check engine TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine Illustration:
what to do and where21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a) Place SST and a dial indicator onto the overdrive brake
piston as shown in the illustration.
Task heading : what to do
SST 09350−30020 (09350−06120)
Set part No.Component part No.
Detailed text : how to do task
(b) Measure the stroke applying and releasing the compressed
Piston stroke: 1.40  1.70 mm (0.0551  0.0669 in.)
Specification air (392 − 785 kPa, 4 − 8 kgf.cm2 or 57 − 114 psi) as
shown in the illustration. IN−2
− INTRODUCTIONHOW TO USE THIS MANUAL
2 Author: Date:
1996 TOYOTA T100 (RM449U)
The procedures are presented in a step−by−step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section for quick ref-
erence.
8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine FI1066
IN0IL−01
Z11554
Seal Lock Adhesive
IN−4
− INTRODUCTIONREPAIR INSTRUCTIONS
4 Author: Date:
1996 TOYOTA T100 (RM449U)
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Observe the following operations:
(1) Before performing electrical work, disconnect the
negative (−) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the negative
(−) terminal cable which is grounded to the vehicle
body.
(3) To prevent damage to the battery terminal, loosen
the cable nut and raise the cable straight up without
twisting or prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals with
the nut loose, and tighten the nut after installation.
Do not use a hammer to tap the cable ends onto the
terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are secure and correct.
(e) Non−reusable parts
(1) Always replace cotter pins, gaskets, O−rings and oil
seals etc. with new ones.
(2) Non−reusable parts are indicated in the component
illustrations by the ”” symbol.
(f) Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.

Downloaded from www.Manualslib.com manuals search engine IN0253
WRONG CORRECT
IN0252
WRONG CORRECT
IN0002
Example IN−6
− INTRODUCTIONREPAIR INSTRUCTIONS
6 Author: Date:
1996 TOYOTA T100 (RM449U)
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN−8).
(1) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels at the opposite
end in order to ensure safety.
(2) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on a vehicle raised on a jack alone, even for a small
job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU, ECM,
PCM or TCM unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by
static electricity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission−related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step−down
adapter for adjustment. Once the hose has been
stretched, it may leak.
(m) Tag hoses before disconnecting them:
(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.

Downloaded from www.Manualslib.com manuals search engine B01124
Front IN−10
− INTRODUCTIONFOR ALL OF VEHICLES
10 Author: Date:
1996 TOYOTA T100 (RM449U)
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the center airbag sensor if
shocks are likely to be applied to the sensor during
repairs.
(6) Never disassemble and repair the center airbag
sensor assembly, steering wheel pad in order to re-
use it.
(7) If the center airbag sensor assembly, steering
wheel pad have been dropped, or if there are
cracks, dents or other defects in the case, bracket
or connector, replace them with new ones.
(8) Do not expose the center airbag sensor assembly,
steering wheel pad directly to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kΩ/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work on the supplemental restraint system is
completed, check the SRS warning light (See page
DI−365).
(c) FRONT AIRBAG SENSOR
(1) Never reuse the front airbag sensors involved in a
collision that activated the supplemental restraint
system. (Replace both left and right airbag sen-
sors.)
(2) Install the front airbag sensor with the arrow on the
sensor facing toward the front of the vehicle.
The front airbag sensor set bolts have been anti−
rust treated. When the sensor is removed, always
replace the set bolts with new ones.
(3) The front airbag sensor is equipped with an electri-
cal connection check mechanism. Be sure to lock
this mechanism securely when connecting the con-
nector.
(4) If connector is not securely locked, a malfunction
code will be the diagnosis system (See page
RS−2).

Downloaded from www.Manualslib.com manuals search engine IN02J−03
Vehicle Brought Workshop
Customer Problem
Analysis
Symptom Confirmation
and Diagnostic Trouble
Code Check
Symptom Simulation
Diagnostic Trouble
Code Chart
Matrix Chart of Problem
Symptoms
Circuit Inspection or Parts
Inspection
Repair
Confirmation Test
End 1
2
43
5
6
7
8Ask the customer about the conditions and the
environment when the problem occurred.1
Confirm the symptoms and the problem conditions,
and check the diagnostic trouble codes.
(When the problem symptoms do not appear
during confirmation, use the symptom simulation
method described later on.)2, 3
Check the results obtained in Step 2, then confirm
the inspection procedure for the system or the part
which should be checked using the diagnostic
trouble code chart or the matrix chart of problem
symptoms.4, 5, 6
Check and repair the affected system or part in
accordance with the instructions in Step 6. 7
After completing repairs, confirm that the problem
has been eliminated.
(If the problem is not reproduced, perform the
confirmation test under the same conditions and
in the same environment as when it occurred for
the first time.)8
IN−16− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TOYOTA T100 (RM449U)
HOW TO PROCEED WITH TROUBLESHOOTING
Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro-
cedure is shown. Details are provided in each section, showing the most effective methods for each circuit.
Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that
circuit.

Downloaded from www.Manualslib.com manuals search engine Important Points in the Customer Problem Analysis
 What −−−−− Vehicle model, system name
 When −−−−− Date, time, occurrence frequency
 Where −−−−− Road conditions
 Under what conditions? −−−−− Running conditions, driving conditions, weather conditions
 How did it happen? −−−−− Problem symptoms
(Sample) Engine control system check sheet.
ENGINE CONTROL SYSTEM Check Sheet
Customer’s Name
Driver’s Name
Data Vehicle
Brought in
License No.
Model and Model
Year
Frame No.
Engine Model
Odometer Reading
km
miles
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Drive ability
Engine Stall
Others
Engine does not crankNo initial combustionNo complete combustion
Engine cranks slowly
Other
Incorrect first idleIdling rpm is abnormalHigh ( rpm)Low ( rpm)
Rough idling
Other
HesitationBack fireMuffler explosion (after−fire)Surging
Knocking
Other
Soon after startingAfter accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D
Other
Datas Problem
ConstantSometimes ( times per day/month)
Inspector’s
Name
CUSTOMER PROBLEM ANALYSIS CHECK
− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−17
1996 TOYOTA T100 (RM449U)
1. CUSTOMER PROBLEM ANALYSIS
In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be
cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it
is extremely important to ask the customer about the problem and the conditions at the time it occurred.
Important Point in the Problem Analysis:
The following 5 items are important points in the problem analysis. Past problems which are thought to be
unrelated and the repair history, etc. may also help in some cases, so as much information as possible should
be gathered and its relationship with the problem symptoms should be correctly ascertained for reference
in troubleshooting. A customer problem analysis table is provided in the troubleshooting section for each
system for your use.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE
Diagnostic Trouble
Code Check (Make a
note of and then clear)Confirmation
of SymptomsDiagnostic Trouble
Code CheckProblem Condition
Diagnostic Trouble
Code DisplayProblem symptoms
existSame diagnostic
trouble code is
displayedProblem is still occurring in the diagnostic
circuit.
Normal code is
displayedThe problem is still occurring in a place
other than in the diagnostic circuit.
(The diagnostic trouble code displayed
first is either for a past problem or it is a
secondary problem.)
No problem
symptoms existThe problem occurred in the diagnostic
circuit in the past.
Normal Code DisplayProblem symptoms
existNormal code is
displayedThe problem is still occurring in a place
other than in the diagnostic circuit.
No problem
symptoms existNormal code is
displayedThe problem occurred in a place other
than in the diagnostic circuit in the past.
IN−18− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TOYOTA T100 (RM449U)
2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK
The diagnostic system in the TOYOTA T100 fulfills various functions. The first function is the Diagnostic
Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU
memory at the time of occurrence, to be output by the technician during troubleshooting. Another function
is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly.
By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can
be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA
T100.
SystemDiagnostic Trouble
Code CheckInput Signal Check
(Sensor Check)Other Diagnosis
Function
Engine (3RZ−FE, 5VZ−FE)
Automatic Transmission
Anti−Lock Brake system
Supplemental Restraint System
Cruise Control (with Test Mode)
 (with Test Mode)






Cancel Signal
Check
In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diag-
nostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition,
it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic
trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes
should be checked before and after the symptom confirmation to determine the current conditions, as shown
in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting
for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent
to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble
code check.

Downloaded from www.Manualslib.com manuals search engine Diagnostic trouble code check
Making a note of and clearing of the diagnostic trouble codes displayed
Symptom confirmation
No problem symptoms
exist Problem symptoms
exist
Simulation test using the symptom
simulation methods
 Normal code displayed
 Problem symptoms exist Normal code displayed
 No problem symptoms exist Diagnostic trouble code check
Troubleshooting of problem indicated
by diagnostic trouble code Diagnostic trouble code displayed
 Problem symptoms exist
System Normal Troubleshooting of each
problem symptom
If a diagnostic trouble code was
displayed in the initial diagnostic
trouble code check, it indicates
that the trouble may have occurred
in a wire harness or connector in
that circuit in the past. Therefore,
check the wire harness and con-
nectors (See page IN−26).
− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−19
1996 TOYOTA T100 (RM449U)
Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshoot-
ing using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnos-
tic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to
diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms.

Downloaded from www.Manualslib.com manuals search engine V07268
VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
WIRE HARNESS
PARTS AND SENSOR1
Slightly shake the connector vertically and horizontally.
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough-
ly.
Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check if the
malfunction occurs.Shake Slightly
Swing Slightly
Vibrate Slightly
HINT: Applying strong vibration to relays may result in open
relays. IN−20
− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TOYOTA T100 (RM449U)
3. SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customer’s vehicle. No matter how much experience a
technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem
symptoms he will tend to overlook something important in the repair operation and make a wrong guess
somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the en-
gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the prob-
lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the
vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which
is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex-
ternal causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-
toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the problem symp-
toms at the same time. Refer to the matrix chart of problem symptoms for each system to narrow down the
possible causes of the symptom.

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HEAT METHOD: When the problem seems to occur when the suspect area is heated. 2
NOTICE:
(1) Do not heat to more than 60 °C (140 °F). (Temperature
is limited not to damage the components.)
(2) Do not apply heat directly to parts in the ECU.
3 WATER SPRINKLING METHOD:
NOTICE:
(1) Never sprinkle water directly into the engine
compartment, but indirectly change the temperature and
humidity by applying water spray onto the radiator front
surface.
(2) Never apply water directly onto the electronic
components.
4 OTHER: When a malfunction seems to occur when electrical load is excessive.When the malfunction seems to occur on a rainy day or in a
high−humidity condition. Heat the component that is the likely cause of the malfunction
with a hair dryer or similar object. Check to see if the malfunction
occurs.
Sprinkle water onto the vehicle and check to see if the malfunc-
tion occurs.
Turn on all electrical loads including the heater blower, head
lights, rear window defogger, etc. and check to see if the mal-
function occurs.ON (Service hint)
If a vehicle is subject to water leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, special caution must be taken.
Malfunc-
tion
− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−21
1996 TOYOTA T100 (RM449U)