OEM 2003 Toyota Avalon Power Steering Pump

2003 Toyota Avalon Parts Questions & Experts Answers

• Q: How to service and repair the power steering pump on 2003 Toyota Avalon?

  A: The PS vane pump should first undergo torque measurement followed by checks for smooth rotation and absence of abnormal noises before proceeding to effort and repair operations. Stop the vane pump pulley from rotation using Special Service Tool: 09960-10010 (09962-01000, 09963-01000) to loosen and remove the nut before taking off the pulley and nut from the vane pump shaft. Follow the procedure to remove the brackets by using a tool to extract 3 bolts and 2 nuts and then switch to removing the suction port union and its O-ring. The next step requires removal of the pressure port union, flow control valve, spring and O-ring from the pressure port union. The procedure requires laundering 4 bolts and 2 O-rings to detach the rear housing which exposes the wave washer, side plate, gasket, cam ring and 10 vane plates and vane pump rotor until all parts are retrieved without dropping any. Extract the vane pump shaft together with both straight pins from the front housing. The inspection of the bushing and vane pump shaft requires a micrometer and caliper gauge to verify the oil clearance falls between 0.03 and 0.05 mm (0.0012 to 0.0020 inch), keeping the maximum clearance below 0.07 mm (0.0028 inch). Check the height and thickness and length of the vane pump rotor along with vane plates against their minimum dimensions: height 8.6 mm (0.339 inch), thickness 1.397 mm (0.0550 inch), length 14.991 mm (0.5902 inch). Ensure that the measurement between the vane pump rotor groove and vane plate stays within the specified maximum limit of 0.035 mm (0.0014 inch). The flow control valve must be inspected with power steering fluid coating before inserting it seamlessly into the hole followed by compressed air pressure testing at 392 - 490 kPa (4 - 5 kgf/cm2, 57 - 71 psi). Assess the free length of the spring by using vernier calipers to confirm it exceeds 32.3 mm (1.272 inch). You must exchange the oil seal by first using a screwdriver with a vinyl tape layer to gently remove it while coating a fresh oil seal lip with power steering fluid and utilizing Special Service Tool: 09950-60010 (09951-00330) 09950-70010 (09951-07100) to install the new component correctly. Reassembly begins when all specified components receive a power steering fluid coating before installing two new straight pins using a plastic hammer and proceeding with the vane pump shaft followed by the cam ring facing outward yet the vane pump rotor facing outward with a new snap ring. Begin by fitting 10 vane plates that have their rounded side facing outwards and using a new gasket with the side plate oriented so its straight pins are properly aligned. The wave washer installation should be completed by inserting its protrusions into the side plate slots before power steering fluid treatment of two new O-rings and their placement onto the rear housing requires 4 bolts tightened to 17 Nm (170 kgf-cm, 12 ft. lbs.). Attach the spring and flow control valve with its proper orientation while mounting the pressure port union with a new O-ring and power steering fluid coating before tightening it to 83 Nm (850 kgf-cm, 62ft lbs. torque). The suction port union must be installed with a new O-ring and bolt which requires 13 Nm (130 kgf-cm, 9 ft. lbs.) torque and then the front and rear brackets must be secured by 3 bolts and 2 nuts torqued to 43 Nm (440 kgf-cm, 32 ft. lbs.). Use Special Service Tool: 09960-10010 (09962-01000, 09963-01000) to prevent pulley rotation before torquing the nut to 44 Nm (450 kgf-cm, 33 ft. lbs.). Finally, check the PS vane pump rotating torque measurement.