fluid and install it to the vane pump side plate front.
   Fig 19: Installing O-Ring

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3. Align the dent of the vane pump side plate front with that of the vane pump housing front to install.

Fig 20: Aligning Dent Of Vane Pump Side Plate Front

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1. Align the dent of the vane pump cam ring with that of the vane pump side plate front, and install the vane pump cam ring with the inscribed mark facing upward (the vane pump housing rear side).

Fig 21: Aligning Dent Of Vane Pump Cam Ring With Vane Pump Side Plate Front

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1. Install the vane pump rotor.

   HINT:

   The vane pump rotor has no specific direction.

   Fig 22: Installing Vane Pump Rotor

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2. Coat the 10 vane pump plates with power steering fluid.
3. Install the vane pump plates.

Fig 23: Installing Vane Pump Plates

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1. Using a small screwdriver and a snap ring expander, install a new snap ring to the w/pulley shaft sub-assy.

Fig 24: Installing New Snap Ring To W/Pulley Shaft Sub-Assy

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1. Coat a new O-ring with power steering fluid and install it to the vane pump housing rear.
2. Align the straight pin of the vane pump housing rear with the dents of the vane pump cam ring and vane pump side plate front.
3. Install the vane pump housing rear to the vane pump housing front.
4. Tighten the 4 bolts.

   Torque: 22 N.m (225 kgf.cm, 16 ft.lbf) 

Fig 25: Installing Vane Pump Housing Rear

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1. Hold the vane pump assy in a vice.
2. Check that the pump rotates smoothly without abnormal noise.
3. Temporarily install the service bolt.

   Recommend service bolt: (9111-51050) 

   Thread diameter: 10 mm (0.39 in.) 

   Thread pitch: 1.25 mm (0.0492 in.) 

   Bolt length: 50 mm (1.97 in.) 

4. Using a torque wrench, check the pump rotating torque.

   Rotating torque: 

   0.27 N.m (2.8 kgf.cm, 2.4 in. lbf or less 

If the rotating torque is not as specified above, check installation of the vane pump housing oil seal.

Fig 26: Installing Service Bolt

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1. Coat the spring and the flow control valve with power steering fluid.
2. Install the spring and the flow control valve in the correct direction as shown in the illustration.
3. Coat a new O-ring with power steering fluid and install it to the pressure port union.
4. Install the pressure port union to the vane pump housing front.

   Torque: 69 N.m (705 kgf.cm, 51 ft.lbf) 

Fig 27: Installing Flow Control Valve

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1. Coat a new O-ring with power steering fluid and install it to the suction port union.
2. Install the suction port union with the bolt to the vane pump housing front.

   Torque: 12 N.m (125 kgf.cm, 9 ft.lbf) 

1. Install the vane pump bracket with the 3 bolts.

   Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) 

1. Install the pressure feed tube assy and a new gasket to the vane pump assy with the union bolt.

   Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

HINT:

Make sure that the stopper of the pressure feed tube touches the vane pump housing front as shown in the illustration, then install the union bolt.

Fig 28: Installing Pressure Feed Tube Assy

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1. Install the vane pump assy together with the pressure feed tube assy with the nut and 2 bolts.

   Torque: 

   Nut: 43 N.m (440 kgf.cm, 32 ft.lbf) 

   Bolt: 39 N.m (400 kgf.cm, 29 ft.lbf) 

1. Connect the pressure feed tube.
2. Put a wrench on the pressure feed tube hose side to hold it.
3. Put SST on the flare nut as shown in the illustration on the left.

   SST 09023-12700

4. Using a torque wrench, tighten the flare nut.

   Torque: 40 N.m (410 kgf.cm, 30 ft.lbf) 

   HINT:

   • Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
   • This torque value is effective when SST is parallel to the torque wrench.
5. Install the 3 clips and the 3 bolts.
6. Connect the vacuum hoses to the vacuum switch.
7. Using pliers, engage the vacuum hose clips.

Fig 29: Attaching SST

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1. Connect the oil reservoir to vane pump hose.
2. Using pliers, engage the hose clip.

1. Put a wrench on the drive belt tensioner set bolt.
2. Turn the drive belt tensioner set bolt counterclockwise and hold it.
   NOTE:

   • The drive belt tensioner set bolt is a left-hand screw.
   • The drive belt tensioner set bolt comes loose when turning it clockwise.
   Fig 30: Tightening Drive Belt Tensioner Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the fan and generator V belt.
4. Release the drive belt tensioner.

HINT:

The drive belt tensioner is an auto tensioner.

Fig 31: Identifying Correct And Wrong Condition Of Belt

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1. Install the air cleaner assy together with the intake air connector pipe with the 2 bolts.
2. Connect the air flow meter connector to the air cleaner assy.

1. Connect the intake air connector pipe to the throttle body.
2. Tighten the clamp to hold the intake air connector pipe and the throttle body.

1. Install the air cleaner inlet No. 1 with the 2 bolts.

If any leakage is found on the power steering system, repair or replace the related parts.