Toyota T100 1996 Bedienungsanleitung

1996 TOYOTA T100

Factory Service Manual

INDEX

IN Introduction

MA Maintenance

PP Preparation

SS Service Specifications

DI Diagnostics

EM Engine Mechanical (3RZ-FE)

Engine Mechanical (5VZ-FE)

EC Emissions Control (3RZ-FE)

Emissions Control (5VZ-FE)

MF MFI System (3RZ-FE)

SF SFI System (5VZ-FE)

CO Cooling (3RZ-FE)

Cooling (5VZ-FE)

LU Lubrication (3RZ-FE)

Lubrication (5VZ-FE)

IG Ignition (3RZ-FE)

Ignition (5VZ-FE)

ST Starting (3RZ-FE)

Starting (5VZ-FE)

CH Charging (3RZ-FE)

Charging (5VZ-FE)

CL Clutch

MT Manual Transmission (R150, R150F)

Manual Transmission (W59)

AT Automatic Transmission

TR Transfer

PR Propeller Shaft

SA Suspension and Axle

BR Brake

SR Steering

RS Supplemental Restraint System

BE Body Electrical

BO Body

AC Air Conditioning

IN – INTRODUCTION

HOW TO USE THIS MANUAL IN-1

IDENTIFICATION INFORMATION IN-3

REPAIR INSTRUCTIONS IN-4

FOR ALL OF VEHICLES IN-9

HOW TO TROUBLESHOOT ECU

CONTROLLED SYSTEMS IN-15

TERMS IN-31

IN02D−02

N17080

Filler Cap

Float

Reservoir Tank

zGrommet

Clip

Slotted Spring Pin

N·m (kgf·cm, ft·lbf) : Specified torque

zNon−reusable part

Cylinder

Piston

Push Rod

Washer

Snap Ring

Boot

zGasket

Lock Nut

Clevis Pin

Clevis

12 ( 120, 9)

15 ( 155, 11)

−INTRODUCTION HOW TO USE THIS MANUAL

IN−1

1Author: Date:

1996 TOYOTA T100 (RM449U)

HOW TO USE THIS MANUAL

GENERAL INFORMATION

1. INDEX

An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you

in finding your way through the manual, the Section Title and major heading are given at the top of every

page.

2. PRECAUTION

At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained

in that section.

Read these precautions before starting any repair task.

3. TROUBLESHOOTING

TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the

cause. The fundamentals of how to proceed with troubleshooting are described on page IN−16.

Be sure to read this before performing troubleshooting.

4. PREPARATION

Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-

cial Service Materials) which should be prepared before beginning the operation and explains the purpose

of each one.

5. REPAIR PROCEDURES

Most repair operations begin with an overview illustration. It identifies the components and shows how the

parts fit together.

Example:

Illustration:

what to do and where

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a) Place SST and a dial indicator onto the overdrive brake

piston as shown in the illustration.

Task heading : what to do

SST 09350−30020 (09350−06120)

Set part No. Component part No.

Detailed text : how to do task

(b) Measure the stroke applying and releasing the compressed

Piston stroke: 1.40 1.70 mm (0.0551  0.0669 in.)

Specification

air (392 −785 kPa, 4 −8 kgf.cm2or 57 −114 psi) as

shown in the illustration.

IN−2

−INTRODUCTION HOW TO USE THIS MANUAL

2Author: Date:

1996 TOYOTA T100 (RM449U)

The procedures are presented in a step−by−step format:

SThe illustration shows what to do and where to do it.

SThe task heading tells what to do.

SThe detailed text tells how to perform the task and gives other information such as specifications

and warnings.

Example:

This format provides the experienced technician with a FAST TRACK to the information needed. The upper

case task heading can be read at a glance when necessary, and the text below it provides detailed informa-

tion. Important specifications and warnings always stand out in bold type.

6. REFERENCES

References have been kept to a minimum. However, when they are required you are given the page to refer

to.

7. SPECIFICATIONS

Specifications are presented in bold type throughout the text where needed. You never have to leave the

procedure to look up your specifications. They are also found in Service Specifications section for quick ref-

erence.

8. CAUTIONS, NOTICES, HINTS:

SCAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other

people.

SNOTICES are also presented in bold type, and indicate the possibility of damage to the components

being repaired.

SHINTS are separated from the text but do not appear in bold. They provide additional information to

help you perform the repair efficiently.

9. SI UNIT

The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of

Unit), and alternately expressed in the metric system and in the English System.

Example:

Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

IN02E−02

B13830

−INTRODUCTION IDENTIFICATION INFORMATION

IN−3

3Author: Date:

1996 TOYOTA T100 (RM449U)

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION AND

ENGINE SERIAL NUMBER

1. VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is stamped on the vehicle

identification number plate and certification label, as shown in

the illustration.

A: Vehicle Identification Number Plate

B: Certification Label

2. ENGINE SERIAL NUMBER

The engine serial number is stamped on the engine block as

shown, in the illustration.

FI1066

IN0IL−01

Z11554

Seal Lock Adhesive

IN−4

−INTRODUCTION REPAIR INSTRUCTIONS

4Author: Date:

1996 TOYOTA T100 (RM449U)

REPAIR INSTRUCTIONS

GENERAL INFORMATION

BASIC REPAIR HINT

(a) Use fender, seat and floor covers to keep the vehicle

clean and prevent damage.

(b) During disassembly, keep parts in the appropriate order

to facilitate reassembly.

(1) Before performing electrical work, disconnect the

negative (−) terminal cable from the battery.

(2) If it is necessary to disconnect the battery for in-

spection or repair, always disconnect the negative

(−) terminal cable which is grounded to the vehicle

body.

(3) To prevent damage to the battery terminal, loosen

the cable nut and raise the cable straight up without

twisting or prying it.

(4) Clean the battery terminals and cable ends with a

clean shop rag. Do not scrape them with a file or oth-

er abrasive objects.

(5) Install the cable ends to the battery terminals with

the nut loose, and tighten the nut after installation.

Do not use a hammer to tap the cable ends onto the

terminals.

(6) Be sure the cover for the positive (+) terminal is

properly in place.

(d) Check hose and wiring connectors to make sure that they

are secure and correct.

(e) Non−reusable parts

(1) Always replace cotter pins, gaskets, O−rings and oil

seals etc. with new ones.

(2) Non−reusable parts are indicated in the component

illustrations by the ”z” symbol.

(f) Precoated parts

Precoated parts are bolts and nuts, etc. that are coated

with a seal lock adhesive at the factory.

(1) If a precoated part is retightened, loosened or

caused to move in any way, it must be recoated with

the specified adhesive.

(2) When reusing precoated parts, clean off the old

adhesive and dry with compressed air. Then apply

the specified seal lock adhesive to the bolt, nut or

threads.

BE1367

Medium Current Fuse and High Current Fuse

Equal Amperage Rating

V00076

AbbreviationPart NameSymbolIllustration

FUSE

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

FUSIBLE LINK

CIRCUIT BREAKER

FUSE

M−FUSE

H−FUSE

−INTRODUCTION REPAIR INSTRUCTIONS

IN−5

5Author: Date:

1996 TOYOTA T100 (RM449U)

(3) Precoated parts are indicated in the component il-

lustrations by the ”L” symbol.

(g) When necessary, use a sealer on gaskets to prevent

leaks.

(h) Carefully observe all specifications for bolt tightening

torques. Always use a torque wrench.

(i) Use of special service tools (SST) and special service ma-

terials (SSM) may be required, depending on the nature

of the repair. Be sure to use SST and SSM where speci-

fied and follow the proper work procedure. A list of SST

and SSM can be found in the preparation part at the front

of each section in this manual.

(j) When replacing fuses, be sure the new fuse has the cor-

rect amperage rating. DO NOT exceed the rating or use

one with a lower rating.

IN0253

WRONG CORRECT

IN0252

WRONG CORRECT

IN0002

Example

IN−6

−INTRODUCTION REPAIR INSTRUCTIONS

6Author: Date:

1996 TOYOTA T100 (RM449U)

(k) Care must be taken when jacking up and supporting the

vehicle. Be sure to lift and support the vehicle at the prop-

er locations (See page IN−8).

(1) If the vehicle is to be jacked up only at the front or

rear end, be sure to block the wheels at the opposite

end in order to ensure safety.

(2) After the vehicle is jacked up, be sure to support it

on stands. It is extremely dangerous to do any work

on a vehicle raised on a jack alone, even for a small

job that can be finished quickly.

(l) Observe the following precautions to avoid damage to the

following parts:

(1) Do not open the cover or case of the ECU, ECM,

PCM or TCM unless absolutely necessary. (If the IC

terminals are touched, the IC may be destroyed by

static electricity.)

(2) To disconnect vacuum hoses, pull off the end, not

the middle of the hose.

(3) To pull apart electrical connectors, pull on the con-

nector itself, not the wires.

(4) Be careful not to drop electrical components, such

as sensors or relays. If they are dropped on a hard

floor, they should be replaced and not reused.

(5) When steam cleaning an engine, protect the elec-

tronic components, air filter and emission−related

components from water.

(6) Never use an impact wrench to remove or install

temperature switches or temperature sensors.

(7) When checking continuity at the wire connector, in-

sert the tester probe carefully to prevent terminals

from bending.

(8) When using a vacuum gauge, never force the hose

onto a connector that is too large. Use a step−down

adapter for adjustment. Once the hose has been

stretched, it may leak.

(m) Tag hoses before disconnecting them:

(1) When disconnecting vacuum hoses, use tags to

identify how they should be reconnected to.

(2) After completing a job, double check that the vacu-

um hoses are properly connected. A label under the

hood shows the proper layout.

−INTRODUCTION REPAIR INSTRUCTIONS

IN−7

7Author: Date:

1996 TOYOTA T100 (RM449U)

(n) Unless otherwise stated, all resistance is measured at an

ambient temperature of 20°C (68°F). Because the resis-

tance may be outside specifications if measured at high

temperatures immediately after the vehicle has been run-

ning, measurement should be made when the engine has

cooled down.

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