OEM 2002 Toyota Avalon Power Steering Pump

2002 Toyota Avalon Power Steering Pump Parts Q&A

• Q: How to service and repair the power steering pump on 2002 Toyota Avalon?

  A: Initiate power steering pump service and repair operations by first checking the PS vane pump rotating torque until it rotates with normal sounds without exceeding 0.3 Nm (2.8 kgf-cm, 2.4 inch lbs.). Use Special Service Tool: 09960-10010 (09962-01000, 09963-01000) to stop vane pump pulley rotation before untightening and removing the nut and pulley attached to the pump shaft. After disconnecting 3 bolts and 2 nuts from the front and rear brackets you can take out the suction port union and its O-ring. Remove the pressure port union together with its flow control valve and spring as well as its O-ring before continuing. The maintenance process begins with removing the rear housing through 4 bolts and two O-rings until you can access the wave washer together with the side plate and gasket and cam ring and ten vane plates and vane pump rotor while being cautious about drops from the plates. Take out the vane pump shaft together with its two straight pins from the front housing. Use a micrometer and caliper gauge to check vane pump shaft and bushing oil clearance before inspection. The measurement should fall within 0.03 - 0.05 mm (0.0012 - 0.0020 inch) nighttime standards but never exceed 0.07 mm (0.0028 inch). The height of vane pump rotor parts and vane plates must be 8.6 mm (0.339 inch) and their thickness must be 1.397 mm (0.0550 inch) while their length must be at minimum 14.991 mm (0.5902 inch). The vane pump clearance measurement between rotor groove and vane plate requires monitoring to be less than the maximum threshold of 0.035 mm (0.0014 inch). Power steering fluid coating on the flow control valve should be checked for smooth operation and leakage under compressed air pressure of 392 - 490 kPa (4 - 5 kgf/cm2, 57 - 71 psi) to confirm no air leaks from the end holes. Measuring the free length of the spring requires vernier calipers which should be at least 32.3 mm (1.272 inch). Carefully use this method to replace the oil seal with a screwdriver wrapped in vinyl tape and coat its lip with power steering fluid while using Special Service Tool: 09950-60010 (09951-00330), 09950-70010 (09951-07100) to install the new lip properly. To reassemble the system use power steering fluid for coating the indicated parts before inserting two new straight pins with the assistance of a plastic hammer and installing the vane pump shaft followed by the cam ring and vane pump rotor both facing outward and completing the installation with a new snap ring. Place the rounded side of the 10 vane plates toward the outside while using a new gasket and ensuring the side plate lines up with the straight pins. Add the wave washer by fitting its protrusions to the side plate slots and follow by coating two new O-rings with power steering fluid and installing them to the rear housing and tightening the 4 bolts to 17 Nm (170 kgf-cm, 12 ft. lbs.). Place the spring into position along with the flow control valve in the correct direction and a new O-ring wetted with power steering fluid on the pressure port union and fasten it with 83 Nm torque (850 kgf-cm or 62 ft. lbs). Begin by installing the suction port union with its new O-ring at 13 Nm (130 kgf-cm, 9 ft. lbs.) torque rating and proceeding to fasten the front and rear brackets using both three bolts and two nuts at 43 Nm (440 kgf-cm, 32 ft. lbs. torque rating. After stopping the pulley rotation with Special Service Tool 09960-10010 (09962-01000, 09963-01000), torque the nut to 44 Nm (450 kgf-cm, 33 ft. lbs.) while measuring the PS vane pump rotating torque again.