service TOYOTA T100 1996 Factory Service Manual

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1996 TOYOTA T100
Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine INDEX
IN Introduction
MA Maintenance
PP Preparation
SS Service Specifications
DI Diagnostics
EM Engine Mechanical (3RZ-FE)
Engine Mechanical (5VZ-FE)
EC Emissions Control (3RZ-FE)
Emissions Control (5VZ-FE)
MF MFI System (3RZ-FE)
SF SFI System (5VZ-FE)
CO Cooling (3RZ-FE)
Cooling (5VZ-FE)
LU Lubrication (3RZ-FE)
Lubrication (5VZ-FE)
IG Ignition (3RZ-FE)
Ignition (5VZ-FE)
ST Starting (3RZ-FE)
Starting (5VZ-FE)
CH Charging (3RZ-FE)
Charging (5VZ-FE)
CL Clutch
MT Manual Transmission (R150, R150F)
Manual Transmission (W59)
AT Automatic Transmission
TR Transfer
PR Propeller Shaft
SA Suspension and Axle
BR Brake
SR Steering
RS Supplemental Restraint System
BE Body Electrical
BO Body
AC Air Conditioning

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N17080
Filler Cap
Float
Reservoir Tank
 Grommet
Clip
Slotted Spring Pin
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot
 Gasket
Lock Nut
Clevis Pin
Clevis
12 ( 120, 9)
15 ( 155, 11)
− INTRODUCTIONHOW TO USE THIS MANUAL
IN−1
1 Author: Date:
1996 TOYOTA T100 (RM449U)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the Section Title and major heading are given at the top of every
page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN−16.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:

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 BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
Abbreviation Part Name Symbol Illustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKERFUSE
M−FUSE
H−FUSE
FL
CB
− INTRODUCTIONREPAIR INSTRUCTIONS
IN−5
5 Author: Date:
1996 TOYOTA T100 (RM449U)
(3) Precoated parts are indicated in the component il-
lustrations by the ”” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in the preparation part at the front
of each section in this manual.
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.

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BO4111
Negative Cable
− INTRODUCTIONFOR ALL OF VEHICLES
IN−9
9 Author: Date:
1996 TOYOTA T100 (RM449U)
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG
(a) The TOYOTA T100 is equipped with an SRS (Supple-
mental Restraint System), such as the driver airbag.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the battery (See page DI−365).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative (−) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back−up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (−) terminal cable from the battery, the SRS
may deploy.)
When the negative (−) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back−up power supply from out-
side the vehicle.
(3) Even in cases of a minor collision where the SRS
does not deploy, the steering wheel pad should be
inspected (See page RS−9).

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− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−15
15 Author: Date:
1996 TOYOTA T100 (RM449U)
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the TOYOTA T100. In general, the ECU controlled
system is considered to be a very intricate system requiring a high level of technical knowledge and expert
skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshoot-
ing of these systems is not complex. If you have adequate understanding of the system and a basic knowl-
edge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem.
This manual is designed through emphasis of the above standpoint to help service technicians perform ac-
curate and effective troubleshooting, and is compiled for the following major ECU controlled systems:
SystemPage
1. 3RZ−FE EngineDI−1
2. 5VZ−FE EngineDI−127
3. Automatic TransmissionDI−263
4. Anti−Lock Brake systemDI−319
5. Supplemental Restraint SystemDI−363
6. Cruise ControlDI−408
The troubleshooting procedure and how to make use of it are described on the above pages.

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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)

Downloaded from www.Manualslib.com manuals search engine IN02L−01
− INTRODUCTIONTERMS
IN−31
31 Author: Date:
1996 TOYOTA T100 (RM449U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti−Lock Brake System
A.D.D.Automatic Disconnecting Differential
A/TAutomatic Transmission
AT FAutomatic Transmission Fluid
BTDCBefore Top Dead Center
Calif.California
CBCircuit Breaker
Diff.LockDifferential Locking System
DPDash Pot
ECUElectronic Control Unit
E/GEngine
ELREmergency Locking Retractor
ESAElectronic Spark Advance
EXExhaust (Manifold, Valve)
FIPGFormed in Place Gasket
FLFusible Link
FPUFuel Pressure Up
FrFront
IGIgnition
INIntake (Manifold, Valve)
J/BJunction Block
LHLeft−Hand
LLCLong Life Coolant (Year Around Coolant)
LSPVLoad Sensing Proportioning Valve
Max.Maximum
Min.Minimum
MPMultipurpose
M/TManual Transmission
O/D, ODOverdrive
OHCOver Head Camshaft
O/SOversize
PCVPositive Crankcase Ventilation
PSPower Steering
RHRight−Hand
RrRear
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
SWSwitch
TDCTop Dead Center
TEMP.Temperature

Downloaded from www.Manualslib.com manuals search engine IN−34
− 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