check engine light TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine S05619
Upper Level
Lower Level
Except Delco Battery
CH02B−03
B01312
B02086
and Delco Battery CH−2
− CHARGING (3RZ−FE)CHARGING SYSTEM
1996 TOYOTA T100 (RM449U)
ON−VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Maintenance−Free Battery:
If under the lower level, replace the battery (or add distilled wa-
ter if possible). Check the charging system.
Except Maintenance−Free Battery:
If under the lower level, add distilled water.
2. Except Maintenance−Free Battery:
CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity:
1.25 − 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.
3. Maintenance−Free Battery:
CHECK BATTERY VOLTAGE
(a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, turn the ignition switch ON and turn on the electrical
system (headlight, blower motor, rear defogger etc.) for
60 seconds to remove the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
tems.
(c) Measure the battery voltage between the negative (−)
and positive (+) terminals of the battery.
Standard voltage:
12.7 − 12.9 V at 20°C (68°F)
HINT:
Before measuring the voltage, turn the ignition switch
OFF and turn off the electrical systems (headlight, blower
motor, rear defogger etc.) for 60 seconds to remove the
surface charge.
If the vehicle has been running, wait 20 minutes or more
after the vehicle stops before measuring the battery volt-
age.
If the voltage is less than specification, charge the battery.
HINT:
Check the indicator as shown in illustration.

Downloaded from www.Manualslib.com manuals search engine P15119
CH0743
Delco Battery
Green Dot Dark Clear
P06717
− CHARGING (3RZ−FE)CHARGING SYSTEM
CH−3
1996 TOYOTA T100 (RM449U)
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
(b) Check the fusible link and fuses for continuity.
5. Delco Battery:
CHECK HYDROMETER
Green Dot visible:
Battery is adequately charged.
Dark (Green Dot not visible):
Battery must be charged.
Clear or Light Yellow:
Replace battery.
HINT:
There is no need to add water during the entire service life of
the battery.
6. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:
Cracks on the ribbed side of the belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be re-
placed.

Downloaded from www.Manualslib.com manuals search engine Z00038
Nippondenso
Borroughs
P06723
CORRECT WRONG
B02087
CH−4
− CHARGING (3RZ−FE)CHARGING SYSTEM
1996 TOYOTA T100 (RM449U)
(b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG 20 (95506−00020) or
Borroughs No. BT−33−73F
Drive belt tension:
New belt
175 ± 5 lbf
Used belt
115 ± 20 lbf
If necessary, adjust the drive belt tension.
HINT:
”New belt” refers to a belt which has been used less than
5 minutes on a running engine.
”Used belt” refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
After installing the drive belt, check that it fits properly in
the ribbed grooves. Check with your hand to confirm that
the belt has not slipped out of the groove on the bottom
of the crank pulley.
After installing a new belt, run the engine for approx. 5
minutes and then recheck the tension.
7. VISUALLY CHECK GENERATOR WIRING AND LIS-
TEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
8. INSPECT DISCHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the discharge
warning light comes on.
(b) Start the engine. Check that the light goes off.
If the light does not operate as specified, troubleshoot the dis-
charge warning light circuit.
9. CHECK CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit according to the manufacturers instruc-
tions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:
Disconnect the wire from terminal B of the generator
and connect the wire to the negative (−) terminal of
the ammeter.

Downloaded from www.Manualslib.com manuals search engine P20582
Terminal F
− CHARGING (3RZ−FE)CHARGING SYSTEM
CH−5
1996 TOYOTA T100 (RM449U)
Connect the test lead from the positive (+) terminal
of the ammeter to terminal B of the generator.
Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
Ground the negative (−) lead of the voltmeter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage:
10 A or less
Standard voltage:
At 25 °C (77°F): 14.0 − 15.0 V
At 115 °C(239 °F): 13.5 − 14.3 V
If the voltage reading is greater than standard voltage, replace
the voltage regulator.
If the voltage reading is less than standard voltage, check the
voltage regulator and generator as follows:
With terminal F grounded, start the engine and
check the voltage reading of terminal B.
If the voltage reading is higher than standard volt-
age, replace the voltage regulator.
If the voltage reading is less than standard voltage,
repair the generator.
10. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater fan control switch
to HI.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
If the ammeter reading is less than standard amperage, repair
the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

Downloaded from www.Manualslib.com manuals search engine CH02P−03
S05376
Except Maintenance−Free Battery
Z18827
Voltmeter Maintenance−Free Battery
− CHARGING (5VZ−FE)CHARGING SYSTEM
CH−1
1220 Author: Date:
1996 TOYOTA T100 (RM449U)
CHARGING SYSTEM
ON−VEHICLE INSPECTION
CAUTION:
Check that the battery cables are connected to the
correct terminals.
Disconnect the battery cables when the battery is giv-
en a quick charge.
Do not perform tests with a high voltage insulation re-
sistance tester.
Never disconnect the battery while the engine is run-
ning.
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Maintenance−Free Battery:
If under the lower level, replace the battery (or add distilled wa-
ter if possible) and check the charging system.
Except Maintenance−Free Battery:
If under the lower level, add distilled water.
2. Except Maintenance−Battery:
CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity: At 20°C (68°F): 1.25 − 1.29
If the specific gravity is less than specification, charge the bat-
tery.
3. Maintenance−Free Battery:
CHECK BATTERY VOLTAGE
Measure the battery voltage between the negative (−) and posi-
tive (+) terminals of the battery.
Standard voltage: At 20°C (68°F): 12.7 − 12.9 V
HINT:
Before measuring the voltage, turn the ignition switch
OFF and turn off the electrical systems (headlight, blower
motor, rear defogger etc.) for 60 seconds to remove the
surface charge.

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Terminal F
CH−4
− CHARGING (5VZ−FE)CHARGING SYSTEM
1223 Author: Date:
1996 TOYOTA T100 (RM449U)
If the voltage reading is less than the standard voltage, check
the voltage regulator and generator as follows:
With terminal F grounded, start the engine and
check the voltage reading of terminal B.
If the voltage reading is higher than the standard
voltage, replace the voltage regulator.
If the voltage reading is less than the standard volt-
age, repair the generator.
9. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater fan control switch
to HI.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than standard amperage, repair
the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

Downloaded from www.Manualslib.com manuals search engine Z17110
No continuity
Z17111
No continuity
Z17112No continuity
CL0363
Continuity
CL0364
No continuity CL−4
− CLUTCHCLUTCH PEDAL
1239 Author: Date:
1996 TOYOTA T100 (RM449U)
8. CHECK CONTINUITY OF CLUTCH START CANCEL
SWITCH
(a) Check that there is no continuity when connecting the
positive (+) lead from the ohmmeter to terminal 2 and the
negative (−) lead to terminal 1.
(b) Check that there is no continuity when connecting the
positive (+) lead from the ohmmeter to terminal 3 and the
negative (−) lead to terminal 1.
(c) Check the there is no continuity between terminals 2 and
3.
If continuity is not as specified, replace the clutch start cancel
switch.
9. CHECK OPERATION OF CLUTCH START CANCEL
SWITCH
(a) Connect positive (+) lead from the battery to terminal 3
and connect negative (−) lead to terminal 1.
(b) Check that there is no continuity when connecting the
positive (+) lead from the ohmmeter to terminal 2 and the
negative (−) lead to terminal 1.
(c) When pushing the switch, check that the indicator light
connect on and there is continuity between terminal 1 and
2.
(d) Check that there is no continuity between terminals 1 and
2 when disconnect the battery lead.
If continuity is not as specified, replace the clutch start cancel
switch.

Downloaded from www.Manualslib.com manuals search engine Q00550
MT04U−01
Z03541
− MANUAL TRANSMISSION (R150, R150F)INPUT SHAFT
MT−23
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.

Downloaded from www.Manualslib.com manuals search engine Z03554
MT04Y−05
Z03555
AB
C
Z03556
WM0064
MT−28
− MANUAL TRANSMISSION (R150, R150F)OUTPUT SHAFT
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT OUTPUT SHAFT
(a) Using a micrometer, measure the output shaft flange
thickness.
Minimum thickness: 4.70 mm (0.1850 in.)
If the thickness is less than the minimum, replace the output
shaft.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal.
Minimum diameter:
A 1st gear: 38.860 mm (1.5299 in.)
B 2nd gear: 46.860 mm (1.8449 in.)
C 3rd gear: 37.860 mm (1.4905 in.)
If the outer diameter is less than the minimum, replace the out-
put shaft.
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)
If the runout exceeds the maximum, replace the output shaft.
2. INSPECT 1ST AND 3RD GEARS SYNCHRONIZER
RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.

Downloaded from www.Manualslib.com manuals search engine D00871
MT03Q−01
D00872
− MANUAL TRANSMISSION (W59)INPUT SHAFT
MT−19
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.5 mm (0.020 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.