TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SF0AQ−02
− MFI (3RZ−FE)INJECTOR
MF−17
1996 TOYOTA T100 (RM449U)
COMPONENTS

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 SF0AS−03
P21648
Z14631
SST
(Hose)
SST
(Union)
Union
Bolt
Gasket
P15780
SST
(Union)
Fuel Return Hose Fuel Pressure
Regulator
SST
(Hose)
B02507
− MFI (3RZ−FE)INJECTOR
MF−19
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT INJECTOR INJECTION
CAUTION:
Keep injector clean of sparks during the test.
(a) Connect SST (union and hose) to the fuel filter outlet with
2 gaskets and the union bolt.
SST 09268−41046 (90405−09015)
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Remove the fuel pressure regulator.
(c) Install the O−ring to the fuel inlet of pressure regulator.
(d) Connect SST (hose) to the fuel inlet of the pressure regu-
lator with SST (union) and the 2 bolts.
SST 09268−41046 (09268−41091)
(e) Connect the fuel return hose to the fuel outlet of the pres-
sure regulator.
(f) Install the grommet and O−ring to the injector.
(g) Connect SST (union and hose) to the injector, and hold
the injector and union with SST (clamp).
SST 09268−41046
(h) Put the injector into a graduated cylinder.
HINT:
Install a suitable vinyl hose onto the injector to prevent gasoline
from splashing out.
(i) Connect the TOYOTA hand−held tester to the DLC3.
(See page MF−5)

Downloaded from www.Manualslib.com manuals search engine B02508
B02509
MF−20
− MFI (3RZ−FE)INJECTOR
1996 TOYOTA T100 (RM449U)
(j) Connect SST (wire) to the injector and battery for 15 se-
conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842−30070
Volume:
69 − 88 cm
3 (4.2 − 5.3 cu in.) per 15 seconds
Difference between each injector:
5 cm
3 (0.3 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of SST
(wire) from the battery and check the fuel leakage from
the injector.
SST 09842−30070
Fuel drop:
1 drop or less per 3 minutes
(b) Turn the ignition switch to LOCK.
(c) Disconnect the negative (−) terminal cable from battery.
(d) Remove SST and TOYOTA hand−held tester.
SST 09268−41046
(e) Reinstall the fuel pressure regulator to the delivery pipe.

Downloaded from www.Manualslib.com manuals search engine P14758
New
GrommetNew
O−Ring
SF0AT−03
P14756
Upward
Turn
Push
P14757
P24768
− MFI (3RZ−FE)INJECTOR
MF−21
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL INJECTORS TO DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to a new O−ring and install
it to the injector.
(c) While turning the injector left and right, install it to the de-
livery pipe. Install the 4 injectors.
(d) Position the injector connector upward.
2. INSTALL INJECTORS AND DELIVERY PIPE
(a) Place the 4 new insulators and in position on the spacers.
(b) Place the 4 injectors together with the delivery pipe in
position on the cylinder head.
(c) Temporarily install the 2 bolts holding the delivery pipe to
the cylinder head.
(d) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O−rings. Replace the O−rings.
(e) Position the injector connector upward.
(f) Tighten the 2 bolts holding the delivery pipe to the cylinder
head.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
3. INSTALL THROTTLE BODY (See page MF−30)
4. REINSTALL HIGH−TENSION CORDS TO SPARK
PLUGS
5. INSTALL NO.1 AND NO.2 PCV HOSES
6. INSTALL AIR INTAKE CONNECTOR
7. M/T:
CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
8. A/T:
CONNECT THROTTLE AND ACCELERATOR CABLES
TO THROTTLE BODY

Downloaded from www.Manualslib.com manuals search engine MF−22
− MFI (3RZ−FE)INJECTOR
1996 TOYOTA T100 (RM449U)
9. INSTALL MAF METER, RESONATOR AND AIR
CLEANER CAP
10. FILL WITH ENGINE COOLANT
11. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine SF0AU−02
P21793Non−reusable part
39 (400, 29)
1.5 (15, 13 in.·lbf)3.9 (40, 35 in.·lbf)
N·m (kgf·cm, ft·lbf)
3.5 (35, 31 in.·lbf)
: Specified torqueNo.1 Fuel Tank Band
− MFI (3RZ−FE)FUEL TANK AND LINE
MF−23
975 Author: Date:
1996 TOYOTA T100 (RM449U)
FUEL TANK AND LINE
COMPONENTS
CAUTION:
Always use new gaskets when replacing the fuel tank or component parts.
Apply the proper torque to all parts tightened.

Downloaded from www.Manualslib.com manuals search engine BO0919
Crack
Leakage
Deformation
Z10162
SST
SST: 09631−22020Use SST
30 N·m
(310 kgf·cm, 22 ft·lbf)
Fulcrum
Length
30 cm
(11.81 in.)
FU0041
Pipe
0 − 3 mm (0 − 0.12 in.) 2 − 5 mm (0.08 − 0.20 in.)
Hose
Clip
SF0AV−02
MF−24
− MFI (3RZ−FE)FUEL TANK AND LINE
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT FUEL TANK AND LINE
(a) Check the fuel lines for cracks or leakage, and all connec-
tions for deformation.
(b) Check the fuel tank vapor vent system hoses and connec-
tions for looseness, sharp bends or damage.
(c) Check the fuel tank for deformation, cracks, fuel leakage
or tank band looseness.
(d) Check the filler neck for damage or fuel leakage.
(e) Hose and tube connections are as shown in the illustra-
tion.
If a problem is found, repair or replace the part as necessary.

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 MF−26
− MFI (3RZ−FE)THROTTLE BODY
978 Author: Date:
1996 TOYOTA T100 (RM449U)
(e) Check the throttle opener setting speed.
Throttle opener setting speed: 1,200 − 1,400 rpm
If the throttle opener setting is not as specified, replace the
throttle body.
(f) Stop the engine.
(g) Connect the vacuum hose to the throttle opener.
(h) Start the engine, and check that the idle speed returns to
the correct speed.
(i) Disconnect TOYOTA hand−held tester or OBDII scan
tool.