sensor TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P00496
Adhesive
P10226
Seal Width
2 − 3 mm EM−106
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
22. INSTALL OIL FILTER (See page LU−3 )
23. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833 − 00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, install the oil pressure switch.
SST 09816−30010
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
24. INSTALL GENERATOR ADJUSTING BAR
Torque: 42 N·m (420 kgf·cm, 31 ft·lbf)
25. INSTALL WATER PUMP (See page CO−7)
26. INSTALL KNOCK SENSORS
Using SST, install the 2 knock sensors.
SST 09816−30010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
27. INSTALL NO.2 IDLER PULLEY BRACKET
Torque: 38 N·m (380 kgf·cm, 28 ft·lbf)
28. INSTALL WATER BYPASS PIPE WITH KNOCK SEN-
SOR WIRE
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the bypass
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
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 groove of the bypass pipe.
Seal packing:
Part No. 08826 − 00100 or equivalent
Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Downloaded from www.Manualslib.com manuals search engine P00601
Adhesive
P21461
1
5
3
7
2 68
4
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−107
1996 TOYOTA T100 (RM449U)
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) Install the bypass pipe with the 2 bolts and nut.
Torque: 8.5 N·m (85 kgf·cm, 75 in.·lbf)
(d) Connect the 2 knock sensor connectors.
29. INSTALL CYLINDER HEADS
30. INSTALL PULLEYS AND TIMING BELT
(See page EM−19)
31. REMOVE ENGINE STAND
32. INSTALL REAR END PLATE
Torque: 7.5 N·m (75 kgf·cm, 66 in.·lbf)
33. A/T:
INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)
34. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine EC02U−03
P21187
P21181
− EMISSION CONTROL (3RZ−FE)THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEMEC−11
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE CENTER EXHAUST PIPE
(a) Disconnect the 2 rings from the support bracket.
(b) Remove the 2 nuts and gasket, and disconnect the
heated oxygen sensor (bank 1 sensor 2).
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
HINT:
At the time of assembly please refer to the following item.
Install the heated oxygen sensor with a new gasket.
(c) Remove the 4 bolts, TWC joint retainer, center exhaust
pipe and 2 gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
HINT:
At the time of assembly please refer to the following item.
Place 2 new gaskets on the front exhaust and tail pipes, and
temporarily install the center exhaust pipe.
2. REINSTALL CENTER EXHAUST PIPE

Downloaded from www.Manualslib.com manuals search engine EC02Z−03
S05202
EC−8
− EMISSION CONTROL (5VZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE EGR PIPE
Remove the 6 nuts, EGR pipe and 2 gaskets.
HINT:
At the time of installation, please refer to the following item.Ins-
tall 2 new gaskets.
Torque:
Nut A: 18.5 N·m (185 kgf·cm, 14 ft·lbf)
Nut B: 8.0 N·m (80 kgf·cm, 71 in.·lbf)
3. REMOVE EGR GAS TEMPERATURE SENSOR
4. REMOVE EGR VALVE
(a) Disconnect these hoses from the EGR valve:
Vacuum hose (from VSV for EGR)
EGR hose (from EGR vacuum modulator)
Water hose (from water bypass pipe)
Water bypass hose (from IAC valve)
(b) Remove the 2 nuts, EGR valve and gasket.
Torque: 18.5 N·m (185 kgf·cm, 14 ft·lbf)
HINT:
Use a new gasket.
At the time of installation, please refer to the following item.
(c) Check for sticking and heavy carbon deposits. If problem
is found, replace the EGR valve.

Downloaded from www.Manualslib.com manuals search engine EC031−04
P21187
P21181
− EMISSION CONTROL (5VZ−FE)THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEMEC−13
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE CENTER EXHAUST PIPE
(a) 2WD:
Disconnect the 2 rings from the support bracket.
(b) Remove the 2 nuts and gasket, and disconnect the
heated oxygen sensor (bank 1 sensor 2).
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
HINT:
Use a new gasket.
(c) Remove the 4 bolts, TWC joint retainer, center exhaust
pipe and 2 gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
2. REINSTALL CENTER EXHAUST PIPE
HINT:
Place 2 new gaskets on the front exhaust and tail pipes, and
temporarily install the center exhaust pipe.

Downloaded from www.Manualslib.com manuals search engine MF – MFI SYSTEM (3RZ-FE)

MFI SYSTEM MF-1
FUEL PUMP MF-5
FUEL PRESSURE REGULATOR MF-13
INJECTOR MF-16
FUEL TANK AND LINE MF-23
THROTTLE BODY MF-25
IDLE AIR CONTROL (IAC) VALVE MF-31
MASS AIR FLOW (MAF) METER MF-36
EFI MAIN RELAY MF-40
CIRCUIT OPENING RELAY MF-41
VSV FOR EVAPORATIVE EMISSION
(EVAP) MF-43
VSV FOR EXHAUST GAS
RECIRCULATION (EGR) MF-44
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR MF-45
INTAKE AIR TEMPERATURE (IAT)
SENSOR MF-46
KNOCK SENSOR MF-47
EXHAUST GAS RECIRCULATION
(EGR) GAS TEMPERATURE SENSOR MF-48
HEATED OXYGEN SENSOR MF-49
ENGINE CONTROL MODULE (ECM) MF-50
FUEL CUT RPM MF-54

Downloaded from www.Manualslib.com manuals search engine SF0AF−04
− MFI (3RZ−FE)MFI SYSTEM
MF−1
953 Author: Date:
1996 TOYOTA T100 (RM449U)
MFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCON-
NECT NEGATIVE (−) TERMINAL CABLE FROM BAT-
TERY
HINT:
Any diagnostic trouble code retained by the ECM will be erased
when the battery negative (−) terminal cable is removed from
the battery.
Therefore, if necessary, read the diagnostic trouble code(s) be-
fore removing the negative (−) terminal cable from the battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME
WHEN WORKING ON FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATH-
ER PARTS
4. MAINTENANCE PRECAUTIONS
(a) Precaution when the connecting gauge.
Use battery as the power source for the timing light, etc.
(b) In the event of engine misfire, these precautions should
be taken.
(1) Check proper connection of battery terminals, etc.
(2) Handle high−tension cords carefully.
(3) After repair work, check that the ignition coil termi-
nals and all other ignition system lines are recon-
nected securely.
(4) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(c) Precautions when the handling heated oxygen sensors.
(1) Do not allow oxygen sensor to drop or hit against an
object.
(2) Do not allow the sensor to come into contact with
water.
If Vehicle is Equipped with Mobile Radio System (ham, cb, etc.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
5. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV
hose, etc. may cause the engine to run out of tune.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will cause air suction and cause the engine to run
out of tune.

Downloaded from www.Manualslib.com manuals search engine SF1QI−01
MF−18
− MFI (3RZ−FE)INJECTOR
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. 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.
3. M/T:
DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
4. A/T:
DISCONNECT THROTTLE AND ACCELERATOR
CABLES FROM THROTTLE BODY
5. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the 2 air hoses.
(b) Remove the 2 bolts, hose clamp and intake air connector.
6. REMOVE NO. 1 AND NO. 2 PCV HOSES
7. DISCONNECT HIGH−TENSION CORDS FROM SPARK
PLUGS
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
Disconnect the distributor connector.
8. REMOVE THROTTLE BODY (See page MF−28)
9. REMOVE DELIVERY PIPE AND INJECTORS

Downloaded from www.Manualslib.com manuals search engine B02580
SF1QK−01
− MFI (3RZ−FE)THROTTLE BODY
MF−25
977 Author: Date:
1996 TOYOTA T100 (RM449U)
THROTTLE BODY
ON−VEHICLE INSPECTION
1. INSPECT THROTTLE BODY
(a) Check that the throttle linkage moves smoothly.
(b) Check the vacuum at each port.
(1) Start the engine.
(2) Check the vacuum with your finger.
Port nameAt idleAt 3,500 rpm
PNo vacuumVacuum
ENo vacuumVacuum
RNo vacuumVacuum
2. INSPECT THROTTLE POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Apply vacuum to the throttle opener.
(c) Using an ohmmeter, measure the resistance between
each terminal.
Throttle valve
conditionBetween
terminalsResistance
Fully closedVTA − E20.2 − 5.7 kΩ
Fully closedIDL − E22.3 kΩ or less
OpenIDL − E2Infinity
Fully openVTA − E22.0 − 10.2 kΩ
−VC − E22.5 − 5.9 kΩ
(d) Connect the sensor connector.
3. INSPECT THROTTLE OPENER
(a) Warm up engine
Allow the engine to warm up to normal operating tempera-
ture.
(b) Connect TOYOTA hand−held tester or OBD II scan tool.
(c) Check idle speed
Idle speed: 700 rpm
(d) Disconnect the vacuum hose from the throttle opener,
and plug the hose end.

Downloaded from www.Manualslib.com manuals search engine SF0B2−02
P24769
P21655
P21654
MF−28
− MFI (3RZ−FE)THROTTLE BODY
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP, MAF METER AND
RESONATOR
(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.
3. M/T:
DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
4. A/T:
DISCONNECT ACCELERATOR AND THROTTLE
CABLES FROM THROTTLE BODY
5. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the 2 air hoses.
(b) Remove the 2 bolts, hose clamp and intake air connector.
6. REMOVE NO.1 AND NO.2 PCV HOSES
7. REMOVE THROTTLE BODY
(a) Disconnect the throttle position sensor connector.
(b) Disconnect the IAC valve connector.
(c) Disconnect the EVAP hose.
(d) Disconnect the 3 vacuum hoses.
(e) Remove the 2 bolts, 2 nuts and disconnect the throttle
body from the air intake chamber.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(f) Remove the throttle body gasket.
HINT:
At the time assembly please refer to the following items.
Install the throttle body with a new gasket.
(g) Disconnect the No.1 and No.2 water bypass hoses from
the throttle body, and remove the throttle body.