TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine LU03B−04
P20937
Seal Width
A
B2 − 3 mm
A
B
P20930
New O−Ring
P20971
Mark
Key
LU−14
− LUBRICATION (5VZ−FE)OIL PUMP
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pump
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pump, as shown in the il-
lustration.
Seal packing:
Part No. 08826−00080 or equivalent
Install nozzle that has been cut out to a 2 − 3 mm
(0.08 − 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Place a new O−ring into the groove of the cylinder block.
(d) Install the oil pump to the crankshaft with the spline teeth
of the drive rotor engaged with the large teeth of the
crankshaft.

Downloaded from www.Manualslib.com manuals search engine Z14383B A
B
BB
B
B
LU0609
Seal Packing
− LUBRICATION (5VZ−FE)OIL PUMP
LU−15
1996 TOYOTA T100 (RM449U)
(e) Install the oil pump with the 8 bolts, and ground strap.
Torque:
Bolt A: 20 N·m (200 kgf·cm, 15 ft·lbf)
Bolt B: 42 N·m (420 kgf·cm, 31 ft·lbf)
2. INSTALL CRANK SHAFT POSITION SENSOR
3. INSTALL OIL PAN BAFFLE PLATE
4. INSTALL OIL STRAINER
Place a new gasket and install the oil strainer.
Torque:7.5 N·m (76 kgf·cm, 66 in.·lbf)
5. CLEAN OIL PAN
Remove any old packing (FIPG) material and be careful not to
drop any oil on the contacting surfaces of the, oil pan, cylinder
block and sealing grooves.
Using a razor blade and gasket scraper, remove all
the remaining seal packing (FIPG) material from the
gasket surfaces.
Thoroughly clean all components to remove all the
loose material.
Clean both sealing surfaces with a non−residue sol-
vent.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
6. INSTALL OIL PAN
(a) Apply seal packing to the oil pan, as shown in the illustra-
tion.
Seal packing:
Part No. 08826−00080 or equivalent
Install a nozzle that has been cut to a 3 − 4 mm (0.12
− 0.16 in.) opening.
HINT:
Avoid applying an excess amount to the surface.
If parts are not assembled within 5 minutes of apply-
ing the seal packing, the effectiveness of the seal
packing is lost and the seal packing must be re-
moved and reapplied.
Immediately remove the nozzle from the tube and
reinstall the cap after using the seal packing.
(b) Install the oil pan with the 4 nuts and 15 bolts.
Torque:7.6 N·m (78 kgf·cm, 67 in.·lbf)
7. INSTALL FLYWHEEL HOUSING UNDER AND COVER
DUST
8. INSTALL STIFFENER PLATE
9. CONNECT STARTER WIRE CLAMP
10. A/T:
INSTALL OIL COOLER TUBE AND CLAMP
11. INSTALL CRANKSHAFT TIMING PULLEY
(See page EM−19)

Downloaded from www.Manualslib.com manuals search engine LU−16
− LUBRICATION (5VZ−FE)OIL PUMP
1996 TOYOTA T100 (RM449U)
12. 4WD:
INSTALL FRONT DIFFERENTIAL
(See page SA−68)
13. FILL WITH ENGINE OIL
14. START ENGINE AND CHECK FOR LEAKS
15. INSTALL ENGINE UNDER COVER
16. RECHECK ENGINE OIL LEVEL

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− LUBRICATION (5VZ−FE)OIL COOLER
LU−17
1137 Author: Date:
1996 TOYOTA T100 (RM449U)
OIL COOLER
COMPONENTS

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LU03D−03
LU−18
− LUBRICATION (5VZ−FE)OIL COOLER
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DISCONNECT OIL COOLER HOSES
Disconnect the No.1 and No.2 oil cooler hoses.
3. REMOVE OIL COOLER
Remove the bolt, relief valve, gaskets and oil cooler.
Torque:59 N·m (600 kgf·cm, 43 ft·lbf)
HINT:
Replace the O−ring with a new part.
Use a new gasket to the relief valve.

Downloaded from www.Manualslib.com manuals search engine LU03E−03
− LUBRICATION (5VZ−FE)OIL COOLER
LU−19
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT OIL COOLER
Check the oil cooler for damage or clogging.
If necessary, replace the oil cooler.

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LU−20
− LUBRICATION (5VZ−FE)OIL COOLER
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page LU−18).

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IGNITION SYSTEM IG-1
DISTRIBUTOR IG-6
CRANKSHAFT POSITION SENSOR IG-13

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CHECK CONNECTION OF IGNITION COIL ANDIGNITER AND DISTRIBUTOR CONNECTOR
SPARK TEST
CHECK RESISTANCE OF HIGH−TENSION
TRY ANOTHER IGNITER Maximum resistance; 25 kΩ per cord CORD (See step 2.)
CHECK POWER SUPPLY TO IGNITION COIL
AND IGNITER
1. Turn ignition switch to ON.
2. Check that there is battery voltage at
ignition coil positive (+) terminal.
Check wiring between ECM, distributor
CHECK RESISTANCE OF IGNITION COIL(See step 4)
Resistance:Cold
SecondaryHot
9.0 − 15.4 kΩ11.4 − 18.1 kΩ
GENERATOR (PICKUP COIL)
(See step 5)
Resistance: Cold
G and GHot
185 − 275 Ω240 − 325 Ω CHECK RESISTANCE OF SIGNAL
POSITION SENSOR
(See page IG−14)
Resistance: Cold
NE and NEHot
1,630 − 2,740 Ω2,065 − 3,225 Ω CHECK RESISTANCE OF CRANKSHAFT
CHECK IGT SIGNAL FROM ECM
(See page DI−103)
OK NO
BAD
OK
OK
OK
OK
OK
Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
Replace the ignition coil.
Replace the distributor housing as-
sembly.
Replace the crankshaft position sensor.
and igniter, and then try another ECM.
BAD
BAD
BAD
BAD
BAD
BAD Primary0.36 − 0.55 Ω0.45 − 0.65 Ω
Replace the distributor housing assembly.
CHECK AIR GAP OF DISTRIBUTOR (See page DI−103)
BAD Air gap: 0.2 − 0.4 mm (0.008 − 0.016 in.)
OK
− IGNITION (3RZ−FE)IGNITION SYSTEM
IG−1
1141 Author: Date:
1996 TOYOTA T100 (RM449U)
IGNITION SYSTEM
ON−VEHICLE INSPECTION
NOTICE:
”Cold” and ”Hot” in the following sentences express the temperature of the coils themselves. ”Cold” is from
−10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F).
1. INSPECT IGNITOR AND SPARK TEST
Check that the spark occurs.
(1) Disconnect the high−tension cords from the spark plugs.
(2) Remove the spark plugs.
(3) Install the spark plugs to each high−tension cord.
(4) Ground the spark plug.
(5) Check if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1
− 2 seconds at a time.
If the spark does not occur, perform the test as follows:

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CORRECT
WRONG
IG−2
− IGNITION (3RZ−FE)IGNITION SYSTEM
1142 Author: Date:
1996 TOYOTA T100 (RM449U)
2. INSPECT HIGH−TENSION CORDS
(a) Disconnect the MAF meter connector and IAT sensor
connector.
(b) Loosen the hose clamp, disconnect the air cleaner hose
from the intake air connector.
(c) Remove the air cleaner cap and MAF meter assembly.
(d) Disconnect the air hose (for IAC) from the air connector.
(e) Remove the 2 bolts.
(f) Loosen the hose clamp, disconnect the intake air connec-
tor from the throttle body.
(g) Disconnect the high−tension cords from the spark plugs.
NOTICE:
Pulling on or bending the cords may damage the conductor in-
side.
(h) Disconnect the high−tension cords from the ignition coils.
(1) Using a screwdriver, lift up the lock claw and discon-
nect the holder from the distributor cap.
(2) Disconnect the high−tension cord at the grommet.
NOTICE:
Pulling on or bending the cords may damage the conduc-
tor inside.
Do not wipe any of the oil from the grommet after the high−
tension cord is disconnected.