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Toyota RAV4 1999 Manual
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Toyota RAV4 1999 Manual

Toyota RAV4 1999 Manual

1999-2000 steering power rack & pinion - trucks
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DESCRIPTION & OPERATION
System consists of a rack and pinion assembly, hydraulic power steering pump, hoses and control valves. On
some models an air control valve is used to increase idle speed when power steering pump is under load.
LUBRICATION
FLUID TYPE
Use Dexron-II or Dexron-III ATF fluid.
FLUID LEVEL CHECK
When fluid is at normal operating temperature, fluid level should be between HOT marks on fluid reservoir.
When fluid is cold, fluid level should be between COLD marks on fluid reservoir. Add as necessary.
HYDRAULIC SYSTEM BLEEDING
1. With engine off, check fluid level in power steering pump reservoir. See FLUID LEVEL CHECK .
Raise and support vehicle. Turn wheels fully in both directions. Lower vehicle. Start engine and run at
idle.
2. Turn wheels fully to lock in one direction. Hold for a few seconds. Turn wheels fully to opposite lock.
Hold for a few seconds. Repeat process several times.
3. Check fluid. If there is no evidence of excess bubbles or foaming, bleeding is complete. If not, repeat
process until no bubbling is evident. Adjust fluid level as necessary.
ADJUSTMENTS
POWER STEERING PUMP BELT
Using belt tension gauge, measure belt tension. See BELT TENSION SPECIFICATIONS table.
BELT TENSION SPECIFICATIONS
(1)
Application
RAV4
New
(2)
Used
Sienna
New
(2)
Used
1999 Toyota RAV4
1999 Toyota RAV4
1999-2000 STEERING Power Rack & Pinion - Trucks
1999-2000 STEERING Power Rack & Pinion - Trucks
1999-2000 STEERING
Power Rack & Pinion - Trucks
Lbs. (kg)
95-145 (43-66)
60-100 (27-45)
150-185 (68-84)
95-135 (43-61)

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Summary of Contents for Toyota RAV4 1999

  • Page 1 1999 Toyota RAV4 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks 1999-2000 STEERING Power Rack & Pinion - Trucks 1999-2000 STEERING Power Rack & Pinion - Trucks DESCRIPTION & OPERATION System consists of a rack and pinion assembly, hydraulic power steering pump, hoses and control valves. On some models an air control valve is used to increase idle speed when power steering pump is under load.
  • Page 2 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Tacoma, Tundra & 4Runner 135-180 (61-82) 85-120 (39-54) Used Land Cruiser uses automatic belt tensioner. Belt is used if it has been in operation for longer than 5 minutes.

  • Page 3: Removal And Installation

    1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks and measure turning force. See STEERING EFFORT SPECIFICATIONS table. Repair or replace power steering pump if force exceeds specifications. STEERING EFFORT SPECIFICATIONS Application INCH Lbs. (N.m) RAV4 & Sienna 52 (5.9)
  • Page 4 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 1: Identifying Components For Removal Of Power Steering Pump & Gear (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Removal (Sienna)
  • Page 5 3. Remove oil pressure switch from union bolt. Remove union bolt and gasket. Remove pressure feed line. Fig. 2: Locating & Loosening Hidden Bolt Located Behind Power Steering Pump Drive Pulley (Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Removal (Tacoma & 4Runner 4-Cylinder) 1.
  • Page 6 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks 1. Remove air cleaner assembly. Disconnect and plug return hose. Use drain pan to catch power steering fluid when connections are released. 2. Disconnect oil pressure switch connector. Remove oil pressure switch from pressure feed line. Remove union bolt and gaskets.
  • Page 7 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks SUSPENSION. Remove front exhaust pipe. Remove stabilizer bar with link. 3. Disconnect lower steering column shaft from steering gear. Disconnect pressure and return lines from steering gear. Remove line clamps.
  • Page 8 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks To install, reverse removal procedure. After installation, place front wheels in straight-ahead position. Center steering wheel spiral cable, then install steering wheel and pad. Check front wheel alignment. Removal (Tundra) 1.
  • Page 9 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks 5. Remove rear housing snap ring. Wrap tape on serrated part of pump shaft. Using soft-face hammer, tap out rear housing, washer and side rear plate. Remove "O" rings.
  • Page 10 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks...
  • Page 11 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Inspection 1. Using micrometer, measure diameter of pump shaft. Using calipers, measure diameter or pump housing shaft bushing. Determine amount of clearance. Clearance should be .0012-.0020" (.030-.050 mm).
  • Page 12 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks 5. Coat a NEW "O" ring with power steering fluid. Install "O" ring into pump rear housing. Using soft-face hammer, tap rear housing to front housing. Install NEW snap ring.
  • Page 13 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 4: Exploded View Of Power Steering Pump (Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Inspection...
  • Page 14 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks 1. Using micrometer, measure diameter of pump shaft. Using calipers, measure diameter or pump housing shaft bushing. Determine amount of clearance. Clearance should be .0012-.0020" (.030-.050 mm). Clearance should not exceed .0028" (.071 mm). If clearance exceeds maximum specification, replace front housing and pump shaft.
  • Page 15 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks 3. Remove union bolt and "O" ring from pressure port. Remove flow control valve and spring. See Fig. 5 . Remove pump bracket. 4. Remove rear housing bolts and 2 "O" rings. Remove wave washer, side plate and gasket.
  • Page 16 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 5: Exploded View Of Power Steering Pump (Tacoma & 4Runner 4-Cylinder) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Inspection...
  • Page 17 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks 1. Using micrometer, measure diameter of pump shaft. Using calipers, measure diameter or pump housing shaft bushing. Determine amount of clearance. Clearance should be .0012-.0020" (.030-.050 mm). Clearance should not exceed .0028" (.071 mm). If clearance exceeds maximum specification, replace front housing and pump shaft.
  • Page 18 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks pump rotating torque. Rotating torque should be 2.4 INCH lbs. (.3 N.m) or less. 2. While holding pulley, remove pulley nut. Remove fluid reservoir. Remove and discard "O" ring.
  • Page 19 Fig. 6: Exploded View Of Power Steering Pump (Tacoma & 4Runner V6 Shown; Land Cruiser & Tundra Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Inspection 1. Using micrometer, measure diameter of pump shaft. Using calipers, measure diameter or pump housing...
  • Page 20 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks shaft bushing. Determine amount of clearance. Clearance should be .0012-.0020" (.030-.050 mm). Clearance should not exceed .0028" (.071 mm). If clearance exceeds maximum, replace front housing and pump shaft.
  • Page 21 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks 1. Secure rack and pinion housing in soft-jaw vise (DO NOT over-tighten vise). Remove 2 turn pressure tube union bolts, gaskets and tubes. See Fig. 7 . 2. Place reference marks on tie rod end and rack end. Loosen lock nut. Remove screw and loosen clamp.
  • Page 22 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 7: Exploded View Of Power Rack & Pinion Steering Gear Assembly (RAV4 - 1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  • Page 23 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 8: Exploded View Of Power Rack & Pinion Steering Gear Assembly (RAV4 - 2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  • Page 24 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Inspection 1. With rack mounted horizontally on "V" blocks, use dial indicator to measure rack runout. Runout should not exceed .012" (.3 mm). Check rack and teeth for wear and damage. Replace rack if necessary.
  • Page 25 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 9: Performing Air Tightness Check Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Coat Teflon rings with power steering fluid. Install control valve assembly into rack housing. Press NEW bearing into place on top of control valve. Press NEW oil seal into place after coating lip with power steering fluid.
  • Page 26 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 10: Installing & Setting Control Valve Lock Nut (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Apply thread lock sealant to 2-3 threads of rack housing cap. Install and tighten cap to specification. See TORQUE SPECIFICATIONS .
  • Page 27 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 11: Setting Assembly Preload (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. Apply thread lock sealant to rack guide spring cap lock nut. Using 21-mm wrench to hold spring cap from rotating, use torque wrench to tighten lock nut to specification.
  • Page 28 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks NOTE: When removing oil seals, be sure to note direction seals are facing for reinstallation in same direction. 1. Secure rack and pinion housing in soft-jaw vise (DO NOT over-tighten vise). Remove 2 turn pressure tubes and "O"...
  • Page 29 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 12: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Sienna - 1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  • Page 30 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 13: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Sienna - 2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  • Page 31 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 14: Removing Cylinder End Stopper (Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Using brass bar and hammer, tap rack and bushing out of housing. Remove bushing from rack. Remove "O"...
  • Page 32 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks accommodate installation. Coat Teflon ring with power steering fluid. Press ring firmly into rack groove. 7. If necessary, use screwdriver to remove 4 Teflon rings from control valve assembly. Coat NEW rings with power steering fluid.
  • Page 33 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks 15. Ensure steering rack hole (next to rack end) is not clogged with grease. Clean as necessary. Install boots and clamps. Pinch clamps until there is .08" (2.0 mm), or less, clearance between clamp ends.
  • Page 34 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 15: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Tacoma 2WD - 1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  • Page 35 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks...
  • Page 36 1999-2000 STEERING Power Rack & Pinion - Trucks Fig. 16: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Tacoma 2WD - 2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Inspection 1. With rack mounted horizontally on "V" blocks, use dial indicator to measure rack runout. Runout should not exceed .012"...
  • Page 37 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks with power steering fluid. 7. Place NEW gasket on rack housing. Position control valve housing. Install and tighten mounting bolt. See TORQUE SPECIFICATIONS . Hold control valve shaft from turning, and install NEW self-locking nut on lower end of shaft.
  • Page 38 8. Position rack housing vertically, and press oil seal and spacer from housing. See Fig. 18 . Fig. 17: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Tacoma 4WD & 4Runner Shown; Land Cruiser & Tundra Are Similar - 1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  • Page 39 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks...
  • Page 40 Fig. 18: Exploded View Of Power Rack & Pinion Steering Gear Assembly (Tacoma 4WD & 4Runner Shown; Land Cruiser & Tundra Are Similar - 2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Inspection 1. With rack mounted horizontally on "V" blocks, use dial indicator to measure rack runout. Runout should not exceed .012"...

  • Page 41: Torque Specifications

    1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks shaft with tape. Push control valve assembly into housing. Coat NEW "O" ring with power steering fluid and install into bearing guide nut. Install and tighten nut. See TORQUE SPECIFICATIONS . Stake guide nut.
  • Page 42 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Rack End 56 (76) Rack Guide Spring Cap Lock Nut 51 (69) Tie Rod End Lock Nuts 41 (56) Tie Rod End Nuts 53 (72) TORQUE SPECIFICATIONS (RAV4) Application Ft.
  • Page 43 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Power Steering Pump Air Control Valve 27 (37) Front Bracket Bolts 32 (43) Mounting & Adjusting Bolts 32 (43) Pressure Port Union 62 (84) Pulley Nut 32 (43) Rear Housing Bolts...
  • Page 44 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Rear Housing Bolts 17 (23) Reservoir Mounting Bolts Front Rear 17 (23) Pressure Feed Tube-To-Pump Union Bolt 34 (46) Rack & Pinion Assembly Mounting Bolts/Nuts 148 (201) Control Valve Housing-To-Rack Housing Bolts...
  • Page 45 1999 Toyota RAV4 1999-2000 STEERING Power Rack & Pinion - Trucks Cylinder End Stopper 58 (79) Rack End 56 (76) Rack Guide Spring Cap Lock Nut 51 (69) Rack Housing Bracket Bolt/Nut 123 (167) Tie Rod End Lock Nuts 41 (56)