TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P04690
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.

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IG−5
1145 Author: Date:
1996 TOYOTA T100 (RM449U)
(e) Inspect primary coil resistace.
Using an ohmmeter, measure resistance between the
positive (+) and negative (−)terminals.
Primary coil resistance:
Cold: 0.36 − 0.55 kΩ
Hot: 0.45 − 0.65 kΩ
If the resistance is not as specified, replace the ignition coil.
(f) Inspect secondary coil resistance.
Usibg anohmmeter, measure resistance between posi-
tive (+) and high−tension terminals.
Secondary coil resistance:
Cold: 9.0 − 15.4 kΩ
Hot: 11.4 − 18.1 kΩ
If the resistance is not as specified, replace the ignition coil.
5. INSPECT DISTRIBUTOR
(a) Inspect the air gap.
Using a feeler gange, measure the air gap between the
signal rotor and pickup coil projection.
Air gap: 0.2 − 0.4 mm (0.008 − 0.016 in.)
If the air gap is not as specified, replace the distributor housing
assembly.
(b) Inspect signal generator (pickup coil) resistance. .
Using an ohmmeter, measure resistance between termi-
nals
Pickup coil resistance:
Cold: G (+) and G (−): 185 − 275 Ω
Hot: G (+) and G (−): 240 − 325 Ω
If the resistance is not as specified, replace the distributor hous-
ing assembly.

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P20586P20938B11227
IG−6
− IGNITION (3RZ−FE)DISTRIBUTOR
1146 Author: Date:
1996 TOYOTA T100 (RM449U)
DISTRIBUTOR
COMPONENTS

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− IGNITION (3RZ−FE)DISTRIBUTOR
IG−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT DISTRIBUTOR CONNECTOR
2. DISCONNECT HIGH−TENSION CORDS FROM DIS-
TRIBUTOR CAP (See page IG−1)
3. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise until the timing mark
is aligned with ”0” mark on the oil pump cover.
(b) Remove the 3 bolts and distributor cap.
(c) Check that distributor rotor direction is as shown. If not,
turn the crankshaft pulley one complete revolution.
4. REMOVE DISTRIBUTOR
(a) Remove the 2 mounting bolts, and pull out the distributor.
(b) Remove the O−ring from the distributor housing.

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IG−8
− IGNITION (3RZ−FE)DISTRIBUTOR
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE ROTOR
2. REMOVE IGNITION COIL DUST COVER
(a) Remove the dust cover.
(b) Remove the dust proof packing.
HINT:
At the time of reassembly, please refer to the following item. Use
new dust proof packing.
3. REMOVE IGNITION COIL
(a) Remove the 2 nuts, and disconnect the 3 wires from the
ignition coil terminals.
NOTICE:
At the time of reassembly, please refer to the following
items.
When connecting the wires to the ignition coil, insert
the properly into the groove found on the side of the
ignition coil.
Be sure the wire do not contact with signal rotor or
distributor housing.
(b) Remove the 4 screws and ignition coil.
NOTICE:
At the time of reassembly, please refer to the following
items.
Apply seal packing to the ignition coil installing serface of
the housing, as shown in the illustration.
Seal packing: Part No. 08826 − 00080 or equivalent

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IG−9
1996 TOYOTA T100 (RM449U)
4. REMOVE SIGNAL GENERATOR (PICKUP COIL)
(a) Remove the 2 screws.
NOTICE:
At the time of reassembly, please refer to the following
items.
Be sure that the wires do not contact with the signal
rotor.
Align the rotor tooth with the pickup coil.
Using a thickness gauge, set the air gap and tighten
the 2 screws.
Air gap: 0.2 − 0.4 mm (0.008 − 0.016 in.)
(b) Remove the signal generator (pickup coil) from the distrib-
utor housing.
5. REMOVE CONDENSER
Remove the screw and condenser.

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IG−10
− IGNITION (3RZ−FE)DISTRIBUTOR
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SHAFT
Turn the shaft and check that it is not rough or worn.
If it feels rough or worn, replace the distributor housing assem-
bly.

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− IGNITION (3RZ−FE)DISTRIBUTOR
IG−11
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page IG−8)

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IG−12
− IGNITION (3RZ−FE)DISTRIBUTOR
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. CHECK NO. 1 CYLINDER TO TDC/COMPORESSION
If necessary, remove the cylinder head cover, and check these
conditions:
Turn the crankshaft pulley clockwise and align its
groove with the timing mark ”0” of the oil pump cov-
er.
Verify that the timing marks with 1 and 2 dots are in
straight line on the cylinder head surface as shown
in the illustration.
If not, turn the crankshaft 1 revolition (360 °) and align the mark
as above.
2. INSTALL DISTRIBUTOR
(a) Install a new O−ring to the distributor.
HINT:
Always use a new O−ring when installing the distributor.
(b) Align the protrusion of the distributor housing with the
groove on the driven gear.
(c) Apply a light coat of engine oil on the O−ring.
(d) Install the distributor with the 2 bolts.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
3. INSTALL DISTRIBUTOR CAP
4. RECONECT HIGH−TENSION CORDS TO DISTRIBU-
TOR CAP
5. CONNECT DISTRIBUTOR CONNECTOR
6. CHECK IGNITION TIMING (See page EM−11)