Toyota T100 1996 Service Manual
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Toyota T100 1996 Service Manual

Toyota T100 1996 Service Manual

1996 toyota t100
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1996 TOYOTA T100
Factory Service Manual

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Summary of Contents for Toyota T100 1996

  • Page 1 1996 TOYOTA T100 Factory Service Manual...
  • Page 2 INDEX Introduction MA Maintenance PP Preparation SS Service Specifications 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) Ignition (3RZ-FE) Ignition (5VZ-FE)

  • Page 3: Table Of Contents

    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 IN-15 CONTROLLED SYSTEMS TERMS IN-31...

  • Page 4: How To Use This Manual

    Grommet Slotted Spring Pin 12 ( 120, 9) Clevis 15 ( 155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part N17080 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 5 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) 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 6: Identification Information

    A: Vehicle Identification Number Plate B: Certification Label ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown, in the illustration. B13830 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 7: Repair Instructions

    When reusing precoated parts, clean off the old Seal Lock Adhesive adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or Z11554 threads. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 8 DO NOT exceed the rating or use Equal Amperage Rating one with a lower rating. BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M−FUSE HIGH CURRENT FUSE H−FUSE FUSIBLE LINK CIRCUIT BREAKER V00076 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 9 When disconnecting vacuum hoses, use tags to identify how they should be reconnected to. After completing a job, double check that the vacu- um hoses are properly connected. A label under the hood shows the proper layout. IN0002 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 10 20°C (68°F). Because the resis- tance 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 (RM449U) Author : Date :...
  • Page 11 ........Safety stand B01123 1996 TOYOTA T100 (RM449U)

  • Page 12: For All Of Vehicles

    IN02H−03 PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG The TOYOTA T100 is equipped with an SRS (Supple- mental Restraint System), such as the driver airbag. Failure to carry out service operations in the correct se- quence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident.
  • Page 13 Be sure to lock this mechanism securely when connecting the con- nector. If connector is not securely locked, a malfunction code will be the diagnosis system (See page RS−2). 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 14 Refer to SR−33 of this manual concerning correct steer- ing wheel installation. Red Mark R11910 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 15 SST before disposal (See page RS−11). Carry out the operation in a safe place away from electrical noise. Correct Wrong Example: Z13953 Example: Z13950 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 16 This may cause the engine to misfire and create an extra load on the converter. Avoid coasting with ignition turned off and prolonged braking. Do not dispose of used catalyst along with parts contaminated with gasoline or oil. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 17 Avoid winding the antenna feeder together with the other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. Confirm that the antenna and feeder are correctly adjusted. Do not install powerful mobile communications system. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 18 IN02I−02 GENERAL INFORMATION A large number of ECU controlled systems are used in the TOYOTA T100. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshoot- ing of these systems is not complex.
  • Page 19 After completing repairs, confirm that the problem has been eliminated. (If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) 1996 TOYOTA T100 (RM449U)
  • Page 20 Surging Drive ability Knocking Other Soon after starting After accelerator pedal depressed Engine Stall After accelerator pedal released During A/C operation Shifting from N to D Other Others Datas Problem Constant Sometimes ( times per day/month) 1996 TOYOTA T100 (RM449U)
  • Page 21 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA T100 fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting.
  • Page 22 Therefore, check the wire harness and con- nectors (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 23 Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check if the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. V07268 1996 TOYOTA T100 (RM449U)
  • Page 24 OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the mal- function occurs. V07469 1996 TOYOTA T100 (RM449U)
  • Page 25 (DI − 43) ”A” Circuit Malfunction D ECM Throttle/ Pedal Position Sensor/Switch D Throttle position sensor ”A” Circuit Range/Performance Insufficient Coolant Temp. for Closed D Open or short in heated oxygen sensor circuit D Heated oxygen sensor 1996 TOYOTA T100 (RM449U)
  • Page 26 1. A/C signal circuit (Compressor circuit) High engine idle speed (Poor idling) 2. ECM power source circuit DI − 101 1. A/C signal circuit idling) 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit 1996 TOYOTA T100 (RM449U)

  • Page 27: Circuit Inspection

    LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. V08423 1996 TOYOTA T100 (RM449U)
  • Page 28 In this case, care must be taken not to bend the terminals. (with harness) D Indicates the condition of the connector of ECU during the check. E6 Connector E6 Connector Connector being checked is disconnected. Connector being checked is connected. V08425 1996 TOYOTA T100 (RM449U)
  • Page 29 HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. 1996 TOYOTA T100 (RM449U)
  • Page 30 NOTICE: When testing a gold−plated female terminal, always use a gold−plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. 1996 TOYOTA T100 (RM449U)
  • Page 31 Between terminal 1 of connector ”B2” and terminal 1 of connector ”C” → No continuity (open) Therefore, it is found out that there is an open circuit B04722 between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 1996 TOYOTA T100 (RM449U)
  • Page 32 Between terminal 2 of connector ”A” and body ground → No continuity Z17009 Therefore, it is found out that there is a short circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. 1996 TOYOTA T100 (RM449U)
  • Page 33 Resistance: 1 Ω or less Ground IN0383 Disconnect the ECU connector, check the ground ECU Side terminals on the ECU side and the wire harness side for bend and check the contact pressure. Ground W/H Side Ground IN0384 1996 TOYOTA T100 (RM449U)
  • Page 34 Manual Transmission O/D, OD Overdrive Over Head Camshaft Oversize Positive Crankcase Ventilation Power Steering Right−Hand Rear Supplemental Restraint System Special Service Materials Special Service Tools Standard Switch Top Dead Center TEMP. Temperature 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 35 IN−32 INTRODUCTION − TERMS Transmission Undersize Vacuum Control Valve Vacuum Switching Valve Vacuum Transmitting Valve With Without Two Wheel Drive Vehicles (4x2) Four Wheel Drive Vehicles (2x2) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 36 − TERMS IN02M−01 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE−J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their Toyota equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )−−ABBREVIATIONS...
  • Page 37 Smoke Puff Limiter − Service Reminder Indicator − System Readiness Test − Scan Tool − Throttle Body Throttle Body Single Point Injection Throttle Body Fuel Injection Central Fuel Injection (Ci) Turbocharger Turbocharger Torque Converter Clutch Torque Converter 1996 TOYOTA T100 (RM449U)
  • Page 38 Voltage Regulator Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type) Wide Open Throttle Full Throttle WU−OC Warm Up Oxidation Catalytic Converter − WU−TWC Warm Up Three−Way Catalytic Converter Manifold Converter Third Gear − Fourth Gear − 1996 TOYOTA T100 (RM449U)

  • Page 39: Table Of Contents

    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: Outside Vehicle

    Check that all doors and the tailgate operate smoothly, and that all latches lock securely. Check that the engine hood secondary latch secures the hood from opening when the primary latch is released. 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 41: Inside Vehicle

    For fold−down seat backs, check that the latches lock securely. SEAT BELTS Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. Check that the belt webbing is not cut, frayed, worn or damaged. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 42 Check the lock release button of the selector lever for proper and smooth operation. On a safe incline, check that the vehicle is held securely with the selector lever in ”P” position and all brakes released. 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 43: Under Hood

    EXHAUST SYSTEM Visually inspect for cracks, holes or loose supports. If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 44 CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT, RHODE ISLAND and NEW HAMPSHIRE: INSPECT CHARCOAL CANISTER (3RZ−FE: See page EC−5) (5VZ−FE: See page EC−5) REPLACE GASKET IN FUEL TANK CAP (3RZ−FE: See page EC−5) (5VZ−FE: See page EC−5) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 45 INSPECT EXHAUST PIPES AND MOUNTINGS Visually inspect the pipes, hangers and connections for severe corrosion, leaks or damage. ADJUST VALVE CLEARANCE (3RZ−FE: See page EM−5) (5VZ−FE: See page EM−4) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 46 If there are traces of the indicator contacting the disc rotor, the disc pad should be replaced. INSPECT REAR BRAKE LININGS AND DRUMS (2WD: See page BR−42) (4WD: See page BR−48) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 47 Inspect the drive shaft boots for clamp looseness, grease leak- age or damage. B02089 INSPECT BALL JOINTS AND DUST COVERS Inspect the ball joints for excessive looseness. Inspect the dust cover for damage. B02090 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 48 If the level is low, add oil until it begins to run out of the filler hole. B02093 Transmission oil (M/T): R150F: See page MT−10 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 49 Remove the drain plug and drain the oil. Reinstall drain plug securely. Add new oil until it begins to run out of the filler hole. (2WD) Transmission oil (M/T): R150: See page MT−5 B02095 W59: See page MT−5 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 50 Start the engine and shift the selector into all positions from ”P” through ”L” and then shift into ”P”. With the engine idling, check the fluid level. Add fluid up to the ”COOL” level on the dipstick. B02098 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 51 Grease grade: Propeller shaft (Except Double−cardan joint) Lithium base chassis grease NLGI No.2 Double−cardan joint Molybdenum disulphide lithium base chassis grease NLGI No.2 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 52 Fold−down seat backs lock securely Road test: Engine and chassis parts do not have abnormal noises. Vehicle does not wander or pull to one side. Brakes work properly and do not drag. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 53 MA−14 MAINTENANCE − CHASSIS Be sure to deliver a clean vehicle and especially check: Steering wheel Shift lever knob All switch knobs Door handles Seats 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 54 PP – PREPARATION MAINTENANCE PP-1 ENGINE MECHANICAL (3RZ-FE) PP-2 ENGINE MECHANICAL (5VZ-FE) PP-8 EMISSION CONTROL (3RZ-FE) PP-14 EMISSION CONTROL (5VZ-FE) PP-16 MFI (3RZ-FE) PP-19 SFI (5VZ-FE) PP-22 COOLING (3RZ-FE) PP-25 COOLING (5VZ-FE) PP-28 LUBRICATION (3RZ-FE) PP-33 LUBRICATION (5VZ-FE) PP-38 IGNITION (3RZ-FE) PP-43 IGNITION (5VZ-FE) PP-46...
  • Page 55 PP−1 PREPARATION − MAINTENANCE MAINTENANCE PP0G5−01 EQUIPMENT Mirror Brake hose Torque wrench 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 56 Crankshaft rear oil seal 09223−50010 Crankshaft Front oil Seal Replacer 09236−00101 Water Pump Overhaul Tool Set (09236−15010) Bearing Stay Valve stem oil seal 09248−55040 Valve Clearance Adjust Tool Set (09248−05410) Valve Lifter Press 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 57 Crankshaft rear oil seal 09636−20010 Upper Ball Joint Dust Cover Crankshaft timing gear Replacer 09816−30010 Oil Pressure Switch Socket Knock sensor 09843−18020 Diagnosis Check Wire 09950−40010 Puller B Set (09951−04010) Hanger 150 (09952−04010) Slide Arm 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 58 Puller C Set (09951−05010) Hanger 150 (09952−05010) Slide Arm (09953−05010) Center Bolt 100 (09954−05020) Claw No.2 09960−10010 Variable Pin Wrench Set (09962−01000) Variable Pin Wrench Arm Assy (09963−00500) Pin 5 (09963−01000) Pin 10 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 59: Recommended Tools

    PP−5 PREPARATION − ENGINE MECHANICAL (3RZ−FE) PP0G7−02 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 09200−00010 Engine Adjust Kit . 09258−00030 Hose Plug Set . Plug for the vacuum hose, fuel hose etc. 1996 TOYOTA T100 (RM449U)
  • Page 60 Engine tune−up tester Heater Magnetic finger Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench V−block Valve seat cutter Vernier calipers 1996 TOYOTA T100 (RM449U)
  • Page 61 Over the space between the cylinder (FIPG) head and timing chain cover 08826−00080 Seal Packing Black or equivalent Semi−circular plug (FIPG) Oil pan Rear oil seal retainer 08833−00070 Adhesive 1324, Spark plug tube THREE BOND 1324 or equivalent 1996 TOYOTA T100 (RM449U)
  • Page 62 Bolt 09222−30010 Connecting Rod Bushing Remover & Replacer 09223−15030 Oil Seal & Bearing Replacer Crankshaft rear oil seal 09228−07501 Oil Filter Wrench 09248−55040 Valve Clearance Adjust Tool Set (09248−05410) Valve Lifter Press 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 63 Crankshaft timing pulley (09954−05010) Claw No.1 Crankshaft timing pulley (09954−05030) Claw No.3 Crankshaft pulley 09950−70010 Handle Set (09951−07150) Handle 150 Crankshaft rear oil seal Valve guide bushing 09960−10010 Variable Pin Wrench Set 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 64 PP−10 PREPARATION − ENGINE MECHANICAL (5VZ−FE) (09962−01000) Variable Pin Wrench Arm Assy Camshaft timing pulley Camshaft sub−gear (09963−01000) Pin 10 Camshaft timing pulley (09963−00600) Pin 6 Camshaft sub−gear 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 65 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 vacuum hose, fuel hose etc. 09904−00010 Expander Set . 1996 TOYOTA T100 (RM449U)
  • Page 66 OBDII scan tool Engine speed Heater Magnetic finger Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter Vernier calipers 1996 TOYOTA T100 (RM449U)
  • Page 67 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 equivalent 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 1996 TOYOTA T100 (RM449U)
  • Page 68 PP−14 PREPARATION − EMISSION CONTROL (3RZ−FE) EMISSION CONTROL (3RZ−FE) PP0GA−02 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 69 PP−15 PREPARATION − EMISSION CONTROL (3RZ−FE) PP0GB−01 EQUIPMENT Tachometer Torque wrench Vacuum gauge 1996 TOYOTA T100 (RM449U)
  • Page 70 PP−16 PREPARATION − EMISSION CONTROL (5VZ−FE) EMISSION CONTROL (5VZ−FE) PP32Z−01 SST (Special Service Tools) 09843−18020 Diagnosis Check Wire 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 71 PP−17 PREPARATION − EMISSION CONTROL (5VZ−FE) PP014−04 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 1996 TOYOTA T100 (RM449U)
  • Page 72 PP−18 PREPARATION − EMISSION CONTROL (5VZ−FE) PP018−04 EQUIPMENT OBDII scan tool Engine speed Torque wrench Vacuum gauge 1996 TOYOTA T100 (RM449U)
  • Page 73 EFI Fuel Pressure Gauge 09631−22020 Power Steering Hose Nut Fuel line flare nut 14 x 17 mm Wrench Set 09816−30010 Oil Pressure Switch Socket Knock sensor 09842−30070 Wiring ”F” EFI Inspection 09843−18020 Diagnosis Check Wire 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 74 PP−20 PREPARATION − MFI (3RZ−FE) PP0GD−02 RECOMMENDED TOOLS 09200−00010 Engine Adjust Kit . 09258−00030 Hose Plug Set . Plug for vacuum hose, fuel hose etc. 09082−00050 TOYOTA Electrical Tester Set. 1996 TOYOTA T100 (RM449U)
  • Page 75 PP−21 PREPARATION − MFI (3RZ−FE) PP0GE−02 EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector Heater Soft brush Throttle body Sound scope Injector Tachometer Thermometer Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 76 EFI Fuel Pressure Gauge 09631−22020 Power Steering Hose Nut Fuel line flare nut 14 x 17 mm Wrench Set 09816−30010 Oil Pressure Switch Socket 09842−30070 Wiring ”F” EFI Inspection 09843−18020 Diagnosis Check Wire 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 77 PP−23 PREPARATION − SFI (5VZ−FE) PP01E−04 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 09200−00010 Engine Adjust Kit . 09258−00030 Hose Plug Set . Plug for the vacuum hose, fuel hose etc. 1996 TOYOTA T100 (RM449U)
  • Page 78 PP−24 PREPARATION − SFI (5VZ−FE) PP01F−02 EQUIPMENT OBDII scan tool Engine speed Graduated cylinder Injector Carburetor cleaner Throttle body Sound scope Injector Torque wrench Soft brush Throttle body 1996 TOYOTA T100 (RM449U)
  • Page 79 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 Service Tool Set (09231−01010) Overhaul Handle (09231−01020) Punch Assembly (09231−01030) Claw (09231−00060) No.3 Plug 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 80 PP−26 PREPARATION − COOLING (3RZ−FE) PP0GF−02 EQUIPMENT Heater Thermostat Radiator cap tester Thermometer Thermostat Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 81 PP−27 PREPARATION − COOLING (3RZ−FE) PP0GG−01 COOLANT Item Capacity Classification Engine coolant 8.7 liters (9.2 US qts, 7.7 lmp. qts) Ethylene−glycol base (w/ Heater) 1996 TOYOTA T100 (RM449U)
  • Page 82 PP−28 PREPARATION − COOLING (5VZ−FE) COOLING (5VZ−FE) PP3MB−01 SST (Special Service Tools) 09843−18020 Diagnosis Check Wire 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 83 PP−29 PREPARATION − COOLING (5VZ−FE) PP3MC−01 RECOMMENDED TOOLS 09042−00010 Torx Socket T30 . 1996 TOYOTA T100 (RM449U)
  • Page 84 PP−30 PREPARATION − COOLING (5VZ−FE) PP01J−02 EQUIPMENT Heater Radiator cap tester Thermometer Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 85 Capacity Classification Ethylene−glycol base 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 (10.8 US qts, 9.0 lmp. qts) 1996 TOYOTA T100 (RM449U)
  • Page 86 PP−32 PREPARATION − COOLING (5VZ−FE) PP337−01 SSM (Special Service Materials) 08826−00100 Seal Packing 1282B, THREE BOND 1282B or equivalent (FIPG) 1996 TOYOTA T100 (RM449U)
  • Page 87 PP−33 PREPARATION − LUBRICATION (3RZ−FE) LUBRICATION (3RZ−FE) PP0GH−01 SST (Special Service Tools) 09228−07501 Oil Filter Wrench 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 88 PP−34 PREPARATION − LUBRICATION (3RZ−FE) PP0GI−01 RECOMMENDED TOOLS 09200−00010 Engine Adjust Kit . 1996 TOYOTA T100 (RM449U)
  • Page 89 PP−35 PREPARATION − LUBRICATION (3RZ−FE) PP0GJ−02 EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 90 Drain and refill recommended viscosity oil, with SAE 5W−30 w/ Oil filter change 5.3 liters (5.6 US qts, 4.7 lmp. qts) being preferred engine oil w/o Oil filter change 5.0 liters (5.3 US qts, 4.4 lmp. qts) 1996 TOYOTA T100 (RM449U)
  • Page 91 PP−37 PREPARATION − LUBRICATION (3RZ−FE) PP33E−01 SSM (Special Service Materials) 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 1996 TOYOTA T100 (RM449U)
  • Page 92 − LUBRICATION (5VZ−FE) LUBRICATION (5VZ−FE) PP01R−01 SST (Special Service Tools) 09032−00100 Oil Pan Seal Cutter 09228−07501 Oil Filter Wrench 09309−37010 Transmission Bearing Replacer Camshaft front oil seal 09816−30010 Oil Pressure Switch Socket 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 93 PP−39 PREPARATION − LUBRICATION (5VZ−FE) PP01S−02 RECOMMENDED TOOLS 09200−00010 Engine Adjust Kit . 1996 TOYOTA T100 (RM449U)
  • Page 94 PP−40 PREPARATION − LUBRICATION (5VZ−FE) PP01T−02 EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 95 Dry fill 5.5 liters (5.8 US qts, 4.8 lmp. qts) Drain and refill w/ Oil filter change 4.7 liters (5.0 US qts, 4.1 lmp. qts) w/o Oil filter change 4.4 liters (4.7 US qts, 3.9 lmp. qts) 1996 TOYOTA T100 (RM449U)
  • Page 96 PP−42 PREPARATION − LUBRICATION (5VZ−FE) PP33F−01 SSM (Special Service Materials) 08826−00080 Seal Packing Black or equivalent (FIPG) 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 1996 TOYOTA T100 (RM449U)
  • Page 97 PP−43 PREPARATION − IGNITION (3RZ−FE) IGNITION (3RZ−FE) PP0GM−02 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 09200−00010 Engine Adjust Kit . 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 98 PP−44 PREPARATION − IGNITION (3RZ−FE) PP0GN−03 EQUIPMENT Spark plug cleaner Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 99 PP−45 PREPARATION − IGNITION (3RZ−FE) PP3MD−01 SSM (Special Service Materials) 08826−00080 Seal Packing Black or equivalent (FIPG) 1996 TOYOTA T100 (RM449U)
  • Page 100 PP−46 PREPARATION − IGNITION (5VZ−FE) IGNITION (5VZ−FE) PP01Z−03 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 09200−00010 Engine Adjust Kit . 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 101 PP−47 PREPARATION − IGNITION (5VZ−FE) PP020−02 EQUIPMENT Spark plug cleaner 1996 TOYOTA T100 (RM449U)
  • Page 102 STARTING (3RZ−FE) STARTING (3RZ−FE) PP0GO−01 SST (Special Service Tools) 09286−46011 Injection Pump Spline Shaft Armature bearing Puller 09810−38140 Starter Magnet Switch Nut Wrench Terminal nut 09820−00030 Alternator Rear Bearing Replacer Armature rear bearing 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 103 PP−49 PREPARATION − STARTING (3RZ−FE) PP0GP−02 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 1996 TOYOTA T100 (RM449U)
  • Page 104 PP−50 PREPARATION − STARTING (3RZ−FE) PP0GQ−01 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V−block Commutator Vernier calipers Commutator, Brush 1996 TOYOTA T100 (RM449U)
  • Page 105 PREPARATION − STARTING (5VZ−FE) STARTING (5VZ−FE) PP3ME−01 SST (Special Service Tools) 09286−46011 Injection Pump Spline Shaft Armature bearing Puller 09810−38140 Starter Magnet Switch Nut Wrench Terminal kit 09820−00030 Alternator Rear Bearing Replacer 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 106 PP−52 PREPARATION − STARTING (5VZ−FE) PP025−04 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 1996 TOYOTA T100 (RM449U)
  • Page 107 PP−53 PREPARATION − STARTING (5VZ−FE) PP026−02 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V−block Commutator Vernier calipers Commutator, Brush 1996 TOYOTA T100 (RM449U)
  • Page 108 Alternator Rear Bearing Puller 09820−00030 Alternator Rear Bearing Replacer 09820−63010 Alternator Pulley Set Nut Wrench 09950−60010 Replacer Set (09951−00260) Replacer 26 Rotor front bearing (09951−00500) Replacer 50 Rotor front bearing (09952−06010) Adapter Rotor front bearing 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 109 PP−55 PREPARATION − CHARGING (3RZ−FE) PP3MF−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 09905−00013 Snap Ring Pliers . 1996 TOYOTA T100 (RM449U)
  • Page 110 PP−56 PREPARATION − CHARGING (3RZ−FE) PP0GT−02 EQUIPMENT Ammeter (A) Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring), Brush 1996 TOYOTA T100 (RM449U)
  • Page 111 Alternator Rear Bearing Puller 09820−00030 Alternator Rear Bearing Replacer 09820−63010 Alternator Pulley Set Nut Wrench 09950−60010 Replacer Set (09951−00260) Replacer 26 Rotor front bearing (09952−06010) Adapter Rotor front bearing (09951−00500) Replacer 50 Rotor front bearing 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 112 PP−58 PREPARATION − CHARGING (5VZ−FE) PP3MG−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 09905−00013 Snap Ring Pliers . 1996 TOYOTA T100 (RM449U)
  • Page 113 PP−59 PREPARATION − CHARGING (5VZ−FE) PP02C−04 EQUIPMENT Ammeter (A) Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring), Brush 1996 TOYOTA T100 (RM449U)
  • Page 114 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 Bearing Replacer 09333−00013 Clutch Diaphragm Spring Aligner 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 115 PP−61 PREPARATION − CLUTCH PP0EO−03 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 09905−00013 Snap Ring Pliers . 1996 TOYOTA T100 (RM449U)
  • Page 116 PP−62 PREPARATION − CLUTCH PP0EP−01 EQUIPMENT Caliper Dial indicator Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 117 Differential Drive Pinion Rear Input shaft bearing Bearing Replacer 09921−00010 Spring Tension Tool 2WD: Speedometer driven gear oil seal 09950−00020 Bearing Remover 09950−60010 Replacer Set (09951−00510) Replacer 51 Front bearing retainer oil seal 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 118 PP−64 PREPARATION − MANUAL TRANSMISSION (R150, R150F) (09951−00570) Replacer 57 Extension housing oil seal Transfer adaptor oil seal (09951−00620) Replacer 62 Counter rear bearing 09950−70010 Handle Set (09951−07150) Handle 150 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 119 PP−65 PREPARATION − MANUAL TRANSMISSION (R150, R150F) PP3LS−01 RECOMMENDED TOOLS 09031−00030 Pin Punch . 09042−00020 Torx Socket T40 . 09905−00012 Snap Ring No.1 Expander . 1996 TOYOTA T100 (RM449U)
  • Page 120 PP−66 PREPARATION − MANUAL TRANSMISSION (R150, R150F) PP0ES−01 EQUIPMENT Dial indicator Micrometer Torque wrench Feeler gauge Magnetic finger 1996 TOYOTA T100 (RM449U)
  • Page 121 MANUAL TRANSMISSION (R150, R150F) PP0ET−01 LUBRICANT Item Capacity Classification Manual transmission oil 2WD: 2.6 liters (2.7 US qts, 2.3 Imp. qts) API GL−4 or GL−5 4WD: 2.2 liters (2.3 US qts, 1.9 Imp. qts) SAE 75W−90 1996 TOYOTA T100 (RM449U)
  • Page 122 PP−68 PREPARATION − MANUAL TRANSMISSION (R150, R150F) PP33I−01 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 equivalent 1996 TOYOTA T100 (RM449U)
  • Page 123 Reverse Gear Remover (09313−00030) Rear Bearing Replacer (09313−00040) Plate ”A” (09313−00050) Plate ”B” 09316−60011 Transmission & Transfer Bearing No.3 clutch hub Replacer Counter gear center bearing outer race (09316−00011) Replacer Pipe (09316−00071) Replacer ”F” 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 124 Front bearing retainer oil seal (09951−00510) Replacer 51 Counter gear center bearing outer race (09951−00560) Replacer 56 Output shaft rear bearing outer race Extension housing oil seal 09950−70010 Handle Set (09951−07150) Handle 150 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 125 PP−71 PREPARATION − MANUAL TRANSMISSION (W59) PP3LQ−01 RECOMMENDED TOOLS 09031−00030 Pin Punch . 09042−00020 Torx Socket T40 . 09905−00012 Snap Ring No.1 Expander . 1996 TOYOTA T100 (RM449U)
  • Page 126 PP−72 PREPARATION − MANUAL TRANSMISSION (W59) PP0BG−01 EQUIPMENT Dial indicator Calipers Micrometer Torque wrench Feeler gauge Magnetic finger 1996 TOYOTA T100 (RM449U)
  • Page 127 PP−73 PREPARATION − MANUAL TRANSMISSION (W59) PP0BH−01 LUBRICANT Item Capacity Classification API GL−4 or GL−5 Manual transmission oil 2.6 liters (2.7 US qts, 2.3 Imp. qts) SAE 75W−90 1996 TOYOTA T100 (RM449U)
  • Page 128 PP−74 PREPARATION − MANUAL TRANSMISSION (W59) PP33J−01 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 equivalent 1996 TOYOTA T100 (RM449U)

  • Page 129: Automatic Transmission

    Replacer 8 09308−10010 Oil Seal Puller 09325−40010 Transmission Oil Plug 09350−30020 TOYOTA Automatic Transmission Tool Set (09351−32010) One−way Clutch Test Tool (09351−32020) Stator Stopper 09921−00010 Spring Tension Tool Speedometer driven gear oil seal 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 130 PP−76 PREPARATION − AUTOMATIC TRANSMISSION PP0FM−03 RECOMMENDED TOOLS 09031−00030 Pin Punch . 09082−00040 TOYOTA Electrical Tester. 09905−00012 Snap Ring No.1 Expander . 1996 TOYOTA T100 (RM449U)
  • Page 131 PP−77 PREPARATION − AUTOMATIC TRANSMISSION PP0FN−02 EQUIPMENT OBD II scan tool Ohmmeter Voltmeter Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Straight edge Torque converter clutch Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 132 7.2 liters (7.6 US qts, 6.3 Imp.qts) Drain and refill 1.6 liters (1.7 US qts, 1.4 Imp.qts) ATF DEXRON ®II (A340E) Dry fill 7.6 liters (8.0 US qts, 6.7 Imp.qts) Drain and refill 2.0 liters (2.1 US qts, 1.8 Imp.qts) 1996 TOYOTA T100 (RM449U)
  • Page 133 PP−79 PREPARATION − AUTOMATIC TRANSMISSION PP33L−01 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 equivalent 1996 TOYOTA T100 (RM449U)
  • Page 134 Rear Wheel Bearing Replacer Planetary gear outer bearing (09252−10010) No. 1 Replacer Handle 09550−00032 Replacer 09554−30011 Differential Oil Seal Replacer Planetary gear outer bearing 09555−55010 Differential Drive Pinion Planetary gear outer bearing Bearing Replacer 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 135 PP−81 PREPARATION − TRANSFER 09921−00010 Spring Tension Tool 09950−00020 Bearing Remover Driven sprocket rear beating Front drive clutch sleeve Rear output shaft bearing 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 136 PP−82 PREPARATION − TRANSFER PP33M−01 RECOMMENDED TOOLS 09031−00030 Pin Punch . 09905−00012 Snap Ring No.1 Expander . 1996 TOYOTA T100 (RM449U)
  • Page 137 PP−83 PREPARATION − TRANSFER PP0G2−01 EQUIPMENT Calipers Dial indicator Micrometer Torque wrench Feeler gauge 1996 TOYOTA T100 (RM449U)
  • Page 138 PP−84 PREPARATION − TRANSFER PP0G3−01 LUBRICANT Item Capacity Classification API GL−4 or GL−5 Transfer oil 1.1 liters (1.2 US qts, 1.0 lmp.qts) SAE 75W−90 1996 TOYOTA T100 (RM449U)
  • Page 139 PP−85 PREPARATION − TRANSFER PP33N−01 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 equivalent 1996 TOYOTA T100 (RM449U)

  • Page 140: 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 Universal Joint Bearing Remover Spider bearing removal and installa- & Replacer tion 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 141 PP−87 PREPARATION − PROPELLER SHAFT PP0EZ−01 EQUIPMENT Dial indicator Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 142 Rear axle 09330−00021 Companion Flange Holding Tool Front differential Rear differential 09350−20015 TOYOTA Automatic Transmission Front differential Tool Set (09369−20040) Piston Spring Compressor Set 09308−10010 Oil Seal Puller Front differential Rear differential 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 143 Drive Pinion Front Bearing Front differential Remover 09607−60020 Front Wheel Adjusting Nut Wrench Front axle (4WD) 09628−62011 Ball Joint Puller Front axle Front suspension (4WD) 09636−20010 Upper Ball Joint Dust Cover Front differential Replacer 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 144 (09710−05081) Rear Base 09710−30021 Suspension Bushing Tool Set Front suspension (2WD) (09710−03031) Bushing Remover (09710−03041) Bushing Remover Base (09710−03051) Bushing Replacer (09710−03061) Bushing Replacer Base 09710−30055 Suspension Arm Bushing Remover Front differential 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 145 (09911−00011) Puller Clamp (09912−00010) Puller Slide Hammer (09914−00011) Rear Axle Shaft Puller Attachment 09950−00020 Bearing Remover Front differential Rear differential 09950−30010 Puller A Set Front differential Rear differential 09950−40010 Puller B Set 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 146 09950−60020 Replacer Set No.2 Front axle (4WD) Front differential Rear differrential (09951−00710) Replacer 71 Front axle (2WD) Front differential Rear differential (09951−00720) Replacer 72 Front axle (4WD) (09951−00790) Replacer 79 Front differential 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 147 Handle Set Front axle Front differential Rear differential Rear axle (09951−07100) Handle 100 Front axle (4WD) (09951−07150) Handle 150 Front axle Front differential Rear axle Rear differential (09951−07200) Handle 200 Front suspension(4WD) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 148 − SUSPENSION AND AXLE PP0F6−01 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 E14 . 09082−00040 TOYOTA Electrical Tester. 1996 TOYOTA T100 (RM449U)
  • Page 149 PP−95 PREPARATION − SUSPENSION AND AXLE PP0F7−01 EQUIPMENT Dial indicator Torque wrench Drill Spring tension gauge Micrometer 1996 TOYOTA T100 (RM449U)
  • Page 150 1.86 liters (1.97 US qts, 1.64 lmp.qts) 75W−90 Hypoid gear oil API GL−5 Above − 18 °C (0°F) Rear differential 2.35 liter (2.22 US qts, 2.67 lmp.qts) SAE 90 Below − 18 °C (0°F) SAE 80W − 90 or 80W 1996 TOYOTA T100 (RM449U)
  • Page 151 PP−97 PREPARATION − SUSPENSION AND AXLE PP33P−01 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent 08833−00100 THREE BOND 1360K or equivalent 1996 TOYOTA T100 (RM449U)
  • Page 152 Brake Line Union Nut 10 x 12 mm Wrench 09843−18020 Diagnosis Check Wire 09990−00150 ABS Actuator Checker and Sub−harness 09990−00200 ABS Actuator Checker Sub−harness ”C” 09990−00310 ABS Actuator Checker Sub−harness ”J” 09990−00370 ABS Actuator Checker Sheet ”L” 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 153 PP−99 PREPARATION − BRAKE PP0FB−03 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 09905−00013 Snap Ring Pliers . 1996 TOYOTA T100 (RM449U)
  • Page 154 PP−100 PREPARATION − BRAKE PP0FC−01 EQUIPMENT Torque wrench Micrometor Brake disc Dial indicator Brake disc Vernier calipers Brake drum 1996 TOYOTA T100 (RM449U)
  • Page 155 PP−101 PREPARATION − BRAKE PP0FD−01 LUBRICANT Item Capacity Classification Brake fluid − SAE J1703 or FMVSS No.116 DOT 3 Power steering fluid − ATF DEXRON® II 1996 TOYOTA T100 (RM449U)
  • Page 156 PP−102 PREPARATION − BRAKE PP33Q−01 SSM (Special Service Materials) 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent 1996 TOYOTA T100 (RM449U)
  • Page 157 Tilt Handle Bearing Replacer PS gear (2WD) 09612−24014 Steering Gear Housing Overhaul Tool Set (09613−22011) Steering Rack Shaft Bushing PS gear (2WD) Puller 09612−65014 Steering Worm Bearing Puller (09612−01030) Claw ”C” PS gear (4WD) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 158 09631−10030 Oil Seal Remover PS vane pump (3RZ−FE) 09631−12071 Steering Rack Oil Seal Test Tool PS gear (2WD) 09631−20070 Seal Ring Guide PS gear (2WD) 09631−20081 Seal Ring Tool PS gear (2WD) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 159 09910−00015 Puller Set (09911−00011) Puller Clamp Tilt steering column (09912−00010) Puller Slide Hammer Tilt steering column 09922−10010 Variable Open Wrench PS gear (2WD) 09950−40010 Puller B Set (09957−04010) Attachment Tilt steering column 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 160 PS gear (2WD) (09951−00240) Replacer 24 PS gear (2WD) (09951−00250) Replacer 25 PS gear (2WD) (09951−00260) Replacer 26 PS gear (2WD) (09951−00300) Replacer 30 Idler arm (09951−00310) Replacer 31 PS gear (2WD) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 161 PS gear (2WD) (09951−07200) Handle 200 PS gear (2WD, 4WD) Idler arm (09951−07360) Handle 360 PS gear (2WD) 09960−10010 Variable Pin Wrench Set (09962−01000) Variable Pin Wrench Arm Assy PS vane pump (3RZ−FE, 5VZ−FE) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 162 PP−108 PREPARATION − STEERING (09963−01000) Pin 10 PS vane pump (3RZ−FE, 5VZ−FE) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 163 Torx Socket T30 . Non−tilt steering column Tilt steering column 09043−38100 Hexagon 10 mm Wrench PS gear (4WD) 09904−00010 Expander Set . (09904−00050) No. 4 Claw 09905−00012 Snap Ring No.1 Expander . 09905−00013 Snap Ring Pliers . 1996 TOYOTA T100 (RM449U)
  • Page 164 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−FE) Micrometer PS vane pump (3RZ−FE, 5VZ−FE) Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 165 PP−111 PREPARATION − STEERING PP0FX−01 LUBRICANT Item Capacity Classification Power steering fluid 0.8 liters (0.85 US qts, 0.70 Imp.qts) ATF DEXRON®II or III Total 1996 TOYOTA T100 (RM449U)
  • Page 166 PP−112 PREPARATION − STEERING PP33R−01 SSM (Special Service Materials) 08833−00080 Adhesive 1344 PS gear (2WD) THREE BOND 1344 LOCTITE 242 or equivalent 08826−00090 Seal Packing 1281, Idler arm THREE BOND 1281 or equivalent (FIPG) 1996 TOYOTA T100 (RM449U)

  • Page 167: Supplemental Restraint System

    PP−113 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM PP0FR−01 SST (Special Service Tools) 09082−00700 SRS Airbag Deployment Tool 09843−18020 Diagnosis Check Wire 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 168 PP−114 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM PP0FS−02 RECOMMENDED TOOLS 09042−00020 Torx Socket T40 . Center aribag sensor assembly 09082−00040 TOYOTA Electrical Tester. 1996 TOYOTA T100 (RM449U)
  • Page 169 Diam.: 6.0 mm (0.236 in.) Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.) Airbag disposal Tire with disc wheel Width: 185 mm (7.28 in.) Airbag disposal Inner diam.: 360 mm (14.17 in.) vinyl bag Airbag disposal 1996 TOYOTA T100 (RM449U)
  • Page 170 PP−116 PREPARATION − BODY ELECTRICAL BODY ELECTRICAL PP06F−09 SST (Special Service Tools) 09843−18020 Diagnosis Check Wire 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 171 PP−117 PREPARATION − BODY ELECTRICAL PP06G−08 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 removing and installing steering wheel pad 1996 TOYOTA T100 (RM449U)
  • Page 172 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 Dry cell battery Fuel sender gauge Torque wrench 1996 TOYOTA T100 (RM449U)
  • Page 173 PP−119 PREPARATION − BODY BODY PP0FZ−02 SST (Special Service Tools) 09806−30010 Windshield Moulding Remover 09812−00010 Door Hinge Set Bolt Wrench 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 174 PP−120 PREPARATION − BODY PP0EW−01 LUBRICANT Item Capacity Classification MP grease − − 1996 TOYOTA T100 (RM449U)
  • Page 175 Back WindowGlass (35 − 45 °C or 59 − 95 °F) 08850−00090 Windshield glass adhesive set Windshield No.45 or equivalent Back WindowGlass (35−45 °C or 95 − 95 °F) 08850−00801 Windshield Glass Adhesive Set Windshield or equivalent 1996 TOYOTA T100 (RM449U)

  • Page 176: Air Conditioning

    Refrigerant Charging Gauge (07117−88060) Refrigerant Charging Hose Discharge (Red) (07117−88070) Refrigerant Charging Hose Suction (Blue) (07117−88080) Refrigerant Charging Hose Utility (Green) 07112−66040 Magnetic Clutch Remover 07112−76060 Magnetic Clutch Stopper 07116−38360 Gas Leak Detector Assembly 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 177 PP−123 PREPARATION − AIR CONDITIONING PP3LU−01 RECOMMENDED TOOLS 09082−00050 TOYOTA Electrical Tester Set. 1996 TOYOTA T100 (RM449U)
  • Page 178 PP−124 PREPARATION − AIR CONDITIONING PP0E4−02 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Thermistor Torque wrench Dial indicator Magnetic clutch Plastic hammer Magnetic clutch Hexagon wrench Expansion valve 1996 TOYOTA T100 (RM449U)
  • Page 179 − 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 cc (1.4 fl. oz.) When replacing compressor 140 cc (4.8 fl. oz.) 1996 TOYOTA T100 (RM449U)
  • Page 180 SS – SERVICE SPECIFICATIONS STANDARD BOLT SS-1 MAINTENANCE SS-3 ENGINE MECHANICAL (3RZ-FE) SS-4 ENGINE MECHANICAL (5VZ-FE) SS-9 EMISSION CONTROL (3RZ-FE) SS-14 EMISSION CONTROL (5VZ-FE) SS-16 MFI (3RZ-FE) SS-17 SFI (5VZ-FE) SS-19 COOLING (3RZ-FE) SS-21 COOLING (5VZ-FE) SS-23 LUBRICATION (3RZ-FE) SS-25 LUBRICATION (5VZ-FE) SS-27 IGNITION (3RZ-FE)
  • Page 181 Hexagon head bolt Protruding lines Grooved Hexagon flange bolt Protruding w/ washer lines hexagon bolt Hexagon head bolt Welded bolt Protruding lines Hexagon head bolt Protruding lines V06821 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 182 SS−2 SERVICE SPECIFICATIONS − STANDARD BOLT SS00G−01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Hexagon head bolt Class Hexagon flange bolt N·m kgf·cm kgf·cm ft·lbf N·m ft·lbf in.·lbf in.·lbf in.·lbf in.·lbf in.·lbf in.·lbf V00079 1996 TOYOTA T100 (RM449U)
  • Page 183 SS−3 SERVICE SPECIFICATIONS − MAINTENANCE MAINTENANCE SS091−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front seat mount bolts Strut bar bracket x Frame Leaf spring U−bolt mounting nuts 1350 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 184 0.024 − 0.055 mm (0.0009 − 0.0022 in.) Maximum 0.07 mm (0.0028 in.) Manifold Warpage Maximum Intake 0.20 mm (0.0078 in.) Exhaust 0.50 mm (0.0197 in.) Air intake Warpage Maximum 0.20 mm (0.0078 in.) chamber 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 185 0.400 − 0.500 mm (0.0157 − 0.0194 in.) ”N” 0.400 − 0.500 mm (0.0157 − 0.0194 in.) Maximum No.1 0.40 mm (0.0157 in.) No.2 0.50 mm (0.0196 in.) Piston pin installing temperature 80 − 90°C (176 − 194°F) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 186 Journal oil clearance STD No.1 0.040 − 0.076 mm (0.0016 − 0.0031 in.) STD No.2 0.060 − 0.096 mm (0.0024 − 0.0038 in.) Maximum No.1 0.15 mm (0.0059 in.) No.2 0.15 mm (0.0059 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 187 Timing chain cover x Cylinder block Bolt A Bolt B 24.5 Bolt C Nut D Timing chain cover mounting bolt No.1 water bypass pipe mounting nut Crankshaft pulley x Crankshaft 2,650 No.2 and No.3 crankshaft pulley x Crankshaft pulley 1996 TOYOTA T100 (RM449U)
  • Page 188 Engine front mounting insulator x Frame Clutch release cylinder bracket x Transmission Clutch release cylinder x Transmission Stabilizer bar bracket mounting bolt Stabilizer bar x Lower suspension arm Intake air connector x Cylinder head Radiator x Body 1996 TOYOTA T100 (RM449U)
  • Page 189 0.025 − 0.060 mm (0.0010 − 0.0024 in.) Exhaust 0.030 − 0.065 mm (0.0012 − 0.0026 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) Margin thickness 1.0 mm (0.039 in.) Minimum 0.5 mm (0.020 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 190 No.2 0.400 − 0.600 mm (0.0157 − 0.0236 in.) 0.150 − 0.550 mm (0.0059 − 0.0217 in.) Maximum No.1 1.100 mm (0.0433 in.) No.2 1.200 mm (0.0472 in.) 1.150 mm (0.0453 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 191 54.745 − 54.755 mm (2.1553 − 2.1557 in.) Circle runout Maximum 0.06 mm (0.0024 in.) Main journal taper and out−of−round Maximum 0.02 mm (0.0008 in.) Crank pin taper and out−of−round Maximum 0.02 mm (0.0008 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 192 Main bearing cap x Cylinder block Turn 90° Turn 90° Turn 90° Rear oil seal retainer x Cylinder block 71 in.·lbf Oil cooler union x Cylinder block Oil hole cover plate x Cylinder block Engine coolant drain cock x Cylinder block 1996 TOYOTA T100 (RM449U)
  • Page 193 Front exhaust pipe x Exhaust crossover pipe Front exhaust pipe x Center exhaust pipe Front exhaust pipe support bracket x Front exhaust pipe Front exhaust pipe support bracket x Transmission Center exhaust pipe x Tailpipe Center exhaust pipe support bracket x Body 1996 TOYOTA T100 (RM449U)
  • Page 194 − EMISSION CONTROL (3RZ−FE) EMISSION CONTROL (3RZ−FE) SS094−01 SERVICE DATA VSV for EVAP Resistance at 20°C (68°F) 30 − 34 Ω VSV for EGR Resistance at 20°C (68°F) 33 − 39 Ω 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 195 EGR valve x Air intake chamber EGR valve x EGR pipe EGR pipe x Exhaust manifold EGR pipe x Cylinder head Heated oxygen sensor x Center exhaust pipe Front exhaust pipe x Center pipe Center pipe x Tail pipe 1996 TOYOTA T100 (RM449U)
  • Page 196 EGR pipe x LH exhaust manifold 18.5 EGR pipe stay x Cylinder head 71 in.·lbf Heated oxygen sensor x Center exhaust pipe Front exhaust pipe x Center exhaust pipe Center exhaust pipe x Tailpipe 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 197 Bank 1 sensor 1 at 20°C (68°F) 11 − 16 Ω Bank 1 sensor 2 at 20°C (68°F) 11 − 16 Ω Fuel cut RPM Fuel return rpm 1,400 rpm 1,500 rpm 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 198 Fuel tank filler pipe x Fuel tank 31 in.·lbf Fuel inlet pipe x Body 47 in.·lbf Fuel tank band x Body MAF meter x Air cleaner cap ECT sensor x Cylinder head Knock sensor x Cylinder block 1996 TOYOTA T100 (RM449U)
  • Page 199 M/T Bank 1 Sensor 1 at 20 °C (68 °F) 5 − 7 Ω sensor Others at 20 °C (68 °F) 11 − 16 Ω Fuel return rpm 1,000 rpm Fuel cut rpm 1,200 rpm 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 200 71 in.·lbf A/C idle−up valve x Intake air connector ECT sensor x Intake manifold Knock sensor x Cylinder block EGR gas temperature sensor x EGR valve Heated oxygen sensor x Front exhaust pipe, Center exhaust pipe 1996 TOYOTA T100 (RM449U)
  • Page 201 8 mm (0.31 in.) or more Radiator cap Relief valve opening pressure 74 − 103 kPa (0.75 − 1.05 kgf/cm , 10.7 − 14.9 psi) Minimum 59 kPa (0.6 kgf/cm , 8.5 psi) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 202 Fluid coupling x Fan 49 in.·lbf Water pump x Cylinder block expect bolt A 78 in.·lbf for bolt A 24.5 Water inlet x Water inlet housing Radiator support x Radiator tank 49 in.·lbf Radiator mounting bolt 1996 TOYOTA T100 (RM449U)
  • Page 203 8.5 mm (0.335 in .) or more Radiator cap Relief valve opening pressure 74 − 103 kPa (0.75 − 1.05 kgf/cm , 10.7 − 14.9 psi) Minimum 59 kPa (0.6 kgf/cm , 8.5 psi) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 204 SERVICE SPECIFICATIONS − COOLING (5VZ−FE) SS00Z−06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Fan x Fan pulley bracket 48 in.·lbf Water pump x Cylinder block − Short bolt Water inlet x Water pump Radiator support x Body 1996 TOYOTA T100 (RM449U)
  • Page 205 0.30 mm (0.0118 in.) Tip clearance 0.011 − 0.240mm (0.0043 − 0.0094 in.) Maximum 0.25 mm (0.0098 in.) Side clearance 0.030 − 0.090 mm (0.0012 − 0.0035 in.) Maximum 0.15 mm (0.0059 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 206 SS−26 SERVICE SPECIFICATIONS − LUBRICATION (3RZ−FE) SS09B−02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pan x Drain plug 1996 TOYOTA T100 (RM449U)
  • Page 207 0.30 mm (0.0118 in.) Tip clearance 0.11 − 0.24 mm (0.0043 − 0.0094 in.) Maximum 0.35 mm (0.0138 in.) Side clearance 0.03 − 0.09 mm (0.0012 − 0.0035 in.) Maximum 0.15 mm (0.0059 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 208 Oil pump x Oil pump body cover Oil pump x Cylinder block Bolt A Bolt B Oil pump x Relief valve Oil strainer x Cylinder block 66 in.·lbf Oil pan x Cylinder block 67 in.·lbf Oil cooler x Cylinder block 1996 TOYOTA T100 (RM449U)
  • Page 209 185 − 275 Ω at hot G+ − G− 240 − 325 Ω Crankshaft Resistance at cold NE+ − NE− 1,630 − 2,740 Ω position at hot NE+ − NE− 2,065 − 3,225 Ω sensor 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 210 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head Distributor x Cylinder head Crankshaft position sensor x Timing chain cover 74 in.·lbf Generator bracket x Cylinder block 74.5 Generator bracket x Timing chain cover 1996 TOYOTA T100 (RM449U)
  • Page 211 9.3 −16.0 kΩ 11.7 − 18.8 kΩ Camshaft position Resistance Cold 835 − 1,400 Ω sensor 1,060 − 1,645 Ω Crankshaft posi- Resistance Cold 1,630 − 2,740 Ω tion sensor 2,065 − 3,225 Ω 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 212 SS017−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head Ignition coil x Cylinder head 69 in.·lbf Camshaft position sensor x Cylinder head 69 in.·lbf Crankshaft position sensor x Oil pump 69 in.·lbf 1996 TOYOTA T100 (RM449U)
  • Page 213 34.0 mm (1.34 in.) Undercut depth 0.7 mm (0.028 in.) Minimum 0.2 mm (0.008 in.) Circle runout Maximum 0.05 mm (0.0020 in.) Magnetic switch Contact plate for wear Maximum 0.9 mm (0.035 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 214 1.8 kW, 2.0 kW type 34 in.·lbf Terminal nut x Terminal 30 of starter Terminal nut x Terminal C of starter Magnetic switch end cover x Magnetic switch 1.2 kW, 1.4 kW type 1.8 kW, 2.0 kW type 1996 TOYOTA T100 (RM449U)
  • Page 215 34 mm (1.340 in.) Undercut depth 0.7 mm (0.028 in.) Minimum 0.2 mm (0.008 in.) Circle runout Maximum 0.05 mm (0.0020 in.) Magnetic switch Contact plate for wear Maximum 0.9 mm (0.035 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 216 13 in.·lbf 1.8 kW type 34 in.·lbf Terminal nut x Terminal C of starter, Terminal 30 of starter Magnetic switch end cover x Magnetic switch 1.2 kW, 1.4 kW type 22 in.·lbf 1.8 kW type 30 in.·lbf 1996 TOYOTA T100 (RM449U)
  • Page 217 Brush exposed length 10.5 mm (0.413 in.) Minimum 1.5 mm (0.059 in.) Voltage Regulating voltage at 25 °C (77 °F) 14.0 − 15.0 V regulator at 115 °C (239 °F) 13.5 − 14.3 V 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 218 36 in.·lbf Pivot bolt (For generator) Generator x Generator bracket Lock bolt (For generator) Generator x Adjusting bar Bearing retainer x Drive end frame 23 in.·lbf Voltage regulator and brush holder x Rectifier end frame 17 in.·lbf 1996 TOYOTA T100 (RM449U)
  • Page 219 Brush exposed length 10.5 mm (0.413 in.) Minimum 1.5 mm (0.059 in.) Voltage regulator Regulating voltage at 25 °C (77 °F) 14.0 − 15.0 V at 115 °C (239 °F) 13.5 − 14.3 V 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 220 Rear end cover x Rectifier holder 40 in.·lbf Terminal insulator x Rectifier holder 41.5 36 in.·lbf Generator x Generator bracket (3RZ−FE) Generator x Adjusting bar (3RZ−FE) Generator x Generator bracket (5VZ−FE) Generator x Adjusting bar (5VZ−FE) 18.5 1996 TOYOTA T100 (RM449U)
  • Page 221 Max. 0.1 mm (0.004 in.) Diaphragm spring finger wear Max. depth 0.6 mm (0.024 in.) Diaphragm spring finger wear Max. width 5.0 mm (0.197 in.) Diaphragm spring tip non−alignment Max. 0.5 mm (0.020 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 222 SERVICE SPECIFICATIONS − CLUTCH SS07U−03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Clutch line union Master cylinder installation nut Bleeder plug Clutch cover x Flywheel Release cylinder installation bolt Release fork support 5VZ−FE Release fork support 3RZ−FE 1996 TOYOTA T100 (RM449U)
  • Page 223 1.85−1.90 mm (0.0728−0.0748 in.) Mark C 1.90−1.95 mm (0.0748−0.0768 in.) Mark D 1.95−2.00 mm (0.0768−0.0787 in.) Mark E 2.00−2.05 mm (0.0787−0.0807 in.) Mark F 2.05−2.10 mm (0.0807−0.0827 in.) Mark G 2.10−2.15 mm (0.0827−0.0846 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 224 Front bearing retainer (from retainer end) 11.7 ± 0.5 mm (0.461 ± 0.020 in.) Extension housing 0 ± 0.5 mm (0 ± 0.020 in.) Transfer adaptor 45.6 ± 0.5 mm (1.795 ± 0.020 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 225 Clutch housing x Transmission case Oil receiver x Extension housing Back−up light switch Restrict pin Control shift lever retainer x Transfer adaptor Control shift lever retainer x Extension housing Filler and drain plug Speedometer driven gear (2WD) 1996 TOYOTA T100 (RM449U)
  • Page 226 2.55 − 2.60 mm (0.1004 − 0.1024 in.) Mark 13 2.61 − 2.66 mm (0.1028 − 0.1047 in.) Mark 14 2.68 − 2.73 mm (0.1055 − 0.1075 in.) Mark 15 2.74 − 2.79 mm (0.1079 − 0.1098 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 227 Oil seal drive in depth Front bearing retainer (from retainer end) 12.2 ± 0.5 mm (0.480 ± 0.020 in.) Extension housing 0 ± 0.5 mm (0 ± 0.020 in.) Speedometer drive gear 25 mm (0.98 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 228 Shift lever housing x Shift and select lever shaft Control shift lever retainer x Extension housing Drain and filler plugs Back−up light switch Clutch housing x Transmission case Rear bearing retainer x Intermediate plate Speedometer driven gear 1996 TOYOTA T100 (RM449U)
  • Page 229 72 − 77 km/h (45 − 48 mph) (5VZ−FE / A340F) (Throttle valve opening 5%) Lock−up ON 75 − 80 km/h (47 − 50 mph) Lock−up OFF 68 − 73 km/h (42 − 45 mph) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 230 110 − 118 km/h (68 − 73 mph) 2 → 1 44 − 48 km/h (27 − 30 mph) L position (Throttle valve fully opened) 2 → 1 53 − 58 km/h (33 − 36 mph) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 231 (5VZ−FE) Park/neutral position switch (Nut) 35 in.·lbf Park/neutral position switch (Bolt) No.2 vehicle speed sensor 48 in.·lbf Speedometer driven gear sleeve x Locking plate ATF temperature sensor x Transmission Shift lever assembly x Steering column assembly 1996 TOYOTA T100 (RM449U)
  • Page 232 SS−52 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION Shift lever sub−assembly x Control shaft assembly Casing cap x Control shaft support sub−assembly 1996 TOYOTA T100 (RM449U)
  • Page 233 2.85 − 2.90 mm (0.1122 − 0.1142 in.) 2.90 − 2.95 mm (0.1142 − 0.1161 in.) 2.95 − 3.00 mm (0.1161 − 0.1181 in.) 3.00 − 3.05 mm (0.1181 − 0.1201 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 234 5.0 − 5.6 mm (0.197 − 0.220 in.) Oil seal Shift fork shaft oil seal depth −0.5 − 0.5 mm (−0.020 − 0.020 in.) Speedometer driven gear oil seal depth 25 mm (0.98 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 235 Straight screw plug for shift fork shaft Separator with oil strainer Oil pump body x Front case Straight screw plug for ring gear Straight screw plug for oil pump body Oil pump plate x Oil pump body 65 in.·lbf 1996 TOYOTA T100 (RM449U)
  • Page 236 Green 1.384 mm (0.0545 in.) Red 1.435 mm (0.0565 in.) Black 1.486 mm (0.0585 in.) Copper 1.511 mm (0.0895 in.) Silver 1.537 mm (0.0605 in.) Yellow 1.588 mm (0.0625 in.) Blue 1.638 mm (0.0645 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 237 2WD (TMC−made) and 4WD 2WD (DANA−made) Front propeller shaft No.2 dust cover set bolts Front propeller shaft No.2 dust cover set nuts Front propeller shaft dust cover bracket x Bracket Front propeller shaft dust cover bracket x Transfer 1996 TOYOTA T100 (RM449U)
  • Page 238 A: Ground clearance of spindle center. B: Ground clearance of lower suspension arm bolt center. : C − D C: Ground clearance of rear axle shaft center. D: Ground clearance of leaf spring front hanger pin center. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 239 A: Ground clearance of spindle center. B: Ground clearance of lower suspension arm bolt center. : C − D C: Ground clearance of rear axle shaft center. D: Ground clearance of leaf spring front hanger pin center. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 240 Inside wheel 40°23’ ± 2° (40.38° ± 2°) Outside wheel 35°31’ (35.52°) Extra cab Inside wheel 40°50’ ± 2° (40.83° ± 2°) Outside wheel 35°41’ (35.68°) Left−right error 30’ (0.5°) or less 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 241 A: Ground clearance of spindle center. B: Ground clearance of lower suspension arm bolt center. : C − D C: Ground clearance of leaf spring front bushing center. D: Ground clearance of rear axle shaft center. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 242 Side gear shaft tube LH side oil seal drive in depth 2.5 mm (0.098 in.) A.D.D. sleeve fork to clutch sleeve clearance 0.35 mm (0.0138 in.) Differential bearing press in depth 2.0 mm (0.079 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 243 Drive pinion bearing washer thickness 2.51 mm (0.0988 in.) 2.54 mm (0.1000 in.) 2.57 mm (0.1012 in.) 2.60 mm (0.1024 in.) 2.63 mm (0.1035 in.) 2.66 mm (0.1047 in.) 2.69 mm (0.1059 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 244 2.94 mm (0.1157 in.) 2.96 mm (0.1165 in.) 2.98 mm (0.1173 in.) 3.00 mm (0.1181 in.) 3.02 mm (0.1189 in.) 3.04 mm (0.1197 in.) 3.06 mm (0.1205 in.) 3.08 mm (0.1213 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 245 2.04 mm (0.0803 in.) 2.05 mm (0.0807 in.) 2.06 mm (0.0811 in.) 2.07 mm (0.0815 in.) 2.08 mm (0.0819 in.) 2.09 mm (0.0823 in.) 2.10 mm (0.0827 in.) 2.11 mm (0.0831 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 246 2.21 mm (0.0870 in.) 2.22 mm (0.0874 in.) 2.23 mm (0.0878 in.) 2.24 mm (0.0882 in.) 2.25 mm (0.0886 in.) 2.26 mm (0.0890 in.) 2.27 mm (0.0894 in.) 2.28 mm (0.0898 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 247 1,870 Upper suspension arm x Torque arm Upper suspension arm shaft lock nut 2,300 Shock absorber x Frame Lower suspension arm x Shock absorber 1,400 Lower suspension arm x Stabilizer bar Stabilizer bar bracket x Frame 1996 TOYOTA T100 (RM449U)
  • Page 248 Hanger pin x Leaf spring Hanger pin lock bolt Leaf spring center bolt Hub nut 1,050 Spring bumper seat set bolt ABS speed sensor x Rear axle housing 71 in.·lbf Brake line Parking brake set bolt Drain plug Filler plug 1996 TOYOTA T100 (RM449U)
  • Page 249 Rear brake shoe lining thickness Minimum 1.0 mm (0.039 in.) Rear brake drum to shoe clearance 0.6 mm (0.024 in.) Parking brake lever travel at 196 N (20 kgf, 44 lbf) 11 − 17 clicks 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 250 LSP & BV x Frame ABS actuator x ABS actuator bracket 48 in.·lbf ABS actuator bracket x Body Speed sensor installation bolt 71 in.·lbf Front speed sensor wire harness clamp 44 in.·lbf Rear speed sensor wire harness clamp 1996 TOYOTA T100 (RM449U)
  • Page 251 Flow control valve spring length Minimum 32.3 mm (1.272 in.) Pump rotating torque Maximum 0.25 N·m (2.5 kgf·cm, 2.2 in.·lbf) or less PS GEAR 2WD: Steering rack runout Maximum 0.3 mm (0.0118 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 252 0.3−0.5 N·m (3−5.5 kgf·cm, 2.6−4.8 in.·lbf) Total preload 0.5−0.9 N·m (5−9.5 kgf·cm, 4.3−8.3 in.·lbf) STEERING LINKAGE Tie rod length Approximately 329.2 mm (12.961 in.) Idler arm rotating torque 0.5−2.9 N·m (5−30 kgf·cm, 5−26 in.·lbf) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 253 PS GEAR 2WD: Control valve housing x Rack housing Self−locking nut Rack housing cap Rack guide spring cap lock nut 51 (60) 521 (700) 38 (51) Rack x Rack end 61 (83) 618 (850) 45 (62) 1996 TOYOTA T100 (RM449U)
  • Page 254 Idler arm assembly x Frame 1450 Relay rod x Idler arm assembly Steering damper set bolt and nut Relay rod x Steering damper IDLER ARM Idler arm x Idler arm bracket ( ): For use without SST 1996 TOYOTA T100 (RM449U)
  • Page 255 SERVICE SPECIFICATIONS − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM SS08E−01 SERVICE DATA FRONT AIRBAG SENSOR S − Less then 1 Ω S − 1 MΩ or Higher S − 755 − 885 Ω 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 256 SS−76 SERVICE SPECIFICATIONS − SUPPLEMENTAL RESTRAINT SYSTEM SS08D−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Steering wheel Steering wheel pad 78 in.·lbf Airbag sensor assembly Front airbag sensor 1996 TOYOTA T100 (RM449U)
  • Page 257 Approx. 137.0 Ω A − C Approx. 123.0 Ω B − C Approx. 260.0 Ω FUEL RECEIVER GAUGE (w/o Tachometer) Resistance (Ω) A − B Approx. 150.0 Ω A − C Approx. 80.0 Ω 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 258 3 − Ground (Constant) Battery positive voltage 5 − Ground (Ignition Switch position: LOCK) No voltage 5 − Ground (Ignition switch position: ACC) Battery positive voltage 7 − Ground (Ignition switch position: LOCK) No voltage 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 259 8 − Ground (Ignition switch position: ACC or ON) Battery positive voltage (Radio switch ON and cassette OFF) 4 − Ground (Ignition switch position: LOCK or ACC) No voltage 4 − Ground (Ignition switch position: ON) Battery positive voltage 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 260 Adjustable anchor x Body Shoulder anchor x Adjustable anchor ELR x Body Lap outer anchor x Body Inner belt x Body Rear Seat Belt − − − Shoulder anchor x Body ELR x Body 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 261 SS−81 SERVICE SPECIFICATIONS − BODY Part tightened N·m kgf·cm ft·lbf Lap outer anchor x Body Inner belt x Body 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 262 New belt 160 ± 25 lbf Used belt 100 ± 20 lbf Idle−up speed − 3RZ − FE 900 rpm 5VZ − FE 850 rpm Magnetic clutch clearance 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 263 Cooling unit x Liquid tube Expansion valve x Evaporator Expansion valve x Liquid tube Receiver x Liquied tube 48 in.·lbf Condenser x Liquid tube Condenser x Discharge hose Pressure switch x Liquied tube Pressure plate x Compressor 13.2 1996 TOYOTA T100 (RM449U)
  • 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 See the indicated pages for detailed explanations. Customer Problem Analysis P. DI−2 Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3 P. DI−3 If the display indicates a communication fault in the tool, inspect DLC3 P. DI−3 Check DTC and Freezed Frame Data (Precheck) Record or Print DTC and Freezed Frame Data P.
  • Page 266 Other Condition of MIL Remains on Sometimes lights up Does not light up Normal Malfunction code(s) (code Normal Mode (Precheck) Freezed frame data ( DTC Inspection Normal Malfunction code(s) (code Check Mode Freezed frame data ( 1996 TOYOTA T100 (RM449U)
  • Page 267 When troubleshooting OBD II vehicles, the only dif- ference from the usual troubleshooting procedure is that you connect to the vehicle the OBD II scan tool complying with SAE J1978 or TOYOTA hand− held tester, and read off various data output from the vehicle’s ECM.
  • Page 268 Line / Pulse generation During transmission Chassis Ground ↔ Body Ground / 1 Ω or less Always Signal Ground ↔ Body Ground / 1 Ω or less Always Battery Positive ↔ Body Ground / 9 − 14 V Always 1996 TOYOTA T100 (RM449U)
  • Page 269 If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD II scan tool or TOYOTA hand−held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the ve- hicle side or tool side.
  • Page 270 NOTICE: When simulating symptoms with an OBD II scan tool (ex- cluding TOYOTA hand−held tester) to check the DTCs, use normal mode. For code on the DTC chart subject to ”2 trip detection logic”, turn the ignition switch OFF after the symptom is simulated the 1st time.
  • Page 271 Disconnecting the battery terminals or EFI fuse. NOTICE: If the TOYOTA hand−held tester switches the ECM from normal mode to check mode or vice−versa, or if the igni- tion switch is turned from ON to ACC or OFF during check mode, the DTCs and freezed frame data will be erased.
  • Page 272 Visual check that the air filter is not dirty or excessive oily. HINT: If necessary, clean the filter with compressed air. First blow from inside thoroughly, then blow from outside of the filter. Inside Repair or replace. P00495 1996 TOYOTA T100 (RM449U)
  • Page 273 Switch off all the accessories. Switch off the air conditioning. Shift the transmission into ”N” position. Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3 on the vehicle. CHECK: Use CURRENT DATA to check the idle speed.
  • Page 274 Be sure that enough fuel is in the tank. Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand− held tester main switch ON. Use ”ACTIVE TEST” mode to operate the fuel pump.
  • Page 275 So do not decide whether a part is faulty or not solely according to the ”Normal Condition” here. CARB mandated signals. TOYOTA hand−held tester display Measurement Item Normal Condition* Fuel System Bank 1 FUEL SYS #1 OPEN: Air−fuel ratio feedback stopped...
  • Page 276 DI−12 DIAGNOSTICS − ENGINE (3RZ−FE) TOYOTA Enhanced Signals. TOYOTA hand−held tester display Measurement Item Normal Condition* MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 rpm MISFIRE LOAD Engine load for first misfire range Misfire 0: 0 g/r INJECTOR Fuel injection time for cylinder No.1...
  • Page 277 Heated Oxygen Sensor Circuit P0136 Malfunction S Heated oxygen sensor (DI−53) (Bank 1 Sensor 2) Heated Oxygen Sensor Heater P0141 Circuit Malfunction S Same as DTC No. P0135 (DI−51) (Bank 1 Sensor 2) @@@ MIL lights up 1996 TOYOTA T100 (RM449U)
  • Page 278 S Short in EGR gas temp. sensor circuit S ECM S Three−way catalytic convertor P0420 Catalyst System Efficiency S Open or short in heated oxygen sensor circuit (DI−86) Below Threshold S Heated oxygen sensor @@@ MIL lights up 1996 TOYOTA T100 (RM449U)
  • Page 279 ECM BATT Malfunction (DI−112) S ECM S Short in park/neutral position switch circuit P1780 Park/Neutral Position Switch S Park/neutral position switch (DI−114) Malfunction S ECM *: − @@@ MIL does not light up, @@@ MIL lights up 1996 TOYOTA T100 (RM449U)
  • Page 280 DI−16 DIAGNOSTICS − ENGINE (3RZ−FE) DI0T9−02 PARTS LOCATION Camshaft Position Sensor (Built into Distributor) P24451 1996 TOYOTA T100 (RM449U)
  • Page 281 V−R ↔ BR IG switch ON, Disconnect E7 of ECM connector 9 − 14 Maintain engine speed at 2,500 rpm for 2 min. after OX1 (E6−6) − E1 (E7−14) B ↔ BR Pulse generation warming up 1996 TOYOTA T100 (RM449U)
  • Page 282 ACT (E4−8) − E1 (E7−14) L−B ↔ BR A/C switch ON at idling Below 2.0 A/C switch ON at idling Below 2.0 AC1 (E4−10) − E1 (E7−14) B−R ↔ BR A/C switch OFF idling 9 − 14 1996 TOYOTA T100 (RM449U)
  • Page 283 V−R ↔ BR IG switch ON, Disconnect E7 of ECM connector 9 − 14 Maintain engine speed at 2,500 rpm for 2 min. after OX1 (E6−5) − E1 (E7−24) B ↔ BR Pulse generation warming up 1996 TOYOTA T100 (RM449U)
  • Page 284 ACT (E4−6) − E1 (E7−24) L−B ↔ BR A/C switch ON at idling Below 2.0 A/C switch ON at idling Below 2.0 AC1 (E4−7) − E1 (E7−24) B−R ↔ BR A/C switch OFF idling 9 − 14 1996 TOYOTA T100 (RM449U)
  • Page 285 Surging (Poor driveability) 1. Fuel pump control circuit DI−118 Soon after starting (Engine stall) 1. Fuel pump control circuit DI−118 1. A/C signal circuit (Compressor circuit) AC−79 During A/C operation (Engine stall) 2. Engine control module (ECM) IN−26 1996 TOYOTA T100 (RM449U)
  • Page 286 HINT: After confirming DTC P0100 use the OBD II scan tool or TOYOTA hand−held tester to confirm the mass air flow ratio from ”CURRENT DATA”. Mass Air Flow Value (gm/sec.)

  • Page 287: Inspection Procedure

    PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch Start the engine. CHECK: Read mass air flow rate on the OBD II scan tool or TOYOTA hand−held tester.
  • Page 288 Measure voltage between terminal VG of ECM connector and body ground while engine is idling. VG (+) Voltage: For A/T 1.0 − 1.5 V (A/C switch OFF) P23804 P23805 A00044 Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 289 A00045 Check and replace ECM (See page IN−26). Check for open in harness and connector between mass air flow meter and ECM (See page IN−26). Repair or replace harness or connector. Replace mass air flow meter. 1996 TOYOTA T100 (RM449U)
  • Page 290 Refer to DTC P0110 (Intake Air Temp Circuit Malfunction) on page DI−27 for the WIRING DIAGRAM. INSPECTION PROCEDURE Are there any other codes (besides DTC P0101) being output? Go to relevant DTC chart. Replace mass air flow meter. 1996 TOYOTA T100 (RM449U)
  • Page 291 Open or short in intake air temp. sensor circuit S Intake air temp. sensor S ECM HINT: After confirming DTC P110 use the OBD II scan tool or TOYOTA nand−held tester to confirm the intake air temp. from ”CURRENT DATA”. Temp. Displayed Malfunction −...
  • Page 292 PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3. Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand−held tester.
  • Page 293 Connect the sensor wire harness terminals together. Intake Air Temp. Turn the ignition switch ON. Sensor CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. (M/T)(A/T) BE6653 Temp. value: 140°C (284°F) or more P19555 A00046 Confirm good connection at sensor.
  • Page 294 E6 E6 (M/T)(A/T) connector (See page DI−3). Turn the ignition switch ON. CHECK: For M/T Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. Temp. value: 140°C (284°F) or more For A/T BE6653 P19553 Open in harness between terminals E2 or THA,...
  • Page 295 Disconnect the intake air temp. sensor connector. Turn the ignition switch ON. Intake Air Temp. CHECK: Sensor Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. (M/T)(A/T) Temp. value: − 40°C (− 40°F) BE6653 P19554 A00048 Replace intake air temp.
  • Page 296 HINT: Sensor The intake air temp. sensor connector is disconnected. Turn the ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. For M/T Temp. value: − 40°C (− 40°F) E6 Connector...
  • Page 297 Open or short in engine coolant temp. sensor circuit S Engine coolant temp. sensor S ECM HINT: After confirming DTC P0115 use the OBD II scan tool or TOYOTA hand−held tester to confirm the engine coolant temp. from ”CURRENT DATA”. Temp. Displayed Malfunction −...
  • Page 298 PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand−held tester.
  • Page 299 Before checking, do a visual and contact pressure check for the ECM connector (See page DI−3). (M/T)(A/T) Turn the ignition switch ON. CHECK: For M/T Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. Temp. value: 140°C (284°F) or more For A/T BE6653 P19553...
  • Page 300 Disconnect the engine coolant temp. sensor connector. Turn the ignition switch ON. Engine Coolant CHECK: Temp. Sensor Read temp. value on the OBD II scan tool or TOYOTA hand− E6 E6 held tester. E6 E6 (M/T)(A/T) Temp. value: − 40°C (− 40°F)
  • Page 301 Temp. Sensor The engine coolant temp. sensor connector is disconnected. Turn the ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. For M/T Temp. value: − 40°C (− 40°F) E6 Connector...
  • Page 302 Perform troubleshooting of DTC P0115 first. Are there any other codes (besides DTC P0116) being output? Go to relevant DTC chart. Check thermostat (See page CO−9). Replace thermostat. Replace engine coolant temp. sensor (See page MF−45). 1996 TOYOTA T100 (RM449U)
  • Page 303 If there is open circuit in IDL line, DTC P0120 does not indicate. After confirming DTC P0120 use the OBD II scan tool or TOYOTA hand−held tester to confirm the throttle valve opening percentage and closed throttle position switch condition.
  • Page 304 PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3. Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch CHECK: Read the throttle valve opening percentage.
  • Page 305 Terminals Throttle valve Resistance 1 − 4 ⎯ 2.5 − 5.9 kΩ P23809 2 − 4 Fully closed 0.2 − 5.7 kΩ 2 − 4 Fully open 2.0 − 10.2 kΩ Replace throttle position sensor. 1996 TOYOTA T100 (RM449U)
  • Page 306 Voltage: 4.5 − 5.5 V For A/T VCC (+) E2 (−) BE6653 Check and replace ECM (See page IN−26). P23812 A00028 P23813 Check for open in harness and connector be- tween ECM and sensor (VCC line) (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 307 30 km/h (19 mph and 0 km/h (0 mph) INSPECTION PROCEDURE Are there any other codes (besides DTC P0121) being output? Go to relevant DTC chart. Replace throttle position sensor. 1996 TOYOTA T100 (RM449U)
  • Page 308 (d) 140 sec. or more after starting engine HINT: After confirming DTC P0125 use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of heated oxygen sensor from "CURRENT DATA". If voltage output of heated oxygen sensor is 0 V, heated oxygen sensor circuit may be open or short.
  • Page 309 To Body Ground P19611 INSPECTION PROCEDURE 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: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3.
  • Page 310 Check for open and short in harness and connector between ECM and heated oxygen sensor (bank 1 sensor 1) (See page IN−26). Repair or replace harness or connector. Replace heated oxygen sensor (bank 1 sensor 1). 1996 TOYOTA T100 (RM449U)
  • Page 311 If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand−held tester, turn the ignition switch OFF after performing steps (3) to (5), then perform steps (3) to (5) again.
  • Page 312 Repair or replace harness or connector. Check for heated oxygen sensor data. PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Warm up the engine to normal operating temp. CHECK: Read heated oxygen sensor output voltage and short−term fuel trim.
  • Page 313 Warm up the heated 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. Heated oxygen sensor output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the following table)
  • Page 314 (2 trip detection logic) HINT: Sensor 1 refers to the sensor closer to the engine body. INSPECTION PROCEDURE Are there any other codes (besides DTC P0133) being output? Go to relevant DTC chart. Replace heated oxygen sensor. 1996 TOYOTA T100 (RM449U)
  • Page 315 (2 trip detection logic) HINT: Sensor 1 refers to the sensor closer to the engine body. Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC P0125 on page DI−44. 1996 TOYOTA T100 (RM449U)
  • Page 316 P23815 A00056 Check and replace ECM (See page IN−26). Check resistance of heated oxygen sensor heater. Replace heated oxygen sensor. Check and repair harness or connector be- tween EFI main relay, heated oxygen sensor and ECM. 1996 TOYOTA T100 (RM449U)
  • Page 317 Are there any other codes (besides DTC P0136) being output? Go to relevant DTC chart. Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 318 ENGINE (3RZ−FE) Check output voltage of heated oxygen sensor (bank 1 sensor 2). PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. 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.
  • Page 319 If the total of the short−term fuel trim value and long−term fuel trim value is within ± 25 %, the system is functioning normally. INSPECTION PROCEDURE Check air induction system (See page MF−1). Repair or replace. 1996 TOYOTA T100 (RM449U)
  • Page 320 ENGINE (3RZ−FE) Check for heated oxygen sensor (bank 1 sensor 1 ) data. PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Warm up the engine to normal operating temp. CHECK: Read heated oxygen sensor output voltage and short−term fuel trim.
  • Page 321 ENGINE (3RZ−FE) Check mass air flow meter and engine coolant temp. sensor (See page DI−22,DI−33). Repair or replace. Check for spark and ignition (See page IG−1). Repair or replace. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 322 S Engine coolant temp. sensor HINT: When the 2 more codes for a misfiring cylinder are recorded repeatedly but no random misfire code is re- corded, it indicates that the misfires were detected and recorded at different times. 1996 TOYOTA T100 (RM449U)
  • Page 323 With the engine idling, measure between terminals #10, #20 and E01 of ECM. HINT: The correct waveform is as shown. (Magnification) 10 V/ 10 V/ Division Division 100 msec./Division (Idling) 1 msec./Division (Idling) Injection duration FI6588 FI6538 A00064 1996 TOYOTA T100 (RM449U)
  • Page 324 To prevent excess fuel being injected from the injectors P03792 during this test, don’t crank the engine for more than 5 − 10 P25086 A00065 seconds at a time. Spark jumps across electrode gap. Replace or check ignition system (See page IG−1). 1996 TOYOTA T100 (RM449U)
  • Page 325 Check for open and short in harness and con- nector between injector and ECM (See page IN−26). Check fuel pressure (See page MF−5). Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page MF−10). 1996 TOYOTA T100 (RM449U)
  • Page 326 Replace injector. Check EGR system (See page EC−7). Repair EGR system. Check mass air flow meter and engine coolant temp. sensor (See page DI−22, DI−33). Repair or replace. Check compression pressure, valve clear- ance and valve timing. 1996 TOYOTA T100 (RM449U)
  • Page 327 S ECM If the ECM detects the above diagnosis conditions, it operates the fail safe function in which the corrective retard angle value is set to the maximum value. WIRING DIAGRAM Knock Sensor 1 (M/T) (A/T) P19613 1996 TOYOTA T100 (RM449U)
  • Page 328 AB0117 P23818 P24201 A00067 Check knock sensor (See page MF−47). Replace knock sensor. Check for open and short in harness and connector between ECM and knock sensor (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 329 Spread the time on the horizontal axis, and confirm that period of the wave is 151 μsec (Normal mode vibration frequency of knock sensor: 6.6 kHz). HINT: If normal mode vibration frequency is not 6.6 kHz the sensor is 100 μsec./Division malfunctioning. A00068 1996 TOYOTA T100 (RM449U)
  • Page 330 S Starter No crankshaft position sensor signal to ECM with engine S ECM speed 600 rpm or more (2 trip detection logic) WIRING DIAGRAM Camshaft Position Sensor (Built into distributor) G− NE− (M/T)(A/T) Crankshaft Position Sensor A00059 1996 TOYOTA T100 (RM449U)
  • Page 331 Division 10 msec./Division (Idling) FI7059 FI7060 A00069 Replace crankshaft position sensor. Check for open and short in harness and connector between ECM and crank- shaft position sensor (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 332 DI−68 DIAGNOSTICS − ENGINE (3RZ−FE) Inspect sensor installation and teeth of signal plate. Tighten the sensor. Replace signal plate. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 333 Deviation on crankshaft position sensor signal and camshaft P0336 S Distributor installation position sensor signal S ECM INSPECTION PROCEDURE Check valve timing (See page EM−38). Adjust valve timing. Check distributor installation (See page EM−5). Reinstall distributor. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 334 Reference: INSPECTION USING OSCILLOSCOPE Refer to DTC P0335 on page DI−66. Replace distributor housing. Check for open and short in harness and connector between ECM and distributor (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 335 DI−71 DIAGNOSTICS − ENGINE (3RZ−FE) Check air gap (See page EM−1). Replace distributor housing. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 336 WIRING DIAGRAM From Battery From IG Switch B−W No.1 EFI Relay VSV for EGR 6 22 W−R W−R W−R E7 E7 B−Y R/B No.2 G−W E6 E6 BR−B E6 E6 EGR Gas (M/T)(A/T) Temp. Sensor P19921 1996 TOYOTA T100 (RM449U)
  • Page 337 (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 does not light up, the system is normal.
  • Page 338 Connect TOYOTA hand−held tester and read value of EGR gas temp. value. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand−held tester main switch ON. CHECK: Read EGR gas temp. on the TOYOTA hand−held tester.
  • Page 339 The EGR gas temp. sensor connector is disconnected. Before checking, do a visual check and contact pressure check for the ECM connector (See page IN−26). (M/T)(A/T) CHECK: Read EGR gas temp. on the TOYOTA hand−held tester. For M/T EGR gas temp.: 159.3°C (318.7°F) For A/T BE6653 P19553 Open in harness between terminals E2 or THG.
  • Page 340 Select the ”ACTIVE TEST” mode on the TOYOTA hand−held tester. CHECK: System is OFF System is ON Check operation of VSV when it is operated by the TOYOTA hand−held tester. 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.
  • Page 341 PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand−held tester main switch ON. Select the ”ACTIVE TEST” mode on the TOYOTA hand−held tester (EGR system ON). Race the engine at 4,000 rpm for 3 min.
  • Page 342 DI−78 DIAGNOSTICS − ENGINE (3RZ−FE) OBD II scan tool (excluding TOYOTA hand−held tester): Check resistance of EGR gas temp. sensor. PREPARATION: EGR Gas Temp. Sensor Connector Disconnect the EGR gas temp. sensor connector. CHECK: Measure resistance between terminals of EGR gas temp. sen- sor connector.
  • Page 343 Open in harness between terminals E2 or THG. P24203 A00073 Repair or replace harness. Confirm connection at ECM. If OK, replace ECM. Check connection of vacuum hose and EGR hose (See page EC−2). Repair or replace. 1996 TOYOTA T100 (RM449U)
  • Page 344 FI7205 Go to step 7. FI7206 A00074 Check operation for VSV for EGR (See page MF−44). Replace VSV for EGR. Check for open in harness and connector be- tween R/B NO.2 and ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 345 4,000 rpm. P24228 Resistance of EGR gas temp. sensor after 3 min.: 4.3 kΩ or less HINT: Resistance: 188.6 − 439.0 kΩ at 20°C (68°F) Replace EGR gas temp. sensor. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 346 Connect TOYOTA hand−held tester and read EGR gas temp. value. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand−held tester main switch ON. CHECK: Read EGR gas temp. on the TOYOTA hand−held tester.
  • Page 347 Check for short in harness and ECM. PREPARATION: Disconnect the EGR gas temp. sensor connector. CHECK: EGR Gas Temp. Read EGR gas temp. on the TOYOTA hand−held tester. Sensor 3 14 E6 E6 EGR gas temp.: 3.1°C (37.6°F) E6 E6 (M/T)(A/T) Replace EGR gas temp.
  • Page 348 Replace VSV for EGR. Check for open 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): Check resistance of EGR gas temp. sensor. PREPARATION: EGR Gas Temp. Sensor Disconnect the EGR gas temp.
  • Page 349 Check operation of VSV for EGR (See page MF−44). Replace VSV for EGR. Check for open in harness and connector between R/B N0.2 and ECM (See page IN−26). Repair or replace harness or connector. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 350 (bank 1 sensor 1, 2) have same S Heated oxygen sensor (bank 1 sensor 1, 2) amplitude (2 trip detection logic) CONFIRMATION ENGINE RACING PATTERN Engine Speed 2500 − 3000 rpm Idling Time IG SW OFF Check 3 minutes Warmed up P25762 1996 TOYOTA T100 (RM449U)
  • Page 351 − ENGINE (3RZ−FE) (1) Connect the OBD ll scan tool or TOYOTA hand−held tester to the DLC3. (2) Start engine and warm it up with all accessories switched OFF until the water temperature is stable. (3) Race the engine at 2500 − 3000 rpm for about 3 min.
  • Page 352 (2 trip detection logic) S Vacuum hose cracks, hole, blocked, damaged or disconnected S Charcoal canister WIRING DIAGRAM From From IG Switch Battery R/B No.2 VSV for EVAP W−R W−G W−G E7 E5 (M/T)(A/T) W−R A00647 1996 TOYOTA T100 (RM449U)
  • Page 353 − ENGINE (3RZ−FE) INSPECTION PROCEDURE TOYOTA hand−held tester: Connect TOYOTA hand−held tester and check operation of VSV for EVAP. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand−held tes- ter main switch ON.
  • Page 354 Repair or replace. Check and repair charcoal canister (See page EC−5). OBD II scan tool (excluding TOYOTA hand−held tester): Check operation of VSV for EVAP (See page MF−43). Replace VSV for EVAP. Check voltage between terminal PRG of ECM connector and body ground.
  • Page 355 DI−91 DIAGNOSTICS − ENGINE (3RZ−FE) Check connection of vacuum hose (See Fig 1 in circuit description). Repair or replace. Check charcoal canister (See page EC−5). Repair or replace. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 356 S No.1 vehicle speed sensor P0500 (2 trip detection logic) S ECM (a) Vehicle is being driven S Speedometer cable WIRING DIAGRAM From Cruise Control ECU Combination Meter No.1 Vehicle G (M/T) G (M/T) Speed Sensor (M/T)(A/T) G (A/T) P19617 1996 TOYOTA T100 (RM449U)
  • Page 357 Voltage is generated intermittently. For A/T SP1 (+) 4.5 − 5.5 V BE6653 P24206 P24205 A00082 Turn wheel AT7809 Check and repair harness and connector be- tween combination meter and ECM. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 358 (2 trip detection logic) S Air intake (hose loose) WIRING DIAGRAM From Battery Valve From V−Y IG Switch E7 E7 W−R 10 7 V−R E7 E7 (M/T)(A/T) No.1 B−W EFI Relay W−R W−B B−Y R/B No.2 1996 TOYOTA T100 (RM449U) P19957...
  • Page 359 Measure voltage between terminals RSO and RSC of ECM connector and body ground. Voltage: 9 − 14 V E7 Connector For A/T RSO (+) RSC (+) BE6653 E7 Connector P24207 P24208 A00083 Go to step 4. 1996 TOYOTA T100 (RM449U)
  • Page 360 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). Check operation of IAC valve (See page MF−31). Repair or replace IAC valve. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 361 S Closed throttle position switch (2 trip detection logic) S ECM HINT: After confirming DTC P0510 use the TOYOTA hand−held tester to confirm the closed throttle position switch signal from ”CURRENT DATA”. Throttle Valve Closed Throttle Position Switch Signal Malfunction...
  • Page 362 Connect the sensor wire harness terminals between ter- minals 3 and 4. Throttle Position Turn the ignition switch ON. Sensor CHECK: E6 E6 Read CTP switch signal on the TOYOTA hand−held tester. 11 10 E6 E6 12 11 CTP switch signal: ON E6 E6 E6 E6...
  • Page 363 Before checking, do a visual check and contact pressure check for the connector (See page IN−26). E6 E6 Turn the ignition switch ON. (M/T)(A/T) CHECK: Read CTP switch signal on the TOYOTA hand−held tester. For M/T IDL (+) CTP switch signal: ON For A/T IDL (+)
  • Page 364 Connect the TOYOTA hand−held tester to the DLC3. Disconnect the throttle position sensor connector. Turn the ignition switch ON. Throttle Position CHECK: Sensor Read CTP switch signal on the TOYOTA hand−held tester. E6 E6 11 10 CTP switch signal: OFF E6 E6 12 11...
  • Page 365 E6 E6 HINT: 11 10 Throttle position sensor connector is disconnected. E6 E6 12 11 CHECK: E6 E6 Read CTP switch signal on TOYOTA hand−held tester. E6 E6 (M/T)(A/T) For M/T CTP switch signal: OFF E6 Connector For A/T E6 Connector...
  • Page 366 DI−102 DIAGNOSTICS − ENGINE (3RZ−FE) OBD II scan tool (excluding TOYOTA hand−held tester): Check for open in harness or ECM. PREPARATION: Disconnect the throttle position sensor connector. Turn the ignition switch ON. CHECK: Throttle Position Measure voltage between terminals 3 and 4 of throttle position Sensor sensor connector.
  • Page 367 No IGF signal to ECM for 4 consecutive IGT signal during P1300 S Igniter engine running S ECM WIRING DIAGRAM W−R W−R IG Switch R/B No.2 B−R B−R Spark plug Tachometer B−L E7 E7 B−W B−Y E7 E7 (M/T)(A/T) Ignition Igniter Coil S00874 1996 TOYOTA T100 (RM449U)
  • Page 368 Check spark plug and spark (See page IG−1). Go to step 4. Check for open and short in harness and connector in IGF signal circuit between ECM and igniter (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 369 A00087 Replace igniter. Check and replace ECM (See page IN−26). Check for open and short in harness and connector in IGT signal circuit between ECM and igniter (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 370 IGT signal waveform During cranking or idling, check waveform between terminals 2 V/ IGT and E1 of ECM. Division HINT: The correct waveforms are as shown. 10 msec./Division (Iding) FI6680 Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 371 When the ignition switch is turned to ”ON” and ”STA” position, measure voltage between terminal 3 of igniter connector and body ground. 3 (+) Voltage: 9 − 14 V BE6653 P24215 A00089 Check and repair igniter power source circuit. 1996 TOYOTA T100 (RM449U)
  • 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). Repair or replace harness or connector. Check ignition coil (See page IG−1). Replace ignition coil. Replace igniter. 1996 TOYOTA T100 (RM449U)
  • Page 373 No crankshaft position sensor signal to ECM with engine P1335 S Crankshaft position sensor speed 1,000 rpm or more S ECM WIRING DIAGRAM Refer to DTC P0335 on page DI−66. INSPECTION PROCEDURE Refer to DTC P0335 on page DI−66. 1996 TOYOTA T100 (RM449U)
  • Page 374 In this circuit, diagnosis can only be made in the check mode. WIRING DIAGRAM Park/Neutral Position Switch B (A/T) B−Y B−Y B (M/T) R/B No. 2 Starter Relay IE1 21 Clutch Start B−R Swtich (A/T) (M/T) Battery Starter P19741 1996 TOYOTA T100 (RM449U)
  • Page 375 Connect the TOYOTA hand−held tester and check STA signal. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn ignition switch ON and TOYOTA hand−held tester main switch ON. CHECK: Read STA signal on the TOYOTA hand−held tester while starter operates.
  • Page 376 Open in back up power source circuit S ECM HINT: If DTC P1600 appear, the ECM does not store another DTC. WIRING DIAGRAM B−G B−G BATT (M/T) (M/T) B−G W−R (M/T)(A/T) R/B No.2 B−G (A/T) Battery S00876 1996 TOYOTA T100 (RM449U)
  • Page 377 Check continuity of EFI fuse. Continuity Check for short in all the harness and compo- nents connected to EFI fuse. R/B No.2 FI7107 Check and repair harness or connector be- tween battery, EFI fuse and ECM. 1996 TOYOTA T100 (RM449U)
  • Page 378 (a) Vehicle speed: 70 km/h (44 mph) or more (b) Engine speed: 1,500 − 2,500 rpm HINT: After confirming DTC P1780 use the TOYOTA hand−held tester to confirm the PNP switch signal from ”CUR- RENT DATA”. WIRING DIAGRAM Refer to DTC P1780 on page DI−114.
  • Page 379 EFI main relay (Making: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM B−R B−Y J/B No.1 Switch W−R W−R W−R 12 12 W−R (M/T) (M/T) E4 E4 W−R W−R (A/T) R−L Relay W−R 14 24 E7 E7 R/B No.2 (M/T) (A/T) B−W Battery A00646 1996 TOYOTA T100 (RM449U)
  • Page 380 Check for open in harness and connector between terminal E1 of ECM and body ground (See page IN−26). Repair or replace harness or connector. Check EFI main relay (Marking: EFI) (See page MF−40). Replace EFI main relay. 1996 TOYOTA T100 (RM449U)
  • Page 381 J/B No.1 FI7106 Check ignition switch (See page BE−12). Replace ignition switch. Check for open in harness and connector be- tween IG switch and EFI main relay, EFI main relay and body ground (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 382 While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the fuel pump also keeps operating. EFI Relay Circuit Opening Relay Fuel Pump IG Switch Park/Neutral Position Switch (A/T) Starter Relay (STA Signal) From Clutch Battery Crankshaft Start (NE Signal) Position Switch Sensor (M/T) Starter A00650 1996 TOYOTA T100 (RM449U)
  • Page 383 DI−119 DIAGNOSTICS − ENGINE (3RZ−FE) WIRING DIAGRAM W−B W−B W−B B−W B−W B−W B−R W−B W−B (A/T) B−Y B−Y W−R W−R A00649 1996 TOYOTA T100 (RM449U)
  • Page 384 − ENGINE (3RZ−FE) INSPECTION PROCEDURE TOYOTA hand−held tester: Connect TOYOTA hand−held tester and check operation of fuel pump. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand− held tester main switch ON.
  • Page 385 Voltage: 9 − 14 V For A/T FC (+) Check for open in harness and connector be- tween EFI main relay and circuit opening relay, BE6653 P24224 circuit opening relay and ECM. P24225 A00095 1996 TOYOTA T100 (RM449U)
  • Page 386 Remove the circuit opening relay (See page MF−42). CHECK: Apply battery voltage between terminals 3 and 6. Check continuity between terminal 1 and 2. Terminals 1 and 2 Continuity 3 (+) 6 (−) A00686 Replace circuit opening relay. 1996 TOYOTA T100 (RM449U)
  • Page 387 Voltage: 9 − 14 V Check for starter signal circuit (See page DI−110). A00687 Check for open in harness and connector between terminal 6 of circuit opening relay connector and body ground (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 388 DI−124 DIAGNOSTICS − ENGINE (3RZ−FE) OBD II scan tool (excluding TOYOTA hand−held tester): Check operation of fuel pump. PREPARATION: Remove the right cowl side trim (See page MF−50). Turn the ignition switch ON. FC (+) For M/T CHECK: Connect between terminal FC of ECM connector and body ground.
  • Page 389 Repair or replace fuel pump. Check for open in harness and connector between circuit opening relay and fuel pump, fuel pump and body ground (See page IN−26). Repair or replace harness or connector. Check and replace ECM. 1996 TOYOTA T100 (RM449U)
  • Page 390 Check voltage between terminal 3 of circuit opening relay connector and body ground (See page MF−42). Check for starter signal circuit (See page DI−110). Check for open in harness and connector be- tween terminal 6 of circuit opening relay con- nector and body ground (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 391 See the indicated pages for detailed explanations. Customer Problem Analysis P. DI−128 Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3 P. DI−129 If the display indicates a communication fault in the tool, inspect DLC3 P. DI−129 Check DTC and Freezed Frame Data (Precheck) Record or Print DTC and Freezed Frame Data P.
  • Page 392 Other Condition of MIL Remains on Sometimes lights up Does not light up Normal Malfunction code(s) (code Normal Mode (Precheck) Freezed frame data ( DTC Inspection Normal Malfunction code(s) (code Check Mode Freezed frame data ( 1996 TOYOTA T100 (RM449U)
  • Page 393 When troubleshooting OBD II vehicles, the only dif- ference from the usual troubleshooting procedure is that you connect to the vehicle the OBD II scan tool complying with SAE J1978 or TOYOTA hand− held tester, and read off various data output from the vehicle’s ECM.
  • Page 394 ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a mal- function that is only detected once or momentarily (TOYOTA hand−held tester only). *2 trip detection logic: When a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory.
  • Page 395 If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD II scan tool or TOYOTA hand−held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the ve- hicle side or tool side.
  • Page 396 NOTICE: When simulating symptoms with an OBD II scan tool (ex- cluding TOYOTA hand−held tester) to check the DTCs, use normal mode. For code on the DTC chart subject to ”2 trip detection logic”, turn the ignition switch OFF after the symptom is simulated the 1st time.
  • Page 397 Disconnecting the battery terminals or EFI fuse. NOTICE: If the TOYOTA hand−held tester switches the ECM from normal mode to check mode or vice−versa, or if the igni- tion switch is turned from ON to ACC or OFF during check mode, the DTCs and freezed frame data will be erased.
  • Page 398 Visual check that the air filter is not dirty or excessive oily. HINT: If necessary, clean the filter with compressed air. First blow from inside thoroughly, then blow from outside of the filter. Inside Repair or replace. P00495 1996 TOYOTA T100 (RM449U)
  • Page 399 Switch off all the accessories. Switch off air conditioning. Shift the transmission into ”N” position. Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3 on the vehicle. CHECK: Use ”CURRENT DATA” to check the idle speed.
  • Page 400 Be sure that enough fuel is in the tank. Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand− held tester main switch ON. Use ”ACTIVE TEST” mode to operate the fuel pump.
  • Page 401 To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 − 10 seconds at a time. Proceed to page IG−1 and continue to trouble- shoot. Proceed to problem symptoms table on page DI−148. 1996 TOYOTA T100 (RM449U)
  • Page 402 So do not decide whether a part is faulty or not solely according to the ”Normal Condition” here. CARB mandated signals. TOYOTA hand−held tester display Measurement Item Normal Condition* Fuel System Bank 1 FUEL SYS #1 OPEN: Air−fuel ratio feedback stopped...
  • Page 403 DI−139 DIAGNOSTICS − ENGINE (5VZ−FE) TOYOTA Enhanced Signals. TOYOTA hand−held tester display Measurement Item Normal Condition*1 MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 rpm MISFIRE LOAD Engine load for first misfire range Misfire 0: 0 g/r INJECTOR Fuel injection time for cylinder No.1...
  • Page 404 Heated Oxygen Sensor Circuit P0136 Malfunction S Heated oxygen sensor (DI−178) (Bank 1 Sensor 2) Heated Oxygen Sensor Heater P0141 Circuit Malfunction S Same as DTC No. P0135 (DI−176) (Bank 1 Sensor 2) @@@ MIL lights up 1996 TOYOTA T100 (RM449U)
  • Page 405 Below Threshold circuit S Heated oxygen sensor (bank 1 sensor 1, 2) : MIL lights up : MIL lights up or blinking Only for 2WD models with a load capacity of 0.5 ton and regular cab. 1996 TOYOTA T100 (RM449U)
  • Page 406 Knock Control CPU Malfunction S ECM (DI−246) S Short in park/neutral position switch circuit P1780 Park/Neutral Position Switch S Park/neutral position switch (DI−247) Malfunction S ECM *: − @@@ MIL does not light up, @@@ MIL lights up 1996 TOYOTA T100 (RM449U)
  • Page 407 Sensor Ignition Coil VSV for EVAP Injector EFI Main Relay Knock Sensor 1 (Marking : EFI) Knock Sensor 2 DLC1 *: Only for 2WD models with a load capacity of 0.5 ton and regular cab. A00783 1996 TOYOTA T100 (RM449U)
  • Page 408 (See page DI−183) IG switch ON 9 − 14 #60 (E7−8) − E01 (E7−13) Y−B ↔ BR Pulse generation Idling (See page DI−183) Pulse generation IGT1 (E7−23) − E1 (E7−24) B−L ↔ BR Idling (See page DI−235) 1996 TOYOTA T100 (RM449U)
  • Page 409 B−R ↔ BR A/C switch OFF at Idling 9 − 14 SDL (E4−19) − E1 (E7−24) W ↔ BR During transmission Pulse generation *: Only for 2WD models with a load capacity of 0.5 ton and regular cab. 1996 TOYOTA T100 (RM449U)
  • Page 410 (See page DI−235) IG switch ON and apply vacuum to the throttle opener/THrottle 0 − 3 valve fully closed IDL (E7−32) − E2 (E6−22) Y−L ↔ BR−B IG switch ON 9 − 14 Throttle valve fully open 1996 TOYOTA T100 (RM449U)
  • Page 411 3.9 − 5.0 IG switch ON 9 − 14 FC (E5−4) − E1 (E5−16) G−Y ↔ BR Idling 0 − 3.0 *: Only for 2WD models with a load capacity of 0.5 ton and regular cab. 1996 TOYOTA T100 (RM449U)
  • Page 412 Surging (Poor driveability) 1. Fuel pump control circuit DI−255 Soon after starting (Engine stall) 1. Fuel pump control circuit DI−255 1. A/C signal circuit (Compressor circuit) AC−79 During A/C operation (Engine stall) 2. Engine control module (ECM) IN−26 1996 TOYOTA T100 (RM449U)
  • Page 413 HINT: After confirming DTC P0100 use the OBD II scan tool or TOYOTA hand−held tester to confirm the mass air flow ratio from ”CURRENT DATA”. Mass Air Flow Value (gm/sec.)
  • Page 414 PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch Start the engine. CHECK: Read mass air flow rate on the OBD II scan tool or TOYOTA hand−held tester.
  • Page 415 Measure voltage between terminal VG of ECM connector and body ground while engine is idling. VG (+) For A/T Voltage: 1.1 − 1.5 V (P or N position and A/C switch OFF) P23805 A00100 P24311 Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 416 A00101 Check and replace ECM (See page IN−26). Check for open in harness and connector between mass air flow meter and ECM (See page IN−26). Repair or replace harness or connector. Replace mass air flow meter. 1996 TOYOTA T100 (RM449U)
  • Page 417 (a) VTA y 0.63 V (b) Mass air flow meter output t 1.06 V INSPECTION PROCEDURE Are there any other codes (besides DTC P0101) being output? Replace mass air flow meter. Go to relevant DTC chart. 1996 TOYOTA T100 (RM449U)
  • Page 418 Open or short in intake air temp. sensor circuit S Intake air temp. sensor S ECM HINT: After confirming DTC P0110 use the OBD II scan tool or TOYOTA hand−held tester to confirm the intake air temp. from ”CURRENT DATA”. Temp. Displayed Malfunction −...
  • Page 419 PREPARATION: Connector the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand−held tester.
  • Page 420 Connect the sensor wire harness terminals together. Intake Air Turn the ignition switch ON. Temp. Sensor CHECK: 12 14 Read temp. value on the OBD II scan tool or TOYOTA 9 22 hand−held tester. (M/T) (A/T) BE6653 Temp. value: 140°C (284°F) or more...
  • Page 421 Disconnect the mass air flow meter connector. Turn the ignition switch ON. Intake Air Temp. Sensor CHECK: 12 14 Read temp. value on the OBD II scan tool or TOYOTA hand−held tester. 9 22 (M/T) (A/T) Temp. value: − 40°C (− 40°F)
  • Page 422 P0115 Open or short in engine coolant temp. sensor circuit S ECM HINT: After confirming DTC P0115 use the OBD II scan tool or TOYOTA hand−held tester to confirm the engine coolant temp. from ”CURRENT DATA”. Temp. Displayed Malfunction − 40°C (− 40°F) Open circuit 140°C (284°F) or more...
  • Page 423 PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand−held tester.
  • Page 424 For M/T ECM connector (See page IN−26). Turn the ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand−held tester. For A/T Temp. value: 140°C (284°F) or more Open in harness between terminals E2 or THW, BE6653 repair or replace harness.
  • Page 425 HINT: The engine coolant temp. sensor connector is disconnected. Turn the ignition switch ON. For M/T CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand−held tester. Temp. value: − 40°C (− 40°F) E6 Connector For A/T...
  • Page 426 If DTCs P0115 and P0116 are output simultaneously, engine coolant temp. sensor circuit may be open.Per- form troubleshooting of DTC P0115 first. Are there any other codes (besides DTC P0116) being output? Go to relevant DTC chart. Check thermostat (See page CO−9). Replace thermostat. Replace engine coolant temp. sensor. 1996 TOYOTA T100 (RM449U)
  • Page 427 (b) VTA 4.9 V S ECM HINT: After confirming DTC P0120 use the OBD II scan tool or TOYOTA hand−held tester to confirm the throttle valve opening percentage and closed throttle position switch condition. Throttle valve opening position Trouble Area...
  • Page 428 DI−164 DIAGNOSTICS − ENGINE (5VZ−FE) WIRING DIAGRAM Throttle Position Sensor G−B Y−B BR−B (M/T) (A/T) A00004 1996 TOYOTA T100 (RM449U)
  • Page 429 PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3. Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch CHECK: Read the throttle valve opening percentage.
  • Page 430 Fully open 2.72 ∼ 5.2 V Check for open and short in harness and connector between ECM and throttle position BE6653 P23811 sensor (VTA line) (See page IN−26). P24315 A00107 Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 431 Voltage: 4.5 − 5.5 V E2 (−) VCC (+) For A/T BE6653 P23813 A00108 P24316 Check and replace ECM (See page IN−26). Check for open in harness and connector between ECM and sensor (VCC line) (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 432 30 km/h (19 mph) and 0 km/h (0 mph) INSPECTION PROCEDURE Are there any other codes (besides DTC P0121) being output? Go to relevant DTC chart. Replace throttle position sensor. 1996 TOYOTA T100 (RM449U)
  • Page 433 (bank1 sensor 1) circuit (b) Vehicle speed: 40 − 100 km/h (25 − 62 mph) S Heated oxygen sensor (bank 1 sensor 1) (c) Throttle valve does not fully closed (d) 140 sec. or more after starting engine 1996 TOYOTA T100 (RM449U)
  • Page 434 ENGINE (5VZ−FE) HINT: After confirming DTC P0125 use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of heated oxygen sensor from "CURRENT DATA". If voltage output of heated oxygen sensor is 0 V, heated oxygen sensor circuit may be open or short.
  • Page 435 Check for open and short in harness and connector between ECM and heated oxygen sensor (bank 1 sensor 1) (See page IN−26). Repair or replace harness or connector. Replace heated oxygen sensor (bank 1 sensor 1). 1996 TOYOTA T100 (RM449U)
  • Page 436 If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand−held tester, turn the ignition switch OFF after performing steps (3) to (5), then perform steps (3) to (5) again.
  • Page 437 Repair or replace harness or connector. Check for heated oxygen sensor data. PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Warm up the engine to normal operating temp. CHECK: Read heated oxygen sensor output voltage and short−term fuel trim.
  • Page 438 Warm up the heated 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. Heated oxygen sensor output voltage: Alternates repeatedly between less than 0.35 V and more than 0.55 V (See the following table)
  • Page 439 (2 trip detection logic) HINT: Sensor 1 refers to the sensor closer to the engine body. INSPECTION PROCEDURE Are there any other codes (besides DTC P0133) being output? Go to relevant DTC chart. Replace heated oxygen sensor. 1996 TOYOTA T100 (RM449U)
  • Page 440 Connect terminal HT1 to bank 1 sensor 1. Connect terminal HT2 to bank 1 sensor 2. HT1 (+) HT2 (+) Voltage: 9 − 14 V For A/T Check and replace ECM (See page IN−26). BE6653 P24318 A00109 P24317 1996 TOYOTA T100 (RM449U)
  • Page 441 DIAGNOSTICS − ENGINE (5VZ−FE) Check resistance of heated oxygen sensor heater (See page SF−60). Replace heated oxygen sensor. Check and repair harness or connector between EFI main relay, heated oxygen sensor and ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 442 Are there any other codes (besides DTC P0136) being output? Go to relevant DTC chart. Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 443 ENGINE (5VZ−FE) Check output voltage of heated oxygen sensor. PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. 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.
  • Page 444 If the total of the short−term fuel trim value and long−term fuel trim value is within ± 25 %, the system is functioning normally. INSPECTION PROCEDURE Check air induction system (See page SF−5). Repair or replace. 1996 TOYOTA T100 (RM449U)
  • Page 445 ENGINE (5VZ−FE) Check for heated oxygen sensor (bank 1 sensor 1) data. PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Warm up the engine to normal operating temp. CHECK: Read heated oxygen sensor (bank 1 sensor 1) output voltage and short−term fuel trim.
  • Page 446 ENGINE (5VZ−FE) Check mass air flow meter and engine coolant temp. sensor (See page SF−29, SF−52). Repair or replace. Check for spark and ignition (See page IG−1). Repair or replace. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 447 *: Only for 2WD models with a load capacity of 0.5 ton and regular cab. HINT: When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no Random Misfire code is recorded, it indicates that the misfires were detected and recorded at different times. 1996 TOYOTA T100 (RM449U)
  • Page 448 With the engine idling, measure between terminals #10 − #60 and E01 of ECM. HINT: The correct waveform is as shown. (Magnification) 10 V 10 V /Division /Division 1 msec./Division (Idling) 100 msec./Division (Idling) Injection duration FI6588 FI6538 A00064 1996 TOYOTA T100 (RM449U)
  • Page 449 To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 − 10 sec. at a time. Spark jumps across electrode gap. Replace or check ignition system (See page IG−1). 1996 TOYOTA T100 (RM449U)
  • Page 450 Check for open and short in harness and con- nector between injector and ECM (See page IN−26). Check fuel pressure (See page SF−5). Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF−5). 1996 TOYOTA T100 (RM449U)
  • Page 451 Check mass air flow meter and engine coolant temp. sensor (See page SF−29 and SF−52). Repair or replace. Check the compression pressure (See page EM−2), valve clearance (See page EM−4) and valve timing (See page EM−17). 1996 TOYOTA T100 (RM449U)
  • Page 452 If the ECM detects the above diagnosis conditions, it operates the fail safe function in which the corrective retard angle value is set to the maximum value. WIRING DIAGRAM Knock Sensor 1 (On right bank) KNK1 Knock Sensor 2 (On left bank) KNK2 (M/T)(A/T) P19919 1996 TOYOTA T100 (RM449U)
  • Page 453 INSPECTION PROCEDURE HINT: DTC P0325 is for the right bank knock sensor circuit. DTC P0330 is for the left bank knock sensor circuit. Connect OBD II scan tool or TOYOTA hand−held tester and check knock sensor circuit. PREPARATION: Connect the OBD II scan tool or TOYOTA hand−held tes- ter to the DLC3.
  • Page 454 Spread the time on the horizontal axis, and confirm that period of the wave is 141 μsec (Normal mode vibration frequency of knock sensor: 7.1 kHz). HINT: If normal mode vibration frequency is not 7.1 kHz, the sensor 100 μsec./Division FI6510 is malfunctioning. A00113 FI6607 1996 TOYOTA T100 (RM449U)
  • Page 455 P0335 S Starter No crankshaft position sensor signal to ECM with engine S ECM speed 600 rpm or more (2 trip detection logic) WIRING DIAGRAM Camshaft Position Sensor G− NE− (M/T) (A/T) Crankshaft Position Sensor P25501 1996 TOYOTA T100 (RM449U)
  • Page 456 /Division 10 msec./Division (Idling) FI7059 FI7060 A00069 Replace crankshaft position sensor. Check for open and short in harness and connector between ECM and crank- shaft position sensor (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 457 DI−193 DIAGNOSTICS − ENGINE (5VZ−FE) Inspect sensor installation and teeth of signal plate. Tighten the sensor. Replace signal plate. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 458 Reference INSPECTION USING OSCILLOSCOPE Refer to DTC P0335 on page DI−191. Replace camshaft position sensor. Check for open and short in harness and connector between ECM and camshaft position sensor (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 459 DI−195 DIAGNOSTICS − ENGINE (5VZ−FE) Inspect sensor installation. Tighten the sensor. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 460 From Battery From IG Switch B−W No.1 EFI Relay VSV for EGR 18 8 W−R R−W W−R W−R E4 E5 B−Y EGR Gas Temp. Sensor R/B No.2 E6 E6 9 22 BR−B E6 E6 (M/T)(A/T) P19921 1996 TOYOTA T100 (RM449U)
  • Page 461 (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 does not light up, the system is normal.
  • Page 462 Connect TOYOTA hand−held tester and read value of EGR gas temp. value. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand−held tester main switch ON. CHECK: Read EGR gas temp. on the TOYOTA hand−held tester.
  • Page 463 9 22 E6 E6 for the ECM connector (See page IN−26). (M/T)(A/T) CHECK: For M/T Read EGR gas temp. on the TOYOTA hand−held tester. EGR gas temp.: 159°C (318.2°F) For A/T BE6653 P19553 Open in harness between terminals E2 or THG.
  • Page 464 Select the ”ACTIVE TEST” mode on the TOYOTA hand−held tester. CHECK: System is OFF System is ON Check operation of VSV when it is operated by the TOYOTA hand−held tester. EGR system is OFF: Air flows from port E to the air filter. EGR system is ON: Filter Air flows from port E to port G.
  • Page 465 PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand−held tester main switch ON. Select the ”ACTIVE TEST” mode on the TOYOTA hand−held tester (EGR system ON). Race the engine at 4,000 rpm for 3 min.
  • Page 466 DI−202 DIAGNOSTICS − ENGINE (5VZ−FE) OBD II scan tool (excluding TOYOTA hand−held tester): Check resistance of EGR gas temp. sensor. PREPARATION: EGR Gas Temp. Sensor Connector Disconnect the EGR gas temp. sensor connector. CHECK: Measure resistance between terminals of EGR gas temp. sen- sor connector.
  • Page 467 Open in harness between terminals E2 or THG. P24203 A00804 Repair or replace harness. P24323 Confirm connection at ECM. If OK, replace ECM. Check connection of vacuum hose and EGR hose (See page EC−2). Repair or replace. 1996 TOYOTA T100 (RM449U)
  • Page 468 A00774 Go to step 7. A00775 A00782 Check operation for VSV for EGR (See page SF−49). Replace VSV for EGR. Check for open in harness and connector be- tween R/B No.2 and ECM (See page EC−1 1996 TOYOTA T100 (RM449U)
  • Page 469 Connector P24227 Resistance of EGR gas temp. sensor after 3 min.: 4.3 kΩ or less HINT: Resistance: 188.6 ∼ 439.0 kΩ at 20°C (68°F) Replace EGR gas temp. sensor. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 470 Connect TOYOTA hand−held tester and read EGR gas temp. value. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand−held tester main switch ON. CHECK: Read EGR gas temp. on the TOYOTA hand−held tester.
  • Page 471 Check for short in harness and ECM. PREPARATION: Disconnect the EGR gas temp. sensor connector. CHECK: EGR Gas Temp. Read EGR gas temp. on the TOYOTA hand−held tester. Sensor 14 21 E6 E6 9 22 EGR gas temp.: 3.1°C (37.6°F)
  • Page 472 Replace VSV for EGR. Check for short in harness and connector be- tween VSV and ECM (See page IN−26). OBD II scan tool (excluding TOYOTA hand−held tester): Check resistance of EGR gas temp. sensor. PREPARATION: Disconnect the EGR gas temp. sensor connector.
  • Page 473 Check operation of VSV for EGR (See page SF−49). Replace VSV for EGR. Check for short in harness and connector between VSV and ECM (See page IN−26). Repair or replace harness or connector. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 474 S Heated oxygen sensor (bank 1 sensor 1, 2) (2 trip detection logic) CONFIRMATION ENGINE RACING PATTERN Engine Speed 2500 − 3000 rpm Idling Time IG SW OFF Warmed up 3 minutes Check P25762 1996 TOYOTA T100 (RM449U)
  • Page 475 − ENGINE (5VZ−FE) (1) Connect the TOYOTA hand−held tester to the DLC3, or connect the probe of the oscilloscope between terminals OX1, OX2 and E1 of ECM. (2) Start engine and warm it up with all accessories switched OFF until water temp. is stable.
  • Page 476 S Vapor pressure sensor S Vacuum hose cracks, holed blocked, damaged or low compared with atmospheric pressure disconnected ((1), (4), (5) and (6) in fig. 1) (2 trip detection logic) S Charcoal canister cracks, holed or damaged 1996 TOYOTA T100 (RM449U)
  • Page 477 (for Vapor Pressure Sensor) S00594 INSPECTION PROCEDURE TOYOTA hand−held tester: Check VSV connector for EVAP, VSV connector for vapor pressure sensor and vapor pressure sensor connector for looseness and disconnection. Repair or connect VSV or sensor connector. 1996 TOYOTA T100 (RM449U)
  • Page 478 Remove the glove compartment (See page SF−61). Turn ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of ECM con- nector. VC(+) E2(−) Voltage: 4.5 − 5.5 V BE6653 A06382 S00564 Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 479 6 S 0 0 0 4 A06383 Go to step 6. Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN−26). Repair or replace harness or connector. Replace vapor pressure sensor. 1996 TOYOTA T100 (RM449U)
  • Page 480 Disconnect the VSV vacuum hose for EVAP from the charcoal canister. Start the engine. CHECK: When the VSV for the EVAP is operated by the TOYOTA VSV is OFF hand−held tester, check whether the disconnected hose ap- plies suction to your finger.
  • Page 481 Check for open and short in harness and connector between EFI main relay (Marking: EFI), VSV for EVAP and ECM (See page IN−26). Repair or replace harness or connector. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 482 DI−218 DIAGNOSTICS − ENGINE (5VZ−FE) Connect TOYOTA hand−held tester, when VSV connector for vapor pressure sen- sor is disconnected and VSV for EVAP is ON, measure voltage between terminals PTNK and E2 of ECM connector. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3.
  • Page 483 Check operation of VSV for vapor pressure sensor (See page SF−50). Replace VSV. 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). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 484 Select the ”ACTIVE TEST” mode on the TOYOTA hand− Sensor held tester. VSV for Start the engine. EVAP The VSV for the EVAP is ON by the TOYOTA hand−held tester and remains on for 5 sec. 5 sec. 5 sec. CHECK: Measure Voltage Measure voltage between terminals PTNK and E2 of ECM con- E2 (−)
  • Page 485 DI−221 DIAGNOSTICS − ENGINE (5VZ−FE) OBD II scan tool (excluding TOYOTA hand−held tester): Check VSV connector for EVAP, VSV connector for vapor pressure sensor and vapor pressure sensor connector for looseness and disconnection. Repair or connect VSV or sensor connectors.
  • Page 486 6 S 0 0 0 4 A06383 Go to step 6. Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN−26). Repair or replace harness or connector. Replace vapor pressure sensor. 1996 TOYOTA T100 (RM449U)
  • Page 487 Air does not flow from port E to port F. BE6653 P24245 VSV is OFF VSV is ON P24350 FI7205 FI7206 A00118 Go to step 9. Check operation of VSV for EVAP (See page SF−50). Replace VSV. 1996 TOYOTA T100 (RM449U)
  • Page 488 Air flows from port E to port F. (2) VSV is OFF: Air flows from port E to port G. OFF ON BE6653 P24353 P24352 S05700 Check and replace charcoal canister (See page VSV is OFF VSV is ON S05703 A00786 EC−1). 1996 TOYOTA T100 (RM449U)
  • Page 489 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). Repair or replace harness or connector. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 490 No speed sensor signal to ECM under conditions (a) S No.1 vehicle speed sensor P0500 (2 trip detection logic) S ECM (a) Vehicle is being driven S Speedometer cable WIRING DIAGRAM From Cruise Control ECU Combination Meter Speed Sensor (M/T)(A/T) S05704 1996 TOYOTA T100 (RM449U)
  • Page 491 SP1 (+) Voltage is generated intermittently. For A/T 4 ∼ 6 V BE6653 P24205 A00120 P24324 Turn Wheel AT7809 Check and repair harness and connector between combination meter and ECM. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 492 S Open or short in A/C signal circuit S Air intake (hose loose) WIRING DIAGRAM From Battery Valve From B−R IG Switch E7 E7 W−R BR−R E7 E7 (M/T)(A/T) No.1 B−W EFI Relay W−R W−B B−Y R/B No.2 1996 TOYOTA T100 (RM449U) P19957...
  • Page 493 Measure voltage between terminals RSO and RSC of the ECM connector and body ground. Voltage: 9 − 14 V E7 Connector RSO (+) RSC (+) For A/T E7 Connector BE6653 P24208 A00121 P24325 Go to step 5. 1996 TOYOTA T100 (RM449U)
  • Page 494 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). Check operation of the IAC valve (See page SF−43). Repair or replace IAC valve. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 495 S Closed throttle position switch when the vehicle is driven (2 trip detection logic) S ECM HINT: After confirming DTC P0510 use the TOYOTA hand−held tester to confirm the closed throttle position switch signal from ”CURRENT DATA”. Throttle Valve Closed throttle position Switch Signal...
  • Page 496 Connect sensor wire harness terminals between termi- nals 3 and 4. Turn ignition switch ON. CHECK: Read CTP switch signal on the TOYOTA hand−held tester. A16045 CTP switch signal: ON Confirm good connection at sensor. If OK, re- place throttle position sensor.
  • Page 497 Turn ignition switch ON. CHECK: Read CTP switch signal on the TOYOTA hand−held tester. CTP switch signal: ON Open in harness between ECM and throttle A16046 position sensor, repair or replace harness.
  • Page 498 DI−234 DIAGNOSTICS − ENGINE (5VZ−FE) OBDII scan tool (excluding TOYOTA hand−held tester): Check for open in harness or ECM PREPARATION: Disconnect the throttle position sensor connector. Turn ignition switch ON. CHECK: Measure voltage between terminals 3 and 4 of throttle position sensor connector.
  • Page 499 DTC Detecting Condition Trouble Area No IGF signal to ECM for 6 consecutively IGT signals during S Open or short in IGF or IGT circuit from igniter to ECM P1300 engine running S Igniter S ECM 1996 TOYOTA T100 (RM449U)
  • Page 500 No.2 BR−W BR−B E7 E7 No.2 B−R 21 26 IGT3 B−W B−W E7 E7 No.3 17 12 B−Y E7 E7 (M/T)(A/T) Battery Tachometer S00903 INSPECTION PROCEDURE Check spark plug (See page IG−1). Go to step 4. 1996 TOYOTA T100 (RM449U)
  • Page 501 Turn the ignition switch ON. CHECK: Measure voltage between terminal IGF of ECM connector and body ground. IGF (+) For A/T Voltage: 4.5 − 5.5 V BE6653 P24211 A00122 P24326 Replace igniter. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 502 VOLT During idling, check waveform between terminals IGT1 − 3, IGF and E1 of ECM. IGT1 HINT: The correct waveforms are as shown. IGT2 IGT3 20 msec./Division (Idling) P20870 Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 503 Measure voltage between terminal 9 of igniter connector and body ground, when ignition switch is turned to ”ON” and ”START” position. Voltage: 9 − 14 V BE6653 A00124 P24329 Check and repair igniter power source circuit. 1996 TOYOTA T100 (RM449U)
  • 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). Repair or replace harness or connector. Check ignition coil (See page IG−1). Replace ignition coil. Replace igniter. 1996 TOYOTA T100 (RM449U)
  • Page 505 No crankshaft position sensor signal to ECM with engine S Crankshaft position sensor P1335 speed 1,000 rpm or more S Starter S ECM WIRING DIAGRAM Refer to DTC P0335 on page DI−191. INSPECTION PROCEDURE Refer to DTC P0335 on page DI−191. 1996 TOYOTA T100 (RM449U)
  • Page 506 S Open or short in starter signal circuit P1500 No starter signal to ECM S Open or short in ignition switch or starter relay circuit S ECM HINT: In this circuit, diagnosis can only be made in the check mode. WIRING DIAGRAM S00900 1996 TOYOTA T100 (RM449U)
  • Page 507 Connect the TOYOTA hand−held tester and check STA signal. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn ignition switch ON and push TOYOTA hand−held tester main switch ON. CHECK: Read STA signal on the TOYOTA hand−held tester while starter operates.
  • Page 508 S Open in back up power source circuit P1600 Open in back up power source circuit S ECM HINT: If DTC P1600 appear, the ECM does not store another DTC. WIRING DIAGRAM BATT B−G B−G W−R (M/T)(A/T) R/B No.2 Battery S00899 1996 TOYOTA T100 (RM449U)
  • Page 509 Remove the EFI fuse from the R/B No.2. CHECK: Check continuity of EFI fuse. Continuity R/B No.2 FI7107 Check for short in all harness and components connected to EFI fuse. Check and repair harness or connector between battery, EFI fuse and ECM. 1996 TOYOTA T100 (RM449U)
  • Page 510 S ECM WIRING DIAGRAM Refer to page DI−188 for the WIRING DIAGRAM. INSPECTION PROCEDURE Are there any other codes (besides DTC P1605) being output? Go to relevant DTC chart. Check and replace ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 511 (a) Vehicle speed: 70 km/h (44 mph) or more (b) Engine speed: 1,500 ∼ 2,500 rpm HINT: After confirming DTC P1780 use the TOYOTA hand−held tester to confirm the PNP switch signal from ”CUR- RENT DATA”. WIRING DIAGRAM Refer to DTC P1780 on page DI−247.
  • Page 512 Switch (A/T) (A/T) B−O B (M/T) Starter Clutch Start Relay Cancel Switch B−R (M/T) B−R 11 13 B−W (M/T) (M/T) No.2 E4 E7 (M/T)(A/T) B−W B−W (A/T) (A/T) Clutch Start Switch B−W B−W Starter Battery A00772 1996 TOYOTA T100 (RM449U)
  • Page 513 Connect TOYOTA hand−held tester and check STA signal. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. 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 starter operates.
  • Page 514 DI−250 DIAGNOSTICS − ENGINE (5VZ−FE) OBD II scan tool (excluding TOYOTA hand−held tester): Check voltage between terminal STA of ECM connector and body ground. PREPARATION: START Remove the right cowl side trim (See page SF−61). CHECK: For M/T STA (+) Measure voltage between terminal STA of ECM connector and body ground, during engine cranking.
  • Page 515 EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM B−R B−Y Switch J/B No.1 W−R 12 22 W−R W−R E4 E4 W−R Relay R−L W−R 24 16 E7 E5 (M/T)(A/T) R/B No.2 Battery B−W A00779 1996 TOYOTA T100 (RM449U)
  • Page 516 Check for open in harness and connector between terminal E1 of ECM and body ground (See page IN−26). Repair or replace harness or connector. Check EFI main relay (Marking: EFI) (See page SF−45). Replace EFI main relay. 1996 TOYOTA T100 (RM449U)
  • Page 517 Check IGN fuse. PREPARATION: Remove the IGN fuse from the J/B No.1. IGN Fuse CHECK: J/B No.1 Check continuity of IGN fuse. Continuity FI7106 Check for short in all harness and components connected to IGN fuse. 1996 TOYOTA T100 (RM449U)
  • Page 518 − ENGINE (5VZ−FE) Check ignition switch (See page BE−12). Replace ignition switch. Check for open in harness and connector be- tween IG switch and EFI main relay, EFI main relay and body ground (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 519 EFI Relay Circuit Opening Relay Fuel Pump IG Switch Clutch Start Cancel Switch (M/T) FC Tr Park/Neutral Position Switch (A/T) Starter Relay From (STA Signal) Clutch Battery Crankshaft Start (NE Signal) Position Switch Sensor (M/T) Starter A01010 1996 TOYOTA T100 (RM449U)
  • Page 520 DI−256 DIAGNOSTICS − ENGINE (5VZ−FE) WIRING DIAGRAM W−B W−B W−B W−B W−B B−R B−R B−O B−O W−B B−W A00651 1996 TOYOTA T100 (RM449U)
  • Page 521 − ENGINE (5VZ−FE) INSPECTION PROCEDURE TOYOTA hand−held tester: Connect TOYOTA hand−held tester and check operation of fuel pump. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand− held tester main switch ON.
  • Page 522 Voltage: 9 − 14 V FC (+) For A/T Check for open in harness and connector be- tween EFI main relay and circuit opening relay, BE6653 and ECM (See page IN−26). P24225 A00128 P24335 1996 TOYOTA T100 (RM449U)
  • Page 523 Check circuit opening relay. PREPARATION: Remove the circuit opening relay (See page SF−46). CHECK: Apply battery voltage between terminals 3 and 6. Check continuity between terminal 1 and 2. Continuity 3 (+) Replace circuit opening relay. 6 (−) A00686 1996 TOYOTA T100 (RM449U)
  • Page 524 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−held tester): Check operation of fuel pump. PREPARATION: Remove the right cowl side trim (See page SF−61).
  • Page 525 DI−255, step 4). Check for open in harness and connector be- tween EFI main relay and circuit opening relay and ECM (See page IN−26). Check fuel pump (See page SF−5). Repair or replace fuel pump. 1996 TOYOTA T100 (RM449U)
  • Page 526 (See page DI−255, step 8). Check for starter signal circuit (See page DI−248). Check for open in harness and connector be- tween terminal 6 of circuit opening relay con- nector and body ground (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 527 Customer Problem Analysis DI−264 Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3 If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the DI−265 scan tool/TOYOTA hand−held tester, inspect DLC3 P.
  • Page 528 Slip or shudder j No kick−down j Others Malfunction Check Item j Remains ON j Normal Indicator Lamp 1st Time j Normal code j Malfunction code (Code DTC Check 2nd Time j Normal code j Malfunction code (Code 1996 TOYOTA T100 (RM449U)
  • Page 529 To check the DTCs, connect an OBD II scan tool or TOYOTA Hand−Held Tester TOYOTA hand−held tester to DLC3 on the vehicle. The OBD II scan tool or TOYOTA hand−held tester also enables you to erase the DTCs and check freeze frame data and various forms of engine data (For instruction book).
  • Page 530 By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up and for a malfunction that is only detected once or momentarily (TOYOTA hand−held tester) (See page DI−265). *2 trip detection logic: When a logic malfunction is first detected, the mal- function is temporarily stored in the ECM memory.
  • Page 531 Prepare an OBD II scan tool (complying with SAE A00653 J1978) or TOYOTA hand−held tester. Connect the OBD II scan tool or TOYOTA hand− TOYOTA Hand−Held Tester held tester to DLC3 at the lower of the instrument panel.
  • Page 532 Prepare a TOYOTA hand−held tester. Connect the TOYOTA hand−held tester to DLC3 at the lower of the instrument panel. Turn the ignition switch ON and switch the TOYOTA hand−held tester ON. 0.13 Second Switch the TOYOTA hand−held tester from Normal FI3605 mode to Check mode (Check that the MIL flashes).
  • Page 533 Shift into the 2 position and fully depress the accelerator pedal and check the following points: Check up−shift operation. Check to see that the 1 → 2 up−shift takes place and that the shift point conforms to the automatic shift schedule (See page SS−49). 1996 TOYOTA T100 (RM449U)
  • Page 534 L position and return to P position. Pull out the dipstick and wipe it clean. Push it back fully into the pipe. Pull it out and check that the fluid level is in the HOT range. AT3417 1996 TOYOTA T100 (RM449U)
  • Page 535 If the indicator is not aligned with the correct position, carry out the following adjustment procedures. Remove the nut on the No.1 gear shifting rod. No.1 Gear Shifting Rod Push the No.1 gear shifting rod fully downward. Q03104 1996 TOYOTA T100 (RM449U)
  • Page 536 Chock the 4 wheels. Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3. Fully apply the parking brake. Keep your left foot pressed firmly on the brake pedal.
  • Page 537 S O/D one−way clutch not operating properly S Line pressure too low S Direct clutch worn N → R time lag is longer S 1st and reverse brake worn S O/D one−way clutch not operating properly 1996 TOYOTA T100 (RM449U)
  • Page 538 If pressure is low in the D position only S Forward clutch defective S R position circuit fluid leakage If pressure is low in the R position only S Direct clutch defective S 1st and reverse brake defective 1996 TOYOTA T100 (RM449U)
  • Page 539 If the L, 2 and D position gear positions are difficult to positions are difficult to distinguish, do the following road test. If any abnormality is found in the above test, the problem is in the transmission itself. Connect the solenoid wire. Cancel out DTC. (See page DI−265). 1996 TOYOTA T100 (RM449U)
  • Page 540 S Open or short in No.2 vehicle speed sensor circuit P1700 Malfunction S No.2 vehicle speed sensor (DI−300) (No.2 Vehicle Speed Sensor) S ECM S Short in park/neutral position switch circuit P1780 Park/Neutral Position Switch S Park/neutral position switch (DI−306) Malfunction S ECM 1996 TOYOTA T100 (RM449U)
  • Page 541 DI−277 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI98H−01 PARTS LOCATION D10997 1996 TOYOTA T100 (RM449U) D10998...
  • Page 542 DI−278 DIAGNOSTICS − AUTOMATIC TRANSMISSION No.1 Vehicle Speed Sensor (In Combination Meter) O/D Main Switch Cruise Control ECU DLC3 Stop Light Switch Q07506 1996 TOYOTA T100 (RM449U)
  • Page 543 IG switch ON, Accel. pedal is depressed 9 − 14 IG switch ON, Accel. pedal is released Below 0.3 − 0.8 VTA − E2 (E6, 10 − E6, 9) Y−B ↔ BR−B IG switch ON, Accel. pedal is depressed 3.2 − 4.9 1996 TOYOTA T100 (RM449U)
  • Page 544 IG switch ON, Accel. pedal is depressed 3.2 − 4.9 IG switch ON, Transfer N position Below 3 TFN − E1 (E4, 17 − E5, 16) Y ↔ BR IG switch ON, Transfer other than N position 9 − 14 1996 TOYOTA T100 (RM449U)
  • Page 545 IG switch ON, Transfer other than L4 position Below 1.5 IG switch ON, Transfer H2 position 9 − 14 4WD − E1 (E4, 26 − E5, 16) R−G ↔ BR IG switch ON, Transfer other than H2 position Below 3 1996 TOYOTA T100 (RM449U)
  • Page 546 2. ECM DI−279 Up−shift to O/D from 3rd while engine is cold 1. ECM DI−279 No kick−down 1. ECM DI−279 1. Stop light swich circuit DI−316 Engine stalls when starting off or stopping 2. ECM DI−279 1996 TOYOTA T100 (RM449U)
  • Page 547 3. Off−vehicle repair matrix chart DI−282 1. Throttle cable DI−265 2. No.1 gear shifitng rod DI−265 Slip or shudder (Forward and reverse) 3. Oil strainer AT−12 4. Pressure relief valve 5. Off−vehicle repair matrix chart DI−282 1996 TOYOTA T100 (RM449U)
  • Page 548 No engine braking (1st: L position) 2. Off−vehicle repair matrix chart DI−282 1. 2nd coast modulator valve No engine braking (2nd: 2 position) 2. Off−vehicle repair matrix chart DI−282 1. 1−2 shift valve No kick−down 2. 2−3 shift valve 1996 TOYOTA T100 (RM449U)
  • Page 549 1. 2nd coast brake (B Poor acceleration (All position) 1. Torque converter clutch AT−38 1. O/D direct clutch (C Poor acceleration (O/D) 2. O/D planetary gear unit Engine stalls when starting off or stopping 1. Torque converter clutch AT−38 1996 TOYOTA T100 (RM449U)
  • Page 550 DI−286 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI0VK−01 CIRCUIT INSPECTION P0500 Vehicle Speed Sensor Malfunction (No.1 Vehicle Speed Sensor) See page 3RZ−FE DI−92, 5VZ−FE DI−226. 1996 TOYOTA T100 (RM449U)
  • Page 551 (b) After engine has been operating for 15 minutes or S ECM more, resistance at temp. sensor is more than 156 kΩ WIRING DIAGRAM 4 − 6 V G−B ATF Temp. Sensor BR−B *1: 3RZ−FE *2: 5VZ−FE Q07378 1996 TOYOTA T100 (RM449U)
  • Page 552 20°C (68°F): Approx. 13.0 kΩ 110°C (230°F): Approx. 800 Ω Q07637 Replace ATF temperature sensor. Check harness and connector between ATF temperature sensor and ECM (See page IN−26). Repair or replace harness or connector. Check and replace ECM. 1996 TOYOTA T100 (RM449U)

  • Page 553: System Description

    When battery positive voltage is supplied to the shift sole- noid valve, check that the solenoid valve opens. Q07640 Replace shift solenoid valve No.1 or No.2. Check valve body (See page DI−282). Repair or replace valve body. Repair or replace transmission (See page AT−26, AT−33). 1996 TOYOTA T100 (RM449U)
  • Page 554 S ECM lighting up MIL again: (a) Solenoid resistance is 8 Ω or less (short circuit) when sole- noid is energized (b) Solenoid resistance is 100 kΩ or more (open circuit) when solenoid is not energized 1996 TOYOTA T100 (RM449U)
  • Page 555 PREPARATION: 3RZ−FE Disconnect the connector from the ECM. CHECK: Measure resistance between terminal S1 or S2 of ECM connec- tor and body ground. Resistance: 11 − 15 Ω 5VZ−FE Q07641 D00006 Q07642 Check and replace ECM. 1996 TOYOTA T100 (RM449U)
  • Page 556 Check the harness and connector between terminal S1 or S2 of ECM connector and terminal S1 or S2 of solenoid connector. There is no open and no short circuit. 5VZ−FE Q07643 Q07644 D00007 Q05336 Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 557 Connect positive lead to terminal of solenoid connector, negative lead to solenoid body. Q07645 D00005 Q07646 (a) Resistance: 11 − 15 Ω (b) The solenoid makes an operating noise. Replace solenoid valve. Repair or replace solenoid wire. 1996 TOYOTA T100 (RM449U)
  • Page 558 , 71 psi) of compressed air, check that the solenoid valve does not leak air. When battery voltage is supplied to the shift solenoid valve, check that the solenoid valve opens. Q07640 Replace solenoid valve SL. 1996 TOYOTA T100 (RM449U)
  • Page 559 DI−295 DIAGNOSTICS − AUTOMATIC TRANSMISSION Check valve body (See page DI−282). Repair or replace valve body. Replace torque converter clutch (See page AT−26, AT−33). 1996 TOYOTA T100 (RM449U)
  • Page 560 S Shift solenoid valve SL noid is energized S ECM (b) Solenoid resistance is 100 kΩ or more (open circuit) when solenoid is not energized WIRING DIAGRAM Transmission Shift Solenoid Valve SL Y−B *1: 3RZ−FE *2: 5VZ−FE Q07379 1996 TOYOTA T100 (RM449U)
  • Page 561 Measure resistance between terminal SL of ECM connector and body ground. PREPARATION: 3RZ−FE Disconnect the connector from the ECM. CHECK: Measure resistance between terminal SL of ECM connector and body ground. Resistance: 11 − 15 Ω 5VZ−FE Q07647 D00008 Q07648 Check and replace ECM. 1996 TOYOTA T100 (RM449U)
  • Page 562 Disconnect the solenoid connector from the transmission. CHECK: Check the harness between terminal SL of ECM connector and terminal SL of transmission solenoid connector. There is no open or short circuit. 5VZ−FE Q07649 Repair or replace tharness or connector. Q07650 Q05336 D00009 1996 TOYOTA T100 (RM449U)
  • Page 563 Connect positive lead to terminal of solenoid connector, negative lead to solenoid body. Q07645 D00005 Q07646 (a) Resistance: 11 − 15 Ω (b) The shift solenoid valve SL makes operation noise. Replace shift solenoid valve SL. Repair or replace solenoid wire. 1996 TOYOTA T100 (RM449U)
  • Page 564 (b) Vehicle speed: 9 km/h (5.6 mph) or more for as least 4 seconds (c) Park/neutral position switch: OFF (Other than P or N) Reference − Wavefrom between terminals SP2 and SP2 when vehicle speed is approx. 60 km/h (37 mph). 5 V/div. 2 msec./div. AT8761 1996 TOYOTA T100 (RM449U)
  • Page 565 PREPARATION: Connect an OBD II scan tool or TOYOTA hand−held tes- ter to the DLC3. 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.
  • Page 566 (b) Voltage is generated intermittently. HINT: Magnet The voltage generated is extremely low. Q08218 Replace No.2 vehicle speed sensor. Check and repair the harness and connector between ECM and No.2 vehicle speed sensor (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 567 (c) Park/neutral position switch: OFF (Other than P or N) (d) Transfer position: Other than N position (A340F only) Reference Wavefrom between terminals SP2 and E1 when vehicle speed is approx. 60 km/h (37 mph). 2 V/div. 10 msec. /division D00251 1996 TOYOTA T100 (RM449U)
  • Page 568 PREPARATION: Connect an OBD II scan tool or TOYOTA hand−held tes- ter to the DLC3. 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.
  • Page 569 Resistance: Changes between 0 Ω and ∞ Ω Q07654 Replace No.2 vehicle speed sensor. Check and repair harness and connector between ECM and No.2 vehicle speed sensor (See page IN−26). Check and repair sensor rotor. 1996 TOYOTA T100 (RM449U)
  • Page 570 WIRING DIAGRAM Combination Meter Park/Neutral Position Switch V−W V−W Diode GR−R B−O P−G P−G B−O R−W R−B B−O B−Y B−O 1A 1A Ignition Switch B−Y B−Y E4 E7 B−O R/B No.2 R/B No.2 Battery 3RZ−FE 5VZ−FE Q10012 1996 TOYOTA T100 (RM449U)
  • Page 571 When using TOYOTA hand−held tester: PREPARATION: Connect a TOYOTA hand−held tester to the DLC3. 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 LOW signals on the TOYOTA hand−held...
  • Page 572 4 − 9 − 2 − 4 − 3 − 4 − Replace park/neutral position switch. Repair or replace harness and connector between battery and park/neutral position switch, park/neutral position switch and ECM (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 573 Turn the ignition switch ON. CHECK: Measure voltage between terminal OD1 of ECM and body ground. Voltage: 4 − 6 V (−) D00053 Proceed to next circuit inspection shown on problem symptoms table (See page DI−282). 1996 TOYOTA T100 (RM449U)
  • Page 574 Voltage: 4 − 6 V D10999 Check and replace cruise control ECU. Check harness and connector between cruise control ECU and ECM (See page IN−26). Repair or replace harness or connector. Check and replace ECM. 1996 TOYOTA T100 (RM449U)
  • Page 575 Y−G B−O B−Y GAUGE Integration Relay Battery Main Switch R/B No.2 R/B No.2 *O/D Main Switch Contacts go open with switch pushed in. Contacts go closed with switch pushed once again. *1: 3RZ−FE *2: 5VZ−FE Q10013 1996 TOYOTA T100 (RM449U)
  • Page 576 Check the O/D OFF indicator light when O/D main switch is pushed again to OFF. (a) O/D OFF indicator light goes off O/D Main Switch (b) O/D OFF indicator light lights up BE3840 Q06780 AT5623 D00221 Go to step 4. 1996 TOYOTA T100 (RM449U)
  • Page 577 Check OVRDRIVE CUT SW2 signal. When using TOYOTA hand−held tester: PREPARATION: Connect a TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand−held tes- ter main switch ON. CHECK: Read the ”OVRDRIVE CUT SW2” signal on the TOYOTA hand−held tester.
  • Page 578 Check continuity resistance between terminal 1 and 2 of O/D main switch connector. O/D main switch condition Specified condition ON (Pushed in) No continuity Q07663 OFF (Pushed once agin) Continuity Replace O/D main switch. Check and replace the combination meter (See page BE−38). 1996 TOYOTA T100 (RM449U)
  • Page 579 Replace O/D main switch. Check harness and connector between O/D OFF indicator light and O/D main switch, O/D OFF indicator light and ECM (See page IN−26). Repair or replace harness or connector. Check and replace ECM. 1996 TOYOTA T100 (RM449U)
  • Page 580 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 to the ECM. Then the ECM cancels operation of the lock−up clutch while braking is in progress. WIRING DIAGRAM D09979 1996 TOYOTA T100 (RM449U)
  • Page 581 Read the STP signal on the TOYOTA hand−held tester. Brake Pedal STP Signal Depressed Release When not using OBD II scan tool or TOYOTA hand−held tes- ter: PREPARATION: Turn the ignition switch ON. CHECK: Check the voltage between terminal B/K of the ECM connector and body ground.
  • Page 582 Proceed to next circuit inspection shown on problem symptoms table (See page DI−282). Check harness and connector between stop light switch and ECM (See page IN−26). Repair or replace harness or connector. Check and replace ECM. 1996 TOYOTA T100 (RM449U)
  • Page 583 Circuit Inspection Check for Fluid Leakage DI−362 DI−332 ∼ DI−360 Identification of Problem Repair Confirmation Test Step 8 : Diagnostic steps permitting the use of the TOYOTA hand−held tester or TOYOTA break−out−box. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 584 ABS does not operate. Symptoms ABS does not operate efficiently. ABS Warning Light Remains ON Does not Light Up Abnormal Normal Code Malfunction Code (Code 1st Time DTC Check Normal Code Malfunction Code (Code 2nd Time 1996 TOYOTA T100 (RM449U)
  • Page 585 If 2 or more malfunctions are indicated at the same time the low- est numbered DTC will be displayed 1st. Code 11 and 21 0.5 sec. 0.5 sec. 1.5 sec. 2.5 sec. 4 sec. Code 11 Code 21 R01346 1996 TOYOTA T100 (RM449U)
  • Page 586 TOYOTA break−out−box to the vehicle. Read the ECU input/output values by following the prompts on the tester screen. HINT: TOYOTA TOYOTA hand−held tester has a ”Snapshot” function. This re- brake−out−box cords the measured values and is effective in the diagnosis of N09348 intermittent problems.
  • Page 587 , Tc and E of the DLC1, and ignition switch turned OFF. Check the deceleration sensor detection point. Turn the ignition switch OFF. Using SST, connect terminals Ts and E of the DLC1. 09843−18020 Start the engine. DLC1 A00778 1996 TOYOTA T100 (RM449U)
  • Page 588 0.13 sec. BR1865 Drive the vehicle straight ahead at about 20 km/h (12.4 mph) or more, and depress the brake pedal 0.13 sec. Braking moderately. Check that the warning light turns on while braking. 0.13 sec. R05596 1996 TOYOTA T100 (RM449U)
  • Page 589 S Right rear speed sensor rotor sensor Abnormal change in output voltage of left rear speed S Left rear speed sensor rotor sensor S Deceleration sensor Deceleration sensor is faulty S Sensor installation *: 4WD models 1996 TOYOTA T100 (RM449U)
  • Page 590 Some tire is different size from the other tires (DI−346) S ECU S Battery Low battery positive voltage or abnormally high battery S IC regulator (DI−347) positive voltage S Open or short in power source circuit S ECU 1996 TOYOTA T100 (RM449U)
  • Page 591 Open or short in deceleration sensor circuit S Open or short in deceleration sensor circuit (DI−351) S ECU Pump motor is locked S ABS pump motor (DI−353) Open in pump motor ground Always Malfunction in ECU S ECU *: 4WD models 1996 TOYOTA T100 (RM449U)
  • Page 592 DI−328 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI0ZT−03 PARTS LOCATION F14854 1996 TOYOTA T100 (RM449U)
  • Page 593 RSS (A15 − 23) − GND (A15 − 11, 24) Continuity IG switch OFF Below 1.5 IG switch ON, PKB lever pulled PKB (A15 − 9) − GND (A15 − 11, 24) 10 − 14 IG switch ON, PKB lever released 1996 TOYOTA T100 (RM449U)
  • Page 594 DI−330 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM *: 4WD Vehicle 1996 TOYOTA T100 (RM449U)
  • Page 595 Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS ECU. DTC check cannot be done. 1. ABS warning light circuit. DI−354 2. Tc terminal circuit. DI−358 Speed sensor signal check 1. Ts terminal circuit. DI−360 cannot be done. 2. ABS ECU. 1996 TOYOTA T100 (RM449U)
  • Page 596 ABS control. WIRING DIAGRAM ABS ECU ABS Contorl Relay R−B Motor Relay G−B R− W−B Solenoid Relay R−W DLC1 10 2 No.2 W−R ABS ECU W−B R−L R−Y Battery R−L ABS Actuator F14589 1996 TOYOTA T100 (RM449U)
  • Page 597 A4 − 3, A4 − 3 and A16 − 11. Continuity HINT: Actuator There is a resistance of 26 ∼ 40 Ω between terminals A4 − 4 and A4 − 3. ABS ECU R13727 Repair or replace harness or ABS actuator. 1996 TOYOTA T100 (RM449U)
  • Page 598 ABS ECU (See page IN−26). Repair or replace harness or connector. If same code is still output after DTC is deleted, check contact condition of each connection. If connections are normal, ECU may be defective. 1996 TOYOTA T100 (RM449U)
  • Page 599 ABS control. WIRING DIAGRAM ABS ECU ABS Contorl Relay R−B Motor Relay G−B R− W−B Solenoid Relay R−W DLC1 10 2 No.2 W−R ABS ECU W−B R−L R−Y Battery R−L ABS Actuator F14589 1996 TOYOTA T100 (RM449U)
  • Page 600 A4 − 5, A4 − 5 and A16 − 8. Continuity HINT:. There is a resistance of 26 ∼ 40 Ω between terminals A4 − 2 and A4 − 5 Actuator ABS ECU R13728 Repair or replace harness or ABS actuator. 1996 TOYOTA T100 (RM449U)
  • Page 601 ABS ECU (See page IN−26). Repair or replace harness or connector. If same code is still output after DTC is deleted, check contact condition of each connection. If connections are normal, ECU may be defective. 1996 TOYOTA T100 (RM449U)
  • Page 602 SRR or SRH is 0 V or battery positive voltage. Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. 1996 TOYOTA T100 (RM449U)
  • Page 603 Check continuity between terminals A4 − 4 and A3 − 1, 2, 3, 4, 5, 6 of ABS actuator connector. Continuity HINT: Resistance of each solenoid coil F14588 SFRH, SFLH, SRH: 5.0 Ω SFRR, SFLR, SRR: 2.2 Ω Replace ABS actuator. 1996 TOYOTA T100 (RM449U)
  • Page 604 Check for open and short in harness and connector between ABS ECU and actuator (See page IN−26). Repair or replace harness or connector. If same code is still output after DTC is deleted, check contact condition of each connection. If connector are normal, ECU may be defective. 1996 TOYOTA T100 (RM449U)
  • Page 605 DTC No. 34 is for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. 1996 TOYOTA T100 (RM449U)
  • Page 606 DI−342 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM WIRING DIAGRAM ABS ECU Right Front Speed Sensor A16 FR− Y−G Left Front Speed Sensor FL− Read Speed Sensor Right RR− BR−B Left RL− F00358 1996 TOYOTA T100 (RM449U)
  • Page 607 Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI−321). Check for open and short in harness and connector between each speed sensor and ECU (See page IN−26). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 608 The installation bolt is tightened properly and there is no clearance between the sensor and steering knuckle or rear axle carrier. Replace speed sensor or rotor. BR3795 NOTICE: Check the speed sensor signal last (See page DI−321). Check and repalce ABS ECU. 1996 TOYOTA T100 (RM449U)
  • Page 609 Check front speed sensor (See page DI−341). Replace front speed sensor. Check for open or short in harness and connector between speed sensor and ECU (See page IN−26). Repair or replace harness or connector. Check and replace ABS ECU. 1996 TOYOTA T100 (RM449U)
  • Page 610 S Tire size seconds with 1 or 2 tires of different size. S ECU INSPECTION PROCEDURE Check tire size. Replace tires so that all 4 tires are of the same size. Check and replace ABS ECU. 1996 TOYOTA T100 (RM449U)
  • Page 611 If trouble occurs in the power source circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. WIRING DIAGRAM Fuse Box on J/B No.1 ABS ECU IG Switch B−Y ECU−IG No.2 4WD: Deceleration Sensor W−B W−B Battery F00359 1996 TOYOTA T100 (RM449U)
  • Page 612 Check continuity between terminals GND of ABS ECU connector and body ground. CHECK: LOCK Measure resistance between terminals GND of ABS ECU con- nector and body ground. Resistance: 1 Ω or less (−) BE6653 F00004 R15783 Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 613 Check continuity of ECU−IG fuse. Continuity ECU−IG Fuse A00777 Check for short in all harness and components connected to ECU−IG fuse (See attached wiring diagram). Check for open in harness and connector between ABS ECU and battery (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 614 Check deceleration sensor (See page DI−321). Replace deceleration sensor. Check for open or short in harness and connector between sensor and ECU (See page IN−26). Repair or replace harness or connector. Check and replace ABS ECU. 1996 TOYOTA T100 (RM449U)
  • Page 615 GST. During this time, a trouble signal is detected for 0.5 sec. WIRING DIAGRAM ABS ECU Fuse Box on J/B No.1 ABS ECU ECU−IG A14 4 L−W IG Switch Deceleration Sensor GGND A14 6 W−B GGND F00360 1996 TOYOTA T100 (RM449U)
  • Page 616 Measure voltage between terminals GS1, GS2, GST of ECU and Body ground. BE6653 R15784 F00459 Voltage: GS1, GS2: about 5 V GST: As shown below IG SW 12 V 1.5 sec. 0.5 sec. F00012 Check and replace ABS ECU. Check and replace deceleration sensor. 1996 TOYOTA T100 (RM449U)
  • Page 617 If trouble occurs in the ABS pump motor, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. WIRING DIAGRAM ABS ECU ABS Contorl Relay R−B Motor Relay G−B R− W−B Solenoid Relay R−W DLC1 10 2 No.2 W−R ABS ECU W−B R−L R−Y Battery R−L ABS Actuator F14589 1996 TOYOTA T100 (RM449U)
  • Page 618 DTC. WIRING DIAGRAM Battery ABS Contorl Relay IG Switch Motor Relay ABS ECU ABS ECU Integration W−B Solenoid Relay Relay Short Pin B−Y B−Y Actuator Warning Light Actuator B−R B−R ABS ECU F14591 1996 TOYOTA T100 (RM449U)
  • Page 619 ABS warning light does not light up Go to step 1 ABS warning light remains on Go to step 3 Check ABS warning light. See Combination Meter Troubleshooting on page BE−2. Repair bulb or combination meter assembly. 1996 TOYOTA T100 (RM449U)
  • Page 620 − 4 and the lead to terminal A5 − 5. Recheck continuity be- tween terminals. R14144 Replace ABS control relay. Check for open in harness and connector between DLC1, ABS control relay and body ground (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 621 DLC1 and ECU (See page IN−26). Check ABS control relay (See step 2). Replace ABS control relay. Check for short in harness and connector between DLC1 and ABS control relay (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 622 (−) Measure voltage between terminals Tc and E of DLC1. Voltage: 10 − 14 V AB0119 S08097 F00445 If ABS warning light does not blink even after Tc and E are connected, ECU may be defective. 1996 TOYOTA T100 (RM449U)
  • Page 623 − ANTI−LOCK BRAKE SYSTEM Check for open and short in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN−26). Repair or replace harness or connector. Check and replace ABS ECU. 1996 TOYOTA T100 (RM449U)
  • Page 624 (−) Measure voltage between terminals Ts and E of DLC1. Voltage: 10 − 14 V AB0119 S08096 F00446 If ABS warning light does not blink even after Ts and E are connected, ECU may be defective. 1996 TOYOTA T100 (RM449U)
  • Page 625 − ANTI−LOCK BRAKE SYSTEM Check for open and short in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN−26). Repair or replace harness or connector. Check and replace ABS ECU. 1996 TOYOTA T100 (RM449U)
  • Page 626 DI−362 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI10Y−01 Check for fluid Leakage Check for fluid leakage from actuator or hydraulic lines. F00447 1996 TOYOTA T100 (RM449U)
  • Page 627 Circuit Inspection DI−373 Identification of Problem Repair Malfunction Code Clearance DI−365 Malfunction Code DTC Check DI−365 Normal Code Confirmation Test : Diagnostic steps permitting Step the use of the TOYOTA hand−held tester. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 628 Does Not Light Up SRS Warning Light Inspection 2nd Time Remains ON Sometimes Lights Up Does Not Light Up 1st Time Normal Code Malfunction Code [ Code. DTC Inspection 2nd Time Normal Code Malfunction Code [ Code. 1996 TOYOTA T100 (RM449U)
  • Page 629 The light will blink 2 times per second. Malfunction code indication: 0.25 The first blinking output indicates the first digit AT0716 of a 2−digit DTC. After a 1.5 second pause, the second blinking output will indicate the second digit. 1996 TOYOTA T100 (RM449U)
  • Page 630 Code 11 tion on page DI−403. AB0056 DTC CHECK (Using TOYOTA hand−held tester) Hook up the TOYOTA hand−held tester to the DLC1. 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.
  • Page 631 SRS warning light will blink in a 50 msec. cycle to indicate the codes have been cleared. DTC CLEARANCE (Using TOYOTA hand−held tester) Hook up the TOYOTA hand−held tester to the DLC1. Clear the DTCs by following the prompts on the tester screen.
  • Page 632 RH and LH Front Airbag Sensors Airbag Sensor Assembly Connector (Connector ”1”) Before Release After Release Paper Short Spring Spiral Cable Connector (Connector ”2”) Short Spring Before Release After Release Paper AB0027 W03146 W03147 AB0130 AB0045 AB0046 H00320 1996 TOYOTA T100 (RM449U)
  • Page 633 10 seconds the SRS warning light will automatically go out. When 2 or more codes are indicated, the lowest numbered code will apper first. If a code not listed on the chart is displayed, the center airbag sensor assembly is faulty. 1996 TOYOTA T100 (RM449U)
  • Page 634 DI−370 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI0XL−02 PARTS LOCATION SRS Warning Light Front Airbag Sensor RH Steering Wheel Pad (with Airbag) Front Airbag Sensor LH Spiral Cable Junction Block No.1 Center Airbag Sensor Assembly R12499 1996 TOYOTA T100 (RM449U)
  • Page 635 Electrical Connection Check Mechanism − Electrical Connection Check Mechanism SRS Warning Light D− Squib (Driver) Squib (Driver) Diagnosis Ground Ground Front Airbag Sensor RH Front Airbag Sensor LH Power Source (IGN Fuse) Power Source (CIG Fuse) 1996 TOYOTA T100 (RM449U)
  • Page 636 ON.) S DTC not displayed. S SRS warning light is always lit up a DTC check procedure. S Tc terminal circuit DI−403 S DTC displayed without Tc and E1 terminal connection. 1996 TOYOTA T100 (RM449U)
  • Page 637 S Spiral cable malfunction S Wire harness S Center airbag sensor assembly malfunction WIRING DIAGRAM Center Airbag Sensor Assembly Front Airbag Sensor RH D Squib W−B Spiral Cable B−L D− W−B Front Airbag Sensor LH R15205 1996 TOYOTA T100 (RM449U)
  • Page 638 +SL of center airbag sensor assembly connector.) CHECK: Center Airbag Sensor Assembly Measure resistance between terminals +SR, +SL of harness side connector of center airbag sensor assembly and body ground. Resistance: 755 − 855 Ω (−) H18108 Go to step 7. 1996 TOYOTA T100 (RM449U)
  • Page 639 AB0118 AB0119 AB0069 Check DTC. S08098 W02042 H00324 DTC 11 is not output. HINT: Codes other than code 11 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. 1996 TOYOTA T100 (RM449U)
  • Page 640 From results of above inspection, malfunctioning part can now be considered normal. To make sure of this, use simulation method to check. If malfunctioning part can not be detected by imulation method, replace all SRS components including wire harness. 1996 TOYOTA T100 (RM449U)
  • Page 641 D+ and body ground. Resistance: 1MΩ or higher (−) W05583 R14301 H00326 Repair or replace spiral cable. Repair or replace harness or connector between center airbag sensor assembly and spiral cable. 1996 TOYOTA T100 (RM449U)
  • Page 642 Do not press ohmmeter probes too strongly against terminals of front airbag sensor. Make sure front airbag sensor connector is properly connected. Replace front airbag sensor. Repair or replace harness or connector between center airbag sensor assembly and front airbag sensor. 1996 TOYOTA T100 (RM449U)
  • Page 643 S Spiral cable S Open circuit in RH and LH front airbag sensor harness S Center airbag sensor assembly S Spiral cable malfunction S Wire harness S Center airbag sensor assembly malfunction WIRING DIAGRAM See page DI−373. 1996 TOYOTA T100 (RM449U)
  • Page 644 Connect negative (−) terminal cable to battery. Turn ignition switch to ON. CHECK: Measure voltage between terminals D+ or D− of harness side connector of center airbag sensor assembly and body ground. (−) Voltage: 0 V H18109 Go to step 5. 1996 TOYOTA T100 (RM449U)
  • Page 645 S08098 W02043 H00329 09843−18020 Check DTC. DTC 12 is not output. HINT: Codes other than code 12 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. 1996 TOYOTA T100 (RM449U)
  • Page 646 Codes other than code 12 may be output at this time. but they are not relevant to this check. Replace steering wheel pad. From results of above inspection, malfunctioning part can now be considered normal. To make sure of this, use simulation method to check. 1996 TOYOTA T100 (RM449U)
  • Page 647 D+ and body ground. Voltage: 0 V (−) Repair or replace spiral cable. W05583 AB0119 R14288 H00331 Repair or replace harness or connector between center airbag sensor assembly and spiral cable. 1996 TOYOTA T100 (RM449U)
  • Page 648 (−) H01000 AB0119 R14288 H01133 Repair or replace spiral cable. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 TOYOTA T100 (RM449U)
  • Page 649 For the connector (on the spiral cable side) between the spiral ← → cable and steering wheel pad, measure the resistance between D+ and D−. D− Resistance: Below 1 Ω (−) H01001 H02196 H02142 Go to step 5. 1996 TOYOTA T100 (RM449U)
  • Page 650 AB0118 AB0119 AB0069 Check DTC. S08098 W02044 H00338 DTC 14 is not output. HINT: Codes other than code 14 may be output at this time, but they are relevant to this check. Go to step 7. 1996 TOYOTA T100 (RM449U)
  • Page 651 Codes other than code 14 may be output at this time, but they are not relevant to this check. Replace steering wheel pad. From results of above inspection, malfunctioning part can now be considered normal. To make sure of this, use simulation method to check. 1996 TOYOTA T100 (RM449U)
  • Page 652 Check spiral cable. Repair or replace spiral cable. From results of above inspection, malfunctioning part can now be considered normal. To make sure of this, use simulation method to check. 1996 TOYOTA T100 (RM449U)
  • Page 653 Replace center airbag sensor assembly. AB0118 AB0119 H01140 R13006 W02044 From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 TOYOTA T100 (RM449U)
  • Page 654 Preparaiton (See step 1 on page DI−396) Check front airbag sensor circuit (Measure resistance between terminals +SR and +SL of center airbag sensor assembly connector and body ground.) (See step 2 on page DI−373). Go to step 8. 1996 TOYOTA T100 (RM449U)
  • Page 655 Turn ignition switch ON. CHECK: −SR Measure voltage between terminals +SR and body ground, +SL and body ground of harness side connector of center air- (−) bag sensor assembly. H18109 Voltage: 0 V Repair or replace wire harness. 1996 TOYOTA T100 (RM449U)
  • Page 656 Replace center airbag sensor assembly. From results of above inspection, malfunction part can now be considered normal. To make sure of this, use simulation method to check. Check connection of center airbag sensor assembly connector. Repair. 1996 TOYOTA T100 (RM449U)
  • Page 657 (See step 3). Repair or replace wire harness. From results of above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 TOYOTA T100 (RM449U)
  • Page 658 CHECK: Measure voltage between terminals IG and ACC of center air- bag sensor assembly and body ground. (−) Voltage: Below 16 V H18114 Check battery and charging system. (3RZ−FE: See page CH−2) (5VZ−FE: See page CH−1) 1996 TOYOTA T100 (RM449U)
  • Page 659 Repeat operation in steps (a) and (b) at least 5 times. Using SST, connect terminals Tc and E1 of DLC1. 09843−18020 Check the DTC. Using simulation method, reproduce malfunc- tion symptoms (See page IN−16). AB0118 AB0119 S08098 FI1394 H00342 Replace center airbag sensor assembly. 1996 TOYOTA T100 (RM449U)
  • Page 660 10 seconds the SRS warning light automatically goes off. DTC No. Diagnosis (Normal) Source voltage drop WIRING DIAGRAM GR−R GR−R L−R Integration Relay B−Y B−Y W−R W−R B−R Short Ignition J/B No.1 Connector Switch R/B No.2 R−L Center Airbag Battery Sensor Assembly R15204 1996 TOYOTA T100 (RM449U)
  • Page 661 DTC. If a normal code is output, replace center airbag sensor assembly. From results of above inspection, malfunctioning part can now be considered normal. To make sure of this, use simulation method to check. 1996 TOYOTA T100 (RM449U)
  • Page 662 When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by the blinking of the SRS warn- ing light. WIRING DIAGRAM Center Airbag Sensor Assembly DLC1 Y−B Y−B Y−B P−B P−B P−B Relay Block Short No.2 Connector P−B ECU−B SRS Warning Light R15207 1996 TOYOTA T100 (RM449U)
  • Page 663 Disconnect center airbag sensor assembly connector. Connect negative (−) terminal cable to battery. CHECK: Check operation of SRS warning light. H18115 Check SRS warning light circuit or terminal AB circuit of DLC1. Replace center airbag sensor assembly. 1996 TOYOTA T100 (RM449U)
  • Page 664 HINT: Fuse may be burnt out even if it appears to be OK during visual inspection. N14677 If fuse is OK, install it. Go to step 6. Check connection of center airbag sensor assembly connector. Repair. 1996 TOYOTA T100 (RM449U)
  • Page 665 Turn ignition switch to ACC or ON. CHECK: Measure voltage LA terminal of harness side connector of cen- ter airbag sensor assembly and body ground. (−) Voltage: 10 − 16 V H18116 Check SRS warning light bulb/repair SRS warning light circuit. 1996 TOYOTA T100 (RM449U)
  • Page 666 From results of above inspection, malfunctioning part can now be considered normal. To make sure of this, use simulation method to check. Is new ECU−B fuse burnt out again? Using simulation method, reproduce malfunction symptoms. (See page IN−16) Check harness between ECU−B fuse and SRS warning light. 1996 TOYOTA T100 (RM449U)
  • Page 667 By connecting terminal Tc and E1 of the DLC1, the airbag sensor assembly is set in the DTC output mode. The DTCs are displayed by the blinking of the SRS warning light. WIRING DIAGRAM Center Airbag Sensor Assembly Y−B DLC1 Y−B Y−B Short Connector R15206 1996 TOYOTA T100 (RM449U)
  • Page 668 Check voltage between terminals Tc and E1 of DLC1. PREPARATION: Turn ignition switch to ACC or ON. CHECK: Measure voltage between terminals Tc and E1 of DLC1. Voltage: 10 − 16 V (−) AB0118 AB0119 H00030 R14305 Go to step 4. 1996 TOYOTA T100 (RM449U)
  • Page 669 Check voltage between terminals Tc of DLC1 and body ground. CHECK: Measure voltage between terminal Tc of DLC1 and body ground. Voltage: 10 − 16 V (−) Check harness between terminal E1 of DLC1 and body ground. AB0119 AB0118 H00031 R14304 1996 TOYOTA T100 (RM449U)
  • Page 670 Check operation of SRS warning light. SRS waning light comes on. NOTICE: Never make a mistake with the terminal connection posi- tion as this cause a malfunction. Check harness between center airbag sensor assembly and DLC1. Replace center airbag sensor assembly. 1996 TOYOTA T100 (RM449U)
  • Page 671 Disconnect center airbag sensor assembly connector. CHECK: Check resistance between terminal Tc of center airbag sensor assembly connector and body ground. R14303 Resistance: 1MΩ or Higher Repair or replace harness or connector. Replace center airbag sensor assembly. 1996 TOYOTA T100 (RM449U)

  • Page 672: Cruise Control System

    Input Signal Check Circuit Inspection Parts Inspection DI−420 − DI−458 Identification of Problem Repair Step 2, 5, 8, 10: Diagnostic steps permitting the use of the TOYOTA hand−held tester or TOYOTA break−out−box. Confirmation Test 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 673 Cruise MAIN j Remains ON j Does not light up j Blinking indicator light 1st Time j Normal Code j Malfunction Code (Code DTC Check 2nd Time j Normal Code j Malfunction Code (Code 1996 TOYOTA T100 (RM449U)
  • Page 674 BE4034 Using diagnosis check wire, check the output of DTC. DLC1 Turn the ignition switch ON. Using SST, connect terminals Tc and E of DLC1. 09843−18020 Read the DTC on the CRUISE MAIN indicator light. I22833 1996 TOYOTA T100 (RM449U)
  • Page 675 Read the ECU input/output values by following the prompts on the tester screen. HINT: TOYOTA hand−held tester has a ”Snapshot” function. This re- TOYOTA Break−out−box N09348 cords the measured values and is effective in the diagnosis of intermittent problems.
  • Page 676 Momentarily press the control switch is turned to N17520 SET/COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap−down function). 1996 TOYOTA T100 (RM449U)
  • Page 677 Pull the cruise control switch to CANCEL After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed prior to the can- cellation. 1996 TOYOTA T100 (RM449U)
  • Page 678 S Clutch start switch S Parking brake switch Light ON Drive approx. 40 km/h Speed sensor circuit is (25 mph) or over normal Drive approx 40 km/h Speed sensor circuit is Light (25 mph) or below normal 1996 TOYOTA T100 (RM449U)
  • Page 679 When 2 or more codes are indicated, the lowest numbered code will be displayed first. *When the vehicle speed decreases on uphill roads, the speed can be set again and drive can be continued (This is not a malfunction.). 1996 TOYOTA T100 (RM449U)
  • Page 680 DI−416 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI0YO−05 PARTS LOCATION I22834 1996 TOYOTA T100 (RM449U)
  • Page 681 BATT ↔ GND R ↔ B−O Constant 10 − 16 V (C15−15 ↔ C15−13) Depress brake pedal 10 − 16 V STP− ↔ GND G−W ↔ B−O (C15−16 ↔ C15−13) Release brake pedal Below 1 V 1996 TOYOTA T100 (RM449U)
  • Page 682 Ignition switch ON 1.0 − 1.2 V Actuator control plate fully closed VR3 ↔ GND L ↔ B−O Constant Below 1 V (C15−26 ↔ C15−13) L− ↔ GND Y−R ↔ B−O Constant Below 1 V (C15−10 ↔ C15−13) 1996 TOYOTA T100 (RM449U)
  • Page 683 DTC is not output, or is output when it should not be. 2. Cruise Control ECU IN−26 Cruise MAIN indicator light remains ON or fails to light up. 1. Cruise MAIN Indicator Light Switch Circuit − 1996 TOYOTA T100 (RM449U)
  • Page 684 Duty Ratio = x 100 (%) A + B 1 cycle DTC No. Detection Item Trouble Area S Actuator motor S Short in actuator motor circuit. S Wire harness S Cruise control ECU WIRING DIAGRAM I22682 1996 TOYOTA T100 (RM449U)
  • Page 685 Replace cruise control actuator. Check for open and short in harness and connectors between cruise control ECU and actuator motor (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 686 Detection Item Trouble Area S Actuator S Short in actuator magnetic clutch circuit. S Stop light switch S Open (0.8 sec.) in actuator magnetic clutch circuit. S Wire harness S Cruise control ECU WIRING DIAGRAM I22681 1996 TOYOTA T100 (RM449U)
  • Page 687 Disconnect the stop light switch connector. CHECK: Check continuity between terminals. Switch position Continuity Switch pin free 2 − 4 (Brake pedal depressed) Switch pin pushed in 1 − 3 (Brake pedal released) I22835 Replace stop light switch. 1996 TOYOTA T100 (RM449U)
  • Page 688 Check for open and short in harness and connectors between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 689 The circuit detects the rotation position of the actuator control plate and sends a signal to the ECU. DTC No.. Detection Item Trouble Area S Actuator S Position sensor detects abnormal voltage. S Wire harness S Cruise control ECU WIRING DIAGRAM I22680 1996 TOYOTA T100 (RM449U)
  • Page 690 Check resistance between terminals VR1 and VR3 of actuator position sensor. PREPARATION: Turn ignition switch OFF. Disconnect the actuator connector. CHECK: Measure resistance between actuator terminals 1 and 3 of ac- tuator connector. Resistance: Approx. 2.2 kΩ (25 °C) I00006 Replace cruise control actuator. 1996 TOYOTA T100 (RM449U)
  • Page 691 Replace cruise control actuator. Check for open and short in harness and connector between cruise control ECU and actuator position sensor (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 692 DTC No. Detection Item Trouble Area S Vehicle speed sensor S Speed signal is not input to the cruise control ECU while S Wire harness cruise control is set. S Cruise control ECU WIRING DIAGRAM I22673 1996 TOYOTA T100 (RM449U)
  • Page 693 Repair or replace harness, connector or com- bination meter assembly. Check harness and connector between cruise control ECU and combination me- ter, combination meter and vehicle speed sensor (See page IN−16). Repair or replace harness or connector. 1996 TOYOTA T100 (RM449U)
  • Page 694 DI−430 DIAGNOSTICS − CRUISE CONTROL SYSTEM Check vehicle speed sensor (See page BE−38). Replace vehicle speed sensor. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 695 This circuit sends the SET/COAST, RESUME/ACCEL and CANCEL signals (each voltage) to the ECU. DTC No. Detection Item Trouble Area S Cruise control switch S Short in control switch circuit. S Wire harness S Voltage abnormality in control switch circuit S Cruise control ECU WIRING DIAGRAM I22674 1996 TOYOTA T100 (RM449U)
  • Page 696 Neutral 10 − 16 RES/ACC 0.8 − 14 V (−) SET/COAST 2.4 − 4.0 V CANCEL 5.1 − 8.3 V AB0119 I00136 I00162 Proceed to next circuit inspection shown in problem symptom table (See page DI−419). 1996 TOYOTA T100 (RM449U)
  • Page 697 Check harness and connector between cruise control ECU and cruise control switch, IN−16 cruise control switch and body ground (See page Repair or replace harness or connector. Input signal check (See step 1). Wait and see. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 698 OFF. Also, when the brake is ON, the magnetic clutch circuit is cut mechanically by the stop light switch, turning the cruise control OFF (See page DI−422 for operation of the magnetic clutch). WIRING DIAGRAM I22687 1996 TOYOTA T100 (RM449U)
  • Page 699 Check the indicator light when the brake pedal is de- SW OFF Stop Light pressed. Light switch ON SW ON The indicator light goes off when the brake pedal is depressed. Proceed to next circuit inspection shown in problem symptoms table (See page DI−419). 1996 TOYOTA T100 (RM449U)
  • Page 700 Check for open in harness and connectors between terminal STP− of cruise con- trol ECU and stop light switch (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 701 If the idle switch is malfunctioning, problem symptoms also occur in the en- gine, so also inspect the engine. WIRING DIAGRAM I22676 1996 TOYOTA T100 (RM449U)
  • Page 702 Check harness and connector between ECM and throttle position sensor (See page IN−16). Repair or replace harness or connector. Check throttle position sensor circuit. (3RZ−FE: See page MF−25) (5VZ−FE: See page SF−31) Replace throttle position sensor. 1996 TOYOTA T100 (RM449U)
  • Page 703 Check for open and short in harness and connector between cruise control ECU and throttle position sensor, throttle position sensor and body ground (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 704 OD to ECM to cut overdrive until the end of the uphill slope, and the gear shifts are reduced and gear shift points in the electronically controlled transmission are changed. WIRING DIAGRAM I22685 1996 TOYOTA T100 (RM449U)
  • Page 705 Turn ignition switch ON. Disconnect the ECU connector. CHECK: Measure voltage between terminal OD of ECU connector on the harness side and body ground. Voltage: 10 − 16 V (−) AB0119 I00025 I00012 Go to step 5. 1996 TOYOTA T100 (RM449U)
  • Page 706 IN−26) Check harness and connector between terminal OD of cruise control ECU and terminal OD1 of ECM (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 707 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 cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM I22684 1996 TOYOTA T100 (RM449U)
  • Page 708 Turn PNP switch Light OFF (Shift to SW OFF except D position) The indicator light goes off when shifting into except D position. Proceed to next circuit inspection shown in problem symptoms table (See page DI−419). 1996 TOYOTA T100 (RM449U)
  • Page 709 (See page DI−419). Check harness and connector between cruise control ECU and park/neutral position switch (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 710 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 control driving, the cruise control ECU cancels cruise control. WIRING DIAGRAM I22683 1996 TOYOTA T100 (RM449U)
  • Page 711 Check the indicator light when clutch pedal is depressed. Light OFF (Depress SW OFF clutch pedal) The indicator light goes off when depressing the clutch pedal . Proceed to next circuit inspection shown in problem symptoms table (See page DI−419). 1996 TOYOTA T100 (RM449U)
  • Page 712 (See page DI−419). Check for open in harness and connector between ECU and GAUGE fuse (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 713 CRUISE CONTROL SYSTEM DI35A−02 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 are grounded. WIRING DIAGRAM I22678 1996 TOYOTA T100 (RM449U)
  • Page 714 Turn ignition switch ON. CHECK: Measure voltage between terminals B and GND of ECU con- nector. Voltage: 10 − 16 V (−) AB0119 I00014 I00027 Proceed to next circuit inspection shown in problem symptoms table (See page DI−419). 1996 TOYOTA T100 (RM449U)
  • Page 715 Measure resistance between terminal GND of ECU connector and body ground. Resistance: Below 1 Ω I00018 Repair or replace harness or connector. Check and repair harness and connector be- tween cruise control ECU and battery (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 716 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI35B−02 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, etc.. WIRING DIAGRAM I22675 1996 TOYOTA T100 (RM449U)
  • Page 717 (−) Voltage: 10 − 16 V I00016 Proceed to next circuit inspection shown in problem symptoms table (See page DI−419). Check and repair harness and connector be- tween battery and cruise control ECU (See page IN−16). 1996 TOYOTA T100 (RM449U)
  • Page 718 Measure voltage between terminal CMS of cruise control ECU connector when main switch is held ON and OFF. Main switch Voltage I22836 10 − 16 V Below 1 V Proceed to next circuit inspection shown in problem symptoms table (See page DI−419). 1996 TOYOTA T100 (RM449U)
  • Page 719 2 − 4 Continuity Replace control switch. Check harness and connector between cruise control ECU and main switch (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 720 DI−456 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI35D−02 Tc Circuit CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that DTC output is required. WIRING DIAGRAM I22677 1996 TOYOTA T100 (RM449U)
  • Page 721 (See page DI−419). Check harness and connector between cruise control ECU and DLC1, DLC1 and body ground (See page IN−16). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−26). 1996 TOYOTA T100 (RM449U)
  • Page 722 Freeplay: less than 10 mm HINT: If the control cable is very loose, the vehicle’s loss of speed going uphill will be large. If the control cable is too tight, the idle RPM will become high. 1996 TOYOTA T100 (RM449U)
  • Page 723 EM – ENGINE 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 EM-104...
  • Page 724 IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regula- A03712 P15056 tions. 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 725: Troubleshooting

    S Clogged fuel return line High High (Black smoke from exhaust) S Faulty MAF meter S Defective ECT sensor S Defective IAT sensor S Faulty engine control module (ECM) S Faulty injector 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 726 If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 727 EM−4 ENGINE MECHANICAL (3RZ−FE) − COMPRESSION REINSTALL SPARK PLUGS Torque:19 N·m (200 kgf·cm, 14 ft·lbf) REINSTALL HIGH−TENSION CORDS TO SPARK PLUGS REINSTALL AIR INTAKE CONNECTOR (See page EM−70) 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 728: Valve Clearance

    Remove the 10 bolts, cylinder head cover and gasket. A03713 P24401 SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley clockwise and align its groove with the ”0” mark on the timing chain cover. P14695 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 729 When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it shal- lowly from the outside of the cylinder head, at a slight angle. P15044 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 730 Place a new adjusting shim on the valve lifter. SST (B) Using SST (A), press down the valve lifter and re- move SST (B). 09248−55040 (09248−05410, 09248−05420) Recheck the valve clearance. P15043 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 731 EM−8 ENGINE MECHANICAL (3RZ−FE) − VALVE CLEARANCE V00831 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 732 EM−9 ENGINE MECHANICAL (3RZ−FE) − VALVE CLEARANCE V00832 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 733 REINSTALL THROTTLE BODY (See page MF−30) REINSTALL HIGH−TENSION CORDS TO SPARK PLUGS REINSTALL NO.1 AND NO.2 PCV HOSES REINSTALL AIR INTAKE CONNECTOR (See page EM−70) REFILL WITH ENGINE COOLANT CHECK IGNITION TIMING 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 734: Ignition Timing

    CONNECT TOYOTA HAND−HELD TESTER OR OBDII TOYOTA Hand−Held Tester SCAN TOOL Connect the TOYOTA hand−held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand−held tester or OBDII scan tool operators manual for further details. DLC3 FI7231 CHECK IGNITION TIMING Using SST, connect terminals TE1 and E1 of the DLC1.

  • Page 735: Idle Speed

    MFI system wiring connectors fully plugged Ignition timing set correctly Transmission in neutral position CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (See page EM−11) INSPECT IDLE SPEED Race the engine speed at 2,500 rpm for approx. 90 seconds.

  • Page 736: Timing Chain

    TIMING CHAIN TIMING CHAIN EM06X−02 COMPONENTS 27 (270, 20) 25 (250, 20) 18 (185, 13) 29 (300, 22) 27 (270, 20) 200 (2,650, 191) P21630 : Specified torque N·m (kgf·cm, ft·lbf) A03720 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 737 Remove the lock, pivot bolts and the generator. Remove the bolt and adjusting bar. Remove the 3 bolts and bracket. A03721 P14907 REMOVE CRANKSHAFT POSITION SENSOR Remove the 2 bolts and crankshaft position sensor. Remove the O−ring from the crankshaft position sensor. P14953 1996 TOYOTA T100 (RM449U)
  • Page 738 If necessary, remove the pulley with SST and crankshaft pulley bolt. 09950−50010 (09951−05010, 09952−05010, 09953−05010, 09954−05020) P18141 REMOVE TIMING CHAIN COVER Remove the 2 water by pass pipe mounting nuts. Remove the 2 timing chain cover mounting bolts. A03725 P14986 1996 TOYOTA T100 (RM449U)
  • Page 739 Remove the bolt, nut and No.1 damper. P14923 REMOVE NO.2, NO.3 VIBRATION DAMPERS AND NO.2 CHAIN TENSIONER Install a pin to the No.2 chain tensioner and lock the plunger. P15081 Remove the bolt and No.2 damper. A03727 P14932 1996 TOYOTA T100 (RM449U)
  • Page 740 Remove the bolt from the balance shaft drive gear. Remove the balance shaft drive gear with shaft. Remove the No.2 timing chain with the No.2 crankshaft timing sprocket. A03730 P14920 REMOVE NO.4 VIBRATION DAMPER Remove the 2 bolts and No.4 damper. P14962 1996 TOYOTA T100 (RM449U)
  • Page 741 113.8 mm (4.480 in.) Crankshaft 59.4 mm (2.339 in.) Balance shaft 75.9 mm (2.988 in.) Minimum sprocket diameter: Z11088 A03752 No.2 crankshaft 96.7 mm (3.807 in.) If the diameter is less than minimum, replace the chain, gears and sprocket. 1996 TOYOTA T100 (RM449U)
  • Page 742 P14929 Inspect the oil jet (No.2 chain tensioner). Check the oil jet for damage or clogging. If necessary, replace the oil jet (No.2 chain tensioner). P14934 1996 TOYOTA T100 (RM449U)
  • Page 743 Assemble the chain tensioner with the pin installed, then remove the pin after assembly. When doing this, avoid pushing the No.2 vibration damper against the chain. Install the No.2 chain tensioner with the nut. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) A03755 P15080 1996 TOYOTA T100 (RM449U)
  • Page 744 Install the No.1 damper with the bolt and nut. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Install the slipper with the bolt. Torque: 27 N·m (270 kgf·cm, 20 ft·lbf) Check that the slipper moves smoothly. P14923 INSTALL CRANKSHAFT TIMING GEAR P14919 1996 TOYOTA T100 (RM449U)
  • Page 745 Bolt A: 20 N·m (200 kgf·cm, 14 ft·lbf) Bolt B: 24.5 N·m (250 kgf·cm, 18 ft·lbf) Bolt C: 44 N·m (440 kgf·cm, 32 ft·lbf) Nut D: 20 N·m (200 kgf·cm, 14 ft·lbf) Remove the cord from the chain. A03761 1996 TOYOTA T100 (RM449U)
  • Page 746 A03763 P15097 Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) INSTALL OIL STRAINER Install a new gasket and oil strainer with the 2 bolts and 2 nuts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) A03764 P14954 1996 TOYOTA T100 (RM449U)
  • Page 747 Install the bracket with the 3 bolts. Torque: Bolt A: 74.5 N·m (760 kgf·cm, 55 ft·lbf) Bolt B: 18 N·m (185 kgf·cm, 13 ft·lbf) Install the adjusting bar with the bolt. Torque: 63.5 N·m (650 kgf·cm, 47 ft·lbf) Z11309 1996 TOYOTA T100 (RM449U)
  • Page 748 Pivot Bolt Install and adjust the drive belt (See page CH−2). INSTALL ENGINE UNDER COVER P14842 Install the engine under cover with the bolts. INSTALL CYLINDER HEAD (See page EM−50) START ENGINE AND CHECK FOR LEAKS 1996 TOYOTA T100 (RM449U)

  • Page 749: Cylinder Head

    ENGINE MECHANICAL (3RZ−FE) − CYLINDER HEAD CYLINDER HEAD EM075−02 COMPONENTS 21 (210, 15) 49 (500, 36) 29 (300, 22) 29 (300, 22) 29 (300, 22) 29 (300, 22) : Specified torque N·m (kgf·cm, ft·lbf) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 750 EM−27 ENGINE MECHANICAL (3RZ−FE) − CYLINDER HEAD x 10 21 (210,15) See page EM−50 1st 39 (400, 29) 2nd Turn 90° 46 (465, 34) 3rd Turn 90° :Specified torque N·m (kgf·cm, ft·lbf) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 751 09960−10010 (09962−01000, 09963−01000) Disconnect the 2 air hoses from air intake chamber. Remove the 2 bolts, and disconnect the PS pump. Remove the 4 bolts and PS pump bracket. REMOVE NO.1 AND NO.2 PCV HOSES P15755 1996 TOYOTA T100 (RM449U)
  • Page 752 Disconnect the 2 engine wire clamps. Remove the bolt and disconnect the engine wire. DISCONNECT INJECTOR CONNECTORS REMOVE CYLINDER HEAD REAR COVER Disconnect the heater water bypass hose. Remove the 3 bolts and the rear cover and gasket. A03783 P14635 1996 TOYOTA T100 (RM449U)
  • Page 753 Disconnect the brake booster vacuum hose from intake chamber. Remove the 3 bolts, 2 nuts, air intake chamber and gas- ket. A02538 REMOVE FUEL INLET TUBE Remove the 2 union bolts, 4 gaskets and fuel inlet tube. A03787 P24691 1996 TOYOTA T100 (RM449U)
  • Page 754 REMOVE EXHAUST MANIFOLD Remove the 2 bolts, 2 nuts and heat insulator. Remove the 6 nuts, exhaust manifold and gasket. REMOVE NO.1 ENGINE HANGER Remove the bolt and No.1 engine hanger. Remove the bolt and ground strap. P14686 1996 TOYOTA T100 (RM449U)
  • Page 755 A01399 REMOVE CHAIN TENSIONER Remove the 2 nuts, chain tensioner and gasket. P14636 REMOVE CAMSHAFT TIMING GEAR Remove the 2 semi−circular plugs. Place the matchmarks on the camshaft timing gear and No.1 timing chain. A03790 P15751 1996 TOYOTA T100 (RM449U)
  • Page 756 Secure the exhaust camshaft sub−gear to the main gear with a service bolt. Recommended service bolt: Thread diameter 6 mm (0.24 in.) Thread pitch 1.0 mm (0.039 in.) P14645 Bolt length 16 − 20 mm (0.63 − 0.79 in.) Z11081 1996 TOYOTA T100 (RM449U)
  • Page 757 Do not pry on or attempt to force the camshaft with a tool or other object. P14675 DISASSEMBLE EXHAUST CAMSHAFT Mount the hexagon wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. P14911 1996 TOYOTA T100 (RM449U)
  • Page 758 Using snap ring pliers, remove the snap ring. P14906 Remove these parts: Wave washer Camshaft sub−gear Camshaft gear spring A03791 Z11080 REMOVE CYLINDER HEAD Remove the 2 bolts in front of the head before the other head bolts are removed. P14709 1996 TOYOTA T100 (RM449U)
  • Page 759 If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylin- der head and cylinder block. P14721 1996 TOYOTA T100 (RM449U)
  • Page 760 Using needle−nose pliers, remove the oil seal. P14713 Using compressed air and a magnetic finger, remove the spring seat by blowing air. HINT: Arrange the valves, valve springs, spring seats and spring re- tainers in correct order. P14712 1996 TOYOTA T100 (RM449U)
  • Page 761 Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact sur- face. P14692 CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings. P14660 1996 TOYOTA T100 (RM449U)
  • Page 762 If cracked, replace the cylinder head. P14696 CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM0580 1996 TOYOTA T100 (RM449U)
  • Page 763 Gradually heat the cylinder head to 80 − 100°C (176 − 212°F). Using SST and a hammer, tap out the guide bushing. 09201−10000 (09201−01060), 09550−10012 (09252−10010) P14670 Using a caliper gauge, measure the bushing bore diame- ter of the cylinder head. P14667 1996 TOYOTA T100 (RM449U)
  • Page 764 44.5° Z00054 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 minimum, replace the valve. Margin Thickness EM0181 1996 TOYOTA T100 (RM449U)
  • Page 765 If not, correct the valve seats as follows: P04415 Intake: If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. 30° 45° 1.0 − 1.4 mm Z11441 1996 TOYOTA T100 (RM449U)
  • Page 766 Place the camshaft on V−blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the cam- shaft. P14704 1996 TOYOTA T100 (RM449U)
  • Page 767 Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the cam- shaft. If necessary, replace the bearing caps and cylinder head as a set. P14665 Completely remove the Plastigage. 1996 TOYOTA T100 (RM449U)
  • Page 768 INSPECT AIR INTAKE CHAMBER Using a precision straight edge and thickness gauge, measure the surface contacting the intake manifold for warpage. Maximum warpage: 0.20 mm (0.0078 in.) If warpage is greater than maximum, replace the air intake chamber. P14624 1996 TOYOTA T100 (RM449U)
  • Page 769 Free P04666 Released the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. Lock P04667 1996 TOYOTA T100 (RM449U)
  • Page 770 Standard diameter: Elongated Thread 10.76 − 10.97 mm (0.4236 − 0.4319 in.) Minimum diameter: 10.40 mm (0.4094 in.) If the diameter is less than minimum, replace the bolt. Measuring Point A02827 1996 TOYOTA T100 (RM449U)
  • Page 771 P14662 INSTALL VALVES Using SST, push in a new oil seal. 09236−00101 (09236−15010) HINT: Different oil seals are used for the intake and exhaust. Code mark (Intake side only): ”H” P14651 1996 TOYOTA T100 (RM449U)
  • Page 772 Using a plastic−faced hammer, lightly tap the valve stem tip to ensure a proper fit. INSTALL VALVE LIFTERS AND SHIMS Install the valve lifter and shim. Check that the valve lifter rotates smoothly by hand. P14702 1996 TOYOTA T100 (RM449U)
  • Page 773 Retighten the cylinder head bolts by an additional 90°. Check that the painted mark is now facing rearward. Front Painted Mark Z15489 Install and torque the 2 mounting bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) P14709 1996 TOYOTA T100 (RM449U)
  • Page 774 To avoid this, these steps should be carried out. 1996 TOYOTA T100 (RM449U)
  • Page 775 Do not use these marks. Aligh (Dot Mark) P14699 Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other. Install the bearing caps in their proper locations. P14701 1996 TOYOTA T100 (RM449U)
  • Page 776 A01399 INSTALL CAMSHAFT TIMING GEAR HINT: Check that the matchmarks on the camshaft timing gear and timing chain are aligned. Place the gear over the straight pin of the intake cam- shaft. P14698 1996 TOYOTA T100 (RM449U)
  • Page 777 Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) Check that the hook of the tensioner is not released. NOTICE: If the plunger springs out during installation of the chain Push tensioner, repeat the operation in step (b) before installing the tensioner. P14683 1996 TOYOTA T100 (RM449U)
  • Page 778 0.15 − 0.25 mm (0.006 − 0.010 in.) Exhaust 0.25 − 0.35 mm (0.010 − 0.014 in.) INSTALL SPARK PLUGS Using a 16 mm plug wrench, install the spark plug. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 1996 TOYOTA T100 (RM449U)
  • Page 779 Install a new gasket and exhaust manifold with the 6 nuts. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Install the heat insulator with the 2 bolts and 2 nuts. Torque: 5.5 N·m (55 kgf·cm, 48 in.·lbf) P14686 1996 TOYOTA T100 (RM449U)
  • Page 780 Install a new gasket and the air intake chamber with the 3 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) Connect the vacuum hose to the gas filter. Connect the brake booster vacuum hose to the intake camber. A02538 1996 TOYOTA T100 (RM449U)
  • Page 781 Knock sensor connector Crankshaft position sensor connector Connect the 5 engine wire clamps. Connect the engine wire to the intake chamber with the 2 bolts. Connect these connectors: EGR VSV connector EGR gas temperature sensor connector 1996 TOYOTA T100 (RM449U)
  • Page 782 INSTALL AIR INTAKE CONNECTOR Install the air intake connector with the 2 bolts and hose clamp. Connect the 2 air hoses. M/T: CONNECT ACCELERATOR CABLE TO THROTTLE BODY A/T: CONNECT THROTTLE AND ACCELERATOR CABLES P24651 TO THROTTLE BODY 1996 TOYOTA T100 (RM449U)
  • Page 783 FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS P15087 CHECK IGNITION TIMING (See page EM−11) VEHICLE ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT LEVEL 1996 TOYOTA T100 (RM449U)

  • Page 784: Engine Unit

    EM−61 ENGINE MECHANICAL (3RZ−FE) − ENGINE UNIT ENGINE UNIT EM07H−03 COMPONENTS 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 785 Drive Belt (M/T) Clutch Release Cylinder Stabilizer Bar PS Pump PS Pump Pulley Drive Belt Cushion Bracket Bracket Cushion Rropeller Shaft : Specified torque N·m (kgf·cm, ft·lbf) z Non − reusable part A02533 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 786 EM−63 ENGINE MECHANICAL (3RZ−FE) − ENGINE UNIT P21702 P21922 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 787 EM−64 ENGINE MECHANICAL (3RZ−FE) − ENGINE UNIT Z14987 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 788 DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY A/T: DISCONNECT ACCELERATOR AND THROTTLE CABLES FROM THROTTLE BODY REMOVE INTAKE AIR CONNECTOR Disconnect the 2 air hoses and vs hose. Remove the 2 bolts, hose clamp and intake air connector. 1996 TOYOTA T100 (RM449U)
  • Page 789 Remove the 2 bolts, and disconnect the PS pump. HINT: Put aside the pump, and suspend it. DISCONNECT GENERATOR WIRE Disconnect the generator connector. Remove the nut, and disconnect the generator wire and P15094 wire clip. 1996 TOYOTA T100 (RM449U)
  • Page 790 P15089 Remove both stabilizer bar bushings and brackets, and remove the stabilizer bar. REMOVE PROPELLER SHAFT (See page PR−3) DISCONNECT SPEED METER CABLE NOTICE: Do not lose the felt protector and washers. P15072 1996 TOYOTA T100 (RM449U)
  • Page 791 Remove the 7 bolts holding the mounting bracket to the mounting insulator and cross member. P15099 REMOVE ENGINE WITH TRANSMISSION Install a rear engine hanger in the correct direction. Part No: HANGER, ENGINE, NO.2 12282−75020 BOLT 91512−61020 Torque: 42 N·m (420 kgf·cm,30 ft·lbf) P23949 1996 TOYOTA T100 (RM449U)
  • Page 792 Lift the engine with transmission out of the vehicle slowly and carefully. NOTICE: Make sure the engine is clear of all wiring and hoses. Place the engine and transmission assembly onto the stand. SEPARATE ENGINE AND TRANSMISSION P15092 1996 TOYOTA T100 (RM449U)
  • Page 793 INSTALL CLUTCH RELEASE CYLINDER Connect the clutch line with the bolt. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Install the clutch release cylinder with the 2 bolts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) A/T: INSTALL CROSS SHAFT P15137 1996 TOYOTA T100 (RM449U)
  • Page 794 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) R05270 M/T: INSTALL SHIFT LEVER ASSEMBLY Install baffle and shift lever assembly with the 6 bolts. Install the shift lever boot with the 4 screws. Install the shift lever knob. P15078 1996 TOYOTA T100 (RM449U)
  • Page 795 Torque: 58 N·m (590 kgf·cm, 43 ft·lbf) Using SST, install the PS pump pulley with the nut. 09960−10010 (09962−01000, 09963−01000) Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) P15094 CONNECT HOSES Connect these hoses: Fuel return hose Fuel inlet hose P15086 1996 TOYOTA T100 (RM449U)
  • Page 796 Install the intake air connector with the 2 bolts and hose clamp. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Connect the 2 air hoses. M/T: CONNECT ACCELERATOR CABLE TO THROTTLE BODY A/T: P24651 CONNECT ACCELERATOR AND THROTTLE CABLES TO THROTTLE BODY 1996 TOYOTA T100 (RM449U)
  • Page 797 CHECK IGNITION TIMING (See page EM−11) INSTALL ENGINE UNDER COVER Install the engine under cover with the 4 bolts. INSTALL HOOD VEHICLE ROAD TEST Check for abnormal noise, shock, slippage, and smooth opera- tion. RECHECK ENGINE COOLANT AND ENGINE OIL LEV- 1996 TOYOTA T100 (RM449U)

  • Page 798: Cylinder Block

    EM−75 ENGINE MECHANICAL (3RZ−FE) − CYLINDER BLOCK CYLINDER BLOCK EM07K−03 COMPONENTS P21632 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 799 09816−30010 REMOVE RH ENGINE MOUNTING BRACKET Remove the 4 bolts and bracket. REMOVE LH ENGINE MOUNTING BRACKET Remove the 5 bolts and bracket. P15971 REMOVE REAR OIL SEAL RETAINER Remove the 6 bolts and retainer. P14771 1996 TOYOTA T100 (RM449U)
  • Page 800 Measure the Plastigage at its widest point. Standard oil clearance: 0.030 − 0.055 mm (0.0012 − 0.0022 in.) U/S 0.25 0.031 − 0.071 mm (0.0012 − 0.0026 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) P14781 1996 TOYOTA T100 (RM449U)
  • Page 801 Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in cor- rect order. P14783 1996 TOYOTA T100 (RM449U)
  • Page 802 Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. P14787 If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. Place the crankshaft on the cylinder block. 1996 TOYOTA T100 (RM449U)
  • Page 803 64.004 − 64.010 mm (2.5198 − 2.5201 in.) STD Mark ”2” 64.011 − 64.016 mm (2.5201 − 2.5203 in.) STD Mark ”3” 64.017 − 64.022 mm (2.5203 − 2.5205 in.) U/S 0.25 64.000 − 64.024 mm (2.5197 − 2.5206 in.) 1996 TOYOTA T100 (RM449U)
  • Page 804 0.07 − 0.13 mm (0.0027 − 0.0051 in.) Maximum thrust clearance: 0.2 mm (0.0079 in.) If the thrust clearance is greater than maximum, replace the bal- P14745 ance shaft thrust washer. If necessary, replace the balance shaft. 1996 TOYOTA T100 (RM449U)
  • Page 805 Balance shaft thrust spacer. Balance shaft timing gear. Z11075 DISASSEMBLE NO.2 BALANCE SHAFT Mount the hexagon wrench head portion of the balance shaft in a vise. NOTICE: Be careful not to damage the balance shaft. P14818 1996 TOYOTA T100 (RM449U)
  • Page 806 Using plastic−faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct order. P03870 1996 TOYOTA T100 (RM449U)
  • Page 807 Standard diameter: 94.990 − 95.003 mm (3.7398 − 3.7403 in.) Maximum diameter: 95.06 mm (3.7425 in.) If the diameter is greater than maximum, rebore all the 4 cylin- ders. If necessary, replace the cylinder block. Z10815 1996 TOYOTA T100 (RM449U)
  • Page 808 Check the orifice for clogging. If necessary, replace the orifice. CLEAN PISTON Using a gasket scraper, remove the carbon from the pis- ton top. P14767 Using a groove cleaning tool or broken ring, clean the pis- ton ring grooves. P14822 1996 TOYOTA T100 (RM449U)
  • Page 809 Ring groove clearance: No.1 0.020 − 0.070 mm (0.0008 − 0.0028 in.) No.2 0.030 − 0.070 mm (0.0012 − 0.0028 in.) If the clearance is not as specified, replace the piston. P14821 1996 TOYOTA T100 (RM449U)
  • Page 810 Using a connecting rod aligner and thickness gauge, check the connecting rod alignment. Check for out−of−alignment. Maximum out−of−alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out−of−alignment is greater than maximum, replace the con- necting rod assembly. P03829 1996 TOYOTA T100 (RM449U)
  • Page 811 If the oil clearance is greater than maximum, replace the bush- ing. If necessary, replace the piston and piston pin as a set. IF NECESSARY, REPLACE CONNECTING ROD BUSHING Using SST and a press, press out the bushing. 09207−76010 EM7426 1996 TOYOTA T100 (RM449U)
  • Page 812 If the outside diameter is less than limit, replace the con- necting rod bolt and nut as a set. 23 mm (0.91 in.) EM8714 1996 TOYOTA T100 (RM449U)
  • Page 813 95.433 − 95.443 mm (3.7572 − 3.7576 in.) Calculate amount to bore cylinders Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 37.5 mm (1.47 in.) from the piston head. P14765 1996 TOYOTA T100 (RM449U)
  • Page 814 59.740 − 59.750 mm (2.3520 − 2.3524 in.) Others 59.745 − 59.755 mm (2.3522 − 2.3526 in.) Crank pin diameter: 52.987 − 53.000 mm (2.0861 − 2.0866 in.) U/S 0.25 52.745 − 52.755 mm (2.0766 − 2.0770 in.) 1996 TOYOTA T100 (RM449U)
  • Page 815 IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure in step 20). Install new main journal and/or crankshaft pin undersized bearings. 1996 TOYOTA T100 (RM449U)
  • Page 816 09223 − 50010 P14863 REPLACE CRANKSHAFT REAR OIL SEL If rear oil seal retainer is removed from cylinder block. Using a screwdriver and a hammer, tap out the oil seal. P14984 1996 TOYOTA T100 (RM449U)
  • Page 817 Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. 09223 − 15030, 09608 − 30012 (09608 − 04020) P14966 1996 TOYOTA T100 (RM449U)
  • Page 818 Install the oil ring expander and 2 side rails by hand. P14764 Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark: ”1T” or ”1N” for No.1 ”2T” or ”2N” for No.2 Z10816 1996 TOYOTA T100 (RM449U)
  • Page 819 Be careful not to damage the balance shaft. Install these parts to the balance shaft: No.2 balance shaft No.2 balance shaft thrust plate Balance shaft timing sprocket Install and torque the bolt. Torque: 36 N·m (365 kgf·cm, 26 ft·lbf) Z11076 1996 TOYOTA T100 (RM449U)
  • Page 820 5 lower bearings. HINT: A number is marked on each main bearing cap to indicate the installation position. 2 or 4 P14808 No.1, 5 Bearing Cap 1 or 5 P14809 1996 TOYOTA T100 (RM449U)
  • Page 821 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. P14786 1996 TOYOTA T100 (RM449U)
  • Page 822 P14778 sive steps (steps (b) and (d)). If any connecting rod bolt is broken or deformed, replace Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap. 1996 TOYOTA T100 (RM449U)
  • Page 823 Check that the painted mark on the nut is at a 90° angle in relation to the mark on the bolt. 90° Check that the crankshaft turns smoothly. Check the connecting rod thrust clearance (See page EM−84). Painted Mark P04615 1996 TOYOTA T100 (RM449U)
  • Page 824 Torque: 51 N·m (520 kgf·cm, 34 ft·lbf) Z11442 INSTALL OIL PRESSURE SWITCH Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Adhesive P12478 1996 TOYOTA T100 (RM449U)
  • Page 825 INSTALL FUEL FILTER Install the 2 bolts and fuel filter. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) INSTALL TIMING CHAINS, GEARS AND SPROCKETS (See page EM−20) P14816 INSTALL CYLINDER HEAD (See page EM−50) REMOVE ENGINE STAND 1996 TOYOTA T100 (RM449U)
  • Page 826 Check that the painted mark is now at a 90° angle to the top. A/T: INSTALL DRIVE PLATE Painted Mark Install the front spacer, drive plate and rear spacer with the 10 bolts. Z15493 Torque: 74 N·m (750 kgf·cm, 56 ft·lbf) 1996 TOYOTA T100 (RM449U)

  • Page 827: Exhaust System

    EM−104 ENGINE MECHANICAL (3RZ−FE) − EXHAUST SYSTEM EXHAUST SYSTEM EM07P−02 COMPONENTS 39 (400, 29) 19 (195, 14) 62 (630, 46) : Specified torque N·m (kgf·cm, ft·lbf) Z14985 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 828 EM – ENGINE MECHANICAL (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 EXHAUST SYSTEM EM-108...
  • Page 829 IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regula- tions P15056 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 830 If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. REINSTALL SPARK PLUGS 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 831 EM−3 ENGINE MECHANICAL (5VZ−FE) − COMPRESSION REINSTALL HIGH−TENSION CORDS WITH IGNITION COILS (See page IG−1) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 832 Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the RH EX valve clearance. (See procedure step (a)) RH IN LH IN LH EX P01270 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 833 To prevent it from being stuck, insert it gently from the intake side, at a slight angle. Others SST (B) SST (A) P21225 Using a small screwdriver and magnetic finger, re- SST (B) move the adjusting shim. Magnetic Finger P21222 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 834 09248−55040 (09248−05410, 09248−05420) Recheck the valve clearance. P21223 REINSTALL CYLINDER HEAD COVERS (See page EM−51) REINSTALL INTAKE AIR CONNECTOR (See page EM−69) REFILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 835 EM−7 ENGINE MECHANICAL (5VZ−FE) − VALVE CLEARANCE V06208 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 836 EM−8 ENGINE MECHANICAL (5VZ−FE) − VALVE CLEARANCE V06209 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 837 DLC3 Connect the TOYOTA hand−held tester or OBDII scan tool to the DLC3. FI7231 Please refer to the TOYOTA hand−held tester or OBDII scan tool operator’s manual for further details. CONNECT TIMING LIGHT TO ENGINE CHECK IDLE SPEED Race the engine speed at 2,500 rpm for approx. 90 se- conds.
  • Page 838 SFI system wiring connectors fully plugged Ignition timing check correctly Transmission in neutral position CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (See page EM−9) INSPECT IDLE SPEED Race the engine speed at 2,500 rpm for approx. 90 se- conds.

  • Page 839: Timing Belt

    EM−11 ENGINE MECHANICAL (5VZ−FE) − TIMING BELT TIMING BELT EM06G−03 COMPONENTS P20840 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 840 EM−12 ENGINE MECHANICAL (5VZ−FE) − TIMING BELT 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 841 Disconnect the 3 high−tension cord clamps from the No.2 timing belt cover. Remove the 6 bolts, and timing belt cover. REMOVE FAN BRACKET Remove the nut and PS pump adjusting strut. Remove the bolt, nut, and fan bracket. P20830 1996 TOYOTA T100 (RM449U)
  • Page 842 P20818 REMOVE RH CAMSHAFT TIMING PULLEY WITH TIM- ING BELT Using SST, loosen the pulley bolt. 09960−10010 (09962−01000, 09963−01000) P20831 Remove the bolt, knock pin and camshaft timing pulley with timing belt. P20833 1996 TOYOTA T100 (RM449U)
  • Page 843 REMOVE NO.2 IDLER PULLEY AND NO.1 IDLER PULLEY Remove the bolt and No.2 idler pulley. Using a 10 mm hexagon wrench, remove the pivot bolt, P20499 No.1 idler pulley and plate washer. 1996 TOYOTA T100 (RM449U)
  • Page 844 TIMING BELT 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. 09950−50010 (09951−05010, 09952−05010, 09953−05020, 09954−05010) P20816 1996 TOYOTA T100 (RM449U)
  • Page 845 INSPECT IDLER PULLEYS Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. P20043 Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. P12604 1996 TOYOTA T100 (RM449U)
  • Page 846 Never hold the tensioner push rod facing downward. P18764 Measure the protrusion of the push rod from the housing end. Protrusion Protrusion: 10.0 − 10.8 mm (0.394 − 0.425 in.) If the protrusion is not as specified, replace the tensioner. P18770 1996 TOYOTA T100 (RM449U)
  • Page 847 Install the timing belt on the crankshaft timing pulley, No.1 idler and water pump pulleys. P20499 INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward. Front P20823 1996 TOYOTA T100 (RM449U)
  • Page 848 09960−10010 (09962−01000, 09963−01000) Torque: 110 N·m (1,100 kgf·cm, 81 ft·lbf) P20828 SET NO.1 CYLINDER TO TDC/COMPRESSION Crankshaft Position: Turn the crankshaft pulley, and align its groove with the ”O” timing mark of the No.1 timing belt cover. P20827 1996 TOYOTA T100 (RM449U)
  • Page 849 Using SST, align the timing marks of the LH camshaft pulley and No.3 timing belt cover. 09960−10010 (09962−01000, 09963−01000) Check that the timing belt has tension between the crank- shaft timing and LH camshaft timing pulleys. P20836 1996 TOYOTA T100 (RM449U)
  • Page 850 Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the set- ting position of the push rod. Release the press. P08325 Install the dust boot to the tensioner. P10221 1996 TOYOTA T100 (RM449U)
  • Page 851 Install the belt cover with the 6 bolts. Torque: 9 N·m (90 kgf·cm, 80 in.·lbf) Connect the 3 high−tension cord clamps to the No.2 tim- ing belt cover. Connect the camshaft position sensor connector to the No.2 timing belt cover. 1996 TOYOTA T100 (RM449U)
  • Page 852 CONNECT UPPER RADIATOR HOSE FILL ENGINE WITH COOLANT START ENGINE CHECK FOR LEAKS 4WD: INSTALL ENGINE UNDER COVER ROAD TEST VEHICLE Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT LEVEL 1996 TOYOTA T100 (RM449U)
  • Page 853 EM−25 ENGINE MECHANICAL (5VZ−FE) − CYLINDER HEAD CYLINDER HEAD EM06K−02 COMPONENTS P21777 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 854 EM−26 ENGINE MECHANICAL (5VZ−FE) − CYLINDER HEAD Z18898 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 855 EM−27 ENGINE MECHANICAL (5VZ−FE) − CYLINDER HEAD 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 856 EM−28 ENGINE MECHANICAL (5VZ−FE) − CYLINDER HEAD S05153 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 857 EM−29 ENGINE MECHANICAL (5VZ−FE) − CYLINDER HEAD Z18899 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 858 A/C: REMOVE A/C COMPRESSOR BRACKET REMOVE HIGH−TENSION CORDS WITH IGNITION COILS REMOVE SPARK PLUGS REMOVE TIMING BELT AND CAMSHAFT TIMING PULLEYS (See page EM−13) REMOVE TIMING BELT IDLER NO. 2 (See page EM−13) REMOVE GENERATOR 1996 TOYOTA T100 (RM449U)
  • Page 859 Remove the bolt, and disconnect the ground strap from the intake air connector. Disconnect the DLC1 from the bracket. w/ A/C Disconnect the A/C idle−up valve connector. Remove the 3 bolts, 2 nuts, intake air connector and gas- ket. 1996 TOYOTA T100 (RM449U)
  • Page 860 Remove the 6 nuts, crossover pipe and 2 gaskets. REMOVE LH AND RH EXHAUST MANIFOLDS Remove the 6 nuts and exhaust manifold heat insulators. Remove the 12 nuts, LH, RH exhaust manifolds and gas- P21195 ket. 1996 TOYOTA T100 (RM449U)
  • Page 861 Remove the 4 bearing caps and exhaust camshaft. P21146 Intake: REMOVE CAMSHAFTS OF RH CYLINDER HEAD Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. Remove the 5 bearing caps, oil seal and intake camshaft. P21145 1996 TOYOTA T100 (RM449U)
  • Page 862 Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. Remove the 5 bearing caps, oil seal and intake camshaft. HINT: Arrange the camshafts in the correct order. Arrange the bearing caps in the correct order. P21143 1996 TOYOTA T100 (RM449U)
  • Page 863 Remove the bolt, and disconnect the ground strap. Using an 8 mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then re- 8 mm Hexagon Wrench peat for the other side, as shown. Front Z13745 1996 TOYOTA T100 (RM449U)
  • Page 864 If the cylinder head is difficult to lift off, pry between the cyl- inder head and cylinder block with a screwdriver. Arrange the cylinder heads in the correct order. NOTICE: Be careful not to damage the contact surfaces of the cylin- P00828 der head and cylinder block. 1996 TOYOTA T100 (RM449U)
  • Page 865 Using needle−nose pliers, remove the oil seal. P20988 Using compressed air and a magnetic finger, remove the Magnetic Finger spring seat by blowing air. HINT: Arrange the valves, valve springs, spring seats and spring re- tainers in the correct order. P20841 1996 TOYOTA T100 (RM449U)
  • Page 866 Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact sur- faces. P20512 CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings. P20986 1996 TOYOTA T100 (RM449U)
  • Page 867 If cracked, replace the cylinder head. P20514 CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM0580 1996 TOYOTA T100 (RM449U)
  • Page 868 Wrap the tape approx. 8 mm (0.31 in.) from the valve stem end. Approx. 8 mm NOTICE: Be careful not to damage the valve lifter hole. A01572 Gradually heat the cylinder head to 80 − 100°C (176 − 80 − 100°C (176 − 212°F) 212°F). P20854 1996 TOYOTA T100 (RM449U)
  • Page 869 Gradually heat the cylinder head to 80 − 100°C (176 − Snap Ring 212°F). Using SST and a hammer, tap in a new guide bushing un- til the snap ring makes contact with the cylinder head. 09201−10000 (09201−01060), 09950−70010 (09951−07150) P20984 1996 TOYOTA T100 (RM449U)
  • Page 870 Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than the minimum. EM0255 1996 TOYOTA T100 (RM449U)
  • Page 871 If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat. 60° 45° 1.0 − 1.4 mm Z00139 Hand−lap the valve and valve seat with an abrasive com- pound. After hand−lapping, clean the valve and valve seat. P20513 1996 TOYOTA T100 (RM449U)
  • Page 872 42.31 − 42.41 mm (1.6657 − 1.6697 in.) Exhaust 41.96 − 42.06 mm (1.6520 − 1.6559 in.) Minimum Intake 42.16 mm (1.6598 in.) Exhaust 41.81 mm (1.6461 in.) If the cam lobe height is greater than maximum, replace the camshaft. EM2011 1996 TOYOTA T100 (RM449U)
  • Page 873 Install the camshafts (See page EM−51). Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.033 − 0.080 mm (0.0013 − 0.0031 in.) Maximum thrust clearance: 0.12 mm (0.0047 in.) P20855 1996 TOYOTA T100 (RM449U)
  • Page 874 30.966 − 30.976 mm (1.2191 − 1.2195 in.) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 − 0.052 mm (0.0009 − 0.0020 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) EM2196 1996 TOYOTA T100 (RM449U)
  • Page 875 Air Intake Chamber and intake air connector: Measure the surfaces contacting the intake manifold and intake air connector for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the air intake chamber or intake air connector. P21621 1996 TOYOTA T100 (RM449U)
  • Page 876 Apply a light coat of MP grease to the gasket lip. Return the ventilation plate tab to its original position. P24420 1996 TOYOTA T100 (RM449U)
  • Page 877 Using SST, push in a new oil seal. 09201−41020 P20842 HINT: Intake Exhaust The intake valve oil seal is silver and the exhaust valve oil seal Silver Rubber Black Rubber is black. Coated Surface Plain Surface Z09175 1996 TOYOTA T100 (RM449U)
  • Page 878 Install the camshaft bearing cap with the 2 bolts. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) Install the cylinder head rear plate, ground strap with the bolt and nut. Torque: 8 N·m (80 kgf·cm, 71 in.·lbf) P20844 1996 TOYOTA T100 (RM449U)
  • Page 879 Retighten the cylinder head bolts by 90° in the numerical 90° order shown. 90° 90° Retighten the cylinder head bolts by an additional 90°. 90° Check that the painted mark is now facing rearward. Painted Mark P00868 1996 TOYOTA T100 (RM449U)
  • Page 880 Be careful not to damage the camshaft. Install these parts: Camshaft gear spring Camshaft sub−gear HINT: P21041 Attach the pins on the gears to the gear spring ends. Wave washer Using snap ring pliers, install the snap ring. P21037 1996 TOYOTA T100 (RM449U)
  • Page 881 Apply MP grease to a new oil seal lip. Install the oil seal to the camshaft. P21199 Remove any old packing (FIPG) material. Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No. 08826−00080 or equivalent Seal Packing P12390 1996 TOYOTA T100 (RM449U)
  • Page 882 Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install and uniformly tighten the 8 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) Remove the service bolt. P21205 1996 TOYOTA T100 (RM449U)
  • Page 883 Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) P21201 1996 TOYOTA T100 (RM449U)
  • Page 884 Remove the service bolt. CHECK AND ADJUST VALVE CLEARANCE P21159 INSTALL SEMI−CIRCULAR PLUGS Remove any old packing (FIPG) material. Apply seal packing to the semi−circular plug grooves. Seal packing: Part No. 08826−00080 or equivalent Seal Packing P13274 1996 TOYOTA T100 (RM449U)
  • Page 885 Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf) INSTALL OIL DIPSTICK AND GUIDE Install a new O−ring to the dipstick guide. Apply soapy water to the O−ring. Push in the dipstick guide end into the guide hole of the P21195 oil pan. 1996 TOYOTA T100 (RM449U)
  • Page 886 Torque: 9 N·m (90 kgf·cm, 80 in.·lbf) INSTALL CAMSHAFT POSITION SENSOR Join Line L = 130 mm Torque: 8 N·m (80 kgf·cm, 71 in.·lbf) L = 145 mm (5.12 in.) L = 265 mm (5.71 in.) (10.43 in.) L = Length P21198 1996 TOYOTA T100 (RM449U)
  • Page 887 Install the bolt, and connect the ground strap to the intake air connector. Connect the brake booster vacuum hose to the intake air connector. Connect the 2 fuel return hoses. Install the engine wire with the bolt. w/ A/C Connect the A/C idle−up valve connector. 1996 TOYOTA T100 (RM449U)
  • Page 888 EGR: INSTALL EGR PIPE Install 2 new gaskets and the EGR pipe with the 6 nuts. Torque: Nut A: 18.5 N·m (185 kgf·cm, 13 ft·lbf) Nut B: 8 N·m (80 kgf·cm, 71 in.·lbf) TEMPORARILY INSTALL GENERATOR 1996 TOYOTA T100 (RM449U)
  • Page 889 START ENGINE AND CHECK FOR LEAKS CHECK IGNITION TIMING (See page EM−9) 4WD: INSTALL ENGINE UNDER COVER ROAD TEST VEHICLE Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT LEVEL 1996 TOYOTA T100 (RM449U)
  • Page 890 EM−62 ENGINE MECHANICAL (5VZ−FE) − ENGINE UNIT (2WD) ENGINE UNIT (2WD) EM07R−04 COMPONENTS 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 891 EM−63 ENGINE MECHANICAL (5VZ−FE) − ENGINE UNIT (2WD) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 892 EM−64 ENGINE MECHANICAL (5VZ−FE) − ENGINE UNIT (2WD) Z18855 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 893 ONATOR REMOVE AIR CLEANER CASE AND FILTER DISCONNECT THESE CABLES: w/ Cruise control: Cruise control actuator cable Accelerator cable A/T: Throttle cable DISCONNECT HEATER HOSES DISCONNECT HOSES Disconnect these hoses: Brake booster vacuum hose EVAP hose 1996 TOYOTA T100 (RM449U)
  • Page 894 Do not lose the felt protector and washers. REMOVE FRONT EXHAUST PIPE Disconnect the 2 heated oxygen sensor connectors. Remove the 2 bolts, and retainer holding the front ex- P21437 haust pipe to the center exhaust pipe. 1996 TOYOTA T100 (RM449U)
  • Page 895 Install a engine hanger No.2 in the correct direction. Part No.: Engine hanger No.2 12282−62030 Bolt 91512−61020 Engine Hanger No. 2 Torque:40 N·m (400 kgf·cm, 30 ft·lbf) P21444 Attach the engine hoist chain to the 2 engine hangers. P21459 1996 TOYOTA T100 (RM449U)
  • Page 896 Lift the engine with transmission out of the vehicle slowly and carefully. NOTICE: Make sure the engine is clear of all wiring and hoses. Place the engine and transmission assembly onto the stand. SEPARATE ENGINE AND TRANSMISSION P21458 1996 TOYOTA T100 (RM449U)
  • Page 897 Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) P15099 TIGHTEN RH AND LH ENGINE MOUNTING INSULATOR BOLTS AND NUTS Tighten the 4 bolts and nuts holding the mounting insulators to the body mountings. Torque: 38 N·m (387 kgf·cm, 28 ft·lbf) P23911 1996 TOYOTA T100 (RM449U)
  • Page 898 Connect these wire and connectors: Ground strap Igniter connector P21441 Connect 2 connectors to cowl wire. M/T: Connect 3 connectors to the ECM. A/T: Connect 4 connectors to the ECM. Install the ECM with the 3 bolts. P21435 1996 TOYOTA T100 (RM449U)
  • Page 899 INSTALL AIR CLEANER CASE AND AIR FILTER INSTALL MAF METER, RESONATOR AND AIR CLEANER CAP w/ A/C: CONNECT A/C COMPRESSOR CONNECT PS PUMP INSTALL FAN WITH FLUID COUPLING AND FAN PULLEYS(See page EM−19) INSTALL DRIVE BELT FOR GENERATOR (See page CH−1) 1996 TOYOTA T100 (RM449U)
  • Page 900 FILL TRANSMISSION OIL START ENGINE AND CHECK FOR LEAKS CHECK IGNITION TIMING (See page EM−9) INSTALL HOOD ROAD TEST VEHICLE Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT AND OIL LEVELS 1996 TOYOTA T100 (RM449U)
  • Page 901 EM−73 ENGINE MECHANICAL (5VZ−FE) − ENGINE UNIT (4WD) ENGINE UNIT (4WD) EM1OT−01 COMPONENTS 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 902 EM−74 ENGINE MECHANICAL (5VZ−FE) − ENGINE UNIT (4WD) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 903 EM−75 ENGINE MECHANICAL (5VZ−FE) − ENGINE UNIT (4WD) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 904 REMOVE AIR CLEANER CASE AND FILTER DISCONNECT THESE CABLES: w/ Cruise control: Cruise control actuator cable Accelerator cable A/T: Throttle cable DISCONNECT HEATER HOSES DISCONNECT HOSES Disconnect these hoses: Brake booster vacuum hose EVAP hose A.D.D. vacuum hose 1996 TOYOTA T100 (RM449U)
  • Page 905 Disconnect the 4 ECM connectors. Disconnect the 2 connectors from the cowl wire. P21435 Disconnect these wires and connectors: Igniter connector Ground strap Disconnect the 6 engine wire clamps. Pull out the engine wire from the cabin. P21441 1996 TOYOTA T100 (RM449U)
  • Page 906 P21776 Lift the engine out of the vehicle slowly and carefully. NOTICE: Make sure the engine is clear of all wiring and hoses. Place the engine assembly onto the stand. P21615 1996 TOYOTA T100 (RM449U)
  • Page 907 Connect 3 connectors to the ECM. A/T: Connect 4 connectors to the ECM. Install the ECM with the 3 bolts. INSTALL FRONT DOOR SCUFF PLATE AND COWL SIDE TRIM CONNECT GENERATOR WIRE P21435 Connect the generator connector. 1996 TOYOTA T100 (RM449U)
  • Page 908 INSTALL MAF METER, RESONATOR AND AIR CLEANER CAP w/ A/C: CONNECT A/C COMPRESSOR CONNECT PS PUMP INSTALL FAN WITH FLUID COUPLING AND FAN PUL- LEYS (See page EM−19) INSTALL DRIVE BELT FOR GENERATOR (See page CH−1) 1996 TOYOTA T100 (RM449U)
  • Page 909 FILL WITH ENGINE COOLANT INSTALL ENGINE UNDER COVER INSTALL TRANSMISSION (See page MT−4) INSTALL HOOD PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS 1996 TOYOTA T100 (RM449U)
  • Page 910 EM−82 ENGINE MECHANICAL (5VZ−FE) − CYLINDER BLOCK CYLINDER BLOCK EM07T−02 COMPONENTS 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 911 EM−83 ENGINE MECHANICAL (5VZ−FE) − CYLINDER BLOCK P21786 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 912 REMOVE OIL FILTER AND OIL FILTER UNION Using SST, remove the oil filter. 09228−07501 Using 12 mm hexagon wrench, remove the union. REMOVE RH AND LH ENGINE MOUNTING BRACKET REMOVE COOLANT DRAIN COCK w/o OIL COOLER: REMOVE OIL HOLE COVER PLATE P21466 1996 TOYOTA T100 (RM449U)
  • Page 913 If necessary, replace the crankshaft. P20859 REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Using a punch or numbering stamp, mark the connecting rod and cap to ensure correct reassembly. Remove the connecting rod cap nuts. P20862 1996 TOYOTA T100 (RM449U)
  • Page 914 Install the connecting rod cap with the 2 nuts (See page EM−101). Torque: 1st 25 N·m (250 kgf·cm, 18 ft·lbf) 2nd Turn extra 90° NOTICE: Do not turn the crankshaft. Remove the 2 nuts and connecting rod cap (See proce- dure (b) and (c) above). EM5345 1996 TOYOTA T100 (RM449U)
  • Page 915 Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. P00884 HINT: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in cor- rect order. 1996 TOYOTA T100 (RM449U)
  • Page 916 1st 61 N·m (625 kgf·cm, 45 ft·lbf) 2nd Turn extra 90° NOTICE: Do not turn the crankshaft. Remove the 8 bolts and main bearing cap (See procedure (a) and (b) above). Measure the Plastigage at its widest point. EM4969 1996 TOYOTA T100 (RM449U)
  • Page 917 1.994 − 1.997 mm (0.0785 − 0.0786 in.) Mark ”3” 1.997 − 2.000 mm (0.0786 − 0.0787 in.) Mark ”4” 2.000 − 2.003 mm (0.0787 − 0.0789 in.) Mark ”5” 2.003 − 2.006 mm (0.0789 − 0.0790 in.) 1996 TOYOTA T100 (RM449U)
  • Page 918 If any movement is felt, replace the piston and pin as a set. P21454 REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. HINT: Arrange the piston rings in the correct order only. P21446 1996 TOYOTA T100 (RM449U)
  • Page 919 Using a plastic−faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. P01030 1996 TOYOTA T100 (RM449U)
  • Page 920 Front HINT: There are 3 sizes of the standard cylinder bore diameter, marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the No.5 No.1 No.3 top of the cylinder block. No.2 No.4 No.6 EM6290 1996 TOYOTA T100 (RM449U)
  • Page 921 P00884 CLEAN PISTON Using a gasket scraper, remove the carbon from the pis- ton top. P21450 Using a groove cleaning tool or broken ring, clean the pis- ton ring grooves. P21455 1996 TOYOTA T100 (RM449U)
  • Page 922 Standard ring groove clearance: No.1 0.040 − 0.080 mm (0.0016 − 0.0031 in.) No.2 0.030 − 0.070 mm (0.0012 − 0.0028 in.) If the clearance not as specified, replace the piston. P21456 1996 TOYOTA T100 (RM449U)
  • Page 923 If bend is greater than maximum, replace the connecting rod as- sembly. Z00064 Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod as- sembly. Z00065 1996 TOYOTA T100 (RM449U)
  • Page 924 Using SST and a press, press in the bushing. 09222−30010 Oil Hole P00330 Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (see step 13 above) be- tween the bushing and piston pin. P01038 1996 TOYOTA T100 (RM449U)
  • Page 925 O/S 0.50: 93.856 − 93.886 mm (3.6951 − 3.6963 in.) Calculate amount to the bore cylinders. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 26 mm (1.02 in.) from the piston head. 26 mm P21447 1996 TOYOTA T100 (RM449U)
  • Page 926 Check each main journal and crank pin for taper and out− of−round as shown. Maximum taper and out−of−round: 0.02 mm (0.0008 in.) If the taper or out−of−round is greater than maximum, grind or replace the crankshaft. 1996 TOYOTA T100 (RM449U)
  • Page 927 IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure step 18). Install new main journal and/or crank pin undersized bearings. 1996 TOYOTA T100 (RM449U)
  • Page 928 Z04104 Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. 09223−15030, 09950−70010 (09951−07150) EM7574 1996 TOYOTA T100 (RM449U)
  • Page 929 Position the piston rings so that the ring ends are as Compression Upper Side shown. Ring No.1 Rail NOTICE: Do not align the ring ends. Front Mark Expander (Cavity) Compression Lower Side Ring No.2 Rail P21438 1996 TOYOTA T100 (RM449U)
  • Page 930 PLACE CRANKSHAFT ON CYLINDER BLOCK P10215 PLACE MAIN BEARING CAP AND LOWER THRUST WASHERS ON CYLINDER BLOCK Install the thrust washers on the No.2 journal position of the bearing cap with the grooves facing outward. EM5354 1996 TOYOTA T100 (RM449U)
  • Page 931 Check that the crankshaft turns smoothly. Check the crankshaft thrust clearance (See page EM−92). EM5370 INSTALL PISTON AND CONNECTING ROD AS- SEMBLIES Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. P00591 1996 TOYOTA T100 (RM449U)
  • Page 932 If any one of the connecting rod cap nuts does not meet the torque specification, replace the cap nut. Mark the front of the connecting rod cap nut and bolt with Front paint. Painted Mark P02237 1996 TOYOTA T100 (RM449U)
  • Page 933 INSTALL COOLANT DRAIN COCK Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) INSTALL RH AND LH ENGINE MOUNTING BRACKETS Torque: 44 N·m (440 kgf·cm, 32 ft·lbf) INSTALL OIL FILTER UNION Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 1996 TOYOTA T100 (RM449U)
  • Page 934 Seal packing: Part No. 08826 − 00100 or equivalent 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. P10226 1996 TOYOTA T100 (RM449U)
  • Page 935 Part No. 08833 − 00070, THREE BOND 1324 or equiva- P21461 lent Install the drive plate on the crankshaft. Install and uniformly tighten the 8 mount bolts in several passes, in the sequence shown. Torque: 85 N·m (850 kgf·cm, 63 ft·lbf) 1996 TOYOTA T100 (RM449U)
  • Page 936 EM−108 ENGINE MECHANICAL (5VZ−FE) − EXHAUST SYSTEM EXHAUST SYSTEM EM07F−01 COMPONENTS P24419 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 937 EM−109 ENGINE MECHANICAL (5VZ−FE) − EXHAUST SYSTEM P24450 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 938 EC – EMISSIONS CONTROL (3RZ-FE) EMISSION CONTROL SYSTEM EC-1 PARTS LAYOUT AND SCHEMATIC EC-2 DRAWING POSITIVE CRANKCASE VENTILATION EC-4 (PCV) SYSTEM EVAPORATIVE EMISSION (EVAP) EC-5 CONTROL SYSTEM EXHAUST GAS RECIRCULATION EC-7 (EGR) SYSTEM THREE-WAY CATALYTIC CONVERTER EC-10 (TWC) SYSTEM...

  • Page 939: Emission Control System

    (5) Multiport Fuel Injection * Injects a precisely timed, optimum amount of fuel for reduced exhaust emissions Remark: * For inspection and repair of the MFI system, refer to the MF section this manual. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 940 EC−2 EMISSION CONTROL (3RZ−FE) − PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING EC02O−02 LOCATION 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 941 EC−3 EMISSION CONTROL (3RZ−FE) − PARTS LAYOUT AND SCHEMATIC DRAWING EC02P−02 DRAWING 1996 TOYOTA T100 (RM449U)
  • Page 942 If operation is not as specified, replace the PCV valve. REMOVE CLEAN HOSE FROM PCV VALVE REINSTALL PCV VALVE P05444 VISUALLY INSPECT HOSES AND CONNECTIONS Check for cracks, leaks or damage. P15871 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 943: Control System

    , 0.68 psi) into purge pipe and check that air does not flow from the tank pipe and air flows without resistance from the other pipe. If a problem is found, replace the charcoal canister. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 944 NOTICE: Do not attempt to wash the canister. No activated carbon should come out. REINSTALL CAP TO CHARCOAL CANISTER RECONNECT CHARCOAL CANISTER Torque: 31 N·m (310 kgf·cm, 23 ft·lbf) REINSTALL VSV 1996 TOYOTA T100 (RM449U) Author : Date :...

  • Page 945: Exhaust Gas Recirculation

    TOYOTA Hand−Held Tester SCAN TOOL Connect the TOYOTA hand−held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand−held tester or OBDII scan tool operators manual for further details. INSPECT VSV OPERATION WITH COLD ENGINE DLC3 The engine coolant temperature should be below 50°C...
  • Page 946 EC−8 EMISSION CONTROL (3RZ−FE) − EXHAUST GAS RECIRCULATION (EGR) SYSTEM If you have no TOYOTA hand−held tester, check these Low Vacuum 3−Way procedures: Plug Remove the 3−way connector with the vacuum hose. Connect the vacuum hose (from port Q of EGR vac- uum modulator) to the EGR valve.
  • Page 947 If operation is not as specified, replace the check valve. INSTALL CHECK VALVE HINT: EC0107 Install the check valve with the orange pipe facing the EGR vac- uum modulator side. INSPECT VSV FOR EGR (See page MF−44) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 948 CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENESS OR DAMAGE CHECK EXHAUST PIPE CLUMPS FOR WEAKNESS,CRACKS OR DAMAGE CHECK HEAT INSULATOR FOR DAMAGE CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSU- LATOR 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 949 Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) HINT: At the time of assembly please refer to the following item. Place 2 new gaskets on the front exhaust and tail pipes, and temporarily install the center exhaust pipe. REINSTALL CENTER EXHAUST PIPE P21181 1996 TOYOTA T100 (RM449U)
  • Page 950 EC – EMISSIONS CONTROL (5VZ-FE) EMISSION CONTROL SYSTEM EC-1 PARTS LAYOUT AND SCHEMATIC EC-2 DRAWING POSITIVE CRANKCASE VENTILATION EC-4 (PCV) SYSTEM EVAPORATIVE EMISSION (EVAP) EC-5 CONTROL SYSTEM EXHAUST GAS RECIRCULATION EC-7 (EGR) SYSTEM THREE-WAY CATALYTIC CONVERTER EC-12 (TWC) SYSTEM...
  • Page 951 (5) Sequential Multiport Fuel Injection * Injects a precisely timed, optimum amount of fuel for reduced exhaust emissions Remark: * For inspection and repair of the SFI system, refer to the SF section of this manual. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 952 EC−2 EMISSION CONTROL (5VZ−FE) − PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING EC033−03 LOCATION B13074 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 953 EC−3 EMISSION CONTROL (5VZ−FE) − PARTS LAYOUT AND SCHEMATIC DRAWING EC034−03 DRAWING B13075 1996 TOYOTA T100 (RM449U)
  • Page 954 If operation is not as specified, replace the PCV valve. REMOVE CLEAN HOSE FROM PCV VALVE REINSTALL PCV VALVE P21214 VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. P21676 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 955 0.68 psi) into purge pipe and check that air does not flow from the tank pipe. But the air flows without resistance from the other pipe. If a problem is found, replace the charcoal canister. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 956 NOTICE: Do not attempt to wash the canister. No activated carbon should come out. INSPECT VSV FOR EVAP (See page SF−50) REINSTALL VSV REINSTALL CHARCOAL CANISTER 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 957 EC−7 EMISSION CONTROL (5VZ−FE) − EXHAUST GAS RECIRCULATION (EGR) SYSTEM EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC02V−02 COMPONENTS P21189 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 958 Torque: 18.5 N·m (185 kgf·cm, 14 ft·lbf) HINT: Use a new gasket. At the time of installation, please refer to the following item. Check for sticking and heavy carbon deposits. If problem is found, replace the EGR valve. 1996 TOYOTA T100 (RM449U)
  • Page 959 Check that the vacuum gauge indicates low vacuum at 2,800 rpm. Disconnect the vacuum hose from port R of the EGR vac- uum modulator and connect port R directly to the intake manifold with another hose. P23554 1996 TOYOTA T100 (RM449U)
  • Page 960 Repeat the above test. Check that there is a strong resis- tance to air flow. RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR Connect these vacuum hoses: Vacuum hose to R port Vacuum hose to Q port Vacuum hose to P port P23557 1996 TOYOTA T100 (RM449U)
  • Page 961 EC−11 EMISSION CONTROL (5VZ−FE) − EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC02X−02 INSTALLATION Installation is in the reverse order of removal (See page EC−8). 1996 TOYOTA T100 (RM449U)
  • Page 962 CHECK CONNECTIONS EXHAUST PIPE FOR LOOSENESS OR DAMAGE CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE CHECK HEAT INSULATOR FOR DAMAGE CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 963 Remove the 4 bolts, TWC joint retainer, center exhaust pipe and 2 gasket. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) REINSTALL CENTER EXHAUST PIPE HINT: Place 2 new gaskets on the front exhaust and tail pipes, and temporarily install the center exhaust pipe. P21181 1996 TOYOTA T100 (RM449U)

  • Page 964: Table Of Contents

    MF – MFI SYSTEM (3RZ-FE) MFI SYSTEM MF-1 FUEL PUMP MF-5 FUEL PRESSURE REGULATOR MF-13 INJECTOR MF-16 FUEL TANK AND LINE MF-23 THROTTLE BODY MF-25 IDLE AIR CONTROL (IAC) VALVE MF-31 MASS AIR FLOW (MAF) METER MF-36 EFI MAIN RELAY MF-40 CIRCUIT OPENING RELAY MF-41...

  • Page 965: Mfi System

    Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will cause air suction and cause the engine to run out of tune. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 966 Do not apply unnecessary force to the terminal. After checking, install the water−proofing rubber on the connector securely. Use SST for inspection or test of the injector or its wiring connector. 09842−30070 FI2553 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 967 Delivery Pipe P15750 Install the injector to the delivery pipe and cylinder head as shown in the illustration. Delivery Pipe O−Ring Grommet Injector Insulator P15128 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 968 Turn ignition switch ON and TOYOTA hand−held tester main switch ON. NOTICE: DLC3 Do not start the engine Select the active test mode on the TOYOTA hand− FI7231 held tester. Please refer to the TOYOTA hand−held tester oper- ator’s manual for further details.
  • Page 969 FUEL PUMP TOYOTA Hand−Held Tester SF0AG−03 ON−VEHICLE INSPECTION CHECK FUEL PUMP OPERATION Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand−held tes- ter main switch ON. DLC3 NOTICE: Do not start the engine. FI7231 Select the active test mode on the TOYOTA hand−held...
  • Page 970 Wipe off any splattered gasoline. P24762 Connect the TOYOTA hand−held tester to the DLC3. TOYOTA Hand−Held Tester Turn the ignition switch ON and TOYOTA hand−held tes- ter main switch ON. NOTICE: Do not start the engine. Select the active test mode on the TOYOTA hand−held tester.
  • Page 971 Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) Reconnect the negative (−) terminal cable to the battery. Check for fuel leakage. P24763 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 972 MF−8 MFI (3RZ−FE) − FUEL PUMP SF0AH−03 COMPONENTS 1996 TOYOTA T100 (RM449U)
  • Page 973 Torque: 3.9 N·m ( 40 kgf·cm, 35 in.·lbf) Pull out the pump bracket assembly. Remove the gasket from the pump bracket. HINT: At the time assembly please refer to the following items. B02579 Install the fuel pump bracket with a new gasket. 1996 TOYOTA T100 (RM449U)
  • Page 974 Disconnect the fuel hose from the fuel pump, and remove the fuel pump. Remove the rubber cushion from the fuel pump. P15055 REMOVE FUEL PUMP FILTER FROM FUEL PUMP Using a small screwdriver, remove the clip. Pull out the pump filter. P15059 1996 TOYOTA T100 (RM449U)
  • Page 975 MF−11 MFI (3RZ−FE) − FUEL PUMP SF0AK−02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page MF−10). 1996 TOYOTA T100 (RM449U)
  • Page 976 MF−12 MFI (3RZ−FE) − FUEL PUMP SF0AL−03 INSTALLATION Installation is in the reverse order of removal (See page MF−9). 1996 TOYOTA T100 (RM449U)

  • Page 977: Fuel Pressure Regulator

    MF−13 MFI (3RZ−FE) − FUEL PRESSURE REGULATOR FUEL PRESSURE REGULATOR SF0AM−02 COMPONENTS Vacuum Sensing Fuel Pressure Hose Regulator z O−Ring Fuel Return Hose z Non−reusable part P25123 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 978 Remove the 2 bolts and the fuel pressure regulator. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) Remove the O−ring. HINT: At the time of installation please refer to the following items. Install the pressure regulator with a new O−ring. P14968 1996 TOYOTA T100 (RM449U)
  • Page 979 MF−15 MFI (3RZ−FE) − FUEL PRESSURE REGULATOR SF0AO−03 INSTALLATION Installation is in the reverse order of removal (See page MF−14). 1996 TOYOTA T100 (RM449U)
  • Page 980 Using an ohmmeter, measure the resistance between the terminals. Resistance: 12 − 16 Ω at 20°C (68°F) If the resistance is not as specified, replace the injector. P25103 Reconnect the injector connectors. Reinstall the throttle body. (See page MF−30) 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 981 MF−17 MFI (3RZ−FE) − INJECTOR SF0AQ−02 COMPONENTS 1996 TOYOTA T100 (RM449U)
  • Page 982 REMOVE NO. 1 AND NO. 2 PCV HOSES DISCONNECT HIGH−TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. Disconnect the distributor connector. REMOVE THROTTLE BODY (See page MF−28) REMOVE DELIVERY PIPE AND INJECTORS 1996 TOYOTA T100 (RM449U)
  • Page 983 SST (clamp). 09268−41046 Put the injector into a graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. Connect the TOYOTA hand−held tester to the DLC3. B02507 (See page MF−5) 1996 TOYOTA T100 (RM449U)
  • Page 984 Fuel drop: 1 drop or less per 3 minutes Turn the ignition switch to LOCK. Disconnect the negative (−) terminal cable from battery. Remove SST and TOYOTA hand−held tester. B02509 09268−41046 Reinstall the fuel pressure regulator to the delivery pipe.
  • Page 985 INSTALL THROTTLE BODY (See page MF−30) P24768 REINSTALL HIGH−TENSION CORDS TO SPARK PLUGS INSTALL NO.1 AND NO.2 PCV HOSES INSTALL AIR INTAKE CONNECTOR M/T: CONNECT ACCELERATOR CABLE TO THROTTLE BODY A/T: CONNECT THROTTLE AND ACCELERATOR CABLES TO THROTTLE BODY 1996 TOYOTA T100 (RM449U)

  • Page 986: Table Of Contents

    MF−22 MFI (3RZ−FE) − INJECTOR INSTALL MAF METER, RESONATOR AND AIR CLEANER CAP FILL WITH ENGINE COOLANT RECHECK ENGINE COOLANT LEVEL 1996 TOYOTA T100 (RM449U)
  • Page 987 Apply the proper torque to all parts tightened. 1.5 (15, 13 in.·lbf) 3.9 (40, 35 in.·lbf) 3.5 (35, 31 in.·lbf) 39 (400, 29) No.1 Fuel Tank Band : Specified torque N·m (kgf·cm, ft·lbf) zNon−reusable part P21793 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 988 If a problem is found, repair or replace the part as necessary. (310 kgf·cm, 22 ft·lbf) Fulcrum Length 30 cm (11.81 in.) SST: 09631−22020 Z10162 2 − 5 mm (0.08 − 0.20 in.) Hose Pipe Clip 0 − 3 mm (0 − 0.12 in.) FU0041 1996 TOYOTA T100 (RM449U)

  • Page 989: Throttle Body

    INSPECT THROTTLE OPENER Warm up engine Allow the engine to warm up to normal operating tempera- ture. Connect TOYOTA hand−held tester or OBD II scan tool. Check idle speed Idle speed: 700 rpm Disconnect the vacuum hose from the throttle opener, and plug the hose end.
  • Page 990 Stop the engine. Connect the vacuum hose to the throttle opener. Start the engine, and check that the idle speed returns to the correct speed. Disconnect TOYOTA hand−held tester or OBDII scan tool. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 991 MF−27 MFI (3RZ−FE) − THROTTLE BODY SF0B1−02 COMPONENTS P21635 1996 TOYOTA T100 (RM449U)
  • Page 992 At the time assembly please refer to the following items. Install the throttle body with a new gasket. Disconnect the No.1 and No.2 water bypass hoses from the throttle body, and remove the throttle body. P21654 1996 TOYOTA T100 (RM449U)
  • Page 993 0.50 mm (0.020 in.) IDL − E2 2.3 kΩ or less 0.75 mm (0.030 in.) IDL − E2 Infinity Throttle valve fully open VTA − E2 2.0 − 10.2 kΩ − VC − E2 2.5 − 5.9 kΩ 1996 TOYOTA T100 (RM449U)
  • Page 994 MF−30 MFI (3RZ−FE) − THROTTLE BODY SF0B4−03 INSTALLATION Installation is in the reverse order of removal (See page MF−28). 1996 TOYOTA T100 (RM449U)
  • Page 995 +B and other terminals (RSC, RSO). P15974 Resistance: Cold: 21.5 − 28.5Ω Hot: 17.0 − 24.5Ω If resistance is not as specified, replace the IAC valve. Reconnect the IAC valve connector. 1996 TOYOTA T100 (RM449U) Author : Date :...
  • Page 996 MF−32 MFI (3RZ−FE) − IDLE AIR CONTROL (IAC) VALVE SF0B6−02 COMPONENTS P21639 1996 TOYOTA T100 (RM449U)
  • Page 997 MF−33 MFI (3RZ−FE) − IDLE AIR CONTROL (IAC) VALVE SF0B7−02 REMOVAL REMOVE THROTTLE BODY (See page MF−28) REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. P15135 1996 TOYOTA T100 (RM449U)
  • Page 998 +B and negative (−) lead to terminal RSC, and check that the valve is closed. Closed Battery P15730 Connect the positive (+) lead from the battery to terminal +B and negative (−) lead to terminal RSO, and check that the valve is open. Open Battery P15729 1996 TOYOTA T100 (RM449U)
  • Page 999 − IDLE AIR CONTROL (IAC) VALVE SF0B9−02 INSTALLATION New Gasket INSTALL IAC VALVE Place a new gasket on the throttle body. Install the IAC valve with the 4 screws. INSTALL THROTTLE BODY (See page MF−30) P15136 1996 TOYOTA T100 (RM449U)
  • Page 1000 MF−36 MFI (3RZ−FE) − MASS AIR FLOW (MAF) METER MASS AIR FLOW (MAF) METER SF0AW−03 COMPONENTS 1996 TOYOTA T100 (RM449U) Author : Date :...

Table of Contents