OEM 2004 Toyota Highlander Power Steering Pump

2004 Toyota Highlander Parts Questions & Experts Answers

• Q: How to overhaul the power steering pump on 2004 Toyota Highlander?

  A: Start the power steering pump overhaul by removing the front wheel on the right-hand side then drain the power steering fluid and remove the front fender apron seal on the right-hand side and the fan V belt together with the generator V belt using Special Service Tool: 09249-63010. Unclip the oil reservoir to pump hose No.1 while watching for fluid to avoid V belt contamination and then remove the pressure feed tube assembly by using a 27 mm wrench to hold the pressure port union while taking off the union bolt with its gasket. To proceed further disconnect the oil pressure switch connector then loosen bolt A by using Special Service Tool: 09249-63010 with a 14 mm deep socket wrench and finally separate bolt B and the vane pump assembly. Place the vane pump assembly under a vise controlled by Special Service Tool: 09630-00014 (09631-00132) then unlatch the power steering suction port union by removing its bolt together with O-ring until you completely remove both the suction port union and the flow control valve with its accompanying components. First remove the vane pump housing rear by taking out the four bolts along with its O-ring before you use two screwdrivers to remove the w/pulley shaft sub-assembly. After removing the vane pump rotor and cam ring together with the side plate front you must take out the O-rings from the front components before removing the housing oil seal with caution. Check the oil clearance between the vane pump shaft and bush in the housing front to be less than 0.07 mm (0.0028 in.) while examining the vane pump rotor and plates for proper thickness and clearance with replacement needed for the assembly. Measure the compression spring free length because an amount less than 30.3 mm (1.193 in.) requires replacement. If the pressure port union suffers any damage it should be replaced. The new housing oil seal must receive power steering fluid coating on its lip before installation via Special Service Tools 09950-60010 (09951-00280) and 09950-70010 (09951-07100). Avoid damages to the oil seal lip while carefully inserting the w/pulley shaft sub-assembly before installing side plate front and cam ring with attention to proper alignment. First install the vane pump rotor and plates and add the snap ring after which attach the housing rear portion using a new O-ring while torquing it to 22 Nm (224 kgf-cm, 16 ft-lbf). The service bolt needs installation after examining pump preload for regular rotation. The bolt should rotate with under 0.27 Nm torque (2.8 kgf-cm, 2.4 in.-lbf). Attach the pressure-equipped switch with a new O-ring before torquing it to 21 Nm (214 kgf-cm, 15 ft-lbf). Next install the flow control valve components before torquing its pressure port union to 69 Nm (704 kgf-cm, 51 ft-lbf). Start by installing the power steering suction port union with a new O-ring and then torquing it to 12 Nm (122 kgf-cm, 9 ft-lbf). Next, attach the vane pump assembly while tightening bolt A temporarily before torquing bolt B to 37 Nm (377 kgf-cm, 27 ft-lbf) and bolt A to 26 Nm (264 kgf-cm, 19 ft-lbf) using Special Service Tool: 09249-63010. Reconnect the oil reservoir to pump hose No.1 while installing the fan and generator V belt. The pressure feed tube assembly installation requires a new gasket that should be torqued to 52 Nm (525 kgf-cm, 38 ft-lbf). As the last step, the technician installs the front fender apron seal RH before torquing the front wheel RH to 103 Nm (1,050 kgf-cm, 76 ft-lbf) while bleeding power steering fluid before inspecting for leaks.