TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine CO0373
SST
Punch
Shaft
Guide Block
P14898
8
5324
167
Z04269
PunchTank Plate
Tank
SST
Stopper Guide Book SST
P14858
P14859
CO−18
− COOLING (3RZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)
5. M/T:
STAKE CLAWS OF TANK PLATES
(a) Set the punch of SST to ”LOW”.
SST 09230 − 00010 (09231 − 00010, 09231 − 00020,
09231 − 00030, 09231 − 00040, 09231 − 00050)
(b) Stake the claws of the tank plates with SST in the numeri-
cal order shown in the illustration.
NOTICE:
If the bottom of the core plate is staked with the SST on the
guide block stopper, it may result in water leakage.
HINT:
Stake with just enough pressure to leave a mark on the
claw. The staked plate height (H) should be as follows.
Plate height (H):
9.2 − 9.6 mm (0.362 − 0.378 in.)
Do not stake the are as protruding around the pipes.

Downloaded from www.Manualslib.com manuals search engine P14899
P14860
CO0035
ClearanceTank
Core Plate
Tank Plate
O−Ring
− COOLING (3RZ−FE)RADIATOR
CO−19
1996 TOYOTA T100 (RM449U)
The points shown in the illustration cannot be staked with
the SST. Use pliers and be careful not to damage the core
plates.
6. M/T:
CHECK FOR WATER LEAKS
(a) Tighten the drain plug.
(b) Plug the inlet and outlet pipes of the radiator with SST
SST 09230 − 01010 (09231 − 00060, 09231 − 01010,
09231 − 01020, 09231 − 01030)
(c) Using a radiator cap tester, apply pressure to the radiator.
Test pressure:
147 kPa (1.5 kgf/cm
2, 21 psi)
(d) Check for water leaks.
HINT:
On radiators with resin tanks, these is a clearance between the
core plate and tank plate where a minute amount of air will re-
main, giving the appearance of an air leak when the radiator is
submerged in water. Therefore, before performing the water
leak test, first swirl the water around in the radiator until all air
bubbles disappear.
7. M/T:
PAINT TANK PLATE
HINT:
If the water leak test checks out okay, allow the radiator to dry
completely and then paint the tank plate.

Downloaded from www.Manualslib.com manuals search engine P14853
CO18P−01
P20975
P14852
CO−20
− COOLING (3RZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL SUPPORTS
M/T:
Install the supports with the 4 bolts.
Torque:13 N·m (130 kgf·cm,9 ft·lbf)
A/T:
Install the supports with the 8 bolts.
2. INSTALL RADIATOR
(a) Insert the tabs of the radiator support through the radiator
service holes.
(b) Install the radiator with the 4 bolts.
Torque:31 N·m (310 kgf·cm, 23 ft·lbf)
3. CONNECT RADIATOR OUTLET HOSE
4. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN
WITH FLUID COUPLING AND DRIVE BELT (See page
CO−6)
5. w/ A/C:
INSTALL A/C COMPRESSOR DRIVE BELT
Install and adjust the A/C compressor drive belt (See page
AC−16).
6. INSTALL PS PUMP DRIVE BELT
Install and adjust the PS pump drive belt (See page SR−3).
7. CONNECT RADIATOR RESERVOIR HOSE
8. CONNECT RADIATOR INLET HOSE
9. INSTALL RADIATOR GRILLE
(a) Install the 4 screws, 11 clips and radiator grille.
(b) Install the 4 screws and clearance lights.
10. FILL WITH ENGINE COOLANT
11. START ENGINE AND CHECK FOR LEAKS

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COOLANT CO-1
WATER PUMP CO-3
THERMOSTAT CO-8
RADIATOR CO-12

Downloaded from www.Manualslib.com manuals search engine CO05O−01
− COOLING (5VZ−FE)COOLANT
CO−1
1090 Author: Date:
1996 TOYOTA T100 (RM449U)
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
TANK
The engine coolant level should be between the
”LOW” and ”FULL” lines, when the engine is cold.
If low, check for leaks and add engine coolant up to the ”FULL”
line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap from the water outlet.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or
scale around the radiator cap or radiator filler hole, and
the coolant should be free from oil.
If excessively dirty, clean the coolant passages and replace the
coolant.
(c) Reinstall the radiator cap.

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P20925
Drain Plug CO−2
− COOLING (5VZ−FE)COOLANT
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the drain plugs, and drain the engine coolant.
(c) Close the drain plugs.
2. FILL ENGINE COOLANT
(a) Slowly fill the system with engine coolant.
Use a good brand of ethylene−glycol base engine
coolant and mix it according to the manufacturer’s
directions.
Using engine coolant which includes more than 50
% ethylene−glycol (but not more than 70 %) is rec-
ommended.
NOTICE:
Do not use an alcohol type engine coolant.The engine cool-
ant should be mixed with demineralized water or distilled
water.
Capacity:
2WD
M/T 10.0 liters (10.6 US qts, 8.8 lmp. qts)
A/T 9.9 liters (10.5 US qts, 8.7 lmp. qts)
4WD
M/T 10.0 liters (10.6 US qts, 8.8 lmp. qts)
A/T 10.2 liters (10.8 US qts, 9.0 lmp. qts)
(b) Install the radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) If necessary, refill engine coolant into the reservoir tank
until it is ”FULL” line.
3. CHECK ENGINE COOLANT FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine CO05Q−02
P20840
− COOLING (5VZ−FE)WATER PUMP
CO−3
1092 Author: Date:
1996 TOYOTA T100 (RM449U)
WATER PUMP
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Z15614
CO−4
− COOLING (5VZ−FE)WATER PUMP
1093 Author: Date:
1996 TOYOTA T100 (RM449U)

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− COOLING (5VZ−FE)WATER PUMP
CO−5
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TIMING BELT
(See page EM−13)
2. REMOVE WATER INLET AND THERMOSTAT
3. w/ Oil Cooler:
DISCONNECT NO.2 OIL COOLER HOSE FROM WA-
TER PUMP
4. REMOVE WATER PUMP
Remove the 7 bolts and water pump.

Downloaded from www.Manualslib.com manuals search engine CO05S−01
P20920
P21660
P21515
CO−6
− COOLING (5VZ−FE)WATER PUMP
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT WATER PUMP
(a) Visually check the air hole and water hole for coolant leak-
age.
If leakage is found, replace the water pump.
If engine coolant has leaked onto the timing belt, replace the
timing belt.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.
2. INSPECT FLUID COUPLING
(a) Remove the 4 nuts and fan from the fluid coupling.
(b) Check that the fluid coupling is not damaged and that no
silicon oil leaks.
If necessary, replace the fluid coupling.
3. INSPECT FAN PULLEY BRACKET
(a) Check the turning smoothness of the fan pulley.
If necessary, replace the pulley bracket.
(b) Reinstall the fan to the fluid coupling with the 4 nuts.
Torque:5.4 N·m (75 kgf·cm, 48 in.·lbf)
4. INSPECT TIMING BELT
(See page EM−17)