TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine CO05D−01
P14832
CO−8
− COOLING (3RZ−FE)THERMOSTAT
1996 TOYOTA T100 (RM449U)
REMOVAL
HINT:
Removal of the thermostat would have an adverse effect, caus-
ing a lowering of cooling efficiency. Do not remove the thermo-
stat, even if the engine tends to overheat.
1. DRAIN ENGINE COOLANT
2. DISCONNECT RADIATOR OUTLET HOSE
3. REMOVE WATER INLET AND THERMOSTAT
(a) Remove the 2 nuts holding the water inlet to the inlet
housing, and disconnect the water inlet from the inlet
housing.
(b) Remove the thermostat.
(c) Remove the gasket from the thermostat.

Downloaded from www.Manualslib.com manuals search engine P14835
CO05E−02
P11706
P14836
8 mm
− COOLING (3RZ−FE)THERMOSTAT
CO−9
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening tempera-
ture.
(a) Immerse the thermostat in water and gradually heat the
water.
(b) Check the valve opening temperature.
Valve opening temperature:
80 − 84°C (176 − 183°F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Check the valve lift.
Valve lift:
8 mm (0.31 in.) or more at 95°C (203°C)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve spring is tight when the thermostat
is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.

Downloaded from www.Manualslib.com manuals search engine CO05F−01
P14834
P14833
15°15° CO−10
− COOLING (3RZ−FE)THERMOSTAT
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER INLET HOUSING
(a) Install a new gasket onto the thermostat.
(b) Align the thermostat jiggle valve with the protrusion of the
water inlet housing, and insert the thermostat in the water
inlet housing.
HINT:
The jiggle valve may be set within 15° of either side of the pre-
scribed position.
2. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque:20 N·m (200 kgf·cm, 15 ft·lbf)
3. CONNECT RADIATOR OUTLET HOSE
4. FILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine CO05G−02
− COOLING (3RZ−FE)RADIATOR
CO−11
1080 Author: Date:
1996 TOYOTA T100 (RM449U)
RADIATOR
ON−VEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTICE:
If using a high pressure type cleaner, be careful not to deform the fins of the radiator core (i.e. Main-
tain a distance between the cleaner nozzle and radiator core).

Downloaded from www.Manualslib.com manuals search engine CO05H−02
Z02362
Radiator Cap Tester
Radiator Cap
P14849Radiator Cap Tester
CO−12
− COOLING (3RZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)
ON−VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:
If the radiator cap has contaminations,always rinse it with
water.
Using a radiator cap tester, pump the tester and measure the
relief valve opening pressure.
Standard opening pressure:
74 − 103 kPa (0.75 − 1.05 kgf/cm
2, 10.7 − 14.9 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than standard, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP

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S06060
− COOLING (3RZ−FE)RADIATOR
CO−13
1996 TOYOTA T100 (RM449U)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine P21703
Radiator Cap
Upper Tank
 Tank Plate
 O−Ring
 O−RingCore
 Tank Plate
Lower Tank
 O−Ring Drain Cock
 Non−reusable part CO−14
− COOLING (3RZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine CO18O−01
P14852
P14853
P20975
− COOLING (3RZ−FE)RADIATOR
CO−15
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE BATTERY
3. REMOVE RADIATOR GRILLE
(a) Remove the 4 screws, and clearance lights.
(b) Remove the 4 screws, 11 clips and radiator grille.
4. DISCONNECT RADIATOR INLET HOSE
5. DISCONNECT RADIATOR RESERVOIR HOSE
6. REMOVE PS DRIVE BELT
Loosen the lock bolt and adjusting bolt, and remove the drive
belt.
7. w/ A/C:
REMOVE A/C DRIVE BELT
Loosen the idler pulley nut and adjusting bolt, and remove the
drive belt.
8. REMOVE DRIVE BELT, FAN WITH FLUID COUPLING,
WATER PUMP PULLEY AND FAN SHROUD (See page
CO−4)
9. A/T:
DISCONNECT OIL COOLER HOSES
10. DISCONNECT RADIATOR OUTLET HOSE
11. REMOVE RADIATOR
Remove the 4 bolts and radiator.
12. REMOVE RADIATOR SUPPORTS
M/T:
Remove the 4 bolts and 2 radiator supports.
A/T:
Remove the 8 bolts and 2 radiator supports.

Downloaded from www.Manualslib.com manuals search engine CO05K−02
P08306
P08307 CO0041B02539
87
51 632 4
SST
Tank
Tank Plate
P14857
P14855
CO−16
− COOLING (3RZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. M/T:
REMOVE TANK PLATE
(a) Raise the claws of the tank plates with SST in the numeri-
cal order shown in the illustration.
SST 09230 − 00010 (09231 − 00010, 09231 − 00020,
09231 − 00030 09231 − 00040, 09231 − 00050)
NOTICE:
Be careful not to damage the core plate.
(b) Pull the tank plates outward.
2. M/T:
REMOVE TANK
(a) Pull the tank upward.
(b) Remove the O−ring.

Downloaded from www.Manualslib.com manuals search engine CO05L−02
CO0989
Core Plate
CoreCore Plate
P14856
CO0317O−Ring  Normal
X Twisted
X Twisted
P14854
− COOLING (3RZ−FE)RADIATOR
CO−17
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. M/T:
INSTALL OIL COOLER TO LOWER TANK
Clean the O−ring contact surface of the lower tank.
2. M/T:
CHECK CORE PLATE FOR DAMAGE
HINT:
If the sides of the core plate groove are deformed, reas-
sembly of the tank will be impossible. Therefore, first cor-
rect any deformation with pliers.
Water leakage will result if the bottom of the core plate
groove is damaged or dented. Therefore, repair or re-
place if necessary.
3. M/T:
INSTALL TANK
Install a new O−ring and the tank.
HINT:
Clean the tank and core plate.
Take out any twists.
4. M/T:
INSTALL TANK PLATE
Insert new tank plates from both ends in the direction of the
arrows. Firmly set the tank plates in the core plate.