TOYOTA T100 1996 Factory Workshop Manual

Downloaded from www.Manualslib.com manuals search engine MA0099
OK if coolOK if hot
Add if coolAdd if hot
MA−12
− MAINTENANCECHASSIS
47 Author: Date:
1996 TOYOTA T100 (RM449U)
(f) Check that the fluid level is in the ”HOT” range at the nor-
mal operating temperature (70 − 80°C or 158 − 176°F)
and add as necessary.
NOTICE:
Do not overfill.
10. REPACK FRONT WHEEL BEARINGS AND THRUST
BUSH
(a) Change the front wheel bearing grease.
(2WD: See page SA−19)
(4WD: See page SA−25)
(b) Repack the drive shaft thrust bush grease (See page
SA−41).
11. 4WD:
LUBRICATE PROPELLER SHAFT
Lubricate propeller shaft, referring to the lubrication chart. Be-
fore pumping in grease, wipe off any mud and dust on the
grease fitting.
Grease grade:
Propeller shaft (Except Double−cardan joint)
Lithium base chassis grease NLGI No.2
Double−cardan joint
Molybdenum disulphide lithium base chassis grease
NLGI No.2

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B02099
B02100
− MAINTENANCECHASSIS
MA−13
48 Author: Date:
1996 TOYOTA T100 (RM449U)
12. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
(a) Tighten these parts:
Seat mounting bolts
Torque:
37 N·m (375 kgf·cm, 27 ft·lbf)

2WD:
Strut bar bracket−to−frame mounting bolts
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
Leaf spring U−bolt mounting nuts
Torque: 133 N·m (1,350 kgf·cm, 98 ft·lbf )
(b) Under Severe Conditions:
In addition to the above maintenance items, check for
loose or missing bolts and nuts on the following.
Steering system
Drive train
Suspension system
Fuel tank mounts
Engine mounts, etc.
13. FINAL INSPECTION
(a) Check operation of body parts:
Hood:
Auxiliary catch operates properly
Hood locks securely when closed
Doors:
Door locks operate properly
Doors close properly
Seats:
Seat adjusts easily and locks securely in any
positions
Seat backs lock securely at any angle
Fold−down seat backs lock securely
(b) Road test:
Engine and chassis parts do not have abnormal
noises.
Vehicle does not wander or pull to one side.
Brakes work properly and do not drag.

Downloaded from www.Manualslib.com manuals search engine MA−14
− MAINTENANCECHASSIS
49 Author: Date:
1996 TOYOTA T100 (RM449U)
(c) Be sure to deliver a clean vehicle and especially check:
Steering wheel
Shift lever knob
All switch knobs
Door handles
Seats

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MAINTENANCE PP-1
ENGINE MECHANICAL (3RZ-FE) PP-2
ENGINE MECHANICAL (5VZ-FE) PP-8
EMISSION CONTROL (3RZ-FE) PP-14
EMISSION CONTROL (5VZ-FE) PP-16
MFI (3RZ-FE) PP-19
SFI (5VZ-FE) PP-22
COOLING (3RZ-FE) PP-25
COOLING (5VZ-FE) PP-28
LUBRICATION (3RZ-FE) PP-33
LUBRICATION (5VZ-FE) PP-38
IGNITION (3RZ-FE) PP-43
IGNITION (5VZ-FE) PP-46
STARTING (3RZ-FE) PP-48
STARTING (5VZ-FE) PP-51
CHARGING (3RZ-FE) PP-54
CHARGING (5VZ-FE) PP-57
CLUTCH PP-60
MANUAL TRANSMISSION (R150,
R150F) PP-63
MANUAL TRANSMISSION (W59) PP-69
AUTOMATIC TRANSMISSION PP-75
TRANSFER PP-80
PROPELLER SHAFT PP-86
SUSPENSION AND AXLE PP-88
BRAKE PP-98
STEERING PP-103
SUPPLEMENTAL RESTRAINT SYSTEM PP-113
BODY ELECTRICAL PP-116
BODY PP-119
AIR CONDITIONING PP-122

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− PREPARATIONMAINTENANCE
PP−1
50 Author: Date:
1996 TOYOTA T100 (RM449U)
MAINTENANCE
EQUIPMENT
MirrorBrake hose
Torque wrench

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PP−2
− PREPARATIONENGINE MECHANICAL (3RZ−FE)
51 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE MECHANICAL (3RZ−FE)
SST (Special Service Tools)
09032−00100Oil Pan Seal Cutter
09201−10000Valve Guide Bushing Remover &
Replacer Set
(09201−01060)Valve Guide Bushing Remover &
Replacer 6
09202−70020Valve Spring Compressor
09207−76010Rocker Arm Bushing
09213−54015Crankshaft Pulley Holding Tool
09223−15030Oil Seal & Bearing ReplacerCrankshaft rear oil seal
09223−50010Crankshaft Front oil Seal
Replacer
09236−00101Water Pump Overhaul Tool Set
(09236−15010)Bearing StayValve stem oil seal
09248−55040Valve Clearance Adjust Tool Set
(09248−05410)Valve Lifter Press

Downloaded from www.Manualslib.com manuals search engine − PREPARATIONENGINE MECHANICAL (3RZ−FE)
PP−3
52 Author: Date:
1996 TOYOTA T100 (RM449U)
(09248−05420)Valve Lifter Stopper
09325−20010Transmission Oil Plug
09330−00021Companion Flange Holding ToolCrankshaft pulley
09550−10012Replacer Set ”B”
(09252−10010)No. 1 Replacer Handle−Valve guide busing
09608−30012Front Hub & Drive Pinion Bearing
Tool Set−
(09951−07100)Handle 100Crankshaft rear oil seal
09636−20010Upper Ball Joint Dust Cover
ReplacerCrankshaft timing gear
09816−30010Oil Pressure Switch SocketKnock sensor
09843−18020Diagnosis Check Wire
09950−40010Puller B Set
(09951−04010)Hanger 150
(09952−04010)Slide Arm

Downloaded from www.Manualslib.com manuals search engine PP−4
− PREPARATIONENGINE MECHANICAL (3RZ−FE)
53 Author: Date:
1996 TOYOTA T100 (RM449U)
(09953−04010)Center Bolt 100
(09954−04010)Arm 25
(09955−04060)Claw No.6
09950−50010Puller C Set
(09951−05010)Hanger 150
(09952−05010)Slide Arm
(09953−05010)Center Bolt 100
(09954−05020)Claw No.2
09960−10010Variable Pin Wrench Set
(09962−01000)Variable Pin Wrench Arm Assy
(09963−00500)Pin 5
(09963−01000)Pin 10

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− PREPARATIONENGINE MECHANICAL (3RZ−FE)
PP−5
1996 TOYOTA T100 (RM449U)
RECOMMENDED TOOLS
09082−00050TOYOTA Electrical Tester Set.
09200−00010Engine Adjust Kit .
09258−00030Hose Plug Set .Plug for the vacuum hose, fuel
hose etc.

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PP−6
− PREPARATIONENGINE MECHANICAL (3RZ−FE)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Engine tune−up tester
Heater
Magnetic finger
Micrometer
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring testerValve spring
Steel squareValve spring
Thermometer
Torque wrench
V−block
Valve seat cutter
Vernier calipers