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Toyota T100 1996, Service Manual, Page: 382 / 2062

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Page: 382 / 2062

Toyota T100 1996 Service Manual Download Page 382

A00650

EFI Relay

EFI

AM2

AM1

ALT

Battery

IG Switch

IG

ST

IGN

Park/Neutral

Position Switch

(A/T)

Starter

Relay

Clutch

Start

Switch

(M/T)

Starter

Circuit Opening Relay

L2

L1

Fuel Pump

ECM

FC

Tr

STA

NE

(STA Signal)

(NE Signal)

From

Crankshaft

Position

Sensor

DI

−

118

−

DIAGNOSTICS

ENGINE (3RZ

−

FE)

1996 TOYOTA T100 (RM449U)

Fuel Pump Control Circuit

CIRCUIT DESCRIPTION

In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to
the starter relay coil, the starter relay switches on and current flows to coil L1 of the circuit opening relay.
Thus the circuit opening relay switches on, power is supplied to the fuel pump and the fuel pump operates.
When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil L2 of the circuit
opening relay, the relay witches on and the fuel pump operates.
While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the
fuel pump also keeps operating.

DI0U8

−

03

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Summary of Contents for T100 1996

Page 1: ...1996 TOYOTA T100 Factory Service Manual...

Page 2: ...5VZ FE CO Cooling 3RZ FE Cooling 5VZ FE LU Lubrication 3RZ FE Lubrication 5VZ FE IG Ignition 3RZ FE Ignition 5VZ FE ST Starting 3RZ FE Starting 5VZ FE CH Charging 3RZ FE Charging 5VZ FE CL Clutch MT M...

Page 3: ...IN INTRODUCTION HOW TO USE THIS MANUAL IN 1 IDENTIFICATION INFORMATION IN 3 REPAIR INSTRUCTIONS IN 4 FOR ALL OF VEHICLES IN 9 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN 15 TERMS IN 31...

Page 4: ...eginning of each section a PRECAUTION is given that pertains to all repair operations contained in that section Read these precautions before starting any repair task 3 TROUBLESHOOTING TROUBLESHOOTING...

Page 5: ...can be read at a glance when necessary and the text below it provides detailed informa tion Important specifications and warnings always stand out in bold type 6 REFERENCES References have been kept t...

Page 6: ...INE SERIAL NUMBER 1 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label as shown in the illustration A Vehicle...

Page 7: ...cable ends with a clean shop rag Do not scrape them with a file or oth er abrasive objects 5 Install the cable ends to the battery terminals with the nut loose and tighten the nut after installation...

Page 8: ...cessary use a sealer on gaskets to prevent leaks h Carefully observe all specifications for bolt tightening torques Always use a torque wrench i Use of special service tools SST and special service ma...

Page 9: ...sconnect vacuum hoses pull off the end not the middle of the hose 3 To pull apart electrical connectors pull on the con nector itself not the wires 4 Be careful not to drop electrical components such...

Page 10: ...less otherwise stated all resistance is measured at an ambient temperature of 20 C 68 F Because the resis tance may be outside specifications if measured at high temperatures immediately after the veh...

Page 11: ...23 2WD 4WD JACK POSITION SUPPORT POSITION Front Center of crossmember Rear Under the rear differential Safety stand IN 8 INTRODUCTION REPAIR INSTRUCTIONS 1996 TOYOTA T100 RM449U VEHICLE LIFT AND SUPPO...

Page 12: ...ble codes become the most important source of information when troubleshooting When troubleshooting the supplemental restraint system always inspect the diagnostic trouble codes before disconnecting t...

Page 13: ...m for troubleshooting of the electrical cir cuit 10 Information labels are attached to the periphery of the SRS components Follow the instructions on the notices 11 After work on the supplemental rest...

Page 14: ...9U d SPIRAL CABLE in Combination Switch The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position other wise cable disconnection and other troubl...

Page 15: ...dent if the airbag inflates for some reason 2 Never measure the resistance of the airbag squib This may cause the airbag to deploy which is very dangerous 3 Grease should not be applied to the steerin...

Page 16: ...re encased in a yellow corrugated tube All the connectors for the system are also a standard yellow color If the SRS wire harness be comes disconnected or the connector becomes broken due to an accide...

Page 17: ...ors of the vehicle s electronic system 2 Install the antenna feeder at least 20 cm 7 87 in away from the ECU and sensors of the ve hicle s electronics systems For details about ECU and sensors locatio...

Page 18: ...t ing of these systems is not complex If you have adequate understanding of the system and a basic knowl edge of electricity accurate diagnosis and necessary repair can be performed to locate and fix...

Page 19: ...h should be checked using the diagnostic trouble code chart or the matrix chart of problem symptoms 4 5 6 Check and repair the affected system or part in accordance with the instructions in Step 6 7 A...

Page 20: ...ter accelerator pedal released During A C operation Shifting from N to D Other Datas Problem Constant Sometimes times per day month Inspector s Name CUSTOMER PROBLEM ANALYSIS CHECK INTRODUCTION HOW TO...

Page 21: ...chnician during troubleshooting Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly By using these check functions the problem ar...

Page 22: ...agnostic trouble code was displayed in the initial diagnostic trouble code check it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past Therefore ch...

Page 23: ...blem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere which will only lead to a standstill For example for a problem which only occurs whe...

Page 24: ...ical load is excessive When the malfunction seems to occur on a rainy day or in a high humidity condition Heat the component that is the likely cause of the malfunction with a hair dryer or similar ob...

Page 25: ...fficient Coolant Temp for Closed D Engine coolant temp sensor D Cooling system Engine Coolant Temp Circuit Malfunction D Open or short in throttle position sensor circuit D Throttle position sensor D...

Page 26: ...oes not start 1 Starter and starter relay 1 ECM power source circuit 2 Fuel pump control circuit 3 Engine control module ECM 1 Starter signal circuit 2 Fuel pump control circuit 1 Fuel pump control ci...

Page 27: ...l safe function in which the corrective retard angle value is set to the maximum value D Diagnostic Trouble Code No and Detection Item D Circuit Description The major role and operation etc of the cir...

Page 28: ...nnector back side with harness Ignition Switch LOCK OFF Ignition Switch START LOCK Ignition Switch ON Ignition Switch ACC START ON ACC D Inspection Procedure D Indicates the place to check the voltage...

Page 29: ...low the procedure outlined below whenever these instructions appear OPEN CIRCUIT This could be due to and a disconnected wire harness faulty contact in the connector a connector terminal pulled out et...

Page 30: ...T CIRCUIT CHECK a Disconnect the connectors on both ends b Measure the resistance between the applicable terminals of the connectors and body ground Be sure to carry out this check on the connectors o...

Page 31: ...oltage Check to locate the section a Check the continuity 1 Disconnect connectors A and C and measure the resistance between them In the case of Fig 2 Between terminal 1 of connector A and terminal 1...

Page 32: ...etween Terminal 1 of connector A and Body Ground 5V Between Terminal 1 of connector B and Body Ground 0V Between Terminal 1 of connector C and Body Ground Then it is found out that there is an open ci...

Page 33: ...nal 1 of connector B2 and body ground Continuity short Therefore it is found out that there is a short circuit between terminal 1 of connector B2 and terminal 1 of connector C 8 CHECK AND REPLACE ECU...

Page 34: ...king Retractor ESA Electronic Spark Advance EX Exhaust Manifold Valve FIPG Formed in Place Gasket FL Fusible Link FPU Fuel Pressure Up Fr Front IG Ignition IN Intake Manifold Valve J B Junction Block...

Page 35: ...hor Date 1996 TOYOTA T100 RM449U T M Transmission U S Undersize VCV Vacuum Control Valve VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve w With w o Without 2WD Two Wheel Drive Vehicles 4x2 4W...

Page 36: ...ector 2 Data Link Connector 3 1 Check Connector 2 Total Diagnosis Comunication Link TDCL 3 OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode ECL Engine C...

Page 37: ...ry O2S Oxygen Sensor Oxygen Sensor O2 Sensor O2S OBD On Board Diagnostic On Board Diagnostic OBD OC Oxidation Catalytic Converter Oxidation Catalyst Converter OC CCo OP Open Loop Open Loop PAIR Pulsed...

Page 38: ...Vacuum Switching Valve TVSV TWC Three Way Catalytic Converter Three Way Catalytic TWC CCRO TWC OC Three Way Oxidation Catalytic Converter CCR CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulat...

Page 39: ...MA MAINTENANCE OUTSIDE VEHICLE MA 1 INSIDE VEHICLE MA 2 UNDER HOOD MA 4 ENGINE MA 5 BRAKE MA 7 CHASSIS MA 8...

Page 40: ...the odometer reading miles or the time interval months S Maintenance service after the last period should be performed at the same interval as before unless otherwise noted S Failure to do even one it...

Page 41: ...nd increase exhaust emissions 2 LIGHTS a Check that the headlights stop lights taillights turn signal lights and other lights are all working b Check the headlight aim 3 WARNING LIGHTS AND BUZZERS Che...

Page 42: ...e proper reserve distance and freeplay c Check the brake booster function 16 BRAKES At a safe place check that the brakes do not pull to one side when applied 17 PARKING BRAKE See page BR 8 a Check th...

Page 43: ...ectrolyte level of all battery cells is between the upper and lower level lines on the case 6 BRAKE AND CLUTCH FLUID LEVELS Check that the brake and clutch fluid levels are near the upper level line o...

Page 44: ...r element is not exces sively dirty damaged or oily HINT Oiliness may indicate a stuck PCV valve If necessary replace the air cleaner element b Clean the element with compressed air First blow from ba...

Page 45: ...Visually inspect the fuel lines for cracks leakage loose connec tions deformation or tank band looseness 11 INSPECT EXHAUST PIPES AND MOUNTINGS Visually inspect the pipes hangers and connections for...

Page 46: ...on S Leaks S Bends S Twists b Check all clamps for tightness and connections for leak age c Check that the hoses and lines are clear of sharp edges moving parts and the exhaust system d Check that the...

Page 47: ...s do not have exces sive play S Dust seals are not damaged S 2WD Boot clamps are not loose 2 INSPECT SRS AIRBAG See page RS 2 3 INSPECT STEERING GEAR HOUSING OIL Check the steering gear housing for oi...

Page 48: ...e at the nor mal operating temperature 70 80 C or 158 176 F and add as necessary NOTICE Do not overfill Transmission fluid A T See page DI 265 c Differential Remove the filler plug and feel inside the...

Page 49: ...level is low add oil until it begins to run out of the filler hole Transfer oil See page TR 3 d Differential Remove the filler plug and feel inside the hole with your finger Check that the oil comes...

Page 50: ...See page SA 154 9 REPLACE AUTOMATIC TRANSMISSION FLUID a Remove the drain plug s and drain the fluid b Reinstall the drain plug s securely c With the engine OFF add new fluid through the dipstick tube...

Page 51: ...S AND THRUST BUSH a Change the front wheel bearing grease 2WD See page SA 19 4WD See page SA 25 b Repack the drive shaft thrust bush grease See page SA 41 11 4WD LUBRICATE PROPELLER SHAFT Lubricate pr...

Page 52: ...check for loose or missing bolts and nuts on the following S Steering system S Drive train S Suspension system S Fuel tank mounts S Engine mounts etc 13 FINAL INSPECTION a Check operation of body par...

Page 53: ...MA 14 MAINTENANCE CHASSIS 49 Author Date 1996 TOYOTA T100 RM449U c Be sure to deliver a clean vehicle and especially check S Steering wheel S Shift lever knob S All switch knobs S Door handles S Seats...

Page 54: ...LUBRICATION 5VZ FE PP 38 IGNITION 3RZ FE PP 43 IGNITION 5VZ FE PP 46 STARTING 3RZ FE PP 48 STARTING 5VZ FE PP 51 CHARGING 3RZ FE PP 54 CHARGING 5VZ FE PP 57 CLUTCH PP 60 MANUAL TRANSMISSION R150 R150F...

Page 55: ...PP0G5 01 PREPARATION MAINTENANCE PP 1 50 Author Date 1996 TOYOTA T100 RM449U MAINTENANCE EQUIPMENT Mirror Brake hose Torque wrench...

Page 56: ...01 01060 Valve Guide Bushing Remover Replacer 6 09202 70020 Valve Spring Compressor 09207 76010 Rocker Arm Bushing 09213 54015 Crankshaft Pulley Holding Tool 09223 15030 Oil Seal Bearing Replacer Cran...

Page 57: ...y 09550 10012 Replacer Set B 09252 10010 No 1 Replacer Handle Valve guide busing 09608 30012 Front Hub Drive Pinion Bearing Tool Set 09951 07100 Handle 100 Crankshaft rear oil seal 09636 20010 Upper B...

Page 58: ...Center Bolt 100 09954 04010 Arm 25 09955 04060 Claw No 6 09950 50010 Puller C Set 09951 05010 Hanger 150 09952 05010 Slide Arm 09953 05010 Center Bolt 100 09954 05020 Claw No 2 09960 10010 Variable P...

Page 59: ...RATION ENGINE MECHANICAL 3RZ FE PP 5 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for the vacuum hose...

Page 60: ...necting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune up tester Heater Magnetic finger Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge S...

Page 61: ...Materials 08826 00080 Seal Packing Black or equivalent FIPG Over the space between the cylinder head and timing chain cover 08826 00080 Seal Packing Black or equivalent FIPG Semi circular plug Oil pan...

Page 62: ...Guide Bushing Remover Replacer 6 09201 41020 Valve Stem Oil Seal Replacer 09202 70020 Valve Spring Compressor 09202 00010 Attachment 09213 54015 Crankshaft Pulley Holding Tool 90119 08216 Bolt 09222 3...

Page 63: ...s Check Wire 09950 50010 Puller C Set 09951 05010 Hanger 150 Crankshaft pulley Crankshaft timing pulley 09952 05010 Slide Arm Crankshaft pulley Crankshaft timing pulley 09953 05020 Center Bolt 150 Cra...

Page 64: ...INE MECHANICAL 5VZ FE 59 Author Date 1996 TOYOTA T100 RM449U 09962 01000 Variable Pin Wrench Arm Assy Camshaft timing pulley Camshaft sub gear 09963 01000 Pin 10 Camshaft timing pulley 09963 00600 Pin...

Page 65: ...11 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09040 00010 Hexagon Wrench Set 09090 04010 Engine Sling Device For suspending engine 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for the v...

Page 66: ...ligner Cylinder gauge Dial indicator Dye penetrant Timing light Ignition timing OBDII scan tool Engine speed Heater Magnetic finger Micrometer Piston ring compressor Piston ring expander Plastigage Pr...

Page 67: ...9U SSM Special Service Materials 08826 00080 Seal Packing Black or equivalent FIPG 08826 00100 Seal Packing 1282B THREE BOND 1282B or equivalent FIPG 08833 00070 Adhesive 1324 THREE BOND 1324 or equiv...

Page 68: ...PP0GA 02 PP 14 PREPARATION EMISSION CONTROL 3RZ FE 63 Author Date 1996 TOYOTA T100 RM449U EMISSION CONTROL 3RZ FE RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set...

Page 69: ...PP0GB 01 PREPARATION EMISSION CONTROL 3RZ FE PP 15 1996 TOYOTA T100 RM449U EQUIPMENT Tachometer Torque wrench Vacuum gauge...

Page 70: ...PP32Z 01 PP 16 PREPARATION EMISSION CONTROL 5VZ FE 65 Author Date 1996 TOYOTA T100 RM449U EMISSION CONTROL 5VZ FE SST Special Service Tools 09843 18020 Diagnosis Check Wire...

Page 71: ...PP014 04 PREPARATION EMISSION CONTROL 5VZ FE PP 17 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester...

Page 72: ...PP018 04 PP 18 PREPARATION EMISSION CONTROL 5VZ FE 1996 TOYOTA T100 RM449U EQUIPMENT OBDII scan tool Engine speed Torque wrench Vacuum gauge...

Page 73: ...8 41046 Injection Measuring Tool Set 09268 41091 NO 7 Union 90405 09015 No 1 Union 09268 45012 EFI Fuel Pressure Gauge 09631 22020 Power Steering Hose Nut 14 x 17 mm Wrench Set Fuel line flare nut 098...

Page 74: ...02 PP 20 PREPARATION MFI 3RZ FE 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for vacuum hose fuel hose etc 09082 00050 TOYOTA Electrical Teste...

Page 75: ...EPARATION MFI 3RZ FE PP 21 1996 TOYOTA T100 RM449U EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector Heater Soft brush Throttle body Sound scope Injector Tachometer Thermometer To...

Page 76: ...1046 Injection Measuring Tool Set 09268 41091 NO 7 Union 09268 52011 Injection Measuring Attachment 09268 45012 EFI Fuel Pressure Gauge 09631 22020 Power Steering Hose Nut 14 x 17 mm Wrench Set Fuel l...

Page 77: ...PREPARATION SFI 5VZ FE PP 23 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for the vacuum hose fuel h...

Page 78: ...24 PREPARATION SFI 5VZ FE 1996 TOYOTA T100 RM449U EQUIPMENT OBDII scan tool Engine speed Graduated cylinder Injector Carburetor cleaner Throttle body Sound scope Injector Torque wrench Soft brush Thr...

Page 79: ...rvice Tools 09230 00010 Radiator Service Tool Set 09231 00010 Lock Plate Bender 09231 00020 Lock Plate Bender 09231 00030 Plug Handle 09231 00040 No 1 Plug 09231 00050 No 2 Plug 09230 01010 Radiator S...

Page 80: ...PP0GF 02 PP 26 PREPARATION COOLING 3RZ FE 1996 TOYOTA T100 RM449U EQUIPMENT Heater Thermostat Radiator cap tester Thermometer Thermostat Torque wrench...

Page 81: ...PP0GG 01 PREPARATION COOLING 3RZ FE PP 27 1996 TOYOTA T100 RM449U COOLANT Item Capacity Classification Engine coolant w Heater 8 7 liters 9 2 US qts 7 7 lmp qts Ethylene glycol base...

Page 82: ...PP3MB 01 PP 28 PREPARATION COOLING 5VZ FE 77 Author Date 1996 TOYOTA T100 RM449U COOLING 5VZ FE SST Special Service Tools 09843 18020 Diagnosis Check Wire...

Page 83: ...PP3MC 01 PREPARATION COOLING 5VZ FE PP 29 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09042 00010 Torx Socket T30...

Page 84: ...PP01J 02 PP 30 PREPARATION COOLING 5VZ FE 1996 TOYOTA T100 RM449U EQUIPMENT Heater Radiator cap tester Thermometer Torque wrench...

Page 85: ...6 TOYOTA T100 RM449U COOLANT Item Capacity Classification 2WD M T A T 4WD M T A T 10 0 liters 10 6 US qts 8 8 lmp qts 9 9 liters 10 5 US qts 8 7 lmp qts 10 0 liters 10 6 US qts 8 8 lmp qts 10 2 liters...

Page 86: ...PP337 01 PP 32 PREPARATION COOLING 5VZ FE 1996 TOYOTA T100 RM449U SSM Special Service Materials 08826 00100 Seal Packing 1282B THREE BOND 1282B or equivalent FIPG...

Page 87: ...PP0GH 01 PREPARATION LUBRICATION 3RZ FE PP 33 82 Author Date 1996 TOYOTA T100 RM449U LUBRICATION 3RZ FE SST Special Service Tools 09228 07501 Oil Filter Wrench...

Page 88: ...PP0GI 01 PP 34 PREPARATION LUBRICATION 3RZ FE 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09200 00010 Engine Adjust Kit...

Page 89: ...PP0GJ 02 PREPARATION LUBRICATION 3RZ FE PP 35 1996 TOYOTA T100 RM449U EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench...

Page 90: ...fill Drain and refill w Oil filter change w o Oil filter change 6 0 liters 6 3 US qts 5 3 lmp qts 5 3 liters 5 6 US qts 4 7 lmp qts 5 0 liters 5 3 US qts 4 4 lmp qts API grade SH Energy Conserving II...

Page 91: ...PP33E 01 PREPARATION LUBRICATION 3RZ FE PP 37 1996 TOYOTA T100 RM449U SSM Special Service Materials 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent...

Page 92: ...Author Date 1996 TOYOTA T100 RM449U LUBRICATION 5VZ FE SST Special Service Tools 09032 00100 Oil Pan Seal Cutter 09228 07501 Oil Filter Wrench 09309 37010 Transmission Bearing Replacer Camshaft front...

Page 93: ...PP01S 02 PREPARATION LUBRICATION 5VZ FE PP 39 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09200 00010 Engine Adjust Kit...

Page 94: ...PP01T 02 PP 40 PREPARATION LUBRICATION 5VZ FE 1996 TOYOTA T100 RM449U EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench...

Page 95: ...lter change w o Oil filter change 5 9 liters 6 2 US qts 5 2 lmp qts 5 2 liters 5 5 US qts 4 6 lmp qts 5 2 liters 5 5 US qts 4 6 lmp qts 4 9 liters 5 2 US qts 4 3 lmp qts 5 5 liters 5 8 US qts 4 8 lmp...

Page 96: ...PP 42 PREPARATION LUBRICATION 5VZ FE 1996 TOYOTA T100 RM449U SSM Special Service Materials 08826 00080 Seal Packing Black or equivalent FIPG 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or eq...

Page 97: ...PP0GM 02 PREPARATION IGNITION 3RZ FE PP 43 92 Author Date 1996 TOYOTA T100 RM449U IGNITION 3RZ FE RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09200 00010 Engine Adjust Kit...

Page 98: ...PP0GN 03 PP 44 PREPARATION IGNITION 3RZ FE 1996 TOYOTA T100 RM449U EQUIPMENT Spark plug cleaner Torque wrench...

Page 99: ...PP3MD 01 PREPARATION IGNITION 3RZ FE PP 45 1996 TOYOTA T100 RM449U SSM Special Service Materials 08826 00080 Seal Packing Black or equivalent FIPG...

Page 100: ...PP01Z 03 PP 46 PREPARATION IGNITION 5VZ FE 95 Author Date 1996 TOYOTA T100 RM449U IGNITION 5VZ FE RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09200 00010 Engine Adjust Kit...

Page 101: ...PP020 02 PREPARATION IGNITION 5VZ FE PP 47 1996 TOYOTA T100 RM449U EQUIPMENT Spark plug cleaner...

Page 102: ...1996 TOYOTA T100 RM449U STARTING 3RZ FE SST Special Service Tools 09286 46011 Injection Pump Spline Shaft Puller Armature bearing 09810 38140 Starter Magnet Switch Nut Wrench 14 Terminal nut 09820 000...

Page 103: ...PP0GP 02 PREPARATION STARTING 3RZ FE PP 49 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set...

Page 104: ...Z FE 1996 TOYOTA T100 RM449U EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V block Commut...

Page 105: ...Author Date 1996 TOYOTA T100 RM449U STARTING 5VZ FE SST Special Service Tools 09286 46011 Injection Pump Spline Shaft Puller Armature bearing 09810 38140 Starter Magnet Switch Nut Wrench 14 Terminal k...

Page 106: ...PP025 04 PP 52 PREPARATION STARTING 5VZ FE 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set...

Page 107: ...P 53 1996 TOYOTA T100 RM449U EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V block Commut...

Page 108: ...Rotor rear bearing cover 09286 46011 Injection Pump Spline Shaft Puller Rectifier end frame 09820 00021 Alternator Rear Bearing Puller 09820 00030 Alternator Rear Bearing Replacer 09820 63010 Alterna...

Page 109: ...PP3MF 01 PREPARATION CHARGING 3RZ FE PP 55 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09905 00013 Snap Ring Pliers...

Page 110: ...PP0GT 02 PP 56 PREPARATION CHARGING 3RZ FE 1996 TOYOTA T100 RM449U EQUIPMENT Ammeter A Belt tension gauge Torque wrench Vernier calipers Rotor Slip ring Brush...

Page 111: ...Rotor rear bearing cover 09286 46011 Injection Pump Spline Shaft Puller Rectifier end frame 09820 00021 Alternator Rear Bearing Puller 09820 00030 Alternator Rear Bearing Replacer 09820 63010 Alterna...

Page 112: ...PP3MG 01 PP 58 PREPARATION CHARGING 5VZ FE 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09905 00013 Snap Ring Pliers...

Page 113: ...PP02C 04 PREPARATION CHARGING 5VZ FE PP 59 1996 TOYOTA T100 RM449U EQUIPMENT Ammeter A Belt tension gauge Torque wrench Vernier calipers Rotor Slip ring Brush...

Page 114: ...A T100 RM449U CLUTCH SST Special Service Tools 09023 00100 Union Nut Wrench 10 mm Clutch line 09301 00110 Clutch Guide Tool 09303 35011 Input Shaft Front Bearing Puller 09304 30012 Input Shaft Front B...

Page 115: ...PP0EO 03 PREPARATION CLUTCH PP 61 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09905 00013 Snap Ring Pliers...

Page 116: ...PP0EP 01 PP 62 PREPARATION CLUTCH 1996 TOYOTA T100 RM449U EQUIPMENT Caliper Dial indicator Torque wrench...

Page 117: ...tput shaft rear bearing Output shaft center bearing 09316 60011 Transmission Transfer Bearing Replacer 09316 00011 Replacer Pipe Output shaft rear bearing Gear spline piece No 5 09316 00031 Replacer B...

Page 118: ...NSMISSION R150 R150F 113 Author Date 1996 TOYOTA T100 RM449U 09951 00570 Replacer 57 Extension housing oil seal Transfer adaptor oil seal 09951 00620 Replacer 62 Counter rear bearing 09950 70010 Handl...

Page 119: ...PP3LS 01 PREPARATION MANUAL TRANSMISSION R150 R150F PP 65 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09031 00030 Pin Punch 09042 00020 Torx Socket T40 09905 00012 Snap Ring No 1 Expander...

Page 120: ...PP0ES 01 PP 66 PREPARATION MANUAL TRANSMISSION R150 R150F 1996 TOYOTA T100 RM449U EQUIPMENT Dial indicator Micrometer Torque wrench Feeler gauge Magnetic finger...

Page 121: ...UAL TRANSMISSION R150 R150F PP 67 1996 TOYOTA T100 RM449U LUBRICANT Item Capacity Classification Manual transmission oil 2WD 4WD 2 6 liters 2 7 US qts 2 3 Imp qts 2 2 liters 2 3 US qts 1 9 Imp qts API...

Page 122: ...TION MANUAL TRANSMISSION R150 R150F 1996 TOYOTA T100 RM449U SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG 08833 00080 Adhesive 1344 THREE BOND 1344 LOC...

Page 123: ...09308 00010 Oil Seal Puller Output shaft rear bearing outer race 09308 10010 Oil Seal Puller Extension housing oil seal 09312 20011 Transmission Gear Remover Replacer 5th gear Output shaft rear beari...

Page 124: ...r bearing 09921 00010 Spring Tension Tool Speedometer driven gear oil seal 09950 00020 Bearing Remover 09950 60010 Replacer Set 09951 00440 Replacer 44 Front bearing retainer oil seal 09951 00510 Repl...

Page 125: ...PP3LQ 01 PREPARATION MANUAL TRANSMISSION W59 PP 71 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09031 00030 Pin Punch 09042 00020 Torx Socket T40 09905 00012 Snap Ring No 1 Expander...

Page 126: ...PP0BG 01 PP 72 PREPARATION MANUAL TRANSMISSION W59 1996 TOYOTA T100 RM449U EQUIPMENT Dial indicator Calipers Micrometer Torque wrench Feeler gauge Magnetic finger...

Page 127: ...PP0BH 01 PREPARATION MANUAL TRANSMISSION W59 PP 73 1996 TOYOTA T100 RM449U LUBRICANT Item Capacity Classification Manual transmission oil 2 6 liters 2 7 US qts 2 3 Imp qts API GL 4 or GL 5 SAE 75W 90...

Page 128: ...ARATION MANUAL TRANSMISSION W59 1996 TOYOTA T100 RM449U SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE...

Page 129: ...1 10000 Valve Guide Bushing Remover Replacer Set Speedometer driven gear oil seal 09201 01080 Valve Guide Bushing Remover Replacer 8 09308 10010 Oil Seal Puller 09325 40010 Transmission Oil Plug 09350...

Page 130: ...PP0FM 03 PP 76 PREPARATION AUTOMATIC TRANSMISSION 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09031 00030 Pin Punch 09082 00040 TOYOTA Electrical Tester 09905 00012 Snap Ring No 1 Expander...

Page 131: ...SSION PP 77 1996 TOYOTA T100 RM449U EQUIPMENT OBD II scan tool Ohmmeter Voltmeter Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Straight edge...

Page 132: ...ICANT Item Capacity Classification Automatic transmission fluid A340E Dry fill Drain and refill A340E Dry fill Drain and refill 7 2 liters 7 6 US qts 6 3 Imp qts 1 6 liters 1 7 US qts 1 4 Imp qts 7 6...

Page 133: ...ON AUTOMATIC TRANSMISSION PP 79 1996 TOYOTA T100 RM449U SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE...

Page 134: ...60011 Transmission Transfer Bearing Replacer 09316 00011 Replacer Pipe High and low clutch hub Rear output shaft bearing Front case oil seal 09316 00071 Replacer F Rear output shaft bearing 09330 0002...

Page 135: ...PARATION TRANSFER PP 81 130 Author Date 1996 TOYOTA T100 RM449U 09921 00010 Spring Tension Tool 09950 00020 Bearing Remover Driven sprocket rear beating Front drive clutch sleeve Rear output shaft bea...

Page 136: ...PP33M 01 PP 82 PREPARATION TRANSFER 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09031 00030 Pin Punch 09905 00012 Snap Ring No 1 Expander...

Page 137: ...PP0G2 01 PREPARATION TRANSFER PP 83 1996 TOYOTA T100 RM449U EQUIPMENT Calipers Dial indicator Micrometer Torque wrench Feeler gauge...

Page 138: ...PP0G3 01 PP 84 PREPARATION TRANSFER 1996 TOYOTA T100 RM449U LUBRICANT Item Capacity Classification Transfer oil 1 1 liters 1 2 US qts 1 0 lmp qts API GL 4 or GL 5 SAE 75W 90...

Page 139: ...EPARATION TRANSFER PP 85 1996 TOYOTA T100 RM449U SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or...

Page 140: ...449U PROPELLER SHAFT SST Special Service Tools 09325 40010 Transmission Oil Plug Transmission to prevent oil leakage 09330 00021 Companion Flange Holding Tool Companion flange holding 09332 25010 Univ...

Page 141: ...PP0EZ 01 PREPARATION PROPELLER SHAFT PP 87 1996 TOYOTA T100 RM449U EQUIPMENT Dial indicator Torque wrench...

Page 142: ...differential 09316 12010 Transfer Bearing Replacer Rear differential 09316 20011 Transfer Bearing Replacer Front differential 09316 60011 Transmission Transfer Bearing Replacer Front deifferentian Rea...

Page 143: ...le 09523 36010 Rear Axle Hub Guide Tool Rear differential 09558 10010 Rear Axle Shaft Oil Seal Replacer 09554 14010 Differential Oil Seal Replacer Front differential 09554 30011 Differential Oil Seal...

Page 144: ...Front Suspension Bushing Tool Set Front suspension 4WD 09710 05041 Gate 09710 05051 Remover 09710 05061 Replacer 09710 05081 Rear Base 09710 30021 Suspension Bushing Tool Set Front suspension 2WD 0971...

Page 145: ...9726 35011 Front Lower Arm Bushing Remover Replacer Front suspension 2WD 09751 36011 Brake Line Union Nut 10 x 12 mm Wrench Rear axle 09910 00015 Puller Set Front differential 09911 00011 Puller Clamp...

Page 146: ...rential 09951 00480 Replacer 48 Front axle 2WD Front differential Rear differential 09951 00500 Replacer 50 Front axle 4WD 09951 00530 Replacer 53 Front suspension 4WD 09951 00560 Replacer 56 Rear axl...

Page 147: ...890 Replacer 89 Rear axle 09951 00910 Replacer 91 Front axle 4WD Rear differential 09950 70010 Handle Set Front axle Front differential Rear differential Rear axle 09951 07100 Handle 100 Front axle 4W...

Page 148: ...AND AXLE 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09905 00012 Snap Ring No 1 Expander 09905 00013 Snap Ring Pliers 09025 00010 Torque Wrench 30 kgf cm 09031 00030 Pin Punch 09044 00010 Torx Socket E1...

Page 149: ...PP0F7 01 PREPARATION SUSPENSION AND AXLE PP 95 1996 TOYOTA T100 RM449U EQUIPMENT Dial indicator Torque wrench Drill Spring tension gauge Micrometer...

Page 150: ...shaft Outboard joint grease 176 186 g 6 21 6 56 oz Inboard joint grease 270 280 g 9 52 9 88 oz Front differential 1 86 liters 1 97 US qts 1 64 lmp qts Hypoid gear oil API GL 5 75W 90 Rear differential...

Page 151: ...AND AXLE PP 97 1996 TOYOTA T100 RM449U SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent 08833 0010...

Page 152: ...09709 29017 LSPV Gauge Set mk2 09718 00010 Shoe Hold Down Spring Driver 09737 00010 Brake Booster Push Rod Gauge 09751 36011 Brake Line Union Nut 10 x 12 mm Wrench 09843 18020 Diagnosis Check Wire 09...

Page 153: ...PP0FB 03 PREPARATION BRAKE PP 99 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set 09905 00013 Snap Ring Pliers...

Page 154: ...PP0FC 01 PP 100 PREPARATION BRAKE 1996 TOYOTA T100 RM449U EQUIPMENT Torque wrench Micrometor Brake disc Dial indicator Brake disc Vernier calipers Brake drum...

Page 155: ...PP0FD 01 PREPARATION BRAKE PP 101 1996 TOYOTA T100 RM449U LUBRICANT Item Capacity Classification Brake fluid SAE J1703 or FMVSS No 116 DOT 3 Power steering fluid ATF DEXRON II...

Page 156: ...PP33Q 01 PP 102 PREPARATION BRAKE 1996 TOYOTA T100 RM449U SSM Special Service Materials 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent...

Page 157: ...WD 09608 04031 Front Hub Inner Bearing Cone Replacer PS vane pump 3RZ FE 09610 20012 Pitman Arm Puller Steering linkage 09611 22012 Tie Rod End Puller Steering linkage 09612 00012 Rack Pinion Steering...

Page 158: ...Joint Puller PS gear 4WD Steering linkage 09630 00014 Power Steering Gear Housing Overhaul Tool Set 09631 00051 No 3 Wrench PS gear 4WD 09631 00121 Teflon Ring Former PS gear 4WD 09631 00142 Overhaul...

Page 159: ...PS gear 2WD 09640 10010 Power Steering Pressure Gauge Set 09641 01010 Gauge Assy On vehicle inspection 09641 01030 Attachment B On vehicle inspection 09641 01060 Attachment E On vehicle inspection 099...

Page 160: ...on tilt steering column Tilt steering column 09953 05020 Center Bolt 150 Non tilt steering column Tilt steering column 09954 05020 Claw No 2 Non tilt steering column Tilt steering column 09950 60010 R...

Page 161: ...00410 Replacer 41 PS gear 2WD 09951 00420 Replacer 42 PS gear 4WD 09951 00430 Replacer 43 PS gear 2WD 4WD 09952 06010 Adapter PS gear 2WD 4WD 09950 70010 Handle Set 09951 07150 Handle 150 PS gear 2WD...

Page 162: ...PP 108 PREPARATION STEERING 157 Author Date 1996 TOYOTA T100 RM449U 09963 01000 Pin 10 PS vane pump 3RZ FE 5VZ FE...

Page 163: ...rench 30 kgfcm PS vane pump 3RZ FE 5VZ FE PS gear 2WD 4WD Idler arm 09042 00010 Torx Socket T30 Non tilt steering column Tilt steering column 09043 38100 Hexagon 10 mm Wrench PS gear 4WD 09904 00010 E...

Page 164: ...449U EQUIPMENT Belt tension gauge On vehicle inspection Caliper gauge PS vane pump 3RZ FE 5VZ FE Calipers PS vane pump 3RZ FE 5VZ FE Dial indicator PS gear 2WD 4WD Feeler gauge PS vane pump 3RZ FE 5VZ...

Page 165: ...PP0FX 01 PREPARATION STEERING PP 111 1996 TOYOTA T100 RM449U LUBRICANT Item Capacity Classification Power steering fluid Total 0 8 liters 0 85 US qts 0 70 Imp qts ATF DEXRON II or III...

Page 166: ...TION STEERING 1996 TOYOTA T100 RM449U SSM Special Service Materials 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent PS gear 2WD 08826 00090 Seal Packing 1281 THREE BOND 1281 or equ...

Page 167: ...ARATION SUPPLEMENTAL RESTRAINT SYSTEM PP 113 162 Author Date 1996 TOYOTA T100 RM449U SUPPLEMENTAL RESTRAINT SYSTEM SST Special Service Tools 09082 00700 SRS Airbag Deployment Tool 09843 18020 Diagnosi...

Page 168: ...PP0FS 02 PP 114 PREPARATION SUPPLEMENTAL RESTRAINT SYSTEM 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09042 00020 Torx Socket T40 Center aribag sensor assembly 09082 00040 TOYOTA Electrical Tester...

Page 169: ...IPMENT Torque wrench Bolt Length 35mm 1 38 in Pitch 1 0 mm 0 039 in Diam 6 0 mm 0 236 in Airbag disposal Tire Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Airbag disposal Tire with disc wheel Width...

Page 170: ...PP06F 09 PP 116 PREPARATION BODY ELECTRICAL 165 Author Date 1996 TOYOTA T100 RM449U BODY ELECTRICAL SST Special Service Tools 09843 18020 Diagnosis Check Wire...

Page 171: ...PP 117 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09041 00030 Torx Driver T30 For removing and installing steering wheel pad 09042 00010 Torx Socket T30 For removi...

Page 172: ...TOYOTA T100 RM449U EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Syphon Brake fluid level warning switch Bulb 3W Fuel sender gauge Bulb 3 4W Seat belt warning relay Bulb 21W Turn signal flasher relay...

Page 173: ...PP0FZ 02 PREPARATION BODY PP 119 168 Author Date 1996 TOYOTA T100 RM449U BODY SST Special Service Tools 09806 30010 Windshield Moulding Remover 09812 00010 Door Hinge Set Bolt Wrench...

Page 174: ...PP0EW 01 PP 120 PREPARATION BODY 1996 TOYOTA T100 RM449U LUBRICANT Item Capacity Classification MP grease...

Page 175: ...24 or equivalent Front Door 08850 00070 Windshield glass adhesive set No 15 or equivalent Windshield Back WindowGlass 0 15 C or 32 59 F 08850 00080 Windshield glass adhesive set No 35 or equivalent Wi...

Page 176: ...T Joint 07117 58080 Quick Disconnect Adapter Discharge diam 16 mm 07117 58090 Quick Disconnect Adapter Suction diam 13 mm 07117 78050 Refrigerant Charging Gauge 07117 88060 Refrigerant Charging Hose...

Page 177: ...PP3LU 01 PREPARATION AIR CONDITIONING PP 123 1996 TOYOTA T100 RM449U RECOMMENDED TOOLS 09082 00050 TOYOTA Electrical Tester Set...

Page 178: ...TION AIR CONDITIONING 1996 TOYOTA T100 RM449U EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Thermistor Torque wrench Dial indicator Magnetic clutch Plastic hammer Magnetic clutch Hexagon...

Page 179: ...T100 RM449U LUBRICANT Item Capacity Classification Compressor oil ND OIL 8 or equivalent When replacing receiver 10 cc 0 34 fl oz When replacing condenser 40 cc 1 4 fl oz When replacing evaporator 40...

Page 180: ...TION 3RZ FE SS 25 LUBRICATION 5VZ FE SS 27 IGNITION 3RZ FE SS 29 IGNITION 5VZ FE SS 31 STARTING 3RZ FE SS 33 STARTING 5VZ FE SS 35 CHARGING 3RZ FE SS 37 CHARGING 5VZ FE SS 39 CLUTCH SS 41 MANUAL TRANS...

Page 181: ...lt Hexagon head bolt 2 Protruding lines 2 Protruding lines 3 Protruding lines 4 Protruding lines Hexagon flange bolt w washer hexagon bolt Hexagon flange bolt w washer hexagon bolt Hexagon flange bolt...

Page 182: ...mm Specified torque Hexagon head bolt Hexagon flange bolt N m kgf cm ft lbf N m kgf cm ft lbf in lbf in lbf in lbf in lbf in lbf in lbf SS 2 SERVICE SPECIFICATIONS STANDARD BOLT 1996 TOYOTA T100 RM44...

Page 183: ...TENANCE SS 3 177 Author Date 1996 TOYOTA T100 RM449U MAINTENANCE TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Front seat mount bolts 37 375 27 Strut bar bracket x Frame 2WD 52 530 38 Leaf spr...

Page 184: ...94 in Valve guide bushing Inside diameter Protrusion height Replacing temperature Cylinder head side 6 010 6 030 mm 0 2366 0 2374 in 8 2 8 6 mm 0 323 0 339 in 80 100 C 176 212 F Valve Valve overall le...

Page 185: ...113 8 mm 4 480 in 75 9 mm 2 988 in 96 7 mm 3 807 in Chain tensioner slipper and vibration damper Wear Maximum 1 0 mm 0 039 in Cylinder block Cylinder head surface warpage Maximum Cylinder bore diamete...

Page 186: ...hickness Main journal oil clearance STD No 3 Others U S 0 25 No 3 Others Maximum Main journal diameter STD No 3 Others U S 0 25 No 3 Others Main bearing center wall thickness STD Mark 1 Mark 2 Mark 3...

Page 187: ...Fuel inlet tube x Fuel filter 29 300 22 Fuel inlet tube x Delivery pipe 29 300 22 EGR valve x Air intake chamber EGR pipe 19 195 14 EGR vacuum modulator x Air intake chamber 8 5 85 74 in lbf EGR pipe...

Page 188: ...34 Oil dipstick guide x LH engine mounting bracket 20 200 14 Oil filter bracket union Engine coolant drain plug x Cylinder block 25 250 18 Oil filter bracket x Cylinder block 28 290 21 Water bypass p...

Page 189: ...ition timing w Terminals TE1 and E1 connected of DLC1 8 12 BTDC idle Idle speed 700 50 rpm Intake manifold vacuum at idle speed 60 kPa 450 mmHg 17 7 in Hg or more Timing belt tensioner Protrusion from...

Page 190: ...08 0 0079 in 0 30 mm 0 0188 in 18 2 18 8 mm 0 712 0 740 in Air intake chamber Warpage Maximum 0 10 mm 0 0039 in Intake air connector Warpage Maximum 0 10 mm 0 0039 in Intake manifold Warpage Maximum 0...

Page 191: ...Thrust washer thickness Main journal oil clearance No 1 STD U S 0 25 Others STD U S 0 25 Maximum Main journal diameter STD U S 0 25 Main bearing center wall thickness Reference No 1 Mark 1 Mark 2 Mark...

Page 192: ...tor bracket x LH cylinder head 18 5 185 14 PS pump bracket x RH cylinder head 44 440 32 Intake manifold x Cylinder head 18 180 13 Intake manifold stay x Intake manifold 18 5 185 13 Intake manifold sta...

Page 193: ...8 5 85 75 in lbf Rear end plate x Cylinder block 7 5 75 66 in lbf Drive plate x Crankshaft 83 850 63 Flywheel x Crankshaft 85 850 63 Clutch release cylinder x Transmission 12 120 9 Stabilizer bar brac...

Page 194: ...14 SERVICE SPECIFICATIONS EMISSION CONTROL 3RZ FE 188 Author Date 1996 TOYOTA T100 RM449U EMISSION CONTROL 3RZ FE SERVICE DATA VSV for EVAP Resistance at 20 C 68 F 30 34 VSV for EGR Resistance at 20 C...

Page 195: ...lbf Charcoal canister x Charcoal canister bracket 31 310 23 EGR valve x Air intake chamber 19 195 14 EGR valve x EGR pipe 19 195 14 EGR pipe x Exhaust manifold 20 200 15 EGR pipe x Cylinder head 18 1...

Page 196: ...ft lbf Charcoal canister x Charcoal canister bracket 18 180 13 EGR valve x Air intake chamber 18 5 185 14 EGR valve x EGR pipe 18 5 185 14 EGR pipe x LH exhaust manifold 18 5 185 14 EGR pipe stay x Cy...

Page 197: ...C E2 0 2 5 7 k 2 3 k or less Infinity 2 0 10 2 k 2 5 5 9 k IAC valve Resistance B RSC or RSO 17 0 24 5 10 50 C 21 5 28 5 50 100 C VSV for EVAP Resistance at 20 C 68 F 30 34 VSV for EGR Resistance at 2...

Page 198: ...y pipe 8 8 90 78 in lbf Delivery pipe x Cylinder head 21 210 15 Fuel inlet tube x Fuel filter 29 300 22 Fuel inlet tube x Delivery pipe 29 300 22 Air intake chamber x Intake manifold 21 210 15 Throttl...

Page 199: ...osition sensor Clearance between stop screw and lever 0 mm 0 in VTA E2 0 32 mm 0 013 in IDL E2 0 54 mm 0 021 in IDL E2 Throttle valve fully open VTA E2 VC E2 0 28 6 4 k 0 5 k or less Infinity 2 0 11 6...

Page 200: ...Fuel pump bracket assembly x Fuel tank 3 9 40 35 in lbf Fuel tank band x Body 43 440 32 Fuel tank filler pipe x Fuel tank 3 9 40 35 in lbf Fuel evaporation vent tube x Fuel tank 1 5 15 13 in lbf Fuel...

Page 201: ...TOYOTA T100 RM449U COOLING 3RZ FE SERVICE DATA Thermostat Valve opening temperature Valve lift at 95 C 203 F 80 84 C 176 183 F 8 mm 0 31 in or more Radiator cap Relief valve opening pressure STD Mini...

Page 202: ...kgf cm ft lbf Cylinder block x Drain plug 24 250 18 Fluid coupling x Fan 5 5 55 49 in lbf Water pump x Cylinder block expect bolt A for bolt A 8 9 24 5 90 250 78 in lbf 18 Water inlet x Water inlet h...

Page 203: ...TOYOTA T100 RM449U COOLING 5VZ FE SERVICE DATA Thermostat Valve opening pressure Valve lift at 95 C 203 F 80 84 C 176 183 F 8 5 mm 0 335 in or more Radiator cap Relief valve opening pressure STD Mini...

Page 204: ...5VZ FE 1996 TOYOTA T100 RM449U TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Fan x Fan pulley bracket 5 4 55 48 in lbf Water pump x Cylinder block Short bolt 20 200 14 Water inlet x Water pump...

Page 205: ...ing temperature At 3 000 rpm normal operating temperature 29 kPa 0 3 kgf cm2 4 3 psi or more 245 490 kPa 2 5 5 0 kgf cm2 36 71 psi Oil pump Body clearance STD Maximum Tip clearance STD Maximum Side cl...

Page 206: ...SS09B 02 SS 26 SERVICE SPECIFICATIONS LUBRICATION 3RZ FE 1996 TOYOTA T100 RM449U TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Oil pan x Drain plug 25 250 18...

Page 207: ...rating temperature at idle speed at 3 000 rpm 29 kPa 0 3 kgf cm2 4 3 psi or more 245 520 kPa 2 5 5 3 kgf cm2 36 75 psi Oil pump Body clearance STD Maximum Tip clearance STD Maximum Side clearance STD...

Page 208: ...kgf cm ft lbf Oil pressure switch x Cylinder block 15 150 11 Oil pump x Oil pump body cover 10 105 8 Oil pump x Cylinder block Bolt A Bolt B 20 42 200 420 14 31 Oil pump x Relief valve 37 375 27 Oil s...

Page 209: ...ark plug ND Recommended spark plug NGK Correct electrode gap K16R U BKR5EYA 0 8 mm 0 031 in Ignition coil Resistance Primary coil Cold Hot Secondary coil Cold Hot 0 36 0 55 0 45 0 65 9 0 15 4 k 11 4 1...

Page 210: ...SPECIFICATION Part tightened N m kgf cm ft lbf Spark plug x Cylinder head 20 200 14 Distributor x Cylinder head 19 195 14 Crankshaft position sensor x Timing chain cover 8 5 85 74 in lbf Generator br...

Page 211: ...commended spark plug ND NGK Correct electrode gap for new plug K16TR11 BKR5EKB 11 1 1 mm 0 043 in Ignition coil Primary coil resistance Cold Hot Secondary coil resistance Cold Hot 0 67 1 05 0 85 1 23...

Page 212: ...A T100 RM449U TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Spark plug x Cylinder head 18 180 13 Ignition coil x Cylinder head 7 8 80 69 in lbf Camshaft position sensor x Cylinder head 7 8 80...

Page 213: ...1 40 2 00 kgf 3 1 4 4 lbf 9 8 N 1 00 kgf 2 2 lbf 17 6 23 5 N 1 80 2 40 kgf 4 0 5 3 lbf 11 8 N 1 20 kgf 2 6 lbf 30 0 mm 1 18 in 29 0 mm 1 14 in 0 6 mm 0 024 in 0 2 mm 0 008 in 0 05 mm 0 0020 in 0 9 mm...

Page 214: ...housing 1 2 kW 1 4 kW type 1 8 kW 2 0 kW type 5 9 9 3 60 95 52 in lbf 82 in lbf Starter housing x Magnetic switch 1 2 kW 1 4 kW type 1 8 kW 2 0 kW type 5 9 9 3 60 95 52 in lbf 82 in lbf End cover x F...

Page 215: ...19 6 N 1 40 2 00 kgf 3 1 4 4 lbf 9 8 N 1 00 kgf 2 2 lbf 17 6 23 5 N 1 80 2 40 kgf 4 0 5 3 lbf 11 8 N 1 20 kgf 2 6 lbf 30 mm 1 180 in 29 mm 1 140 in 0 6 mm 0 024 in 0 2 mm 0 008 in 0 05 mm 0 0020 in 0...

Page 216: ...Terminal C of starter 5 9 60 52 in lbf Field frame Magnetic switch x Starter housing 1 2 kW 1 4 kW type 1 8 kW type 5 9 9 3 60 95 52 in lbf 82 in lbf End cover x Field frame 1 2 kW 1 4 kW type 1 8 kW...

Page 217: ...12 9 V Drive belt Tension New belt Used belt 175 51 lbf 115 20 lbf Generator Rated output Rotor coil resistance Slip ring diameter STD Minimum Brush exposed length STD Minimum 12 V 60 A 2 8 3 0 14 2...

Page 218: ...ectifier holder x Coil lead on rectifier end frame 2 0 20 17 in lbf Rear end cover x Rectifier holder 4 5 46 40 in lbf Terminal insulator x Rectifier holder 4 1 41 5 36 in lbf Pivot bolt For generator...

Page 219: ...w belt 3RZ FE 5VZ FE used belt 3RZ FE 5VZ FE 175 5 lbf 160 20 lbf 115 20 lbf 100 20 lbf Generator Rated output Rotor coil resistance Slip ring diameter STD Minimum Brush exposed length STD Minimum 12...

Page 220: ...x Rotor 110 1 125 81 Rectifier holder x Coil lead on rectifier end frame 2 0 20 17 in lbf Voltage regulator and brush holder x Rectifier end frame 2 0 20 17 in lbf Rear end cover x Rectifier holder 4...

Page 221: ...1 0 5 0 mm 0 039 0 197 in Pedal freeplay 5 0 15 0 mm 0 197 0 591 in Clutch release point from pedal full stroke end position 25 mm 0 98 in or more Clutch start switch ON OFF Stroke 5 0 0 5 mm 0 197 0...

Page 222: ...ATION Part tightened N m kgf cm ft lbf Clutch line union 15 155 11 Master cylinder installation nut 13 130 9 Bleeder plug 11 110 8 Clutch cover x Flywheel 19 195 14 Release cylinder installation bolt...

Page 223: ...STD Max 0 015 0 068 mm 0 0006 0 0027 in 0 160 mm 0 0063 in Shift fork to hub sleeve clearance Max 1 0 mm 0 039 in Synchronizer ring to gear clearance Min 0 8 mm 0 031 in Input shaft snap ring thickne...

Page 224: ...mm 0 0039 0 0138 in 0 40 mm 0 0157 in Counter 5th radial clearance STD Max 0 015 0 068 mm 0 0006 0 0027 in 0 160 mm 0 0063 in Reverse idler gear radial clearance STD Max 0 040 0 082 mm 0 0016 0 0032 i...

Page 225: ...Engine rear mounting 2WD 18 180 13 Engine rear mounting bracket x Frame 2WD 58 590 43 Crossmember x Frame 4WD 95 970 70 Transmission x Transfer 4WD 37 380 27 Reverse shift arm bracket set bolt 18 185...

Page 226: ...0076 in Reverse idler gear to shift arm shoe clearance STD Max 0 20 0 41 mm 0 0080 0 0161 in 0 90 mm 0 0354 in Shift fork to hub sleeve clearance Max 1 0 mm 0 039 in Synchronizer ring to 1st and 4th g...

Page 227: ...A Mark B Mark C Mark D Mark E Mark F Mark G 2 05 2 10 mm 0 0807 0 0827 in 2 10 2 15 mm 0 0827 0 0846 in 2 15 2 20 mm 0 0846 0 0866 in 2 20 2 25 mm 0 0866 0 0886 in 2 25 2 30 mm 0 0886 0 0906 in 2 30 2...

Page 228: ...idler gear shaft stopper bolt 25 250 18 Oil separator x Intermediate plate 18 185 13 Front bearing retainer set bolt 25 250 18 Extension housing x Intermediate plate 37 380 27 Restrict pin 40 410 30...

Page 229: ...positions 3RZ FE 5VZ FE 1 950 150 rpm 2 150 150 rpm Time lag N D position N R position Less than 1 2 seconds Less than 1 5 seconds Engine idle speed A C OFF and N position 700 50 rpm Throttle cable ad...

Page 230: ...Throttle valve fully opened 1 2 3 2 2 1 L position Throttle valve fully opened 2 1 55 60 km h 34 37 mph 99 108 km h 62 67 mph 127 136 km h 79 85 mph 120 130 km h 75 81 mph 92 98 km h 57 61 mph 44 48...

Page 231: ...propeller shaft x Rear differential A340F 74 750 54 Center support bearing x Body 36 370 27 Drive plate x Crankshaft 83 850 61 Torque converter clutch x Drive plate 41 420 30 Stiffener plate x Engine...

Page 232: ...SS 52 SERVICE SPECIFICATIONS AUTOMATIC TRANSMISSION 1996 TOYOTA T100 RM449U Shift lever sub assembly x Control shaft assembly 19 195 14 Casing cap x Control shaft support sub assembly 50 510 37...

Page 233: ...25 mm 0 0866 0 0886 in 2 25 2 30 mm 0 0886 0 0906 in 2 30 2 35 mm 0 0906 0 0925 in 2 35 2 40 mm 0 0925 0 0945 in 2 40 2 45 mm 0 0945 0 0965 in 2 45 2 50 mm 0 0965 0 0984 in 2 50 2 55 mm 0 0984 0 1004...

Page 234: ...4 5 Inner bearing depth 0 11 0 86 mm 0 0043 0 0339 in 0 86 mm 0 0339 in 0 009 0 038 mm 0 0004 0 0015 in 0 038 mm 0 0015 in 1 45 1 50 mm 0 0571 0 0591 in 1 50 1 55 mm 0 0591 0 0610 in 1 55 1 60 mm 0 0...

Page 235: ...380 27 Transfer assembly x Transmission 37 380 27 Front retainer 11 115 8 Control retainer or upper cover 18 185 13 Companion flange lock nut 118 1 200 87 Extension housing 11 115 8 Front case x Rear...

Page 236: ...150 mm 0 0827 0 0846 in 2 2 150 2 200 mm 0 0846 0 0866 in 3 2 200 2 250 mm 0 0866 0 0886 in Brown 2 250 2 300 mm 0 0886 0 0906 in Bule 2 300 2 350 mm 0 0906 0 0925 in 6 2 350 2 400 mm 0 0925 0 0945 in...

Page 237: ...ear differential 4WD 76 780 56 Rear propeller shaft x Transfer 4WD 76 780 56 Intermediate shaft x Propeller shaft 4WD 76 780 56 Center support bearing x Body 36 370 27 Intermediate shaft x Center supp...

Page 238: ...tra cab Front 1 74 0 mm 2 913 in Rear 2 122 0 mm 4 803 in Front 1 74 0 mm 2 913 in Rear 2 107 0 mm 4 213 in Front 1 74 0 mm 2 913 in Rear 2 115 5 mm 4 547 in Camber Left right error 0 00 45 0 0 75 45...

Page 239: ...mm 1 965 in Rear 2 63 5 mm 2 500 in VCK11L TRSDKA P235 75R15 Front 1 49 9 mm 1 965 in Rear 2 64 6 mm 2 543 in VCK11L THSDKA 5VZ FE Engine 1 0 ton Front 1 49 9 mm 1 965 in Rear 2 33 0 mm 1 299 in VCK1...

Page 240: ...is inclination STD cab 0 5 ton STD cab 1 0 ton Extra cab Left right error 12 05 45 12 08 0 75 12 10 45 12 17 0 75 12 00 45 12 0 75 45 0 75 or less Toe in Total STD cab 3RZ FE 5VZ FE engine 0 5 ton STD...

Page 241: ...ide wheel Outside wheel Left right error 32 01 2 32 02 2 30 12 30 2 32 14 2 32 23 2 29 59 29 99 30 0 5 or less Wheel alignment Non loaded vehicle condition 4WD Vehicle height VCK21L TRMDKA P235 75R15...

Page 242: ...4WD Drive shaft length 481 2 491 2 mm 18 945 19 339 in Front suspension 2WD Upper ball joint turning torque 2 0 3 9 N m 20 40 kgf cm 17 34 in lbf Lower ball joint turning torque 2 0 7 0 N m 20 70 kgf...

Page 243: ...1 2 83 mm 0 1106 0 1114 in 2 84 2 86 mm 0 1118 0 1126 in 2 87 2 89 mm 0 1130 0 1138 in 2 90 2 92 mm 0 1142 0 1150 in 2 93 2 95 mm 0 1154 0 1161 in 2 96 2 98 mm 0 1165 0 1173 in 2 99 3 01 mm 0 1177 0 1...

Page 244: ...0 05 mm 0 0020 in Differential case runout Maximum 0 04 mm 0 0016 in Differential side gear thrust washer thickness 1 50 mm 0 0590 in 1 55 mm 0 0610 in 1 60 mm 0 0630 in 1 65 mm 0 0650 in 1 70 mm 0 06...

Page 245: ...mm 0 1339 in 42 3 42 mm 0 1346 in 44 3 44 mm 0 1354 in 46 3 46 mm 0 1362 in 48 3 48 mm 0 1370 in Drive pinion bearing adjusting washer thickness 87 1 87 mm 0 0736 in 88 1 88 mm 0 0740 in 89 1 89 mm 0...

Page 246: ...2 2 12 mm 0 0835 in 13 2 13 mm 0 0839 in 14 2 14 mm 0 0843 in 15 2 15 mm 0 0846 in 16 2 16 mm 0 0850 in 17 2 17 mm 0 0854 in 18 2 18 mm 0 0858 in 19 2 19 mm 0 0862 in 20 2 20 mm 0 0866 in 21 2 21 mm 0...

Page 247: ...wer ball joint x Strut bar 75 760 55 Strut bar x Frame 123 1 250 90 Stabilizer bar link set nut 13 130 9 Stabilizer bar bracket x Frame 30 306 22 Hub nut 103 1 050 76 ABS speed sensor x Steering knuck...

Page 248: ...erential carrier x Bearing cap 78 800 58 Clutch case x Tube 78 800 58 Clutch case x Differential carrier 78 800 500 Differential x Front propeller shaft 74 750 54 Clutch case cover x Clutch case 21 21...

Page 249: ...0 mm 2 76 in Brake booster push rod to piston clearance w SST 0 mm 0 in Front brake pad thickness 2WD 1 0 ton STD 9 5 mm 0 374 in 2WD 0 5 ton STD 11 0 mm 0 433 in 4WD STD 9 5 mm 0 374 in Minimum 1 0 m...

Page 250: ...late x Steering knuckle 2WD 108 1 100 80 Front disc x Front axle hub 64 650 47 Front disc brake caliper x Flexible hose 15 155 11 Rear drum brake wheel cylinder x Backing plate 10 100 7 Parking brake...

Page 251: ...or C 12 54 12 60 mm 0 4937 0 4961 in 4 or D 12 47 12 53 mm 0 4909 0 4933 in 5 or E 12 40 12 46 mm 0 4882 0 4906 in 6 or F 12 33 12 39 mm 0 4854 0 4878 in 7 or G 12 26 12 32 mm 0 4827 0 4850 in PS VANE...

Page 252: ...Cross shaft adjusting screw thrust clearance STD 0 03 0 05 mm 0 0012 0 0020 in Cross shaft adjusting screw thrust clearance Maximum 0 05 mm 0 0020 in Worm gear preload 0 3 0 5 N m 3 5 5 kgf cm 2 6 4 8...

Page 253: ...35 360 26 Intermediate shaft x Worm gear valve assembly 4WD 35 360 26 Sliding w shaft york sub assembly x Intermediate shaft 35 360 26 Sliding york sub assembly x Sliding w shaft york sub assembly 35...

Page 254: ...365 450 26 33 PS gear assembly x Body 142 1450 105 Pitman arm x Cross shaft 177 1800 130 Cross shaft adjusting screw set nut 46 470 34 Side cover x Gear housing 61 620 45 Plunger guide nut 20 205 15 W...

Page 255: ...SERVICE SPECIFICATIONS SUPPLEMENTAL RESTRAINT SYSTEM SS 75 249 Author Date 1996 TOYOTA T100 RM449U SUPPLEMENTAL RESTRAINT SYSTEM SERVICE DATA FRONT AIRBAG SENSOR S A Less then 1 S S 1 M or Higher S A...

Page 256: ...NS SUPPLEMENTAL RESTRAINT SYSTEM 1996 TOYOTA T100 RM449U TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Steering wheel 34 350 25 Steering wheel pad 8 8 90 78 in lbf Airbag sensor assembly 21 21...

Page 257: ...t dimmer switch HIGH beam or Flash Battery positive voltage TURN SIGNAL FLASHER Flashes Minute 60 120 SPEEDOMETER Using a speedmeter tester Standard indication mph Allowable range mph 20 18 24 40 38 4...

Page 258: ...Ground Brake pedal position Released Approx 38 0 10 Ground Brake pedal position Depressed No continuity CRUISE CONTROL SWITCH 18 Ground Control switch position OFF No continuity 18 Ground Control swi...

Page 259: ...N Radio switch and cassette ON Battery positive voltage 8 Ground Ignition switch position LOCK No voltage 8 Ground Ignition switch position ACC or ON Radio switch ON and cassette ON No voltage 8 Groun...

Page 260: ...gate hinge x Tail gate 18 185 13 FRONT SEAT Bench Type Seat track x Body 37 375 27 Seat track x Seatback 18 185 13 Outer track x Seat cushion frame 18 185 13 Inner track x Seat cushion frame 18 185 13...

Page 261: ...SERVICE SPECIFICATIONS BODY SS 81 255 Author Date 1996 TOYOTA T100 RM449U Part tightened N m kgf cm ft lbf Lap outer anchor x Body 43 440 32 Inner belt x Body 43 440 32...

Page 262: ...Date 1996 TOYOTA T100 RM449U AIR CONDITIONING SERVICE DATA Refrigerant charge volume 650 50 g 22 92 1 76 oz Drive belt tension New belt 160 25 lbf Used belt 100 20 lbf Idle up speed 3RZ FE 900 rpm 5VZ...

Page 263: ...nut 39 400 29 Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Cooling unit x Suction tube 32 330 24 Cooling unit x Liquid tube 14 140 10 Expansion valve x Evaporator 22 225 16...

Page 264: ...DI DIAGNOSTICS ENGINE 3RZ FE DI 1 ENGINE 5VZ FE DI 127 AUTOMATIC TRANSMISSION DI 263 ANTI LOCK BRAKE SYSTEM DI 319 SUPPLEMENTAL RESTRAINT SYSTEM DI 363 CRUISE CONTROL SYSTEM DI 408...

Page 265: ...mulation P IN 16 Basic Inspection P DI 3 DTC Chart P DI 13 Problem Symptoms Table P DI 21 Circuit Inspection P DI 22 Adjustment Repair DTC Check P DI 3 Titles inside are titles of pages in in the bott...

Page 266: ...peration Shifting from N to D Other Datas Problem Occurred Problem Frequency Condition When Problem Occurs Weather Engine Operation Engine Temp Place Outdoor Temp Constant Sometimes times per day mont...

Page 267: ...to the Data Link Con nector 3 DLC3 on the vehicle The OBD II scan tool or TOYOTA hand held tester also enables you to erase the DTCs and check freezed frame data and vaious forms of engine data For op...

Page 268: ...ratio lean or rich etc at the time of the malfunction Priorities for troubleshooting If troubleshooting priorities for multiple DTCs are given in the applicable DTC chart these should be followed If...

Page 269: ...the MIL does not light up troubleshoot the combination meter 2 When the engine started the MIL should go off If the lamp remains on the diagnosis system has de tected a malfunction or abnormality in t...

Page 270: ...ositive voltage 11 V or more S Throttle valve fully closed S Transmission in P or N position S Air conditioning switched OFF 2 Turn the ignition switch OFF 3 Prepare the TOYOTA hand held tester 4 Conn...

Page 271: ...6 0 msec Returned to normal condition P0110 Intake air temp is fixed at 20 C 68 F Returned to normal condition P0115 Engine coolant temp is fixed at 80 176 F Returned to normal condition P0120 VTA is...

Page 272: ...m can be found quickly and efficiently Therefore use of this check is essential in engine troubleshooting 1 Is battery positive voltage 11 V or more when engine is stopped NO Charge or replace battery...

Page 273: ...check the idle speed OK Idle speed 750 50 rpm NG Proceed to problem symptoms table on page DI 21 OK 6 Check ignition timing PREPARATION a Warm up the engine to normal operating temperature b Shift th...

Page 274: ...this time you will hear a fuel flowing noise NG Proceed to page MF 1 and continue to trouble shoot OK 8 Check for spark PREPARATION a Disconnect the high tension cord from the spark plug b Remove the...

Page 275: ...3 F SHORT FT 1 Short term Fuel Trim Bank 1 0 20 LONG FT 1 Long term Fuel Trim Bank 1 0 20 ENGINE SPD Engine Speed Idling 650 750 rpm VEHICLE SPD Vehicle Speed Vehicle Stopped 0 km h 0 mph IGN ADVANCE...

Page 276: ...oad Fuel cut operating ON CYL 1 CYL 2 CYL 3 CYL 4 Abnormal revolution variation for each cylinder 0 IGNITION Total number of ignition for every 1 000 revolutions 0 2 000 EGRT GAS EGR Gas Temp Sensor V...

Page 277: ...ant temp sensor S ECM f f P0116 DI 38 Engine Coolant Temp Circuit Range Performance Problem S Engine coolant temp sensor S Cooling system f f P0120 DI 39 Throttle Pedal Position Sensor Switch A Circui...

Page 278: ...en or short in knock sensor 1 circuit S Knock sensor 1 looseness S ECM f f P0335 DI 66 Crankshaft Position Sensor A Circuit Malfunction S Open or short in crankshaft position sensor circuit S Cranksha...

Page 279: ...losed throttle position switch circuit S Closed throttle position switch S ECM f f f MIL lights up MANUFACTURER CONTROLLED DTC No See Page Detection Item Trouble Area MIL Memory P1300 DI 103 Igniter C...

Page 280: ...DI0T9 02 P24451 Camshaft Position Sensor Built into Distributor DI 16 DIAGNOSTICS ENGINE 3RZ FE 1996 TOYOTA T100 RM449U PARTS LOCATION...

Page 281: ...1 5 THA E6 7 E2 E6 9 Y G BR B Idling Intake air temp 20 C 68 F 0 5 3 4 THW E6 4 E2 E6 9 G Y BR B Idling Engine coolant temp 80 C 176 F 0 2 1 0 STA E4 11 E1 E7 14 B W BR Cranking 6 0 or more 10 E7 12 E...

Page 282: ...ng Pulse generation See page DI 63 SP1 E4 9 E1 E7 14 G BR IG switch ON Rotate driving wheel slowly Pulse generation See page DI 92 TE1 E6 15 E1 E7 14 V W BR IG switch ON 9 14 W E4 5 E1 E7 14 V BR Idli...

Page 283: ...THA E6 12 E2 E6 9 Y G BR B Idling Intake air temp 20 C 68 F 0 5 3 4 THW E6 4 E2 E6 9 G Y BR B Idling Engine coolant temp 80 C 176 F 0 2 1 0 STA E4 11 E1 E7 24 B W BR Cranking 6 0 or more 10 E7 12 E01...

Page 284: ...page DI 63 NSW E4 22 E1 E7 24 B Y BR IG switch ON Other shift position in P N position 9 14 IG switch ON Shift position in P N position 0 3 0 SP1 E4 8 E1 E7 24 G BR IG switch ON Rotate driving wheel...

Page 285: ...start 1 Starter signal circuit 2 Fuel pump control circuit DI 110 DI 118 High engine idle speed Poor idling 1 A C signal circuit Compressor circuit 2 ECM power source circuit AC 79 DI 115 Low engine...

Page 286: ...ured as the output voltage of the air flow meter The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit with the power transistor controlled so that the poten...

Page 287: ...N PROCEDURE 1 Connect OBD II scan tool or TOYOTA hand held tester and read value of mass air flow rate PREPARATION a Connect the OBD II scan tool or TOYOTA hand held tester to the DLC3 b Turn the igni...

Page 288: ...ass air flow meter con nector and body ground OK Voltage 9 14 V NG Check for open in harness and connector be tween EFI main relay Marking EFI and mass air flow meter See page IN 26 OK 3 Check voltage...

Page 289: ...ss air flow meter 5 Check continuity between terminal E3 of ECM connector and body ground PREPARATION Remove the right cowl side trim See page MF 50 CHECK Check continuity between terminal E3 of ECM c...

Page 290: ...tion logic a Closed throttle position switch ON b Mass air flow meter output 2 2 V c THW y 70 C 158 F S Mass air flow meter Conditions a and b continue with engine speed 1 850 rpm or more a VTA y 0 75...

Page 291: ...sensor from the terminal THA via a resistor R That is the resistor R and the intake air temp sensor are con nected in series When the resistance value of the intake air temp sensor changes in accorda...

Page 292: ...a Connect the OBD II scan tool or TOYOTA hand held tester to DLC3 b Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand held tester main switch ON CHECK Read temp value on the OB...

Page 293: ...ck for open in harness or ECM PREPARATION a Disconnect the intake air temp sensor connector b Connect the sensor wire harness terminals together c Turn the ignition switch ON CHECK Read temp value on...

Page 294: ...page MF 50 b Connect between terminals THA and E2 of the ECM con nector HINT The intake air temp sensor connector is disconnected Before checking do a visual and contact pressure check for the ECM con...

Page 295: ...S ENGINE 3RZ FE DI 31 1996 TOYOTA T100 RM449U 4 Check for short in harness and ECM PREPARATION a Disconnect the intake air temp sensor connector b Turn the ignition switch ON CHECK Read temp value on...

Page 296: ...ort in harness or ECM PREPARATION a Remove the right cowl side trim See page MF 50 b Disconnect the E6 connector of the ECM HINT The intake air temp sensor connector is disconnected c Turn the ignitio...

Page 297: ...n the intake air temp circuit malfunc tion shown on page DI 27 If the ECM detects the DTC P0115 it operates the fail safe function in which the engine coolant temp is assumed to be 80 C 176 F DTC No D...

Page 298: ...on the OBD II scan tool or TOYOTA hand held tester OK Same as actual engine coolant temp HINT S If there is open circuit OBD II scan tool or TOYOTA hand held tester indicates 40 C 40 F S If there is o...

Page 299: ...page MF 50 b Connect between terminals THW and E2 of the ECM con nector HINT The engine coolant temp sensor connector is disconnected Before checking do a visual and contact pressure check for the ECM...

Page 300: ...STICS ENGINE 3RZ FE 1996 TOYOTA T100 RM449U 4 Check for open in harness or ECM PREPARATION a Disconnect the engine coolant temp sensor connector b Turn the ignition switch ON CHECK Read temp value on...

Page 301: ...ort in harness or ECM PREPARATION a Remove the right cowl side trim See page MF 50 b Disconnect the E6 connector of the ECM HINT The engine coolant temp sensor connector is disconnected c Turn the ign...

Page 302: ...C 19 4 F and 10 C 50 F And 5 min or more after engine starts engine coolant temp sensor value is 20 C 68 F or less 2 trip detection logic When engine starts water temp is 10 C 50 F or more And 2 min o...

Page 303: ...e of the throttle valve and becomes approximately 3 2 4 9 V when the throttle valve is fully opened The ECM judges the vehicle driving conditions from these signals input from terminals VTA and IDL an...

Page 304: ...2 Sensor Ground may be open 1 Connect OBD II scan tool or TOYOTA hand held tester and read the throttle valve opening percentage PREPARATION a Connect the OBD II scan tool or TOYOTA hand held tester t...

Page 305: ...n the ignition switch ON CHECK Measure voltage between terminals 1 of wire harness side con nector and body ground OK Voltage 4 5 5 5 V NG Go to step 5 OK 3 Check throttle position sensor PREPARATION...

Page 306: ...K Throttle valve Voltage Fully closed 0 3 0 8 V Fully open 2 7 5 2 V NG Check for open and short in harness and connector between ECM and throttle position sensor VTA line See page IN 26 OK Check and...

Page 307: ...tection Item Trouble Area P0121 After vehicle speed has been exceeded 30 km h 19 mph even once output value of throttle position sensor is out of applicable range while vehicle speed between 30 km h 1...

Page 308: ...ntration in the ex haust gas is reduced and the oxygen sensor informs the ECM of the RICH condition large electromotive force 1 V The ECM judges by the electromotive force from the oxygen sensor wheth...

Page 309: ...IRING DIAGRAM INSPECTION PROCEDURE 1 Connect OBD II scan tool or TOYOTA hand held tester and read value for volt age output of heated oxygen sensor Bank 1 sensor 1 PREPARATION a Connect the OBD II sca...

Page 310: ...996 TOYOTA T100 RM449U 2 Check for open and short in harness and connector between ECM and heated oxygen sensor bank 1 sensor 1 See page IN 26 NG Repair or replace harness or connector OK Replace heat...

Page 311: ...ge and the short term fuel trim value can be read using the OBD II scan tool or TOYOTA hand held tester WIRING DIAGRAM Refer to DTC P0125 on page DI 44 CONFIRMATION DRIVING PATTERN 1 Connect the TOYOT...

Page 312: ...nnect the OBD II scan tool or TOYOTA hand held tester to the DLC3 b Warm up the engine to normal operating temp CHECK Read heated oxygen sensor output voltage and short term fuel trim HINT Read the va...

Page 313: ...th the engine at 2 500 rpm for approx 90 sec CHECK Use the OBD II scan tool or TOYOTA hand held tester read the output voltage of the heated oxygen sensor during idling OK Heated oxygen sensor output...

Page 314: ...0133 Response time for heated oxygen sensor s voltage output to change from rich to lean or from lean to rich is 1 sec or more during idling after engine is warmed up 2 trip detection logic S Heated o...

Page 315: ...etecting Condition Trouble Area P0135 P0141 When heater operates heater current exceeds 2 A 2 trip detection logic S Open or short in heater circuit of heated oxygen sensor S Heated oxygen sensor heat...

Page 316: ...rim See page MF 50 b Turn the ignition switch ON CHECK Measure voltage between terminals HT1 HT2 of ECM connec tor and body ground HINT S Connect terminal HT1 to bank 1 sensor 1 S Connect terminal HT2...

Page 317: ...or less when vehicle is driv en at 50 km h 31 mph or more after engine is warmed up 2 trip detection logic S Heated oxygen sensor HINT Sensor 2 refers to the sensor farther away from the engine body W...

Page 318: ...DLC3 b Warm up the engine to normal operating temp CHECK Read voltage output of the heated oxygen sensor bank 1 sensor 2 when the engine suddenly raced HINT Perform quick racing to 4 000 rpm 3 min us...

Page 319: ...ond a certain value it is de tected as a malfunction and the MIL lights up DTC No DTC Detecting Condition Trouble Area P0171 When air fuel ratio feedback is stable after engine warming up fuel trim is...

Page 320: ...t term fuel trim RESULT Pattern Heated oxygen sensor output voltage Short term fuel trim 1 Lean condition Changes at 0 55 V or less Changes at about 20 2 Rich condition Changes at 0 4 V or more Change...

Page 321: ...1996 TOYOTA T100 RM449U 5 Check mass air flow meter and engine coolant temp sensor See page DI 22 DI 33 NG Repair or replace OK 6 Check for spark and ignition See page IG 1 NG Repair or replace OK Che...

Page 322: ...ing conditions will cause catalyst overheating the MIL blinks when misfiring occurs DTC No DTC Detecting Condition Trouble Area P0300 Misfiring of random cylinders is detected during any particular 20...

Page 323: ...3 26 26 M T A T 10 20 E01 E02 ECM FI6588 FI6538 A00064 10 V Division GND 10 V Division 100 msec Division Idling GND Magnification 1 msec Division Idling Injection duration DIAGNOSTICS ENGINE 3RZ FE DI...

Page 324: ...carbon deposit present Not wet with gas oline or oil 2 Electrode gap 0 8 mm 0 031 in PREPARATION a Install the spark plug to the high tension code b Disconnect the injector connector c Ground the spa...

Page 325: ...gnition switch ON CHECK Measure voltage between applicable terminal of ECM connec tor and body ground OK Voltage 9 14 V OK Go to step 4 NG 3 Check resistance of injector of misfiring cylinder See page...

Page 326: ...r injection See page MF 16 NG Replace injector OK 6 Check EGR system See page EC 7 NG Repair EGR system OK 7 Check mass air flow meter and engine coolant temp sensor See page DI 22 DI 33 NG Repair or...

Page 327: ...it becomes deformed which occurs when the cylinder block vi brates due to knocking If engine knocking occurs ignition timing is retarded to suppress it DTC No DTC Detecting Condition Trouble Area P032...

Page 328: ...nd PREPARATION a Remove the right cowl side trim See page MF 51 b Disconnect the E6 connector of ECM CHECK Measure resistance between terminal KNK of ECM connector and body ground OK Resistance 1 M or...

Page 329: ...sensor NO Check and replace ECM See page IN 26 Reference INSPECTION USING OSCILLOSCOPE S With the engine racing 4 000 rpm measure between terminal KNK of ECM and body ground HINT The correct waveform...

Page 330: ...34 teeth and is mounted on the crankshaft The NE signal sensor generates 34 signals of every engine revolution The ECM detects the standard crankshaft angle based on the G signals and the actual cran...

Page 331: ...k resistance of crankshaft position sensor See page IG 14 Reference INSPECTION USING OSCILLOSCOPE During cranking or idling check between terminals G and G NE and NE of ECM HINT The correct waveforms...

Page 332: ...DI 68 DIAGNOSTICS ENGINE 3RZ FE 1996 TOYOTA T100 RM449U 3 Inspect sensor installation and teeth of signal plate NG Tighten the sensor Replace signal plate OK Check and replace ECM See page IN 26...

Page 333: ...safe function stopping the fuel injection DTC No DTC Detecting Condition Trouble Area P0336 Deviation on crankshaft position sensor signal and camshaft position sensor signal S Valve timing S Distrib...

Page 334: ...ion The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals DTC No DTC Detecting Condition Trouble Area P0340 No cam...

Page 335: ...DIAGNOSTICS ENGINE 3RZ FE DI 71 1996 TOYOTA T100 RM449U 3 Check air gap See page EM 1 NG Replace distributor housing OK Check and replace ECM See page IN 26...

Page 336: ...reduce NOx emissions The amount of EGR is regulated by the EGR vacuum modulator according to the engine load If even one of the following conditions is fulfilled the VSV is turned ON by a signal from...

Page 337: ...mph for 3 min or more 4 Idle the engine for about 2 min 5 Do steps 3 and 4 again 6 Check the READINESS TESTS mode on the OBD II scan tool or TOYOTA hand held tester If COMPL is displayed and the MIL d...

Page 338: ...e TOYOTA hand held tester main switch ON CHECK Read EGR gas temp on the TOYOTA hand held tester OK EGR gas temp 10 C 50 F or more HINT If there is an open circuit the TOYOTA hand held tester indicates...

Page 339: ...ct between terminals THG and E2 of the ECM con nector HINT The EGR gas temp sensor connector is disconnected Before checking do a visual check and contact pressure check for the ECM connector See page...

Page 340: ...CK Check operation of VSV when it is operated by the TOYOTA hand held tester OK EGR system is OFF Air flows from port E to port F EGR system is ON Air does not flow from port E to port F OK Go to step...

Page 341: ...ester to the DLC3 b Turn the ignition switch ON and push the TOYOTA hand held tester main switch ON c Select the ACTIVE TEST mode on the TOYOTA hand held tester EGR system ON d Race the engine at 4 00...

Page 342: ...tor CHECK Measure resistance between terminals of EGR gas temp sen sor connector OK Resistance 600 k or less HINT If there is open circuit ohmmeter indicates 720 k or more NG Check and replace EGR gas...

Page 343: ...See page MF 50 b Turn the ignition switch ON CHECK Measure voltage between terminals of THG and E2 of ECM connector HINT The EGR gas temp sensor connector is disconnected OK Voltage 4 5 5 5 V OK Open...

Page 344: ...Disconnect the E7 connector of ECM c Turn the ignition switch ON CHECK Check VSV function 1 Connect between terminal EGR of ECM and body ground ON 2 Disconnect between terminal EGR of ECM and body gr...

Page 345: ...mp sensor PREPARATION a Disconnect the EGR gas temp sensor connector b Start the engine and warm it up c Disconnect the VSV connector for EGR d Race the engine at 4 000 rpm or 3 min CHECK Measure resi...

Page 346: ...r circuit S ECM EGR valve is always open 2 trip detection logic WIRING DIAGRAM Refer to DTC P0401 on page DI 72 SYSTEM CHECK DRIVING PATTERN Refer to DTC P0401 on page DI 72 INSPECTION PROCEDURE TOYOT...

Page 347: ...ON Disconnect the EGR gas temp sensor connector CHECK Read EGR gas temp on the TOYOTA hand held tester OK EGR gas temp 3 1 C 37 6 F OK Replace EGR gas temp sensor NG 3 Check for short in harness or EC...

Page 348: ...en in harness and connector be tween R B No 2 and ECM See page IN 26 OBD II scan tool excluding TOYOTA hand held tester 1 Check resistance of EGR gas temp sensor PREPARATION Disconnect the EGR gas tem...

Page 349: ...G Repair or replace harness or connector OK 3 Check VSV for EGR See page MF 44 OK Check EGR valve See page EC 7 NG 4 Check operation of VSV for EGR See page MF 44 NG Replace VSV for EGR OK 5 Check for...

Page 350: ...of the oxygen sensor before the catalyst repeat edly changing back and forth from rich to lean If the catalyst is functioning normally the waveform of the oxygen sensor after the catalyst switches bac...

Page 351: ...aveform of the heated oxygen sensor bank 1 sensor 2 OX2 HINT If there is a malfunction in the system the waveform of the heated oxygen sensor bank 1 sensor 2 OX2 is almost the same as that of the heat...

Page 352: ...fuel from the fuel tank is routed through the charcoal canister to the intake manifold for combustion in the cylinders The ECM changes the duty signal to the VSV for EVAP so that the intake quantity o...

Page 353: ...tes ter main switch ON c Select the ACTIVE TEST mode on the TOYOTA hand held tester CHECK Check operation of VSV when it is operated by the TOYOTA hand held tester OK 1 VSV is ON Air flows from port...

Page 354: ...5 OBD II scan tool excluding TOYOTA hand held tester 1 Check operation of VSV for EVAP See page MF 43 NG Replace VSV for EVAP OK 2 Check voltage between terminal PRG of ECM connector and body ground P...

Page 355: ...FE DI 91 1996 TOYOTA T100 RM449U 3 Check connection of vacuum hose See Fig 1 in circuit description NG Repair or replace OK 4 Check charcoal canister See page EC 5 NG Repair or replace OK Check and re...

Page 356: ...icle speed sensor is mounted in the combination meter It contains a magnet which is rotated by the speed meter cable Turning the reed switch ON and OFF 4 times for every revolution of the speedmeter I...

Page 357: ...al NG Check speedometer See page BE 38 OK 2 Check voltage between terminal SP1 of ECM connector and body ground PREPARATION a Remove the right cowl side trim See page MF 50 b Disconnect the cruise con...

Page 358: ...CRIPTION The rotary solenoid type IAC valve is located in front of the in take air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage In this way the in...

Page 359: ...tion system See page MF 1 NG Repair or replace OK 2 Check voltage between terminals RSO and RSC of ECM connector and body ground PREPARATION a Remove the right cowl side trim See page MF 50 b Disconne...

Page 360: ...e See page MF 31 NG Replace IAC valve OK Check for open and short in harness and con nector between R B No 2 and IAC valve IAC valve and ECM See page IN 26 4 Check operation of IAC valve See page MF 3...

Page 361: ...ATA Throttle Valve Closed Throttle Position Switch Signal Malfunction Fully closed OFF Open circuit Fully open ON Short circuit WIRING DIAGRAM Refer to DTC P0120 on page DI 39 INSPECTION PROCEDURE HIN...

Page 362: ...r open in harness or ECM PREPARATION a Connect the TOYOTA hand held tester to the DLC3 b Disconnect the throttle position sensor connector c Connect the sensor wire harness terminals between ter minal...

Page 363: ...e right cowl side trim See page MF 50 b Connect between terminals IDL and E2 of the ECM con nector HINT Throttle position sensor connector is disconnected Before checking do a visual check and contact...

Page 364: ...OYOTA T100 RM449U 4 Check for short in harness or ECM PREPARATION a Connect the TOYOTA hand held tester to the DLC3 b Disconnect the throttle position sensor connector c Turn the ignition switch ON CH...

Page 365: ...harness or ECM PREPARATION a Remove right cowl side trim See page MF 50 b Disconnect the E6 connector of the ECM c Turn the ignition switch ON HINT Throttle position sensor connector is disconnected C...

Page 366: ...REPARATION a Disconnect the throttle position sensor connector b Turn the ignition switch ON CHECK Measure voltage between terminals 3 and 4 of throttle position sensor connector OK Voltage 9 14 V OK...

Page 367: ...imary current flow to the ignition coil based on the engine rpm and ignition timing one revolution ago that is the time the Tr2 turns on When it reaches the ignition timing the ECM turns Tr1 off and o...

Page 368: ...RM449U INSPECTION PROCEDURE 1 Check spark plug and spark See page IG 1 NG Go to step 4 OK 2 Check for open and short in harness and connector in IGF signal circuit between ECM and igniter See page IN...

Page 369: ...a Disconnect the igniter connector b Remove the right cowl side trim See page MF 50 c Turn the ignition switch ON CHECK Measure voltage between terminal IGF of ECM connector and body ground OK Voltage...

Page 370: ...ECM connector and body ground PREPARATION Remove the right cowl side trim See page MF 50 CHECK Measure voltage between terminals IGT of ECM connector and body ground when engine is cranked OK Voltage...

Page 371: ...asure voltage between terminals IGT of ECM connector and body ground when engine is cranked OK Voltage More than 0 1 V and less than 4 5 V NG Check and replace ECM See page IN 26 OK 7 Check voltage be...

Page 372: ...Check for open and short in harness and connector between ignition switch and ignition coil ignition coil and igniter See page IN 26 NG Repair or replace harness or connector OK 9 Check ignition coil...

Page 373: ...er to DTC P0335 on page DI 66 DTC No DTC Detecting Condition Trouble Area P1335 No crankshaft position sensor signal to ECM with engine speed 1 000 rpm or more S Open or short in crankshaft position s...

Page 374: ...flow is slow so fuel vaporazation is poor A rich mixture is therefore necessary in order to achieve good startability While the engine is being cranked the battery voltage is ap plied to terminal STA...

Page 375: ...gnal PREPARATION a Connect the TOYOTA hand held tester to the DLC3 b Turn ignition switch ON and TOYOTA hand held tester main switch ON CHECK Read STA signal on the TOYOTA hand held tester while start...

Page 376: ...CRIPTION Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air fuel ratio adaptive control value memory etc DTC No DTC...

Page 377: ...ove the right cowl side trim See page MF 50 CHECK Measure voltage between terminal BATT of ECM connector and body ground OK Voltage 9 14 V OK Check and replace ECM See page IN 26 NG 2 Check EFI fuse P...

Page 378: ...moved from the N position to the D position this signal is used for air fuel ratio correction and for idle speed control estimated control etc DTC No DTC Detecting Condition Trouble Area P1780 2 or m...

Page 379: ...M T IE1 W R M T W R A T 12 12 E4 E4 14 24 E7 E7 BR A T M T E1 B ECM 8 DIAGNOSTICS ENGINE 3RZ FE DI 115 1996 TOYOTA T100 RM449U ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is...

Page 380: ...See page MF 50 b Turn the ignition switch ON CHECK Measure voltage between terminals B and E1 of ECM con nector OK Voltage 9 14 V OK Proceed to next circuit inspection shown on problem symptoms table...

Page 381: ...EFI main relay Marking EFI and ECM See page IN 26 NG Repair or replace harness or connector OK 6 Check IGN fuse PREPARATION Remove the IGN fuse from the J B No 1 CHECK Check continuity of IGN fuse OK...

Page 382: ...anked current flows from terminal ST of the ignition switch to the starter relay coil the starter relay switches on and current flows to coil L1 of the circuit opening relay Thus the circuit opening r...

Page 383: ...IC IC 2 W R W R W B EA1 9 EA 3 B W B W B W IE1 21 Starter Relay IC M T B W 1 5 2 3 1 2 B R W B W B A T W B B W 3 2 2 2 Relay EFI 2 2 5 1 2 2 2 2 2 R B No 2 2 2 2 W W B Y W R W 14 8 IA3 IA3 W R W 8 EA...

Page 384: ...hand held tester to the DLC3 b Turn the ignition switch ON and push the TOYOTA hand held tester main switch ON c Use ACTIVE TEST mode to operate the fuel pump CHECK Check for fuel pressure in the fuel...

Page 385: ...e voltage between terminals 1 and 4 OK Terminals 1 and 4 Same as battery NG Replace circuit opening relay OK 4 Check voltage between terminal FC of ECM connector and body ground PREPARATION a Remove t...

Page 386: ...rcuit opening relay and fuel pump fuel pump and body ground See page IN 26 NG Repair or replace harness or connector OK Check and replace ECM 7 Check circuit opening relay PREPARATION Remove the circu...

Page 387: ...nector and body ground CHECK Measure voltage between terminal 3 of circuit opening relay connector and body ground when engine is cranked OK Voltage 9 14 V NG Check for starter signal circuit See page...

Page 388: ...e right cowl side trim See page MF 50 b Turn the ignition switch ON CHECK a Connect between terminal FC of ECM connector and body ground b Check for fuel pressure in the fuel return hose when it is pi...

Page 389: ...und See page MF 42 NG Check for open in harness and connector be tween EFI main relay and circuit opening relay circuit opening relay and ECM OK 5 Check fuel pump See page IG 1 NG Repair or replace fu...

Page 390: ...ce circuit opening relay OK 8 Check voltage between terminal 3 of circuit opening relay connector and body ground See page MF 42 NG Check for starter signal circuit See page DI 110 OK Check for open i...

Page 391: ...mulation P IN 16 DTC Chart P DI 140 Problem Symptoms Table P DI 148 Circuit Inspection P DI 149 Adjustment Repair DTC Check P DI 129 Titles inside are titles of pages in in the bottom portion See the...

Page 392: ...eration Shifting from N to D Other Dates Problem Occurred Problem Frequency Condition When Problem Occurs Weather Engine Operation Engine Temp Place Outdoor Temp Constant Sometimes times per day month...

Page 393: ...on to the MIL lighting up when a malfunction is detected the applicable Diagnostic Trouble Codes DTCs prescribed by SAE J2012 are recorded in the ECM memory See page DI 140 If the malfunction does not...

Page 394: ...e engine condition when a misfire DTCs P0300 P0306 or fuel trim malfunction DTCs P0171 P0172 or other mal function first malfunction only is detected S Because freeze frame data records the engine con...

Page 395: ...e a Check the MIL 1 The MIL comes on when the ignition switch is turned ON and the engine is not running HINT If the MIL does not light up troubleshoot the combination meter See page BE 36 2 When the...

Page 396: ...sitive voltage 11 V or more S Throttle valve fully closed S Transmission in P or N position S Air conditioning switched OFF 2 Turn the ignition switch OFF 3 Prepare the TOYOTA hand held tester 4 Conne...

Page 397: ...tively 0 1 V x VTA x 0 95 V P0135 P0141 Heater circuit in which an abnormality is detected is turned off Ignition switch OFF P0325 P0330 Max timing retardation Ignition switch OFF P1300 Fuel cut IGF s...

Page 398: ...ue to trouble shoot YES 3 Does engine start NO Go to step 7 YES 4 Check air filter PREPARATION Remove the air filter CHECK Visual check that the air filter is not dirty or excessive oily HINT If neces...

Page 399: ...to check the idle speed OK Idle speed 650 750 rpm NG Proceed to problem symptoms table on page DI 148 OK 6 Check ignition timing PREPARATION a Warm up the engine to normal operating temperature b Shi...

Page 400: ...d tester main switch ON d Use ACTIVE TEST mode to operate the fuel pump e Please refer to the TOYOTA hand held tester operator s manual for further details f If you have no TOYOTA hand held tester con...

Page 401: ...ignition coil or high tension cord d Disconnect the injector connector e Hold the end about 12 5 mm 0 61 in from the ground CHECK Check if the spark occurs while engine is being cranked NOTICE To prev...

Page 402: ...FT 1 Short term Fuel Trim Bank 1 0 20 LONG FT 1 Long term Fuel Trim Bank 1 0 20 ENGINE SPD Engine Speed Idling 650 750 rpm VEHICLE SPD Vehicle Speed Vehicle stopped 0 km h 0 mph IGN ADVANCE Ignition...

Page 403: ...for each cylinder 0 IGNITION Total number of ignition for every 1 000 revolutions 0 3 000 EGRT GAS 2 EGR Gas Temp Sensor Value EGR not operating Temp between intake air temp and engine coolant temp EG...

Page 404: ...nsor circuit Engine coolant temp sensor ECM P0116 DI 162 Engine Coolant Temp Circuit Range Performance Problem Engine coolant temp sensor Cooling system P0120 DI 163 Throttle Pedal Position Sensor Swi...

Page 405: ...it Knock sensor 1 looseness ECM 1 P0330 DI 188 Knock Sensor 2 Circuit Malfunction Open or short in knock sensor 2 circuit Knock sensor 2 looseness ECM 1 P0335 DI 191 Crankshaft Position Sensor A Circu...

Page 406: ...Air intake hose loose P0510 DI 231 Closed Throttle Position Switch Malfunction Open in closed throttle position switch circuit Closed throttle position switch ECM MIL lights up MANUFACTURER CONTROLLED...

Page 407: ...rk Neutral Position Switch Fuel Pump Ignition Switch VSV for EGR Stop Light Switch VSV for Vapor Pressure Sensor VSV for EVAP EFI Main Relay Marking EFI DLC1 Knock Sensor 2 Knock Sensor 1 Injector Ign...

Page 408: ...0 2 1 0 IDL E6 11 E2 E6 9 Y L BR B IG switch ON and apply vacuum to the throttle opener Throttle valve fully closed 0 3 IG switch ON Throttle valve fully open 9 14 VTA E6 10 E2 E6 9 Y B BR B IG switch...

Page 409: ...Idling A C switch OFF 9 14 FC E7 14 E1 E7 24 G Y BR IG switch ON 9 14 Idling 0 3 OX1 E6 5 E1 E7 24 W BR Maintain engine speed at 2 500 rpm for 2 min after warming up Pulse generation See page DI 172...

Page 410: ...nking 6 0 or more 10 E7 10 E01 E7 34 W R BR IG switch ON 9 14 Idling Pulse generation See page DI 183 20 E7 9 E01 E7 34 W BR IG switch ON 9 14 Idling Pulse generation See page DI 183 30 E7 8 E01 E7 34...

Page 411: ...ge DI 172 HT1 E7 15 E03 E7 1 P G W B Idling Below 3 0 IG switch ON 9 14 HT2 E7 16 E03 E7 1 R G W B Idling Below 3 0 IG switch ON 9 14 KNK1 E6 17 E1 E5 16 B BR Idling Pulse generation See page DI 188 K...

Page 412: ...engine Difficult to start 1 Starter signal circuit 2 Fuel pump control circuit DI 248 DI 255 High engine idle speed Poor idling 1 A C signal circuit Compressor circuit 2 ECM power source circuit AC 7...

Page 413: ...circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit with the power transistor controlled so that the potential of A and B remains equal to maintain the set te...

Page 414: ...PROCEDURE 1 Connect OBD II scan tool or TOYOTA hand held tester and read value of mass air flow rate PREPARATION a Connect the OBD II scan tool or TOYOTA hand held tester to the DLC3 b Turn the igniti...

Page 415: ...air flow meter con nector and body ground OK Voltage 9 14 V NG Check for open in harness and connector between EFI main relay and mass air flow meter See page IN 26 OK 3 Check voltage between termina...

Page 416: ...ce mass air flow meter 5 Check continuity between terminal E3 of ECM and body ground PREPARATION Remove the right cowl side trim See page SF 61 CHECK Check continuity between terminal E3 of ECM connec...

Page 417: ...ns a and b continue with engine speed 900 rpm or less 2 trip detection logic a Throttle valve fully closed b Mass air flow meter output u 2 2 V S Mass air flow meter Conditions a and b continue with e...

Page 418: ...emp sensor from the terminal THA via resistor R That is the resistor R and the intake air temp sensor are con nected in series When the resistance value of the intake air temp sensor changes in accord...

Page 419: ...EPARATION a Connector the OBD II scan tool or TOYOTA hand held tester to the DLC3 b Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand held tester main switch ON CHECK Read temp...

Page 420: ...n tool or TOYOTA hand held tester OK Temp value 140 C 284 F or more OK Confirm good connection at sensor If OK replace mass air flow meter NG 3 Check for open in harness or ECM PREPARATION a Remove th...

Page 421: ...ector b Turn the ignition switch ON CHECK Read temp value on the OBD II scan tool or TOYOTA hand held tester OK Temp value 40 C 40 F OK Replace mass air flow meter NG 5 Check for short in harness or E...

Page 422: ...me as in the intake air temp circuit malfunc tion shown on page DI 154 If the ECM detects the DTC P0115 it operates the fail safe function in which the engine coolant temp is assumed to be 80 C 176 F...

Page 423: ...on the OBD II scan tool or TOYOTA hand held tester OK Same as actual engine coolant temp HINT S If there is open circuit OBD II scan tool or TOYOTA hand held tester indicates 40 C 40 F S If there is...

Page 424: ...coolant temp sensor connector is disconnected Before checking do a visual and contact pressure check for the ECM connector See page IN 26 c Turn the ignition switch ON CHECK Read temp value on the OBD...

Page 425: ...hort in harness or ECM PREPARATION a Remove the right cowl side trim See page SF 61 b Disconnect the E6 connector of the ECM HINT The engine coolant temp sensor connector is disconnected c Turn the ig...

Page 426: ...ion logic S Engine coolant temp sensor S Cooling system If THW 7 C 19 4 F at engine start 5 min or more after starting engine engine coolant temp sensor value is 35 C 95 F or less 2 trip detection log...

Page 427: ...he ECM judges the vehicle driv ing conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air fuel ratio correction power increase correction an...

Page 428: ...A00004 ECM 5 V VCC VTA E2 2 3 1 Throttle Position Sensor E6 E6 E6 E6 E6 E6 1 10 9 1 7 22 G B Y B BR B M T A T DI 164 DIAGNOSTICS ENGINE 5VZ FE 1996 TOYOTA T100 RM449U WIRING DIAGRAM...

Page 429: ...ld tester to DLC3 b Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand held tester main switch ON CHECK Read the throttle valve opening percentage OK Throttle valve Throttle valv...

Page 430: ...lve Resistance 1 2 2 5 5 9 k 1 3 Fully closed 0 2 5 7 k Fully open 2 0 10 2 k NG Replace throttle position sensor OK 4 Check voltage between terminals VTA and E2 of ECM PREPARATION a Remove the right...

Page 431: ...n terminals VCC and E2 of ECM PREPARATION a Remove the right cowl side trim See page SF 61 b Turn the ignition switch ON CHECK Measure voltage between terminals VCC and E2 of ECM con nector OK Voltage...

Page 432: ...cting Condition Trouble Area P0121 After vehicle speed has been exceeded 30 km h 19 mph even once output value of throttle position sensor is out of the applicable range while vehicle speed between 30...

Page 433: ...EAN condition small electromotive force 0 V When the air fuel ratio is RICHER than the stoichiometric air fuel ratio the oxygen concentration in the ex haust gas is reduced and the oxygen sensor infor...

Page 434: ...oxygen sensor from CURRENT DATA If voltage output of heated oxygen sensor is 0 V heated oxygen sensor circuit may be open or short WIRING DIAGRAM INSPECTION PROCEDURE 1 Connect OBD II scan tool or TO...

Page 435: ...1996 TOYOTA T100 RM449U 2 Check for open and short in harness and connector between ECM and heated oxygen sensor bank 1 sensor 1 See page IN 26 NG Repair or replace harness or connector OK Replace hea...

Page 436: ...hort term fuel trim value can be read using the OBD II scan tool or TOYOTA hand held tester WIRING DIAGRAM Refer to DTC P0125 on page DI 169 CONFIRMATION DRIVING PATTERN 1 Connect the TOYOTA hand held...

Page 437: ...ARATION a Connect the OBD II scan tool or TOYOTA hand held tester to the DLC3 b Warm up the engine to normal operating temp CHECK Read heated oxygen sensor output voltage and short term fuel trim RESU...

Page 438: ...oxygen sensor with the engine at 2 500 rpm for approx 90 sec CHECK Use the OBD II scan tool or TOYOTA hand held tester read the output voltage of the heated oxygen sensor during idling OK Heated oxyg...

Page 439: ...P0133 Response time for heated oxygen sensor s voltage output to change from rich to lean or from lean to rich is 1 sec or more during idling after engine is warmed up 2 trip detection logic S Heated...

Page 440: ...ated oxygen sensor heater ECM Heater current of 0 2 A or less when heater operates 2 trip detection logic HINT S Sensor 1 refers to the sensor closer to the engine body S Sensor 2 refers to the sensor...

Page 441: ...77 1996 TOYOTA T100 RM449U 2 Check resistance of heated oxygen sensor heater See page SF 60 NG Replace heated oxygen sensor OK Check and repair harness or connector between EFI main relay heated oxyge...

Page 442: ...less when vehicle is driven at 50 km h 31 mph or more after the engine is warmed up 2 trip detection logic S Heated oxygen sensor HINT Sensor 2 refers to the sensor farther away from the engine body...

Page 443: ...Warm up the engine to normal operating temp CHECK Read voltage output of the heated oxygen sensor bank 1 sensor 2 when the engine suddenly raced HINT Perform quick racing to 4 000 rpm 3 min using the...

Page 444: ...eyond a certain value it is detected as a malfunction and the MIL lights up DTC No DTC Detecting Condition Trouble Area P0171 When air fuel ratio feedback is stable after engine warming up fuel trim i...

Page 445: ...rt term fuel trim RESULT Pattern Heated oxygen sensor output voltage Short term fuel trim 1 Lean condition Changes at 0 55 V or less Changes at about 20 2 Rich condition Changes at 0 35 V or more Chan...

Page 446: ...1996 TOYOTA T100 RM449U 5 Check mass air flow meter and engine coolant temp sensor See page SF 29 SF 52 NG Repair or replace OK 6 Check for spark and ignition See page IG 1 NG Repair or replace OK Che...

Page 447: ...conditions will cause catalyst overheating the MIL blinks when misfiring occurs DTC No DTC Detecting Condition Trouble Area P0300 Misfiring of random cylinders is detected during any particular 200 o...

Page 448: ...A T EB 12 10 11 9 25 8 10 7 9 6 8 5 13 34 26 33 10 20 30 40 50 60 E01 E02 ECM FI6588 FI6538 A00064 10 V Division 10 V Division GND GND 100 msec Division Idling 1 msec Division Idling Injection duratio...

Page 449: ...ded spark plug ND K16TR11 NGK BKR5EKB 11 2 No large carbon deposit present Not wet with gosoline or oil 3 Electrode gap 1 0 1 1 mm 0 039 0 043 in PREPARATION a Install the spark plug to the ignition c...

Page 450: ...1 b Turn the ignition switch ON CHECK Measure voltage between applicable terminal of ECM connec tor and body ground OK Voltage 9 14 V OK Go to step 4 NG 3 Check resistance of injector of misfiring cyl...

Page 451: ...EGR system See page EC 9 NG Repair EGR system OK Only for 2WD models with a load capacity of 0 5 ton and regular cab 7 Check mass air flow meter and engine coolant temp sensor See page SF 29 and SF 52...

Page 452: ...ecomes deformed which occurs when the cylinder block vibrates due to knocking If engine knocking occurs ignition timing is retarded to suppress it DTC No DTC Detecting Condition Trouble Area P0325 No...

Page 453: ...tor EC1 c Connect the terminals of the disconnected EC1 male con nector and EC1 female as follows Male connector Female connector Terminal 1 Terminal 2 Terminal 2 Terminal 1 d Turn the ignition switch...

Page 454: ...nk side S If DTC P0330 has changed to P0325 check the knock sensor circuit on the left bank side NG Repair or replace harness or connector OK Replace knock sensor Reference INSPECTION USING OSCILLOSCO...

Page 455: ...pump body The NE signal plate has 34 teeth The NE signal sensor generates 34 signals of every engine revolution The ECM detects the standard crankshaft angle based on the G signals and the actual cra...

Page 456: ...k resistance of crankshaft position sensor See page IG 13 Reference INSPECTION USING OSCILLOSCOPE During cranking or idling check between terminals G and G NE and NE of ECM HINT The correct waveforms...

Page 457: ...DIAGNOSTICS ENGINE 5VZ FE DI 193 1996 TOYOTA T100 RM449U 3 Inspect sensor installation and teeth of signal plate NG Tighten the sensor Replace signal plate OK Check and replace ECM See page IN 26...

Page 458: ...ery engine revolution The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals DTC No DTC Detecting Condition Trouble...

Page 459: ...DIAGNOSTICS ENGINE 5VZ FE DI 195 1996 TOYOTA T100 RM449U 3 Inspect sensor installation NG Tighten the sensor OK Check and replace ECM See page IN 26...

Page 460: ...combustion reduce the combustion temp and reduce NOx emissions The amount of EGR is regulated by the EGR vacuum modulator according to the engine load If even one of the following conditions is fulfil...

Page 461: ...56 mph for 3 min or more 4 Idle the engine for about 2 min 5 Do steps 3 and 4 again 6 Check the READINESS TESTS mode on the OBD II scan tool or TOYOTA hand held tester If COMPL is displayed and the MI...

Page 462: ...he TOYOTA hand held tester main switch ON CHECK Read EGR gas temp on the TOYOTA hand held tester OK EGR gas temp 10 C 50 F or more HINT If there is an open circuit the TOYOTA hand held tester indicate...

Page 463: ...ight cowl side trim See page SF 61 b Connect between terminals THG and E2 of the ECM con nector HINT The EGR gas temp sensor connector is disconnected Before checking do a visual check and contact pre...

Page 464: ...for EGR PREPARATION Select the ACTIVE TEST mode on the TOYOTA hand held tester CHECK Check operation of VSV when it is operated by the TOYOTA hand held tester OK EGR system is OFF Air flows from port...

Page 465: ...N a Connect the TOYOTA hand held tester to the DLC3 b Turn the ignition switch ON and push the TOYOTA hand held tester main switch ON c Select the ACTIVE TEST mode on the TOYOTA hand held tester EGR s...

Page 466: ...nnector CHECK Measure resistance between terminals of EGR gas temp sen sor connector OK Resistance 600 k or less HINT If there is open circuit ohmmeter indicates 720 k or more NG Check and replace EGR...

Page 467: ...trim See page SF 61 b Turn the ignition switch ON CHECK Measure voltage between terminals of THG and E2 of ECM connector HINT The EGR gas temp sensor connector is disconnected OK 4 5 5 5 V OK Open in...

Page 468: ...t the E7 or E5 connector of the ECM c Turn the ignition switch ON CHECK Check VSV function 1 Connect between terminal EGR of ECM connector and body ground ON 2 Disconnect between terminal EGR of ECM c...

Page 469: ...emp sensor PREPARATION a Disconnect the EGR gas temp sensor connector b Start the engine and warm it up c Disconnect the VSV connector for EGR d Race the engine at 4 000 rpm or 3 min CHECK Measure res...

Page 470: ...unction S Open in VSV circuit for EGR S Short in EGR gas temp sensor circuit S ECM P0402 EGR valve is always open 2 trip detection logic WIRING DIAGRAM Refer to DTC P0401 on page DI 196 SYSTEM CHECK D...

Page 471: ...RATION Disconnect the EGR gas temp sensor connector CHECK Read EGR gas temp on the TOYOTA hand held tester OK EGR gas temp 3 1 C 37 6 F OK Replace EGR gas temp sensor NG 3 Check for short in harness o...

Page 472: ...for short in harness and connector be tween VSV and ECM See page IN 26 OBD II scan tool excluding TOYOTA hand held tester 1 Check resistance of EGR gas temp sensor PREPARATION Disconnect the EGR gas...

Page 473: ...Repair or replace harness or connector OK 3 Check VSV for EGR See page DI 196 step 5 OK Check EGR valve See page EC 9 NG 4 Check operation of VSV for EGR See page SF 49 NG Replace VSV for EGR OK 5 Che...

Page 474: ...e catalyst repeat edly changing back and forth from rich to lean If the catalyst is functioning normally the waveform of the oxygen sensor after the catalyst switches back and forth between rich and l...

Page 475: ...ack to the ECM check the waveform of the heated oxygen sensor bank 1 sensor 2 OX2 HINT If there is a malfunction in the system the waveform of the heated oxygen sensor bank 1 sensor 2 OX2 is almost th...

Page 476: ...ns leak from the components within the dotted line in fig 1 below or when there is a malfunction in either the VSV for EVAP the VSV for vapor pressure sensor or in the vapor pressure sensor itself DTC...

Page 477: ...ment Panel J B Driver Side J B EFI Relay EB J B No 3 VC E2 E1 E01 E01 TPC EVP 1 PTNK BR EFI A 1 2 LG W L 3 B O 5 V DIAGNOSTICS ENGINE 5VZ FE DI 213 1996 TOYOTA T100 RM449U WIRING DIAGRAM INSPECTION PR...

Page 478: ...sensor CHECK a Check that the vacuum hose is connected correctly b Check the vacuum hose for looseness and disconnection c Check the vacuum hose for cracks hole damage and blockage NG Repair or replac...

Page 479: ...of ECM con nector 1 Disconnect the vacuum hose from the vapor pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum to the vapor pressure sensor NOTICE The vacuum applied to the v...

Page 480: ...the EVAP is operated by the TOYOTA hand held tester check whether the disconnected hose ap plies suction to your finger OK VSV is ON Disconnected hose applies suction to your finger VSV is OFF Disconn...

Page 481: ...operation of VSV for EVAP See page SF 50 NG Replace VSV OK 9 Check for open and short in harness and connector between EFI main relay Marking EFI VSV for EVAP and ECM See page IN 26 NG Repair or repl...

Page 482: ...for the vapor pressure sensor c Select the ACTIVE TEST mode on the TOYOTA hand held tester d Start the engine CHECK Measure voltage between terminals PTNK and E2 of ECM con nector when VSV for EVAP i...

Page 483: ...ck operation of VSV for vapor pressure sensor See page SF 50 NG Replace VSV OK 13 Check for open and short in harness and connector between EFI main relay Marking EFI VSV for vapor pressure sensor and...

Page 484: ...d tester to the DLC3 b Remove the fuel tank cap c Disconnect the VSV connector for the vapor pressure sensor d Select the ACTIVE TEST mode on the TOYOTA hand held tester e Start the engine f The VSV f...

Page 485: ...charcoal canister charcoal canister and VSV for vapor pressure sensor VSV for vapor pressure sensor and vapor pressure sensor CHECK a Check that the vacuum hose is connected correctly b Check the vac...

Page 486: ...of ECM con nector 1 Disconnect the vacuum hose from the vapor pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum to the vapor pressure sensor NOTICE The vacuum applied to the v...

Page 487: ...TION a Remove the right cowl side trim See page SF 61 b Turn the ignition switch ON CHECK Check VSV function 1 Connect between terminal EVP of ECM and body ground 2 Disconnect between terminal EVP of...

Page 488: ...or replace harness or connector OK Check and replace ECM See page IN 26 9 Check VSV for vapor pressure sensor PREPARATION a Remove the right cowl side trim See page SF 61 b Turn the ignition switch O...

Page 489: ...n of VSV for vapor pressure sensor NG Replace VSV OK 11 Check for open and short in harness and connector between EFI main relay Marking EFI VSV for vapor pressure sensor and ECM See page IN 26 NG Rep...

Page 490: ...unted in the combination meter It contains a magnet which is rotated by the speed meter cable Turning the reed switch ON and OFF 4 times for every revolution of the speedmeter It is then transmitted t...

Page 491: ...k speedometer and cable See page BE 38 OK 2 Check voltage between terminal SP1 of ECM connector and body ground PREPARATION a Remove the right cowl side trim See page SF 61 b Disconnect the cruise con...

Page 492: ...ocated in front of the in take air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage In this way the intake air volume bypassing the throttle valve is...

Page 493: ...Repair or replace OK 2 Check A C signal circuit See page AC 79 NG Repair or replace OK 3 Check voltage terminals RSO and RSC of ECM connector and body ground PREPARATION a Remove the right cowl side...

Page 494: ...See page SF 39 NG Replace IAC valve OK Check for open and short in harness and connector between R B No 2 and IAC valve IAC valve and ECM See page IN 26 5 Check operation of the IAC valve See page SF...

Page 495: ...sed throttle position switch does not turn ON even once when the vehicle is driven 2 trip detection logic S Open in closed throttle position switch circuit S Closed throttle position switch S ECM HINT...

Page 496: ...ltaneously E2 sensor ground may be open TOYOTA hand held tester 1 Check for open in harness or ECM PREPARATION a Connect the TOYOTA hand held tester to the DLC3 b Disconnect the throttle position sens...

Page 497: ...onnec tors HINT Throttle position sensor connector is disconnected Before checking do a visual check and contact pressure check for the connector c Turn ignition switch ON CHECK Read CTP switch signal...

Page 498: ...Turn ignition switch ON CHECK Measure voltage between terminals 3 and 4 of throttle position sensor connector OK Voltage 9 14 V OK Confirm good connection at sensor If OK re place throttle position s...

Page 499: ...ers simultaneously with one igni tion coil In the 2 cylinder simultaneous ignition system each of the 2 spark plugs is connected to the end of the secondary winding High voltage generated in the secon...

Page 500: ...park Plug B R B R ECM Ignition Coil B R BR Y BR W B R B R B W 2 1 2 1 2 1 10 2 1 3 8 4 5 6 7 9 To Tachometer M T A T E7 E7 E7 E7 E7 E7 E7 E7 IGT1 23 24 22 25 21 26 17 12 IGT2 IGT3 IGF 5 V DI 236 DIAGN...

Page 501: ...Repair or replace harness or connector OK 3 Disconnect igniter connector and check voltage between terminal IGF of ECM connector and body ground PREPARATION a Disconnect the igniter connector b Remov...

Page 502: ...r See page IN 26 NG Repair or replace harness or connector OK 5 Check voltage between terminals IGT1 3 of ECM connector and body ground PREPARATION Remove the right cowl side trim See page SF 61 CHECK...

Page 503: ...owl side trim See page SF 61 CHECK Measure voltage between terminals IGT1 3 of ECM connector and body ground when engine is cranked OK Voltage More than 0 1 V and less than 5 0 V NG Check and replace...

Page 504: ...Check for open and short in harness and connector between ignition switch and ignition coil ignition coil and igniter See page IN 26 NG Repair or replace harness or connector OK 9 Check ignition coil...

Page 505: ...DTC P0335 on page DI 191 DTC No DTC Detecting Condition Trouble Area P1335 No crankshaft position sensor signal to ECM with engine speed 1 000 rpm or more S Open or short in crankshaft position sensor...

Page 506: ...ine is being cranked the battery positive volt age is applied to terminal STA of the ECM The starter signal is mainly used to increase the fuel injection volume for the starting injection control and...

Page 507: ...PREPARATION a Connect the TOYOTA hand held tester to the DLC3 b Turn ignition switch ON and push TOYOTA hand held tester main switch ON CHECK Read STA signal on the TOYOTA hand held tester while star...

Page 508: ...ttery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air fuel ratio adaptive control value memory etc DTC No DTC Detecting...

Page 509: ...Remove the right cowl side trim See page SF 61 CHECK Measure voltage between terminal BATT of ECM connector and body ground OK Voltage 9 14 V OK Check and replace ECM See page IN 26 NG 2 Check EFI fus...

Page 510: ...alfunction on page DI 188 DTC No DTC Detecting Condition Trouble Area P1605 Engine control computer malfunction for knock control S ECM WIRING DIAGRAM Refer to page DI 188 for the WIRING DIAGRAM INSPE...

Page 511: ...the N position to the D position this signal is used for air fuel ratio correction and for idle speed control estimated control etc DTC No DTC Detecting Condition Trouble Area P1780 2 or more switches...

Page 512: ...T AM1 14 1 3 6 22 5 6 15 2 2 M T A T A T DI 248 DIAGNOSTICS ENGINE 5VZ FE 1996 TOYOTA T100 RM449U Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is cranked the intake air flow is slow so f...

Page 513: ...ON a Connect the TOYOTA hand held tester to the DLC3 b Turn the ignition switch ON and push the TOYOTA hand held tester main switch ON CHECK Read STA signal on the TOYOTA hand held tester while starte...

Page 514: ...REPARATION Remove the right cowl side trim See page SF 61 CHECK Measure voltage between terminal STA of ECM connector and body ground during engine cranking OK Voltage 6 V or more OK Proceed to next c...

Page 515: ...2 2 2 2 2 5 2 3 1 2 EFI Relay E7 E5 24 16 E1 B EA EB EA1 DIAGNOSTICS ENGINE 5VZ FE DI 251 1996 TOYOTA T100 RM449U ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON bat...

Page 516: ...ee page SF 61 b Turn the ignition switch ON CHECK Measure voltage between terminals B and E1 of ECM con nector OK Voltage 9 14 V OK Proceed to next circuit inspection shown on problem symptoms table S...

Page 517: ...EFI fuse OK 5 Check for open harness and connector between EFI main relay Marking EFI and battery EFI main relay Marking EFI and ECM See page IN 26 NG Repair or replace harness or connector OK 6 Chec...

Page 518: ...5VZ FE 1996 TOYOTA T100 RM449U 7 Check ignition switch See page BE 12 NG Replace ignition switch OK Check for open in harness and connector be tween IG switch and EFI main relay EFI main relay and bo...

Page 519: ...he NE signal is input to the ECM In the diagram below when the engine is cranked current flows from terminal ST of the ignition switch to the starter relay coil the starter relay switches on and curre...

Page 520: ...2 2 2 5 1 2 2 2 2 2 2 5 R B 1 2 2 2 3 1 W W B Y IA3 IGN B M T B Neutral Position A T Fuel Pump W B BJ1 BJ2 BJ2 W B w ABS w o ABS 11 w ABS w o ABS 10 16 Clutch Start Switch M T Cancel No 2 Starter J B...

Page 521: ...TOYOTA hand held tester to the DLC3 b Turn the ignition switch ON and push the TOYOTA hand held tester main switch ON c Use ACTIVE TEST mode to operate the fuel pump CHECK Check for fuel pressure in t...

Page 522: ...b Measure voltage between terminals 1 and 4 OK Voltage Same as battery NG Replace circuit opening relay OK 4 Check voltage between terminal FC of ECM connector and body ground PREPARATION a Remove the...

Page 523: ...circuit opening relay and fuel pump fuel pump and body ground See page IN 26 NG Repair or replace harness or connector OK Check and replace ECM See page IN 26 7 Check circuit opening relay PREPARATION...

Page 524: ...signal circuit See page DI 248 OK Check for open in harness and connector be tween terminal 6 of circuit opening relay con nector and body ground See page IN 26 OBD II scan tool excluding TOYOTA hand...

Page 525: ...opening relay See page DI 255 step 3 NG Replace circuit opening relay OK 4 Check voltage between terminal FC of ECM connector and body ground See page DI 255 step 4 NG Check for open in harness and c...

Page 526: ...or OK Check and replace ECM See page IN 26 7 Check circuit opening relay See page DI 255 step 7 NG Replace circuit opening relay OK 8 Check voltage between terminal 3 of circuit opening relay connecto...

Page 527: ...C3 P DI 265 2 3 4 5 6 symptom does not occur Problem Symptom Confirmation 8 7 Symptom Simulation P IN 16 symptom occur DTC Check P DI 265 OK Code 11 Preliminary Check P DI 265 DTC Chart P DI 276 Mecha...

Page 528: ...Any position Particular position No up shift 1st 2nd 2nd 3rd 3rd O D No down shift O D 3rd 3rd 2nd 2nd 1st Lock up malfunction Shift point too high or too low Harsh engagement N D Lock up Any drive po...

Page 529: ...ystem components which affect vehicle emissions In addition to the MIL lighting up when a malfunction is detected the applicable DTCs pre scribed by SAE J2012 are recorded in the ECM memory 3RZ FE See...

Page 530: ...C3 The vehicle s ECM uses the V P W Variable Pulse Width for communication to comply with SAE J1850 The termi nal arrangement of DLC3 complies with SAE J1962 and matches the V P W format Terminal No C...

Page 531: ...frame data and note them down 1 Prepare an OBD II scan tool complying with SAE J1978 or TOYOTA hand held tester 2 Connect the OBD II scan tool or TOYOTA hand held tester to DLC3 at the lower of the in...

Page 532: ...he MIL flashes 7 Start the engine MIL goes out after the engine starts 8 Simulate the conditions of the malfunction de scribed by the customer NOTICE Leave the ignition switch ON until you have checke...

Page 533: ...O D up shifts Evaluation Problem Possible cause If the shock is excessive S Line pressure is too high S Accumulator is defective S Check ball is defective 3 Check for abnormal noises and vibration Run...

Page 534: ...e is defective 3 Check for abnormal noises during acceleration and deceleration d R position test Shift into the R position and fully depress the accelerator pedal and check for slipping CAUTION Befor...

Page 535: ...el at the normal operating tem perature 70 80 C 158 176 F and add as nec essary NOTICE Do not overfill d Check the fluid leaks Check for leaks in the transmission If there are leaks it is necessary to...

Page 536: ...bf h Check the idle speed Idle speed In N position and air conditioner OFF 3RZ FE 700 50 rpm 5VZ FE 700 50 rpm 6 MECHANICAL SYSTEM TESTS a Measure the stall speed The object of this test is to check t...

Page 537: ...e lapse or lag before the shock can be felt This is used for checking the condition of the O D direct clutch forward clutch direct clutch and 1st and reverse brake NOTICE S Do the test at normal opera...

Page 538: ...test if the rear wheels begin to rotate before the engine speed reaches specified stall speed 8 In the same manner do the test in R position Specified line pressure 3RZ FE Condition D position kPa kgf...

Page 539: ...he shift and gear positions correspond with the table below S While driving shift through the L 2 and D positions Check that the gear change corresponds to the shift position Shift Position Gear Posit...

Page 540: ...rical Malfunction Shift Solenoid Valve No 1 Open or short in shift solenoid valve No 1 circuit Shift solenoid valve No 1 ECM P0755 DI 289 Shift Solenoid B Malfunction Shift Solenoid Valve No 2 Shift s...

Page 541: ...DI98H 01 D10997 D10998 DIAGNOSTICS AUTOMATIC TRANSMISSION DI 277 1996 TOYOTA T100 RM449U PARTS LOCATION...

Page 542: ...Q07506 No 1 Vehicle Speed Sensor In Combination Meter O D Main Switch Cruise Control ECU DLC3 Stop Light Switch ECM DI 278 DIAGNOSTICS AUTOMATIC TRANSMISSION 1996 TOYOTA T100 RM449U...

Page 543: ...4 10 OD2 E1 E4 5 E7 24 Y G BR O D main switch ON Pushed in 9 14 O D main switch OFF Pushed once again Below 3 OIL E2 E7 21 E6 9 G B BR B ATF temperature 110 C 230 F or more Below 1 5 L E1 E4 15 E7 24...

Page 544: ...E1 E4 6 E5 16 Y G BR O D main switch ON Pushed in 9 14 O D main switch OFF Pushed once again Below 3 OIL E2 E6 12 E6 22 G B BR B ATF temperature 110 C 230 F or more Below 1 5 L E1 E4 3 E5 16 V W BR I...

Page 545: ...TA T100 RM449U L4 E1 E7 29 E5 16 R BR IG switch ON Transfer L4 position 7 5 14 IG switch ON Transfer other than L4 position Below 1 5 4WD E1 E4 26 E5 16 R G BR IG switch ON Transfer H2 position 9 14 I...

Page 546: ...ough there are no abnormalities in any of the other circuits then check and replace the ECM Chapter 1 Electronic Circuit Matrix Chart Symptom Suspect Area See page No up shift A particular gear from 1...

Page 547: ...shift valve 2 Off vehicle repair matrix chart L DI 282 No down shift 2nd 1st 1 1 2 shift valve 2 Off vehicle repair matrix chart L DI 282 No lock up or No lock up off 1 Lock up relay valve 2 Off vehi...

Page 548: ...shifting rod 3 Off vehicle repair matrix chart DI 265 DI 265 DI 282 No engine braking 1st L position 1 Low coast modulator valve 2 Off vehicle repair matrix chart L DI 282 No engine braking 2nd 2 pos...

Page 549: ...Harsh engagement N 2 1 Forward clutch C1 2 O D one way clutch F0 3 No 2 one way clutch F2 L L L Harsh engagement N L 1 Forward clutch C1 2 1st and reverse brake B3 3 O D one way clutch F0 4 No 2 one w...

Page 550: ...DI0VK 01 DI 286 DIAGNOSTICS AUTOMATIC TRANSMISSION 1996 TOYOTA T100 RM449U CIRCUIT INSPECTION DTC P0500 Vehicle Speed Sensor Malfunction No 1 Vehicle Speed Sensor See page 3RZ FE DI 92 5VZ FE DI 226...

Page 551: ...CRIPTION The ATF temperature sensor converts fluid temperature into a resistance value which is input into the ECM DTC No DTC Detecting Condition Trouble Area P0710 Either a or b is detected for 0 5 s...

Page 552: ...ture sensor CHECK Measure resistance between terminals of ATF temperature sensor at 20 C 68 F and 110 C 230 F OK Resistance 20 C 68 F Approx 13 0 k 110 C 230 F Approx 800 NG Replace ATF temperature se...

Page 553: ...logic S Shift solenoid valve No 1 No 2 is stuck open or closed S Valve body is blocked up or stuck HINT Check the shift solenoid valve No 1 when DTC P0750 is output and check shift solenoid valve No...

Page 554: ...ircuits develops an open or short the ECM turns the other shift solenoid ON and OFF to shift to the gear positions shown in the table below The ECM also turns the shift solenoid valve SL OFF at the sa...

Page 555: ...0006 3RZ FE 5VZ FE S2 S1 S2 S1 DIAGNOSTICS AUTOMATIC TRANSMISSION DI 291 1996 TOYOTA T100 RM449U WIRING DIAGRAM INSPECTION PROCEDURE 1 Measure resistance between terminal S1 or S2 of ECM connector and...

Page 556: ...or between ECM connector and automatic transmis sion solenoid connector PREPARATION Disconnect the solenoid connector from the automatic trans mission CHECK Check the harness and connector between ter...

Page 557: ...ve the oil pan b Remove the shift solenoid valve No 1 or No 2 CHECK a Measure resistance between solenoid connector and so lenoid body b Connect positive lead to terminal of solenoid connector negativ...

Page 558: ...valve body and torque converter clutch DTC No DTC Detecting Condition Trouble Area P0770 Lock up does not occur when driving in the lock up range normal driving at 80 km h 50 mph or lock up remains ON...

Page 559: ...DIAGNOSTICS AUTOMATIC TRANSMISSION DI 295 1996 TOYOTA T100 RM449U 2 Check valve body See page DI 282 NG Repair or replace valve body OK Replace torque converter clutch See page AT 26 AT 33...

Page 560: ...ing on the lock up relay valve which then controls operation of the lock up clutch Fail safe function If the ECM detects a malfunction it turns the shift solenoid valve SL OFF DTC No Detection ItemDTC...

Page 561: ...OYOTA T100 RM449U INSPECTION PROCEDURE 1 Measure resistance between terminal SL of ECM connector and body ground PREPARATION Disconnect the connector from the ECM CHECK Measure resistance between term...

Page 562: ...connector between ECM connector and automatic transmission solenoid connector PREPARATION Disconnect the solenoid connector from the transmission CHECK Check the harness between terminal SL of ECM con...

Page 563: ...emove the shift solenoid valve SL CHECK a Measure resistance between terminal SL of shift solenoid valve and solenoid body b Connect positive lead to terminal of solenoid connector negative lead to so...

Page 564: ...d lock up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal If the No 2 vehicle speed sensor malfunctions the ECM uses input...

Page 565: ...OYOTA hand held tester PREPARATION a Connect an OBD II scan tool or TOYOTA hand held tes ter to the DLC3 b Start the engine and OBD II scan tool or TOYOTA hand held tester main switch ON CHECK Drive t...

Page 566: ...2 of vehicle speed sensor b Check voltage between terminals 1 and 2 of vehicle speed sensor when a magnet is put close to the front end of the vehicle speed sensor then taken away quickly OK a Resist...

Page 567: ...es it in controlling the shift points and the operation of the look up clutch This sensor outputs one pulse for every one revolution of the output shaft If the No 2 vehicle speed sensor malfunctions t...

Page 568: ...TA hand held tes ter to the DLC3 b Start the engine and OBD II scan tool or TOYOTA hand held tester main switch ON CHECK Drive the vehicle and read vehicle speed value OK Vehicle speed matches tester...

Page 569: ...r from the transmission CHECK Check that there is continuity between terminals of No 2 vehicle speed sensor connector when a magnet is put close to it as shown OK Resistance Changes between 0 and NG R...

Page 570: ...Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park neutral position switch detects the shift lever position and sends signals to the ECM The ECM receives signals NSW R 2 and L from the p...

Page 571: ...t a TOYOTA hand held tester to the DLC3 b Turn the ignition switch ON and TOYOTA hand held tes ter main switch ON CHECK Shift lever into the P R N 2 and L positions and read the PNP REVERSE 2ND and LO...

Page 572: ...HECK Check continuity between each terminal shown below when the shift lever is moved to each position OK Shift Position Terminal No to continuity Terminal No to continuity P 4 7 5 6 R 4 8 N 4 10 5 6...

Page 573: ...g overdrive may be prohibited temporarily under some condition The cruise control ECU sends O D cut signals to the ECM as necessary and the ECM cancels O D shifting until these signals are discontinue...

Page 574: ...Disconnect the cruise control ECU connector b Turn the ignition switch ON CHECK Measure voltage between terminal OD of cruise control ECU harness side connector and body ground OK Voltage 4 6 V OK Che...

Page 575: ...O Y G W W W W 6 5 2 2 2 2 2 1 1 9 9 2 3 1A 14 1 2 O3 O3 E4 C13 C12 IA3 8 7 5 6 Y G W B IC 1 2 O D Main Switch DIAGNOSTICS AUTOMATIC TRANSMISSION DI 311 1996 TOYOTA T100 RM449U O D Main Switch O D OFF...

Page 576: ...ator light does not light up 1 Check operation of O D main switch PREPARATION Turn the ignition switch ON CHECK a Check the O D OFF indicator light when O D main switch is pushed in to ON b Check the...

Page 577: ...r main switch ON CHECK Read the OVRDRIVE CUT SW2 signal on the TOYOTA hand held tester OK O D main switch condition OVRDRIVE CUT SW2 signal ON Pushed in ON OFF Pushed once again OFF When not using TOY...

Page 578: ...connector OK Check O D main switch 4 Check O D main switch PREPARATION Disconnect the O D main switch connector CHECK Check continuity resistance between terminal 1 and 2 of O D main switch connector...

Page 579: ...nector CHECK Check continuity between terminals 1 and 2 of O D main switch connector OK O D main switch Specified condition ON No continuity OFF Continuity NG Replace O D main switch OK 2 Check harnes...

Page 580: ...ON The purpose of this circuit is to prevent the engine from stalling while driving in lock up condition when brakes are suddenly applied When the brake pedal is operated this switch sends a signals t...

Page 581: ...tester PREPARATION a Connect an OBD II scan tool or TOYOTA hand held tes ter to the DLC3 b Turn the ignition switch ON and OBD II scan tool or TOY OTA hand held tester main switch ON CHECK Read the ST...

Page 582: ...OTA T100 RM449U OK Proceed to next circuit inspection shown on problem symptoms table See page DI 282 NG 3 Check harness and connector between stop light switch and ECM See page IN 26 NG Repair or rep...

Page 583: ...Sensor Check Circuit Inspection P DI 332 DI 360 DTC Chart P DI 326 Malfunction code Problem Symptoms Table P DI 331 Check for Fluid Leakage P DI 362 Identification of Problem Normal code Repair Confi...

Page 584: ...ncy Problem Occurs Continuous Intermittent times a day ABS does not operate ABS does not operate efficiently ABS Warning Light Abnormal Remains ON Does not Light Up DTC Check 1st Time 2nd Time Normal...

Page 585: ...t circuit See page DI 354 b Check the DTC 1 Using SST connect terminals Tc and E1 of the DLC1 SST 09843 18020 2 Disconnect the short pin from the DLC1 3 Turn the ignition switch ON 4 Read the DTC from...

Page 586: ...be done by removing the ECU B fuse but in this case other memory systems will also be cancelled out d Using TOYOTA brake out box and TOYOTA hand held tester measure the ECU terminal value 1 Hook up th...

Page 587: ...onds 6 Stop the vehicle 7 Using SST connect terminals Tc and E1 of the DLC1 SST 09843 18020 8 Read the number of blinks of the ABS warning light HINT S See the list of DTC on page DI 326 S If every se...

Page 588: ...n If the sensor installation is OK replace the decel eration sensor 7 Jack down the vehicle slowly 8 Jack up the front side of the vehicle slowly as shown HINT When measuring the height measure at the...

Page 589: ...of right front speed sensor S Right front speed sensor S Sensor installation 72 Low output voltage of left front speed sensor S Left front speed sensor S Sensor installation 73 Low output voltage of r...

Page 590: ...on solenoid circuit for right front wheel S ABS actuator S Open or short in SFRR or SFRH circuit S ECU 22 DI 338 Open or short circuit in 2 position solenoid circuit for left front wheel S ABS actuato...

Page 591: ...leration sensor S Wire harness for deceleration sensor system S ECU 44 DI 351 Open or short in deceleration sensor circuit S Deceleration sensor S Open or short in deceleration sensor circuit S ECU 51...

Page 592: ...DI0ZT 03 F14854 DI 328 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 1996 TOYOTA T100 RM449U PARTS LOCATION...

Page 593: ...witch ON ABS warning light ON 10 14 IG switch ON ABS warning light OFF STP A15 21 GND A15 11 24 Below 1 5 Stop light switch OFF 8 14 Stop light switch ON Tc A15 20 GND A15 11 24 10 14 IG switch ON Ts...

Page 594: ...DI 330 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 1996 TOYOTA T100 RM449U 4WD Vehicle...

Page 595: ...a checker If abnormal check the hydraulic circuit for leakage See page DI xx DI 321 DI 347 DI 341 BR 58 ABS does not operate efficiently Only when 1 4 are all normal and the problem is still occurrin...

Page 596: ...ay goes on DTC No DTC Detecting Condition Trouble Area 11 Conditions 1 and 2 continue for 0 2 sec or more 1 ABS control solenoid relay terminal SR voltage Battery positive voltage 2 ABS control soleno...

Page 597: ...or CHECK Measure the voltage between terminals A5 2 and A5 6 of ABS control relay harness side connector OK Voltage 10 14 V NG Check and repair harness or connector OK 2 Check continuity between termi...

Page 598: ...erminals A5 2 and A5 5 Open CHECK a Apply battery positive voltage between terminals A5 1 and A6 3 b Check continuity between each terminal of ABS control solenoid relay OK Terminals A5 5 and A5 6 Ope...

Page 599: ...s the ABS pump motor DTC No DTC Detecting Condition Trouble Area 13 Conditions 1 and 2 continued for 0 2 sec or more 1 ABS control motor relay terminal MR voltage Battery positive voltage 2 ABS contro...

Page 600: ...CHECK Measure voltage between terminal A6 1 of ABS control relay harness side connector and body ground OK Voltage 10 14 V NG Check and repair harness or connector OK 2 Check continuity between termi...

Page 601: ...6 1 and A6 2 Open CHECK a Apply battery positive voltage between terminals A6 3 and A6 4 b Check continuity between terminals of ABS control relay OK Terminals A6 1 and A6 2 Continuity NG Replace ABS...

Page 602: ...ECU 22 Conditions 1 through 3 continue for 0 02 sec or more 1 ABS control solenoid relay terminal SR voltage Battery positive voltage 2 Voltage of ABS ECU terminal AST Battery positive voltage 3 When...

Page 603: ...R SFLR SFLH SFRR SFRH SRR SRH 6 3 4 5 1 12 13 2 1 25 26 2 F14588 1 2 4 5 3 4 A3 A4 6 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM DI 339 1996 TOYOTA T100 RM449U WIRING DIAGRAM INSPECTION PROCEDURE 1 Check ABS...

Page 604: ...k for open and short in harness and connector between ABS ECU and actuator See page IN 26 NG Repair or replace harness or connector OK If same code is still output after DTC is deleted check contact c...

Page 605: ...least 7 times in time between switching the ignition switch ON and switching it OFF 3 Abnormal fluctuation of speed sensor signals with ve hicle speed 20 km h 12 mph or more 4 An open is detected in...

Page 606: ...16 A15 A15 A15 A15 A15 FR A16 FR FSS FL FL RR RR RSS RL RL IA3 IA3 IA3 BJ2 BJ2 BJ2 BJ2 BJ2 BJ2 A20 A20 A20 A20 A7 A7 Y G W R R G B W BR B P L 6 2 1 2 1 4 3 G R B W P 11 12 16 14 15 6 7 9 5 A8 A8 2 1 7...

Page 607: ...ctor and body ground OK Resistance 1 M or higher Rear PREPARATION Disconnect the speed sensor connector CHECK Measure resistance between terminals 1 and 2 3 and 4 of speed sensor connector OK Resistan...

Page 608: ...bjects on the sensor tip Rear PREPARATION Remove the axle shaft See page SA 131 CHECK Check the sensor rotor serrations OK No scratches or missing teeth CHECK Check the sensor tip OK No scratches or f...

Page 609: ...witch ON then OFF 8 times in succession S Front axle hub S Right front left front speed sensor S Wire harness for sensor system S ECU INSPECTION PROCEDURE 1 Check front axle hub See page SA 15 or SA 2...

Page 610: ...SCRIPTION DTC No DTC Detecting Condition Trouble Area 37 Driving at more than 30 km h 19 mph for more than 60 seconds with 1 or 2 tires of different size S Tire size S ECU INSPECTION PROCEDURE 1 Check...

Page 611: ...CIRCUIT DESCRIPTION This is the power source for the ECU hence the actuators DTC No DTC Detecting Condition Trouble Area 41 Vehicle speed is 3 km h 1 9 mph or more and voltage of ECU terminal IG1 rema...

Page 612: ...and GND of ABS ECU connector PREPARATION Remove the ABS ECU with the connectors still connected CHECK a Turn the ignition switch ON b Measure voltage between terminals IG1 and GND of ABS ECU connecto...

Page 613: ...ck ECU IG fuse PREPARATION Remove the ECU IG fuse from the J B No 1 CHECK Check continuity of ECU IG fuse OK Continuity NG Check for short in all harness and components connected to ECU IG fuse See at...

Page 614: ...n 30 km h 0 km h for 16 times con tinuously 2 When the brake pedal is not depressed at vehicle speed of 5 km h or more forward and backward G more than 0 4 G is detected for 30 seconds or more S Decel...

Page 615: ...tects deceleration on the vehicle The sensor signal is used in ABS control If the sensor func tions abnormally the ABS warning light comes on but the ABS still operates DTC No DTC Detecting Condition...

Page 616: ...ge IN 26 NG Repair or replace harness or connector OK 2 Check voltage between terminals GS1 GS2 GST of ABS ECU and body ground PREPARATION a Remove the ABS ECU with the connectors still con nected b D...

Page 617: ...4 3 1 3 5 1 2 6 1 5 10 10 2 2 9 2 2 5 4 11 8 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM DI 353 1996 TOYOTA T100 RM449U DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Are...

Page 618: ...Pin 10 1 2 6 5 4 4 1 4 3 2 2 9 9 4 8 GAUGE 12 WA 5 24 DI 354 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 1996 TOYOTA T100 RM449U ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble it ligh...

Page 619: ...oubleshooting in accordance with the chart below for each trouble symptom ABS warning light does not light up Go to step 1 ABS warning light remains on Go to step 3 1 Check ABS warning light See Combi...

Page 620: ...inals A5 2 and A5 5 Open CHECK a Apply battery positive voltage between terminals A5 1 and A6 3 b Check continuity between each terminal of ABS control relay OK Terminals A5 5 and A5 6 Open Terminals...

Page 621: ...d by code output NO 4 Does ABS warning light go off if short pin is removed NO Check for short in harness and connector be tween warning light DLC1 and ECU See page IN 26 YES 5 Check ABS control relay...

Page 622: ...g terminals Tc and E1 of the DLC1 causes the ECU to display the DTC by flashing the ABS warning light WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC1 CHECK a Tu...

Page 623: ...AKE SYSTEM DI 359 1996 TOYOTA T100 RM449U 2 Check for open and short in harness and connector between ABS ECU and DLC1 DLC1 and body ground See page IN 26 NG Repair or replace harness or connector OK...

Page 624: ...eed sensor signal which cannot be detected with the DTC check Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage...

Page 625: ...AKE SYSTEM DI 361 1996 TOYOTA T100 RM449U 2 Check for open and short in harness and connector between ABS ECU and DLC1 DLC1 and body ground See page IN 26 NG Repair or replace harness or connector OK...

Page 626: ...F00447 DI 362 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 1996 TOYOTA T100 RM449U Check for fluid Leakage Check for fluid leakage from actuator or hydraulic lines DI10Y 01...

Page 627: ...ck Step Diagnostic steps permitting the use of the TOYOTA hand held tester 3 4 1 2 3 4 5 7 8 9 10 11 12 5 10 11 12 Symptom Simulation IN 16 Does Not Light Up Normal Code Normal Code Normal Code Malfun...

Page 628: ...Diagnosis System Inspection SRS Warning Light Inspection DTC Inspection 1st Time 2nd Time 1st Time 2nd Time Inspector s Name Fine Cloudy Rainy Snowy Other Approx Starting Idling Driving Constant speed...

Page 629: ...OFF a short in the SRS warning light circuit can be considered likely Proceed to SRS warning light system malfunction on page DI 398 DI 400 2 DTC CHECK Using diagnosis check wire a Output the DTC 1 Tu...

Page 630: ...up the TOYOTA hand held tester to the DLC1 b Read the DTCs by following the prompts on the tester screen HINT Please refer to the TOYOTA hand held tester operator s manu al for further details 4 DTC C...

Page 631: ...TOYOTA hand held tester a Hook up the TOYOTA hand held tester to the DLC1 b Clear the DTCs by following the prompts on the tester screen HINT Please refer to the TOYOTA hand held tester operator s man...

Page 632: ...Sensors Spiral Cable Connector 1 Connector 2 DI 368 DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM 1996 TOYOTA T100 RM449U CAUTION Never release the airbag activation prevention mechanism on the steering...

Page 633: ...d D squib S Front airbag sensor S Spiral cable S Center airbag sensor assembly S Wire harness ON 14 DI 385 S Open in D squib circuit S Steering wheel pad D squib S Spiral cable S Center airbag sensor...

Page 634: ...nsor RH Front Airbag Sensor LH Junction Block No 1 Center Airbag Sensor Assembly Spiral Cable SRS Warning Light Steering Wheel Pad with Airbag DI 370 DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM 1996 TOY...

Page 635: ...S OF ECU No Symbol Terminal Name A Electrical Connection Check Mechanism B Electrical Connection Check Mechanism 1 LA SRS Warning Light 2 D Squib Driver 3 D Squib Driver 4 TC Diagnosis 5 E2 Ground 6 E...

Page 636: ...S SRS warning light is always lit up even when ignition switch is in the LOCK position S SRS warning light circuit Always lit up when ignition switch is in LOCK position DI 398 S With the ignition swi...

Page 637: ...sor detects the deceleration force in a frontal collision and is located in the front fender apron on the left and right sides For details of the function of each component see OPERATION on page RS 2...

Page 638: ...rcuit CHECK For connector on spiral cable side between spiral cable and steering wheel pad measure resistance between D and body ground OK Resistance 1M or higher NG Go to step 6 OK 3 Check front airb...

Page 639: ...able and steering wheel pad c Connect negative terminal cable to battery and wait at least 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least 20 se conds b Clear malfunction code st...

Page 640: ...and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 365 c Turn ignition switch to LOCK and wait at least 20 se conds d Turn ignition switch to ACC or ON and wait at lea...

Page 641: ...ARATION Disconnect connector between center airbag sensor assembly and spiral cable CHECK For connector on spiral cable side between spiral cable and steering wheel pad measure resistance between D an...

Page 642: ...en each terminal of front airbag sensor OK Terminal Resistance S A Less than 1 S S 1 M or higher S A 755 855 NOTICE S Do not press ohmmeter probes too strongly against terminals of front airbag sensor...

Page 643: ...ont fender on the left and right sides For details of the function of each components see page OPERATION on page RS 2 DTC 12 is recorded when a B short is detected in the squib circuit or front airbag...

Page 644: ...DI 396 2 Check D squib circuit Measure voltage between terminals D or D of center air bag sensor assembly connector and body ground PREPARATION a Connect negative terminal cable to battery b Turn igni...

Page 645: ...able side of connector between spiral cable and steering wheel pad e Connect negative terminal cable to battery and wait at least 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least...

Page 646: ...ast 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 365 c Turn ignition switch to LOCK and wait at least 20 se c...

Page 647: ...gnition switch to LOCK b Disconnect connector between center airbag sensor as sembly and spiral cable c Turn ignition switch ON CHECK For connector on spiral cable side between spiral cable and steeri...

Page 648: ...b Disconnect connector between center airbag sensor as sembly and spiral cable c Turn ignition switch ON CHECK Measure voltage at D D on spiral cable side of connector be tween spiral cable and steeri...

Page 649: ...tecting Condition Trouble Area 14 S Open circuit in D wire harness or D wire harness of squib S D squib malfunction S Spiral cable malfunction S Center airbag sensor assembly malfunction S Steering wh...

Page 650: ...tween spiral cable and steering wheel pad c Connect negative terminal cable to battery and wait at least 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least 20 se conds b Clear malfu...

Page 651: ...ast 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least 20 se conds b Clear malfunction code stored in memory See page DI 365 c Turn ignition switch to LOCK and wait at least 20 se c...

Page 652: ...connector CHECK For the connector on the center airbag sensor assembly side between the center airbag sensor assembly and spiral cable measure the resistance between D and D OK OK Resistance Below 1...

Page 653: ...memory See page DI 365 c Turn ignition switch to LOCK and wait at least 20 se conds d Turn ignition switch to ACC or ON and wait at least 20 se conds e Using SST connect terminals Tc and E1 of DLC1 S...

Page 654: ...ith the terminals for diagnosis use on the sensor side If the connector is not properly connected the diagnosis system may detect only a malfunction code even through the SRS is func tioning normally...

Page 655: ...inals SR SL of center airbag sensor assembly connector and body ground PREPARATION a Connect negative terminal cable to the battery and wait at least 2 seconds b Turn ignition switch ON CHECK Measure...

Page 656: ...b Clear malfunction code stored in memory See page DI 365 c Turn ignition switch to LOCK and wait at least 20 se conds d Turn ignition switch to ACC or ON and wait at least 20 se conds e Using SST co...

Page 657: ...und on the wire harness side of the center airbag sensor as sembly CHECK Measure resistance between terminal SR SL and body ground of front airbag sensor connector OK Resistance Less than 1 NOTICE Lig...

Page 658: ...assembly is detected DTC No DTC Detecting Condition Trouble Area 31 S Center airbag sensor assembly malfunction S Center airbag sensor assembly INSPECTION PROCEDURE HINT When a malfunction code other...

Page 659: ...on code CHECK a Turn ignition switch to LOCK and wait at least 20 se conds b Turn ignition switch to ACC or ON and wait at least 20 se conds c Repeat operation in steps a and b at least 5 times d Usin...

Page 660: ...he center airbag sensor assem bly in case the source voltage drops When the battery voltage drops the voltage increase circuit DC DC converter functions to increase the voltage of the SRS to normal vo...

Page 661: ...V at IG2 and ACC e Turn electric system switch OFF f Turn ignition switch to LOCK g Remove voltmeter and connect center airbag sensor as sembly connector 2 Does SRS warning light turn off PREPARATION...

Page 662: ...gnition switch is in LOCK position CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter When the SRS is normal the SRS warning light lights up for approx 6 seconds after the i...

Page 663: ...EPARATION a Turn ignition switch to LOCK b Disconnect negative terminal cable from the battery and wait at least 90 seconds c Disconnect center airbag sensor assembly connector d Connect negative term...

Page 664: ...nd then turns off automatically If there is a malfunction in the SRS the SRS warning light lights up to inform the driver of the abnormality When terminal Tc and E1 of the DLC1 are connected the DTC i...

Page 665: ...page DI 396 4 Check SRS warning light circuit PREPARATION a Connect negative terminal cable to battery b Turn ignition switch to ACC or ON CHECK Measure voltage LA terminal of harness side connector...

Page 666: ...terminal cable to battery and wait at least 2 seconds d Turn ignition switch to ACC or ON CHECK Check operation of SRS warning light OK SRS warning light comes on NO Check terminal LA of center airba...

Page 667: ...DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI 403 1996 TOYOTA T100 RM449U Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting terminal Tc and E1 of the DLC1 the airbag sensor assembly is set in the D...

Page 668: ...do following troubleshooting 1 Does SRS warning light up for approx 6 seconds PREPARATION Check operation of SRS warning light after ignition switch is turned from LOCK position to ACC or ON position...

Page 669: ...TAL RESTRAINT SYSTEM DI 405 1996 TOYOTA T100 RM449U 3 Check voltage between terminals Tc of DLC1 and body ground CHECK Measure voltage between terminal Tc of DLC1 and body ground OK Voltage 10 16 V OK...

Page 670: ...nector e Insert service wire into terminal Tc from back side as shown f Connect center airbag sensor assembly connector with service wire g Connect negative terminal cable to battery h Turn ignition s...

Page 671: ...er airbag sensor assembly and body ground PREPARATION a Turn ignition switch to LOCK b Disconnect negative terminal cable from the battery and wait at least 90 seconds c Disconnect center airbag senso...

Page 672: ...d Items inside are titles of pages in this manual with the page number indicated in the bottom portion See the indicated pages for detailed explanations 1 2 3 4 5 6 7 8 9 10 Step 2 5 8 10 Diagnostic s...

Page 673: ...te cruise control again j Yes j No j Cancel does not occur j With brake ON j Except D position shift j At 40 km h 25 mph or less j When control SW turns to CANCEL position j Cruise control malfunction...

Page 674: ...not normal proceed to trouble shooting See page BE 36 for the combination meter section b Check the DTC HINT If a malfunction occurs in the No 1 vehicle speed sensors or ac tuator etc during cruise co...

Page 675: ...A BREAK OUT BOX AND TOYOTA HAND HELD TESTER a Hook up the TOYOTA break out box and TOYOTA hand held tester to the vehicle b Read the ECU input output values by following the prompts on the tester scre...

Page 676: ...e the control switch turned to RES ACC and that the ve hicle cruises at the set speed when the switch is re leased 4 Momentarily press the control switch upward in the RES ACC and then immediately rel...

Page 677: ...S Push the main switch OFF S Pull the cruise control switch to CANCEL e Inspect the RESUME switch 1 Push the main switch ON 2 Drive at a desired speed 40 km h 25 mph or high er 3 When operating one of...

Page 678: ...normal Speed sensor circuit is normal Each cancel switch is normal 5 DI 414 DIAGNOSTICS CRUISE CONTROL SYSTEM 1996 TOYOTA T100 RM449U 5 INPUT SIGNAL CHECK HINT S For check No 1 No 3 Turn ignition swi...

Page 679: ...harness S Cruise control ECU 21 DI 428 S Vehicle Speed Sensor Circuit S Vehicle speed sensor S Wire harness S Cruise control ECU 23 DI 428 S Actuator Control Cable S Vehicle Speed Sensor circuit S Ve...

Page 680: ...DI0YO 05 I22834 DI 416 DIAGNOSTICS CRUISE CONTROL SYSTEM 1996 TOYOTA T100 RM449U PARTS LOCATION...

Page 681: ...V OD GND C15 9 C15 13 Y R B O During cruise control driving OD switch ON 10 16 V During cruise control driving OD switch OFF 3rd driving Below 1 V L GND C15 10 C15 13 Y R B O During cruise control dr...

Page 682: ...nition switch ON 4 7 5 2 V During driving 3 7 V IDL GND C15 23 C15 13 Y L B O Ignition switch ON Throttle valve fully closed Below 1 V Ignition switch ON Throttle valve fully opened 10 16 V ECT GND C1...

Page 683: ...ol Cable 2 Stop Light Switch Circuit 3 Actuator Motor Circuit 4 Cruise Control ECU DI 458 DI 434 DI 420 IN 26 Cruise control not cancelled even when transmission is shifted to N postion 1 Cruise Contr...

Page 684: ...from the ECU Acceleration and deceleration signals are trans mitted by changes in the Duty Ratio See note below Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle For exa...

Page 685: ...nnector CHECK Measure resistance between terminals 6 and 7 HINT If control plate position is fully opened or fully closed resistance can not be measured OK Resistance more than 4 2 NG Replace cruise c...

Page 686: ...ssed the stop light switch turns ON supplying electrical power to the stop light Power supply to the magnetic clutch is mechanically cut and the magnetic clutch is turned OFF When driving downhill if...

Page 687: ...TOP fuse from instrument panel junction block CHECK Check fuse continuity OK Continuity NG Replace STOP fuse OK 2 Check stop light switch PREPARATION Disconnect the stop light switch connector CHECK C...

Page 688: ...the actuator connector CHECK Measure resistance between terminals 4 and 5 OK Resistance 34 65 X 42 35 NG Replace cruise control actuator OK 4 Check for open and short in harness and connectors between...

Page 689: ...ion Sensor Circuit CIRCUIT DESCRIPTION The circuit detects the rotation position of the actuator control plate and sends a signal to the ECU DTC No Detection Item Trouble Area 13 S Position sensor det...

Page 690: ...om the decel eration side to the acceleration side OK Voltage Fully closed Approx 1 3 V Fully opened Approx 4 0 V As the control plate is turned the voltage should in crease gradually without interrup...

Page 691: ...con nector while turning control plate slowly by hand from the decel eration side to the acceleration side OK Voltage 1 3 4 0 V HINT As the control plate is turned the voltage should increase grad ual...

Page 692: ...en by the gear of the transmission For each rotation of the shaft the vehicle speed sensor sends a 4 pulse signal through the combination meter to the cruise control ECU See the following This signal...

Page 693: ...40 km h 25 mph and at vehicle speed be low 40 km h 25 mph OK Vehicle speed above 40 km h 25 mph Indicator light blinks Vehicle speed below 40 km h 25 mph Indicator light stays on OK Check and replace...

Page 694: ...DI 430 DIAGNOSTICS CRUISE CONTROL SYSTEM 1996 TOYOTA T100 RM449U 4 Check vehicle speed sensor See page BE 38 NG Replace vehicle speed sensor OK Check and replace cruise control ECU See page IN 26...

Page 695: ...IT DESCRIPTION This circuit sends the SET COAST RESUME ACCEL and CANCEL signals each voltage to the ECU DTC No Detection Item Trouble Area 32 S Short in control switch circuit S Cruise control switch...

Page 696: ...on the left should be output when each switch is ON The signal should disappear when the switch is turned OFF CANCEL switch The indicator light goes off when the cancel switch is turned ON OK Wait an...

Page 697: ...ch connector when control switch is operated Switch position Resistance Neutral No continuity RES ACC 50 80 SET COAST 180 220 CANCEL 400 440 NG Replace control switch OK 4 Check harness and connector...

Page 698: ...e cancel conditions are Battery positive voltage at terminal STP When the brake is ON battery positive voltage is normally applied through the STOP fuse and stop light switch to terminal STP of the EC...

Page 699: ...that stop light comes on when brake pedal is depressed and turns off when brake pedal is released NG Check stop light system See page BE 30 OK 2 Input signal check CHECK a See input signal check on DI...

Page 700: ...e voltage between terminal STP of cruise control ECU connector and body ground when the brake pedal is de pressed and released OK Depressed 10 16 V Released Below 1 V OK Proceed to next circuit inspec...

Page 701: ...ON a signal is sent to the ECU The ECU uses this signal to correct the dis crepancy between the throttle valve position and the actuator position sensor value to enable accurate cruise control at the...

Page 702: ...tween terminal IDL of ECU connector and body ground when the throttle valve is fully closed and fully opened OK Throttle valve position Voltage Fully opened 10 16 V Fully closed Below 1 V OK Proceed t...

Page 703: ...ion sensor connector when the throttle valve is fully closed and fully opened OK Throttle valve position Resistance Fully opened 1 M or higher Fully closed Below 500 NG Replace throttle position senso...

Page 704: ...l the end of the up hill slope is sent from the cruise control ECU to the electronically controlled transmission Terminal ECT of the cruise control ECU detects the shift change signal output to electr...

Page 705: ...f OD switch ON OFF NG Check and repair electronically controlled transmission See page DI 311 OK 2 Check voltage between terminal OD of harness side connector of cruise control ECU and body ground PRE...

Page 706: ...ion Voltage ON Below 1 V OFF 10 16 V OK Proceed to next circuit inspection shown in problem symptoms table See page DI 419 NG 4 Check harness and connector between terminal ECT of cruise control ECU a...

Page 707: ...utral Position Switch Circuit CIRCUIT DESCRIPTION When the shift position is in except D position a signal is sent from the park neutral position switch to the ECU When this signal is input during cru...

Page 708: ...that the starter operates normally and that the engine starts NG Proceed to engine troubleshooting 3RZ FE See page DI 1 5VZ FE See page DI 127 OK 2 Input signal check PREPARATION See input signal chec...

Page 709: ...nal N C of ECU connec tor and body ground when shifting into D position and other positions OK Shift Position Voltage D position 10 16 V Other positions Below 1 V OK Proceed to next circuit inspection...

Page 710: ...Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed the clutch switch sends a signal to the cruise control ECU When the signal is input to the cruise control ECU during cruise contro...

Page 711: ...that the starter operates normally and that the engine starts NG Proceed to engine troubleshooting 3RZ FE See page DI 1 5VZ FE See page DI 127 OK 2 Input signal check PREPARATION See input signal che...

Page 712: ...cruise control ECU connector and body ground when clutch pedal is depressed and released OK Shift Position Voltage Clutch pedal released Below 1 V Clutch pedal depressed 10 16 V OK Proceed to next ci...

Page 713: ...STEM DI 449 1996 TOYOTA T100 RM449U ECU Power Source Circuit CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors etc when terminal GND and the cruise control ECU case a...

Page 714: ...of ECU IG fuse OK Continuity NG Check for short in all the harness and compo nents connected to ECU IG fuse OK 2 Check voltage between terminals B and GND of cruise control ECU connector PREPARATION...

Page 715: ...al GND of cruise control ECU connector and body ground See page IN 16 CHECK Measure resistance between terminal GND of ECU connector and body ground OK Resistance Below 1 NG Repair or replace harness...

Page 716: ...CRUISE CONTROL SYSTEM 1996 TOYOTA T100 RM449U Back up Power Source Circuit CIRCUIT DESCRIPTION The ECU back up power source provides power even when the ignition is OFF and it is used for DTC memory e...

Page 717: ...d compo nents connected to the ECU B fuse OK 2 Check voltage between terminal BATT of cruise control ECU connector and body ground See page IN 16 PREPARATION Remove the ECU with connector still connec...

Page 718: ...PROCEDURE 1 Check voltage between terminal CMS of cruise control ECU connector and body ground PREPARATION a Remove the ECU with connector still connected b Turn ignition switch ON CHECK Measure volt...

Page 719: ...ck continuity between terminals 2 and 4 of control switch connector when main switch is held ON and OFF OK Switch position Tester connection Specified condition OFF 2 4 No continuity Hold ON 2 4 Conti...

Page 720: ...I22677 DI 456 DIAGNOSTICS CRUISE CONTROL SYSTEM 1996 TOYOTA T100 RM449U Tc Circuit CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that DTC output is required WIRING DIAGRAM DI35D 02...

Page 721: ...ion switch ON CHECK Measure voltage between terminals Tc and E1 of DLC1 OK Voltage 10 16 V OK Proceed to next circuit inspection shown in problem symptoms table See page DI 419 NG 2 Check harness and...

Page 722: ...e throttle link are properly installed and that the cable and link are connected correctly b Check that the actuator and bell crank are operating smoothly c Check that the cable is not loose or too ti...

Page 723: ...E MECHANICAL 3RZ FE CO HC EM 1 COMPRESSION EM 3 VALVE CLEARANCE EM 5 IGNITION TIMING EM 11 IDLE SPEED EM 12 TIMING CHAIN EM 13 CYLINDER HEAD EM 26 ENGINE UNIT EM 61 CYLINDER BLOCK EM 75 EXHAUST SYSTEM...

Page 724: ...lines properly connected HINT All vacuum hoses for EGR systems etc should be properly connected f SFI system wiring connectors fully plugged g Ignition timing set correctly h Transmission in neutral...

Page 725: ...rly gapped plugs S Open or crossed high tension cords S Cracked distributor cap 2 Incorrect valve clearance 3 Leaky EGR valves 4 Leaky exhaust valves 5 Leaky cylinder Low High Rough Idle Fluctuating H...

Page 726: ...compression pressure HINT Always use a fully charged battery to obtain engine speed of 250 rpm or more d Repeat steps a through c for each cylinder NOTICE This measurement must be done in as short a...

Page 727: ...NICAL 3RZ FE COMPRESSION 719 Author Date 1996 TOYOTA T100 RM449U 6 REINSTALL SPARK PLUGS Torque 19 N m 200 kgf cm 14 ft lbf 7 REINSTALL HIGH TENSION CORDS TO SPARK PLUGS 8 REINSTALL AIR INTAKE CONNECT...

Page 728: ...ION CORDS FROM SPARK PLUGS NOTICE Pulling on or bending the cords may damage the conductor inside 5 REMOVE THROTTLE BODY See page MF 28 6 DISCONNECT ENGINE WIRE a Disconnect these connectors S w A C A...

Page 729: ...5 0 25 mm 0 006 0 010 in Exhaust 0 25 0 35 mm 0 010 0 014 in b Turn the crankshaft pulley 1 revolution 360 and align its groove with timing mark 0 of the timing chain cover c Check only the valves ind...

Page 730: ...valve clearance comes within the specified value T Thickness of removed shim A Measured valve clearance N Thickness of new shim Intake N T A 0 20 mm 0 008 in Exhaust N T A 0 30 mm 0 012 in S Select a...

Page 731: ...he face Intake valve clearance Cold 0 15 0 25 mm 0 006 0 010 in EXAMPLE The 2 800 mm 0 1102 in shim is installed and measured clearance is 0 440 mm 0 0173 in Replace the 2 800 mm 0 1102 in shim with a...

Page 732: ...ted on the face Exhaust valve clearance Cold 0 25 0 35 mm 0 010 0 014 in EXAMPLE The 2 800 mm 0 1102 in shim is installed and measured clearance is 0 440 mm 0 0173 in Replace the 2 800 mm 0 1102 in sh...

Page 733: ...h the 10 bolts 12 RECONNECT ENGINE WIRE a Connect the 5 engine wire clamps b Connect these connectors S ECT sensor connector S Oil pressure sensor connector S w A C A C compressor connector 13 REINSTA...

Page 734: ...ster or OBDII scan tool operators manual for further details 3 CHECK IGNITION TIMING a Using SST connect terminals TE1 and E1 of the DLC1 SST 09843 18020 b Using a timing light connect the tester to N...

Page 735: ...perly connected HINT All vacuum hoses for EGR system etc should be properly connected f MFI system wiring connectors fully plugged g Ignition timing set correctly h Transmission in neutral position 2...

Page 736: ...A03720 25 250 20 29 300 22 27 270 20 200 2 650 191 18 185 13 27 270 20 N m kgf cm ft lbf Specified torque ENGINE MECHANICAL 3RZ FE TIMING CHAIN EM 13 728 Author Date 1996 TOYOTA T100 RM449U TIMING CH...

Page 737: ...lock pivot and adjusting bolts of the genera tor and remove the drive belts c Remove the 4 water pump pulley mounting nuts d Pull out the fan with fluid coupling and water pump pulley e Remove the No...

Page 738: ...mage the oil pan flanges of the oil pan and cylinder block 11 REMOVE OIL STRAINER Remove the 2 bolts 2 nuts oil strainer and gasket 12 REMOVE CRANKSHAFT PULLEY a w A C Remove the 4 bolts No 2 and No 3...

Page 739: ...MING CHAIN AND CAMSHAFT TIMING GEAR 15 REMOVE CRANKSHAFT TIMING GEAR HINT If necessary remove the gear with SST and crankshaft pulley bolt SST 09950 40010 09951 04010 09952 04010 09953 04010 09954 040...

Page 740: ...bolts and No 3 damper d Remove the nut and No 2 chain tensioner 18 REMOVE NO 2 TIMING CHAIN a Remove the bolt from the balance shaft drive gear b Remove the balance shaft drive gear with shaft c Remov...

Page 741: ...r than maximum replace the chain HINT Make the same measurements pulling at 3 or more places se lected at random b Wrap the chain around the timing gear and timing sprock et c Using vernier calipers m...

Page 742: ...r is greater than maximum replace the slipper and or dampers 3 INSPECT NO 2 CHAIN TENSIONER a Inspect the chain tensioner S Check that the plunger moves smoothly when the ratchet pawl is raised with y...

Page 743: ...ind the large timing mark of the balance shaft drive gear c Insert the balance shaft drive gear shaft through the bal ance shaft drive gear so that it fits into the thrust plate hole Then align the sm...

Page 744: ...r with the bolt Torque 27 N m 270 kgf cm 20 ft lbf d Remove a pin from the No 2 chain tensioner and free the plunger 4 INSTALL NO 1 TIMING CHAIN TENSIONER SLIPPER AND NO 1 VIBRATION DAMPER a Install t...

Page 745: ...the timing mark of the crankshaft timing gear with the mark link of the No 1 timing chain and install the No 1 timing chain c Tie the No 1 timing chain with a cord as shown in the il lustration and ma...

Page 746: ...cm 14 ft lbf 8 INSTALL CRANKSHAFT PULLEY a Align the pulley set key with the key groove of the pulley and slide on the pulley b Using SST install and torque the pulley bolt SST 09213 54015 09330 00021...

Page 747: ...8826 00080 or equivalent S Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening or 3 4 mm 0 012 0 016 in opening HINT Avoid applying an excessive amount to the surface S Parts must be a...

Page 748: ...ELT a Place the fan with fluid coupling water pump pulley and fan shroud in position b Temporarily install the water pump pulley mounting nuts c Install the No 1 fan shroud with the 4 bolts d Install...

Page 749: ...2 21 210 15 29 300 22 29 300 22 29 300 22 49 500 36 Specified torque N m kgf cm ft lbf 29 300 22 EM 26 ENGINE MECHANICAL 3RZ FE CYLINDER HEAD 741 Author Date 1996 TOYOTA T100 RM449U CYLINDER HEAD COMP...

Page 750: ...x 10 See page EM 50 46 465 34 21 210 15 1st 39 400 29 2nd Turn 90 3rd Turn 90 N m kgf cm ft lbf Specified torque ENGINE MECHANICAL 3RZ FE CYLINDER HEAD EM 27 742 Author Date 1996 TOYOTA T100 RM449U...

Page 751: ...CELERATOR CABLE FROM THROTTLE BODY 4 REMOVE INTAKE AIR CONNECTOR a Disconnect the 2 air hoses and VS hose b Remove the 2 bolts hose clamp and intake air connector 5 REMOVE PS PUMP DRIVE BELT AND IDLER...

Page 752: ...nect these connectors S w A C A C compressor connector S Oil pressure sensor connector S ECT sensor connector S EGR gas temperature sensor connector S EGR VSV connector b Remove the 2 bolts and discon...

Page 753: ...vacuum modulator and gasket 15 REMOVE INTAKE CHAMBER STAY Remove the 2 bolts and intake chamber stay 16 REMOVE FUEL RETURN PIPE a Disconnect these hoses S Fuel return hose from fuel pressure regulator...

Page 754: ...very pipe e Remove the O ring and grommet from each injector 20 REMOVE INTAKE MANIFOLD Remove the 3 bolts 2 nuts intake manifold and gasket 21 REMOVE FRONT EXHAUST PIPE a Remove the 2 bolts and retain...

Page 755: ...d align its groove with the 0 mark on the timing chain cover b Check that the timing marks 1 and 2 dots of the camshaft drive and driven gears are in straight line on the cylinder head surface as show...

Page 756: ...camshaft is small the camshaft must be kept level while it is being removed If the camshaft is not kept level the portion of the cylinder head receiving the shaft thrust may crack or be damaged caus i...

Page 757: ...emove the bearing cap bolts with the camshaft gear pulled up NOTICE Do not pry on or attempt to force the camshaft with a tool or other object d Remove intake camshaft 1 Uniformly loosen and remove 10...

Page 758: ...ng SST turn the sub gear clockwise and remove a service bolt SST 09960 10010 09962 01000 09963 00500 c Using snap ring pliers remove the snap ring d Remove these parts 1 Wave washer 2 Camshaft sub gea...

Page 759: ...rpage or cracking could result from re moving bolts in incorrect order c Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench HINT If th...

Page 760: ...ms in correct order 2 REMOVE VALVES a Using SST compress the valve spring and remove the 2 keepers SST 09202 70020 b Remove the spring retainer valve spring and valve c Using needle nose pliers remove...

Page 761: ...ock surface c Using compressed air blow carbon and oil from the bolt holes CAUTION Protect your eyes when using high compressed air 2 REMOVE GASKET MATERIAL Using a gasket scraper remove all the gaske...

Page 762: ...cylinder block and the manifolds for warpage Maximum warpage Cylinder block side 0 05 mm 0 0020 in Manifold side 0 10 mm 0 0039 in If warpage is greater than maximum replace the cylinder head 7 INSPE...

Page 763: ...c Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement Standard oil clearance Intake 0 025 0 060 mm 0 0010 0 0024 in Exhaust 0 030 0 065 mm 0 0012 0 0026 in...

Page 764: ...1 in replace the cylinder head e Gradually heat the cylinder head to 80 100 C 176 212 F f Using SST and a hammer tap in a new guide bushing to where there 8 2 8 6 mm 0 323 0 339 in protruding from the...

Page 765: ...INSPECT AND CLEAN VALVE SEATS a Using a 45 carbide cutter resurface the valve seats Remove only enough metal to clean the seats b Check the valve seating position Apply a light coat of prussian blue...

Page 766: ...the valve spring Maximum deviation 2 0 mm 0 079 in If the deviation is greater than maximum replace the valve spring b Using a spring tester measure the tension of the valve spring at the specified i...

Page 767: ...ng caps and cyl inder head as a set 18 INSPECT CAMSHAFT GEAR SPRING Using a vernier caliper measure the free distance between the spring ends Free distance 22 5 22 9 mm 0 886 0 902 in If the free dist...

Page 768: ...0 0079 in Maximum backlash 0 30 mm 0 0188 in If the backlash is greater than maximum replace the cam shafts 22 INSPECT VALVE LIFTERS AND LIFTER BORES a Using a caliper gauge measure the lifter bore d...

Page 769: ...n If warpage is greater than maximum replace the manifold 25 INSPECT EXHAUST MANIFOLD Using a precision straight edge and thickness gauge measure the surface contacting the cylinder head for warpage M...

Page 770: ...ST and a hammer tap in a new tube gasket as shown in the illustration SST 09950 60010 09951 00260 09951 00490 09950 70010 09951 07150 c Apply a light coat of MP grease to the gasket lip 28 INSPECT CYL...

Page 771: ...position away from the edge onto the spark plug tube Standard protrusion 47 0 mm 1 850 in b Apply adhesive to the spark plug tube hole of the cylinder head Sealant Part No 08833 00070 Adhesive 1324 T...

Page 772: ...Valve spring 4 Spring retainer c Using SST compress the valve spring and place the 2 keepers around the valve stem SST 09202 70020 d Using a plastic faced hammer lightly tap the valve stem tip to ensu...

Page 773: ...htened in 3 progressive steps steps b and d S If any cylinder head bolt is broken or deformed replace it a Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolt...

Page 774: ...with the spring ends c Using snap ring pliers install the snap ring d Using SST align the holes of the camshaft main gear and sub gear by turning sub gear clockwise and install a service bolt SST 0996...

Page 775: ...n the threads and under the heads of the bearing cap bolts 5 Install and uniformly tighten the 10 bearing cap bolts in the sequence shown Torque 15 5 N m 160 kgf cm 12 ft lbf b Install exhaust camshaf...

Page 776: ...bolt 8 Check that the intake and exhaust camshafts turn smoothly 5 SET NO 1 CYLINDER TO TDC COMPRESSION a Turn the crankshaft pulley clockwise and align its groove with the timing mark 0 of the timing...

Page 777: ...front side b Release the ratchet pawl fully push in the plunger and ap ply the hook to the pin so that the plunger cannot spring out c Turn the crankshaft pulley clockwise to provide some slack for th...

Page 778: ...Turn the crankshaft pulley and align its groove with the timing mark 0 of the timing chain cover NOTICE Always turn the crankshaft clockwise b Check that the timing marks 1 and 2 dots of the camshaft...

Page 779: ...g marks with 1 and 2 dots are in straight line on the cylinder head surface as shown in the illustration If not turn the crankshaft 1 revolution 360 and align the mark as above 14 INSTALL CYLINDER HEA...

Page 780: ...lbf e Install camshaft position sensor 18 INSTALL INTAKE MANIFOLD Install a new gasket and intake manifold with the 3 bolts and 2 nuts Torque 29 N m 300 kgf cm 22 ft lbf 19 INSTALL INJECTORS AND DELIV...

Page 781: ...hose to water bypass pipe c Install 2 new gaskets and EGR pipe with the bolt and 4 nuts Torque Bolt 18 N m 185 kgf cm 14 ft lbf Nut A 19 N m 195 kgf cm 14 ft lbf Nut B 20 N m 200 kgf cm 15 ft lbf 25 I...

Page 782: ...the PS pump bracket with the 4 bolts Torque 20 N m 200 kgf cm 14 ft lbf b Connect the PS pump to the bracket with the 2 bolts Torque 58 N m 590 kgf cm 43 ft lbf c Connect the 2 air hoses to the intake...

Page 783: ...l the air cleaner cap MAF meter and resonator with the 4 clips c Connect the MAF meter connector IAT sensor connector and wire clamp 38 FILL WITH ENGINE COOLANT 39 START ENGINE AND CHECK FOR LEAKS 40...

Page 784: ...EM07H 03 ENGINE MECHANICAL 3RZ FE ENGINE UNIT EM 61 776 Author Date 1996 TOYOTA T100 RM449U ENGINE UNIT COMPONENTS...

Page 785: ...S Pump Stabilizer Bar w AC A C Compressor Bracket Drive Belt Bracket Cushion Rropeller Shaft z Gasket Drive Belt Drive Belt PS Pump Pulley Bracket Cushion z 62 630 46 39 400 29 N m kgf cm ft lbf Speci...

Page 786: ...P21702 P21922 ENGINE MECHANICAL 3RZ FE ENGINE UNIT EM 63 778 Author Date 1996 TOYOTA T100 RM449U...

Page 787: ...Z14987 EM 64 ENGINE MECHANICAL 3RZ FE ENGINE UNIT 779 Author Date 1996 TOYOTA T100 RM449U...

Page 788: ...ND RES ONATOR a Disconnect the MAF meter connector IAT sensor con nector and wire clamp b Loosen the air cleaner hose clamp c Loosen the 4 clips and remove the air cleaner cap MAF meter and resonator...

Page 789: ...bolts and A C compressor bracket 15 DISCONNECT HEATER HOSES 16 DISCONNECT HOSES Disconnect these hoses S Brake booster vacuum hose S EVAP hose S 2 PS air hoses S Fuel return hose S Fuel inlet hose 17...

Page 790: ...d strap from cowl top panel e Disconnect the 4 engine wire clamps f Pull out the engine wire from the cabin 21 M T REMOVE SHIFT LEVER ASSEMBLY a Remove the shift lever knob b Remove the 4 screws and s...

Page 791: ...h release cylin der b Remove the bolt and disconnect the clutch line 27 A T REMOVE CROSS SHAFT 28 DISCONNECT STARTER WIRE a Remove the nut and disconnect the starter wire b Disconnect the starter conn...

Page 792: ...hangers c Remove the 4 bolts and nuts holding the engine front mounting insulators to the frame d Lift the engine with transmission out of the vehicle slowly and carefully NOTICE Make sure the engine...

Page 793: ...the transmission slightly by raising the engine with a jack and a wooden block under the transmission b Install the engine rear mounting bracket to the frame Torque 25 N m 260 kgf cm 19 ft lbf c Lower...

Page 794: ...r Torque 39 N m 400 kgf cm 29 ft lbf e Connect the 2 heated oxygen sensor connectors 9 CONNECT SPEEDOMETER CABLE 10 INSTALL PROPELLER SHAFT See page PR 9 11 INSTALL STABILIZER BAR a Place the stabiliz...

Page 795: ...TALL FRONT DOOR SCUFF PLATE AND COWL SIDE TRIM a Install the cowl side trim with the clip b Install the front door scuff plate with the 4 screws 15 CONNECT GENERATOR WIRE a Connect the generator conne...

Page 796: ...with the 4 bolts Torque 44 N m 440 kgf cm 32 ft lbf b Install the A C compressor with the 4 bolts Torque 25 N m 250 kgf cm 18 ft lbf c Connect the A C compressor connector 20 INSTALL INTAKE AIR CONNEC...

Page 797: ...onnect the MAF meter connector IAT sensor connector and wire clamp 25 INSTALL RADIATOR See page CO 20 26 INSTALL RADIATOR RESERVOIR TANK 27 FILL WITH ENGINE OIL 28 FILL WITH ENGINE COOLANT 29 FILL TRA...

Page 798: ...EM07K 03 P21632 ENGINE MECHANICAL 3RZ FE CYLINDER BLOCK EM 75 790 Author Date 1996 TOYOTA T100 RM449U CYLINDER BLOCK COMPONENTS...

Page 799: ...LTER Remove the 2 bolts and fuel filter 8 REMOVE KNOCK SENSOR Using SST remove the knock sensor SST 09816 30010 9 REMOVE WATER BYPASS PIPE Remove the bolt and water bypass pipe 10 REMOVE OIL FILTER AN...

Page 800: ...ed hammer lightly tap the connecting rod bolts and lift off the connecting rod cap HINT Keep the lower bearing inserted with the connecting rod cap d Cover the connecting rod bolts with a short piece...

Page 801: ...n U S 0 25 56 000 56 018 mm 2 2047 2 2054 in Crankshaft crank pin diameter STD 52 987 53 000 mm 2 0861 2 0866 in U S 0 25 52 745 52 755 mm 2 0766 2 0770 in Standard sized bearing center wall thickness...

Page 802: ...y loosen and remove the main bearing cap bolts in several passes in the sequence shown b Using the removed main bearing cap bolts pry the main bearing cap back and forth and remove the main bearing ca...

Page 803: ...0022 in Others 0 024 0 049 mm 0 0009 0 0019 in U S 0 25 No 3 0 030 0 070 mm 0 0012 0 0028 in Others 0 025 0 065 mm 0 0010 0 0026 in Maximum clearance 0 10 mm 0 0039 in HINT S If the oil clearance is...

Page 804: ...0829 0 0831 in k Completely remove the Plastigage 22 REMOVE CRANKSHAFT a Lift out the crankshaft b Remove the upper main bearings and upper thrust wash ers from the cylinder block HINT Arrange the mai...

Page 805: ...the balance shaft bearing on the cylinder block side HINT S No 1 balance shaft RH Has indentations S No 2 balance shaft LH Has no indentations 26 DISASSEMBLE NO 1 BALANCE SHAFT a Mount the hexagon wr...

Page 806: ...he piston and pin as a set 29 REMOVE PISTON RINGS a Using a piston ring expander remove the 2 compression rings b Remove the 2 side rails and oil ring by hand HINT Arrange the rings in correct order o...

Page 807: ...ing the cylinder head gasket for warpage Maximum warpage 0 05 mm 0 0020 in If warpage is greater than maximum replace the cylinder block 3 INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cy...

Page 808: ...Using vernier calipers measure the thread outside diameter of the bolt Standard outside diameter 10 76 10 97 mm 0 4236 0 4319 in Minimum outside diameter 10 40 mm 0 4094 in If the diameter is less tha...

Page 809: ...c Subtract the piston diameter measurement from the cylin der bore diameter measurement Standard oil clearance 0 047 0 070 mm 0 0019 0 0028 in If the oil clearance is greater than maximum replace all...

Page 810: ...0 0196 in Code mark N 0 400 0 500 mm 0 0157 0 0196 in If the end gap is not as specified replace the piston ring If the end gap is not as specified even with a new piston ring rebore all the 4 cylinde...

Page 811: ...de diameter 24 008 24 017 mm 0 9452 0 9455 in b Using a micrometer measure the piston pin diameter Piston pin diameter 24 000 24 009 mm 0 9449 0 9452 in c Subtract the piston pin diameter measurement...

Page 812: ...and push it into the connect ing rod with your thumb 16 INSPECT CONNECTING ROD BOLTS a Install the cap nut to the connecting rod bolt Check that the cap nut can be turned easily by hand to the end of...

Page 813: ...iameter mea surement from the balance shaft bearing inside diameter measurement Standard oil clearance No 1 0 040 0 076 mm 0 0016 0 0031 in No 2 0 060 0 096 mm 0 0024 0 0038 in Maximum oil clearance N...

Page 814: ...KSHAFT FOR RUNOUT a Place the crankshaft on V blocks b Using a dial indicator measure the circle runout at the center journal Maximum circle runout 0 03 mm 0 0012 in If the circle runout is greater th...

Page 815: ...urnal and crank pin for taper and out of round as shown Maximum taper and out of round 0 005 mm 0 0002 in If the taper and out of round is greater than maximum replace the crankshaft 21 IF NECESSARY G...

Page 816: ...oil seal until its surface is flush with the oil pump case edge SST 09223 50010 3 Apply MP grease to the oil seal lip b If oil pump is installed to the cylinder block 1 Using a screwdriver pry out the...

Page 817: ...9608 04020 3 Apply MP grease to the seal lip b If rear oil seal retainer is installed to cylinder block 1 Using knife cut off the oil seal lip 2 Using a screwdriver pry out the oil seal NOTICE Be care...

Page 818: ...ND CONNECTING ROD a Install a new snap ring on one side of the piston pin hole b Gradually heat the piston to at 80 90 C 176 194 F c Coat the piston pin with engine oil d Align the front marks of the...

Page 819: ...nce shaft RH Has indentations b No 2 balance shaft LH Has no indentations 6 ASSEMBLY NO 1 BALANCE SHAFT a Mount the hexagon wrench head portion of the balance shaft in a vise NOTICE Be careful not to...

Page 820: ...scratching the balance shaft bearing on the cylinder block side b Install the No 1 balance shaft with the bolt c Install the No 2 balance shaft with the 2 bolts Torque 18 N m 185 kgf cm 13 4 ft lbf 9...

Page 821: ...ng outward b Install the 5 main bearing caps in their proper locations HINT Each bearing cap has a number and front mark 13 INSTALL MAIN BEARING CAP BOLTS HINT S The main bearing cap bolts are tighten...

Page 822: ...he connecting rod bolts with a short piece of hose to protect the crankshaft from damage b Using a piston ring compressor push the correctly num bered piston and connecting rod assemblies into each cy...

Page 823: ...the connecting rod cap nuts does not meet the torque specification replace the connecting rod bolt and cap nut as a set c Mark the front of the connecting rod cap nut and bolt with paint d Retighten t...

Page 824: ...26 00080 or equivalent S Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening HINT Avoid applying an excessive amount to the surface S Parts must be assembled within 5 minutes of ap pli...

Page 825: ...14 mm hexagon wrench install the oil filter bracket union Torque 25 N m 250 kgf cm 18 ft lbf 23 INSTALL OIL FILTER AND BRACKET a Install a new O ring and oil filter bracket with the 2 bolts and nut T...

Page 826: ...ft lbf 31 M T INSTALL FLYWHEEL a Install and uniformly tighten 10 new bolts to the flywheel in several passes in the sequence shown Torque 26 5 N m 270 kgf cm 19 ft lbf b Mark the top of the flywheel...

Page 827: ...M07P 02 Z14985 Specified torque z z 39 400 29 z 62 630 46 19 195 14 N m kgf cm ft lbf z EM 104 ENGINE MECHANICAL 3RZ FE EXHAUST SYSTEM 819 Author Date 1996 TOYOTA T100 RM449U EXHAUST SYSTEM COMPONENTS...

Page 828: ...5VZ FE CO HC EM 1 COMPRESSION EM 2 VALVE CLEARANCE EM 4 IGNITION TIMING EM 9 IDLE SPEED EM 10 TIMING BELT EM 11 CYLINDER HEAD EM 25 ENGINE UNIT 2WD EM 62 ENGINE UNIT 4WD EM 73 CYLINDER BLOCK EM 82 EX...

Page 829: ...systems etc should be properly connected f SFI system wiring connectors fully plugged g Ignition timing checked correctly h Transmission in neutral position i Tachometer and CO HC meter calibrated by...

Page 830: ...y charged battery to obtain engine speed of 250 rpm or more d Repeat steps a through c for each cylinder NOTICE This measurement must be done in as short a time as pos sible Compression pressure 1 200...

Page 831: ...ENGINE MECHANICAL 5VZ FE COMPRESSION EM 3 822 Author Date 1996 TOYOTA T100 RM449U 6 REINSTALL HIGH TENSION CORDS WITH IGNITION COILS See page IG 1...

Page 832: ...hat the timing marks 1 dot of the camshaft drive and driven gears are in straight line on the cylinder heads surface as shown in the illustration If not turn the crankshaft 1 revolution 360 and align...

Page 833: ...shim S Turn the camshaft so that the cam lobe for the valve to be adjusted faces up S Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft S Using SST A press...

Page 834: ...mm 0 007 in Exhaust N T A 0 32 mm 0 013 in S Select a new shim with a thickness as close as pos sible to the calculated values HINT Shims are available in 17 sizes in increments of 0 050 mm 0 0020 in...

Page 835: ...PLE The 2 800 mm 0 1102 in shim is installed and measured clearance is 0 450 mm 0 0177 in Replace the 2 800 mm 0 1102 in shim with a No 12 shim New shim thickness mm in HINT New shims have the thickne...

Page 836: ...MPLE The 2 800 mm 0 1102 in shim is installed and measured clearance is 0 450 mm 0 0177 in Replace the 2 800 mm 0 1102 in shim with a No 12 shim New shim thickness mm in Shim No Thickness Thickness Sh...

Page 837: ...further details 3 CONNECT TIMING LIGHT TO ENGINE 4 CHECK IDLE SPEED a Race the engine speed at 2 500 rpm for approx 90 se conds b Check the idle speed Idle speed 700 50 rpm 5 INSPECT IGNITION TIMING a...

Page 838: ...d HINT w EGR All vacuum hoses for EGR system etc should be properly connected f SFI system wiring connectors fully plugged g Ignition timing check correctly h Transmission in neutral position 2 CONNEC...

Page 839: ...EM06G 03 P20840 ENGINE MECHANICAL 5VZ FE TIMING BELT EM 11 830 Author Date 1996 TOYOTA T100 RM449U TIMING BELT COMPONENTS...

Page 840: ...EM 12 ENGINE MECHANICAL 5VZ FE TIMING BELT 831 Author Date 1996 TOYOTA T100 RM449U...

Page 841: ...N PUL LEYS 9 DISCONNECT PS PUMP FROM ENGINE HINT Put aside the pump and suspend it 10 w A C DISCONNECT A C COMPRESSOR FROM ENGINE HINT Put aside the compressor and suspend it 11 w A C REMOVE A C COMPR...

Page 842: ...not turn the crankshaft pulley 1 revolution 360 HINT When re using timing belt Place the matchmarks on the timing belt and camshaft timing pulleys and place matchmark on tim ing belt to match the end...

Page 843: ...he pulley with SST and service bolt SST 09950 50010 09551 05010 09552 05010 09553 05020 09554 05030 19 REMOVE STARTER WIRE BRACKET AND NO 1 TIM ING BELT COVER a Remove the 2 bolts starter wire bracket...

Page 844: ...TOYOTA T100 RM449U 23 REMOVE CRANKSHAFT TIMING PULLEY Remove crankshaft timing pulley HINT If the pulley cannot be removed by hand use SST and service bolt to remove the crankshaft timing pulley SST 0...

Page 845: ...on b If the belt teeth are cracked or damaged check to see if either camshaft is locked c If there is noticeable wear or cracks on the belt face check to see if there are nicks on the side of the idle...

Page 846: ...on the push rod side the tensioner is all right If leakage is found replace the tensioner b Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn t move If...

Page 847: ...ll the No 2 idler pulley with the bolt Torque 40 N m 400 kgf cm 30 ft lbf d Check that the pulley moves smoothly 3 TEMPORARILY INSTALL TIMING BELT NOTICE The engine should be cold a Use the crankshaft...

Page 848: ...e illustration b Install the timing belt cover with the 4 bolts Torque 9 N m 90 kgf cm 80 in lbf c Install the starter wire bracket with the 2 bolts 6 INSTALL CRANKSHAFT PULLEY a Align the pulley set...

Page 849: ...of the No 1 timing belt cover If the installation mark do not align shift the meshing of the tim ing belt and crankshaft timing pulley until they align b Remove any oil or water on the LH camshaft ti...

Page 850: ...ng belt cover e Slide the RH camshaft timing pulley on the camshaft f Using SST align the knock pin hole of the camshaft with the knock pin groove marked R of the pulley and install the knock pin SST...

Page 851: ...CKET a Install the fan bracket with the bolt and nut b Install the PS pump adjusting strut with the nut 15 INSTALL NO 2 TIMING BELT COVER a Check that the timing belt cover gasket has no cracks or pee...

Page 852: ...n lbf 20 INSTALL NO 2 FAN SHROUD 21 INSTALL AND ADJUST DRIVE BELT FOR GENERA TOR See page CH 1 22 w A C INSTALL AND ADJUST DRIVE BELT FOR A C COM PRESSOR 23 INSTALL AND ADJUST DRIVE BELT FOR PS PUMP 2...

Page 853: ...EM06K 02 P21777 ENGINE MECHANICAL 5VZ FE CYLINDER HEAD EM 25 844 Author Date 1996 TOYOTA T100 RM449U CYLINDER HEAD COMPONENTS...

Page 854: ...Z18898 EM 26 ENGINE MECHANICAL 5VZ FE CYLINDER HEAD 845 Author Date 1996 TOYOTA T100 RM449U...

Page 855: ...ENGINE MECHANICAL 5VZ FE CYLINDER HEAD EM 27 846 Author Date 1996 TOYOTA T100 RM449U...

Page 856: ...S05153 EM 28 ENGINE MECHANICAL 5VZ FE CYLINDER HEAD 847 Author Date 1996 TOYOTA T100 RM449U...

Page 857: ...Z18899 ENGINE MECHANICAL 5VZ FE CYLINDER HEAD EM 29 848 Author Date 1996 TOYOTA T100 RM449U...

Page 858: ...PS PUMP a Stretch the belt and loosen the fan pulley mounting nuts 9 w A C REMOVE DRIVE BELT FOR A C COMPRESSOR 10 REMOVE DRIVE BELT FOR GENERATOR 11 REMOVE NO 2 FAN SHROUD 12 REMOVE FAN WITH FLUID C...

Page 859: ...ector for EGR b Disconnect these hoses 1 2 PCV hoses 2 2 water bypass hoses 3 Air assist hose from throttle body 4 2 Vacuum sensing hoses from VSV S w A C Air hose from A C idle up valve 5 EVAP hose 6...

Page 860: ...ver 28 REMOVE FUEL PRESSURE REGULATOR 29 REMOVE INTAKE MANIFOLD ASSEMBLY a Disconnect the fuel inlet hose b Remove the 2 bolts and the intake manifold stay c Remove the 8 bolts 4 nuts 4 plate washers...

Page 861: ...s these steps should be carried out a Align the timing marks 2 dot marks of the camshaft drive and driven gears by turning the camshaft with a wrench b Secure the exhaust camshaft sub gear to the main...

Page 862: ...camshaft with a wrench b Secure the exhaust camshaft sub gear to the main gear with a service bolt Recommended service bolt Thread diameter 6 mm Thread pitch 1 0 mm Bolt length 16 20 mm HINT When remo...

Page 863: ...n the sub gear clockwise and remove the service bolt SST 09960 10010 09962 01000 09963 00600 c Using snap ring pliers remove the snap ring d Remove these parts S Wave washer S Camshaft sub gear S Cams...

Page 864: ...r head bolts and plate washers NOTICE Head warpage or cracking could result from removing bolts in an incorrect order d Lift the cylinder head from the dowels on the cylinder block and place the 2 cyl...

Page 865: ...ALVE LIFTERS AND SHIMS Pull out the valve lifter and shim by hand HINT Arrange the valve lifters and shims in correct order 3 REMOVE VALVES a Using SST compress the valve spring and remove the 2 keepe...

Page 866: ...ock surfaces c Using compressed air blow carbon and oil from the bolt holes CAUTION Protect your eyes when using high compressed air 2 REMOVE GASKET MATERIAL Using a gasket scraper remove all the gask...

Page 867: ...he surfaces contacting the cylinder block and manifolds for war page Maximum warpage 0 10 mm 0 0039 in If warpage is greater than maximum replace the cylinder head 7 INSPECT FOR CRACKS Using a dye pen...

Page 868: ...em diameter measurement from the guide bushing inside diameter measurement Oil clearance Standard Intake Exhaust 0 025 0 060 mm 0 0010 0 0024 in 0 030 0 065 mm 0 0012 0 0026 in Maximum Intake Exhaust...

Page 869: ...in Bushing size 10 985 11 027 0 4325 0 4341 Use STD 11 050 11 077 0 4350 0 4361 Use O S 0 05 If the bushing bore diameter of the cylinder head is greater than 11 027 mm 0 4341 in machine the bushing...

Page 870: ...lve face angle Valve face angle 44 5 c Check the valve head margin thickness Standard margin thickness 1 0 mm 0 039 in Minimum margin thickness 0 5 mm 0 020 in If the margin thickness is less than min...

Page 871: ...the valve face and seat for these S If blue appears 360 around the face the valve is concentric If not replace the valve S If blue appears 360 around the valve seat the guide and face are concentric...

Page 872: ...g at the specified installed length Installed tension 186 206 N 19 0 21 0 kgf 41 9 46 3 lbf at 33 3 mm 1 311 in If the installed tension is not as specified replace the valve spring 14 INSPECT CAMSHAF...

Page 873: ...CAMSHAFT JOURNAL OIL CLEARANCE a Clean the bearing caps and camshaft journals b Place the camshafts on the cylinder head c Lay a strip of Plastigage across each of the camshaft jour nals d Install th...

Page 874: ...dard backlash 0 020 0 200 mm 0 0008 0 0079 in Maximum backlash 0 30 mm 0 0188 in If the backlash is greater than maximum replace the cam shafts 22 INSPECT VALVE LIFTERS AND LIFTER BORES a Using a cali...

Page 875: ...e the surfaces contacting the cylinder head and intake air connector for warpage Maximum warpage 0 10 mm 0 0039 in If warpage is greater than maximum replace the intake man ifold b Exhaust Manifolds M...

Page 876: ...lipping out b Using a screwdriver and hammer tap out the gasket NOTICE Do not scratch or damage the joint of the cylinder head cov er c Using needle nose pliers pry out the gasket d Using a 32 mm sock...

Page 877: ...SPARK PLUG TUBES HINT When using a new cylinder head spark plug tubes must be installed a Apply adhesive to the end of the spark plug tube Adhesive Part No 08833 00070 THREE BOND 1324 or equiva lent b...

Page 878: ...proper fit 3 INSTALL VALVE LIFTERS AND SHIMS a Install the valve lifter and shim b Check that the valve lifter rotates smoothly by hand 4 INSTALL CAMSHAFT HOUSING PLUGS a Remove any old packing FIPG m...

Page 879: ...in 3 progressive steps steps b d and e S If any bolt is broken or deformed replace it a Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts b Install and un...

Page 880: ...the cylinder head bolt on each cylinder head then repeat for the other side as shown Torque 18 N m 185 kgf cm 13 ft lbf 4 CONNECT GROUND STRAP Install the bolt and connect the ground strap 5 ASSEMBLE...

Page 881: ...is small the camshaft must be held level while it is being installed If the camshaft is not level the portion of the cylinder head re ceiving the shaft thrust may crack or be damaged causing the cams...

Page 882: ...N m 160 kgf cm 12 ft lbf i Install the exhaust camshaft j Apply new engine oil to the thrust portion and journal of the camshaft k Align the timing marks 2 dot marks of the camshaft drive and driven g...

Page 883: ...d out a Apply new engine oil to the thrust portion and journal of the camshaft b Place the intake camshaft at 90 angle of timing mark 1 dot mark on the cylinder head c Apply MP grease to a new oil sea...

Page 884: ...t on the cylinder head d Install the 4 bearing caps in their proper locations e Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts f Install and uniformly tighten...

Page 885: ...Install the 2 cylinder head covers Torque 6 N m 60 kgf cm 53 in lbf 12 INSTALL RH AND LH EXHAUST MANIFOLDS a Install 2 new gaskets the RH and LH exhaust manifolds with the 12 nuts Torque 40 N m 400 kg...

Page 886: ...intake manifold stay with the 2 bolts Torque 18 5 N m 185 kgf cm 13 ft lbf c Connect the fuel inlet hose 18 INSTALL FUEL PRESSURE REGULATOR See page SF 16 19 INSTALL NO 3 TIMING BELT COVER a Check th...

Page 887: ...S ECT sensor connector S Knock sensor connector S Camshaft position sensor connector 22 INSTALL INTAKE AIR CONNECTOR a Install a new gasket and the intake air connector with the 3 bolts and 2 nuts To...

Page 888: ...nector S IAC valve connector S w EGR EGR gas temperature sensor connector S VSV connector for EGR 24 INSTALL AIR INTAKE CHAMBER STAY a Install the air intake chamber stay with the 2 bolts Torque 14 mm...

Page 889: ...ADJUST DRIVE BELT FOR GENERA TOR See page CH 1 37 w A C INSTALL AND ADJUST DRIVE BELT FOR A C COM PRESSOR 38 INSTALL AND ADJUST DRIVE BELT FOR PS PUMP 39 CONNECT HEATER HOSE AND UPPER RADIATOR HOSE 4...

Page 890: ...EM07R 04 EM 62 ENGINE MECHANICAL 5VZ FE ENGINE UNIT 2WD 881 Author Date 1996 TOYOTA T100 RM449U ENGINE UNIT 2WD COMPONENTS...

Page 891: ...ENGINE MECHANICAL 5VZ FE ENGINE UNIT 2WD EM 63 882 Author Date 1996 TOYOTA T100 RM449U...

Page 892: ...Z18855 EM 64 ENGINE MECHANICAL 5VZ FE ENGINE UNIT 2WD 883 Author Date 1996 TOYOTA T100 RM449U...

Page 893: ...FAN WITH FLUID COUPLING AND FAN PUL LEYS See page CO 5 10 DISCONNECT PS PUMP FROM ENGINE HINT Put aside the pump and suspend it 11 w A C REMOVE A C COMPRESSOR FROM ENGINE HINT Put aside the compressor...

Page 894: ...NECTORS a Remove the 3 bolts and ECM b M T Disconnect the 3 ECM connectors c A T Disconnect the 4 ECM connectors d Disconnect the 2 connectors from the cowl wire e Disconnect these wires and connector...

Page 895: ...E CROSS SHAFT a Remove the clip and disconnect the shifting rod b Remove the nut 4 bolts and the cross shaft 28 PLACE JACK UNDER TRANSMISSION 29 REMOVE ENGINE REAR MOUNTING BRACKET Remove the 8 bolts...

Page 896: ...ts and nuts holding the engine front mounting insulators to the frame e Lift the engine with transmission out of the vehicle slowly and carefully NOTICE Make sure the engine is clear of all wiring and...

Page 897: ...up and put the transmission onto the frame f Remove the engine chain hoist from the engine g Remove the 2 bolts and engine hanger No 2 h w A C Install the bolt and connect the A C compressor wire 3 I...

Page 898: ...33 ft lbf c Connect a new gasket and the front exhaust pipe assem bly to the center exhaust pipe with the 2 bolts and retainer Torque 48 N m 490 kgf cm 35 ft lbf d Connect the 2 heated oxygen sensor c...

Page 899: ...tive terminal cable to battery c Install the bolt and connect the ground strap 16 CONNECT HOSES Connect these hoses S Fuel return hose S Fuel inlet hose S Brake booster vacuum hose S EVAP hose S A D D...

Page 900: ...INSTALL RADIATOR ASSEMBLY See page CO 19 28 FILL WITH ENGINE OIL 29 FILL WITH ENGINE COOLANT 30 FILL TRANSMISSION OIL 31 START ENGINE AND CHECK FOR LEAKS 32 CHECK IGNITION TIMING See page EM 9 33 INS...

Page 901: ...EM1OT 01 ENGINE MECHANICAL 5VZ FE ENGINE UNIT 4WD EM 73 892 Author Date 1996 TOYOTA T100 RM449U ENGINE UNIT 4WD COMPONENTS...

Page 902: ...EM 74 ENGINE MECHANICAL 5VZ FE ENGINE UNIT 4WD 893 Author Date 1996 TOYOTA T100 RM449U...

Page 903: ...ENGINE MECHANICAL 5VZ FE ENGINE UNIT 4WD EM 75 894 Author Date 1996 TOYOTA T100 RM449U...

Page 904: ...FLUID COUPLING AND FAN PUL LEYS See page EM 13 10 DISCONNECT PS PUMP FROM ENGINE HINT Put aside the pump and suspend it 11 w A C DISCONNECT A C COMPRESSOR HINT Put aside the compressor and suspend it...

Page 905: ...the A D D indicator switch connector 18 DISCONNECT GENERATOR WIRE a Disconnect the generator connector b Remove the nut and disconnect the generator wire and wire clip 19 REMOVE FRONT DOOR SCUFF PLATE...

Page 906: ...r No 2 in the correct direction Part No Engine hanger No 2 12282 62030 Bolt 91512 61020 Torque 40 N m 400 kgf cm 30 ft lbf c Attach the engine hoist chain to the 2 engine hangers d Remove the 4 bolts...

Page 907: ...Remove the 2 bolts and engine hanger No 2 g w A C Install the bolt and connect the A C compressor wire 2 TIGHTEN RH AND LH ENGINE MOUNTING INSULATOR BOLTS AND NUTS Tighten the 4 bolts and nuts holding...

Page 908: ...Install the bolt and connect the ground strap 7 CONNECT HOSES Connect these hoses S Fuel return hose S Fuel inlet hose S Brake booster vacuum hose S EVAP hose S A D D vacuum hose 8 CONNECT HEATER HOS...

Page 909: ...OR PS PUMP 18 INSTALL RADIATOR ASSEMBLY See page CO 19 19 FILL WITH ENGINE OIL 20 FILL WITH ENGINE COOLANT 21 INSTALL ENGINE UNDER COVER 22 INSTALL TRANSMISSION See page MT 4 23 INSTALL HOOD 24 PERFOR...

Page 910: ...EM07T 02 EM 82 ENGINE MECHANICAL 5VZ FE CYLINDER BLOCK 901 Author Date 1996 TOYOTA T100 RM449U CYLINDER BLOCK COMPONENTS...

Page 911: ...P21786 ENGINE MECHANICAL 5VZ FE CYLINDER BLOCK EM 83 902 Author Date 1996 TOYOTA T100 RM449U...

Page 912: ...sensor connectors b Remove the 2 bolts nut and water bypass pipe 8 REMOVE NO 2 IDLER PULLEY BRACKET Remove the 3 bolts and idler pulley bracket 9 REMOVE KNOCK SENSORS Using SST remove the 2 knock sens...

Page 913: ...ainer by prying the portions between the oil seal retainer and main bear ing cap 23 CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator measure the thrust clearance while mov ing the connecti...

Page 914: ...se to protect the crankshaft from damage e Clean the crank pin and bearing f Check the crank pin and bearing for pitting and scratches If the crank pin or bearing is damaged replace the bearings If ne...

Page 915: ...cap There are 3 sizes of standard bearings marked 1 2 and 3 accordingly Reference Standard bearing center wall thickness Mark 1 1 484 1 488 mm 0 0584 0 0586 in Mark 2 1 488 1 492 mm 0 0586 0 0587 in...

Page 916: ...and re move the main bearing cap lower main bearings and low er thrust washers No 2 journal position of main bearing cap only HINT Keep the lower main bearings and lower thrust washers togeth er with...

Page 917: ...ing stan dard clearance will be No 1 0 010 0 049 mm 0 0004 0 0020 in Others 0 014 0 053 mm 0 0006 0 0021 in If the oil clearance is greater than maximum replace the bear ings If necessary grind or rep...

Page 918: ...996 64 000 mm 2 5195 2 5197 in Mark 1 63 990 63 996 mm 2 5193 2 5195 in Mark 2 63 985 63 990 mm 2 5191 2 5193 in k Completely remove the Plastigage 28 REMOVE CRANKSHAFT a Lift out the crankshaft b Re...

Page 919: ...ing a small screwdriver pry out the 2 snap rings b Gradually heat the piston to about 60 C 140 F c Using a plastic faced hammer and brass bar lightly tap out the piston pin and remove the connecting r...

Page 920: ...LINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge measure the surfaces contacting the cylinder head gasket for warpage Maximum warpage 0 05 mm 0 0020 in If warpage is greater...

Page 921: ...3 6815 in STD Mark 2 93 510 93 520 mm 3 6815 3 6819 in STD Mark 3 93 520 93 530 mm 3 6819 3 6823 in Maximum diameter STD 93 730 mm 3 6902 in O S 0 50 94 230 mm 3 7098 in If the diameter is greater tha...

Page 922: ...856 93 886 mm 3 6951 3 6963 in b Measure the cylinder bore diameter in the thrust direc tions See step 5 c Subtract the piston diameter measurement from the cylin der bore diameter measurement Standa...

Page 923: ...33 in No 2 1 200 mm 0 0472 in Oil Side rail 1 150 mm 0 0453 in If the end gap is greater than maximum replace the piston ring If the end gap is greater than maximum even with a new piston ring rebore...

Page 924: ...rement from the bushing inside diameter measurement Standard oil clearance 0 005 0 011 mm 0 0002 0 0004 in Maximum oil clearance 0 05 mm 0 0020 in If the oil clearance is greater than maximum replace...

Page 925: ...outer diameter 7 860 8 000 mm 0 3094 0 3150 in Minimum outer diameter 7 600 mm 0 2992 in HINT If the location of this area cannot be judged by visual inspection measure the outer diameter at the loca...

Page 926: ...e runout at the No 2 and No 3 journals Maximum circle runout 0 06 mm 0 0024 in If the circle runout is greater than maximum replace the crank shaft 18 INSPECT MAIN JOURNALS AND CRANK PINS a Using a mi...

Page 927: ...YOTA T100 RM449U 19 IF NECESSARY GRIND AND HONE MAIN JOURNALS AND OR CRANK PINS a Grind and hone the main journals and or crank pins to the finished undersized diameter See procedure step 18 b Install...

Page 928: ...the oil seal 2 Using SST and a hammer tap in a new oil seal until its surface is flush with the rear oil seal retainer edge SST 09223 15030 09950 70010 09951 07150 3 Apply MP grease to the oil seal li...

Page 929: ...hole HINT Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston b Gradually heat the piston to about 60 C 140 F c Coat the piston pin with engine oil d A...

Page 930: ...sition with the main bearing caps Install the 20 mm 0 79 in bearings in the other positions S Upper bearings have an oil holes lower bearings do not a Align the bearing claw with the claw groove of th...

Page 931: ...earing cap bolts b Install and uniformly tighten the 8 main bearing cap bolts in several passes in the sequence shown Torque 61 N m 625 kgf cm 45 ft lbf If any one of the main bearing cap bolts does n...

Page 932: ...rod b Install the connecting rod cap with the front mark facing forward 11 INSTALL CONNECTING ROD CAP NUTS HINT S The connecting rod cap nuts are tightened in 2 progres sive steps steps b and d S If...

Page 933: ...Apply seal packing to the oil seal retainer as shown in the illustration Seal packing Part No 08826 00080 or equivalent S Install a nozzle that has been cut to a 2 3 mm 0 08 0 12 in opening S Parts mu...

Page 934: ...09816 30010 Torque 39 N m 400 kgf cm 29 ft lbf 27 INSTALL NO 2 IDLER PULLEY BRACKET Torque 38 N m 380 kgf cm 28 ft lbf 28 INSTALL WATER BYPASS PIPE WITH KNOCK SEN SOR WIRE a Remove any old packing FIP...

Page 935: ...NGINE STAND 32 INSTALL REAR END PLATE Torque 7 5 N m 75 kgf cm 66 in lbf 33 A T INSTALL DRIVE PLATE a Apply adhesive to 2 or 3 threads of the mount bolt end Adhesive Part No 08833 00070 THREE BOND 132...

Page 936: ...EM07F 01 P24419 EM 108 ENGINE MECHANICAL 5VZ FE EXHAUST SYSTEM 927 Author Date 1996 TOYOTA T100 RM449U EXHAUST SYSTEM COMPONENTS...

Page 937: ...P24450 ENGINE MECHANICAL 5VZ FE EXHAUST SYSTEM EM 109 928 Author Date 1996 TOYOTA T100 RM449U...

Page 938: ...NTROL SYSTEM EC 1 PARTS LAYOUT AND SCHEMATIC DRAWING EC 2 POSITIVE CRANKCASE VENTILATION PCV SYSTEM EC 4 EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EC 5 EXHAUST GAS RECIRCULATION EGR SYSTEM EC 7 THREE W...

Page 939: ...containing HC being released from the fuel tank 2 The function of each system is shown in these table System Abbreviation Function 1 Positive Crankcase Ventilation 2 Evaporative Emission Control 3 Ex...

Page 940: ...EC02O 02 EC 2 EMISSION CONTROL 3RZ FE PARTS LAYOUT AND SCHEMATIC DRAWING 930 Author Date 1996 TOYOTA T100 RM449U PARTS LAYOUT AND SCHEMATIC DRAWING LOCATION...

Page 941: ...EC02P 02 EMISSION CONTROL 3RZ FE PARTS LAYOUT AND SCHEMATIC DRAWING EC 3 1996 TOYOTA T100 RM449U DRAWING...

Page 942: ...O PCV VALVE 3 INSPECT PCV VALVE OPERATION a Blow into the cylinder head cover side and check that air passes through easily CAUTION Do not suck air through the valve Petroleum substances inside the va...

Page 943: ...ed or damaged If necessary repair or replace the cap 4 REMOVE VSV Remove the screw from the charcoal canister 5 REMOVE CHARCOAL CANISTER 6 REMOVE CAP FROM CHARCOAL CANISTER 7 VISUALLY INSPECT CHARCOAL...

Page 944: ...NISTER Clean the filter by blowing 294 kPa 3 kgf cm2 43 psi of com pressed air into tank pipe while holding purge pipe closed NOTICE S Do not attempt to wash the canister S No activated carbon should...

Page 945: ...ay connector connect a vacuum gauge to the hose between the EGR valve and EGR vacuum modulator 3 INSPECT SEATING OF EGR VALVE Start the engine and check that the engine starts and runs at idle 4 CONNE...

Page 946: ...ACUUM GAUGE Remove the vacuum gauge and reconnect the vacuum hoses to the proper locations 9 INSPECT EGR VALVE a Apply vacuum directly to the EGR valve with the engine idling b Check that the engine r...

Page 947: ...peed at 3 500 rpm d Repeat the above test Check that there is a strong resis tance to air flow If operation is not as specified replace the EGR vacuum modu lator 14 RECONNECT VACUUM HOSES TO EGR VACUU...

Page 948: ...FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it touches the three way catalytic convert er repair or replace it 2 CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENE...

Page 949: ...or bank 1 sensor 2 Torque 20 N m 200 kgf cm 14 ft lbf HINT At the time of assembly please refer to the following item Install the heated oxygen sensor with a new gasket c Remove the 4 bolts TWC joint...

Page 950: ...NTROL SYSTEM EC 1 PARTS LAYOUT AND SCHEMATIC DRAWING EC 2 POSITIVE CRANKCASE VENTILATION PCV SYSTEM EC 4 EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EC 5 EXHAUST GAS RECIRCULATION EGR SYSTEM EC 7 THREE W...

Page 951: ...g released from the fuel tank 2 The function of each system is shown in these table System Abbreviation Function 1 Positive Crankcase Ventilation 2 Evaporative Emission Control 3 Exhaust Gas Recircula...

Page 952: ...EC033 03 B13074 EC 2 EMISSION CONTROL 5VZ FE PARTS LAYOUT AND SCHEMATIC DRAWING 941 Author Date 1996 TOYOTA T100 RM449U PARTS LAYOUT AND SCHEMATIC DRAWING LOCATION...

Page 953: ...EC034 03 B13075 EMISSION CONTROL 5VZ FE PARTS LAYOUT AND SCHEMATIC DRAWING EC 3 1996 TOYOTA T100 RM449U DRAWING...

Page 954: ...INSPECT PCV VALVE OPERATION a Blow air into the cylinder head cover side and check that air passes through easily CAUTION Do not suck air through the valve Petroleum substances inside the valve are h...

Page 955: ...p and or gasket are deformed or damaged If necessary repair or replace the cap 4 REMOVE VSV 5 REMOVE CHARCOAL CANISTER 6 VISUALLY INSPECT CHARCOAL CANISTER Look for cracks or damage 7 CHECK FOR CLOGGE...

Page 956: ...CLEAN FILTER IN CANISTER Clean the filter by blowing 294 kPa 3 gf cm2 43 psi of com pressed air into tank pipe while holding purge pipe closed NOTICE S Do not attempt to wash the canister S No activat...

Page 957: ...EC02V 02 P21189 EMISSION CONTROL 5VZ FE EXHAUST GAS RECIRCULATION EGR SYSTEM EC 7 946 Author Date 1996 TOYOTA T100 RM449U EXHAUST GAS RECIRCULATION EGR SYSTEM COMPONENTS...

Page 958: ...bf Nut B 8 0 N m 80 kgf cm 71 in lbf 3 REMOVE EGR GAS TEMPERATURE SENSOR 4 REMOVE EGR VALVE a Disconnect these hoses from the EGR valve S Vacuum hose from VSV for EGR S EGR hose from EGR vacuum modula...

Page 959: ...he hose between the EGR valve and VSV 3 INSPECT SEATING OF EGR VALVE Check that the engine starts and runs at idle 4 CONNECT TERMINALS TE1 AND E1 Using SST connect terminals TE1 and E1 of the DLC1 SST...

Page 960: ...or dies c Reconnect the vacuum hoses to their proper locations If no problem is found during this inspection system is normal otherwise inspect each part 10 DISCONNECT VACUUM HOSES FROM EGR VACUUM MO...

Page 961: ...EC02X 02 EMISSION CONTROL 5VZ FE EXHAUST GAS RECIRCULATION EGR SYSTEM EC 11 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page EC 8...

Page 962: ...FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it contacts the three way catalytic converter repair or re place it 2 CHECK CONNECTIONS EXHAUST PIPE FOR LOOSEN...

Page 963: ...t bracket b Remove the 2 nuts and gasket and disconnect the heated oxygen sensor bank 1 sensor 2 Torque 20 N m 200 kgf cm 14 ft lbf HINT Use a new gasket c Remove the 4 bolts TWC joint retainer center...

Page 964: ...MAF METER MF 36 EFI MAIN RELAY MF 40 CIRCUIT OPENING RELAY MF 41 VSV FOR EVAPORATIVE EMISSION EVAP MF 43 VSV FOR EXHAUST GAS RECIRCULATION EGR MF 44 ENGINE COOLANT TEMPERATURE ECT SENSOR MF 45 INTAKE...

Page 965: ...per connection of battery terminals etc 2 Handle high tension cords carefully 3 After repair work check that the ignition coil termi nals and all other ignition system lines are recon nected securely...

Page 966: ...rminal con tact can further troubles e Do not open the ECM cover f When inspecting during rainy weather take care to pre vent entry of water Also when washing the engine compartment prevent water from...

Page 967: ...Type Always use a new gasket 2 Union Bolt Type Tighten the union bolt by hand 3 Union Bolt Type Tighten the union bolt to the specified torque Torque 29 N m 300 kgf cm 22 ft lbf 4 Flare Nut Type Appl...

Page 968: ...ld tester 4 Please refer to the TOYOTA hand held tester oper ator s manual for further details 5 If you have no TOYOTA hand held tester connect the positive and negative leads from the bat tery to the...

Page 969: ...ative leads from the battery to the fuel pump connector See page MF 10 f Check that there is pressure in the hose from the fuel filter HINT At this time you will hear fuel return noise If there is no...

Page 970: ...ery to the fuel pump connector See page MF 10 k Reconnect the negative terminal cable to the battery l Turn the ignition switch ON m Measure the fuel pressure Fuel pressure 265 304 kPa 2 7 3 1 kgf cm2...

Page 971: ...as specified check the fuel pump pressure regulator and or injector v After checking fuel pressure disconnect the negative terminal cable from the battery and carefully remove SST to prevent gasoline...

Page 972: ...SF0AH 03 MF 8 MFI 3RZ FE FUEL PUMP 1996 TOYOTA T100 RM449U COMPONENTS...

Page 973: ...ANK See page MF 23 2 REMOVE FUEL PUMP BRACKET ASSEMBLY FROM FUEL TANK a Disconnect the fuel pump connector from the clamp b Remove the 7 bolts Torque 3 9 N m 40 kgf cm 35 in lbf c Pull out the pump br...

Page 974: ...mp operates NOTICE These tests must be done quickly within 10 seconds to prevent the coil from burning out Keep the fuel pump as far away from the battery as possible Always do the switching at the ba...

Page 975: ...SF0AK 02 MFI 3RZ FE FUEL PUMP MF 11 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page MF 10...

Page 976: ...SF0AL 03 MF 12 MFI 3RZ FE FUEL PUMP 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page MF 9...

Page 977: ...5123 z Non reusable part Vacuum Sensing Hose z O Ring Fuel Pressure Regulator Fuel Return Hose MFI 3RZ FE FUEL PRESSURE REGULATOR MF 13 965 Author Date 1996 TOYOTA T100 RM449U FUEL PRESSURE REGULATOR...

Page 978: ...TURN HOSE FROM FUEL PRESSURE REGULATOR HINT Put a suitable container or shop towel under the pressure regu lator 3 REMOVE FUEL PRESSURE REGULATOR a Remove the 2 bolts and the fuel pressure regulator T...

Page 979: ...SF0AO 03 MFI 3RZ FE FUEL PRESSURE REGULATOR MF 15 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page MF 14...

Page 980: ...2 If you have no sound scope you can check the in jector transmission operation with your finger If no sound or unusual sound is heard check the wiring connec tor injector or injection signal from th...

Page 981: ...SF0AQ 02 MFI 3RZ FE INJECTOR MF 17 1996 TOYOTA T100 RM449U COMPONENTS...

Page 982: ...d resonator 3 M T DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 4 A T DISCONNECT THROTTLE AND ACCELERATOR CABLES FROM THROTTLE BODY 5 REMOVE INTAKE AIR CONNECTOR a Disconnect the 2 air hoses b Remov...

Page 983: ...fuel pressure regulator c Install the O ring to the fuel inlet of pressure regulator d Connect SST hose to the fuel inlet of the pressure regu lator with SST union and the 2 bolts SST 09268 41046 0926...

Page 984: ...injector 5 cm3 0 3 cu in or less If the injection volume is not as specified replace the injector 2 INSPECT LEAKAGE a In the condition above disconnect the test probes of SST wire from the battery an...

Page 985: ...b Place the 4 injectors together with the delivery pipe in position on the cylinder head c Temporarily install the 2 bolts holding the delivery pipe to the cylinder head d Check that the injectors rot...

Page 986: ...MF 22 MFI 3RZ FE INJECTOR 1996 TOYOTA T100 RM449U 9 INSTALL MAF METER RESONATOR AND AIR CLEANER CAP 10 FILL WITH ENGINE COOLANT 11 RECHECK ENGINE COOLANT LEVEL...

Page 987: ...lbf 3 5 35 31 in lbf Specified torque No 1 Fuel Tank Band MFI 3RZ FE FUEL TANK AND LINE MF 23 975 Author Date 1996 TOYOTA T100 RM449U FUEL TANK AND LINE COMPONENTS CAUTION S Always use new gaskets whe...

Page 988: ...INSPECT FUEL TANK AND LINE a Check the fuel lines for cracks or leakage and all connec tions for deformation b Check the fuel tank vapor vent system hoses and connec tions for looseness sharp bends o...

Page 989: ...ect the sensor connector b Apply vacuum to the throttle opener c Using an ohmmeter measure the resistance between each terminal Throttle valve condition Between terminals Resistance Fully closed VTA E...

Page 990: ...tle opener setting speed 1 200 1 400 rpm If the throttle opener setting is not as specified replace the throttle body f Stop the engine g Connect the vacuum hose to the throttle opener h Start the eng...

Page 991: ...SF0B1 02 P21635 MFI 3RZ FE THROTTLE BODY MF 27 1996 TOYOTA T100 RM449U COMPONENTS...

Page 992: ...VE INTAKE AIR CONNECTOR a Disconnect the 2 air hoses b Remove the 2 bolts hose clamp and intake air connector 6 REMOVE NO 1 AND NO 2 PCV HOSES 7 REMOVE THROTTLE BODY a Disconnect the throttle position...

Page 993: ...ttle opener b Check that there is no clearance between the throttle stop screw and throttle lever when the closed throttle position 3 INSPECT THROTTLE POSITION SENSOR a Apply vacuum to the throttle op...

Page 994: ...SF0B4 03 MF 30 MFI 3RZ FE THROTTLE BODY 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page MF 28...

Page 995: ...for 5 se conds check that they return to idle speed If the rpm operation is not as specified check the IAC valve wir ing and ECU d Remove SST SST 09843 18020 2 INSPECT IAC VALVE RESISTANCE NOTICE Cold...

Page 996: ...SF0B6 02 P21639 MF 32 MFI 3RZ FE IDLE AIR CONTROL IAC VALVE 1996 TOYOTA T100 RM449U COMPONENTS...

Page 997: ...SF0B7 02 P15135 MFI 3RZ FE IDLE AIR CONTROL IAC VALVE MF 33 1996 TOYOTA T100 RM449U REMOVAL 1 REMOVE THROTTLE BODY See page MF 28 2 REMOVE IAC VALVE Remove the 4 screws IAC valve and gasket...

Page 998: ...TOYOTA T100 RM449U INSPECTION INSPECT IAC VALVE OPERATION a Connect the positive lead from the battery to terminal B and negative lead to terminal RSC and check that the valve is closed b Connect the...

Page 999: ...t MFI 3RZ FE IDLE AIR CONTROL IAC VALVE MF 35 1996 TOYOTA T100 RM449U INSTALLATION 1 INSTALL IAC VALVE a Place a new gasket on the throttle body b Install the IAC valve with the 4 screws 2 INSTALL THR...

Page 1000: ...SF0AW 03 MF 36 MFI 3RZ FE MASS AIR FLOW MAF METER 988 Author Date 1996 TOYOTA T100 RM449U MASS AIR FLOW MAF METER COMPONENTS...

Page 1001: ...MAF METER a Disconnect the MAF meter connector IAT sensor con nector and wire clamp b Loosen the air cleaner hose clamp c Loosen the 4 clips and remove the air cleaner cap and MAF meter 2 REMOVE MAF M...

Page 1002: ...h ON c Connect the MAF meter connector d Using a voltmeter connect the positive tester probe to terminal VG and negative tester probe to terminal E3 e Blow air into the MAF meter and check that the vo...

Page 1003: ...RM449U INSTALLATION 1 INSTALL MAF METER TO AIR CLEANER CAP a Install the IAT sensor to the air cleaner cap b Place a new gasket on the air cleaner cap c Install the MAF meter with the 4 nuts Torque 8...

Page 1004: ...NTINUITY a Using an ohmmeter check that there is continuity be tween terminals 1 and 2 If there is no continuity replace the relay b Check that there is no continuity between terminals 3 and 5 If ther...

Page 1005: ...SF0BB 02 Z14696 MFI 3RZ FE CIRCUIT OPENING RELAY MF 41 993 Author Date 1996 TOYOTA T100 RM449U CIRCUIT OPENING RELAY COMPONENTS...

Page 1006: ...eplace the relay b Check that there is continuity between terminals B and FC If there is no continuity replace the relay c Check that there is no continuity between terminals B and FP If there is cont...

Page 1007: ...een the terminals Resistance 30 34 at 20 C 68 F If there is no continuity replace the VSV 2 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the bod...

Page 1008: ...meter check that there is continuity between the terminals Resistance 33 39 at 20 C 68 F If there is no continuity replace the VSV 2 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no con...

Page 1009: ...T sensor connector b Using a 19 mm deep socket wrench remove the ECT sensor and gasket 3 INSPECT ENGINE COOLANT TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the ter minals Resis...

Page 1010: ...3RZ FE INTAKE AIR TEMPERATURE IAT SENSOR 998 Author Date 1996 TOYOTA T100 RM449U INTAKE AIR TEMPERATURE IAT SENSOR INSPECTION 1 REMOVE IAT SENSOR 2 INSPECT IAT SENSOR Using an ohmmeter measure the re...

Page 1011: ...nsor connector b Using SST remove the knock sensor SST 09816 30010 2 INSPECT KNOCK SENSOR Using an ohmmeter check that there is no continuity between the terminal and body If there is continuity repla...

Page 1012: ...IRCULATION EGR GAS TEMPERATURE SENSOR INSPECTION 1 REMOVE EGR GAS TEMPERATURE SENSOR 2 INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the ter minals Resistance 64...

Page 1013: ...STANCE OF HEATED OXYGEN SENSORS a Disconnect the heated oxygen sensor connectors b Using an ohmmeter measure the resistance between ter minals B and HT Resistance Bank 1 Sensor 1 5 7 at 20 C 68 F Bank...

Page 1014: ...SF0BM 02 P21637 MF 50 MFI 3RZ FE ENGINE CONTROL MODULE ECM 1002 Author Date 1996 TOYOTA T100 RM449U ENGINE CONTROL MODULE ECM COMPONENTS...

Page 1015: ...CM MF 51 1996 TOYOTA T100 RM449U REMOVAL 1 REMOVE FRONT DOOR SCUFF PLATE Remove the 4 screws and front scuff plate 2 REMOVE COWL SIDE TRIM Remove the clip and cowl side trim 3 REMOVE ECM a Disconnect...

Page 1016: ...SF0BO 01 MF 52 MFI 3RZ FE ENGINE CONTROL MODULE ECM 1996 TOYOTA T100 RM449U INSPECTION See page DI 17...

Page 1017: ...SF0BP 02 MFI 3RZ FE ENGINE CONTROL MODULE ECM MF 53 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page MF 51...

Page 1018: ...TESTER OR OBDII SCAN TOOL See page MF 5 3 INSPECT FUEL CUT OFF RPM a Increase the engine speed to at least 3 000 rpm b Using a sound scope check for injector operating noise c Check that when the thr...

Page 1019: ...ROL IAC VALVE SF 39 EFI MAIN RELAY SF 45 CIRCUIT OPENING RELAY SF 46 VSV FOR FUEL PRESSURE CONTROL SF 47 VSV FOR EXHAUST GAS CONTROL VALVE SF 49 VSV FOR EVAPORATIVE EMISSION EVAP SF 50 ENGINE COOLANT...

Page 1020: ...2 After repair work check that the ignition coil termi nals and all other ignition system lines are recon nected securely 3 When cleaning the engine compartment be espe cially careful to protect the e...

Page 1021: ...and even slight terminal con tact can further troubles e Do not open the ECM cover f When inspecting during rainy weather take care to pre vent entry of water Also when washing the engine compartment...

Page 1022: ...rubber plug b When connecting the flare nut or union bolt on the high pressure pipe union observe these procedures 1 Union Bolt Type Always use 2 new gaskets 2 Union Bolt Type Tighten the union bolt b...

Page 1023: ...mainte nance anywhere on the fuel system 1 Connect the TOYOTA hand held tester to the DLC3 2 Turn the ignition switch ON and push the TOYOTA hand held tester main switch ON NOTICE Do not start the eng...

Page 1024: ...fuel pump connector f Check that there is pressure in the fuel inlet hose from the fuel filter HINT If there is fuel pressure you will hear the sound of fuel flowing If there is no pressure check the...

Page 1025: ...the DLC3 l Reinstall the No 2 timing belt cover with the 6 bolts m Start the engine n Disconnect the vacuum sensing hose from the fuel pres sure regulator and plug the hose end o Measure the fuel pres...

Page 1026: ...1013 Author Date 1996 TOYOTA T100 RM449U v Reinstall the fuel pipe with 4 new gaskets and the 2 union bolts Torque 34 3 N m 350 kgf cm 25 ft lbf w Reconnect the negative terminal cable to the battery...

Page 1027: ...SF0BU 02 SF 8 SFI 5VZ FE FUEL PUMP 1996 TOYOTA T100 RM449U FUEL PUMP COMPONENTS...

Page 1028: ...fuel pump 1 REMOVE FUEL TANK HINT Check for fuel leakage 2 REMOVE FUEL PUMP BRACKET ASSEMBLY FROM FUEL TANK a Disconnect the fuel pump connector from the clamp b Remove the 7 bolts Torque 3 9 N m 40...

Page 1029: ...mp connector b Pull off the lower side of the fuel pump from the pump bracket c Disconnect the fuel hose from the fuel pump and remove the fuel pump d Remove the rubber cushion from the fuel pump 2 RE...

Page 1030: ...p and or set plate 2 INSPECT FUEL PUMP OPERATION Connect the positive lead from the battery to terminal 1 of the connector and the negative lead to terminal 2 Check that the fuel pump operates NOTICE...

Page 1031: ...SF0BY 01 SF 12 SFI 5VZ FE FUEL PUMP 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page SF 10...

Page 1032: ...SF0BZ 01 SFI 5VZ FE FUEL PUMP SF 13 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SF 9...

Page 1033: ...SF0C0 04 SF 14 SFI 5VZ FE FUEL PRESSURE REGULATOR 1020 Author Date 1996 TOYOTA T100 RM449U FUEL PRESSURE REGULATOR COMPONENTS...

Page 1034: ...P21128 Engine Wire Fuel Pressure Regulator Fuel Returen Hose z O Ring z Non reusable part SFI 5VZ FE FUEL PRESSURE REGULATOR SF 15 1021 Author Date 1996 TOYOTA T100 RM449U...

Page 1035: ...URN HOSE FROM FUEL PRESSURE REGULATOR CAUTION Put a shop rag under the pressure regulator 4 REMOVE FUEL PRESSURE REGULATOR a Remove the bolt holding the engine wire to the LH cylin der head cover b Di...

Page 1036: ...livery pipe c Check that the pressure regulator rotates smoothly NOTICE If it does not rotate smoothly the O ring may be pinched so remove the pressure regulator and repeat steps a to c above d Instal...

Page 1037: ...SF0C3 04 SF 18 SFI 5VZ FE INJECTOR 1024 Author Date 1996 TOYOTA T100 RM449U INJECTOR COMPONENTS...

Page 1038: ...Z15607 SFI 5VZ FE INJECTOR SF 19 1025 Author Date 1996 TOYOTA T100 RM449U...

Page 1039: ...TION Catch leaking fuel in a container 5 REMOVE FUEL PIPE 6 DISCONNECT INJECTOR CONNECTORS 7 REMOVE DELIVERY PIPES AND INJECTORS NOTICE Be careful not to drop the injectors when removing the delivery...

Page 1040: ...O ring to the injector e Connect SST union and hose to the injector and hold the injector and union with SST clamp SST 09268 41046 f Put the injector into the graduated cylinder HINT Install a suitabl...

Page 1041: ...SF 22 SFI 5VZ FE INJECTOR 1996 TOYOTA T100 RM449U d Remove SST SST 09268 41046 e Disconnect the TOYOTA hand held tester from the DLC3...

Page 1042: ...ard e Place the 4 spacers in position on the intake manifold f Place the delivery pipes with the 6 injectors in position on the intake manifold g Temporarily install the 4 bolts holding the delivery p...

Page 1043: ...b Install the clamp bolt Torque 8 N m 80 kgf cm 71 in lbf c Tighten the union bolt Torque 34 3 N m 350 kgf cm 25 ft lbf 5 INSTALL FUEL PRESSURE REGULATOR See page SF 17 6 VISUALLY INSPECT AIR ASSIST...

Page 1044: ...FUEL TANK AND LINE SF 25 1031 Author Date 1996 TOYOTA T100 RM449U FUEL TANK AND LINE PRECAUTION S Always use new gaskets when replacing the fuel tank or component parts S Apply the proper torque to a...

Page 1045: ...SF0CB 01 P20166 SF 26 SFI 5VZ FE FUEL TANK AND LINE 1996 TOYOTA T100 RM449U COMPONENTS...

Page 1046: ...INSPECT FUEL TANK AND LINE a Check the fuel lines for cracks or leakage and all connec tions for deformation b Check the fuel tank vapor vent system hoses and connec tions for looseness sharp bends or...

Page 1047: ...METER 1034 Author Date 1996 TOYOTA T100 RM449U MASS AIR FLOW MAF METER REMOVAL 1 DISCONNECT AIR CLEANER CAP FROM MAF METER 2 REMOVE MAF METER a Disconnect the MAF meter connector b Remove the 2 bolts...

Page 1048: ...k 0 C 32 F THA E2 2 3 k 20 C 68 F THA E2 0 9 1 3 k 40 C 104 F THA E2 0 4 0 7 k 60 C 140 F THA E2 0 2 0 4 k 80 C 176 F If the resistance is not as specified replace the MAF meter 2 INSPECT MAF METER OP...

Page 1049: ...SF0C9 02 SF 30 SFI 5VZ FE MASS AIR FLOW MAF METER 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SF 28...

Page 1050: ...with your finger Port name At idle 3 500 rpm or more E No vacuum Vacuum R No vacuum Vacuum 2 INSPECT THROTTLE POSITION SENSOR a Apply vacuum to the throttle opener b Disconnect the sensor connector c...

Page 1051: ...ith the DP adjusting screw i Remove your finger from the hole and check that the en gine returns to idle speed in approx 1 second j Reinstall the DP separator filter and cap HINT Install the filter wi...

Page 1052: ...SFI 5VZ FE THROTTLE BODY SF 33 1039 Author Date 1996 TOYOTA T100 RM449U g Start the engine and check that the idle speed returns to the correct speed...

Page 1053: ...SF0CE 03 S05190 SF 34 SFI 5VZ FE THROTTLE BODY 1996 TOYOTA T100 RM449U COMPONENTS...

Page 1054: ...se vacuum hoses from the throttle body 1 Vacuum hose of throttle opener 2 w EGR Vacuum hose from port R of EGR vacuum modula tor 3 w EGR Vacuum hose from port E of EGR vacuum modula tor b Disconnect t...

Page 1055: ...E POSITION SENSOR a Apply vacuum to the throttle opener b Insert a thickness gauge between the throttle stop screw and stop lever c Using an ohmmeter measure the resistance between each terminal Clear...

Page 1056: ...HROTTLE BODY SF 37 1996 TOYOTA T100 RM449U f Recheck the continuity between terminals IDL and E2 Clearance between lever and stop screw Continuity IDL E2 0 32 mm 0 013 in Continuity 0 54 mm 0 021 in N...

Page 1057: ...SF0CH 02 SF 38 SFI 5VZ FE THROTTLE BODY 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SF 35...

Page 1058: ...gine speed operation is not as specified check the IAC valve wiring and ECM d Remove the SST from the DLC1 SST 09843 18020 2 INSPECT IAC VALVE RESISTANCE NOTICE Cold and Hot in the following sentences...

Page 1059: ...900 1 300 rpm for 10 se conds check that it returns to idle speed d Stop the engine e Disconnect the air assist hose from the IAC valve and plug it f Start the engine and check that the idle speed rea...

Page 1060: ...SF0CJ 01 S05191 SFI 5VZ FE IDLE AIR CONTROL IAC VALVE SF 41 1996 TOYOTA T100 RM449U COMPONENTS...

Page 1061: ...F 42 SFI 5VZ FE IDLE AIR CONTROL IAC VALVE 1996 TOYOTA T100 RM449U REMOVAL 1 REMOVE THROTTLE BODY See page SF 35 2 REMOVE IAC VALVE Remove the 4 screws IAC valve and gasket HINT Place a new gasket on...

Page 1062: ...ON INSPECT IAC VALVE OPERATION a Connect the positive lead from the battery to terminal B and negative lead to terminal RSC and check that the valve is closed b Connect the positive lead from the batt...

Page 1063: ...SF0CM 01 SF 44 SFI 5VZ FE IDLE AIR CONTROL IAC VALVE 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SF 42...

Page 1064: ...UITY a Using an ohmmeter check that there is continuity be tween terminals 1 and 2 If there is no continuity replace the relay b Check that there is no continuity between terminals 3 and 5 If there is...

Page 1065: ...e is no continuity replace the relay b Check that there is continuity between terminals B and FC If there is no continuity replace the relay c Check that there is no continuity between terminals B and...

Page 1066: ...e connector and 2 vacuum hoses and re move the 2 bolts and VSV 2 INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter check that there is continuity between the terminals Resistance 33 39 at 20 C 69 F If th...

Page 1067: ...ss the terminals c Check that air flows from port E to the filter If operation is not as specified replace the VSV 5 REINSTALL VSV a Install the VSV with the 2 bolts Torque 8 N m 80 kgf cm 71 in lbf b...

Page 1068: ...68 F If there is no continuity replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the body If there is continuity replace the VSV 4...

Page 1069: ...stance between the ter minals Resistance 29 33 at 20 C 68 F If resistance is not as specified replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each...

Page 1070: ...SF0CR 03 SFI 5VZ FE ENGINE COOLANT TEMPERATURE ECT SENSOR SF 51 1057 Author Date 1996 TOYOTA T100 RM449U ENGINE COOLANT TEMPERATURE ECT SENSOR COMPONENTS...

Page 1071: ...NO 2 TIMING BELT COVER a Disconnect the PS air hose from the clamp b Disconnect the 3 cord clamps of the high tension cords from the belt cover c Remove the 6 bolts timing belt cover and gasket d Disc...

Page 1072: ...ified replace the ECT sensor 7 REINSTALL ECT SENSOR a Install a new gasket to the ECT sensor b Using a 19 mm deep socket install the ECT sensor Torque 20 N m 200 kgf cm 14 ft lbf c Connect the ECT sen...

Page 1073: ...SF0CU 02 SF 54 SFI 5VZ FE KNOCK SENSOR 1060 Author Date 1996 TOYOTA T100 RM449U KNOCK SENSOR COMPONENTS...

Page 1074: ...S05210 SFI 5VZ FE KNOCK SENSOR SF 55 1061 Author Date 1996 TOYOTA T100 RM449U...

Page 1075: ...Z15606 SF 56 SFI 5VZ FE KNOCK SENSOR 1062 Author Date 1996 TOYOTA T100 RM449U...

Page 1076: ...NOCK SEN SOR WIRE See page EM 84 10 REMOVE KNOCK SENSORS Using SST remove the knock sensor SST 09816 30010 11 INSPECT KNOCK SENSORS Using an ohmmeter check that there is no continuity between the term...

Page 1077: ...SF 58 SFI 5VZ FE KNOCK SENSOR 1996 TOYOTA T100 RM449U 19 INSTALL INTAKE AIR CONNECTOR See page EM 51 20 INSTALL AIR CLEANER HOSE 21 FILL WITH ENGINE COOLANT 22 CHECK ENGINE COOLANT LEVEL...

Page 1078: ...PERATURE SENSOR INSPECTION 1 REMOVE EGR GAS TEMPERATURE SENSOR 2 INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter measure the resistance between the ter minals Resistance 64 97 k at 50 C 122 F 11...

Page 1079: ...NCE OF HEATED OXYGEN SENSORS a Disconnect the oxygen sensor connector b Using an ohmmeter measure the resistance between the terminals B and HT Resistance M T Bank 1 Sensor 1 5 7 at 20 C 68 F Others 1...

Page 1080: ...SF0CX 01 P20917 SFI 5VZ FE ENGINE CONTROL MODULE ECM SF 61 1067 Author Date 1996 TOYOTA T100 RM449U ENGINE CONTROL MODULE ECM COMPONENTS...

Page 1081: ...SF0CY 02 SF 62 SFI 5VZ FE ENGINE CONTROL MODULE ECM 1996 TOYOTA T100 RM449U INSPECTION 1 REMOVE ECM 2 INSPECT ECM See page DI 144 3 REINSTALL ECM...

Page 1082: ...d tester or OBDII scan tool to the DLC3 b Please refer to the TOYOTA hand held tester or OBDII scan tool operator s manual for further details 3 INSPECT FUEL CUT OFF PRM a Increase the engine speed to...

Page 1083: ...CO COOLING 3RZ FE COOLANT CO 1 WATER PUMP CO 3 THERMOSTAT CO 7 RADIATOR CO 11...

Page 1084: ...LL line 2 CHECK ENGINE COOLANT QUALITY a Remove the radiator cap CAUTION To avoid the danger of being burned do not remove the radiator cap while the engine and radiator are still hot as fluid and ste...

Page 1085: ...e the drain cock plug Torque Torque Engine drain plug 24 N m 250 kgf cm 18 ft lbf 2 FILL ENGINE COOLANT a Slowly fill the system with coolant S Use a good brand of ethylene glycol base coolant and mix...

Page 1086: ...CO058 02 S06062 COOLING 3RZ FE WATER PUMP CO 3 1072 Author Date 1996 TOYOTA T100 RM449U WATER PUMP COMPONENTS...

Page 1087: ...BELT FAN WITH FLUID COUPLING WATER PUMP PULLEY AND FAN SHROUD a Stretch the belt and loosen the water pump pulley nuts b Loosen the lock pivot and adjusting bolts of the genera tor and remove the dri...

Page 1088: ...he water hole for coolant leakage If leakage is found replace the water pump b Turn the pulley and check that the water pump bearing moves smoothly and quietly If necessary replace the water pump 2 IN...

Page 1089: ...CO05B 02 CO 6 COOLING 3RZ FE WATER PUMP 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page CO 4...

Page 1090: ...CO05C 02 P21642 COOLING 3RZ FE THERMOSTAT CO 7 1076 Author Date 1996 TOYOTA T100 RM449U THERMOSTAT COMPONENTS...

Page 1091: ...cooling efficiency Do not remove the thermo stat even if the engine tends to overheat 1 DRAIN ENGINE COOLANT 2 DISCONNECT RADIATOR OUTLET HOSE 3 REMOVE WATER INLET AND THERMOSTAT a Remove the 2 nuts h...

Page 1092: ...eat the water b Check the valve opening temperature Valve opening temperature 80 84 C 176 183 F If the valve opening temperature is not as specified replace the thermostat c Check the valve lift Valve...

Page 1093: ...ermostat jiggle valve with the protrusion of the water inlet housing and insert the thermostat in the water inlet housing HINT The jiggle valve may be set within 15 of either side of the pre scribed p...

Page 1094: ...U RADIATOR ON VEHICLE CLEANING Using water or a steam cleaner remove any mud or dirt from the radiator core NOTICE If using a high pressure type cleaner be careful not to deform the fins of the radiat...

Page 1095: ...cap tester pump the tester and measure the relief valve opening pressure Standard opening pressure 74 103 kPa 0 75 1 05 kgf cm2 10 7 14 9 psi HINT Use the tester s maximum reading as the opening pres...

Page 1096: ...CO05I 01 S06060 COOLING 3RZ FE RADIATOR CO 13 1996 TOYOTA T100 RM449U COMPONENTS...

Page 1097: ...P21703 Radiator Cap Upper Tank z Tank Plate z O Ring z O Ring Core z Tank Plate Lower Tank z O Ring Drain Cock z Non reusable part CO 14 COOLING 3RZ FE RADIATOR 1996 TOYOTA T100 RM449U...

Page 1098: ...MOVE PS DRIVE BELT Loosen the lock bolt and adjusting bolt and remove the drive belt 7 w A C REMOVE A C DRIVE BELT Loosen the idler pulley nut and adjusting bolt and remove the drive belt 8 REMOVE DRI...

Page 1099: ...ASSEMBLY 1 M T REMOVE TANK PLATE a Raise the claws of the tank plates with SST in the numeri cal order shown in the illustration SST 09230 00010 09231 00010 09231 00020 09231 00030 09231 00040 09231 0...

Page 1100: ...the core plate groove are deformed reas sembly of the tank will be impossible Therefore first cor rect any deformation with pliers S Water leakage will result if the bottom of the core plate groove is...

Page 1101: ...09231 00020 09231 00030 09231 00040 09231 00050 b Stake the claws of the tank plates with SST in the numeri cal order shown in the illustration NOTICE If the bottom of the core plate is staked with th...

Page 1102: ...9231 01030 c Using a radiator cap tester apply pressure to the radiator Test pressure 147 kPa 1 5 kgf cm2 21 psi d Check for water leaks HINT On radiators with resin tanks these is a clearance between...

Page 1103: ...m 310 kgf cm 23 ft lbf 3 CONNECT RADIATOR OUTLET HOSE 4 INSTALL WATER PUMP PULLEY FAN SHROUD FAN WITH FLUID COUPLING AND DRIVE BELT See page CO 6 5 w A C INSTALL A C COMPRESSOR DRIVE BELT Install and...

Page 1104: ...CO COOLING 5VZ FE COOLANT CO 1 WATER PUMP CO 3 THERMOSTAT CO 8 RADIATOR CO 12...

Page 1105: ...2 CHECK ENGINE COOLANT QUALITY a Remove the radiator cap from the water outlet CAUTION To avoid the danger of being burned do not remove the ra diator cap while the engine and radiator are still hot a...

Page 1106: ...ne glycol base engine coolant and mix it according to the manufacturer s directions S Using engine coolant which includes more than 50 ethylene glycol but not more than 70 is rec ommended NOTICE Do no...

Page 1107: ...CO05Q 02 P20840 COOLING 5VZ FE WATER PUMP CO 3 1092 Author Date 1996 TOYOTA T100 RM449U WATER PUMP COMPONENTS...

Page 1108: ...Z15614 CO 4 COOLING 5VZ FE WATER PUMP 1093 Author Date 1996 TOYOTA T100 RM449U...

Page 1109: ...UMP CO 5 1996 TOYOTA T100 RM449U REMOVAL 1 REMOVE TIMING BELT See page EM 13 2 REMOVE WATER INLET AND THERMOSTAT 3 w Oil Cooler DISCONNECT NO 2 OIL COOLER HOSE FROM WA TER PUMP 4 REMOVE WATER PUMP Rem...

Page 1110: ...at the water pump bearing moves smoothly and quietly If necessary replace the water pump 2 INSPECT FLUID COUPLING a Remove the 4 nuts and fan from the fluid coupling b Check that the fluid coupling is...

Page 1111: ...l S Using a non residue solvent clean both sealing surfaces b Apply seal packing to the water pump groove Seal packing Part No 08826 00100 or equivalent S Install a nozzle that has been cut to a 2 3 m...

Page 1112: ...on Reusable part Specified torque N m kgf cm ft lbf 20 200 14 Water Inlet Thermostat z Gasket Wire Clamp Lower Radiator Hose CO 8 COOLING 5VZ FE THERMOSTAT 1097 Author Date 1996 TOYOTA T100 RM449U THE...

Page 1113: ...T100 RM449U REMOVAL 1 DRAIN ENGINE COOLANT 2 DISCONNECT LOWER RADIATOR HOSE 3 REMOVE THERMOSTAT a Remove the 3 nuts water inlet and thermostat with gas ket from the water pump Torque 20 N m 200 kgf cm...

Page 1114: ...and heat the water grad ually b Check the valve opening temperature and valve lift Valve opening temperature 80 84 C 176 183 F Valve lift At 95 C 203 F 8 5 mm 0 335 in or more If the valve opening te...

Page 1115: ...ATION 1 INSTALL THERMOSTAT a Place a new gasket to the thermostat b Install the thermostat with the jiggle valve downward c Install the water inlet with the 3 bolts Torque 20 N m 200 kgf cm 14 ft lbf...

Page 1116: ...U RADIATOR ON VEHICLE CLEANING Using water or a steam cleaner remove any mud or dirt from the radiator core NOTICE If using a high pressure type cleaner be careful not to de form the fins of the radia...

Page 1117: ...sure the relief valve opening pressure Standard opening pressure 74 103 kPa 0 75 1 05 kgf cm2 10 7 14 9 psi Minimum opening pressure 59 kPa 0 6 kgf cm2 8 5 psi HINT Use the tester s maximum reading as...

Page 1118: ...CO060 01 Z15608 CO 14 COOLING 5VZ FE RADIATOR 1996 TOYOTA T100 RM449U COMPONENTS...

Page 1119: ...P20979 COOLING 5VZ FE RADIATOR CO 15 1996 TOYOTA T100 RM449U...

Page 1120: ...ve the 4 screws 11 clips and radiator grille 3 DISCONNECT UPPER RADIATOR HOSE 4 DISCONNECT RADIATOR RESERVOIR HOSE 5 DISCONNECT LOWER RADIATOR HOSE 6 REMOVE RADIATOR NO 2 FAN SHROUD 7 A T DISCONNECT O...

Page 1121: ...AN SHROUD Remove the 4 bolts and No 1 fan shroud 2 REMOVE RADIATOR SUPPORTS Using a torx wrench remove the 8 torx screws and the 2 radia tor supports Torx wrench T30 Part No 09042 00010 or locally man...

Page 1122: ...CO063 01 CO 18 COOLING 5VZ FE RADIATOR 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page CO 17...

Page 1123: ...CO064 01 COOLING 5VZ FE RADIATOR CO 19 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page CO 16...

Page 1124: ...LU LUBRICATION 3RZ FE OIL AND FILTER LU 1 OIL PUMP LU 5...

Page 1125: ...SH Energy Conserving II or SJ Energy Conserving or ILSAC multigrade engine oil SAE 5W 30 is the bset choise for your vehicle for good fuel economy and good starting in cold weather 2 CHECK ENGINE OIL...

Page 1126: ...rature 6 CHECK OIL PRESSURE Oil pressure At idle 29 kPa 0 3 kgf cm2 4 3 psi or more At 3 000 rpm 245 490 kPa 2 5 5 0 kgf cm2 36 71 psi 7 REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH a R...

Page 1127: ...by oil should be worn The skin should be thoroughly washed with soap and water or use water less hand cleaner to remove any used engine oil Do not use gasoline thinners or solvents In order to preserv...

Page 1128: ...et Torque 25 N m 250 kgf cm 18 ft lbf b Fill with fresh engine oil Oil capacity Drain and refill w Oil filter change 5 3 liters 5 6 US qts 4 7 lmp qts w o Oil filter change 5 0 liters 5 3 US qts 4 4 l...

Page 1129: ...LU02V 02 P21633 Specified torque 200 2 650 191 N m kgf cm ft lbf LUBRICATION 3RZ FE OIL PUMP LU 5 1113 Author Date 1996 TOYOTA T100 RM449U OIL PUMP COMPONENTS...

Page 1130: ...P21644 LU 6 LUBRICATION 3RZ FE OIL PUMP 1114 Author Date 1996 TOYOTA T100 RM449U...

Page 1131: ...LU02W 01 LUBRICATION 3RZ FE OIL PUMP LU 7 1996 TOYOTA T100 RM449U REMOVAL 1 REMOVE TIMING CHAIN COVER See page EM 14 2 REMOVE NO 1 TIMING CHAIN AND CAMSHAFT TIMING GEAR See page EM 14...

Page 1132: ...TOYOTA T100 RM449U DISASSEMBLY 1 REMOVE DRIVE AND DRIVEN ROTORS Remove the 9 screws pump cover drive rotor driven rotor and O ring 2 REMOVE RELIEF VALVE a Using snap ring pliers remove the snap ring...

Page 1133: ...greater than maximum replace the ro tors as a set If necessary replace the oil pump assembly 3 INSPECT ROTOR SIDE CLEARANCE Using a thickness gauge and precision straight edge measure the clearance b...

Page 1134: ...hammer tap out the oil seal 2 Using SST and a hammer tap in a new oil seal until its surface is flush with the oil pump case edge SST 09223 50010 3 Apply MP grease to the oil seal lip b If oil pump is...

Page 1135: ...EMBLY 1 INSTALL RELIEF VALVE a Install these parts 1 Relief valve 2 Spring s 3 Retainer b Using snap ring pliers install the snap ring 2 INSTALL DRIVE AND DRIVEN ROTORS a Place the drive and driven ro...

Page 1136: ...LU031 01 LU 12 LUBRICATION 3RZ FE OIL PUMP 1996 TOYOTA T100 RM449U INSTALLATION 1 INSTALL NO 1 TIMING CHAIN AND CAMSHAFT TIMING GEAR See page EM 20 2 INSTALL TIMING CHAIN COVER See page EM 20...

Page 1137: ...LU LUBRICATION 5VZ FE OIL AND FILTER LU 1 OIL PUMP LU 5 OIL COOLER LU 17...

Page 1138: ...be between the L and F marks on the dip stick 3 CHECK OIL LEVEL The oil level should be between the L and F marks on the lev el gauge If low check for leakage and add oil up to the F mark If low check...

Page 1139: ...TA T100 RM449U 9 INSTALL OIL PRESSURE SWITCH a Apply adhesive to 2 or 3 threads Adhesive Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent b Using SST install the oil pressure switch SST 0...

Page 1140: ...d by oil should be worn The skin should be thoroughly washed with soap and water or use water less hand clean er to remove any used engine oil Do not use gasoline thin ners or solvents In order to pre...

Page 1141: ...sket b Fill the engine with new oil Oil capacity Item Capacity liters US qts lmp qts Drain and refill w Oil filter change 2WD 4WD w o Oil filter change 2WD 4WD Dry fill 2WD 4WD 5 2 5 5 4 6 4 7 5 0 4 1...

Page 1142: ...LU035 03 P20840 LUBRICATION 5VZ FE OIL PUMP LU 5 1125 Author Date 1996 TOYOTA T100 RM449U OIL PUMP COMPONENTS...

Page 1143: ...LU 6 LUBRICATION 5VZ FE OIL PUMP 1126 Author Date 1996 TOYOTA T100 RM449U...

Page 1144: ...LUBRICATION 5VZ FE OIL PUMP LU 7 1127 Author Date 1996 TOYOTA T100 RM449U...

Page 1145: ...P20978 LU 8 LUBRICATION 5VZ FE OIL PUMP 1128 Author Date 1996 TOYOTA T100 RM449U...

Page 1146: ...UST 7 DISCONNECT STARTER WIRE CLAMP 8 REMOVE CRANKSHAFT POSITION SENSOR 9 REMOVE OIL PAN a Remove the 15 bolts and 4 nuts b Using SST and a brass bar separate the oil pan from the cylinder block SST 0...

Page 1147: ...ROTORS a Remove the 8 screws and pump body cover Torque 10 N m 105 kgf cm 8 ft lbf b Remove the drive and driven rotors HINT Place the drive and driven rotor into pump body with the marks facing the...

Page 1148: ...body clearance is greater than maximum replace the ro tors as a set If necessary replace the oil pump assembly 3 INSPECT ROTOR TIP CLEARANCE Using a thickness gauge measure the clearance between the...

Page 1149: ...seal 2 Using SST and a hammer tap in a new oil seal until its surface is flush with the oil pump body edge SST 09309 37010 3 Apply MP grease to the oil seal lip b If oil pump is installed to the cylin...

Page 1150: ...LU03A 01 LUBRICATION 5VZ FE OIL PUMP LU 13 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page LU 10...

Page 1151: ...e loose material S Using a non residue solvent clean both sealing surfaces b Apply seal packing to the oil pump as shown in the il lustration Seal packing Part No 08826 00080 or equivalent S Install n...

Page 1152: ...oose material S Clean both sealing surfaces with a non residue sol vent NOTICE Do not use a solvent which will affect the painted surfaces 6 INSTALL OIL PAN a Apply seal packing to the oil pan as show...

Page 1153: ...ATION 5VZ FE OIL PUMP 1996 TOYOTA T100 RM449U 12 4WD INSTALL FRONT DIFFERENTIAL See page SA 68 13 FILL WITH ENGINE OIL 14 START ENGINE AND CHECK FOR LEAKS 15 INSTALL ENGINE UNDER COVER 16 RECHECK ENGI...

Page 1154: ...LU03C 03 LUBRICATION 5VZ FE OIL COOLER LU 17 1137 Author Date 1996 TOYOTA T100 RM449U OIL COOLER COMPONENTS...

Page 1155: ...DRAIN ENGINE COOLANT 2 DISCONNECT OIL COOLER HOSES Disconnect the No 1 and No 2 oil cooler hoses 3 REMOVE OIL COOLER Remove the bolt relief valve gaskets and oil cooler Torque 59 N m 600 kgf cm 43 ft...

Page 1156: ...LU03E 03 LUBRICATION 5VZ FE OIL COOLER LU 19 1996 TOYOTA T100 RM449U INSPECTION INSPECT OIL COOLER Check the oil cooler for damage or clogging If necessary replace the oil cooler...

Page 1157: ...LU03F 02 LU 20 LUBRICATION 5VZ FE OIL COOLER 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page LU 18...

Page 1158: ...IG IGNITION 3RZ FE IGNITION SYSTEM IG 1 DISTRIBUTOR IG 6 CRANKSHAFT POSITION SENSOR IG 13...

Page 1159: ...ace the ignition coil Replace the distributor housing as sembly Replace the crankshaft position sensor and igniter and then try another ECM BAD BAD BAD BAD BAD BAD Primary 0 36 0 55 0 45 0 65 Replace...

Page 1160: ...the 2 bolts f Loosen the hose clamp disconnect the intake air connec tor from the throttle body g Disconnect the high tension cords from the spark plugs NOTICE Pulling on or bending the cords may dama...

Page 1161: ...to the distributor cap as shown in the illustration NOTICE Check that the holder is correctly installed to the grommet and distributor cap as shown in the illustration k Check that the lock claw of th...

Page 1162: ...f Using a 16 mm plug wrench install the spark plug Torque 20 N m 200 kgf cm 14 ft lbf g Connect the high tension cords to the spark plugs NOTICE Check that the holder is correctly installed to the gro...

Page 1163: ...inals Secondary coil resistance Cold 9 0 15 4 k Hot 11 4 18 1 k If the resistance is not as specified replace the ignition coil 5 INSPECT DISTRIBUTOR a Inspect the air gap Using a feeler gange measure...

Page 1164: ...IG0IW 02 P20586 P20938 B11227 IG 6 IGNITION 3RZ FE DISTRIBUTOR 1146 Author Date 1996 TOYOTA T100 RM449U DISTRIBUTOR COMPONENTS...

Page 1165: ...DC COMPRESSION a Turn the crankshaft pulley clockwise until the timing mark is aligned with 0 mark on the oil pump cover b Remove the 3 bolts and distributor cap c Check that distributor rotor directi...

Page 1166: ...e ignition coil terminals NOTICE At the time of reassembly please refer to the following items S When connecting the wires to the ignition coil insert the properly into the groove found on the side of...

Page 1167: ...refer to the following items S Be sure that the wires do not contact with the signal rotor S Align the rotor tooth with the pickup coil S Using a thickness gauge set the air gap and tighten the 2 scre...

Page 1168: ...1 IG 10 IGNITION 3RZ FE DISTRIBUTOR 1996 TOYOTA T100 RM449U INSPECTION INSPECT SHAFT Turn the shaft and check that it is not rough or worn If it feels rough or worn replace the distributor housing ass...

Page 1169: ...IG0J0 01 IGNITION 3RZ FE DISTRIBUTOR IG 11 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page IG 8...

Page 1170: ...urface as shown in the illustration If not turn the crankshaft 1 revolition 360 and align the mark as above 2 INSTALL DISTRIBUTOR a Install a new O ring to the distributor HINT Always use a new O ring...

Page 1171: ...m 760 kgf cm 55 ft lbf Bolt B 18 N m 180 kgf cm 13 ft lbf 4 DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5 REMOVE CRANKSHAFT POSITION SENSOR a Remove the 2 bolts and crankshaft position sensor Tor...

Page 1172: ...the tempera ture of the sensors themselves Cold is from 10 C 14 F to 50 C 122 F and Hot is from 50 C 122 F to 100 C 212 F INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter measure the r...

Page 1173: ...IG03M 01 IGNITION 3RZ FE CRANKSHAFT POSITION SENSOR IG 15 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page IG 13...

Page 1174: ...IG IGNITION 5VZ FE IGNITION SYSTEM IG 1 IGNITION COIL IG 6 CAMSHAFT POSITION SENSOR IG 9 CRANKSHAFT POSITION SENSOR IG 12...

Page 1175: ...nition switch to ignition coil and igniter Replace the ignition coil Replace the camshaft position sensor Replace the crankshaft position sensor and igniter and then try another ECM BAD BAD BAD BAD BA...

Page 1176: ...nnect the high tension cords from the ignition coils 1 Using a screwdriver lift up the lock claw and discon nect the holder from the ignition coils 2 Disconnect the high tension cord at the grommet DO...

Page 1177: ...t 2 Align the spline of the ignition coil with the spline of the holder and push in the cord NOTICE Check that the holder is correctly installed to the grommet and distributor cap as shown in the illu...

Page 1178: ...are traces of oil remove it with gasoline before using the spark plug cleaner d Visually inspect the spark plugs Check the spark plug for thread damage and insulator damage If abnormal replace the sp...

Page 1179: ...d high tension terminals Secondary coil resistance Cold 9 3 16 0 k Hot 11 7 18 8 k If the resistance is not as specified replace the ignition coil g Reinstall the ignition coils h Reconnect the igniti...

Page 1180: ...IG03P 03 IG 6 IGNITION 5VZ FE IGNITION COIL 1161 Author Date 1996 TOYOTA T100 RM449U IGNITION COIL COMPONENTS...

Page 1181: ...TER AS SEMBLY 2 DISCONNECT HIGH TENSION CORDS FROM IGNITION COILS See page IG 1 3 REMOVE IGNITION COILS a Disconnect the 3 connectors from the ignition coils b Remove the 3 bolts and 3 ignition coils...

Page 1182: ...IG03R 01 IG 8 IGNITION 5VZ FE IGNITION COIL 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page IG 7...

Page 1183: ...IG03S 03 IGNITION 5VZ FE CAMSHAFT POSITION SENSOR IG 9 1164 Author Date 1996 TOYOTA T100 RM449U CAMSHAFT POSITION SENSOR COMPONENTS...

Page 1184: ...R a Remove the high tension cord clamps from the No 2 tim ing belt cover b Remove the PS pump hose from the No 2 timing belt cov er clamp c Remove the 6 bolts and No 2 timing belt cover 3 REMOVE CAMSH...

Page 1185: ...IG03U 02 IGNITION 5VZ FE CAMSHAFT POSITION SENSOR IG 11 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page IG 10...

Page 1186: ...Author Date 1996 TOYOTA T100 RM449U CRANKSHAFT POSITION SENSOR REMOVAL 1 REMOVE ENGINE UNDER COVER 2 REMOVE CRANKSHAFT POSITION SENSOR a Disconnect the crankshaft position sensor connector b Remove t...

Page 1187: ...s express the temperature of the sensor itself Cold is from 10 C 14 F to 50 C 122 F and Hot is from 50 C 122 F to 100 C 212 F INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter measure th...

Page 1188: ...IG03X 02 IG 14 IGNITION 5VZ FE CRANKSHAFT POSITION SENSOR 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page IG 12...

Page 1189: ...ST STARTING 3RZ FE STARTER ST 1 STARTER RELAY ST 17...

Page 1190: ...ST02W 03 B01307 Starter Wire Starter Connector Starter STARTING 3RZ FE STARTER ST 1 1170 Author Date 1996 TOYOTA T100 RM449U STARTER COMPONENTS...

Page 1191: ...ST 2 STARTING 3RZ FE STARTER 1171 Author Date 1996 TOYOTA T100 RM449U...

Page 1192: ...3RZ FE STARTER ST 3 1996 TOYOTA T100 RM449U REMOVAL 1 DISCONNECT STARTER CONNECTOR 2 REMOVE NUT AND DISCONNECT STARTER WIRE Torque 8 8 N m 90 kgf cm 70 in lbf 3 REMOVE 2 BOLTS AND STARTER Torque 39 N...

Page 1193: ...e field frame with the armature from the magnet ic switch assembly NOTICE At the time of notice please refer to the following items Align the protrusion of the field frame with cutout of the magnetic...

Page 1194: ...and end cover from the field frame Torque 1 2 kW 1 4 kW type 1 5 N m 15 kgf cm 13 in lbf 1 8 kW 2 0 kW type 3 8 N m 39 kgf cm 34 in lbf b Remove the O ring from the field frame HINT At the time of ass...

Page 1195: ...OMMUTATOR CIRCLE RUNOUT a Place the commutator on V blocks b Using a dial indicator measure the circle runout Maximum circle runout 0 05 mm 0 0020 in If the circle runout is greater than maximum corre...

Page 1196: ...field frame If there is continuity repair or replace the field frame 9 INSPECT BRUSH LENGTH Using vernier calipers measure the brush length Standard length 1 2 kW 1 4 kW type 15 5 mm 0 610 in 1 8 kW 2...

Page 1197: ...ive and negative brush holders If there is continuity repair or replace the brush holder 12 INSPECT GEAR TEETH Check the gear teeth on the pinion gear idler gear and clutch assembly for wear or damage...

Page 1198: ...9286 46011 b Press in a new bearing 16 INSPECT FRONT BEARING Turn the bearing by hand while applying inward force If the resistance is felt or if the bearing sticks replace the bear ing 17 IF NECESSAR...

Page 1199: ...O PULL IN COIL OPEN CIRCUIT TEST Using an ohmmeter check that there is continuity between ter minals 50 and C If there is no continuity check and replace the magnetic switch 19 DO HOLD IN COIL CIRCUIT...

Page 1200: ...b Terminal C Remove the terminal nut wave washer terminal insulator outside O ring terminal bolt contact plate and terminal insulator inside c Terminal 30 Remove the terminal nut wave washer terminal...

Page 1201: ...rily tighten the terminal nuts 5 TIGHTEN TERMINAL NUT a Put a wooden block on the contact plate and press it down with a hand press Dimensions of wooden block 20 x 37 x 40 mm 0 79 x 1 46 x 1 57 in Pre...

Page 1202: ...LUNGER Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag 7 REINSTALL MAGNETIC SWITCH END COVER Install the plunger new gasket end cover and lead clamp with the...

Page 1203: ...ST031 02 ST 14 STARTING 3RZ FE STARTER 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page ST 4...

Page 1204: ...D IN TEST With battery connected as above with the clutch pinion gear out disconnect the negative lead from terminal C Check that the pinion gear remains out 3 INSPECT CLUTCH PINION GEAR RETURN Discon...

Page 1205: ...ST033 02 ST 16 STARTING 3RZ FE STARTER 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page ST 3...

Page 1206: ...driver s side 2 INSPECT STARTER RELAY CONTINUITY a Using an ohmmeter check that there is continuity be tween terminals 1 and 2 If there is no continuity replace the relay b Check that there is no con...

Page 1207: ...ST STARTING 5VZ FE STARTER ST 1 STARTER RELAY ST 16...

Page 1208: ...ST036 04 P20589 Starter Connector Starter Wire Starter STARTING 5VZ FE STARTER ST 1 1187 Author Date 1996 TOYOTA T100 RM449U STARTER COMPONENTS...

Page 1209: ...ST 2 STARTING 5VZ FE STARTER 1188 Author Date 1996 TOYOTA T100 RM449U...

Page 1210: ...ST 3 1996 TOYOTA T100 RM449U REMOVAL REMOVE STARTER a Disconnect the starter connector b Remove the nut and disconnect the starter wire Torque 8 8 N m 90 kgf cm 78 in lbf c Remove the 2 bolts and sta...

Page 1211: ...f 1 8 kW type 9 3 N m 95 kgf cm 82 in lbf c Pull out the field frame with the armature from the magnet ic switch assembly NOTICE At the time of reassembly please refer to the following item Align the...

Page 1212: ...emove the steel ball from the clutch shaft hole 4 REMOVE BRUSH HOLDER a Remove the 2 screws 2 O rings and end cover from the field frame Torque 1 2 kW 1 4 kW type 1 5 N m 15 kgf cm 13 in lbf 1 8 kW ty...

Page 1213: ...4 INSPECT COMMUTATOR CIRCLE RUNOUT a Place the commutator on V blocks b Using a dial indicator measure the circle runout Maximum circle runout 0 05 mm 0 0020 in If the circle runout is greater than ma...

Page 1214: ...il end and field frame If there is continuity repair or replace the field frame 9 INSPECT BRUSH LENGTH Using vernier calipers measure the brush length Standard length 1 2 kW 1 4 kW type 15 5 mm 0 610...

Page 1215: ...continuity repair or replace the brush holder 12 INSPECT GEAR TEETH Check the gear teeth on the pinion gear idler gear and clutch assembly for wear or damage If damaged replace the gear or clutch asse...

Page 1216: ...ng 17 IF NECESSARY REPLACE FRONT BEARING a Using SST remove the bearing SST 09286 46011 b Using SST and a press press in a new bearing SST 09820 00030 NOTICE Be careful of the bearing installation dir...

Page 1217: ...ar Maximum wear 0 9 mm 0 035 in If the depth of wear is greater than the maximum replace the contact plate 3 REMOVE TERMINAL KIT PARTS a Using SST loosen the terminal nuts SST 09810 38140 b Terminal C...

Page 1218: ...stall the packing to the terminal insulator and install them HINT Match the protrusion of the insulator with the indentation of the housing 7 Wave washer 8 Terminal nut b Terminal C Install these new...

Page 1219: ...ct plate may tilt due to coil deformation or the tightening of the nut b Using SST tighten the nuts to the specified torque SST 09810 38140 Torque 17 N m 173 kgf cm 12 ft lbf NOTICE If the nut is over...

Page 1220: ...ER ST 13 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page ST 4 HINT Use high temperature grease to lubricate the bearings gears return spring and steel bal...

Page 1221: ...IN TEST With battery connected as above with the clutch pinion gear out disconnect the negative lead from terminal C Check that the pinion gear remains out 3 INSPECT CLUTCH PINION GEAR RETURN Disconn...

Page 1222: ...ST03D 02 STARTING 5VZ FE STARTER ST 15 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page ST 3...

Page 1223: ...2 INSPECT STARTER RELAY CONTINUITY a Using an ohmmeter check that there is continuity be tween terminals 1 and 2 If there is no continuity replace the relay b Check that there is no continuity between...

Page 1224: ...CH CHARGING 3RZ FE CHARGING SYSTEM CH 1 GENERATOR CH 6...

Page 1225: ...G SYSTEM PRECAUTION S Check that the battery cables are connected to the correct terminals S Disconnect the battery cables when the battery is given a quick charge S Do not perform tests with a high v...

Page 1226: ...Battery CHECK BATTERY VOLTAGE a After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the en gine turn the ignition switch ON and turn on the electrical...

Page 1227: ...ity 5 Delco Battery CHECK HYDROMETER Green Dot visible Battery is adequately charged Dark Green Dot not visible Battery must be charged Clear or Light Yellow Replace battery HINT There is no need to a...

Page 1228: ...fter installing a new belt run the engine for approx 5 minutes and then recheck the tension 7 VISUALLY CHECK GENERATOR WIRING AND LIS TEN FOR ABNORMAL NOISES a Check that the wiring is in good conditi...

Page 1229: ...ge replace the voltage regulator If the voltage reading is less than standard voltage check the voltage regulator and generator as follows S With terminal F grounded start the engine and check the vol...

Page 1230: ...CH02C 03 Z14840 CH 6 CHARGING 3RZ FE GENERATOR 1208 Author Date 1996 TOYOTA T100 RM449U GENERATOR COMPONENTS...

Page 1231: ...ock bolt pivot bolt nut and adjusting bolt b Remove the drive belt 2 REMOVE GENERATOR a Disconnect the generator connector b Remove the nut and disconnect the generator wire c Disconnect the wire harn...

Page 1232: ...screws brush holder and cover b Remove the brush holder cover from the brush holder 3 REMOVE VOLTAGE REGULATOR Remove the 3 screws and voltage regulator 4 REMOVE RECTIFIER HOLDER a Remove the 4 screw...

Page 1233: ...tion shown in the illustration NOTICE To prevent damage to the rotor shaft do not loosen the pulley nut more than one half of a turn f Remove the generator from SST C g Turn SST B and remove SST A and...

Page 1234: ...r If there is continuity replace the rotor 3 INSPECT SLIP RINGS a Check that the slip rings are not rough or scored If rough or scored replace the rotor b Using a vernier caliper measure the slip ring...

Page 1235: ...exposed length Exposed length 10 5 mm 0 413 in d Check that the brush moves smoothly in the brush holder e Cut off the excess wire f Apply insulation paint to the soldered point 8 INSPECT POSITIVE RE...

Page 1236: ...Using SST and a press press out the bearing SST 09950 60010 09951 00260 09952 06010 c Using SST and a press press in a new bearing SST 09950 60010 09951 00500 d Install the bearing retainer with the...

Page 1237: ...CHARGING 3RZ FE GENERATOR CH 13 1996 TOYOTA T100 RM449U c Place the bearing cover inside on the rotor d Using SST and a press press in a new bearing SST 09820 00030 e Using SST push in the bearing co...

Page 1238: ...rator washer installation directon 4 INSTALL RECTIFIER END FRAME a Using a 29 mm socket wrench and press slowly press in the rectifier end frame b Install the 4 nuts Torque 4 5 N m 46 kgf cm 39 in lbf...

Page 1239: ...the 4 screws Torque 2 0 N m 20 kgf cm 18 in lbf 7 INSTALL VOLTAGE REGULATOR AND BRUSH HOLD ER a Install the brush holder cover to the brush holder NOTICE Be careful of the holder installation directi...

Page 1240: ...CH 16 CHARGING 3RZ FE GENERATOR 1996 TOYOTA T100 RM449U 9 CHECK THAT ROTOR ROTATES SMOOTHLY...

Page 1241: ...CH02H 02 CHARGING 3RZ FE GENERATOR CH 17 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page CH 7...

Page 1242: ...CH CHARGING 5VZ FE CHARGING SYSTEM CH 1 GENERATOR CH 5...

Page 1243: ...ee Battery If under the lower level replace the battery or add distilled wa ter if possible and check the charging system Except Maintenance Free Battery If under the lower level add distilled water 2...

Page 1244: ...AND FUSES a Check that the battery terminals are not loose or cor roded b Check the fusible link and fuses for continuity 5 INSPECT DRIVE BELT a Visually check the belt for excessive wear frayed cord...

Page 1245: ...ormal noise from the generator while the engine is running 8 CHECK CHARGING CIRCUIT WITHOUT LOAD HINT If a battery generator tester is available connect the tester to the charging circuit according to...

Page 1246: ...han the standard voltage replace the voltage regulator S If the voltage reading is less than the standard volt age repair the generator 9 INSPECT CHARGING CIRCUIT WITH LOAD a With the engine running a...

Page 1247: ...ear Bearing Bearing Cover inside Bearing Cover outside Rear End Cover Brush Holder Cover Brush Brush Holder Spring Voltage Regulator Terminal Insulator Rectifier Holder Rubber Insulator x4 Rectifier E...

Page 1248: ...ect the connector from the generator b Remove the nut and disconnect the wire from the genera tor 2 REMOVE GENERATOR DRIVE BELT a Loosen the adjust lock nut adjusting bolt and pivot bolt b Remove the...

Page 1249: ...screws brush holder and cover b Remove the brush holder cover from the brush holder 3 REMOVE VOLTAGE REGULATOR Remove the 3 screws and voltage regulator 4 REMOVE RECTIFIER HOLDER a Remove the 4 screw...

Page 1250: ...on shown in the illustration NOTICE To prevent damage to the rotor shaft do not loosen the pulley nut more than one half of a turn f Remove the generator from SST C g Turn SST B and remove SST A and B...

Page 1251: ...ween the slip ring and rotor If there is continuity replace the rotor 3 INSPECT SLIP RINGS a Check that the slip rings are not rough or scored If rough or scored replace the rotor b Using vernier cali...

Page 1252: ...he exposed length Exposed length 10 5 mm 0 413 in d Check that the brush moves smoothly in the brush holder e Cut off the excess wire f Apply insulation paint to the soldered point 8 INSPECT POSITIVE...

Page 1253: ...REPLACE FRONT BEARING a Remove the 4 screws and bearing retainer b Using SST and a press press out the bearing SST 09950 60010 09951 00260 09952 06010 c Using SST and a press press in a new bearing SS...

Page 1254: ...NECESSARY REPLACE REAR BEARING a Using SST remove the bearing cover and bearing SST 09820 00021 b Remove the bearing cover inside c Place the bearing cover inside on the rotor d Using SST and a press...

Page 1255: ...of the generator washer installation direction b Using a 29 mm socket wrench and press slowly press in the rectifier end frame c Install the 4 nuts Torque 4 5 N m 46 kgf cm 39 in lbf 4 INSTALL PULLEY...

Page 1256: ...remove SST A and B 5 INSTALL RECTIFIER HOLDER a Install the 4 rubber insulators on the lead wires NOTICE Be careful of the rubber insulators installation direction b Install the rectifier with the 4...

Page 1257: ...rox 1 mm 0 04 in between the brush holder and voltage regu lator Torque 2 0 N m 20 kgf cm 17 in lbf d Fit the brush holder cover 7 INSTALL REAR END COVER a Install the end cover with the 3 nuts Torque...

Page 1258: ...CH02O 02 CH 16 CHARGING 5VZ FE GENERATOR 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page CH 6...

Page 1259: ...CL CLUTCH TROUBLESHOOTING CL 1 CLUTCH PEDAL CL 2 CLUTCH MASTER CYLINDER CL 5 CLUTCH RELEASE CYLINDER CL 10 CLUTCH UNIT CL 15...

Page 1260: ...L 5 CL 10 Clutch noisy 1 Release bearing Worn dirty or damaged 2 Input shaft bearing Worn dirty or damaged 3 Clutch disc torsion rubber Damaged CL 15 CL 15 Clutch slips 1 Clutch pedal Freeplay out of...

Page 1261: ...PLAY ARE CORRECT S Push in on the pedal until the beginning of clutch resis tance is felt Pedal freeplay 5 0 15 0 mm 0 197 0 591 in S Gently push on the pedal until the resistance begins to in crease...

Page 1262: ...the distance not as specified perform the following operation S Check pedal height S Check push rod play and pedal freeplay S Bleed the clutch line S Check the clutch cover and disc 6 CHECK CLUTCH ST...

Page 1263: ...heck the there is no continuity between terminals 2 and 3 If continuity is not as specified replace the clutch start cancel switch 9 CHECK OPERATION OF CLUTCH START CANCEL SWITCH a Connect positive le...

Page 1264: ...Push Rod Pin Lock Nut Boot Washer Piston Spring z Non reusable part Clutch Line Master Cylinder Slotted Spring Pin Reservoir Tank z Grommet Body CLUTCH CLUTCH MASTER CYLINDER CL 5 1240 Author Date 199...

Page 1265: ...1 DRAW OUT FLUID WITH SYRINGE 2 DISCONNECT CLUTCH LINE Using SST disconnect the line Use a container to catch the fluid SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft lbf 3 REMOVE CLIP AND CLEVIS PIN...

Page 1266: ...6 TOYOTA T100 RM449U DISASSEMBLY 1 REMOVE RESERVOIR TANK a Using a pin punch and hammer drive out the slotted spring pin b Remove the reservoir tank and grommet 2 REMOVE PUSH ROD Pull back the boot an...

Page 1267: ...6 TOYOTA T100 RM449U REASSEMBLY 1 COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE AS SHOWN 2 INSERT PISTON INTO CYLINDER 3 INSTALL PUSH ROD ASSEMBLY WITH SNAP RING 4 INSTALL RESERVOIR TANK a Install t...

Page 1268: ...02C 02 CLUTCH CLUTCH MASTER CYLINDER CL 9 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page CL 6 HINT After installation bleed system and adjust clutch peda...

Page 1269: ...Plug Release Cylinder Body Clutch Line Bleeder Plug Push Rod Release Cylinder Body Boot Piston Spring N m kgf cm ft lbf Specified torque CL 10 CLUTCH CLUTCH RELEASE CYLINDER 1245 Author Date 1996 TOYO...

Page 1270: ...L 11 1996 TOYOTA T100 RM449U REMOVAL 1 DISCONNECT CLUTCH LINE Using SST disconnect the line Use a container to catch the fluid SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft lbf 2 REMOVE 2 BOLTS AND P...

Page 1271: ...F 01 Q02475 CL 12 CLUTCH CLUTCH RELEASE CYLINDER 1996 TOYOTA T100 RM449U DISASSEMBLY 1 PULL OUT BOOT WITH PUSH ROD 2 REMOVE PISTON Using compressed air remove the piston with the spring from the cylin...

Page 1272: ...CLUTCH CLUTCH RELEASE CYLINDER CL 13 1996 TOYOTA T100 RM449U REASSEMBLY 1 COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE AS SHOWN 2 INSTALL PISTON WITH SPRING INTO CYLINDER 3 INSTALL BOOT WITH PUSH...

Page 1273: ...CL02H 02 CL 14 CLUTCH CLUTCH RELEASE CYLINDER 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page CL 11 HINT After installation bleed clutch system...

Page 1274: ...ing Clutch Disc Clutch Release Bearing Clutch Release Fork Clutch Cover z Non reusable part Clutch Release Fork Support Boot 3RZ FE Clip Clutch Disc CLUTCH CLUTCH UNIT CL 15 1250 Author Date 1996 TOYO...

Page 1275: ...OVER AND DISC a Place matchmarks on the flywheel and clutch cover b Loosen each set bolt one turn at a time until spring tension is released c Remove the set bolts and pull off the clutch cover with t...

Page 1276: ...mum runout 0 8 mm 0 031 in If necessary replace the clutch disc 3 INSPECT FLYWHEEL RUNOUT Using a dial indicator check the flywheel runout Maximum runout 0 1 mm 0 004 in If necessary replace the flywh...

Page 1277: ...6 INSPECT DIAPHRAGM SPRING FOR WEAR Using calipers measure the diaphragm spring for depth and width of wear Maximum Depth A 0 6 mm 0 024 in Width B 5 0 mm 0 197 in If necessary replace the clutch cov...

Page 1278: ...CK DIAPHRAGM SPRING TIP ALIGNMENT Using a dial indicator with roller instrument check the dia phragm spring tip alignment Maximum non alignment 0 5 mm 0 020 in If alignment is not as specified using S...

Page 1279: ...CL 20 CLUTCH CLUTCH UNIT 1996 TOYOTA T100 RM449U 5 INSTALL TRANSMISSION TO ENGINE W59 See page MT 3 R150 2WD See page MT 3 R150F 4WD See page MT 6...

Page 1280: ...OTING MT 2 MANUAL TRANSMISSION UNIT 2WD MT 3 MANUAL TRANSMISSION UNIT 4WD MT 6 MANUAL TRANSMISSION ASSEMBLY MT 11 INPUT SHAFT MT 22 OUTPUT SHAFT MT 25 COUNTER GEAR AND REVERSE IDLER GEAR MT 34 FRONT B...

Page 1281: ...s S Using a razor blade and gasket scraper remove all the old FIPG material from the gasket sur faces S Thoroughly clean all components to remove all the loose material S Clean both sealing surfaces w...

Page 1282: ...Area See page Noise 1 Oil Level low 2WD 4WD 2 Oil Wrong 2WD 4WD 3 Gear Worn or damaged 4 Bearing Worn or damaged MT 4 MT 7 MT 4 MT 7 MT 11 MT 11 Oil leakage 1 Oil Level too high 2WD 4WD 2 Gasket Damag...

Page 1283: ...MT04K 04 D10947 MANUAL TRANSMISSION R150 R150F MANUAL TRANSMISSION UNIT 2WD MT 3 1258 Author Date 1996 TOYOTA T100 RM449U MANUAL TRANSMISSION UNIT 2WD COMPONENTS...

Page 1284: ...80 kgf cm 27 ft lbf 3 REMOVE STARTER Remove the 2 bolts and starter Torque 39 N m 400 kgf cm 29 ft lbf 4 REMOVE TRANSMISSION FROM ENGINE a Remove the 6 transmission mounting bolts from the en gine Tor...

Page 1285: ...3 MANUAL TRANSMISSION R150 R150F MANUAL TRANSMISSION UNIT 2WD MT 5 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page MT 4 HINT After installation do the roa...

Page 1286: ...MT04N 04 D10949 MT 6 MANUAL TRANSMISSION R150 R150F MANUAL TRANSMISSION UNIT 4WD 1261 Author Date 1996 TOYOTA T100 RM449U MANUAL TRANSMISSION UNIT 4WD COMPONENTS...

Page 1287: ...to the following item Apply MP grease to the tip of the shift lever 2 REMOVE TRANSFER SHIFT LEVER Using snap ring pliers remove the snap ring and pull out the shift lever HINT At the time of installa...

Page 1288: ...LH AND REAR END PLATE Remove the 8 bolts stiffener plate RH and LH and rear end plate Torque 37 N m 380 kgf cm 27 ft lbf 11 REMOVE STABILIZER BAR See page SA 126 12 JACK UP TRANSMISSION SLIGHTLY Using...

Page 1289: ...ting bolts Torque 37 N m 380 kgf cm 27 ft lbf b Pull the transfer straight up and remove it from the trans mission HINT Take care not to damage the adaptor rear oil seal with the trans fer input gear...

Page 1290: ...4 MT 10 MANUAL TRANSMISSION R150 R150F MANUAL TRANSMISSION UNIT 4WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page MT 7 HINT After installation do the ro...

Page 1291: ...MT04Q 04 D10950 MANUAL TRANSMISSION R150 R150F MANUAL TRANSMISSION ASSEMBLY MT 11 1266 Author Date 1996 TOYOTA T100 RM449U MANUAL TRANSMISSION ASSEMBLY COMPONENTS...

Page 1292: ...Counter Gear z Front Bearing Interlock Pin Straight Pin Shift Fork Shaft No 1 Slotted Spring Pin Shift Fork No 3 2WD 2WD Shift Fork No 1 Reverse Idler Gear Magnet Shift Fork Shaft No 3 Shift Lever Hou...

Page 1293: ...e transmission case Torque 36 N m 370 kgf cm 27 ft lbf 4 REMOVE CONTROL SHIFT LEVER RETAINER a Remove the 6 2WD or 4 4WD bolts Torque 18 N m 185 kgf cm 13 ft lbf b Remove the retainer and gasket 2WD o...

Page 1294: ...NER a Remove the 8 bolts Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 17 N m 170 kgf cm 12 ft lbf b Using a plastic hammer tap the front bearing retainer FIPG Part No 0...

Page 1295: ...the intermediate plate in a vise 13 REMOVE STRAIGHT SCREW PLUG LOCKING BALL AND SPRING a Using a hexagon wrench remove the 4 plugs Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent...

Page 1296: ...SHAFT NO 3 AND SHIFT FORK NO 3 a Pull out the shift fork shaft No 3 from the shift fork No 3 reverse shift fork and intermediate plate b Remove the shift fork No 3 from the groove of hub sleeve No 3...

Page 1297: ...UT SHAFT REAR BEARING a Using 2 screwdrivers and a hammer tap out the snap ring HINT At the time of reassembly please refer to the following item Select a snap ring that allows the minimum axial play...

Page 1298: ...of reassembly please refer to the following items S 2WD Using SST and a hammer drive in a new bearing SST 09309 35010 S 4WD Using SST and a hammer drive in a new bearing SST 09316 60011 09316 00011 0...

Page 1299: ...G 3 10 3 15 0 1220 0 1240 b Using SST remove the gear spline piece No 5 SST 09950 50010 c Remove the counter 5th gear with the hub sleeve No 3 HINT At the time of reassembly please refer to the follo...

Page 1300: ...ATE a Remove the output shaft counter gear and input shaft as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer b Remove the...

Page 1301: ...R150 R150F MANUAL TRANSMISSION ASSEMBLY MT 21 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page MT 13 HINT Coat all of the sliding and rotating surfaces wit...

Page 1302: ...4T 01 WM0301 Snap Ring z Bearing Input Shaft Bearing Synchronizer Ring z Non reusable part MT 22 MANUAL TRANSMISSION R150 R150F INPUT SHAFT 1277 Author Date 1996 TOYOTA T100 RM449U INPUT SHAFT COMPONE...

Page 1303: ...pound between the synchronizer ring and gear cone Lightly rub the synchronizer ring and gear cone together NOTICE Ensure the fine lapping compound is completely washed off after rubbing c Check again...

Page 1304: ...ing b Using a press remove the bearing c Using SST and a press install a new bearing SST 09506 35010 d Select a snap ring that allows minimum axial play Mark Thickness mm in A 2 10 2 15 0 0827 0 0846...

Page 1305: ...MT04W 05 D10951 MANUAL TRANSMISSION R150 R150F OUTPUT SHAFT MT 25 1280 Author Date 1996 TOYOTA T100 RM449U OUTPUT SHAFT COMPONENTS...

Page 1306: ...GEAR RADIAL CLEARANCE Using a dial indicator measure the radial clearance of each gear Standard clearance 1st gear 0 020 0 073 mm 0 0008 0 0029 in 2nd and 3rd gears 0 015 0 068 mm 0 0006 0 0027 in Ma...

Page 1307: ...AR SHIFTING KEY AND SPRING FROM CLUTCH HUB NO 1 a Remove the reverse gear from the clutch hub No 1 b Push the shifting key spring with a screwdriver remove the 3 shifting keys and key springs 6 REMOVE...

Page 1308: ...an the minimum replace the out put shaft c Using a dial indicator check the shaft runout Maximum runout 0 06 mm 0 0024 in If the runout exceeds the maximum replace the output shaft 2 INSPECT 1ST AND 3...

Page 1309: ...b Install the synchronizer inner ring middle ring and outer ring to each gear c Check the braking effect of the synchronizer ring Turn the synchronizer ring in one direction while pushing it to the ge...

Page 1310: ...Position the key springs so that their end gaps are not aligned 2 INSTALL CLUTCH HUB NO 1 INTO REVERSE GEAR a Install the 3 shifting key springs to the clutch hub No 1 b While pushing the shifting key...

Page 1311: ...0 0787 0 0807 F 2 05 2 10 0 0807 0 0827 G 2 10 2 15 0 0827 0 0846 b Using a snap ring expander install the snap ring 5 INSPECT 3RD GEAR THRUST CLEARANCE See page MT 26 6 INSTALL 2ND GEAR AND REVERSE G...

Page 1312: ...on the output shaft b Apply gear oil to the needle roller bearing c Assemble the 1st gear synchronizer ring and needle roll er bearing d Install the assembly on the output shaft with the synchro nizer...

Page 1313: ...F OUTPUT SHAFT MT 33 1996 TOYOTA T100 RM449U 11 INSPECT 1ST GEAR THRUST CLEARANCE See page MT 26 12 INSPECT 2ND GEAR THRUST CLEARANCE See page MT 26 13 INSTALL 5TH GEAR Using SST and a press install t...

Page 1314: ...h Gear Needle Roller Bearing Straight Pin Thrust Washer Counter Gear Rear Bearing z Non reusable part Reverse Synchronizer Ring Shifting Key Shifting Key Spring 5th Synchronizer Ring Reverse Synchroni...

Page 1315: ...a Remove the synchronizer ring assembly from the hub sleeve No 3 b Turn the reverse synchronizer pull ring c Remove the reverse synchronizer ring and 5th synchro nizer ring from the synchronizer pull...

Page 1316: ...ce exceeds the maximum replace the gear bear ing or shaft 2 INSPECT COUNTER GEAR Using a micrometer measure the outer diameter of the counter gear journal Minimum diameter 27 860 mm 1 0968 in If the o...

Page 1317: ...RADIAL CLEAR ANCE Using a dial indicator measure the reverse idler gear radial clearance Standard clearance 0 040 0 082 mm 0 0016 0 0032 in Maximum clearance 0 130 mm 0 0051 in If the clearance excee...

Page 1318: ...nap ring b Using SST and a press remove the bearing SST 09950 00020 c Replace the side race d Using a socket wrench and press install a new bearing and side race e Select a snap ring that allows the m...

Page 1319: ...the hole of the shifting key b Push the 3 shifting keys with the 3 key springs to the re verse synchronizer ring c Install the synchronizer cone ring to the reverse synchro nizer pull ring and turn t...

Page 1320: ...0322 z Non reusable part Front Bearing Retainer z Oil Seal MT 40 MANUAL TRANSMISSION R150 R150F FRONT BEARING RETAINER OIL SEAL 1295 Author Date 1996 TOYOTA T100 RM449U FRONT BEARING RETAINER OIL SEAL...

Page 1321: ...1 1996 TOYOTA T100 RM449U REPLACEMENT IF NECESSARY REPLACE FRONT BEARING RETAINER OIL SEAL a Using a screwdriver pry out the oil seal b Using SST and a hammer drive in a new oil seal SST 09950 60010 0...

Page 1322: ...Oil Receiver Pipe Oil Receiver Reverse Restrict Pin Extension Housing z Non reusable part L Precoated part Slotted Spring Pin L Speedometer Driven Gear Plug L Plug L Plug MT 42 MANUAL TRANSMISSION R1...

Page 1323: ...on c Install the reverse restrict pin 1 Install the reverse restrict pin to the extension hous ing or transfer adaptor 2 Using a pin punch and hammer drive in the slotted spring pin as shown 3 Apply s...

Page 1324: ...FER ADAPTOR 1996 TOYOTA T100 RM449U 3 4WD IF NECESSARY REPLACE TRANSFER ADAPTOR OIL SEAL a Using a screwdriver pry out the oil seal b Using SST and a hammer drive in a new oil seal SST 09950 60010 099...

Page 1325: ...SION SYSTEM MT 1 TROUBLESHOOTING MT 2 MANUAL TRANSMISSION UNIT MT 3 MANUAL TRANSMISSION ASSEMBLY MT 6 INPUT SHAFT MT 18 OUTPUT SHAFT MT 21 COUNTER GEAR AND REVERSE IDLER GEAR MT 30 FRONT BEARING RETAI...

Page 1326: ...Using a razor blade and gasket scraper remove all the old FIPG material from the gasket sur faces S Thoroughly clean all components to remove all the loose material S Clean both sealing surfaces with...

Page 1327: ...Symptom Suspect Area See page Noise 1 Oil Level low 2 Oil Wrong 3 Gear Worn or damaged 4 Bearing Worn or damaged MT 4 MT 4 MT 6 MT 6 Oil leakage 1 Oil Level too high 2 Gasket Damaged 3 Oil seal Worn...

Page 1328: ...MT03J 02 D10953 MANUAL TRANSMISSION W59 MANUAL TRANSMISSION UNIT MT 3 1302 Author Date 1996 TOYOTA T100 RM449U MANUAL TRANSMISSION UNIT COMPONENTS...

Page 1329: ...lts and starter Torque 39 N m 400 kgf cm 29 ft lbf 4 REMOVE TRANSMISSION FROM ENGINE a Remove the 3 transmission mounting bolts from the en gine Torque 72 N m 730 kgf cm 53 ft lbf b Pull out the trans...

Page 1330: ...T03L 02 MANUAL TRANSMISSION W59 MANUAL TRANSMISSION UNIT MT 5 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page MT 4 HINT After installation do the road tes...

Page 1331: ...9 Boot Back Up Light Switch Restrict Pin Control Shift Lever Retainer Oil Baffle Plate Restrict Pin Extension Housing Speedometer Driven Gear Non reusable part Precoated part Input Shaft x 6 x 9 Stra...

Page 1332: ...D10956 MANUAL TRANSMISSION W59 MANUAL TRANSMISSION ASSEMBLY MT 7 1306 Author Date 1996 TOYOTA T100 RM449U...

Page 1333: ...tainer and oil baffle plate 5 REMOVE 2 RESTRICT PINS AND GASKETS HINT At the time of reassembly please refer to the following item Install the black pin on the reverse gear 5th gear side Torque 40 N m...

Page 1334: ...ate plate NOTICE At the time of reassembly please refer to the following item Align each bearing outer race and each shift fork shaft end with the case holes FIPG Part No 08826 00090 THREE BOND 1281 o...

Page 1335: ...que 25 N m 250 kgf cm 18 ft lbf c Remove the reverse idler gear and shaft with the snap ring d Remove the No 1 shift fork and shaft e Using a magnetic finger remove the No 1 and No 2 inter lock pins H...

Page 1336: ...with the snap ring HINT At the time of reassembly please refer to the following item Align the No 3 shift fork with the No 3 hub sleeve groove put the reverse shift arm into the pivot of bearing retai...

Page 1337: ...5 0 0866 0 0886 7 2 26 2 31 0 0890 0 0909 b Using SST remove the rear bearing spacer counter 5th gear and bearing SST 09950 40010 NOTICE Be careful not to catch the output shaft rear bearing roller on...

Page 1338: ...nimum axial play Mark Thickness mm in 2 2 06 2 11 0 0811 0 0831 3 2 12 2 17 0 0835 0 0854 4 2 18 2 23 0 0858 0 0878 5 2 24 2 29 0 0882 0 0902 d Using SST remove the No 3 clutch hub SST 09950 40010 HIN...

Page 1339: ...mum axial play Mark Thickness mm in 8 2 31 2 36 0 0909 0 0929 9 2 37 2 42 0 0933 0 0953 10 2 43 2 48 0 0957 0 0976 11 2 49 2 54 0 0980 0 1000 12 2 55 2 60 0 1004 0 1024 13 2 61 2 66 0 1028 0 1047 14 2...

Page 1340: ...2 45 2 50 0 0965 0 0984 15 2 50 2 55 0 0984 0 1004 16 2 55 2 60 0 1004 0 1024 17 2 61 2 66 0 1028 0 1047 18 2 67 2 72 0 1051 0 1071 19 2 73 2 78 0 1075 0 1094 20 2 79 2 84 0 1098 0 1118 21 2 85 2 90...

Page 1341: ...to remove the counter gear center bearing outer race SST 09950 60010 09951 00510 09950 70010 09951 07150 S Install the outer race after installing the counter gear S Install the output shaft into the...

Page 1342: ...ION W59 MANUAL TRANSMISSION ASSEMBLY MT 17 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page MT 8 HINT Coat all of the sliding and rotating surfaces with ge...

Page 1343: ...Q00884 Snap Ring Snap Ring Bearing Input Shaft Synchronizer Ring Roller Bearing Non reusable part z z MT 18 MANUAL TRANSMISSION W59 INPUT SHAFT 1317 Author Date 1996 TOYOTA T100 RM449U INPUT SHAFT CO...

Page 1344: ...nd between the synchronizer ring and gear cone Lightly rub the synchronizer ring and gear cone together NOTICE Ensure the fine lapping compound is completely washed off after rubbing c Check again the...

Page 1345: ...sing a press remove the bearing c Using SST and a press install a new bearing SST 09506 35010 d Select a snap ring that allows the minimum axial play Mark Thickness mm in 1 2 05 2 10 0 0807 0 0827 2 2...

Page 1346: ...No 1 Clutch HUb Needle Roller Bearing Output Shaft Shifting Key Shifting Key Spring No 1 Hub Sleeve Synchronizer Ring Non reusable part z 3rd Gear Bearing Inner Race 1st Gear Shifting Key Synchronizer...

Page 1347: ...009 0 060 mm 0 0004 0 0024 in 3rd gear 0 015 0 066 mm 0 0006 0 0026 in Maximum clearance 1st and 2nd gears 0 150 mm 0 0059 in 3rd gear 0 200 mm 0 0079 in If the clearance exceeds the maximum replace t...

Page 1348: ...h a screwdriver remove the 3 shifting keys and key springs 7 REMOVE NO 2 HUB SLEEVE ASSEMBLY AND 3RD GEAR a Using a snap ring expander remove the snap ring b Using a press remove the No 2 hub sleeve s...

Page 1349: ...ff after rubbing c Check again the braking effect of the synchronizer ring d Using a feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 0 5 mm...

Page 1350: ...in If the clearance exceeds the maximum replace the shift fork or hub sleeve 4 INSPECT OUTPUT SHAFT AND INNER RACE a Using vernier calipers measure the output shaft flange thickness Minimum thickness...

Page 1351: ...eter measure the outer diameter of the in ner race Minimum diameter 42 975 mm 1 6919 in If the outer diameter is less than the minimum replace the inner race e Using a dial indicator check the shaft r...

Page 1352: ...2 CLUTCH HUBS INTO HUB SLEEVE a Install the 3 shifting key springs to the clutch hub b While pushing the shifting key spring with a screwdriver install the 3 shifting keys c While pushing the 3 shift...

Page 1353: ...0 0756 0 0776 13 1 98 2 03 0 0780 0 0799 14 2 04 2 09 0 0803 0 0823 15 2 10 2 15 0 0827 0 0846 b Using a snap ring expander install the snap ring 4 INSPECT 3RD GEAR THRUST CLEARANCE See page MT 21 5...

Page 1354: ...d bearing inner race d Install the assembly on the output shaft with the synchro nizer ring slots aligned with the shifting keys and turn the inner race to align it with the locking ball 8 INSTALL OUT...

Page 1355: ...everse Synchronizer Ring No 3 Hub Sleeve 5th Synchronizer Ring Synchronizer Cone Bearing Needle Roller Bearing Shifting Key Spacer Non reusable part z Snap Ring Snap Ring Snap Ring Bearing z Bearing z...

Page 1356: ...3 hub sleeve b Turn the reverse synchronizer pull ring c Remove the reverse synchronizer ring and 5th synchro nizer ring from the synchronizer pull ring and cone ring d Turn the reverse synchronizer p...

Page 1357: ...re the outer diameter of the counter shaft journal Minimum diameter Part A 26 975 mm 1 0620 in Part B 29 950 mm 1 1791 in If the outer race is less than the minimum replace the counter gear 3 INSPECT...

Page 1358: ...gear c Check the braking effect of the synchronizer ring Turn the synchronizer ring in one direction while pushing it to the gear cone Check that the ring locks If it does not lock replace the synchro...

Page 1359: ...ove the side race Using SST and a socket wrench remove the side race SST 09950 40010 e Using a socket wrench and press install a new bearing side race and inner race f Select a snap ring that allows t...

Page 1360: ...UNTER GEAR AND REVERSE IDLER GEAR MT 35 1996 TOYOTA T100 RM449U c Using SST tap out the bearing outer race SST 09950 60010 09951 00510 09950 70010 09951 07150 HINT After the outer race has been instal...

Page 1361: ...e synchronizer key spring install the shifting key and key spring to the reverse synchronizer ring b Using a screwdriver push the 3 key springs into the syn chronizer ring spring gaps c Install the sy...

Page 1362: ...D00880 Front MANUAL TRANSMISSION W59 COUNTER GEAR AND REVERSE IDLER GEAR MT 37 1996 TOYOTA T100 RM449U g While pushing 3 shifting keys install the synchronizer ring assembly to the No 3 hub sleeve...

Page 1363: ...WM0295 Front Bearing Retainer Non reusable part z Oil Seal z MT 38 MANUAL TRANSMISSION W59 FRONT BEARING RETAINER OIL SEAL 1337 Author Date 1996 TOYOTA T100 RM449U FRONT BEARING RETAINER OIL SEAL COM...

Page 1364: ...T 39 1996 TOYOTA T100 RM449U REPLACEMENT IF NECESSARY REPLACE FRONT BEARING RETAINER OIL SEAL a Using a screwdriver pry out the oil seal b Using SST and a press install a new oil seal SST 09950 60010...

Page 1365: ...Lever Housing Dust Deflector Oil Seal Extension Housing Snap Ring Outer Race Shift and Select Lever Oil Receiver Pipe Non reusable Part Precoated Part z L z z z L MT 40 MANUAL TRANSMISSION W59 EXTENS...

Page 1366: ...nd slide out the shaft b Inspect the reverse restrict pin Turn and push the reverse restrict pin by hand Check for smooth operation c Install the reverse restrict pin 1 Install the lever housing 2 Usi...

Page 1367: ...0 09951 00560 09950 70010 09951 07150 d Using a screwdriver install the snap ring 3 IF NECESSARY REPLACE EXTENSION HOUSING OIL SEAL a Using SST remove the oil seal SST 09308 00010 or 09308 10010 w out...

Page 1368: ...T 4 SPEEDOMETER DRIVEN GEAR AT 8 VEHICLE SPEED SENSOR AT 10 PARK NEUTRAL POSITION PNP SWITCH AT 11 VALVE BODY ASSEMBLY AT 12 PARKING LOCK PAWL AT 17 THROTTLE CABLE AT 18 SHIFT LOCK SYSTEM AT 19 AUTOMA...

Page 1369: ...SION AUTOMATIC TRANSMISSION SYSTEM AT 1 1342 Author Date 1996 TOYOTA T100 RM449U AUTOMATIC TRANSMISSION SYSTEM PRECAUTION If the vehicle is equipped with a mobile communication system refer to the pre...

Page 1370: ...nd 2nd gear no up shift f Operating O D Direct Clutch C0 O D Input Shaft O D Brake B0 2nd Coast Brake B1 Direct Clutch C2 Forward Clutch C1 2nd Brake B2 1st Reverse Brake B3 Rear Planetary carrier Rea...

Page 1371: ...LLER SHAFT See page PR 3 2 REMOVE REAR OIL SEAL NOTICE Clean the extension housing before removing the oil seal Using SST remove the oil seal SST 09308 10010 3 INSTALL NEW OIL SEAL a Using SST and a h...

Page 1372: ...See page AT 10 4 JACK UP TRANSMISSION SLIGHTLY Securely support the transmission on a transmission jack Lift the transmission slightly from the crossmember 5 3RZ FE REMOVE REAR MOUNTING BRACKET FROM...

Page 1373: ...en it 9 REMOVE SPEEDOMETER DRIVE GEAR AND BALL a Using a snap ring expander remove the snap ring b Remove the speedometer drive gear and ball 10 3RZ FE REMOVE SENSOR ROTOR a Remove the sensor rotor an...

Page 1374: ...ll b Using a snap ring expander install the snap ring 15 INSTALL EXTENSION HOUSING AND GASKET a Apply sealant or equivalent to the 6 bolts Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or eq...

Page 1375: ...ide 18 N m 185 kgf cm 13 ft lbf Frame side 58 N m 590 kgf cm 42 ft lbf 18 5VZ FE INSTALL REAR MOUNTING BRACKET TO REAR SUP PORT MEMBER Install the 8 bolts from the rear mounting bracket Torque Rear mo...

Page 1376: ...m the speedometer drive gear as sembly e Remove the clip and speedometer driven gear from the speedometer driven gear sleeve 2 REMOVE SPEEDOMETER DRIVEN GEAR OIL SEAL Using SST remove the oil seal SST...

Page 1377: ...Q04730 AUTOMATIC TRANSMISSION SPEEDOMETER DRIVEN GEAR AT 9 1350 Author Date 1996 TOYOTA T100 RM449U f Tighten the serrated collar with pliers...

Page 1378: ...TOR 2 REMOVE NO 2 VEHICLE SPEED SENSOR a A340E Remove the bolt and No 2 vehicle speed sensor b A340F Remove the bolt and No 2 vehicle speed sensor c Remove the O ring from it 3 INSTALL NO 2 VEHICLE SP...

Page 1379: ...ark neutral position switch 3 INSTALL PARK NEUTRAL POSITION SWITCH a Install the park neutral position switch and bolt Torque 13 N m 130 kgf cm 9 ft lbf b Install a new lock plate and the nut Torque 3...

Page 1380: ...lication Otherwise the FIPG material must be re moved and reapplied 1 REMOVE DRAIN PLUG AND DRAIN ATF Torque 20 N m 205 kgf cm 15 ft lbf 2 REMOVE OIL PAN NOTICE Some fluid will remain in the oil pan a...

Page 1381: ...5 A340E REMOVE OIL STRAINER NOTICE Be careful as some fluid will come out with the oil strainer a Separate the solenoid wire from the oil strainer b Remove the 3 bolts oil strainer and 2 gaskets 6 A34...

Page 1382: ...e throttle cable from the cam c Remove the valve body NOTICE Be careful not to drop the check ball body and spring 10 INSTALL VALVE BODY a Align the groove of the manual valve with the pin of the leve...

Page 1383: ...w gaskets to the oil strainer b Install the 3 bolts Torque 10 N m 100 kgf cm 7 ft lbf c Clamp the solenoid wire 14 A340F INSTALL OIL STRAINER a Install 2 new gaskets to the oil strainer case b Install...

Page 1384: ...magnets c Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan d Apply FIPG to the oil pan as shown in the illustraiton FIPG Part...

Page 1385: ...12 2 REMOVE PARKING LOCK PAWL BRACKET 3 REMOVE SPRING FROM PARKING LOCK PAWL SHAFT 4 REMOVE PARKING LOCK PAWL AND SHAFT 5 INSTALL PARKING LOCK PAWL AND SHAFT 6 INSTALL SPRING TO PARKING LOCK PAWL SHAF...

Page 1386: ...throttle cable 4 INSTALL THROTTLE CABLE a Make sure to push it in all the way b Install the bolt 5 INSTALL VALVE BODY See page AT 12 6 IF THROTTLE CABLE IS NEW STAKE STOPPER ON INNER CABLE HINT New c...

Page 1387: ...ition to the P position With the brake pedal depressed check the select lock cancel c Check that the lock pin has no unusual operation sound d Remove the center cluster finish lower panel See page BO...

Page 1388: ...ol Shaft Support Sub Assembly Parking Lock Cable Assembly Plate Washer Snap Ring Shift Lever Plate Sub Assembly Slotted Spring Pin Bushing Clamp Clamp Boot Spring N m kgf cm ft lbf Specified torque 19...

Page 1389: ...AT026 01 AUTOMATIC TRANSMISSION SHIFT LOCK SYSTEM AT 21 1996 TOYOTA T100 RM449U REMOVAL See page SR 13...

Page 1390: ...nd spring 4 REMOVE SHIFT LEVER PLATE SUB ASSEMBLY CONTROL SELECT SHAFT AND SPRING a Using a pin punch and hammer tap out the slotted spring pin and control select shaft CAUTION Be careful when tapping...

Page 1391: ...ert the spring and control select shaft b Install the shift lever sub assembly with the bolt and nut Torque 19 N m 195 kgf cm 14 ft lbf 3 INSTALL SHIFT LEVER PLATE SUB ASSEMBLY a Install the shift lev...

Page 1392: ...ntrol lever when the control shaft is in play Freeplay 6 mm 0 24 in e Release the select lock and measure the freeplay of the tip of the control lever when the shift lock plate and stop per lock in th...

Page 1393: ...ink Torque 4 9 N m 50 kgf cm 43 in lbf f Tighten the screw Torque 1 4 N m 14 kgf cm 12 in lbf g Turn the ignition switch key plate in the ACC position h Set the control shaft in the D position i Measu...

Page 1394: ...s Shaft Rear Mounting Insulator Rear End Plate z O Ring Oil Filler Pipe No 2 Gear Shifting Rod z Non reusable part Propeller Shaft x6 Rear Mounting Bracket AT02A 02 AT 26 AUTOMATIC TRANSMISSION AUTOMA...

Page 1395: ...Rod No 1 Throttle Cable Clamp Torque Converter Clutch Rear End Plate Propeller Shaft z Non reusable part Oil Filler Pipe z O Ring Rear Mounting Bracket Cross Shaft x6 Throttle Cable Rear Mounting Ins...

Page 1396: ...ring HINT At the time of reassembly please refer to the following item Replace used O ring with a new one 7 REMOVE PROPELLER SHAFT See page PR 3 8 3RZ FE REMOVE FRONT EXHAUST PIPE a Disconnect the ox...

Page 1397: ...efer to the following item Replace the used 3 gaskets with new ones 10 DISCONNECT SPEEDOMETER CABLE a Loosen the serrated collar with pliers Do not lose the felt dust protector and washer b Disconnect...

Page 1398: ...move the 4 nuts bolts and rear end plate Torque 37 N m 380 kgf cm 27 ft lbf 20 3RZ FE DISCONNECT REAR MOUNTING INSULATOR Remove the 3 bolts and disconnect the rear mounting insulator Torque 18 N m 180...

Page 1399: ...0 kgf cm 29 ft lbf b Remove the 3 transmission mounting bolts from the en gine Torque 71 N m 730 kgf cm 53 ft lbf c Pull out the transmission toward the rear 25 5VZ FE REMOVE TRANSMISSION FROM ENGINE...

Page 1400: ...rom the installed surface of the transmission housing to the installed surface of the torque converter clutch Correct distance More than 31 75 mm 1 2500 in for 3RZ FE More than 17 95 mm 0 7067 in for...

Page 1401: ...ng Bush No 2 Gear Shifting Rod Rear End Plate x6 Cross Shaft Rear Mounting Isulator Rear Support Member Dynamic Damper Transfer Under Cover Retainer TWC z Gasket Front Exhaust Pipe z Gasket Bracket St...

Page 1402: ...oot c Using pliers remove the snap ring and pull out the shift lever from the transfer HINT At the time of reassembly please refer to the following item Apply MP grease to the transfer shift lever 4 R...

Page 1403: ...NSMISSION AND TRANSFER 16 REMOVE CROSS SHAFT a Remove the clip and disconnect the No 2 gear shifting rod b Remove the nut washer 4 bolts and the cross shaft Torque A Transmission side 13 N m 130 kgf c...

Page 1404: ...25 DISCONNECT REAR MOUNTING INSULATOR a Remove the 2 bolts and dynamic damper Torque 61 N m 620 kgf cm 44 ft lbf b Remove the 4 bolts and rear mounting bracket Torque 18 N m 180 kgf cm 13 ft lbf 26 RE...

Page 1405: ...TION Using calipers and a straight edge measure from the installed surface of the transmission housing Correct distance More than 17 95 mm 0 7067 in 2 INSTALL TRANSMISSION Installation is in the rever...

Page 1406: ...ce of the one way clutch SST 09350 30020 09351 32020 c With the torque converter clutch standing on its side check that the clutch locks when turned counterclock wise and rotates freely and smoothly c...

Page 1407: ...emporarily mount the torque converter clutch to the drive plate Set up a dial indicator measure the torque corverter clutch sleeve runout Maximum runout 0 30 mm 0 0118 in If runout is not within the s...

Page 1408: ...FER TRANSFER SYSTEM TR 1 TROUBLESHOOTING TR 2 TRANSFER UNIT TR 3 TRANSFER ASSEMBLY TR 5 OIL PUMP BODY TR 17 DRIVEN SPROCKET TR 21 REAR OUTPUT SHAFT TR 23 INPUT SHAFT TR 30 PLANETARY GEAR TR 33 OIL SEA...

Page 1409: ...nd gasket scraper remove all the old FIPG material from the gasket sur faces S Thoroughly clean all components to remove all the loose material S Clean both sealing surfaces with a non residue solvent...

Page 1410: ...mbers indicate the priority of the likely cause of the problem Check each part in order If necessary replace these parts Symptom Suspect Area See page Noise 1 Oil Level low 2 Oil Wrong 3 Transfer faul...

Page 1411: ...retainer Hose depth 13 mm 0 51 in or more 3 REMOVE DYNAMIC DAMPER Remove the 2 bolts and dynamic damper Torque 37 N m 380 kgf cm 27 ft lbf 4 REMOVE ENGINE REAR MOUNTING Remove the 4 bolts and engine r...

Page 1412: ...TR 4 TRANSFER TRANSFER UNIT 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page TR 3 1 APPLY MP GREASE TO TRANSFER ADAPTOR OIL SEAL 2 AFTER INSTALLATION DO R...

Page 1413: ...TR01U 02 z TRANSFER TRANSFER ASSEMBLY TR 5 1385 Author Date 1996 TOYOTA T100 RM449U TRANSFER ASSEMBLY COMPONENTS...

Page 1414: ...TR 6 TRANSFER TRANSFER ASSEMBLY 1386 Author Date 1996 TOYOTA T100 RM449U...

Page 1415: ...position 4 A T REMOVE SHIFT GEAR HEAD NO 1 AND NO 2 a Using a pin punch and hammer drive out the 2 slotted spring pins b Remove the 2 shift gear heads 5 REMOVE FRONT RETAINER a Remove the 7 bolts Torq...

Page 1416: ...lbf HINT At the time of installation install a new gasket 8 REMOVE FRONT COMPANION FLANGE a Using a chisel and hammer loosen the staked part of the nut HINT At the time of installation stake a new loc...

Page 1417: ...1281 or equivalent 11 REMOVE SPEEDOMETER DRIVE GEAR a Remove the speedometer drive gear HINT At the time of installation please refer to the following item Make sure to install the speedometer drive...

Page 1418: ...allation apply liquid sealer to the plugs Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent b Using a magnetic finger remove the spring and ball from the both holes 14 REMOVE FRONT...

Page 1419: ...haft towards the rear case and install the pin while the spring is compressed b Hold the front drive fork shaft in place by hand when re moving the pin punch c Remove the front drive fork shaft spring...

Page 1420: ...llowing items S Place the high and low shift fork into the groove of the clutch sleeve S Make sure to install the shift fork in the correct direction 16 REMOVE REAR OUTPUT SHAFT DRIVEN SPROCKET AND CH...

Page 1421: ...er Torque 18 N m 185 kgf cm 13 ft lbf b Remove the O ring from the oil strainer pipe HINT At the time of installation please refer to the following item Coat a new O ring with gear oil and install it...

Page 1422: ...EARING a Using a snap ring expander remove the snap ring HINT At the time of installation please refer to the following item Select a snap ring that will allow 0 05 0 15 mm 0 0020 0 0059 in axial play...

Page 1423: ...screwdriver remove the snap ring HINT At the time of installation please refer to the following item Be sure the end gap of the snap ring is not aligned with the up per side of the case b Remove the...

Page 1424: ...16 TRANSFER TRANSFER ASSEMBLY 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page TR 7 HINT Coat all of the sliding and rotating surfaces with gear oil befor...

Page 1425: ...TR01X 02 TRANSFER OIL PUMP BODY TR 17 1397 Author Date 1996 TOYOTA T100 RM449U OIL PUMP BODY COMPONENTS...

Page 1426: ...o 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent b Using a magnetic finger remove the spring and ball c Using SST pull out the seat SST 09921 00010 d Remove the O ring from the seat HINT At the...

Page 1427: ...ody 2 INSPECT BOTH ROTORS TIP CLEARANCE Using a feeler gauge measure the clearance between both ro tor tips Standard clearance 0 08 0 16 mm 0 0031 0 0063 in Maximum clearance 0 16 mm 0 0063 in If the...

Page 1428: ...TR0D2 01 TR 20 TRANSFER OIL PUMP BODY 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page TR 18...

Page 1429: ...TR01Z 02 TRANSFER DRIVEN SPROCKET TR 21 1401 Author Date 1996 TOYOTA T100 RM449U DRIVEN SPROCKET COMPONENTS...

Page 1430: ...T BEARING Using a press remove the front bearing 2 REMOVE REAR BEARING Using SST steel bar and a press remove the rear bearing SST 09950 00020 3 INSTALL REAR BEARING Using a press install the rear bea...

Page 1431: ...eeve Snap Ring Shifting Key Spring Snap Ring Ball Bearing Spacer Rear Output Shaft Shifting Key Spring Front Drive Clutch Sleeve Drive Sprocket Needle Roller Bearing Shifting Key Synchronizer Ring z N...

Page 1432: ...SSEMBLY a Using a snap ring expander remove the snap ring b Remove the hub sleeve and 3 shifting keys c Using a press remove the clutch hub 2 key springs and key retainer 3 A T REMOVE HIGH AND LOW HUB...

Page 1433: ...1 TRANSFER REAR OUTPUT SHAFT TR 25 1996 TOYOTA T100 RM449U 5 REMOVE 3 SHIFTING KEYS AND 2 KEY SPRINGS FROM FRONT DRIVE HUB ASSEMBLY Using a screwdriver remove the 2 shifting key springs and 3 shifting...

Page 1434: ...055 mm 0 0004 0 0022 in Maximum clearance 0 055 mm 0 0022 in If the clearance exceeds the maximum replace the drive sprocket rear output shaft or needle roller bearing 3 INSPECT FRONT DRIVE SHIFT FORK...

Page 1435: ...EVE ASSEMBLY SPACER AND REAR BEARING a Apply gear oil to the shaft and needle roller bearing b Install the synchronizer ring c Install the needle roller bearing in the drive sprocket d Install the dri...

Page 1436: ...OTICE Install the key springs positioned so that their end gaps are not in line 5 A T INSERT HIGH AND LOW CLUTCH HUB INTO HUB SLEEVE Install the clutch hub to the hub sleeve 6 M T INSTALL HIGH AND LOW...

Page 1437: ...y and install it to the shaft Mark Thickness mm in A 2 10 2 15 0 0827 0 0846 B 2 15 2 20 0 0846 0 0866 C 2 20 2 25 0 0866 0 0886 D 2 25 2 30 0 0886 0 0906 E 2 30 2 35 0 0906 0 0925 F 2 35 2 40 0 0925...

Page 1438: ...TR025 02 TR 30 TRANSFER INPUT SHAFT 1410 Author Date 1996 TOYOTA T100 RM449U INPUT SHAFT COMPONENTS...

Page 1439: ...36 in b Using a dial indicator measure the inside diameter of the input shaft bushing Maximum inside diameter 39 14 mm 1 5409 in If the inside diameter exceeds the maximum replace the input shaft 3 M...

Page 1440: ...ANSFER INPUT SHAFT 1996 TOYOTA T100 RM449U 4 INSTALL SUN GEAR a Install the sun gear to the input shaft HINT Make sure to install the sun gear in the correct direction b Using snap ring pliers install...

Page 1441: ...TR027 02 TF0492 TRANSFER PLANETARY GEAR TR 33 1413 Author Date 1996 TOYOTA T100 RM449U PLANETARY GEAR COMPONENTS...

Page 1442: ...arance 0 009 0 038 mm 0 0004 0 0015 in Maximum clearance 0 038 mm 0 0015 in If the clearance exceeds the maximum replace the planetary gear assembly 3 IF NECESSARY REPLACE PLANETARY GEAR OUT ER BEARIN...

Page 1443: ...IF NECESSARY REPLACE PLANETARY GEAR INNER BEARING a Using SST and a press remove the bearing SST 09550 10012 09252 10010 09557 10010 b Using SST and a press install a new bearing SST 09550 10012 09252...

Page 1444: ...e Rear Companion Flange z Oil Seal Extension Housing Front Companion Flange z Non reusable part Front Retainer x5 x7 z Oil Seal z Oil Seal z Oil Seal z Oil Seal z O ring TR 36 TRANSFER OIL SEAL 1416 A...

Page 1445: ...face is flush with the retainer upper surface SST 09223 22010 c Coat the lip of the oil seal with MP grease 2 REPLACE FRONT CASE OIL SEAL a Using a screwdriver and hammer drive out the oil seal b Usin...

Page 1446: ...he oil seal with MP grease 4 REPLACE FRONT AND REAR COMPANION FLANGE OIL SEALS a Using a screwdriver and hammer drive out the oil seals from the 2 flanges b Using a socket wrench and hammer drive in a...

Page 1447: ...PR PROPELLER SHAFT TROUBLESHOOTING PR 1 PROPELLER SHAFT ASSEMBLY 2WD PR 2 PROPELLER SHAFT ASSEMBLY 4WD PR 10 SPIDER BEARING PR 18...

Page 1448: ...e problem Check each part in order If necessary replace these parts Symptom Suspect Area See page Noise 1 Center support bearing Worn 2WD 4WD 2 Sleeve yoke spline Worn 2WD 4WD 3 Spider bearing Worn or...

Page 1449: ...z z z z Flange Yoke z z Spider Bearing Snap Ring z z Intermediate Shaft Center Support Bearing Spacer Spacer Center Yoke Spider z Sleeve Yoke Dust Cover z z z Propeller Shaft z z Flange Yoke z Propell...

Page 1450: ...ELLER SHAFT a Place matchmarks on the differential and propeller shaft flanges b Remove the 4 bolts washers and nuts c Remove the 2 mounting bolts and center support bearing from the frame crossmember...

Page 1451: ...G REPLACEMENT on page PR 18 3 TMC made REMOVE CENTER SUPPORT BEARING FROM IN TERMEDIATE SHAFT a Using a hammer and chisel loosen the staked part of the nut b Using SST to hold the flange remove the nu...

Page 1452: ...tor check each runout of shaft Maximum runout 0 8 mm 0 031 in If shaft runout is greater than the maximum replace the shaft 2 INSPECT SPIDER BEARING a Inspect the spider bearing for wear or damage b U...

Page 1453: ...INSTALL CENTER SUPPORT BEARING ON INTER MEDIATE SHAFT HINT Install the center support bearing in the direction as shown 2 INSTALL FLANGE ON INTERMEDIATE SHAFT a Coat the splines of the intermediate sh...

Page 1454: ...le them so that the front yoke of the intermediate shaft and the rear yoke of the propeller shaft are facing in the same direc tion b Torque the bolts Torque 74 N m 750 kgf cm 54 ft lbf 4 DANA made IN...

Page 1455: ...F14974 PR 8 PROPELLER SHAFT PROPELLER SHAFT ASSEMBLY 2WD 1996 TOYOTA T100 RM449U 6 CONNECT PROPELLER SHAFT AND INTERMEDIATE SHAFT Assemble the center yoke See SPIDER BEARING REPLACE MENT on page PR 18...

Page 1456: ...g is installed with facing the drain hole downwards d Align the matchmarks on the flanges and connect the flanges with the 4 bolts washers and nuts e Torque the 4 bolts Torque 74 N m 750 kgf cm 54 ft...

Page 1457: ...PR01M 04 F14977 PR 10 PROPELLER SHAFT PROPELLER SHAFT ASSEMBLY 4WD 1428 Author Date 1996 TOYOTA T100 RM449U PROPELLER SHAFT ASSEMBLY 4WD COMPONENTS...

Page 1458: ...e 3 bolts and propeller shaft dust cover e Suspend the front side of the propeller shaft f Place matchmarks on the transfer and propeller shaft flanges g Remove the 4 nuts and washers h Remove the pro...

Page 1459: ...e propeller shaft 2 Rear SEPARATE PROPELLER SHAFT AND INTERMEDI ATE SHAFT a Place the matchmarks on the flanges b Remove the 4 nuts bolts and washers 3 REMOVE CENTER SUPPORT BEARING FROM IN TERMEDIATE...

Page 1460: ...b Using a dial indicator check the spider bearing axial play by turning the yoke of flange while holding the shaft tight ly Bearing axial play 0 05 mm 0 0020 in 3 INSPECT CENTER SUPPORT BEARING FOR W...

Page 1461: ...to the correct direction as shown in the illustration be low 1 Frsont INSERT SLEEVE YOKE INTO FRONT PROPELLER SHAFT a Apply MP grease to the propeller shaft spline and sleeve yoke sliding surface b A...

Page 1462: ...direction c Using SST to hold the flange press the bearing into posi tion by tightening down a new nut SST 09330 00021 Torque 181 N m 1 850 kgf cm 134 ft lbf d Loosen the nut e Torque the nut again To...

Page 1463: ...ller shaft dust cover with the 3 bolts Torque A bolt 36 N m 370 kgf cm 27 ft lbf B bolt 23 N m 230 kgf cm 17 ft lbf f M T Install the propeller shaft No 2 dust cover with the 2 bolts and nuts Torque B...

Page 1464: ...g to keep the intervals as shown S At the same condition check the center line in the axial direction Adjust the bearing if necessary S Check that the center line of the center bearing is set to the c...

Page 1465: ...e 4 snap rings from the grooves 3 REMOVE SPIDER BEARING a Using SST push out the bearing from the flange SST 09332 25010 HINT Sufficiently raise the part indicated by A so that it does not come into c...

Page 1466: ...ll mark No color mark 5 INSTALL SPIDER BEARING a Apply MP grease to the spider and bearings HINT Be careful not to apply too much grease b Align the matchmarks on the yoke and shaft c Fit a new spider...

Page 1467: ...5 8 2 450 2 500 0 0965 0 0984 2WD DANA made Color Thickness mm in Green 1 384 0 0545 Red 1 435 0 0565 Black 1 486 0 0585 Copper 1 511 0 0595 Silver 1 537 0 0605 Yellow 1 588 0 0625 Blue 1 638 0 0645 b...

Page 1468: ...No 5 Sleeve Yoke No 1 The figure at left shows the locations of the grease fittings as seen from the rear The figure at left shows the locations of the grease fittings as seen from the rear PROPELLER...

Page 1469: ...4WD SA 28 FRONT DRIVE SHAFT 4WD SA 36 FRONT DIFFERENTIAL REAR OIL SEAL 4WD SA 42 FRONT DIFFERENTIAL CARRIER 4WD SA 45 A D D CONTROL SYSTEM SA 69 FRONT SHOCK ABSORBER 2WD SA 72 FRONT SHOCK ABSORBER 4W...

Page 1470: ...T 4WD SA 111 FRONT LOWER BALL JOINT 2WD SA 115 FRONT LOWER BALL JOINT 4WD SA 119 FRONT STABILIZER BAR 2WD SA 123 FRONT STABILIZER BAR 4WD SA 126 REAR AXLE SHAFT SA 129 REAR WHEEL HUB BOLT SA 136 REAR...

Page 1471: ...2 SA 129 Bottoming 1 Vehicle Overloaded 2 Spring Weak 3 Shock absorber Worn out SA 82 SA 85 SA 160 SA 72 SA 77 SA 155 Sways pitches 1 Tires Worn or improperly inflated 2 Stabilizer bar Bent or broken...

Page 1472: ...n or damaged 3 Side gear oil seal Worn or damaged 4 Companion flange Loose or damaged 5 Side gear shaft Damaged SA 42 SA 42 SA 45 SA 42 SA 45 Noise in rear axle 1 Oil level Low or wrong grade 2 Excess...

Page 1473: ...mph Tire size Front kPa kg cm2 psi Rear kPa kg cm2 psi P215 75R15 230 2 3 33 240 2 4 35 P235 75R15 0 5 ton 180 1 8 26 200 2 0 29 P235 75R15 1 0 ton 180 1 8 26 280 2 8 41 b Check the tire runout Tire r...

Page 1474: ...ck the backlash in the bearing shaft direction Maximum 0 05 mm 0 0020 in 5 CHECK FRONT SUSPENSION FOR LOOSENESS 6 CHECK STEERING LINKAGE FOR LOOSENESS 7 CHECK BALL JOINT FOR LOOSENESS 8 CHECK SHOCK AB...

Page 1475: ...75 mph Tire size Front kPa kg cm2 psi Rear kPa kg cm2 psi P235 75R15 180 1 8 26 200 2 0 29 31 x 10 5 R15LT 180 1 8 26 200 2 0 29 31 x 10 5 R15LT Extra cab 200 2 0 29 240 2 4 35 b Check the tire runout...

Page 1476: ...TA T100 RM449U 4 CHECK FRONT SUSPENSION FOR LOOSENESS 5 CHECK STEERING LINKAGE FOR LOOSENESS 6 CHECK BALL JOINT FOR LOOSENESS 7 CHECK SHOCK ABSORBER WORKS PROPERLY S Check for oil leaks S Check mounti...

Page 1477: ...nter C Rear axle shaft height measured at its center D Rear leaf spring front bushing height measured at its center NOTICE Before inspecting the wheel alignment adjust the vehicle height to specificat...

Page 1478: ...7 in HINT If the steering axis inclination is not as specified after camber and caster have been correctly adjusted recheck the steering knuckle and front wheel for distortion or looseness NOTICE Adju...

Page 1479: ...0 5 ton Left right error 40 42 2 40 7 2 30 0 5 34 23 34 38 STD cab 1 0 ton Left right error 39 55 2 39 92 2 30 0 5 34 37 34 67 Extra cab Left right error 40 10 2 40 17 2 30 0 5 34 25 34 47 If the whee...

Page 1480: ...g the wheel alignment adjust the vehicle height to specification If the vehicle height is not standard try to adjust it by pushing down on or lifting the body 2 INSTALL CAMBER CASTER KINGPIN GAUGE OR...

Page 1481: ...mm 0 08 0 08 in If the toe in is not within specification adjust the tie rod end 5 ADJUST CAMBER AND CASTER a Loosen the front and or rear adjusting cam nuts b Adjust the camber and caster by front an...

Page 1482: ...30 30 5 Extra cab 32 14 2 33 23 2 30 30 30 5 If maximum steering angles differ from standard value adjust the wheel angle with the knuckle stopper bolts Torque 47 N m 480 kgf cm 35 ft lbf If the whee...

Page 1483: ...R08019 Front Front Cam Longer Front Cam Shorter Longer Longer Shorter Shorter Rear Cam Rear Cam SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT 4WD SA 13 1452 Author Date 1996 TOYOTA T100 RM449U...

Page 1484: ...SA 14 SUSPENSION AND AXLE FRONT WHEEL ALIGNMENT 4WD 1453 Author Date 1996 TOYOTA T100 RM449U...

Page 1485: ...SA0FH 06 SUSPENSION AND AXLE FRONT AXLE HUB 2WD SA 15 1454 Author Date 1996 TOYOTA T100 RM449U FRONT AXLE HUB 2WD COMPONENTS...

Page 1486: ...30 mm socket remove the nut b Remove the axle hub with the disc together with the outer bearing from the steering knuckle NOTICE Be careful not to drop the outer bearing 6 REMOVE OIL SEAL AND INNER B...

Page 1487: ...SA0FJ 01 W00398 SUSPENSION AND AXLE FRONT AXLE HUB 2WD SA 17 1996 TOYOTA T100 RM449U INSPECTION INSPECT STEERING KNUCKLE Using a dye penetrant check the steering knuckle for cracks...

Page 1488: ...Using a brass bar and hammer remove the inside and outside bearing outer races NOTICE Be careful not to damage the ABS speed sensor rotor b Using SST and a press install a new outside bearing out er r...

Page 1489: ...t nut Torque 142 N m 1 450 kgf cm 105 ft lbf f Install 2 new cotter pins 2 CONNECT KNUCKLE ARM AND TO STEERING KNUCKLE a Clean the threads of the bolts and steering knuckle with toluene or trichloroet...

Page 1490: ...spindle b Install the outer bearing and thrust washer 8 ADJUST PRELOAD a Install and torque the nut Torque 35 N m 360 kgf cm 26 ft lbf b Turn the hub several times to make the bearing more smoothly c...

Page 1491: ...ll the lock cap and a new cotter pin b Install the grease cap 10 INSTALL BRAKE CALIPER Install the 2 brake caliper set bolts Torque 108 N m 1 100 kgf cm 80 ft lbf 11 w ABS CONNECT ABS SPEED SENSOR TO...

Page 1492: ...SA0FM 03 SA 22 SUSPENSION AND AXLE FRONT AXLE HUB 4WD 1461 Author Date 1996 TOYOTA T100 RM449U FRONT AXLE HUB 4WD COMPONENTS...

Page 1493: ...emove the bolt c Remove the 6 mounting nuts and washers d Using a brass bar and hammer tap on the bolts head and remove the 6 cone washers e Install and tighten the 2 bolts and remove the flange f Rem...

Page 1494: ...g a brass bar and hammer remove the inside and outside outer bearing outer races NOTICE Be careful not to damage the ABS speed sensor rotor b Using SST and a hammer install a new outside bearing outer...

Page 1495: ...to damage the ABS speed sensor rotor c Coat the oil seal lip with MP grease 4 INSTALL AXLE HUB TO STEERING KNUCKLE a Place the axle hub to the steering knuckle NOTICE Be careful not to damage the ABS...

Page 1496: ...e 6 nuts Torque 31 N m 315 kgf cm 23 ft lbf e Install the bolt and grease cap Torque 18 N m 185 kgf cm 13 ft lbf 8 INSTALL BRAKE CALIPER a Install the brake caliper to the steering knuckle b Torque th...

Page 1497: ...disc and axle hub b Remove the 6 bolts washers and separate the disc and axle hub c Install the nut to the axle hub bolt d Using an extension bar and press remove the hub bolt 4 INSTALL HUB BOLT a Usi...

Page 1498: ...SA0FR 02 SA 28 SUSPENSION AND AXLE STEERING KNUCKLE 4WD 1467 Author Date 1996 TOYOTA T100 RM449U STEERING KNUCKLE 4WD COMPONENTS...

Page 1499: ...ide bushing and spacer by pulling the bolt and applying a load of 98 N 10 kgf 22 0 lbf Front drive shaft thrust clearance Standard 0 10 0 50 mm 0 0039 0 0197 in Maximum 1 0 mm 0 039 in If the thrust c...

Page 1500: ...sion arm with a jack c Remove the cotter pin and nut from the upper ball joint d Using SST disconnect the steering knuckle from the up per ball joint SST 09628 62011 e Remove the 4 bolts from the lowe...

Page 1501: ...REMOVE DUST COVER Using a screwdriver and hammer remove the dust cover from the steering knuckle 2 REMOVE STEERING KNUCKLE BUSHING a Using SST remove the steering knuckle outside bushing SST 09308 00...

Page 1502: ...SA0FU 01 FA0735 SA 32 SUSPENSION AND AXLE STEERING KNUCKLE 4WD 1996 TOYOTA T100 RM449U INSPECTION INSPECT STEERING KNUCKLE Using a dye penetrant check the steering knuckle for cracks...

Page 1503: ...s install a new needle roller bear ing as shown in the illustration SST 09950 60010 09951 00360 09950 70010 09951 07150 HINT S Bearing must be installed with flat side which has I D and part number fa...

Page 1504: ...ter pin g Install the spacer to the drive shaft h Using snap ring pliers install the snap ring NOTICE If you replace the steering knuckle bushing recheck the drive shaft thrust clearance i Install the...

Page 1505: ...the shock absorber bolt washer and nut to the lower suspension arm Torque 137 N m 1 400 kgf cm 101 ft lbf 4 INSTALL DUST COVER AND NEW OIL SEAL Torque 18 N m 185 kgf cm 13 ft lbf 5 INSTALL FRONT AXLE...

Page 1506: ...SA0FX 02 SA 36 SUSPENSION AND AXLE FRONT DRIVE SHAFT 4WD 1475 Author Date 1996 TOYOTA T100 RM449U FRONT DRIVE SHAFT 4WD COMPONENTS...

Page 1507: ...Loosen the 6 nuts with depressing the brake pedal Torque 83 N m 845 kgf cm 61 ft lbf 2 REMOVE FLANGE See page SA 23 3 REMOVE SNAP RING AND SPACER Using a snap ring expander remove the snap ring from t...

Page 1508: ...BOOT CLAMPS a Using a screwdriver remove the 4 boot clamps b Slide the inboard joint boot toward the outboard joint 3 DISASSEMBLE INBOARD JOINT TULIP a Place matchmarks on the inboard joint tulip and...

Page 1509: ...e outboard joint b Align the matchmarks placed before disassembly c Using a brass bar and hammer tap the tripod onto the drive shaft NOTICE Do not tap the roller d Using a snap ring expander install a...

Page 1510: ...OTH BOOTS a Make sure the 2 boots are on the shaft groove b Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length Standard length 481 2 491 2 mm 18 945...

Page 1511: ...SUSPENSION AND AXLE FRONT DRIVE SHAFT 4WD SA 41 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 37 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT See p...

Page 1512: ...SA0G2 02 SA 42 SUSPENSION AND AXLE FRONT DIFFERENTIAL REAR OIL SEAL 4WD 1481 Author Date 1996 TOYOTA T100 RM449U FRONT DIFFERENTIAL REAR OIL SEAL 4WD COMPONENTS...

Page 1513: ...09330 00021 c Using SST remove the companion flange SST 09950 30010 4 REMOVE OIL SEAL AND OIL SLINGER a Using SST remove the oil seal SST 09308 10010 b Remove the oil slinger 5 REMOVE REAR BEARING AN...

Page 1514: ...ion flange nut c Using SST to hold the flange torque the nut SST 09330 00021 Torque 108 N m 1 100 kgf cm 80 ft lbf 9 ADJUST DRIVE PINION PRELOAD See page SA 57 10 STAKE DRIVE PINION NUT 11 INSTALL FRO...

Page 1515: ...SA0G4 03 SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER 4WD SA 45 1484 Author Date 1996 TOYOTA T100 RM449U FRONT DIFFERENTIAL CARRIER 4WD COMPONENTS...

Page 1516: ...SA 46 SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER 4WD 1485 Author Date 1996 TOYOTA T100 RM449U...

Page 1517: ...Torque 83 N m 845 kgf cm 61 ft lbf b Employ the same manner described above to the other side 4 DISCONNECT VACUUM HOSES AND 4WD INDICA TOR SWITCH CONNECTOR 5 REMOVE CROSSMEMBER Remove the 4 nuts washe...

Page 1518: ...f the runout is greater than the maximum replace the compan ion flange 3 CHECK TOTAL PRELOAD Using a torque wrench measure the total preload Total preload at starting Drive pinion preload plus 0 4 0 6...

Page 1519: ...Remove the O ring from the tube 8 REMOVE CLUTCH CASE a Using a torx socket E14 remove the 2 torx bolts b Using a plastic hammer tap on the clutch case to remove it 9 REMOVE RH SIDE GEAR SHAFT Using SS...

Page 1520: ...he tooth surface at a 90 angle b Using a dial indicator with holding the drive pinion flange and measure the ring gear backlash Backlash 0 13 0 18 mm 0 0051 0 0070 in If the backlash is not within the...

Page 1521: ...the drive pinion SST 09556 30010 b Remove the bearing spacer 18 REMOVE DIFFERENTIAL CASE ASSEMBLY a Place matchmarks on the bearing cap and differential car rier b Remove the 4 bolts and 2 bearing cap...

Page 1522: ...ace matchmarks on the ring gear and differential case b Using a screwdriver and hammer unstake the lock plates c Remove the 10 bolts and 5 lock plates d Using a plastic hammer tap on the ring gear to...

Page 1523: ...SA0353 SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER 4WD SA 53 1996 TOYOTA T100 RM449U c Using a brass bar and hammer remove the 2 bearings...

Page 1524: ...a Remove the clutch hub 1 Using a snap ring expander remove the snap ring 2 Remove the clutch hub from the side gear shaft b Remove the LH side gear shaft from the tube 1 Remove the 3 bearing retainer...

Page 1525: ...e oil seal lip facing upward use press and plate to press in a new oil seal until its end is flush with the surface of the tube 3 Using SST and a press install the oil seal SST 09554 14010 Oil seal dr...

Page 1526: ...ove the 2 bolts and actuator from the clutch case cover 4 Separate the actuator from the clutch case cover and remove the sleeve fork 5 Remove the O ring from the actuator d Install the sleeve fork an...

Page 1527: ...en sure that the backlash is within specifications Washer thickness Thickness mm in Thickness mm in 0 96 1 04 0 0378 0 0409 1 16 1 24 0 0457 0 0488 1 06 1 14 0 0417 0 0449 1 26 1 34 0 0496 0 0528 c In...

Page 1528: ...water d After the moisture on the ring gear has completely evapo rated quickly install the ring gear to the differential case HINT Align the matchmarks on the ring gear and differential case e Tempor...

Page 1529: ...09950 70010 09951 07150 7 INSTALL DRIVE PINION FRONT BEARING a Install the washer on the drive pinion HINT First fit a washer with the same thickness as the washer which was removed then after checki...

Page 1530: ...ar ings Check that the left and right outer races are not inter changed b Install the differential case in the differential carrier 10 ADJUST RING GEAR BACKLASH a Only install the plate washer on the...

Page 1531: ...of the carrier h Place the other plate washer onto the differential case to gether with the outer race and install the differential case with the outer race into the carrier i Tap on the ring gear wit...

Page 1532: ...2 59 0 1012 0 1020 2 81 2 83 0 1106 0 1114 3 05 3 07 0 1201 0 1209 2 60 2 62 0 1024 0 1031 2 84 2 86 0 1118 0 1126 3 08 3 10 0 1213 0 1220 2 63 2 65 0 1035 0 1043 2 87 2 89 0 1130 0 1138 3 11 3 13 0...

Page 1533: ...TA T100 RM449U If the teeth are not contacting properly use the following chart to select a proper washer for correction Washer thickness Thickness mm in Thickness mm in 2 27 0 0894 2 51 0 0988 2 30 0...

Page 1534: ...l install it c Using SST to hold the flange tighten the nut SST 09330 00021 Torque 108 N m 1 100 kgf cm 80 ft lbf 18 ADJUST DRIVE PINION PRELOAD Using a torque wrench measure the drive pinion preload...

Page 1535: ...sh with the differential carrier end SST 09550 00032 09950 70010 09951 07150 b Apply MP grease to the oil seal lip 24 INSTALL RH SIDE GEAR SHAFT a Install a new snap ring to the side gear shaft b Usin...

Page 1536: ...LEEVE 30 INSTALL LH SIDE GEAR SHAFT TO DIFFERENTIAL CARRIER a Remove any old FIPG material and be careful not to drop oil on the contact surfaces of the differential carrier and clutch case b Clean su...

Page 1537: ...o 08826 00090 THREE BOND 1281 or equiva lent HINT Install the carrier cover within 10 minutes after applying FIPG d Install the differential carrier cover with the 8 bolts Torque 47 N m 475 kgf cm 34...

Page 1538: ...ENSION AND AXLE FRONT DIFFERENTIAL CARRIER 4WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 47 AFTER INSTALLATION FILL DIFFERENTIAL WITH HYPOID GEAR...

Page 1539: ...ndicator Switch Actuator Vacuum Tank Transfer Indicator Switch A D D Relay 4WD Indicator A D D Solenoids VSV2 and VSV4 SUSPENSION AND AXLE A D D CONTROL SYSTEM SA 69 1508 Author Date 1996 TOYOTA T100...

Page 1540: ...measure the clearance between the sleeve fork and the clutch sleeve Maximum clearance 0 35 mm 0 0138 in 3 INSPECT A D D ACTUATOR a Check that the sleeve fork moves to the actuator side when a vacuum o...

Page 1541: ...k that continuity exists between terminals 2 and 6 c Connect the positive lead from the battery to terminal 6 and the negative lead to terminal 2 d Using an ohmmeter check that continuity exists betwe...

Page 1542: ...SA0GC 07 SA 72 SUSPENSION AND AXLE FRONT SHOCK ABSORBER 2WD 1511 Author Date 1996 TOYOTA T100 RM449U FRONT SHOCK ABSORBER 2WD COMPONENTS...

Page 1543: ...m 76 ft lbf 2 REMOVE SHOCK ABSORBER a Remove the 2 bolts and disconnect the shock absorber lower side from the lower suspension arm Torque 18 N m 185 kgf cm 13 ft lbf b Hold the shock absorber and rem...

Page 1544: ...PECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber piston rod and check that there is no abnormal resistance or unusual operation sound If there is any abnormality replace the shock...

Page 1545: ...TOYOTA T100 RM449U DISPOSAL 1 FULLY EXTEND SHOCK ABSORBER ROD 2 DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill make a hole in the cylinder as shown to remove the gas inside CAUTION The discharge...

Page 1546: ...SA0GG 01 SA 76 SUSPENSION AND AXLE FRONT SHOCK ABSORBER 2WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 73...

Page 1547: ...SA0GH 02 SUSPENSION AND AXLE FRONT SHOCK ABSORBER 4WD SA 77 1516 Author Date 1996 TOYOTA T100 RM449U FRONT SHOCK ABSORBER 4WD COMPONENTS...

Page 1548: ...ft lbf 2 REMOVE SHOCK ABSORBER a Remove the nut and washer and disconnect the shock absorber lower side from the lower suspension arm Torque 137 N m 1 400 kgf cm 101 ft lbf b Hold the shock absorber a...

Page 1549: ...PECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber piston rod and check that there is no abnormal resistance or unusual operation sound If there is any abnormality replace the shock...

Page 1550: ...TOYOTA T100 RM449U DISPOSAL 1 FULLY EXTEND SHOCK ABSORBER ROD 2 DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill make a hole in the cylinder as shown to remove the gas inside CAUTION The discharge...

Page 1551: ...SA0GL 01 SUSPENSION AND AXLE FRONT SHOCK ABSORBER 4WD SA 81 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 78...

Page 1552: ...SA0GM 07 SA 82 SUSPENSION AND AXLE FRONT TORSION BAR SPRING 2WD 1521 Author Date 1996 TOYOTA T100 RM449U FRONT TORSION BAR SPRING 2WD COMPONENTS...

Page 1553: ...turning the adjusting nut See page SA 7 3 LOOSEN ADJUSTING NUT AND REMOVE ANCHOR ARM HINT At the time of installation tighten the adjusting nut to the bolt protrusion length is of before removal 4 RE...

Page 1554: ...84 SUSPENSION AND AXLE FRONT TORSION BAR SPRING 2WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 83 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT S...

Page 1555: ...SA0GP 02 SUSPENSION AND AXLE FRONT TORSION BAR SPRING 4WD SA 85 1524 Author Date 1996 TOYOTA T100 RM449U FRONT TORSION BAR SPRING 4WD COMPONENTS...

Page 1556: ...vehicle height by turning the adjusting nut See page SA 10 3 LOOSEN ADJUSTING NUT REMOVE ANCHOR AND TORSION BAR SPRING HINT At the time of installation please refer to the following items S Tighten t...

Page 1557: ...ENSION AND AXLE FRONT TORSION BAR SPRING 4WD SA 87 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 86 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT Se...

Page 1558: ...SA0GS 07 SA 88 SUSPENSION AND AXLE FRONT STRUT BAR 2WD 1527 Author Date 1996 TOYOTA T100 RM449U FRONT STRUT BAR 2WD COMPONENTS...

Page 1559: ...washer retainer and cushion on the front side of the strut bar Torque 123 N m 1 250 kgf cm 90 ft lbf HINT At the time of installation after stabilizing the suspension torque the nut b Remove the 2 nu...

Page 1560: ...SA 90 SUSPENSION AND AXLE FRONT STRUT BAR 2WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 89 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT See pa...

Page 1561: ...SA0GV 07 SUSPENSION AND AXLE FRONT UPPER SUSPENSION ARM 2WD SA 91 1530 Author Date 1996 TOYOTA T100 RM449U FRONT UPPER SUSPENSION ARM 2WD COMPONENTS...

Page 1562: ...ort the lower suspension arm with a jack b Remove the 4 nuts and bolts and disconnect the upper suspension arm Torque 31 N m 320 kgf cm 23 ft lbf 5 REMOVE UPPER SUSPENSION ARM a Remove the 2 bolts and...

Page 1563: ...b Using SST remove the 2 bushings SST 09710 30021 09710 03031 09710 03041 2 INSTALL NEW BUSHING a Using SST install 2 new bushings SST 09710 30021 09710 03051 09710 03061 b Install the washer and tigh...

Page 1564: ...4 SUSPENSION AND AXLE FRONT UPPER SUSPENSION ARM 2WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 92 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT...

Page 1565: ...SA0GZ 02 SUSPENSION AND AXLE FRONT UPPER SUSPENSION ARM 4WD SA 95 1534 Author Date 1996 TOYOTA T100 RM449U FRONT UPPER SUSPENSION ARM 4WD COMPONENTS...

Page 1566: ...TORSION BAR SPRING See page SA 86 4 REMOVE UPPER BALL JOINT FROM UPPER SUSPENSION ARM NOTICE Make sure the steering knuckle is positively secured as shown before removing upper ball joint from upper s...

Page 1567: ...70010 09951 07200 5 INSTALL REAR BUSHING a Using SST and press install a new rear bushing SST 09710 26011 09710 05061 09710 05081 HINT Do not apply grease or oil to the bushing b Install the upper sus...

Page 1568: ...SUSPENSION AND AXLE FRONT UPPER SUSPENSION ARM 4WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 96 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT S...

Page 1569: ...SA0H3 07 SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM 2WD SA 99 1538 Author Date 1996 TOYOTA T100 RM449U FRONT LOWER SUSPENSION ARM 2WD COMPONENTS...

Page 1570: ...HOCK ABSORBER FROM LOWER SUSPENSION ARM See page SA 73 5 DISCONNECT STABILIZER BAR FROM LOWER SUSPENSION ARM See page SA 124 6 DISCONNECT STRUT BAR FROM LOWER SUSPENSION ARM See page SA 89 7 DISCONNEC...

Page 1571: ...TOYOTA T100 RM449U REPLACEMENT 1 REMOVE BUSHING a Cut off the bushing rubber as shown in the illustration b Using SST remove the bushing SST 09726 35011 2 INSTALL NEW BUSHING a Apply soapy water on t...

Page 1572: ...2 SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM 2WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 100 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT...

Page 1573: ...SA0H7 02 SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM 4WD SA 103 1542 Author Date 1996 TOYOTA T100 RM449U FRONT LOWER SUSPENSION ARM 4WD COMPONENTS...

Page 1574: ...BILIZER BAR FROM LOWER SUSPENSION ARM See page SA 127 4 DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT a Remove the cotter pin and loosen the nut Torque 142 N m 1 450 kgf cm 105 ft lbf b Using...

Page 1575: ...NT 1 REMOVE FRONT AND REAR BUSHINGS Using SST remove the 2 bushings from the lower suspension arm SST 09726 27012 09726 02051 09726 02061 2 INSTALL FRONT AND REAR BUSHINGS Using SST install 2 new bush...

Page 1576: ...SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM 4WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 104 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT...

Page 1577: ...SA0HB 08 SUSPENSION AND AXLE FRONT UPPER BALL JOINT 2WD SA 107 1546 Author Date 1996 TOYOTA T100 RM449U FRONT UPPER BALL JOINT 2WD COMPONENTS...

Page 1578: ...OYOTA T100 RM449U REMOVAL 1 REMOVE FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 2 REMOVE STEERING KNUCKLE See page SA 16 3 REMOVE UPPER BALL JOINT a Remove the 4 nuts and bolts Torque 31 N m 320...

Page 1579: ...PER BALL JOINT FOR ROTATION CONDITION a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously one tur...

Page 1580: ...E FRONT UPPER BALL JOINT 2WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 108 AFTER INSTALLATION CHECK ABS SPEED SENSOR SIGNAL See page DI 321 AND F...

Page 1581: ...SA0HF 02 SUSPENSION AND AXLE FRONT UPPER BALL JOINT 4WD SA 111 1550 Author Date 1996 TOYOTA T100 RM449U FRONT UPPER BALL JOINT 4WD COMPONENTS...

Page 1582: ...REMOVAL 1 REMOVE FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 2 DISCONNECT UPPER AND LOWER BALL JOINT FROM STEERING KNUCKLE See page SA 23 3 REMOVE UPPER BALL JOINT a Remove the 4 nuts Torque 33...

Page 1583: ...PPER BALL JOINT FOR ROTATION CONDITION a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously one tu...

Page 1584: ...FRONT UPPER BALL JOINT 4WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 112 AFTER INSTALLATION CHECK ABS SPEED SENSOR SIGNAL See page DI 321 AND FR...

Page 1585: ...SA0HJ 08 SUSPENSION AND AXLE FRONT LOWER BALL JOINT 2WD SA 115 1554 Author Date 1996 TOYOTA T100 RM449U FRONT LOWER BALL JOINT 2WD COMPONENTS...

Page 1586: ...996 TOYOTA T100 RM449U REMOVAL 1 REMOVE FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 2 REMOVE STEERING KNUCKLE See page SA 16 3 REMOVE LOWER BALL JOINT a Remove the 4 nuts Torque 75 N m 760 kgf c...

Page 1587: ...ER BALL JOINT FOR ROTATION CONDI TION a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously one tur...

Page 1588: ...E FRONT LOWER BALL JOINT 2WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 116 AFTER INSTALLATION CHECK ABS SPEED SENSOR SIGNAL See page DI 321 AND F...

Page 1589: ...SA0HN 03 SUSPENSION AND AXLE FRONT LOWER BALL JOINT 4WD SA 119 1558 Author Date 1996 TOYOTA T100 RM449U FRONT LOWER BALL JOINT 4WD COMPONENTS...

Page 1590: ...03 N m 1 050 kgf cm 76 ft lbf 2 DISCONNECT UPPER AND LOWER BALL JOINT FROM STEERING KNUCKLE See page SA 23 3 REMOVE LOWER BALL JOINT FROM STEERING KNUCKLE a Remove the cotter pin and nut from the lowe...

Page 1591: ...ER BALL JOINT FOR ROTATION CONDI TION a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously one tur...

Page 1592: ...FRONT LOWER BALL JOINT 4WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 120 AFTER INSTALLATION CHECK ABS SPEED SENSOR SIGNAL See page DI 321 AND FR...

Page 1593: ...SA0HR 07 SUSPENSION AND AXLE FRONT STABILIZER BAR 2WD SA 123 1562 Author Date 1996 TOYOTA T100 RM449U FRONT STABILIZER BAR 2WD COMPONENTS...

Page 1594: ...the nut 3 retainers 2 cushions and stabilizer bar from the lower suspension arm Torque 13 N m 130 kgf cm 9 ft lbf b Remove the nut 2 cushions 2 retainers and disconnect the stabilizer bar Torque 13 N...

Page 1595: ...SA0HT 01 SUSPENSION AND AXLE FRONT STABILIZER BAR 2WD SA 125 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 124...

Page 1596: ...SA0HU 02 SA 126 SUSPENSION AND AXLE FRONT STABILIZER BAR 4WD 1565 Author Date 1996 TOYOTA T100 RM449U FRONT STABILIZER BAR 4WD COMPONENTS...

Page 1597: ...ER BAR a Remove the nut 4 cushions 5 retainers collar and stabi lizer bar from the lower suspension arms Torque 25 N m 260 kgf cm 19 ft lbf b Employ the same manner described above to the other side c...

Page 1598: ...SA0HW 01 SA 128 SUSPENSION AND AXLE FRONT STABILIZER BAR 4WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 127...

Page 1599: ...SA0HX 03 SUSPENSION AND AXLE REAR AXLE SHAFT SA 129 1568 Author Date 1996 TOYOTA T100 RM449U REAR AXLE SHAFT COMPONENTS...

Page 1600: ...SA 130 SUSPENSION AND AXLE REAR AXLE SHAFT 1569 Author Date 1996 TOYOTA T100 RM449U...

Page 1601: ...bolt Maximum 0 1 mm 0 0039 in If the deviation exceeds the maximum replace the axle shaft 4 REMOVE REAR BRAKE ASSEMBLY 2WD See page BR 40 4WD See page BR 45 5 w ABS REMOVE ABS SPEED SENSOR FROM REAR...

Page 1602: ...M AXLE SHAFT Using a snap ring expander remove the snap ring 3 REMOVE REAR AXLE SHAFT FROM BACKING PLATE a Attach 4 washers and nuts to the serration bolts then torque the nuts to install the serratio...

Page 1603: ...09950 60010 09951 00560 b Using SST and a press install a new bearing SST 09950 60010 09951 00610 09950 70010 09951 07150 9 INSTALL NEW OUTER OIL SEAL Using SST and a hammer install a new oil seal SST...

Page 1604: ...Apply MP grease to the oil seal lip 14 INSTALL REAR AXLE SHAFT IN BACKING PLATE a Apply MP grease to the oil seal lip b Install the backing plate and bearing retainer on the rear axle shaft c Using S...

Page 1605: ...R AXLE SHAFT SA 135 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 131 AFTER INSTALLATION BLEED BRAKE SYSTEM See page BR 4 CHECK FOR LEAKS AND ABS SPE...

Page 1606: ...100 RM449U REAR WHEEL HUB BOLT REPLACEMENT 1 REMOVE REAR WHEEL AND BRAKE DRUM 2 REMOVE HUB BOLT Using SST remove the hub bolt SST 09650 17011 3 INSTALL HUB BOLT Hold the axle shaft using plate washer...

Page 1607: ...SA0I2 08 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER SA 137 1576 Author Date 1996 TOYOTA T100 RM449U REAR DIFFERENTIAL CARRIER COMPONENTS...

Page 1608: ...SA 138 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER 1577 Author Date 1996 TOYOTA T100 RM449U...

Page 1609: ...ID GEAR OIL 2 REMOVE REAR AXLE SHAFTS See page SA 131 3 REMOVE PROPELLER SHAFT 2WD See page PR 3 4WD See page PR 11 4 REMOVE DIFFERENTIAL CARRIER ASSEMBLY a Remove the 10 nuts washers and differential...

Page 1610: ...nout 0 05 mm 0 0020 in 3 CHECK RING GEAR BACKLASH Using a dial indicator measure the ring gear backlash Backlash 2WD 0 08 0 13 mm 0 0031 0 0051 in 4WD 0 13 0 18 mm 0 0051 0 0071 in If the backlash is...

Page 1611: ...sing SST remove the companion flange SST 09950 30010 7 REMOVE FRONT OIL SEAL Using SST remove the oil seal from the differential carrier SST 09308 10010 8 REMOVE FRONT BEARING AND BEARING SPECER a Usi...

Page 1612: ...REMOVE DRIVE PINION REAR BEARING Using SST and a press remove the bearing from the drive pin ion SST 09950 00020 HINT If the drive pinion or ring gear are damaged replace them as a set 12 REMOVE FRONT...

Page 1613: ...ut 0 04 mm 0 0016 in c Remove the differential case 15 REMOVE SIDE BEARINGS Using SST remove the 2 side bearings from the differential case SST 09950 40010 09950 60010 09951 00450 HINT Fix the claws o...

Page 1614: ...N AND AXLE REAR DIFFERENTIAL CARRIER 1996 TOYOTA T100 RM449U REPLACEMENT REPLACE COMPANION FLANGE DUST DEFLECTOR a Using SST and a press remove the dust deflector SST 09950 00020 b Using SST and a pre...

Page 1615: ...630 1 85 0 0728 1 65 0 0650 1 90 0 0748 1 70 0 0669 b Install the 2 side gears with the thrust washers pinion gears pinion gear thrust washers and pinion shaft HINT Align the holes of the differential...

Page 1616: ...matchmarks on the ring gear and differential case f After the ring gear cools down enough torque the set bolts to which thread lock has been applied Thread lock Part No 08833 00100 THREE BOND 1360K o...

Page 1617: ...PINION PRELOAD a Install the drive pinion and front bearing HINT Assemble the spacer washers and oil seal after adjusting the gear contact pattern b Using SST install the companion flange SST 09950 30...

Page 1618: ...on the ring gear back side HINT Makes that the ring gear has a backlash b Tap on the ring gear with a plastic hammer so that the washer fit to the bearing c Using a dial indicator measure the side ge...

Page 1619: ...hickness of washers on both sides by an equal amount HINT S There should be no clearance between the plate washer and case S Make sure that there is ring gear backlash 10 ADJUST SIDE BEARING PRELOAD a...

Page 1620: ...13 40 3 40 0 1339 78 2 78 0 1094 10 3 10 0 1220 42 3 42 0 1346 80 2 80 0 1102 12 3 12 0 1228 44 3 44 0 1354 82 2 82 0 1110 14 3 14 0 1236 46 3 46 0 1362 84 2 84 0 1118 16 3 16 0 1244 48 3 48 0 1370 86...

Page 1621: ...ness Mark mm in Thickness Mark mm in 87 1 87 0 0736 01 2 01 0 0791 15 2 15 0 0846 88 1 88 0 0740 02 2 02 0 0795 16 2 16 0 0850 89 1 89 0 0744 03 2 03 0 0799 17 2 17 0 0854 90 1 90 0 0748 04 2 04 0 080...

Page 1622: ...ial carrier end SST 09316 12010 09649 17010 HINT Connect SST with vinyl tape 18 INSTALL COMPANION FLANGE a Install the companion flange on the shaft b Coat the threads of a new nut with hypoid gear oi...

Page 1623: ...bearing spacer and repeat the preload adjusting pro cedure Do not loosen the pinion nut to reduce the preload 20 INSTALL DIFFERENTIAL CASE IN CARRIER See page SA 145 21 RECHECK TOTAL PRELOAD See page...

Page 1624: ...bly in the axle housing Torque 73 N m 740 kgf cm 54 ft lbf 3 INSTALL PROPELLER SHAFT 2WD See page PR 9 4WD See page PR 16 4 INSTALL REAR AXLE SHAFTS See page SA 135 5 FILL DIFFERENTIAL WITH DIFFERENTI...

Page 1625: ...I8 07 W00408 Retainer Bushing Retainer Rear Shock Absorber Retainer Bushing Retainer SUSPENSION AND AXLE REAR SHOCK ABSORBER SA 155 1594 Author Date 1996 TOYOTA T100 RM449U REAR SHOCK ABSORBER COMPONE...

Page 1626: ...RT BODY WITH STANDS a Jack up and support the body on stands b Lower the axle housing until the leaf spring tension is free and keep it at this position 2 REMOVE REAR SHOCK ABSORBER a Remove the 2 rea...

Page 1627: ...SPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds If there is any abnormality replace the shock abso...

Page 1628: ...in SA 158 SUSPENSION AND AXLE REAR SHOCK ABSORBER 1996 TOYOTA T100 RM449U DISPOSAL 1 FULLY EXTEND SHOCK ABSORBER ROD 2 DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill make a hole in the cylinder...

Page 1629: ...SA0IC 01 SUSPENSION AND AXLE REAR SHOCK ABSORBER SA 159 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 156...

Page 1630: ...SA0ID 02 SA 160 SUSPENSION AND AXLE REAR LEAF SPRING 1599 Author Date 1996 TOYOTA T100 RM449U REAR LEAF SPRING COMPONENTS...

Page 1631: ...SUSPENSION AND AXLE REAR LEAF SPRING SA 161 1600 Author Date 1996 TOYOTA T100 RM449U...

Page 1632: ...from the spring seat Torque 26 N m 260 kgf cm 19 ft lbf 5 REMOVE U BOLTS a Remove the 4 U bolt mounting nuts and washer Torque 132 N m 1 350 kgf cm 97 ft lbf b Remove the spring seat and 2 retainers...

Page 1633: ...6 TOYOTA T100 RM449U d Remove the 2 shackle pin mounting nuts and washers Torque 91 N m 930 kgf cm 67 ft lbf HINT At the time of installation after stabilizing the suspension torque the nut e Remove t...

Page 1634: ...el and hammer pry up the spring clip b Remove the center bolt Hold the spring near the center bolt in a vise and remove the center bolt c Replace the spring clip 1 Drill off the head of the rivet and...

Page 1635: ...m 1 050 kgf cm 76 ft lbf b Remove spring bumper 1 STD 0 5 ton Extra cab Remove the 2 bolts spring bumper and spacers Torque 29 N m 300 kgf cm 22 ft lbf HINT At the time of installation install the spa...

Page 1636: ...SA0IG 01 SA 166 SUSPENSION AND AXLE REAR LEAF SPRING 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page SA 162...

Page 1637: ...ER BR 9 BRAKE BOOSTER ASSEMBLY BR 17 FRONT BRAKE PAD 2WD BR 21 FRONT BRAKE PAD 4WD BR 24 FRONT BRAKE CALIPER 2WD BR 26 FRONT BRAKE CALIPER 4WD BR 33 REAR DRUM BRAKE 2WD BR 39 REAR DRUM BRAKE 4WD BR 44...

Page 1638: ...rly as it could affect the performance of the brake system and result in a driving hazard Replace the parts with parts having the same part number or equivalent S It is very important to keep parts an...

Page 1639: ...R 4 BR 26 BR 33 BR 39 BR 44 BR 9 BR 20 Brake drag 1 Brake pedal freeplay Minimum 2 Parking brake lever travel Out of adjustment 3 Parking brake wire Sticking 4 Rear brake shoe clearance Out of adjustm...

Page 1640: ...or booster system DI 362 BR 4 BR 26 BR 33 BR 39 BR 44 BR 26 BR 33 BR 39 BR 44 BR 39 BR 44 BR 26 BR 33 BR 39 BR 44 BR 26 BR 33 BR 39 BR 44 BR 26 BR 33 BR 20 BR 17 Noise from brakes 1 Pad or lining Crac...

Page 1641: ...if necessary 2 BLEED MASTER CYLINDER HINT If the master cylinder was disassembled or if the reservoir be comes empty bleed the air from the master cylinder a Disconnect the brake lines from the master...

Page 1642: ...sistant depresses the pedal loosen the bleeder plug until fluid starts to run out Then close the bleeder plug Torque bleeder plug 11 N m 110 kgf cm 8 ft lbf c Repeat this procedure until there are no...

Page 1643: ...djust the pedal height by turning the pedal push rod e Tighten the push rod lock nut Torque 25 N m 260 kgf cm 19 ft lbf f Install the stop light switch and turn it until it lightly con tacts the pedal...

Page 1644: ...n in the il lustration Pedal freeplay 3 6 mm 0 12 0 24 in HINT The freeplay to the 1st resistance is due to the play between the clevis and pin This is magnified up to 1 3 mm 0 04 0 12 in at the pedal...

Page 1645: ...rear brake shoe clearance has been adjusted a Tighten the adjusting nut until the travel is correct Then tighten the lock nut b After adjusting the parking brake confirm that the rear brakes are not...

Page 1646: ...et Clamp z Non reusable part Check Valve Bracket z Gasket Brake Booster Clamp 3 Way Union N m kgf cm ft lbf Specified torque 15 155 11 13 130 9 13 130 9 15 155 11 Master Cylinder BRAKE BRAKE MASTER CY...

Page 1647: ...iston and Spring Boot Snap Ring No 2 Piston and Spring No 2 Piston and Spring Piston Stopper Bolt zGasket Cylinder Body Cylinder Body Reservoir Set Screw Grommet Lithium soap base glycol grease Non re...

Page 1648: ...luid remain on a painted surface Wash it off immediately 3 DISCONNECT BRAKE LINES Using SST disconnect the brake lines from the master cylinder and 3 way union SST 09751 36011 4 REMOVE MASTER CYLINDER...

Page 1649: ...voir 3 REMOVE 2 GROMMETS 4 PLACE CYLINDER IN VISE 5 REMOVE PISTON STOPPER BOLT Using a screwdriver push the pistons in all the way and remove the piston stopper bolt and gasket HINT Tape the screwdriv...

Page 1650: ...RM449U c Place a rag and 2 wooden blocks on the work table and lightly tap the cylinder flange against the block edges until the No 2 piston drops out of cylinder HINT Make sure the distance A from t...

Page 1651: ...ASTER CYLINDER 1996 TOYOTA T100 RM449U INSPECTION HINT Clean the disassembled parts with compressed air 1 INSPECT CYLINDER BORE FOR RUST OR SCORING 2 INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary c...

Page 1652: ...STER CYLINDER BR 15 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 12 NOTICE Apply lithium soap base glycol grease to the rubber parts indicated by th...

Page 1653: ...tion is in the reverse order of removal See page BR 11 1 BEFORE INSTALLATION ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD See page BR 20 2 AFTER INSTALLATION FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED...

Page 1654: ...the brake pedal and start engine If the pedal goes down slightly operation is normal 2 AIR TIGHTNESS CHECK a Start the engine and stop it after 1 or 2 minutes Depress the brake pedal several times slo...

Page 1655: ...er zNon reusable part 3 Way Union Brake Booster zGasket Clevis Clip Clevis Pin Clamp zGasket N m kgf cm ft lbf Specified torque 15 155 11 13 130 9 25 260 19 13 130 9 BR 18 BRAKE BRAKE BOOSTER ASSEMBLY...

Page 1656: ...OTA T100 RM449U REMOVAL 1 REMOVE MASTER CYLINDER See page BR 11 2 DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 3 REMOVE PEDAL RETURN SPRING 4 REMOVE CLIP AND CLEVIS PIN 5 REMOVE BRAKE BOOSTER a Remove th...

Page 1657: ...r b Set the SST on the gasket and lower the pin until its tip slightly touches the piston SST 09737 00010 c Turn the SST upside down and set it on the booster SST 09737 00010 d Measure the clearance b...

Page 1658: ...Sliding Bushing Brake Caliper Dust Boot Set Ring Torque Plate Piston Piston Seal Boot Gasket z Anti Squeal Shim z z Gasket z Brake Caliper Piston Seal Piston Boot Dust Boot z Bleeder Plug Torque Plate...

Page 1659: ...ake pads S 2 1 ton 4 0 5 ton anti squeal shims S 2 pad wear indicator plates S 4 pad support plates NOTICE The anti squeal springs 1 ton and support plates can be used again provided that they have su...

Page 1660: ...d from the reservoir b Press in piston with a hammer handle or equivalent HINT If the piston is difficult to push in loosen the bleeder plug and push in the piston while letting some brake fluid escap...

Page 1661: ...im Anti Squeal Shim Inner Pad Anti Squeal Spring Pin Clip Brake Caliper Piston Seal Piston Boot Set Ring Disc Piston Seal Piston Boot Set Ring Lithium soap base glycol grease Pad Wear Indicator Plate...

Page 1662: ...AND RUNOUT See page BR 36 5 INSTALL NEW PADS NOTICE When replacing worn pads the anti squeal shims must be replaced together with the pads a Draw out a small amount of brake fluid from the reservoir...

Page 1663: ...liper Piston Seal Piston Torque Plate Pad Anti Squeal Shim Pad Support Plate Boot Set Ring Boot Pad Support Plate zGasket Sliding Pin Inner Anti Squeal Shim Pad Wear Indicator Plate Non reusable part...

Page 1664: ...refer to the following item For correct brake hose routing ensure that the hose hangs down before installing hose to caliper b Use a container to catch the brake fluid 2 REMOVE CALIPER FROM TORQUE PL...

Page 1665: ...NT At the time of reassembly please refer to the following item Use 2 socket wrenches and a vise press in new dust boots 2 REMOVE CYLINDER BOOT SET RING 1 ton AND CYLINDER BOOT Using a screwdriver rem...

Page 1666: ...b Using a screwdriver and hammer tap out the 2 dust boots HINT At the time of reassembly please refer to the following item Using a 19 mm socket and hammer tap in 2 new dust boots into the torque plat...

Page 1667: ...at the minimum thickness or less Replace the disc or grind it on a lathe if it is scored or is worn unevenly 3 MEASURE DISC RUNOUT Using a dial indicator measure the disc runout 10 mm 0 39 in from the...

Page 1668: ...BRAKE CALIPER 2WD BR 31 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 28 NOTICE Apply lithium soap base glycol grease to the parts indicated by the a...

Page 1669: ...BRAKE CALIPER 2WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page BR 34 1 AFTER INSTALLATION FILL BRAKE RESERVOIR BRAKE FLUID AND BLEED BRAKE SYSTEM See p...

Page 1670: ...pring Anti Squeal Shim Clip Set Ring Boot Piston Piston Seal Anti Squeal Shim Brake Caliper Inner Pad Outer Pad Pad Wear Lithium soap base glycol grease Disc brake grease N m kgf cm ft lbf 15 155 11 1...

Page 1671: ...AKE LINE Using SST disconnect the brake line Use a container to catch the brake fluid SST 09751 36011 Torque 15 N m 155 kgf cm 11 ft lbf 3 REMOVE CALIPER Remove the 2 mounting bolts and remove the cal...

Page 1672: ...he 4 cylinder boot set rings and 4 boots 2 REMOVE PISTONS FROM CYLINDER a Prepare the wooden plate to hold the pistons b Place the plate between the pistons and insert a pad at one side c Use compress...

Page 1673: ...m thickness 23 0 mm 0 906 in Replace the disc if the thickness of the disc is at the minimum thickness or less Replace the disc or grind it on a lathe if it is scored or is worn unevenly 3 MEASURE DIS...

Page 1674: ...BRAKE CALIPER 4WD BR 37 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 35 NOTICE Apply lithium soap base glycol grease to the parts indicated by the a...

Page 1675: ...BRAKE CALIPER 4WD 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page BR 34 1 AFTER INSTALLATION FILL BRAKE RESERVOIR BRAKE FLUID AND BLEED BRAKE SYSTEM See p...

Page 1676: ...ng Cup Adjusting Lever Spring Spring zGasket Anchor Spring Shoe Hold Down Spring Return Spring Adjuster Pin z Lithium soap base glycol grease High temperature grease Non reusable part N m kgf cm ft lb...

Page 1677: ...the backing plate b Insert a screwdriver through the hole in the backing plate and hold the automatic adjusting lever away from the ad justing bolt c Using another screwdriver reduce the brake shoe ad...

Page 1678: ...ER a Remove the E ring b Remove the automatic adjusting lever c Remove the C washer d Remove the parking brake lever 7 REMOVE WHEEL CYLINDER a Using SST disconnect the brake line from the cylinder Use...

Page 1679: ...replace the brake shoes HINT If any of the brake shoes have to be replaced replace all of the rear brake shoes in order to maintain even braking 3 MEASURE BRAKE DRUM INSIDE DIAMETER Using a vernier ca...

Page 1680: ...the adjuster does not turn check for incorrect installation of the rear brakes b Adjust the adjuster length to the shortest possible amount c Install the drum d Pull the parking brake lever all the w...

Page 1681: ...ing Brake Cable No 1 Dust Cover Bellcrank No 3 Adjuster Return Spring Anchor Spring Automatic Adjusting Lever Cup E Ring Front Shoe zGasket Brake Drum Inspection Hole plug Pin High temperature grease...

Page 1682: ...d hold the automatic adjusting lever away from the ad justing bolt c Using another screwdriver reduce the brake shoe adjust ment by turning the adjusting bolt 4 REMOVE REAR SHOE a Using SST disconnect...

Page 1683: ...he parking brake lever 8 REMOVE AND DISASSEMBLE PARKING BRAKE BELLCRANK a Remove the clip and disconnect the parking brake cable b Remove the tension spring c Using a screwdriver remove the bellcrank...

Page 1684: ...nect the brake line Use a container to catch the brake fluid SST 09751 36011 Torque 15 N m 155 kgf cm 11 ft lbf b Remove the 2 bolts and the wheel cylinder Torque 10 N m 100 kgf cm 7 ft lbf 10 DISASSE...

Page 1685: ...lace the brake shoes HINT If any of the brake shoes have to be replaced replace all of the rear brake shoes in order to maintain even braking 3 MEASURE BRAKE DRUM INSIDE DIAMETER Using vernier caliper...

Page 1686: ...sting bolt with the lock nut d Connect the parking brake cable to the parking brake bell crank and install the clip e Install the tension spring 2 CHECK OPERATION OF AUTOMATIC ADJUSTING MECHANISM a Mo...

Page 1687: ...b 0 5 ton opt soft ride 850 kg 1 874 lb 4WD 1 050 kg 2 315 lb 2 INSTALL LSPV GAUGE SST AND BLEED AIR SST 09709 29017 3 RAISE FRONT BRAKE PRESSURE TO 7 845 kPa 80 kgf cm2 1 138 psi AND CHECK REAR BRAKE...

Page 1688: ...WD shown for 4WD refer to component illustration on next page Low pressure Lower body High pressure Raise body e Torque the nuts Torque 13 N m 130 kgf cm 9 ft lbf f Adjust the length of the No 2 shack...

Page 1689: ...Plate 2WD Only Clip Plate Washer Shackle No 1 Plate Washer Non reusable part Load Sensing Valve Boot Rubber Plate Collar Load Sensing Spring Boot Bushing Bushing Bushing Load Sensing Spring 15 155 11...

Page 1690: ...CONNECT SHACKLE NO 2 FROM BRACKET a Remove the cotter pin b Remove the nut and cushion retainer and disconnect the shackle No 2 c Remove the 2 bushings and collar 2 REMOVE LSP BV ASSEMBLY a Using SST...

Page 1691: ...ing item Finger tighten the valve body mounting nuts 2 DISCONNECT SPRING FROM VALVE Using pliers remove the clip and the spring from the valve 3 REMOVE SHACKLES NO 1 AND NO 2 a Remove the nuts and bol...

Page 1692: ...5 Wear Limit 0 7 mm BRAKE LOAD SENSING PROPORTIONING AND BY PASS VALVE LSP BV BR 55 1996 TOYOTA T100 RM449U INSPECTION INSPECT VALVE PISTON PIN AND LOAD SENSING CON TACT SURFACE FOR WEAR Wear limit 0...

Page 1693: ...BR09W 01 BR 56 BRAKE LOAD SENSING PROPORTIONING AND BY PASS VALVE LSP BV 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 54...

Page 1694: ...lbf c Connect the shackle No 2 to the shackle bracket Torque 13 N m 130 kgf cm 9 ft lbf d Install a new cotter pin 4 SET REAR AXLE LOAD See page BR 50 5 SET VALVE BODY a When pulling down the load se...

Page 1695: ...re harness through the sub wire harness C and E SST as shown in the illustration SST 09990 00150 09990 00200 09990 00210 b Connect the red cable of the checker to the battery posi tive terminal and bl...

Page 1696: ...d in the MOTOR switch for a few seconds j Depress the brake pedal and hold it for about 15 seconds As you hold the pedal down push the MOTOR switch for a few seconds Check that the brake pedal does no...

Page 1697: ...the brake pedal h Push and hold in the MOTOR switch for a few seconds i Depress the brake pedal and hold it for about 15 seconds As you hold the pedal down push the MOTOR switch for a few seconds Chec...

Page 1698: ...BR09Z 02 F14858 BRAKE ABS ACTUATOR BR 61 1996 TOYOTA T100 RM449U COMPONENTS...

Page 1699: ...que 15 N m 155 kgf cm 11 ft lbf 2 REMOVE ABS ACTUATOR ASSEMBLY a Disconnect the 2 connectors from the actuator b Remove the 2 bolts 2 nuts and ABS actuator assembly Torque 19 N m 195 kgf cm 14 ft lbf...

Page 1700: ...TUATOR BR 63 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page BR 62 1 AFTER INSTALLATION FILL BRAKE RESERVOIR BRAKE FLUID AND BLEED BRAKE SYSTEM See page B...

Page 1701: ...sor Sensor Rotor N m kgf cm ft lbf Specified torque 5 0 51 44 in lbf 8 0 82 71in lbf Speed Sensor 8 0 82 71in lbf 5 0 51 44 in lbf BR 64 BRAKE FRONT SPEED SENSOR 1669 Author Date 1996 TOYOTA T100 RM44...

Page 1702: ...PEED SENSOR a 4WD Remove the 3 clamp bolts holding the sensor harness from the frame upper arm and steering knuckle b 2WD Remove the 2 clamp bolts holding the sensor harness from the frame and upper a...

Page 1703: ...BR0A4 03 BR 66 BRAKE FRONT SPEED SENSOR 1996 TOYOTA T100 RM449U INSTALLATION Installation is reverse in the order of removal See page BR 65 AFTER INSTALLATION CHECK SPEED SENSOR SIGNAL See page DI 341...

Page 1704: ...R0A5 04 R14755 Speed Sensor Sensor Rotor N m kgf cm ft lbf Specified torque 13 130 9 8 0 82 71 in lbf BRAKE REAR SPEED SENSOR BR 67 1672 Author Date 1996 TOYOTA T100 RM449U REAR SPEED SENSOR COMPONENT...

Page 1705: ...nd the fuel tank HINT S When installing the rear sensor wire harness never use the removed resin clips which are service parts S When replacing clips set up new resin clips at the same angle of the re...

Page 1706: ...BR0A7 03 BRAKE REAR SPEED SENSOR BR 69 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page BR 68 AFTER INSTALLATION CHECK SPEED SENSOR SIGNAL See page DI 341...

Page 1707: ...LUID SR 4 AIR CONTROL VALVE SR 8 STEERING WHEEL SR 9 NON TILT STEERING COLUMN SR 10 TILT STEERING COLUMN SR 23 POWER STEERING VANE PUMP 3RZ FE SR 34 POWER STEERING VANE PUMP 5VZ FE SR 44 POWER STEERIN...

Page 1708: ...lt in a driving hazard S The TOYOTA T100 is equipped with SRS Supplemental Restraint System such as the driver airbag Failure to carry out service operation in the correct sequence could cause the SRS...

Page 1709: ...Steering system joints Worn 6 Suspension arm ball joints 7 Steering column Binding 8 Power steering gear SA 3 SA 5 SR 5 SR 3 SA 7 SA 10 SA 109 SA 113 SA 117 SA 121 SR 54 SR 72 Poor return 1 Tires Imp...

Page 1710: ...20 95506 00020 Borroughs No BT 33 73F 3RZ FE Engine Drive belt tension New belt 135 185 lbf Used belt 80 120 lbf 5VZ FE Engine Drive belt tension New belt 135 180 lbf Used belt 85 120 lbf If the best...

Page 1711: ...al times 4 LOWER VEHICLE 5 START ENGINE Run the engine at idle for a few minutes 6 TURN STEERING WHEEL a With the engine idling turn the wheel to left or right full lock and keep it there for 2 3 seco...

Page 1712: ...r cap dipstick If the fluid is cold check that it is within the COLD LEVEL range c Start the engine and run it at idle d Turn the steering wheel from lock to lock several times to boost fluid temperat...

Page 1713: ...air cleaner assembly b Disconnect the pressure feed tube from the PS vane pump 3RZ FE Engine See page SR 36 5VZ FE Engine See page SR 46 c Connect SST as shown bellow SST 09640 10010 09641 01010 09641...

Page 1714: ...h h With the engine idling open the valve fully i Measure the fluid pressure at engine speeds of 1 000 rpm and 3 000 rpm 3RZ FE and 5VZ FE Engines Difference fluid pressure 490 kPa 5 kgf cm2 71 psi or...

Page 1715: ...IR CONTROL VALVE INSPECTION 1 TURN AIR CONDITIONING SWITCH OFF 2 CHECK IDLE UP a Start the engine and run it at idle b Fully turn the steering wheel c Check that the engine rpm decreases when the vacu...

Page 1716: ...to de crease steering wheel freeplay and counterclockwise to increase it HINT Turn the adjusting screw in small increments and check the freeplay between each adjustment d Turn the steering wheel hal...

Page 1717: ...Control Rheostat Front Door Scuff Plate Sliding w Shaft York Sub Assembly Lower Finish Panel No 1 Intermediate Shaft Assembly Engine Hood Release Lever Duct Heater to Register No 2 Intermediate Shaft...

Page 1718: ...over Steering Column Assembly Column Hole Cover x7 Engine Hood Release Lever Lower Finish Panel No 1 Sliding w Shaft York Sub Assembly Intermediate Shaft Assembly Duct Heater to Register No 2 Cowl Sid...

Page 1719: ...Column Tube Key Unlock Warning Switch Ignition Switch z Bushing Column Upper Clamp z Tapered Head Bolt z Snap Ring Main Shaft Assembly Non reusable part Molybdenum disulfide lithium base grease z 35 3...

Page 1720: ...2 and No 3 covers c Using a torx socket wrench loosen the 2 torx screws HINT Loosen the 2 screws until the groove along the screw circumfer ence catches on the screw case d Pull the wheel pad out fro...

Page 1721: ...plate c Remove the clip and cowl side trim d Remove the 4 panel set bolts e Remove the light control rheostat and lock nut 6 REMOVE DUCT HEATER TO REGISTER NO 2 Remove the screw 7 REMOVE COMBINATION S...

Page 1722: ...m gear valve shaft c Remove the bolt A B and C 11 REMOVE INTERMEDIATE SHAFT ASSEMBLY AND SLIDING w SHAFT YORK SUB ASSEMBLY 12 A T REMOVE STEERING COLUMN ASSEMBLY a Remove the locking wire b Remove the...

Page 1723: ...MP a Using a centering punch mark the center of the 2 ta pered head bolts b Using a 3 4 mm 0 12 0 16 in drill drill into the 2 bolts c Using a screw extractor remove the 2 bolts 2 REMOVE MAIN SHAFT AS...

Page 1724: ...WITCH AND KEY UNLOCK WARNING SWITCH See page BE 12 4 IF NECESSARY REPLACE IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH a Remove the 3 screws b Install a new switches with the 3 screws 5 INSPECT BEARI...

Page 1725: ...ILT STEERING COLUMN 1996 TOYOTA T100 RM449U d Align the holes of the tube and the projections of the bush ing and install the bushing into the column tube column lower tube e TILT STEERING COLUMN Inst...

Page 1726: ...LL MAIN SHAFT ASSEMBLY a Using a snap ring expander install a new snap ring to the shaft assembly b Install the shaft assembly into the column tube c Using a snap ring expander install a new snap ring...

Page 1727: ...INSTALL STEERING COLUMN ASSEMBLY Torque the 2 steering column assembly set bolts and nuts Torque 25 N m 260 kgf cm 19 ft lbf 3 INSTALL INTERMEDIATE SHAFT ASSEMBLY AND SLIDING w SHAFT YORK SUB ASSEMBL...

Page 1728: ...R COLUMN COVERS Install the 7 screws 14 CENTER SPIRAL CABLE a Check that the front wheels are facing straight ahead b Turn the spiral counterclockwise by hand until it becomes harder to turn the cable...

Page 1729: ...a Connect the airbag connector b Install the wheel pad after confirming that the circumfer ence groove of the torx screws is caught on the screw case c Using a torx wrench torque the 2 screws Torque 9...

Page 1730: ...Column Hole Sliding w Shaft York Sub Assembly Lower Finish Panel No 1 Engine Hood Release Intermediate Shaft Assembly Register No 2 Duct Heater to Plate Pad Lever Cover Wire Cover Lever AT For 2WD In...

Page 1731: ...w Shaft York Sub Assembly Lower Finish Panel No 1 Column Hole Cover Column Upper Torx Screw Steering Wheel Lower No 2 Cover Intermediate Engine Hood Release Shaft Assembly Duct Heater to Register No...

Page 1732: ...on Switch z E ring Bolt Tilt No 2 Bushing Tension Spring Key Unlock Warning Switch Ignition Switch Column Upper Bracket Column Lower Tilt Lever Ratainer z E ring Tension Speing Tilt No 2 Bolt Tube z B...

Page 1733: ...SR07D 01 SR 26 STEERING TILT STEERING COLUMN 1996 TOYOTA T100 RM449U REMOVAL See page SR 13...

Page 1734: ...MOVE 2 TILT LEVER RETAINERS a Remove the E ring from the tilt lever lock shaft b Remove the nut and retainer 6 REMOVE 2 TILT PAWL STOPPERS 7 REMOVE 2 TILT PAWLS a Remove the tilt lever assembly set bo...

Page 1735: ...sion spring SST 09950 40010 09957 04010 09958 04010 NOTICE Do not bend the universal joint of the main shaft more than 20 b Using a snap ring expander remove the snap ring from the shaft assembly c Re...

Page 1736: ...SR07F 01 STEERING TILT STEERING COLUMN SR 29 1996 TOYOTA T100 RM449U INSPECTION See page SR 17...

Page 1737: ...ing a snap ring expander install a new snap ring 3 INSTALL TURN SIGNAL BRACKET Torque the 2 bolts Torque 7 8 N m 80 kgf cm 69 in lbf 4 SELECT 2 TILT NO 2 BOLTS Select the bolt with the hollow tipped t...

Page 1738: ...the 2 pawl stoppers b Check that the alignment marks on the stopper and pawl align when the stopper is lightly rotated to the pawl side c If the alignment marks are not align select pawl stopper acco...

Page 1739: ...reak off 15 INSTALL SLIDING YORK SUB ASSEMBLY a Align the matchmarks on the sliding york and main shaft b Torque the bolt Torque 35 N m 360 kgf cm 26 ft lbf 16 CHECK TILT STEERING OPERATION a Check th...

Page 1740: ...SR07H 01 STEERING TILT STEERING COLUMN SR 33 1996 TOYOTA T100 RM449U INSTALLATION See page SR 20...

Page 1741: ...ket Belt Adjusting Bolt Drive Belt Power Steering Idle Pulley z z Non reusable part 39 400 29 Specified torque N m kgf cm ft lbf 47 475 34 39 400 29 SR07I 01 SR 34 STEERING POWER STEERING VANE PUMP 3R...

Page 1742: ...ng z Bearing z Snap Ring z Oil Seal z O Ring z O Ring z Gasket z Straight Pin Side Plate Cam Ring Vane Plate Non reusable part Power Steering fluid z O Ring z z Vane Pump Rotor 43 440 32 13 130 9 24 2...

Page 1743: ...r steering idle pulley set bolt b Loosen the belt adjusting bolt 2 DISCONNECT PRESSURE FEED TUBE Using a spanner 24 mm to hold the pressure port union re move the union bolt and the 2 gaskets 3 DISCON...

Page 1744: ...e the O ring from the oil reservoir 4 REMOVE PRESSURE PORT UNION FLOW CONTROL VALVE AND SPRING Remove the O ring from the union 5 REMOVE REAR HOUSING a Remove the 2 bolts and rear housing b Remove the...

Page 1745: ...ure the height thickness and length of the 10 plates Minimum height 8 6 mm 0 339 in Minimum thickness 1 397 mm 0 05500 in Minimum length 14 991 mm 0 59020 in b Using a feeler gauge measure the clearan...

Page 1746: ...a 4 5 kgf cm2 57 71 psi into the opposite side and confirm that air does not come out from the end hole If necessary replace the valve with one having the same letter on the front housing Inscribed ma...

Page 1747: ...facing the correct direction 6 IF NECESSARY REPLACE BEARING a Press out the bearing from the vane pump shaft b Using a snap ring expander remove the snap ring from the shaft NOTICE Be careful not to d...

Page 1748: ...the front housing NOTICE Be careful not to damage the pins 4 INSTALL CAM RING Install the ring with the inscribed mark facing outward 5 INSTALL VANE PUMP ROTOR a Install the rotor with the inscribed m...

Page 1749: ...ion Torque 83 N m 850 kgf cm 61 ft lbf 11 INSTALL OIL RESERVOIR a Coat a new O ring with power steering fluid and install it to the oil reservoir b Install the oil reservoir with the 3 bolts Torque Fr...

Page 1750: ...CT PRESSURE FEED TUBE Torque the union bolt with a new gasket on each side of the tube Torque 47 N m 475 kgf cm 34 ft lbf HINT Make sure the stopper of the tube is touching the PS pump body as shown t...

Page 1751: ...F14897 SR07O 02 SR 44 STEERING POWER STEERING VANE PUMP 5VZ FE 1718 Author Date 1996 TOYOTA T100 RM449U POWER STEERING VANE PUMP 5VZ FE COMPONENTS...

Page 1752: ...aft Vane Pump Pulley Wave Washer Side Plate Cam Ring x10 Vane Plate Non reusable part z z O Ring z O Ring z Power steering fluid z Straight Pin z Oil Seal z Snap Ring 43 440 32 13 130 9 24 240 17 24 2...

Page 1753: ...Take care not to spill fluid on the drive belt 3 DISCONNECT PRESSURE FEED TUBE a Disconnect the connector from the oil pressure switch b Remove the oil pressure switch from the pressure feed tube c R...

Page 1754: ...10 09962 01000 09963 01000 3 REMOVE OIL RESERVOIR a Remove the 3 bolts and oil reservoir b Remove the O ring from the oil reservoir 4 REMOVE PRESSURE PORT UNION FLOW CONTROL VALVE AND SPRING Remove th...

Page 1755: ...measure the oil clear ance Standard clearance 0 003 0 005 mm 0 0012 0 0020 in Maximum clearance 0 07 mm 0 0028 in If it is more than maximum replace the front housing and vane pump shaft 2 INSPECT VAN...

Page 1756: ...0 59051 0 59059 1 44345 26020 14 997 14 999 0 59043 0 59051 2 44345 26030 14 995 14 997 0 59035 0 59043 3 44345 26040 14 993 14 995 0 59027 0 59035 4 44345 26050 14 991 14 993 0 59020 0 59027 3 INSPE...

Page 1757: ...mm 1 272 in If it is not within the specification replace the spring 5 IF NECESSARY REPLACE OIL SEAL a Using a screwdriver with vinyl tape wound around its tip remove the oil seal NOTICE Be careful no...

Page 1758: ...44 2 INSTALL STRAIGHT PINS Using a plastic hammer tap in 2 new pins to the front housing NOTICE Be careful not to damage the pins 3 INSTALL VANE PUMP SHAFT 4 INSTALL CAM RING Install the ring with th...

Page 1759: ...NTROL VALVE AND PRESSURE PORT UNION a Install the valve facing the correct direction See page SR 44 b Coat a new O ring with power steering fluid and install it to the union c Torque the union Torque...

Page 1760: ...b Torque the bolt A and nut B Torque 39 N m 400 kgf cm 29 ft lbf 3 CONNECT PRESSURE FEED TUBE a Torque the union bolt with a new gasket on each side of the tube Torque 47 N m 475 kgf cm 34 ft lbf HIN...

Page 1761: ...rommet z Non reusable part Power steering fluid z z O Ring 90 920 67 88 900 65 35 360 26 88 900 65 90 920 67 88 900 65 25 250 18 19 195 14 13 130 9 10 102 7 Specified torque N m kgf cm ft lbf For use...

Page 1762: ...Rack Guide Cap Lock Nut Spring Cap z Bearing z Self Locking Nut Rack Bushing z O Ring z Oil Seal z Wire z Claw Wash z O Ring Clip z Teflon Ring Lock Nut Rack Boot Clamp Non reusable part Precoated par...

Page 1763: ...onnect the tie rod end from the knuckle arm SST 09610 20012 5 DISCONNECT INTERMEDIATE SHAFT ASSEMBLY See page SR 13 6 DISCONNECT RETURN HOSE 7 DISCONNECT PRESSURE FEED TUBE AND REMOVE RETURN TUBE a Us...

Page 1764: ...O rings from the tube 2 SECURE PS GEAR ASSEMBLY IN VISE Using SST secure the gear assembly in a vise SST 09612 00012 3 REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS Place matchmarks on the tie rod end...

Page 1765: ...10010 NOTICE Use SST 09922 10010 in the direction shown in the illustra tion 7 REMOVE RACK GUIDE SPRING CAP Using a hexagon wrench 21 mm remove the cap 8 REMOVE RACK GUIDE SPRING AND RACK GUIDE 9 REMO...

Page 1766: ...reful not to damage the oil seal lip c Remove the oil seal from the valve assembly 14 REMOVE CYLINDER END STOPPER a Using SST turn the stopper clockwise until the wire end comes out SST 09631 10021 b...

Page 1767: ...SARY REPLACE OIL SEAL AND BEARING a Using SST tap out the oil seal and bearing from the con trol valve housing SST 09950 60010 09951 00250 09950 70010 09951 07150 b Coat a new oil seal lip with power...

Page 1768: ...10 09951 07150 e Coat a new bearing with molybdenum disulfide lithunm base grease f Using SST press in the bearing SST 09950 60010 09951 00310 09950 70010 09951 07150 4 IF NECESSARY REPLACE OIL SEAL a...

Page 1769: ...r steering fluid and install it c Expand a new teflon ring with your fingers NOTICE Be careful not to overexpand the ring d Coat the ring with power steering fluid e Install the ring to the rack and s...

Page 1770: ...63 1996 TOYOTA T100 RM449U d Install the expanded teflon rings to the control valve and snug them down with your fingers e Carefully slide the tapered end of SST over the rings to seat the rings SST...

Page 1771: ...0010 09951 07360 NOTICE S Make sure to install the oil seal facing the correct direction S Take care that the oil seal does not get reversed as you install it 3 INSTALL STEERING RACK HINT If necessary...

Page 1772: ...sing SST turn the cylinder end stopper clockwise until the wire end disappears SST 09631 10021 6 AIR TIGHTNESS TEST a Install SST to the rack housing SST 09631 12071 b Apply 53 3 kPa 400 mmHg 15 75 in...

Page 1773: ...OCTITE 242 or equivalent b Install the rack housing cap Torque 69 N m 700 kgf cm 51 ft lbf c Using a center punch stake the cap at 2 places 13 INSTALL RACK GUIDE RACK GUIDE SPRING AND RACK GUIDE SPRIN...

Page 1774: ...he rack guide spring cap approximately 60 f Using SST rotate the control valve assembly to operate the steering rack 2 or 3 times through its full stroke SST 09616 00010 g Firmly fix the dial indicato...

Page 1775: ...y SST and torque wrench with 5 4 N m 55 kgf cm 48 in lbf of torque applied SST 09922 10010 NOTICE Use SST 09922 10010 in the direction shown in the illustra tion HINT Use a torque wrench with a fulcru...

Page 1776: ...orque wrench check the total preload SST 09616 00010 Preload turning 0 5 1 4 N m 5 14 kgf cm 4 3 12 2 in lbf HINT The total preload must be within the specification throughout the full stroke of the s...

Page 1777: ...clip as shown in the illustration 18 INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS a Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned b After adjusting toe in torq...

Page 1778: ...e wrench with a fulcrum length of 250 mm 9 84 in S This torque value is effective in case that SST is parallel to a torque wrench 4 CONNECT RETURN HOSE 5 CONNECT INTERMEDIATE SHAFT ASSEMBLY See page S...

Page 1779: ...tman Arm Sub Assembly With Relay Rod Spring Washer 44 450 33 36 365 26 Specified torque N m kgf cm ft lbf 35 360 26 44 450 33 36 365 26 142 1450 105 177 1800 130 SR080 01 SR 72 STEERING POWER STEERING...

Page 1780: ...nger Guide Power Steering Gear Housing Needle Roller Bearing z Union Seat z O Ring z Teflon Ring Worm Gear Valve Body Assembly Metal Spacer z Snap ring Non reusable part Power Steering fluid Molybdenu...

Page 1781: ...EL See page SR 13 4 DISCONNECT PITMAN ARM SUB ASSEMBLY WITH RELAY ROD a Remove the pitman arm set nut and spring washer b Using SST disconnect the pitman arm from the gear as sembly SST 09628 62011 5...

Page 1782: ...ver comes off c Remove the O ring from the cover 4 REMOVE SECTOR SHAFT Using a plastic hammer tap on the sector shaft end and pull out the shaft 5 REMOVE POWER PISTON PLUNGER GUIDE NUT COMPRESSION SPR...

Page 1783: ...rust clearance Standard clearance 0 03 0 05 mm 0 0012 0 0020 in Maximum clearance 0 05 mm 0 0020 in 3 IF NECESSARY ADJUST SECTOR SHAFT ADJUSTING SCREW THRUST CLEARANCE a Using a chisel and hammer unst...

Page 1784: ...enum disulfide lithium base grease g Using SST press in the bearing as shown in the illustra tion SST 09950 60010 09951 00360 09951 00420 09952 06010 09950 70010 09951 07200 h Coat a new bearing with...

Page 1785: ...951 00430 09952 06010 09950 70010 09951 07200 NOTICE Make sure to install the oil seal facing the correct direction 5 IF NECESSARY REPLACE TEFLON RING AND O RING a Using a screwdriver remove the teflo...

Page 1786: ...49U 6 IF NECESSARY REPLACE UNION SEATS a Using a screw extractor remove the 2 union seats from the worm gear valve body assembly b Using a hammer and an extension bar tap in 2 new union seats NOTICE B...

Page 1787: ...come off the worm shaft S Be careful not to damage the teflon ring c Torque the 4 bolts Torque 61 N m 620 kgf cm 45 ft lbf d Using SST and a torque wrench check the valve body as sembly rotating torqu...

Page 1788: ...nal pattern Torque 61 N m 620 kgf cm 45 ft lbf 5 DETERMINE CENTER POSITION a Using SST turn the worm gear valve body shaft so full lock in both directions and determine the exact center SST 09616 0001...

Page 1789: ...R 82 STEERING POWER STEERING GEAR 4WD 1996 TOYOTA T100 RM449U 9 CHECK TOTAL PRELOAD Using SST and a torque wrench check total preload SST 09616 00010 Total preload Turning 0 5 0 9 N m 5 9 5 kgf cm 4 3...

Page 1790: ...h 4 CONNECT PITMAN ARM SUB ASSEMBLY WITH RELAY ROD a Align the alignment marks on the pitman arm and sector shaft and connect the pitman arm b Install the spring washer and pitman arm set nut Torque 1...

Page 1791: ...mbly Relay Rod z Cotter Pin LH Tie Rod Assembly Clamp Tie Rod Clamp Clamp Tie Rod Clamp z Sub Assembly Sub Assembly RH Tie Rod z z z z z 22 225 16 22 225 16 22 225 16 22 225 16 90 920 67 177 1800 130...

Page 1792: ...rm from the relay rod SST 09611 22012 3 REMOVE LH AND RH TIE ROD ASSEMBLIE a Remove the cotter pin and nut b Using SST disconnect the tie rod assembly from the relay rod SST 09628 62011 c Remove the c...

Page 1793: ...TEERING STEERING LINKAGE 1996 TOYOTA T100 RM449U 6 REMOVE IDLER ARM ASSEMBLY a Remove the cotter pin and nut b Using SST disconnect the idler arm from the relay rod SST 09610 20012 c Remove the 3 bolt...

Page 1794: ...m 43 ft lbf 3 INSTALL RH AND LH TIE ROD SUB ASSEMBLIES TIE ROD END SUB ASSEMBLIES TIE ROD AND 2 CLAMPS a Screw the tie rod end sub assembly and tie rod sub as sembly into the tie rod HINT The tie rod...

Page 1795: ...e pitman arm and the cross shaft b Install the spring washer and pitman arm set nut Torque 177 N m 1 800 kgf cm 130 ft lbf c Connect the pitman arm to the relay rod d Install the nut and a new cotter...

Page 1796: ...Arm Bracket Non reusable part Molybdenum disulfide lithium base grease Idler Arm z Bushing z Oil Seal z z 78 800 58 Specified torque N m kgf cm ft lbf SR089 02 STEERING IDLER ARM SR 89 1763 Author Da...

Page 1797: ...SR08A 01 SR 90 STEERING IDLER ARM 1996 TOYOTA T100 RM449U REMOVAL See page SR 85...

Page 1798: ...amage the idler arm bracket 2 MEASURE IDLER ARM ROTATING TORQUE a Check that the arm rotates smoothly without abnormal noise b Using a torque wrench check the arm rotating torque Rotating torque 0 5 2...

Page 1799: ...00 3 INSTALL OIL SEAL a Coat a new oil seal lip with molybdenum disulfide lithium base grease b Install the oil seal NOTICE Make sure to install the oil seal facing the correct direction 4 INSTALL IDL...

Page 1800: ...SR08D 01 STEERING IDLER ARM SR 93 1996 TOYOTA T100 RM449U INSTALLATION See page SR 87...

Page 1801: ...RS SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG RS 1 STEERING WHEEL PAD AND SPIRAL CABLE RS 7 AIRBAG SENSOR ASSEMBLY RS 21 FRONT AIRBAG SENSOR RS 26 WIRE HARNESS AND CONNECTOR RS 31...

Page 1802: ...g sensor has been dropped or if there are cracks dents or other defects in the case bracket or connector replace them with new ones S Use a volt ohmmeter with high impedance 10 k V minimum for trouble...

Page 1803: ...hicle body side to the steering wheel 3 SRS WARNING LIGHT The SRS warning light is located on the combination meter It goes on to alert the driver of trouble in the system when a mal function is detec...

Page 1804: ...6 SRS CONNECTORS No Item Application 1 Terminal Twin Lock Mechanism Connectors 2 3 4 2 Airbag Activation Prevention Mechanism Connectors 1 3 4 3 Electrical Connection Check Mechanism Connectors 1 5 4...

Page 1805: ...ing Male Terminal Short Spring Plate RS 4 SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG 1996 TOYOTA T100 RM449U 2 Airbag Activation Prevention Mechanism Each connector contains a short spring plate When th...

Page 1806: ...T SYSTEM SRS AIRBAG RS 5 1996 TOYOTA T100 RM449U 3 Electrical Connection Check Mechanism This mechanism electrically checks if connectors are connected correctly and completely The electri cal connect...

Page 1807: ...to go on at a smaller decelera tion rate than the airbag sensor As illustrated in Fig 2 ignition is caused when current flows to the squib which happens when a safing sensor and the airbag sensor go o...

Page 1808: ...No 3 Cover No 2 Cover Torx Screw Combination Switch Lower Column Cover Lower Finish Panel No 1 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE RS 7 1774 Author Date 1996 TOYOTA T100...

Page 1809: ...RS03K 01 RS 8 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE 1996 TOYOTA T100 RM449U REMOVAL See page SR 13 or SR 33...

Page 1810: ...grooved portion 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED a Do a diagnostic system check See page DI 365 b Do a visual check which includes the following items with the steering whe...

Page 1811: ...YED a Do a diagnostic system check See page DI 365 b Do a visual check which includes the following items with the steering wheel pad with airbag removed from the ve hicle S Check for the deformation...

Page 1812: ...an undeployed airbag S The airbag produces a sizeable exploding sound when it deploys so perform the operation out of doors and where it will not create a nuisance to nearby residents S When deploying...

Page 1813: ...the red clip of the SST to the battery posi tive terminal and the black clip to the battery neg ative terminal HINT Do not connect the yellow connector which will be connected with the supplemental r...

Page 1814: ...icle 2 Press the SST activation switch and deploy the air bag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lights up d Dispose of steering wheel pad with airbag CAUT...

Page 1815: ...storing the steering wheel pad keep the upper sur face of the pad facing upward b Remove the steering wheel pad connector Remove the connector on the rear surface of the steering wheel pad from the b...

Page 1816: ...g wheel pad may come loose due to the shock when the airbag is deployed This is highly dangerous 4 Face the upper surface of the steering wheel pad upward Separately tie the left and right sides of th...

Page 1817: ...2 Move the SST to at least 10 m 33 ft away from steering wheel pad tied down on the disc wheel f Cover steering wheel pad with cardboard box or tires S Covering method using cardboard box Cover the st...

Page 1818: ...ant tires g Deploy the airbag 1 Connect the SST red clip to the battery positive terminal and the black clip to the battery negative terminal 2 Check that no one is within 10 m 33 ft area around the d...

Page 1819: ...6 TOYOTA T100 RM449U S Do not apply water etc to a steering wheel pad with deployed airbag 1 Remove the steering wheel pad from the disc wheel 2 Place the steering wheel pad in a vinyl bag tie the end...

Page 1820: ...al cable S If the airbag has been deployed S If the steering wheel pad or spiral cable has been found to be faulty in troubleshooting S If the steering wheel pad steering or spiral cable has been foun...

Page 1821: ...RS03O 01 RS 20 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE 1996 TOYOTA T100 RM449U INSTALLATION See page SR 20 or SR 33...

Page 1822: ...RS03P 03 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG SENSOR ASSEMBLY RS 21 1788 Author Date 1996 TOYOTA T100 RM449U AIRBAG SENSOR ASSEMBLY COMPONENTS...

Page 1823: ...IC termi nals are touched the IC may be destroyed by static elec tricity 1 REMOVE THESE PARTS a Lower center cover b Cruise control ECU 2 REMOVE AIRBAG SENSOR ASSEMBLY a Disconnect the connector NOTIC...

Page 1824: ...RM449U INSPECTION 1 VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check See page DI 365 2 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check See page DI 3...

Page 1825: ...cases replace the airbag sensor assembly S If the SRS has been deployed in a collision S If the airbag sensor assembly has been found to be faulty in troubleshooting S If the airbag sensor assembly ha...

Page 1826: ...t No 09042 0020 or locally manufactured tool Torque 21 N m 210 kgf cm 15 ft lbf b Connect the connector NOTICE S Installation of the connector is done with the sensor assembly installed Make sure the...

Page 1827: ...ront Airbag Sensor RH Front Airbag Sensor LH Battery Battery Carrier Air Cleaner Assembly RS 26 SUPPLEMENTAL RESTRAINT SYSTEM FRONT AIRBAG SENSOR 1793 Author Date 1996 TOYOTA T100 RM449U FRONT AIRBAG...

Page 1828: ...e SRS parts from another vehicle When replacing parts replace them with new ones S Never reuse the sensor involved in a collision when the SRS has been deployed S Never repair a sensor in order to reu...

Page 1829: ...Do a diagnostic system check See page DI 365 b If the front fender of the car or its periphery is damaged do a visually check for damage to the front airbag sensor which includes the following items e...

Page 1830: ...in a collision Replace both the left and right airbag sensors S If the front airbag sensor has been found to be faulty in troubleshooting S If the front airbag sensor has been found to be faulty duri...

Page 1831: ...ified torque S If the sensor has been dropped or there are cracks dents or other defects in the case brackets or con nector replace the removed sensor always replace the set bolts with new ones S The...

Page 1832: ...l Pad with Airbag Front Airbag Sensor RH Front Airbag Sensor LH Spiral Cable Center Airbag Sensor Assembly SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR RS 31 1798 Author Date 1996 TOYOTA T...

Page 1833: ...wire harness are encased in a yellow corrugated tube and all the connectors in the system are a standard yellow color 1 VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check See page DI 365...

Page 1834: ...found to be faulty in troubleshoot ing S If any part of the SRS wire harness or any connector has been found to be faulty during the check in items See page RS 32 CAUTION S If the wire harness used i...

Page 1835: ...SYSTEM BE 14 TURN SIGNAL AND HAZARD WARNING SYSTEM BE 22 INTERIOR LIGHT SYSTEM BE 24 BACK UP LIGHT SYSTEM BE 26 STOP LIGHT SYSTEM BE 29 WIPER AND WASHER SYSTEM BE 31 COMBINATION METER BE 35 POWER WIN...

Page 1836: ...sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious accident Before servicing including removal or installation of parts inspection or replacement be su...

Page 1837: ...r Relay 3 Headlight Dimmer Switch 4 Wire Harness 5 Headlight Bulb BE 17 BE 17 BE 17 Hi Beam does not light up 1 Headlight Control Relay 2 Headlight Dimmer Relay 3 Headlight Dimmer Switch 4 Wire Harnes...

Page 1838: ...Headlight Dimmer Switch 2 Wire Harness BE 17 Headlight does not light up Taillight is normal 1 Headlight Control Relay 2 D R L Relay 3 D R L No 4 Relay 4 D R L Resistor 5 Headlight Dimmer Switch 6 Lig...

Page 1839: ...Fuse Relay Block 3 GAUGE Fuse Junction Block No 1 4 Door Courtesy Switch 5 Wire Harness BE 17 BE 14 BE 14 BE 25 TURN SIGNAL AND HAZARD WARNING SYSTEM Symptom Suspect Area See page Hazard and Turn do...

Page 1840: ...t remains always on 1 Wire Harness Only one light does not light up 1 Bulb 2 Wire Harness STOP LIGHT SYSTEM Symptom Suspect Area See page Stop light does not light up 1 STOP Fuse Junction Block No 1 2...

Page 1841: ...Wire Harness BE 38 BE 38 BE 36 Oil pressure gauge does not operte or abnormal operation 1 Oil Pressure Receiver Gauge 2 Oil Pressure Sender Gauge 3 Combination Meter Wiring Circuit 4 Wire Harness BE...

Page 1842: ...g Brake Switch 4 Brake Fluid Level Warning Switch BE 36 BE 38 BE 38 COMBINATION METER Indicator Lights Symptom Suspect Area See page O D OFF indicator light does not light up 1 Bulb 2 Combination Mete...

Page 1843: ...ch 6 Wire Harness BE 46 BE 46 BE 47 BE 12 BE 47 2Power window does not operate 1 POWER WINDOW Fuse Junction Block No 1 2 GAUGE Fuse Junction Block No 1 3 Ignition Switch 4 Door Lock Control Relay 5 Po...

Page 1844: ...k switch 1 Door Key Lock and Unlock Switch 2 Wire Harness 3 Door Lock Control Relay 4 Other Parts BE 51 BE 51 Fault in key confine prevention operation 1 Key Unlock Warning Switch 2 Door Courtesy Swit...

Page 1845: ...Z16012 Relay Block Junction Block No 1 BE02V 02 BE 10 BODY ELECTRICAL POWER SOURCE 1810 Author Date 1996 TOYOTA T100 RM449U POWER SOURCE LOCATION...

Page 1846: ...egration Relay Ignition Switch D Key Unlock Warning Switch BE02W 03 BODY ELECTRICAL IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE 11 1811 Author Date 1996 TOYOTA T100 RM449U IGNITION SWITCH AND KEY...

Page 1847: ...ied replace the switch 2 INSPECT KEY UNLOCK WARNING SWITCH CONTI NUITY Switch position Tester connection Specified condition OFF Key removed No continuity ON Key set 4 5 Continuity If continuity is no...

Page 1848: ...nuity 10 Ground Driver s door courtesy switch OFF No continuity 10 Ground Driver s door courtesy switch ON Continuity 12 Ground Passenger s door courtesy switch OFF No continuity 12 Ground Passenger s...

Page 1849: ...ht Headlight 2 D R L Resister Combination Switch D Light Control Switch D Headlight Dimmer Switch Ignition Switch D R L Main Relay Door Courtesy Switch Rear Combination Light Junction Block No 1 D Tai...

Page 1850: ...ring Connector Wiper Switch Horn Contact Light Dimmer Turn Switch Slip Ring w Cruise Control System Switch Body w Intermittent Wiper or Mist Wiper Ball BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM BE...

Page 1851: ...Ball w Intermittent Wiper and Mist Wiper Light Dimmer Turn Switch Slip Ring w Cruise Control System Z14541 Light Dimmer Turn Switch Light Control Switch Ball Spiral Cable Switch Body Wiper Switch Con...

Page 1852: ...sh 10 11 5 12 13 Continuity HEAD Low beam 4 10 11 6 13 Continuity HEAD High beam 4 10 11 5 13 Continuity HEAD Flash 4 10 11 5 12 13 Continuity If continuity is not as specified replace the switch 2 IN...

Page 1853: ...ystem INSPECT INTEGRATION RELAY OPERATION a Connect the positive lead from the battery to terminal 2 and 11 b Connect the negative lead from the battery to terminal 7 and 10 c Check the buzzer sounds...

Page 1854: ...ion switch ON or START Battery positive voltage 6 Ground Constant Battery positive voltage 11 Ground Engine Stop No voltage 11 Ground Engine Running Battery positive voltage If circuit is as specified...

Page 1855: ...CAL HEADLIGHTAND TAILLIGHT SYSTEM 1996 TOYOTA T100 RM449U 10 INSPECT DAYTIME RESISTOR CONTINUITY Condition Tester connection Specified condition Constant 1 2 Approx 337m If continuity is not as specif...

Page 1856: ...djustment in Vertical Direction For Adjustment in Horizontal Direction BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM BE 21 1996 TOYOTA T100 RM449U ADJUSTMENT 1 ADJUST HEADLIGHT AIMING 2 ADJUST SPIRAL...

Page 1857: ...zard Warning Switch Combination Switch D Turn Signal Switch Ignition Switch Turn Signal Flasher Junction Block No 1 D TURN Fuse BE033 04 BE 22 BODY ELECTRICAL TURN SIGNAL AND HAZARD WARNING SYSTEM 182...

Page 1858: ...rom the battery to terminal 3 and the negative lead to terminal 1 b Connect the 2 turn signal light bulbs in parallel to each other to terminals 1 and 2 check that the bulbs flash HINT The turn signal...

Page 1859: ...k D DOME Fuse Spot Light Room Light Door Courtesy Switch Door Courtesy Switch Footwell Light BE035 02 BE 24 BODY ELECTRICAL INTERIOR LIGHT SYSTEM 1824 Author Date 1996 TOYOTA T100 RM449U INTERIOR LIGH...

Page 1860: ...nd body ground c Turn the room light switch DOOR check that there is con tinuity between terminals 1 and 2 If operation is not as specified replace the switch 2 INSPECT DOOR COURTESY SWITCH CONTINUITY...

Page 1861: ...tch Junction Block No 1 D Back up Light Relay A T D GAUGE Fuse Ignition Switch Rear Combination Light BE037 04 BE 26 BODY ELECTRICAL BACK UP LIGHT SYSTEM 1826 Author Date 1996 TOYOTA T100 RM449U BACK...

Page 1862: ...15350 Back up Light Switch M T Vehicle RZN Series VZN Series Back up Light Switch M T Vehicle PNP Switch A T Vehicle BODY ELECTRICAL BACK UP LIGHT SYSTEM BE 27 1827 Author Date 1996 TOYOTA T100 RM449U...

Page 1863: ...ONTINUITY Condition Tester connection Specified condition Free No continuity Push 1 2 Continuity If continuity is not as specified replace the switch 2 INSPECT BACK UP LIGHT RELAY CONTINUITY Condition...

Page 1864: ...i Mount Stop Light Rear Combination Light Stop Light Switch Junction Block No 1 D STOP Fuse BE039 04 BODY ELECTRICAL STOP LIGHT SYSTEM BE 29 1829 Author Date 1996 TOYOTA T100 RM449U STOP LIGHT SYSTEM...

Page 1865: ...ndition Switch pin free Brake pedal depressed 1 2 Continuity Switch pin pushed in Brake pedal released No continuity If continuity is not as specified replace the switch w Cruise Control Switch positi...

Page 1866: ...BE03B 05 I22851 BODY ELECTRICAL WIPER AND WASHER SYSTEM BE 31 1831 Author Date 1996 TOYOTA T100 RM449U WIPER AND WASHER SYSTEM LOCATION...

Page 1867: ...ntinuity ON 1 2 Continuity w Intermittent Wiper Switch position Tester connection Specified condition OFF No continuity ON 1 2 Continuity If continuity is not as specified replace the switch 3 INSPECT...

Page 1868: ...the battery to terminal 3 and the negative lead from the battery to the motor body check that the motor operates at low speed If operation is not as specified replace the motor 5 High Speed INSPECT WI...

Page 1869: ...t the motor stops running at the stop posi tion after the motor operates again If operation is not as specified replace the motor 7 INSPECT WASHER MOTOR OPERATION Connect the positive lead from the ba...

Page 1870: ...BE03D 02 I22848 BODY ELECTRICAL COMBINATION METER BE 35 1835 Author Date 1996 TOYOTA T100 RM449U COMBINATION METER LOCATION...

Page 1871: ...BE03E 02 I22850 BE 36 BODY ELECTRICAL COMBINATION METER 1996 TOYOTA T100 RM449U CIRCUIT...

Page 1872: ...I22849 BODY ELECTRICAL COMBINATION METER BE 37 1996 TOYOTA T100 RM449U...

Page 1873: ...or If error is excessive replace the speedometer b Check the speedometer for pointer vibration and abnor mal noise USA mph CANADA km h Standard indication Allowable range Standard indication Allowable...

Page 1874: ...000 4 850 5 150 7 000 6 790 7 210 If error is excessive replace the tachometer 4 INSPECT VOLT GAUGE SYSTEM Measure the resistance between terminals A and B Resistance Approx 347 If resistance value i...

Page 1875: ...atteries to terminal 2 through a 3 4 W test bulb and the negative lead to terminal 1 c Check the positive lead from the voltmeter to terminal 2 and the negative lead to terminal 1 d Check that the vol...

Page 1876: ...h in fuel check that the bulb goes out If operation is not as specified replace the sender gauge 11 INSPECT ENGINE COOLANT TEMPERATURE RE CEIVER GAUGE OPERATION a Disconnect the connector from the sen...

Page 1877: ...ied replace the receiver gauge 13 INSPECT OIL PRESSURE WARNING LIGHT a Disconnect the connector from the warning switch and ground terminal on the wire harness side connector b Turn the ignition switc...

Page 1878: ...he connector from the sender gauge b Apply battery positive voltage to the sender gauge termi nal through a test LED c Check that the bulb does not light when the engine is stopped d Check that the LE...

Page 1879: ...he warning light come on If the warning light does not light up test the bulb 22 INSPECT WASHER LEVEL SWITCH a Check that there is no continuity between terminals with the switch OFF float up b Check...

Page 1880: ...ce the relay 26 INSPECT INTEGRATION RELAY CIRCUIT See page BE 12 27 INSPECT 4WD INDICATOR LIGHT a Disconnect the connector from the 4WD indicator switch Connect the switch terminal 2 and body ground b...

Page 1881: ...Switch Power Window Switch Power Window Motor Door Lock Control Relay Junction Block No 1 D GAUGE Fuse D POWER WINDOW Fuse BE 46 BODY ELECTRICAL POWER WINDOW CONTROL SYSTEM 1846 Author Date 1996 TOYO...

Page 1882: ...6 Continuity OFF 3 4 6 Continuity DOWN 3 6 4 9 Continuity Passenger s switch Window unlock Switch position Tester connection Specified condition UP 6 7 9 10 Continuity OFF No continuity DOWN 7 9 6 10...

Page 1883: ...ecified replace the motor 4 Passenger s Side INSPECT POWER WINDOW MOTOR OPERATION a Connect the positive lead from the battery to terminal 2 and negative lead to terminal 1 Check that the motor turns...

Page 1884: ...minal 3 of the wire harness c Turn the ignition switch ON and set the power window switch in the down position d As the window goes down check that the current in creases to approximately 7 0 A e Chec...

Page 1885: ...OW Fuse Door Lock Control Relay Door Lock Motor D Door Unlock Detection Switch Ignition Switch D Key Unlock Warning Switch Door Key Lock and Unlock Switch BE03I 03 BE 50 BODY ELECTRICAL POWER DOOR LOC...

Page 1886: ...ester connection Specified condition LOCK 1 5 2 6 Continuity OFF No continuity UNLOCK 2 5 1 6 Continuity If continuity is not as specified replace the switch 2 INSPECT PASSENGER S DOOR LOCK CONTROL SW...

Page 1887: ...inuity OFF No continuity UNLOCK 4 8 Continuity If continuity is not as specified replace the switch 4 INSPECT DRIVER S DOOR LOCK MOTOR OPERA TION a Connect the positive lead from the battery to termin...

Page 1888: ...tch position Tester connection Specified condition OFF Door Lock set to LOCK No continuity ON Door Lock set to UNLOCK 1 5 Continuity If continuity is not as specified replace the switch 8 INSPECT DOOR...

Page 1889: ...FF Door closed No continuity 14 Ground Driver s door courtesy switch ON Door opened Continuity 2 Ground Constant Battery positive voltage 8 Ground Ignition switch LOCK or ACC No voltage 8 Ground Ignit...

Page 1890: ...Power Window Signal INSPECT DOOR LOCK CONTROL RELAY HINT When the relay circuit is as specified inspect the key off power window signal a Connect the connector to the relay b Connect the positive lead...

Page 1891: ...ear View Mirror D Mirror Motor Junction Block No 1 D RADIO Fuse Mirror Switch BE03G 04 BE 56 BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM 1856 Author Date 1996 TOYOTA T100 RM449U POWER MIRROR CONTROL S...

Page 1892: ...inuity LEFT 3 4 1 7 Continuity RIGHT 1 3 4 7 Continuity Right side Switch position Tester connection Specified condition UP 3 4 1 5 Continuity DOWN 1 3 4 5 Continuity LEFT 3 4 1 6 Continuity RIGHT 1 3...

Page 1893: ...96 TOYOTA T100 RM449U c Connect the positive lead from the battery to terminal 2 and the negative lead to terminal 1 Check that the mirror turns upward d Reverse the polarity that the mirror turns dow...

Page 1894: ...ESCRIPTION 1 RADIO WAVE BAND 2 SERVICE AREA There are great differences in the size of the service area for AM and FM monaural Sometimes FM stereo broadcasts cannot be received even though AM comes in...

Page 1895: ...lly strengthen or weaken the resultant sig nal at reception point S Multipath One type of interference caused by bouncing of ra dio waves off of obstructions is called multipath Multipath occurs when...

Page 1896: ...Refer to the O M section Setting the anti theft system HINT S When the audio system is shipped the ID number has not been input so the anti theft system is not in operation S If the ID number has not...

Page 1897: ...stem troubleshooting items marked indicate that Trou bleshooting for ANTI THEFT SYSTEM should be carried out first Problem No Radio No power coming in 1 Power coming in but radio not operating 2 Noise...

Page 1898: ...BODY ELECTRICAL AUDIO SYSTEM BE 63 1996 TOYOTA T100 RM449U 1 ANTI THEFT SYSTEM...

Page 1899: ...amplifier ACC wire harness faulty Power amplifier faulty Check if GND wire harness side to power amplifier is OK Is ACC applied to radio assembly ACC wire harness faulty Check if GND wire harness sid...

Page 1900: ...ng sound from speaker Radio faulty Radio faulty Radio assembly faulty Radio assembly faulty Go to No 17 Is tape player operating normally Speaker faulty Power amplifier faulty Recheck system after rep...

Page 1901: ...iss produced by non functioning speaker Radio faulty Radio assembly faulty Is there continuity in speaker wire harness Temporarily install another speaker Functions OK Speaker wire harness faulty Spea...

Page 1902: ...oor location Adjust antenna trimmer See page BE 82 Speaker faulty Electronic Tuning Radio type Radio or radio assembly faulty Which band is poor If radio side faulty Is tape player operating normally...

Page 1903: ...U Radio assembly faulty Is tape player operating normally Go to No 17 Install properly Speaker faulty Is speaker properly installed Temporarily install another speaker Function OK Radio assembly faul...

Page 1904: ...B Wire harness faulty GND faulty Check if GND wire harness side to power amplifier Check if GND wire harness side to radio or radio assembly Yes No NG OK P Radio Tape Player Separate Power Amplifier...

Page 1905: ...re harness faulty Check if GND wire harness side to tape player is OK GND faulty Yes No NG OK S S S U U U P P P P P S U P S U P S P P Radio Tape Player Separate Power Amplifier Yes Yes No No No Yes NG...

Page 1906: ...No No Is there continuity in ACC speaker wire harness Check if CIG RAD fuse is OK Replace fuse Is ACC applied to power amplifier S P Is ACC applied to tape player ACC wire harness faulty Is ACC appli...

Page 1907: ...lly Cassette tape faulty Functions OK if different cassette tape inserted Is there continuity in speaker wire harness Speaker wire harness faulty Temporarily install another speaker Functions OK Speak...

Page 1908: ...ng normally P Radio Tape Player Separate Power Amplifier Is hiss produced by non functioning speaker Is there continuity in speaker wire harness Temporarily install another speaker Functions OK Speake...

Page 1909: ...ape faulty No Yes No No No No Yes Yes Yes Yes Operates normally after cleaning the heads Head dirty Install properly Speaker faulty Is radio operating normally Is speaker properly installed Temporaril...

Page 1910: ...player Operates normally after cleaning the heads Cassette tape faulty Remove foreign object Head dirty No No No Yes Yes Yes 14 Tape Player APS SKIP RPT BUTTONS NOT OPERATING S Radio Tape Player U Ra...

Page 1911: ...ME fuse is OK Replace fuse Is B applied to power amplifier Yes Yes Yes Yes Yes No No No Cassette tape jammed Tape player faulty S U P S U P B wire harness faulty Is B applied to tape player Is B appli...

Page 1912: ...BODY ELECTRICAL AUDIO SYSTEM BE 77 1996 TOYOTA T100 RM449U...

Page 1913: ...BE 78 BODY ELECTRICAL AUDIO SYSTEM 1996 TOYOTA T100 RM449U...

Page 1914: ...BODY ELECTRICAL AUDIO SYSTEM BE 79 1996 TOYOTA T100 RM449U...

Page 1915: ...02 Ignition Switch Z19225 Radio Assembly Door Speaker Tweeter Speaker Ignition Switch Extra Cab Radio Assembly Door Speaker Rear Speaker BE 80 BODY ELECTRICAL AUDIO SYSTEM 1996 TOYOTA T100 RM449U LOC...

Page 1916: ...L RELAY CIR CUIT Disconnect the connector from the relay and inspect the con nector on wire harness side as shown in the chart below Tester connection Condition Specified condition 2 3 Constant Contin...

Page 1917: ...body damage when the antenna rod is released hold the rod while it comes out 2 INSTALL ANTENNA ROD a Insert the cable of the rod until it reaches the bottom HINT When inserting the cable the teeth on...

Page 1918: ...ire harness between terminal B and DOME fuse Open circuit in wire harness between terminal GND and body ground BODY ELECTRICAL CLOCK BE 83 1883 Author Date 1996 TOYOTA T100 RM449U CLOCK TROUBLESHOOTIN...

Page 1919: ...T100 RM449U 2 PROBLEM NO 2 a Check that the battery positive voltage is 10 16 V If voltage is not as specified replace the battery b Inspect the error of the clock Allowable error per day 1 5 seconds...

Page 1920: ...DOOR BO 6 FRONT WIPER AND WASHER BO 11 WHEEL ARCH MOULDING BO 16 WINDSHIELD BO 19 QUARTER WINDOW GLASS BO 25 BACK WINDOW GLASS BO 29 INSTRUMENT PANEL BO 34 TAIL GATE BO 41 FRONT SEAT BENCH TYPE BO 44...

Page 1921: ...Scraper BO0DT 02 BODY CLIP BO 1 1885 Author Date 1996 TOYOTA T100 RM449U CLIP REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below HINT If...

Page 1922: ...V00012 Removal Installation Shape Example Removal Installation Removal Installation BO 2 BODY CLIP 1886 Author Date 1996 TOYOTA T100 RM449U...

Page 1923: ...straint System such as the driver airbag Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious accide...

Page 1924: ...Bumper Front Balance Panel Turn Signal Light Cushion Side Mounting Bracket Bumper Arm Cushion Turn Signal Light 61 620 45 61 620 45 N m kgf cm ft lbf Specigied torque BO 4 BODY FRONT BUMPER 1888 Autho...

Page 1925: ...and lock cannot be adjusted with it on Substitute the standard bolt for the centering bolt 1 ADJUST HOOD IN FORWARD REARWARD AND LEFT RIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge...

Page 1926: ...or Door Lock Remote Control Door Lock Snap Ring Driver s Door Frame Moulding Door Lock Outside Handle Door Glass Door Glass Run Door Belt Moulding mirror speaker Cylinder Link Inside Handle Armrest Pa...

Page 1927: ...w Tweeter speaker REMOVE SPEAKER AND TWEETER SPEAKER 8 REMOVE DOOR ARMREST BASE 9 REMOVE SERVICE HOLE COVER HINT At the time of reassembly please refer to the follwing item Bring out the links throug...

Page 1928: ...wer door lock Disconnect the connector d Remove the 3 screws Torque 5 9 N m 60 kgf cm 52 in lbf HINT At the time of reassembly please refer to the follwing items S Apply adhesive to the 3 screws Part...

Page 1929: ...N m 260 kgf cm 19 ft lbf 2 ADJUST DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust HINT Substitute the standard bolt for the centering bolt See page BO 5 Torque 2...

Page 1930: ...BO0E0 01 BO 10 BODY FRONT DOOR 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 7...

Page 1931: ...354 Wiper Arm Cowl Louver Wiper Link Wiper Motor N m kgf cm ft lbf Specified torque 20 204 15 20 204 15 BODY FRONT WIPER AND WASHER BO 11 1895 Author Date 1996 TOYOTA T100 RM449U FRONT WIPER AND WASHE...

Page 1932: ...IPER ARMS Torque 20 N m 204 kgf cm 15 ft lbf 2 REMOVE COWL LOUVER 3 REMOVE WIPER MOTOR a Disconnect the connector then unfasten 4 bolts b Connect the claw of the wiper link to the panel c Disconnect t...

Page 1933: ...pper point where the washer fluid hits the windshield and the surge area are within the range indicated by the hatched line A Approx 150 mm 5 91 in B Approx 50 mm 1 97 in C Approx 0 50 mm 0 1 97 in b...

Page 1934: ...0 028 0 030 in BO 14 BODY FRONT WIPER AND WASHER 1996 TOYOTA T100 RM449U ADJUSTMENT ADJUST WASHER NOZZLE Using a tool like that shown in the figure change the direction of the nozzle hole to adjust t...

Page 1935: ...BO0E5 01 BODY FRONT WIPER AND WASHER BO 15 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page BO 12...

Page 1936: ...BO0E6 02 N12569 H01707 Front Wheel Arch Moulding Rear Wheel Arch Moulding BO 16 BODY WHEELARCH MOULDING 1900 Author Date 1996 TOYOTA T100 RM449U WHEEL ARCH MOULDING COMPONENTS...

Page 1937: ...Tape a screwdriver tip before use a Remove the 6 screws and a clip b Using the screwdriver pry up the wheel arch moulding and remove it 2 REMOVE REAR WHEEL ARCH MOULDING HINT Tape a screwdriver tip b...

Page 1938: ...BO0E8 01 BO 18 BODY WHEELARCH MOULDING 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page BO 17...

Page 1939: ...side Moulding Windshield Glass Front Pillar Garnish Cowl Louver Assist Grip Weatherstrip Non reusable part Wiper Arm Dam Sun Visor Holder z Holder z N m kgf cm ft lbf Specigied torque 20 204 15 BODY W...

Page 1940: ...body with the knife 10 REMOVE WINDSHIELD GLASS a Push piano wire through between the body and glass from the interior b Tie both wire ends to a wooden block or similar object HINT Apply adhesive tape...

Page 1941: ...aper remove the adhesive sticking to the glass b Clean the glass with cleaner NOTICE Do not touch the glass after cleaning it 3 POSITION GLASS a Place the glass in correct position b Check that all co...

Page 1942: ...the primer coating dry for 3 minutes or more S Do not keep any of the opened Primer G for later use 8 MIX ADHESIVE COATING NOTICE S Be sure that installation of the moulding is finished within usable...

Page 1943: ...f the vehicle 35 C 95 F 1 5 hours 20 C 68 F 5 hours 5 C 41 F 24 hours 11 INSPECT FOR LEAKS AND REPAIR a Perform a leak test after the hardening time has elapsed b Seal any leak with sealant Part No 08...

Page 1944: ...BO 24 BODY WINDSHIELD 1996 TOYOTA T100 RM449U 21 INSTALL INNER REAR VIEW MIRROR...

Page 1945: ...ter Window Glass Back Panel Trim Rear Seat Outer Belt Front Seat Quarter Trim Outer Belt 43 440 32 9 8 100 7 43 440 32 43 440 32 43 440 32 N m kgf cm ft lbf Specifeid torque 9 8 100 7 BODY QUARTER WIN...

Page 1946: ...HINT Tape the screwdriver tip before use b Remove the 3 bolts and back panel trim Torque 9 8 N m 100 kgf cm 7 in lbf 5 REMOVE REAR SEAT CUSHION a Remove the 3 clips and back panel lower garnishes b R...

Page 1947: ...SS BO 27 1996 TOYOTA T100 RM449U 9 REMOVE QUARTER WINDOW GLASS a Remove the 4 nuts and quarter window glass b Remove the screw and lock handle from the quarter win dow glass c Remove the 2 screws and...

Page 1948: ...BO0EE 01 BO 28 BODY QUARTER WINDOW GLASS 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page BO 26...

Page 1949: ...0 Weatherstrip Back Window Back Window Assembly Slide Type Glass Channel Slide Glass Stopper Fix Frame Weatherstrip BODY BACK WINDOW GLASS BO 29 1913 Author Date 1996 TOYOTA T100 RM449U BACK WINDOW GL...

Page 1950: ...K WINDOW GLASS WITH WINDOW FRAME HINT Tape a screwdriver tip before use a Using a screwdriver loosen the weatherstrip from the body NOTICE Be careful not to damage the body paint b Pry the lip of the...

Page 1951: ...d remove the 2 slide glass panes at the center area of the glass channel 4 REMOVE NON SLIDE GLASS a Pull apart the channels and remove the 2 fix frames as shown b Pull apart the channels and remove th...

Page 1952: ...BO0EI 01 BO 32 BODY BACK WINDOW GLASS 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 31...

Page 1953: ...he contact surface of the body and the weatherstrip lip c Hold the glass in position on the body d Install the glass by pulling the cord from the room side while pushing on the outside of the weathers...

Page 1954: ...Compartment Door Rear Console Box Stereo Opening Cover Steering Wheel Pad Radio Steering Wheel B Lower Finish Panel No 2 Brace No 1 Brace No 2 Side Bracket RH Ash Tray Register No 1 Center Cluster Fi...

Page 1955: ...F F F F F F F F F F V06838 A D G B E H C F I Code Shape Size 6 0 24 L 22 0 87 Code Shape Size Code Shape Size 5 0 20 L 14 0 55 5 0 20 L 18 0 71 8 0 31 L 20 0 79 5 0 20 L 16 0 63 5 0 20 L 14 0 55 6 0 2...

Page 1956: ...BOX 13 REMOVE CENTER CLUSTER FINISH PANEL HINT Tape a screwdriver tip before use a Remove the heater control knobs b Using a screwdriver remove the panel c Remove the radio d Remove the heater control...

Page 1957: ...996 TOYOTA T100 RM449U 21 REMOVE INSTRUMENT PANEL a Disconnect the connectors b Remove the 2 bolts from instrument panel 22 REMOVE INSTRUMENT PANEL REINFORCEMENT a Remove the brace No 3 b Remove the 4...

Page 1958: ...NO 3 2 REMOVE DUCT HEATER TO REGISTER NO 5 3 REMOVE REGISTER NO 2 4 REMOVE CENTER BRACKET 5 REMOVE MOUNTING BRACKET NO 1 AND NO 2 6 REMOVE STAY NO 2 7 REMOVE CENTER REGISTER 8 REMOVE CUP HOLDER 9 REMO...

Page 1959: ...BO0EN 01 BODY INSTRUMENT PANEL BO 39 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 38...

Page 1960: ...BO0EO 01 BO 40 BODY INSTRUMENT PANEL 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page BO 36...

Page 1961: ...tside Handle Tail Gate Lock Link Tail Gate Lock Tail Gate Hinge Tail Gate Service Hole Cover Stay Stopper N m kgf cm ft lbf Specified torque 12 120 9 18 185 13 12 120 9 12 120 9 BODY TAIL GATE BO 41 1...

Page 1962: ...ER 2 REMOVE TAIL GATE LOCK 3 REMOVE TAIL GATE LOCK LINK Torque 12 N m 120 kgf cm 9 ft lbf 4 REMOVE DOOR OUTSIDE HANDLE 5 REMOVE TAIL GATE STAY 6 REMOVE TAIL GATE LOCK STRIKER Torque 12 N m 120 kgf cm...

Page 1963: ...BO0ER 01 BODY TAIL GATE BO 43 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page BO 42...

Page 1964: ...Support Seatback Frame Hog Ring Outer Track LH Seat Cushion Cover Seat Cushion Pad Seat Cushion Frame Outer Track RH Non reusable part z Headrest w o Armrest z Hog Ring z Equalizing Wire BO 44 BODY FR...

Page 1965: ...t Seatback Frame Seatback Pad Seatback Cover Inner Adjuster Seat Adjuster Inner Track Inner Shield Seat Adjuster Outer Shield Headrest Outer Track Center Armrest Cable Inner Track Equalizing Wire Hog...

Page 1966: ...Rear Seat Cushion Cover Rear Seat Cushion Hinge Lower Cover Hinge Cover Hinge Upper Cover Rear Seat Cushion Pad Rear Seat Cushion Rear Seat Cushion BO 46 BODY REAR SEAT 1930 Author Date 1996 TOYOTA T...

Page 1967: ...r Seat Belt Anchor Cap Shoulder Belt Anchor Adjuster Belt RH Belt LH Belt Front Seat Inner Front Seat Inner Belt RH Belt LH Front Seat Inner 43 440 32 N m kgf cm ft lbf Specified torque 43 440 32 43 4...

Page 1968: ...lide Garnish Quarter Trim Front Seat Belt Shoulder Anchor Anchor Cover Front Seat Inner Belt Front Seat Outer Belt 43 440 32 43 440 32 43 440 32 43 440 32 N m kgf cm ft lbf Specified torque BO 48 BODY...

Page 1969: ...Rear Seat Belt Shoulder Anchor Rear Seat Outer Belt Inner Belt Rear Seat N m kgf cm ft lbf Specified torque 43 440 32 43 440 32 43 440 32 43 440 32 Extra cab BODY SEAT BELT BO 49 1933 Author Date 199...

Page 1970: ...t the following static check Also whenever installing a new belt assembly verify the proper operation before installation 2 All seat belts STATIC TEST a Make sure that the belt locks when pulled out q...

Page 1971: ...R UNIT AC 33 COMPRESSOR AND MAGNETIC CLUTCH AC 38 RECEIVER AC 46 CONDENSER AC 49 EVAPORATOR AC 53 HEATER RADIATOR AC 56 EXPANSION VALVE AC 59 WATER VALVE AC 62 BLOWER MOTOR AC 65 BLOWER RESISTOR AC 68...

Page 1972: ...AT CONTAINER OR EXPOSE IT TO NAKED FLAME 5 BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT 6 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERATION SYS TEM If th...

Page 1973: ...iver airbag and passenger air bag Failure to carry out service operations the correct se quence could cause the SRS to unexpectedly deployed during servicing possible the SRS may fail to operate when...

Page 1974: ...nt in sight glass None sufficient or too much Refer item 3 and 4 3 No temperature difference between com pressor inlet and outlet Empty or nearly empty 1 Check for gas leakage with gas leak de tector...

Page 1975: ...due to ambient temperature conditions 1 Normally functioning refrigeration system Gauge reading Low pressure side 0 15 0 25 MPa 1 5 2 5 kgf cm2 High pressure side 1 37 1 57 MPa 14 16 kgf cm2 2 Moistur...

Page 1976: ...frigeration system Insufficient refrigerant in system Refrigerant leaking 1 Check for gas leakage with gas leak detector and repair if neces sary 2 Charge Proper amount of re frigerant 3 If indicated...

Page 1977: ...in expansion valve by blowing with air 3 Replace receiver 4 Evacuate air and charge new refrigerant to proper amount 5 For gas leakage from expan sion valve replace expansion valve 6 Refrigerant overc...

Page 1978: ...lass Air entered in refrigeration system AIr present in refrigeration sys tem Insufficient vacuum purging 1 Check compressor oil to see if it is dirty or insufficient 2 Evacuate air and charge new ref...

Page 1979: ...witch at HI position A C switch ON Temperature control dial at COOL position Magnetic clutch condition Idle up speed 3RZ FE Engine Magnetic clutch not engaged 700 50 rpm Magnetic clutch engaged 900 50...

Page 1980: ...e drain hose make sure that the gas leak detector does not react to the volatile gases If such reaction is unavoidable the vehicle must be lifted up c If gas leak is not detected on the drain hose rem...

Page 1981: ...ng cylinder CAUTION Do not open both high and low hand valves of manifold gauge set c Open the valve of charging cylinder d Press the valve core on the side of manifold gauge and expel the air inside...

Page 1982: ...ystem through the high pressure side S Do not open the low pressure hand valve when the system is being charged with liquid refrigerant a Open the high pressure hand valve fully b Charge specified amo...

Page 1983: ...lower Motor S Blower Resistor Heater Control Assembly S Blower Speed Control Switch S Defroster Mode Switch Heater Unit S Heater Radiator A C Switch Cooling Unit S Evaporator S Expansion Valve S A C A...

Page 1984: ...LATION CONDITION Check that the drive belt fits properly in the ribbed grooves 2 INSPECT DRIVE BELT TENSION Using a belt tension gauge check the drive belt tension Drive belt tension New belt 160 25 l...

Page 1985: ...BELT AC 15 1996 TOYOTA T100 RM449U REMOVAL 1 REMOVE PS PUMP DRIVE BELT 3RZ FE See page SR 36 5VZ FE See page SR 46 2 REMOVE ENGINE UNDER COVER 3 LOOSEN IDLE PULLEY LOCK NUT 4 REMOVE COMPRESSOR DRIVE...

Page 1986: ...GHTEN IDLE PULLEY LOCK NUT TEMPORALLY Torque 2 5 N m 25 kgf cm 22 in lbf 2 INSTALL DRIVE BELT 3 USING ADJUSTING BOLT ADJUST DRIVE BELT TEN SION Drive belt tension New belt 160 25 lbf Used belt 100 25...

Page 1987: ...ten the nuts by hand CAUTION Do not connect the wrong hoses 2 CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand 3 CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 4 REMOVE CAPS...

Page 1988: ...SE BOTH HAND VALVE OF MANIFOLD GAUGE SET 2 DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT Slide the sleeve of the quick disconnect adapter upward to un lock the adap...

Page 1989: ...INE AC 19 1953 Author Date 1996 TOYOTA T100 RM449U REFRIGERANT LINE ON VEHICLE INSPECTION 1 INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2 INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak de...

Page 1990: ...oling Unit Discharge Hose Liquid Tube Receiver Liquid Tube Suction Hose Specified torque z Non reusable part 10 100 7 14 140 10 5 4 55 48 in lbf 32 330 24 10 100 7 10 100 7 14 140 10 AC 20 AIR CONDITI...

Page 1991: ...6 0 60 52 in lbf Condenser x Discharge hose 10 100 7 Condenser x Liquid tube 14 140 10 Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Cooling unit x Liquid tube 14 140 10 Cool...

Page 1992: ...ing A C Amplifier z Packing Lower Unit Case Evaporator Expansion Valve Cooling Unit N m kgf cm ft lbf Specified torque z Non reusable part z O Ring z O Ring Thermistor Pressure Switch Amplifier Cover...

Page 1993: ...UBE AND SUCTION HOSE Loosen the 2 nuts and disconnect the both tube and hose Torque Liquid tube 14 N m 140 kgf cm 10 ft lbf Suction hose 32 N m 330 kgf cm 24 ft lbf CAUTION Cap the open fittings immed...

Page 1994: ...LVE a Pry out the packing b Remove the clamp and disconnect heat sensing tube c Loosen the 2 nuts and remove the expansion valve Torque Expansion valve x Liquid tube 14 N m 140 kgf cm 10 ft lbf Expans...

Page 1995: ...AC0FC 01 AIR CONDITIONING COOLING UNIT AC 25 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 24...

Page 1996: ...AC0FD 01 AC 26 AIR CONDITIONING COOLING UNIT 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 23...

Page 1997: ...2 Brace No 1 Brace Center Defroster Nozzle Heater Unit Heater Air Duct Cooling Unit Heater Radiator pipe Heater Radiator Heater Unit Case Air Vent Duct z O Ring z Non reusable part AIR CONDITIONING HE...

Page 1998: ...se b Disconnect the water hose HINT At the time of installation please refer to the following item S Push the water hose onto the heater radiator pipe as far as the second ridge on the pipe S Install...

Page 1999: ...N06076 AIR CONDITIONING HEATER UNIT AC 29 1996 TOYOTA T100 RM449U 8 REMOVE HEATER AIR DUCT Remove the screw and duct 9 REMOVE HEATER UNIT Remove the 2 bolts nut and heater unit...

Page 2000: ...Remove the 3 screws and 3 plates b Pull out the heater radiator c Remove the 2 clips and heater radiator pipes d Remove the 2 O rings from heater radiator pipes HINT At the time of reassembly please...

Page 2001: ...AC0FH 01 AIR CONDITIONING HEATER UNIT AC 31 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 30...

Page 2002: ...AC0FI 01 AC 32 AIR CONDITIONING HEATER UNIT 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 28...

Page 2003: ...e Compartment Door Lower Center Cover Cooling Unit Blower Unit Glove Compartment Door Reinforcement Blower Unit Case Blower Resistor Blower Motor AIR CONDITIONING BLOWER UNIT AC 33 1967 Author Date 19...

Page 2004: ...TMENT REINFORCE MENT 3 REMOVE INSTRUMENT PANEL LOWER FINISH PAN EL 4 REMOVE COOLING UNIT 5 REMOVE BLOWER UNIT a Disconnect the connectors b Disconnect the air inlet control cable HINT At the time of i...

Page 2005: ...0FL 01 AIR CONDITIONING BLOWER UNIT AC 35 1996 TOYOTA T100 RM449U DISASSEMBLY 1 REMOVE BLOWER MOTOR Remove the 3 screws and blower motor 2 REMOVE BLOWER RESISTOR Remove the 2 screws and blower resisto...

Page 2006: ...AC0FM 01 AC 36 AIR CONDITIONING BLOWER UNIT 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 35...

Page 2007: ...AC0FN 01 AIR CONDITIONING BLOWER UNIT AC 37 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 34...

Page 2008: ...sing a gas leak detector check for leakage of refrigerant If there is any leakage replace the compressor assembly 7 SET OFF MANIFOLD GAUGE SET See page AC 18 8 MAKE THESE VISUAL CHECK a Leakage of gre...

Page 2009: ...fied torque Shim Snap Ring z z O Ring z O Ring Discharge Hose 3RZ FE Engine Models 5VZ FE Engine Models Compressor z Compressor Bracket Suction Hose Suction Hose Compressor 10 100 7 25 250 18 39 400 2...

Page 2010: ...ERY 4 DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 5 REMOVE ENGINE UNDER COVER 6 DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect the both hoses NOTICE Cap the open fitting...

Page 2011: ...REMOVE PRESSURE PLATE a Using SST and a socket wrench remove the shaft bolt SST 07112 76060 Torque 13 2 N m 135 kgf cm 9 ft lbf b Install SST on the pressure plate SST 07112 66040 c Using SST and soc...

Page 2012: ...em The snap ring should be installed so that beveled side faces up b Using a plastic hammer tap the rotor off the shaft NOTICE Be careful not to damage the pulley when tapping on the ro tor 3 REMOVE S...

Page 2013: ...AC0951 Stator AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH AC 43 1996 TOYOTA T100 RM449U c Remove the stator...

Page 2014: ...the pressure plate of the magnetic clutch b Connect the magnetic clutch lead wire to the positive terminal of the battery c Check the clearance between the pressure plate and ro tor when connecting th...

Page 2015: ...en removed HINT Lubricate 2 new O rings with compressor oil and install the hoses 3 INSTALL AND CHECK DRIVE BELT See page AC 16 AC 14 4 INSTALL ENGINE UNDER COVER 5 5VZ FE Engine Models INSTALL PS PUM...

Page 2016: ...ITIONING RECEIVER 1980 Author Date 1996 TOYOTA T100 RM449U RECEIVER ON VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector check for leakage If there is leakage check the tighten...

Page 2017: ...IVER AND COOLING UNIT Remove the bolt and disconnect the liquid tube Torque 5 4 N m 55 kgf cm 48 in lbf NOTICE Cap the open fittings immediately to keep moisture or dirt out of the system HINT At the...

Page 2018: ...AC0FQ 01 AC 48 AIR CONDITIONING RECEIVER 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 47...

Page 2019: ...R DAMAGE If the fins are clogged wash them with water and dry with compressed air NOTICE Be careful not to damage the fins If the fins are bent straighten them with a screwdriver or pliers 2 INSPECT C...

Page 2020: ...ID TUBES a Remove the 2 bolt and disconnect the liquid tubes from receiver Torque 5 4 N m 55 kgf cm 48 in lbf NOTICE Cap the open fittings immediately to keep moisture or dirt out of the system HINT A...

Page 2021: ...ely to keep moisture or dirt out of the system HINT At the time of installation please refer to the following item Lubricate a new O ring with compressor oil and install the tubes 8 REMOVE CONDENSER R...

Page 2022: ...AC0FT 01 AC 52 AIR CONDITIONING CONDENSER 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 50...

Page 2023: ...23 2 REMOVE EVAPORATOR a Using a knife cut off each packing b Remove the 4 screws and 4 clips then separate the up per and lower case c Remove the evaporator HINT At the time of installation please r...

Page 2024: ...NDITIONING EVAPORATOR 1996 TOYOTA T100 RM449U INSPECTION 1 CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air 2 CHECK FITTING FOR CRACKS FOR SCRATCHES If necessa...

Page 2025: ...AC0FW 01 AIR CONDITIONING EVAPORATOR AC 55 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 53...

Page 2026: ...56 AIR CONDITIONING HEATER RADIATOR 1990 Author Date 1996 TOYOTA T100 RM449U HEATER RADIATOR REMOVAL 1 REMOVE HEATER UNIT See page AC 28 2 REMOVE HEATER RADIATOR a Remove the 3 screws 3 plates and cl...

Page 2027: ...AC0FY 01 AIR CONDITIONING HEATER RADIATOR AC 57 1996 TOYOTA T100 RM449U INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air...

Page 2028: ...AC0FZ 01 AC 58 AIR CONDITIONING HEATER RADIATOR 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 56...

Page 2029: ...page AC 17 3 RUN ENGINE a Run the engine at 1 500 rpm for at least 5 minutes b Then check that the high pressure reading is 1 37 1 57 MPa 14 16 kgf cm2 199 228 psi 4 CHECK EXPANSION VALVE If the expa...

Page 2030: ...rom suction tube of evaporator b Loosen the 2 nuts and remove the expansion valve from evaporator and liquid tube Torque Expansion valve x Evaporator 22 N m 225 kgf cm 16 ft lbf Expansion valve x Liqu...

Page 2031: ...AC0G2 01 AIR CONDITIONING EXPANSION VALVE AC 61 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 60...

Page 2032: ...E CONTROL CABLE 3 INSPECT WATER VALVE OPERATION a Check that warm air blown out the vent when the water valve lever is moved to WARM position b Check that cool air blown out when the water valve is mo...

Page 2033: ...nstallation please refer to the following item After installation adjust the control cable See page AC 91 3 DISCONNECT WATER HOSES a Using pliers grip the claws of hose clip and slide the clip along t...

Page 2034: ...AC0G4 01 AC 64 AIR CONDITIONING WATER VALVE 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 63...

Page 2035: ...N05818 AC0G5 01 AIR CONDITIONING BLOWER MOTOR AC 65 1999 Author Date 1996 TOYOTA T100 RM449U BLOWER MOTOR REMOVAL REMOVE BLOWER MOTOR a Disconnect the connector b Remove the 3 screws and blower motor...

Page 2036: ...TOYOTA T100 RM449U INSPECTION INSPECT BLOWER MOTOR OPERATION Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 then check that the motor op erations smoothl...

Page 2037: ...AC0G7 01 AIR CONDITIONING BLOWER MOTOR AC 67 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 65...

Page 2038: ...AC0G8 01 AC 68 AIR CONDITIONING BLOWER RESISTOR 2002 Author Date 1996 TOYOTA T100 RM449U BLOWER RESISTOR REMOVAL REMOVE BLOWER RESISTOR a Disconnect the connector b Remove the 2 screws and blower res...

Page 2039: ...ONING BLOWER RESISTOR AC 69 1996 TOYOTA T100 RM449U INSPECTION INSPECT BLOWER RESISTOR RESISTANCE Tester connection Condition Specified condition 1 2 3 4 Constant Continuity If continuity is not as sp...

Page 2040: ...AC0GA 01 AC 70 AIR CONDITIONING BLOWER RESISTOR 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 68...

Page 2041: ...T100 RM449U THERMISTOR ON VEHICLE INSPECTION 1 REMOVE GLOVE COMPARTMENT DOOR See page BO 36 2 INSPECT THERMISTOR RESISTANCE a Disconnect the connector b Measure resistance between terminals 2 and 4 S...

Page 2042: ...GC 01 I01457 AC 72 AIR CONDITIONING THERMISTOR 1996 TOYOTA T100 RM449U REMOVAL 1 REMOVE EVAPORATOR See page AC 53 2 REMOVE THERMISTOR a Disconnect the connector b Pull out the thermistor from evaporat...

Page 2043: ...NING THERMISTOR AC 73 1996 TOYOTA T100 RM449U INSPECTION INSPECT THERMISTOR RESISTANCE a Place the thermistor in cold water and while changing the temperature of the water measure resistance at the co...

Page 2044: ...AC0GE 01 AC 74 AIR CONDITIONING THERMISTOR 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 72...

Page 2045: ...AC 17 2 REMOVE GLOVE COMPARTMENT DOOR See page BO 36 3 DISCONNECT CONNECTOR FROM COOLING UNIT 4 SET VEHICLE IN THESE CONDITIONS a Running engine at 2 000 rpm b Blower speed control switch at HI c Temp...

Page 2046: ...D TUBE Disconnect the connector and remove the pressure switch Torque 10 N m 100 kgf cm 7 ft lbf HINT S Lock the switch mounted on the tube with an open end wrench being careful not to deform the tube...

Page 2047: ...AC0GH 01 AIR CONDITIONING PRESSURE SWITCH AC 77 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 76...

Page 2048: ...or Date 1996 TOYOTA T100 RM449U HEATER MAIN RELAY INSPECTION INSPECT HEATER MAIN RELAY Making HTR CONTINU ITY Condition Tester connection Specified condition Constant 2 4 3 5 Continuity Apply B betwee...

Page 2049: ...voltage 4 Ground A C switch OFF No voltage 1 ECM terminal ACT Constant Continuity 9 ECM terminal AC1 Constant Continuity 7 Ground A C switch ON Continuity 7 Ground A C switch OFF No continuity If the...

Page 2050: ...0 AIR CONDITIONING AIR CONDITIONING AMPLIFIER 1996 TOYOTA T100 RM449U REMOVAL 1 REMOVE GLOVE COMPARTMENT DOOR See page BO 36 2 REMOVE A C AMPLIFIER a Disconnect the connector b Remove the amplifier fr...

Page 2051: ...AC0GL 01 AIR CONDITIONING AIR CONDITIONING AMPLIFIER AC 81 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 80...

Page 2052: ...ITIONING AIR CONDITIONING SWITCH 2016 Author Date 1996 TOYOTA T100 RM449U AIR CONDITIONING SWITCH REMOVAL REMOVE A C SWITCH Using a screwdriver pry loose the clips and remove the A C switch HINT Tape...

Page 2053: ...e lead to terminal 4 and check that the indicator lights up when A C switch ON b Connect the positive lead from the battery to terminal 3 and check that the indicator dims If operations are not as spe...

Page 2054: ...AC0GO 01 AC 84 AIR CONDITIONING AIR CONDITIONING SWITCH 1996 TOYOTA T100 RM449U INSTALLATION Installation is in the reverse order of removal See page AC 82...

Page 2055: ...OYOTA T100 RM449U HEATER CONTROL ASSEMBLY ON VEHICLE INSPECTION INSPECT HEATER CONTROL LEVER OPERATION Move the control lever and dials left and right check for stiffness and binding the full range of...

Page 2056: ...eater Control Panel A C Switch Air Inlet Control Cable Air Mix Control Cable Water Valve Control Cable Mode Control Cable Heater Control Base Blower Speed Control Switch Defroster Mode Switch Bulb AC...

Page 2057: ...Control Cable AIR CONDITIONING HEATER CONTROL ASSEMBLY AC 87 1996 TOYOTA T100 RM449U REMOVAL 1 REMOVE INSTRUMENT PANEL See page BO 36 2 DISCONNECT HEATER CONTROL CABLES 3 REMOVE HEATER CONTROL ASSEMBL...

Page 2058: ...1 REMOVE BLOWER SPEED CONTROL SWITCH a Pull out the bulb b Disconnect the bulb holder c Using a screwdriver pry loose the clip and push out the blower speed control switch to rear of the heater contr...

Page 2059: ...CONTINU ITY Position Circuit Tester connection Specified condition OFF No continuity LO 5 6 Continuity M1 1 5 6 Continuity M2 2 5 6 Continuity HI 5 6 8 Continuity Illumination circuit 3 4 Continuity...

Page 2060: ...AC0GU 01 AC 90 AIR CONDITIONING HEATER CONTROL ASSEMBLY 1996 TOYOTA T100 RM449U REASSEMBLY Reassembly is in the reverse order of disassmebly See page AC 88...

Page 2061: ...n 2 Mode control lever in FACE position 3 Temperature control lever in Max WARM position b Adjust the air inlet control cable Set the air inlet damper control damper on FRESH posi tion install the con...

Page 2062: ...SSEMBLY 1996 TOYOTA T100 RM449U e Adjust water valve control cable Set the air inlet damper control damper on WARM posi tion install the control cable and lock the clamp HINT Lock the clamp during lig...

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