spark plugs replace TOYOTA T100 1996 Factory Service Manual

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P08488
Back Front
− MAINTENANCEENGINE
MA−5
40 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE
INSPECTION
HINT:
Inspect these items when the engine is cold.
1. (5VZ−FE ENGINE)
REPLACE TIMING BELT
(See page EM−11 )
2. INSPECT DRIVE BELTS
GENERATOR:
(3RZ−FE: See page CH−2)
(5VZ−FE: See page CH−1)
PS:
(3RZ−FE: See page SR−3)
(5VZ−FE: See page SR−3)
A/C:
(3RZ−FE: See page AC−14)
(5VZ−FE: See page AC−14)
3. REPLACE SPARK PLUGS
(3RZ−FE: See page IG−1)
(5VZ−FE: See page IG−1)
4. INSPECT AIR FILTER
(a) Visually check that the air cleaner element is not exces-
sively dirty, damaged or oily.
HINT:
Oiliness may indicate a stuck PCV valve.
If necessary, replace the air cleaner element.
(b) Clean the element with compressed air.
First blow from back side thoroughly, then blow off the
front side of the element.
5. REPLACE AIR FILTER
Replace the used air cleaner element with a new one.
6. REPLACE ENGINE OIL AND OIL FILTER
(3RZ−FE: See page LU−3)
(5VZ−FE: See page LU−3)
7. REPLACE ENGINE COOLANT
(3RZ−FE: See page CO−2)
(5VZ−FE: See page CO−
2)
8. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT,
RHODE ISLAND and NEW HAMPSHIRE:
INSPECT CHARCOAL CANISTER
(3RZ−FE: See page EC−5)
(5VZ−FE: See page EC−5)
9. REPLACE GASKET IN FUEL TANK CAP
(3RZ−FE: See page EC−5)
(5VZ−FE: See page EC−5)

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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 IG0L9−01
CHECK CONNECTION OF IGNITION COIL ANDIGNITER AND DISTRIBUTOR CONNECTOR
SPARK TEST
CHECK RESISTANCE OF HIGH−TENSION
TRY ANOTHER IGNITER Maximum resistance; 25 kΩ per cord CORD (See step 2.)
CHECK POWER SUPPLY TO IGNITION COIL
AND IGNITER
1. Turn ignition switch to ON.
2. Check that there is battery voltage at
ignition coil positive (+) terminal.
Check wiring between ECM, distributor
CHECK RESISTANCE OF IGNITION COIL(See step 4)
Resistance:Cold
SecondaryHot
9.0 − 15.4 kΩ11.4 − 18.1 kΩ
GENERATOR (PICKUP COIL)
(See step 5)
Resistance: Cold
G and GHot
185 − 275 Ω240 − 325 Ω CHECK RESISTANCE OF SIGNAL
POSITION SENSOR
(See page IG−14)
Resistance: Cold
NE and NEHot
1,630 − 2,740 Ω2,065 − 3,225 Ω CHECK RESISTANCE OF CRANKSHAFT
CHECK IGT SIGNAL FROM ECM
(See page DI−103)
OK NO
BAD
OK
OK
OK
OK
OK
Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
Replace the ignition coil.
Replace the distributor housing as-
sembly.
Replace the crankshaft position sensor.
and igniter, and then try another ECM.
BAD
BAD
BAD
BAD
BAD
BAD Primary0.36 − 0.55 Ω0.45 − 0.65 Ω
Replace the distributor housing assembly.
CHECK AIR GAP OF DISTRIBUTOR (See page DI−103)
BAD Air gap: 0.2 − 0.4 mm (0.008 − 0.016 in.)
OK
− IGNITION (3RZ−FE)IGNITION SYSTEM
IG−1
1141 Author: Date:
1996 TOYOTA T100 (RM449U)
IGNITION SYSTEM
ON−VEHICLE INSPECTION
NOTICE:
”Cold” and ”Hot” in the following sentences express the temperature of the coils themselves. ”Cold” is from
−10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F).
1. INSPECT IGNITOR AND SPARK TEST
Check that the spark occurs.
(1) Disconnect the high−tension cords from the spark plugs.
(2) Remove the spark plugs.
(3) Install the spark plugs to each high−tension cord.
(4) Ground the spark plug.
(5) Check if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1
− 2 seconds at a time.
If the spark does not occur, perform the test as follows:

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A01709
A01710
16 mm Plug Wrench
− IGNITION (3RZ−FE)IGNITION SYSTEM
IG−3
1143 Author: Date:
1996 TOYOTA T100 (RM449U)
(i) Using an ohmmeter, measure the resistance.
Maximum resistance: 25 kΩ per cord
If the resistance is greater than the maximum, check the termi-
nals.
If necessary, replace the high−tension cord.
(j) Connect the high−tension cords to the distributor cap. As-
semble the holder and grommet.
HINT:
Connect the high−tension cords to the distributor cap as shown
in the illustration.
NOTICE:
Check that the holder is correctly installed to the grommet
and distributor cap as shown in the illustration.
(k) Check that the lock claw of the holder is engaged by lightly
pulling the holder.
(l) Connect the high−tension cords to the spark plugs.
Secure the high−tension cords with the clamps as shown
in the illustration.
(m) Install the intake air connector.
(n) Install the air cleaner cap and MAF meter assembly.
3. INSPECT SPARK PLUGS
(a) Disconnect the high−tension cords from the spark plugs.
(b) Using a 16 mm plug wrench, remove the spark plug.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

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P03783
P03792
P04690
CORRECT
WRONG IG−4
− IGNITION (3RZ−FE)IGNITION SYSTEM
1144 Author: Date:
1996 TOYOTA T100 (RM449U)
(c) Using a spark plug cleaner or wire brush, clean the spark
plug.
(d) Check the spark plug for electrode wear, threads damage
and insulator damage.
If abnormal, replace the plugs.
Recommended spark plugs:
ND: K16R−U
NGK: BKR5EYA
(e) Carefully bend the outer electrode to obtain the correct
electrode gap.
Correct electrode gap: 0.8 mm (0.031 in.)
(f) Using a 16 mm plug wrench, install the spark plug.
Torque:
20 N·m (200 kgf·cm, 14 ft·lbf)
(g) Connect the high−tension cords to the spark plugs.
NOTICE:
Check that the holder is correctly installed to the grommet
and ignition coil as shown in the illustration.
(h) Check that the lock claw of the holder is engaged by lightly
pulling the holder.
4. INSPECT IGNITION COIL
NOTICE:
”Cold” and ”Hot” in these sentences express the tempera-
ture of the coils them selves.
”Cold” is from − 10 °C (14 °F) to 50 °C (104 °F) and ”Hot”
is from 50 °C (104 °F) to 100 °C (212 °F)
(a) Disconnect the distributor connctor.
(b) Remove the distributor cap.
(c) Remove the rotor.
(d) Remove the ignition coil dust cover.

Downloaded from www.Manualslib.com manuals search engine P23940
P20581
P20439
Ohmmeter IG−2
− IGNITION (5VZ−FE)IGNITION SYSTEM
1157 Author: Date:
1996 TOYOTA T100 (RM449U)
2. INSPECT HIGH−TENSION CORDS
(a) Remove the air cleaner cap and MAF meter assembly.
(b) Disconnect the high−tension cords from the spark plugs.
Disconnect the high−tension cords at the rubber boot.
DO NOT pull on the cords.
NOTICE:
Pulling on or bending the cords may damage the conduc-
tor inside.
(c) Disconnect the high−tension cords from the ignition coils.
(1) Using a screwdriver, lift up the lock claw and discon-
nect the holder from the ignition coils.
(2) Disconnect the high−tension cord at the grommet.
DO NOT pull on the cord.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.Do not wipe any of the oil from the grommet after the
high−tension cord is disconnected.
(d) Inspect the high−tension cord resistance.
Using an ohmmeter, measure the resistance.
Maximum resistance:
25 kΩ per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high−tension cord.

Downloaded from www.Manualslib.com manuals search engine P20430
16 mm Plug Wrench
IG0152
P20433
P20584
IG−4
− IGNITION (5VZ−FE)IGNITION SYSTEM
1159 Author: Date:
1996 TOYOTA T100 (RM449U)
3. INSPECT SPARK PLUGS
(a) Remove the high−tension cords and ignition coils.
(b) Remove the spark plugs.
Using a 16 mm plug wrench, remove the 6 spark plugs
from the RH and LH cylinder heads.
(c) Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry
and then clean with a spark plug cleaner.
Air pressure:
Below 588 kPa (6 kgf/cm
2, 85 psi)
Duration:
20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
(d) Visually inspect the spark plugs.
Check the spark plug for thread damage and insulator
damage.
If abnormal, replace the spark plug.
Recommended spark plug:
ND: K16TR11
NGK: BKR5EKB−11
(e) Adjust the electrode gap.
Carefully bend the outer electrode to obtain the correct
electrode gap.
Correct electrode gap:
1.1 mm (0.043 in.)
(f) Reinstall the spark plugs.
Torque:18 N·m (180 kgf·cm, 13 ft·lbf)
(g) Reinstall the ignition coils. (See page IG−8)
(h) Reconnect the high−tension cords.
4. INSPECT IGNITION COIL
(a) Remove the air cleaner cap and MAF meter assembly.
(b) Disconnect the high−tension cords from the ignition coils.
(c) Disconnect the ignition coil connectors.