OEM 2003 Toyota RAV4 Power Steering Pump

2003 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the power steering pump on 2003 Toyota RAV4?

  A: Begin service and repair of the power steering pump by measuring its PS vane pump rotating torque while checking for smooth pump movement without abnormal noise until you reach a maximum torque value of 0.27 Nm (2.8 kgf-cm, 2.4 inch lbs). Start by unscrewing the suction port union bolt while removing its O-ring then proceed to remove the pressure port union together with flow control valve and spring as well as the O-ring from the pressure port union. After carefully removing the oil pressure switch that should be handled without dropping follow the process to separate the rear housing by unscrewing the 4 bolts and dislodging the O-ring. To start remove the cam ring followed by 10 vane plates and the vane pump rotor and then the side plate while preserving the vane plates from falling. Lastly remove the 2 O-rings from the side plate. Remove the vane pump shaft together with its attached vane pump pulley. The vane pump shaft and bushing oil clearance should be measured by a micrometer and caliper gauge until reaching the specified standard clearance range of 0.021 - 0.043 mm (0.0008 - 0.0017 inch) with a maximum allowance of 0.07 mm (0.0028 inch); a replacement front housing and vane pump shaft is necessary if the clearance exceeds these limits. To properly inspect the vane pump rotor and vane plates check their height, thickness, and length which must be at least 7.6 mm (0.299 inch) while measuring 1.405 mm (0.0553 inch) for both height and thickness and 11.993 mm (0.4722 inch) for length. The vane plate rotor groove clearance requirement is limited to 0.025 mm (0.0010 inch). The flow control valve requires coating with power steering fluid followed by a test for ease of fit into the hole and direct application of compressed air at 392 - 490 kPa (4 - 5 kgf/cm2, 57 - 71 psi) to check for leaks. If the end hole shows any leakage the technician should substitute the valve for one marked A, B, C, D, E, or F. Before replacing the spring the technician must measure its free length with vernier calipers ensuring the length is at least 36.9 mm (1.453 inch). Insert a new oil seal into the correct position by using Special Service Tool: 09950-60010 (09951-00280) / 09950-70010 (09951-07100) and coating its lip beforehand with power steering fluid. Reassemble the unit by applying power steering fluid to all indicated parts before placing the vane pump shaft with pulley then the side plate featuring the 2 new lubricated O-rings in proper alignment with the front housing. Position the cam ring so its inscribed mark points to the outside before placing the vane pump rotor which has its inscribed mark pointing outwards and secure it using a new snap ring. Place ten vane plates with rounded exterior sides facing outward before you apply power steering fluid to a new O-ring and install it to the rear housing while aligning its straight pin through the cam ring dents into both plates and the front housing using four bolts tightened at 22 Nm (220 kgf-cm, 16 ft. lbs.). The installation begins with the oil pressure switch getting tightened to 21 Nm (210 kgf-cm, 15 ft. lbs.) torque, then the spring and flow control valve position should match the correct orientation before installing the pressure port union with a new O-ring that received power steering fluid treatment and requiring a torque of 69 Nm (700 kgf-cm, 51 ft. lbs.). The process of installing the new O-ring includes damping it in fluid and then fitting it to the suction port union where team members should tighten the bolt to 12 Nm (120 kgf-cm, 9 ft. lbs.) before remeasuring the PS vane pump rotating torque.