Air Injection System: Overhaul: Disassembly

To replace relief valve, remove valve with suitable puller (09297-60010). When installing, position new relief valve on pump housing and hold relief valve replacer (09296-60010) on the relief valve. Tap with hammer until valve is seated.
Mount pump in suitable holding fixture (09293-60010).
CAUTION: Do not mount pump housing in vise.

With pulley side down, drive out dowels toward pulley. Remove housing cover attaching bolts and cover, by tapping lightly with plastic hammer.

Fig 1: Relief Valve Removal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Using suitable tool (09298-60010) to hold pulley, remove rotor ring screws. Remove rear rotor ring and bearing assembly, remove rear carbon seal. Remove vane assembly. Remove carbon shoes and springs.

Fig 2: Air Injection Pump (Exploded View)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
To replace bearing in rotor ring, position rotor ring on press with bearing part number facing upward. Using suitable tool (09295-66010) press out bearing.

Fig 3: Rear Rotor Ring Removal
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
To replace pulley, straighten lock washer tab. Remove lock nut. Using suitable puller remove pulley.
NOTE: Lock nut is left hand thread.

Further disassembly of rotor from pump housing is not recommended. If any component of rotor housing requires replacement, entire housing must be replaced.