sensor TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P24689
P14628
Z15935
P14635
EM−58
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
22. INSTALL FUEL RETURN PIPE
(a) Install the fuel return pipe with the 2 bolts.
(b) Connect these hoses:
Fuel return hose to fuel pressure regulator
Fuel return hose to fuel return pipe
23. INSTALL INTAKE CHAMBER STAY
Install the intake chamber stay with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
24. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket, EGR valve and vacuum modulator
with the bolt and 2 nuts.
Torque:
Bolt: 8.5 N·m (85 kgf·cm, 74 in.·lbf)
Nut: 19 N·m (195 kgf·cm, 14 ft·lbf)
(b) Connect these hoses:
2 vacuum hoses to EGR VSV (with clamp)
Water bypass hose to water bypass pipe
(c) Install 2 new gaskets and EGR pipe with the bolt and 4
nuts.
Torque:
Bolt: 18 N·m (185 kgf·cm, 14 ft·lbf)
Nut A: 19 N·m (195 kgf·cm, 14 ft·lbf)
Nut B: 20 N·m (200 kgf·cm, 15 ft·lbf)
25. INSTALL CYLINDER HEAD REAR COVER
(a) Install a new gasket and rear cover with the 3 bolts.
Torque: 13.5 N·m (135 kgf·cm, 10 ft·lbf)
(b) Connect the heater water bypass pipe.
26. CONNECT INJECTOR CONNECTORS
27. CONNECT ENGINE WIRE
(a) Connect the engine wire to the intake manifold with the
bolt.
(b) Connect the 2 engine wire clamps.
(c) Connect the DLC1 to the bracket.
(d) Connect these connectors:
Fuel pressure control VSV connector
Knock sensor connector
Crankshaft position sensor connector
(e) Connect the 5 engine wire clamps.
(f) Connect the engine wire to the intake chamber with the
2 bolts.
(g) Connect these connectors:
EGR VSV connector
EGR gas temperature sensor connector

Downloaded from www.Manualslib.com manuals search engine P15813
P15755SST
P14841
Adjusting Bolt
Look Bolt
P24651
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−59
1996 TOYOTA T100 (RM449U)
ECT sensor connector
Oil pressure sensor connector
w/ A/C:
A/C compressor connector
28. INSTALL THROTTLE BODY (See page MF−30)
29. INSTALL WATER OUTLET
(a) Install a new gasket and water outlet with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Connect the ECT sender gauge connector.
(c) Connect the radiator inlet hose.
30. INSTALL IGNITION COIL.
31. INSTALL NO.1 AND NO.2 PCV HOSES
32. INSTALL PS PUMP AND BRACKET
(a) Install the PS pump bracket with the 4 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Connect the PS pump to the bracket with the 2 bolts.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(c) Connect the 2 air hoses to the intake chamber.
(d) Using SST, install the PS pump pulley with the nut.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
33. INSTALL PS PUMP DRIVE BELT AND IDLER
PULLEY
(a) Install the idler pulley with the 3 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Install and adjust drive belt (See page CH−2).
34. INSTALL AIR INTAKE CONNECTOR
(a) Install the air intake connector with the 2 bolts and hose
clamp.
(b) Connect the 2 air hoses.
35. M/T:
CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
36. A/T:
CONNECT THROTTLE AND ACCELERATOR CABLES
TO THROTTLE BODY

Downloaded from www.Manualslib.com manuals search engine P15087
EM−60
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
37. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP
(a) Connect the air cleaner hose clamp.
(b) Install the air cleaner cap, MAF meter and resonator with
the 4 clips.
(c) Connect the MAF meter connector, IAT sensor connector
and wire clamp.
38. FILL WITH ENGINE COOLANT
39. START ENGINE AND CHECK FOR LEAKS
40. CHECK IGNITION TIMING (See page EM−11)
41. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
42. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM07I−03
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−65
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. DRAIN TRANSMISSION OIL
6. REMOVE HOOD
7. REMOVE RADIATOR RESERVOIR TANK
8. REMOVE RADIATOR (See page CO−15)
9. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
(a) Disconnect the MAF meter connector, IAT sensor con-
nector and wire clamp.
(b) Loosen the air cleaner hose clamp.
(c) Loosen the 4 clips, and remove the air cleaner cap, MAF
meter and resonator.
10. REMOVE AIR CLEANER CASE
(a) Remove the air cleaner element.
(b) Remove the 3 bolts and air cleaner case.
11. M/T:
DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
12. A/T:
DISCONNECT ACCELERATOR AND THROTTLE
CABLES FROM THROTTLE BODY
13. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the 2 air hoses and vs hose.
(b) Remove the 2 bolts, hose clamp and intake air connector.

Downloaded from www.Manualslib.com manuals search engine P15073
P15137
P15099
P23949
EM−68
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
25. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the 2 heated oxygen sensor connectors.
(b) Remove the 2 bolts, and retainer holding the front ex-
haust pipe to the TWC.
(c) Loosen the clamp bolt and disconnect the clamp from the
support bracket.
(d) Remove the 2 bolts and support bracket.
(e) Remove the 3 nuts, front exhaust pipe and 3 gaskets.
26. M/T:
REMOVE CLUTCH RELEASE CYLINDER
(a) Remove the 2 bolts, and disconnect clutch release cylin-
der.
(b) Remove the bolt and disconnect the clutch line.
27. A/T:
REMOVE CROSS SHAFT
28. DISCONNECT STARTER WIRE
(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the starter connector.
(c) Remove the bolt and disconnect ground strap.
29. PLACE JACK UNDER TRANSMISSION
30. REMOVE ENGINE REAR MOUNTING BRACKET
M/T:
Remove the 8 bolts holding the mounting bracket to the
mounting insulator and cross member.
A/T:
Remove the 7 bolts holding the mounting bracket to the
mounting insulator and cross member.
31. REMOVE ENGINE WITH TRANSMISSION
(a) Install a rear engine hanger in the correct direction.
Part No:
HANGER, ENGINE, NO.2 12282−75020
BOLT 91512−61020
Torque: 42 N·m (420 kgf·cm,30 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P15073
P15072
R05270
P15078
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−71
1996 TOYOTA T100 (RM449U)
8. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with new 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 2 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect a new gasket and the front exhaust pipe assem-
bly to the TWC with the 2 bolts and retainer.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(e) Connect the 2 heated oxygen sensor connectors.
9. CONNECT SPEEDOMETER CABLE
10. INSTALL PROPELLER SHAFT (See page PR−9)
11. INSTALL STABILIZER BAR
(a) Place the stabilizer bar in position and install both stabiliz-
er bar bushings and brackets to the frame.
(b) Torque the stabilizer bar mounting bolts.
Torque: 30 N·m (306 kgf·cm, 22 ft·lbf)
(c) Connect the stabilizer bar on both sides to the lower arms
with brackets, cushions and new nuts as shown.
(d) Torque the nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
12. M/T:
INSTALL SHIFT LEVER ASSEMBLY
(a) Install baffle and shift lever assembly with the 6 bolts.
(b) Install the shift lever boot with the 4 screws.
(c) Install the shift lever knob.

Downloaded from www.Manualslib.com manuals search engine EM−74
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
23. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with 3 bolts.
(b) Install the air cleaner element.
24. INSTALL MAF METER, RESONATOR AND AIR
CLEANER CAP
(a) Connect the air cleaner hose clamp.
(b) Install the air cleaner cap, MAF meter and resonator with
the 4 clips.
(c) Connect the MAF meter connector, IAT sensor connector
and wire clamp.
25. INSTALL RADIATOR (See page CO−20)
26. INSTALL RADIATOR RESERVOIR TANK
27. FILL WITH ENGINE OIL
28. FILL WITH ENGINE COOLANT
29. FILL TRANSMISSION OIL
30. INSTALL BATTERY
31. START ENGINE AND CHECK FOR LEAKS
32. CHECK IGNITION TIMING (See page EM−11)
33. INSTALL ENGINE UNDER COVER
Install the engine under cover with the 4 bolts.
34. INSTALL HOOD
35. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, and smooth opera-
tion.
36. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS

Downloaded from www.Manualslib.com manuals search engine EM07L−02
P14816
Knock
SensorSST
P15971
SST
Oil Pressure Switch
P14771
EM−76
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. M/T:
REMOVE FLYWHEEL
Remove the 10 bolts and flywheel.
2. A/T:
REMOVE DRIVE PLATE
Remove the 10 bolts, front spacer, drive plate and rear spacer.
3. REMOVE REAR END PLATE
Remove the 3 bolts and rear end plate.
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE CYLINDER HEAD (See page EM−28)
6. REMOVE TIMING CHAINS, GEARS AND SPROCKET
(See page EM−14)
7. REMOVE FUEL FILTER
Remove the 2 bolts and fuel filter.
8. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816−30010
9. REMOVE WATER BYPASS PIPE
Remove the bolt and water bypass pipe.
10. REMOVE OIL FILTER AND BRACKET
(a) Remove the oil filter (See page LU−3).
(b) Remove the 2 bolts, nut, oil filter bracket and O−ring.
11. REMOVE OIL FILTER BRACKET UNION
Using 14 mm hexagon wrench, remove the union and O−ring.
12. REMOVE ENGINE COOLANT DRAIN PLUG
13. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816−30010
14. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 4 bolts and bracket.
15. REMOVE LH ENGINE MOUNTING BRACKET
Remove the 5 bolts and bracket.
16. REMOVE REAR OIL SEAL RETAINER
Remove the 6 bolts and retainer.

Downloaded from www.Manualslib.com manuals search engine P15971
Oil Pressure Switch
SST
P14816
Knock
SensorSST
EM−102
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(b) Using SST, install the oil pressure switch.
SST 09816−30010
21. INSTALL ENGINE COOLANT DRAIN PLUG
(a) Apply adhesive to 2 or 3 threads of the engine coolant
drain plug.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the engine coolant drain plug.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
22. INSTALL OIL FILTER BRACKET UNION
(a) Install a new O−ring.
(b) Using 14 mm hexagon wrench, install the oil filter bracket
union.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
23. INSTALL OIL FILTER AND BRACKET
(a) Install a new O−ring and oil filter bracket with the 2 bolts
and nut.
Torque: 28 N·m (290 kgf·cm, 21 ft·lbf)
(b) Install the oil filter (See page LU−3).
24. INSTALL WATER BYPASS PIPE
Install the bolt and water bypass pipe.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
25. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816−30010
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
26. INSTALL FUEL FILTER
Install the 2 bolts and fuel filter.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
27. INSTALL TIMING CHAINS, GEARS AND SPROCKETS
(See page EM−20)
28. INSTALL CYLINDER HEAD (See page EM−50)
29. REMOVE ENGINE STAND

Downloaded from www.Manualslib.com manuals search engine EM1OO−01
P20830
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−13
1996 TOYOTA T100 (RM449U)
REMOVAL
1. 4WD:
REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT UPPER RADIATOR HOSE
4. REMOVE DRIVE BELT FOR PS PUMP
5. w/ A/C:
REMOVE DRIVE BELT FOR A/C COMPRESSOR
6. REMOVE DRIVE BELT FOR GENERATOR
7. REMOVE NO. 2 FAN SHROUD
8. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
9. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
10. w/ A/C:
DISCONNECT A/C COMPRESSOR FROM ENGINE
HINT:
Put aside the compressor, and suspend it.
11. w/ A/C:
REMOVE A/C COMPRESSOR BRACKET
12. REMOVE NO.2 TIMING BELT COVER
(a) Disconnect the camshaft position sensor connector from
the No.2 timing belt cover.
(b) Disconnect the 3 high−tension cord clamps from the No.2
timing belt cover.
(c) Remove the 6 bolts, and timing belt cover.
13. REMOVE FAN BRACKET
(a) Remove the nut and PS pump adjusting strut.
(b) Remove the bolt, nut, and fan bracket.