TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine ST03C−03
P20438Battery
Terminal 50Terminal C
P20449
P20448
P20447
Terminal 30
Ammeter
ST−14
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL−IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD−IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (−) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (−) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO−LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
reads the specified current.
Specified current:
1.2 kW, 1.4 kW type
90 A or less at 11.5 V
1.8 kW type
100 A or less at 11.5 V

Downloaded from www.Manualslib.com manuals search engine ST03D−02
− STARTING (5VZ−FE)STARTER
ST−15
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page ST−3).

Downloaded from www.Manualslib.com manuals search engine ST03E−03
P02536
Continuity
No continuity
P02537
Ohmmeter
Battery Continuity ST−16
− STARTING (5VZ−FE)STARTER RELAY
1202 Author: Date:
1996 TOYOTA T100 (RM449U)
STARTER RELAY
INSPECTION
1. REMOVE STARTER RELAY (Marking: ”ST”)
LOCATION: The relay is located in the No.1 junction block on
the driver’s side.
2. INSPECT STARTER RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity be-
tween terminals 1 and 2.
If there is no continuity, replace the relay.
(b) Check that there is no continuity between terminals 3 and
5.
If there is continuity, replace the relay.
3. INSPECT STARTER RELAY OPERATION
(a) Apply battery voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is continuity be-
tween terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY

Downloaded from www.Manualslib.com manuals search engine CH – CHARGING (3RZ-FE)

CHARGING SYSTEM CH-1
GENERATOR CH-6

Downloaded from www.Manualslib.com manuals search engine CH02A−01
− CHARGING (3RZ−FE)CHARGING SYSTEM
CH−1
1203 Author: Date:
1996 TOYOTA T100 (RM449U)
CHARGING SYSTEM
PRECAUTION
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.

Downloaded from www.Manualslib.com manuals search engine S05619
Upper Level
Lower Level
Except Delco Battery
CH02B−03
B01312
B02086
and Delco Battery CH−2
− CHARGING (3RZ−FE)CHARGING SYSTEM
1996 TOYOTA T100 (RM449U)
ON−VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Maintenance−Free Battery:
If under the lower level, replace the battery (or add distilled wa-
ter if possible). Check the charging system.
Except Maintenance−Free Battery:
If under the lower level, add distilled water.
2. Except Maintenance−Free Battery:
CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity:
1.25 − 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.
3. Maintenance−Free Battery:
CHECK BATTERY VOLTAGE
(a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, turn the ignition switch ON and turn on the electrical
system (headlight, blower motor, rear defogger etc.) for
60 seconds to remove the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
tems.
(c) Measure the battery voltage between the negative (−)
and positive (+) terminals of the battery.
Standard voltage:
12.7 − 12.9 V at 20°C (68°F)
HINT:
Before measuring the voltage, turn the ignition switch
OFF and turn off the electrical systems (headlight, blower
motor, rear defogger etc.) for 60 seconds to remove the
surface charge.
If the vehicle has been running, wait 20 minutes or more
after the vehicle stops before measuring the battery volt-
age.
If the voltage is less than specification, charge the battery.
HINT:
Check the indicator as shown in illustration.

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CH0743
Delco Battery
Green Dot Dark Clear
P06717
− CHARGING (3RZ−FE)CHARGING SYSTEM
CH−3
1996 TOYOTA T100 (RM449U)
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
(b) Check the fusible link and fuses for continuity.
5. Delco Battery:
CHECK HYDROMETER
Green Dot visible:
Battery is adequately charged.
Dark (Green Dot not visible):
Battery must be charged.
Clear or Light Yellow:
Replace battery.
HINT:
There is no need to add water during the entire service life of
the battery.
6. INSPECT DRIVE BELT
(a) Visually check the belt for excessive wear, frayed cords
etc.
HINT:
Cracks on the ribbed side of the belt are considered acceptable.
If the belt has chunks missing from the ribs, it should be re-
placed.

Downloaded from www.Manualslib.com manuals search engine Z00038
Nippondenso
Borroughs
P06723
CORRECT WRONG
B02087
CH−4
− CHARGING (3RZ−FE)CHARGING SYSTEM
1996 TOYOTA T100 (RM449U)
(b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG 20 (95506−00020) or
Borroughs No. BT−33−73F
Drive belt tension:
New belt
175 ± 5 lbf
Used belt
115 ± 20 lbf
If necessary, adjust the drive belt tension.
HINT:
”New belt” refers to a belt which has been used less than
5 minutes on a running engine.
”Used belt” refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
After installing the drive belt, check that it fits properly in
the ribbed grooves. Check with your hand to confirm that
the belt has not slipped out of the groove on the bottom
of the crank pulley.
After installing a new belt, run the engine for approx. 5
minutes and then recheck the tension.
7. VISUALLY CHECK GENERATOR WIRING AND LIS-
TEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
8. INSPECT DISCHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the discharge
warning light comes on.
(b) Start the engine. Check that the light goes off.
If the light does not operate as specified, troubleshoot the dis-
charge warning light circuit.
9. CHECK CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit according to the manufacturers instruc-
tions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:
Disconnect the wire from terminal B of the generator
and connect the wire to the negative (−) terminal of
the ammeter.

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Terminal F
− CHARGING (3RZ−FE)CHARGING SYSTEM
CH−5
1996 TOYOTA T100 (RM449U)
Connect the test lead from the positive (+) terminal
of the ammeter to terminal B of the generator.
Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
Ground the negative (−) lead of the voltmeter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage:
10 A or less
Standard voltage:
At 25 °C (77°F): 14.0 − 15.0 V
At 115 °C(239 °F): 13.5 − 14.3 V
If the voltage reading is greater than standard voltage, replace
the voltage regulator.
If the voltage reading is less than standard voltage, check the
voltage regulator and generator as follows:
With terminal F grounded, start the engine and
check the voltage reading of terminal B.
If the voltage reading is higher than standard volt-
age, replace the voltage regulator.
If the voltage reading is less than standard voltage,
repair the generator.
10. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater fan control switch
to HI.
(b) Check the reading on the ammeter.
Standard amperage:
30 A or more
If the ammeter reading is less than standard amperage, repair
the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

Downloaded from www.Manualslib.com manuals search engine CH02C−03
Z14840
CH−6
− CHARGING (3RZ−FE)GENERATOR
1208 Author: Date:
1996 TOYOTA T100 (RM449U)
GENERATOR
COMPONENTS