relay TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine IN0253
WRONG CORRECT
IN0252
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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 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.

Downloaded from www.Manualslib.com manuals search engine − INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−23
1996 TOYOTA T100 (RM449U)
5. PROBLEM SYMPTOMS TABLE
The suspect circuits or parts for each problem symptom are shown in the table below. Use this table to trou-
bleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the prob-
lem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should
be checked.
HINT:
When the problem is not detected by the diagnostic system even though the problem symptom is present,
it is considered that the problem is occurring outside the detection range of the diagnostic system, or that
the problem is occurring in a system other than the diagnostic system.
Symptom
Suspect AreaSee page
Engine does not crank (Does not start)
No initial combustion (Does not start)
No complete combustion (Does not start)1. Starter and starter relay
1. ECM power source circuit
2. Fuel pump control circuit
3. Engine control module (ECM)
1. Starter signal circuit
2. Fuel pump control circuit1. Fuel pump control circuitST − 2, ST − 17
DI − 101
DI − 104
IN − 28
PROBLEM SYMPTOMS TABLE
1. Compression
2. Fuel pump control circuit 1. A/C signal circuit
2. Fuel pump control circuit 1. A/C signal circuit (Compressor circuit)
2. ECM power source circuit 1. Starter signal circuit
2. Fuel pump control circuit1. Starter signal circuit
2. Fuel pump control circuit
3. Compression
idling) High engine idle speed (Poor idling) Hot engine Cold engine (Difficult to start)Engine cranks normally (Difficult to start)
DI − 101 DI − 173
DI − 104 DI − 173
DI − 104 DI − 104
DI − 173
DI − 104
 Problem Symptom Page
Indicates the page where the flow chart for each circuit
is located.
 Circuit Inspection, Inspection Order
Indicates the circuit which needs to be checked for each problem
symptom. Check in the order indicated by the numbers.
 Circuit or Part Name
Indicates the circuit or part which needs to be checked.
AC − 85 EM − 3

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− INTRODUCTIONTERMS
1996 TOYOTA T100 (RM449U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module−
IFIIndirect Fuel InjectionIndirect Injection
IFSInertia Fuel−Shutoff−
ISCIdle Speed Control−
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure−
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface Temperature−
MVZManifold Vacuum Zone−
NVRAMNon−Volatile Random Access Memory−
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn−Board DiagnosticOn−Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module−
PNPPark/Neutral Position−
PROMProgrammable Read Only Memory−
PSPPower Steering Pressure−
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module−
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass−
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter−
SRIService Reminder Indicator−
SRTSystem Readiness Test−
STScan Tool−
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

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MA015−02
B02089
B02090
MA−8
− MAINTENANCECHASSIS
43 Author: Date:
1996 TOYOTA T100 (RM449U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay (See page SR−9).
(b) Check the steering linkage for looseness or damage.
Check that:
Tie rod ends and relay rod ends do not have exces-
sive play.
Dust seals are not damaged.
2WD:
Boot clamps are not loose.
2. INSPECT SRS AIRBAG (See page RS−2)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leaks.
If leakage is found, check for cause and repair.
4. 4WD:
INSPECT DRIVE SHAFT BOOTS
Inspect the drive shaft boots for clamp looseness, grease leak-
age or damage.
5. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.
(b) Inspect the dust cover for damage.

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PP−11 8
− PREPARATIONBODY ELECTRICAL
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Voltmeter
Ammeter
Ohmmeter
Test lead
SyphonBrake fluid level warning switch
Bulb (3W)Fuel sender gauge
Bulb (3.4W)Seat belt warning relay
Bulb (21W)Turn signal flasher relay
Dry cell batteryFuel sender gauge
Torque wrench

Downloaded from www.Manualslib.com manuals search engine SS−74
− SERVICE SPECIFICATIONSSTEERING
1996 TOYOTA T100 (RM449U) Tie rod end lock nut
5657041
Turn pressure tube union nut10 (13)102 (130)7 (9)
PS gear assembly set bolt and nut8890065
Mount bracket x Suspension crossmember8890065
Control valve shaft x Intermediate shaft3536026
Pressure feed tube x Control valve housing19 (25)195 (250)14 (18)
Return tube x Control valve housing19 (25)195 (250)14 (18)
Tie rod end x Steering knuckle9092067
4WD:
Pressure feed tube x PS gear assembly36 (44)365 (450)26 (33)
Return tube x PS gear assembly36 (44)365 (450)26 (33)
PS gear assembly x Body1421450105
Pitman arm x Cross shaft1771800130
Cross shaft adjusting screw set nut4647034
Side cover x Gear housing6162045
Plunger guide nut2020515
Worm gear valve body assembly x Gear housing6162045
Worm gear valve body assembly x Intermediate shaft3536026
STEERING LINKAGE
Pitman arm x Cross shaft1771800130
Pitman arm x Relay rod9092067
Tie rod clamp bolt2222516
Tie rod assembly x Relay rod9092067
Tie rod assembly x Knuckle arm9092067
Idler arm assembly x Frame1421450105
Relay rod x Idler arm assembly5960043
Steering damper set bolt and nut2526019
Relay rod x Steering damper5960043
IDLER ARM
Idler arm x Idler arm bracket7880058
( ): For use without SST

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− SERVICE SPECIFICATIONSBODY ELECTRICAL
SS−77
251 Author: Date:
1996 TOYOTA T100 (RM449U)
BODY ELECTRICAL
SERVICE DATA
DAYTIME RUNNING LIGHT MAIN RELAY (Wire Harness Side)
2 − Ground (Ignition Switch LOCK or ACC)No voltage
2 − Ground (Ignition Switch ON or START)Battery positive voltage
6 − Ground (Constant)Battery positive voltage
11 − Ground (Engine Stop)No voltage
11 − Ground (Engine Running)Battery positive voltage
DAYTIME RUNNING LIGHT MAIN RELAY (Connector connected)
17 − Ground (Headlight dimmer switch LOW beam)No voltage
17 − Ground (Headlight dimmer switch HIGH beam or Flash)Battery positive voltage
TURN SIGNAL FLASHER
Flashes/ Minute60 − 120
SPEEDOMETER (Using a speedmeter tester)
Standard indication (mph)Allowable range (mph)
2018 − 24
4038 − 44
6058 − 66
8078 − 88
10098 − 11 0
12011 8 − 132
Standard indication (km/h)Allowable range (km/h)
2017 − 24
4038 − 46
6057.5 − 67
8077 − 88
10096 − 109
12011 5 − 130
140134 − 151.5
160153 − 173
TACHOMETER (On−Vehicle) / DC 13.5 V 20 °C at (68 °F)
Standard indicationAllowable range
700610 − 750
3,0002,850 − 3,150
5,0004,850 − 5,150
7,0006,790 − 7,210
VOLT GAUGEResistance (Ω)
A − BApprox. 347.0 Ω
FUEL RECEIVER GAUGE (w/ Tachometer)Resistance (Ω)
A − BApprox. 137.0 Ω
A − CApprox. 123.0 Ω
B − CApprox. 260.0 Ω
FUEL RECEIVER GAUGE (w/o Tachometer)Resistance (Ω)
A − BApprox. 150.0 Ω
A − CApprox. 80.0 Ω

Downloaded from www.Manualslib.com manuals search engine SS−78
− SERVICE SPECIFICATIONSBODY ELECTRICAL
252 Author: Date:
1996 TOYOTA T100 (RM449U)B − C
Approx. 55.0 Ω
FUEL SENDER GAUGE
Float position mm (in.)Resistance (Ω)
F: Approx. 95 mmApprox. 3.0 Ω
1/2: Approx. 188.0 mmApprox. 32.5 Ω
E: Approx. 283.0 mmApprox. 110.0 Ω
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (w/ Tachometer)Resistance (Ω)
A − BApprox. 150.0 Ω
A − CApprox. 54.0 Ω
B − CApprox. 138.0 Ω
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (w/ o Tachometer)
A − BApprox. 25.0 Ω
OIL PRESSURE RECEIVER GAUGE
A − BApprox. 25.0 Ω
DOOR LOCK CONTROL RELAY (Wire Harness Side)
2 − Ground (Constant)Battery positive voltage
8 − Ground (Ignition Switch LOCK or ACC)No voltage
8 − Ground (Ignition Switch ON)Battery positive voltage
13 − Ground (Key unlock warning switch OFF (Ignition key removed))No voltage
13 − Ground (Key unlock warning switch ON (Ignition key set))Battery positive voltage
CRUISE CONTROL ECU (wire harness side)
24 − 26 (constant)Approx. 2.0 kΩ
25 − 26 (Actuator arm turned)Resistance change even
10 − Ground (Brake pedal position: Released)Approx. 38.0 Ω
10 − Ground (Brake pedal position: Depressed)No continuity
CRUISE CONTROL SWITCH
18 − Ground (Control switch position: OFF)No continuity
18 − Ground (Control switch position: RESUME/ACCEL)Approx. 68.0 Ω
18 − Ground (Control switch position: SET/COAST)Approx. 198.0 Ω
18 − Ground (Control switch position: CANCEL)Approx. 418.0 Ω
14 − Ground (Ignition switch position: LOCK or ACC)No voltage
14 − Ground (Ignition switch position: ON)Battery positive voltage
15 − Ground (Constant)Battery positive voltage
1 − Ground (Constant)Battery positive voltage
16 − Ground (Brake pedal position: Released)No voltage
16 − Ground (Brake pedal position: Depressed)Battery positive voltage
20 − Ground (With ignition switch ON, Speedsensor shaft turned)Valtage changes repeatedly
CRUISE CONTROL ACTUATOR
1 − 3Approx. 2.0 kΩ
2 − 3 (The arm is moving from the closed to open position)Approx. 0.5 to 1.8 kΩ
ANTENNA MOTOR CONTROL RELAY (Wire harness side)
3 − Ground (Constant)Battery positive voltage
5 − Ground (Ignition Switch position: LOCK)No voltage
5 − Ground (Ignition switch position: ACC)Battery positive voltage
7 − Ground (Ignition switch position: LOCK)No voltage

Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSENGINE (3RZ−FE)
DI−15
1996 TOYOTA T100 (RM449U) DTC No.
(See Page)
Detection ItemTrouble AreaMIL*Memory
P0441
(DI−88)Evaporative Emission Control
System Incorrect Purge Flow
Open or short in VSV circuit for EVAP
VSV for EVAP
ECM
Vacuum hose damaged, blocked or disconnected
Charcoal canister

P0500
(DI−92)Vehicle Speed Sensor
Malfunction
Open or short in No.1 vehicle speed sensor circuit
No.1 vehicle speed sensor
ECM
Speedometer cable

P0505
(DI−94)Idle Control System
MalfunctionIAC valve is stuck or closed
Open or short in IAC valve circuit
Air intake (hose loose)

P0510
(DI−97)Closed Throttle Position
Switch MalfunctionOpen in closed throttle position switch circuit
Closed throttle position switch
ECM

*:  MIL lights up
MANUFACTURER CONTROLLED
DTC No.
(See Page)Detection ItemTrouble AreaMIL*Memory
P1300
(DI−103)Igniter Circuit Malfunction
Open or short in IGF or IGT circuit from igniter to ECM
Igniter
ECM

P1335
(DI−109)Crankshaft Position Sensor
Circuit Malfunction
(during engine running)Open or short in crankshaft position sensor circuit
Crankshaft position sensor
ECM
−
P1500
(DI−11 0)Starter Signal Malfunction
Open or short in starter signal
Open or short in ignition switch or starter relay circuit
ECM
−
P1600
(DI−11 2)ECM BATT MalfunctionOpen in back up power source circuit
ECM
P1780
(DI−11 4)Park/Neutral Position Switch
MalfunctionShort in park/neutral position switch circuit
Park/neutral position switch
ECM

*: −  MIL does not light up,  MIL lights up