TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SR072−01
R07281
Normal Abnormal SR−4
− STEERINGPOWER STEERING FLUID
1678 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL (See page SR−5)
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock
several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the wheel to left or right full
lock and keep it there for 2 − 3 seconds, then turn the
wheel to the opposite full lock and keep it there for 2 − 3
seconds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL (See page SR−5)

Downloaded from www.Manualslib.com manuals search engine SR2267
SR073−04
R07281
Normal Abnormal
R11361
5 mm (0.2 in.)
or less
Engine Idling Engine Stopped
− STEERINGPOWER STEERING FLUID
SR−5
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON®II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir cap dipstick. If the fluid is cold, check that it is within
the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem.
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system.
(i) Check the fluid level.

Downloaded from www.Manualslib.com manuals search engine R14116
Attachment
PS Vane Pump SST
Pressure Feed Tube OUTSST 3RZ−FE 5VZ−FE
ININOUT
AttachmentAttachment
Attachment Pressure Feed Tube PS Vane Pump SR−6
− STEERINGPOWER STEERING FLUID
1996 TOYOTA T100 (RM449U)
2. CHECK STEERING FLUID PRESSURE
(a) 5VZ−FE Engine:
Remove the 5 bolts and air cleaner assembly.
(b) Disconnect the pressure feed tube from the PS vane
pump.
(3RZ−FE Engine: See page SR−36)
(5VZ−FE Engine: See page SR−46)
(c) Connect SST, as shown bellow.
SST 09640−10010 (09641−01010, 09641−01030,
09641−01060)
NOTICE:
Check that the valve of the SST is in the open position.
(d) Bleed the power steering system.
(See page SR−4)
(e) Start the engine and run it at idle.
(f) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)

Downloaded from www.Manualslib.com manuals search engine Z15498
Oil
Reservoir
PS Vane
Pump Closed
SST PS Gear
Z15499
PS GearOil
Reservoir
PS Vane
Pump Open
SST
Z15500
Oil
Reservoir
PS Vane
Pump Lock Position
PS Gear
Open
SST
− STEERINGPOWER STEERING FLUID
SR−7
1996 TOYOTA T100 (RM449U)
(g) With the engine idling, close the valve of the SST and ob-
serve the reading on the SST.
3RZ−FE and 5VZ−FE (2WD) Engines:
Minimum fluid pressure:
7,845 kPa (80 kgf/cm
2, 1138 psi)
5VZ−FE (4WD) Engine:
Minimum fluid pressure:
8,336 kPa (85 kgf/cm
2, 1209 psi)
NOTICE:
Do not keep the valve closed for more than 10 se-
conds.
Do not let the fluid temperature become too high.
(h) With the engine idling, open the valve fully.
(i) Measure the fluid pressure at engine speeds of 1,000 rpm
and 3,000 rpm.
3RZ−FE and 5VZ−FE Engines:
Difference fluid pressure:
490 kPa (5 kgf/cm
2, 71 psi) or less
NOTICE:
Do not turn the steering wheel.
(j) With the engine idling and valve fully opened, turn the
wheel to full lock.
3RZ−FE and 5VZ−FE (2WD) Engines:
Minimum fluid pressure:
7,845 kPa (80 kgf/cm
2, 1138 psi)
5VZ−FE (4WD) Engine:
Minimum fluid pressure:
8,336 kPa (85 kgf/cm
2, 1209 psi)
NOTICE:
Do not maintain lock position for more than 10 se-
conds.
Do not let the fluid temperature become too high.
(k) Disconnect the SST.
(l) Connect the pressure feed tube.
(3RZ−FE Engine: SR−43)
(5VZ−FE Engine: SR−53)
(m) 5VZ−FE Engine:
Install the air cleaner and 3 bolts.
(n) Bleed the power steering system.
(See page SR−4)

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SR−8
− STEERINGAIR CONTROL VALVE
1682 Author: Date:
1996 TOYOTA T100 (RM449U)
AIR CONTROL VALVE
INSPECTION
1. TURN AIR CONDITIONING SWITCH OFF
2. CHECK IDLE−UP
(a) Start the engine and run it at idle.
(b) Fully turn the steering wheel.
(c) Check that the engine rpm decreases when the vacuum
hose is pinched.
(d) Check that the engine rpm increases when the hose is re-
leased.

Downloaded from www.Manualslib.com manuals search engine R07653
SR0097
SR075−01
R09732
− STEERINGSTEERING WHEEL
SR−9
1683 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING WHEEL
INSPECTION
1. CHECK THAT STEERING WHEEL FREEPLAY IS COR-
RECT
With the vehicle stopped and tires pointed straight ahead, rock
the steering wheel gently back and forth with light finger pres-
sure.
Freeplay should not exceed the maximum.
Maimum freeplay: 30 mm (1.18 in.)
4WD:
If the freeplay exceeds the maximum, adjust it in the following
procedure.
2. 4WD:
ADJUST STEERING GEAR
(a) Point the front wheels straight ahead.
(b) Loosen the adjusting screw lock nut.
(c) Turn the sector shaft adjusting screw clockwise to de-
crease steering wheel freeplay and counterclockwise to
increase it.
HINT:
Turn the adjusting screw in small increments and check the
freeplay between each adjustment.
(d) Turn the steering wheel half way around in both direc-
tions.
Check the the freeplay is correct and steering is smooth
and without rough spots.
(e) Torque the adjusting screw lock nut (See page SR−80).
3. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b) Remove the steering wheel pad (See page SR−13).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Reference: 8.3 N·m (85 kgf·cm, 73 in.·lbf)
HINT:
Be sure to consider the tire type, pressure and contact surface
before making your diagnosis.
(e) Torque the steering wheel set nut.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
(f) Install the steering wheel pad (See page SR−20).

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AT:
For 2WDParking Lock Cable
Steering Wheel
Steering Wheel Torx Screw
Steering Wheel Lower
No.2 CoverPad Control Shaft Column Upper
Cover
Lever
 Locking
Wire
Column Hole
CoverSteering Column Assembly
Steering Wheel Lower
No.3 Cover
Torx Screw
Combination Switch
(w/ Spiral Cable)
Column Lower Cover
Light Control Rheostat
Front Door Scuff
Plate Sliding w/ Shaft York
Sub−Assembly
Lower Finish Panel No.1
Intermediate
Shaft Assembly
Engine Hood Release
Lever
Duct Heater to
Register No.2
Intermediate
Shaft Assembly
Cowl Side Trim
 Non−reusable partControl Shaft Assembly
x35 (360, 26)
25 (260, 19)
35 (360, 26)
35 (360, 26)
35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
9.0 (90, 78 in.·lbf)
9.0 (90, 78 in.·lbf)
SR076−01
SR−10
− STEERINGNON−TILT STEERING COLUMN
1684 Author: Date:
1996 TOYOTA T100 (RM449U)
NON−TILT STEERING COLUMN
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine W03128
MT:
Column Upper
Cover
Torx Screw
Steering Wheel
Pad
Steering Wheel
Steering Wheel Lower
No.3 Cover
Torx Screw
Combination Switch
(w/ Spiral Cable)
Column Lower Cover
Light Control Rheostat
Front Door Scuff
Plate Steering Wheel Lower
No.2 Cover
Steering Column Assembly
Column Hole Cover
x7
Engine Hood Release
LeverLower Finish Panel No.1Sliding w/ Shaft York
Sub−Assembly
Intermediate
Shaft Assembly
Duct Heater to
Register No.2
Cowl Side Trim Intermediate
Shaft Assembly For 2WD9.0 (90, 78 in.·lbf)35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
9.0 (90, 78 in.·lbf)
25 (260, 19)
35 (360, 26)
35 (360, 26)
35 (360, 26)
− STEERINGNON−TILT STEERING COLUMN
SR−11
1685 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine Z18646
A/T:Key Cylinder
Key Unlock
Warning Switch
Ignition Switch
Column Upper
BracketKey Cylinder
Column Upper Bracket
Column Tube
Key Unlock
Warning Switch
Ignition Switch
 Bushing
Column Upper Clamp
 Tapered−Head Bolt
 Snap Ring
Main Shaft Assembly
Non−reusable part
Molybdenum disulfide lithium base grease 
35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
SR−12
− STEERINGNON−TILT STEERING COLUMN
1686 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine SR077−01
R07659
Torx Screw Screw Case
Z14903
Airbag Connector
Correct Wrong
R00606
R09597
R11211
Matchmarks SST
− STEERINGNON−TILT STEERING COLUMN
SR−13
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE STEERING WHEEL PAD
NOTICE:
If the airbag connector is disconnected with the igni-
tion switch at ON or ACC, DTCs will be recorded.
Never use airbag parts from another vehicle. When
replacing parts, replace with new parts.
(a) Place the front wheels facing straight ahead.
(b) Remove the steering wheel lower No.2 and No.3 covers.
(c) Using a torx socket wrench, loosen the 2 torx screws.
HINT:
Loosen the 2 screws until the groove along the screw circumfer-
ence catches on the screw case.
(d) Pull the wheel pad out from the steering wheel and dis-
connect the airbag connector.
CAUTION:
When storing the wheel pad, keep the upper surface
of the pad facing upward.
Never disassemble the wheel pad.
NOTICE:
When removing the wheel pad, take care not to pull the air-
bag wire harness.
2. REMOVE STEERING WHEEL
(a) Disconnect the connector.
(b) Remove the steering wheel set nut.
(c) Place matchmarks on the steering wheel and main shaft.
(d) Using SST, remove the wheel.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05020, 09954−05020)