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T100 1996
Toyota T100 1996 Manuals
Manuals and User Guides for Toyota T100 1996. We have
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Toyota T100 1996 manual available for free PDF download: Service Manual
Toyota T100 1996 Service Manual (2062 pages)
1996 TOYOTA T100
Brand:
Toyota
| Category:
Automobile
| Size: 41 MB
Table of Contents
Index
2
Table of Contents
3
General Information
4
How to Use this Manual
4
Identification Information
6
Vehicle Identification and Engine Serial Number
6
Reapair Instructions
7
Basic Repair Hint
7
Vehicle Lift and Support Locations
11
For All of Vehicles
12
Precaution
12
For Vehicles Equipped with SRS Airbag
12
For Vehicles Equipped with a Catalytic Converter
16
If Vehicle Is Equipped with Mobile Communication System
17
How to Troubleshoot ECU Controlled Systems
18
How to Proceed with Troubleshooting
19
Customer Problem Analysis
20
Important Points in the Customer Problem Analysis
20
(Sample) Engine Control System Check Sheet
20
Symptom Confirmaation and Diagnostic Trouble Code Check
21
Diagnostic Trouble Code Check Procedure
21
Symptom Simulation
23
Diagnostic Trouble Code Chart
25
DTC Chart (SAE Controlled)
25
Problem Symptoms Table
26
Circuit Inspection
27
Wiring Diagram
27
Inspection Procedure
28
How to Use the Diagnostic Chart and Inspection Procedure
29
Connector Connection and Terminal Inspection
29
Continuity Check (Open Circuit Check)
30
Resistance Check (Short Circuit Check)
30
Visual Check and Contact Pressure Check
30
Connector Handling
31
Check Open Circuit
31
Check Short Circuit
32
Check and Replace ECU
33
Terms
34
Abbreviations Used in this Manual
34
Glossary of SAE and Toyota Terms
36
Maintenance
39
Outside Vehicle
40
General Maintenance
40
Inside Vehicle
41
Under Hood
43
Engine Inspection
44
Brake Inspection
46
Chassis Inspection
47
Preparation
54
Maintenance Equipment
55
Engine Mechanical (3RZ-FE)
56
SST (Special Service Tools)
56
Recommended Tools
59
Equipment
60
SSM (Special Service Materials)
61
Engine Mechanical (5VZ-FE)
62
Recommended Tools
65
Emission Control (3RZ-FE)
68
Emission Control (5VZ-FE)
70
Mfi (3Rz−Fe)
73
Sfi (5Vz−Fe)
76
Cooling (3RZ-FE)
79
Cooling (5VZ-FE)
82
Coolant
85
Lubrication (3RZ-FE)
87
Lubricant
90
Lubrication (5VZ-FE)
92
Ignition (3RZ-FE)
97
Ignition (5VZ-FE)
100
Starting (3RZ-FE)
102
Starting (5VZ-FE)
105
Charging (3RZ-FE)
108
Charging (5VZ-FE)
111
Clutch
114
Manual Transmission (R150, R150F)
117
Manual Transmission (W59)
123
Automatic Transmission
129
Transfer
134
Propeller Shaft
140
Suspension and Axle
142
Brake
152
Steering
157
Supplemental Restraint System
167
Body Electrical
170
Body
173
Air Conditioning
176
Service Specifications
180
Standard Bolt
181
How to Determine Bolt Strength
181
Specified Torque for Standard Bolts
182
Torque Specifications
183
Maintenance
183
Service Data
184
Engine Mechanical (3Rz-Fe
184
Engine Mechanical (5VZ-FE) Service Data
189
Emission Control (3RZ-FE) Service Data
194
Emission Control (5VZ-FE) Torque Specification
196
MFI (3RZ−FE) Service Data
197
SFI (5VZ−FE) Service Data
199
Cooling (3RZ-FE) Service Data
201
Cooling (5VZ-FE) Service Data
203
Lubrication (3RZ-FE) Service Data
205
Lubrication (5VZ-FE) Service Data
207
Ignition (3RZ-FE) Service Data
209
Ignition (5VZ-FE) Service Data
211
Starting (3RZ-FE) Service Data
213
Starting (5VZ-FE) Service Data
215
Charging (3RZ-FE) Service Data
217
Charging (5VZ-FE) Service Data
219
Clutch Service Data
221
Manual Transmission (R150, R150F) Service Data
223
Manual Transmission (W59) Service Data
226
Automatic Transmission Service Data
229
Transfer Service Data
233
Propeller Shaft Service Data
236
Suspension and Axle Service Data
238
Brake Service Data
249
Steering Service Data
251
Supplemental Restraint System Service Data
255
Body Electrical Service Data
257
Body Torque Specification
260
Body
261
Air Conditioning Service Data
262
Diagnostics
264
Engine (3RZ-FE)
265
Customer Problem Analysis Check
266
Pre-Check
267
Diagnosis System
267
Inspect Diagnosis (Normal Mode)
269
Inspect Diagnosis (Check Mode)
270
Fail-Safe Chart
271
Check for Intermittent Problems
271
Basic Inspection
272
SAE Controlled
277
Parts Location
280
Terminals of ECM
281
For M/T
281
For A/T
283
Circuit Description
286
Mass Air Flow Circuit Malfunction
286
Inspection Procedure
287
Mass Air Flow Circuit Range/Performance Problem
290
Intake Air Temp. Circuit Malfunction
291
Engine Coolant Temp. Circuit Malfunction
297
Engine Coolant Temp. Circuit Range/Performance Problem
302
Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction
303
Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem
307
Insufficient Coolant Temp. for Closed Loop Fuel Control
308
Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1)
311
Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1)
314
Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)
315
Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2)
315
Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2)
317
System too Lean (Fuel Trim)
319
System too Rich (Fuel Trim)
319
Random/Multiple Cylinder Misfire Detected
322
Cylinder Misfire Detected
322
Knock Sensor 1 Circuit Malfunction
327
Crankshaft Position Sensor ”A” Circuit Malfunction
330
Crankshaft Position Sensor ”A” Circuit Range/Performance
333
Camshaft Position Sensor Circuit Malfunction
334
Exhaust Gas Recirculation Flow Insufficient Detected
336
System Check Driving Pattern
337
Exhaust Gas Recirculation Flow Excessive Detected
346
OBD II Scan Tool (Excluding TOYOTA Hand−Held Tester)
348
Catalyst System Efficiency below Threshold
350
Confirmation Engine Racing Pattern
350
Evaporative Emission Control System Incorrect Purge Flow
352
TOYOTA Hand−Held Tester
353
Vehicle Speed Sensor Malfunction
356
Idle Control System Malfunction
358
Closed Throttle Position Switch Malfunction
361
Ignition Circuit Malfunction
367
Crankshaft Position Sensor Circuit Malfunction (During Engine Running)
373
Starter Signal Circuit Malfunction
374
ECM BATT Malfunction
376
Park/Neutral Position Switch Malfunction (A/T Only)
378
ECM Power Source Circuit
379
Fuel Pump Control Circuit
382
Engine (5VZ-FE)
391
Park/Neutral Position Switch Malfunction
511
Starter Signal Circuit
512
Vehicle Speed Sensor Malfunction (No.1 Vehicle Speed Sensor)
550
Transmission Fluid Temperature Sensor Malfunction (ATF Temperature Sensor)
551
Shift Solenoid A/B Malfunction (Shift Solenoid Valve No.1/No.2)
553
System Description
553
Shift Solenoid A/B Electrical Malfunction (Shift Solenoid Valve No.1/No.2)
554
Shift Solenoid E Malfunction (Shift Solenoid Valve SL)
558
Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL)
560
Speed Sensor No.2 Circuit Malfunction (No.2 Vehicle Speed Sensor) (3RZ−FE)
564
Speed Sensor No.2 Circuit Malfunction (No.2 Vehicle Speed Sensor) (5VZ−FE)
567
O/D Cancel Signal Circuit (5VZ−FE Only)
573
O/D Main Switch & O/D off Indicator Light Circuit
575
O/D off Indicator Light Remains on
579
Stop Light Switch Circuit
580
Anti-Lock Brake System
583
ABS Check Sheet
584
Terminals of ECU
593
ABS Control (Solenoid) Relay Circuit
596
ABS Control (Motor) Relay Circuit
599
ABS Actuator Solenoid Circuit
602
Speed Sensor Circuit
605
Neither Front Speed Sensor Rotor Missing
609
Tires of Different Size
610
IG Power Source Circuit
611
Malfunction in Deceleration Sensor
614
Deceleration Sensor Circuit
615
ABS Pump Motor Lock
617
ABS Warning Light Circuit
618
Tc Terminal Circuit
622
Ts Terminal Circuit
624
Check for Fluid Leakage
626
Short in Squib Circuit (to Ground)
637
Short in Squib Circuit or Front Airbag Sensor Circuit (to B+)
643
Open in D Squib Circuit
649
Open in Front Airbag Sensor Circuit
654
Center Airbag Sensor Assembly Malfunction
658
Source Voltage Drop
660
SRS Warning Light Circuit Malfunction (Always Lit Up, When Ignition Switch Is in LOCK Position.)
662
SRS Warning Light Circuit Malfunction (Does Not Light Up, When Ignition Switch Is Turned to ACC or ON.)
664
If DTC Is Not Displayed, Do Following Troubleshooting
668
If DTC Is Displayed Without DTC Check Procedure, Perform Following Trouble-Shooting
671
Cruise Control System
672
Actuator Motor Circuit
684
Actuator Magnetic Clutch Circuit
686
Actuator Position Sensor Circuit
689
Vehicle Speed Sensor Circuit
692
Control Switch Circuit
695
Idle Switch Circuit
701
Electronically Controlled Transmission Communication Circuit
704
Park/Neutral Position Switch Circuit
707
Clutch Switch Circuit
710
ECU Power Source Circuit
713
Back−Up Power Source Circuit
716
Main Switch Circuit
718
Tc Circuit
720
Actuator Control Cable Inspection
722
Engine Mechanical (3RZ-FE)
723
CO/HC Inspection
724
Troubleshooting
725
Compression Inspection
726
Valve Clearance Inspection
728
Adjusting Shim Selection Chart (Intake)
731
Adjusting Shim Selection Chart (Exhaust)
732
Ignition Timing Inspection
734
Idle Speed Inspection
735
Timing Chain Components
736
Cylinder Head Components
749
Removal
751
Diasassembly
760
Inspection
761
Reassembly
771
Installation
773
Engine Unit Components
784
Engine Unit Removal
788
Engine Unit Installation
793
Cylinder Block Components
798
Cylinder Block Disassembly
799
Cylinder Head Inspection
807
Cylinder Head Replacement
816
Cylinder Head Reassembly
818
Exhaust System Components
827
Engine Mechanical (5VZ-FE)
828
Timing Belt
839
Engine Unit (4WD) Components
901
Engine Unit (4WD) Removal
904
Engine Unit (4WD) Installation
907
Cylinder Block Inspection
920
Cylinder Block Replacement
928
Cylinder Block Installation
929
Emission Control (3RZ-FE)
938
Emission Control System Purpose
939
Parts Layout and Schematic Drawing
940
Location
940
Drawing
941
Positive Crankcase Ventilation (PCV) System Inspection
942
Evaporative Emission (EVAP) Control System Inspection
943
Exhaust Gas Recirculation (EGR) System Inspection
945
Three-Way Catalytic Converter (TWC) System Inspection
948
Three-Way Catalytic Converter (TWC) System Replacement
949
Emission Control (5VZ-FE)
950
MFI System (3RZ-FE)
964
MFI System Precaution
965
Fuel Pump On-Vehicle Inspection
969
Fuel Pressure Regulator Components
977
Injector On-Vehicle Inspection
980
Components
981
Fuel Tank and Line Components
987
Fuel Tank and Line Inspection
988
Throttle Body On-Vehicle Inspection
989
Idle Air Control (IAC) Valve On-Vehicle Inspection
995
Mass Air Flow (MAF) Meter Components
1000
EFI Main Relay Inspection
1004
Circuit Opening Relay Components
1005
Circuit Opening Relay Inspection
1006
VSV for Evaporative Emission (EVAP) Inspection
1007
VSV for Exhaust Gas Recirculation (EGR) Inspection
1008
Engine Coolant Temperature (ECT) Sensor Inspection
1009
Intake Air Temperature (IAT) Sensor Inspection
1010
Knock Sensor Inspection
1011
Exhaust Gas Recirculation (EGR) Gas Temperature Sensor Inspection
1012
Heated Oxygen Sensor Inspection
1013
Engine Control Module (ECM) Components
1014
Engine Control Module (ECM) Removal
1015
Fuel Cut RPM Inspection
1018
SFI System (5VZ-FE)
1019
SFI System Precaution
1020
Fuel Pump Components
1027
Fuel Pump Removal
1028
Fuel Pump Disassembly
1029
Fuel Pump Inspection
1030
Fuel Tank and Line Precaution
1044
VSV for Fuel Pressure Control Inspection
1066
VSV for Exhaust Gas Control Valve Inspection
1068
Engine Coolant Temperature (ECT) Sensor Components
1070
Knock Sensor Components
1073
Water Pump
1086
On-Vehicle Inspection
1095
Thermostat Components
1112
Thermostat Removal
1113
Lubrication (3RZ-FE)
1124
Oil and Filter Inspection
1125
Oil Pump Components
1129
Lubrication (5VZ-FE)
1137
Oil Cooler Components
1154
Oil Cooler Removal
1155
Oil Cooler Inspection
1156
Oil Cooler Installation
1157
Ignition (3RZ-FE)
1158
Ignition System On-Vehicle Inspection
1159
Distributor Components
1164
Distributor Removal
1165
Distributor Disassembly
1166
Crankshaft Position Sensor Removal
1171
Crankshaft Position Sensor Inspection
1172
Ignition (5VZ-FE)
1174
Ignition Coil
1180
Camshaft Position Sensor Components
1183
Camshaft Position Sensor Removal
1184
Starting (3RZ-FE)
1189
Starter Components
1190
Starter Relay Inspection
1206
Starting (5VZ-FE)
1207
Test
1221
Starter Relay
1223
Charging System
1225
Generator Components
1230
Generator Removal
1231
Generator Disassembly
1232
Generator Inspection
1234
Generator Reassembly
1238
Charging System On-Vehicle Inspection
1243
Clutch
1259
Troubleshooting
1260
Clutch Pedal Inspection
1261
Clutch Master Cylinder Components
1264
Clutch Master Cylinder Removal
1265
Clutch Master Cylinder Disassembly
1266
Clutch Master Cylinder Reassembly
1267
Clutch Release Cylinder Components
1269
Clutch Release Cylinder Removal
1270
Clutch Release Cylinder Disassembly
1271
Clutch Release Cylinder Reassembly
1272
Clutch Unit Components
1274
Clutch Unit Removal
1275
Clutch Unit Inspection
1276
Clutch Unit Installation
1278
Manual Transmission (R150, R150F)
1280
Manual Transmission System Precaution
1281
Manual Transmission Unit (2WD) Components
1283
Manual Transmission Unit (2WD) Removal
1284
Manual Transmission Unit (4WD) Components
1286
Manual Transmission Unit (4WD) Removal
1287
Manual Transmission Assembly Components
1291
Input Shaft Components
1302
Input Shaft Inspection
1303
Input Shaft Replacement
1304
Output Shaft Components
1305
Output Shaft Disassembly
1306
Counter Gear and Reverse Idler Gear Components
1314
Counter Gear and Reverse Idler Gear Disassembly
1315
Counter Gear and Reverse Idler Gear Inspection
1316
Front Bearing Retainer Oil Seal Components
1320
Front Bearing Retainer Oil Seal Replacement
1321
Extension Housing and Transfer Adaptor Components
1322
Extension Housing and Transfer Adaptor Replacement
1323
Manual Transmission (W59)
1325
Manual Transmission Unit Components
1328
Manual Transmission Unit Removal
1329
Automatic Transmission;
1368
Operation
1370
Extension Housing Oil Seal (A340E) On-Vehicle Repair
1371
Sensor Rotor (A340E) On-Vehicle Repair
1372
Speedometer Driven Gear On-Vehicle Repair
1376
Vehicle Speed Sensor On-Vehicle Repair
1378
Park/Neutral Position (PNP) Switch On-Vehicle Repair
1379
Valve Body Assembly On-Vehicle Repair
1380
Parking Lock Pawl On-Vehicle Repair
1385
Throttle Cable On-Vehicle Repair
1386
Shift Lock System On-Vehicle Inspection
1387
Shift Lock System Components
1388
Automatic Transmission Unit (A340E) Components
1394
5Vz−Fe (A340E)
1395
Automatic Transmission Unit (A340F) Components
1401
Automatic Transmission Unit (A340F) Removal
1402
Torque Converter Clutch and Drive Plate Inspection
1406
Transfer
1408
Transfer System
1409
Transfer Unit
1411
Transfer Assembly
1413
Oil Pump Body
1425
Driven Sprocket
1429
Rear Output Shaft
1431
Input Shaft
1438
Planetary Gear
1441
Oil Seal
1444
Propeller Shaft
1447
Propeller Shaft Assembly (2WD)
1449
Propeller Shaft Assembly (4WD)
1457
Spider Bearing
1465
Suspension and Axle
1469
Tire and Wheel (2WD)
1473
Tire and Wheel (4WD)
1475
Front Wheel Alignment (2WD)
1477
Front Wheel Alignment (4WD)
1480
Front Axle Hub (2WD)
1485
Front Axle Hub (4WD)
1492
Front Wheel Hub Bolt (2WD)
1497
Steering Knuckle (4WD)
1498
Front Drive Shaft (4WD)
1506
Front Differential Rear Oil Seal (4WD)
1512
A.D.D. Control System
1539
Front Shock Absorber (2WD)
1542
Front Shock Absorber (4WD)
1547
Front Torsion Bar Spring (2WD)
1552
Front Torsion Bar Spring (4WD)
1555
Front Strut Bar (2WD)
1558
Front Upper Suspension Arm (2WD)
1561
Front Upper Suspension Arm (4WD)
1565
Front Lower Suspension Arm (2WD)
1569
Front Lower Suspension Arm (4WD)
1573
Front Upper Ball Joint (2WD)
1577
Front Upper Ball Joint (4WD)
1581
Front Lower Ball Joint (2WD)
1585
Front Lower Ball Joint (4WD)
1589
Front Stabilizer Bar (2WD)
1593
Front Stabilizer Bar (4WD)
1596
Rear Axle Shaft
1599
Rear Wheel Hub Bolt
1606
Rear Differential Carrier
1607
Rear Shock Absorber
1625
Rear Leaf Spring
1630
Brake
1637
Brake System
1638
General Description
1638
Brake Fluid
1641
Brake Pedal
1643
Parking Brake Lever
1645
Brake Master Cylinder
1646
Brake Booster Assembly
1654
Front Brake Pad (2WD)
1658
Front Brake Pad (4WD)
1661
Front Brake Caliper (2WD)
1663
Front Brake Caliper (4WD)
1670
Rear Drum Brake (2WD)
1676
Rear Drum Brake (4WD)
1681
Load Sensing Proportioning and By-Pass Valve (LSP & BV)
1687
Front Speed Sensor
1701
Rear Speed Sensor
1704
Steering
1707
Steering System
1708
Drive Belt
1710
Power Steering Fluid Bleeding
1711
Steering Wheel
1716
Non-Tilt Steering Column
1717
Tilt Steering Column
1730
Power Steering Vane Pump (3RZ-FE)
1741
Power Steering Vane Pump (5VZ-FE)
1751
Power Steering Gear (2WD)
1761
Power Steering Gear (4WD)
1779
Steering Linkage
1791
Idler Arm
1796
Supplemental Restraint System
1801
SRS Airbag
1802
Steering Wheel Pad and Spiral Cable
1808
Airbag Sensor Assembly
1822
Front Airbag Sensor
1827
Wire Harness and Connector
1832
Body Electrical
1835
Body Electrical System
1836
Interior Light System
1840
Stop Light System
1840
Combination Meter
1841
Meter, Gauge and Illumination
1841
Power Source
1845
Ignition Switch and Key Unlock Warning Switch
1846
Headlight and Taillight System
1849
Adjustment
1856
Turn Signal and Hazard Warning System
1857
Interior Light System
1859
Back-Up Light System
1861
RZN Series
1862
Stop Light System
1864
Wiper and Washer System
1866
Circuit
1871
Power Window Control System
1881
Power Door Lock Control System
1885
Switch Operation
1888
Power Mirror Control System
1891
Audio System
1894
No Power Coming in
1899
Power Coming In, but Radio Not Operating
1900
Any Speaker Does Not Work
1901
Either am or FM Does Not Work, Reception Poor (Volume Faint), few Preset Tuning Bands
1902
Sound Quality Poor
1903
Cannot Set Station Select Button, Preset Memory Disappears
1904
Cassette Tape Cannot be Inserted
1905
Cassette Tape Inserts, but no Power
1906
Power Coming In, but Tape Player Not Operation
1907
Sound Quality Poor (Volume Faint)
1909
Tape Jammed, Malfunction with Tape Speed or Auto-Reverse
1910
Cassette Tape will Not Eject
1911
Antenna Does Not Fully Extend or Fully Retract
1912
Antenna-Related
1913
Noise Produced by Vibration or Shock While Driving
1913
Noise Produced When Engine Starts
1914
Body
1920
Clip
1921
Front Bumper
1924
Hood
1925
Front Door
1926
Front Wiper and Washer
1931
Wheel Arch Moulding
1936
Windshield
1939
Quarter Window Glass
1945
Back Window Glass
1949
Instrument Panel
1954
Tail Gate
1961
Front Seat (Bench Type)
1964
Front Seat (Split Bench Type)
1965
Rear Seat
1966
Seat Belt
1967
Air Conditioning
1971
Air Conditioning System
1972
Charging
1981
Manifold Gauge Set
1987
Refrigerant Line
1989
Cooling Unit
1992
Heater Unit
1997
Blower Unit
2003
Compressor and Magnetic Clutch
2008
Receiver
2016
Condenser
2019
Evaporator
2023
Heater Radiator
2026
Expansion Valve
2029
Water Valve
2032
Blower Motor
2035
Blower Resistor
2038
Thermistor
2041
Pressure Switch
2045
Heater Main Relay
2048
Air Conditioning Amplifier
2049
Air Conditioning Switch
2052
Heater Control Assembly
2055
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