1996 Toyota T100 Service Manual

1996 TOYOTA T100 Factory Service Manual

INDEX IN Introduction MA Maintenance PP Preparation SS Service Specifications DI Diagnostics EM Engine Mechanical (3RZ-FE) Engine Mechanical (5VZ-FE) EC Emissions Control (3RZ-FE) Emissions Control (5VZ-FE) MF MFI System (3RZ-FE) SF SFI System (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 Manual Transmission (R150, R150F) Manual Transmission (W59) AT Automatic Transmission TR Transfer PR Propeller Shaft SA Suspension and Axle BR Brake SR Steering RS Supplemental Restraint System BE Body Electrical BO Body AC Air Conditioning

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

IN02D−02 N17080 Filler Cap Float Reservoir Tank z Grommet Clip Slotted Spring Pin N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part Cylinder Piston Push Rod Washer Snap Ring Boot z Gasket Lock Nut Clevis Pin Clevis 12 ( 120, 9) 15 ( 155, 11) − INTRODUCTION HOW TO USE THIS MANUAL IN−1 1 Author: Date: 1996 TOYOTA T100 (RM449U) HOW TO USE THIS MANUAL GENERAL INFORMATION 1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. 2. PRECAUTION At the beginning 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 tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN−16. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe- cial Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example:

Illustration: what to do and where 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. Task heading : what to do SST 09350−30020 (09350−06120) Set part No. Component part No. Detailed text : how to do task (b) Measure the stroke applying and releasing the compressed Piston stroke: 1.40 Ċ 1.70 mm (0.0551 Ċ 0.0669 in.) Specification air (392 − 785 kPa, 4 − 8 kgf.cm 2 or 57 − 114 psi) as shown in the illustration. IN−2 − INTRODUCTION HOW TO USE THIS MANUAL 2 Author: Date: 1996 TOYOTA T100 (RM449U) The procedures are presented in a step−by−step format: S The illustration shows what to do and where to do it. S The task heading tells what to do. S The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick ref- erence. 8. CAUTIONS, NOTICES, HINTS: S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. S NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. S HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

IN02E−02 A B13830 − INTRODUCTION IDENTIFICATION INFORMATION IN−3 3 Author: Date: 1996 TOYOTA T100 (RM449U) IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND ENGINE 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 Identification Number Plate B: Certification Label 2. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown, in the illustration.

FI1066 IN0IL−01 Z11554 Seal Lock Adhesive IN−4 − INTRODUCTION REPAIR INSTRUCTIONS 4 Author: Date: 1996 TOYOTA T100 (RM449U) REPAIR INSTRUCTIONS GENERAL INFORMATION BASIC REPAIR HINT (a) Use fender, seat and floor covers to keep the vehicle clean and prevent damage. (b) During disassembly, keep parts in the appropriate order to facilitate reassembly. (c) Observe the following operations: (1) Before performing electrical work, disconnect the negative (−) terminal cable from the battery. (2) If it is necessary to disconnect the battery for in- spection or repair, always disconnect the negative (−) terminal cable which is grounded to the vehicle body. (3) To prevent damage to the battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. (5) Install the cable ends to the battery terminals with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. (d) Check hose and wiring connectors to make sure that they are secure and correct. (e) Non−reusable parts (1) Always replace cotter pins, gaskets, O−rings and oil seals etc. with new ones. (2) Non−reusable parts are indicated in the component illustrations by the ”z” symbol. (f) Precoated parts Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads.

BE1367 Medium Current Fuse and High Current Fuse Equal Amperage Rating V00076 Abbreviation Part Name Symbol Illustration FUSE MEDIUM CURRENT FUSE HIGH CURRENT FUSE FUSIBLE LINK CIRCUIT BREAKER FUSE M−FUSE H−FUSE FL CB − INTRODUCTION REPAIR INSTRUCTIONS IN−5 5 Author: Date: 1996 TOYOTA T100 (RM449U) (3) Precoated parts are indicated in the component illustrations by the ”L” symbol. (g) When necessary, 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 materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in the preparation part at the front of each section in this manual. (j) When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating.

IN0253 WRONG CORRECT IN0252 WRONG CORRECT IN0002 Example IN−6 − INTRODUCTION REPAIR INSTRUCTIONS 6 Author: Date: 1996 TOYOTA T100 (RM449U) (k) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN−8). (1) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety. (2) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. (l) Observe the following precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU, ECM, PCM or TCM unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (2) To disconnect vacuum hoses, pull off the end, not the middle of the hose. (3) To pull apart electrical connectors, pull on the connector itself, not the wires. (4) Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. (5) When steam cleaning an engine, protect the elec- tronic components, air filter and emission−related components from water. (6) Never use an impact wrench to remove or install temperature switches or temperature sensors. (7) When checking continuity at the wire connector, in- sert the tester probe carefully to prevent terminals from bending. (8) When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step−down adapter for adjustment. Once the hose has been stretched, it may leak. (m) Tag hoses before disconnecting them: (1) When disconnecting vacuum hoses, use tags to identify how they should be reconnected to. (2) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout.

− INTRODUCTION REPAIR INSTRUCTIONS IN−7 7 Author: Date: 1996 TOYOTA T100 (RM449U) (n) Unless otherwise stated, all resistance is measured at an ambient temperature of 20°C (68°F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been run- ning, measurement should be made when the engine has cooled down.

1996 Toyota T100 Service Manual

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