belt TOYOTA T100 1996 Factory User Guide

Downloaded from www.Manualslib.com manuals search engine SS09G−02
− SERVICE SPECIFICATIONSCHARGING (3RZ−FE)
SS−37
211 Author: Date:
1996 TOYOTA T100 (RM449U)
CHARGING (3RZ−FE)
SERVICE DATA
BatteryStandard voltage at 20°C (68°F)12.5 −12.9 V
Drive belt
Tension
New belt
Used belt
175 ± 51 lbf
115 ± 20 lbf
GeneratorRated output
Rotor coil resistance
Slip ring diameter STD
Minimum
Brush exposed length STD
Minimum12 V − 60 A
2.8 − 3.0 Ω
14.2 mm − 14.4 mm (0.559 − 0.567 in.)
12.8 mm (0.504 in.)
10.5 mm (0.413 in.)
1.5 mm (0.059 in.)
Voltage
regulatorRegulating voltage at 25 °C (77 °F)
at 115 °C (239 °F)14.0 − 15.0 V
13.5 − 14.3 V

Downloaded from www.Manualslib.com manuals search engine SS01A−12
− SERVICE SPECIFICATIONSCHARGING (5VZ−FE)
SS−39
213 Author: Date:
1996 TOYOTA T100 (RM449U)
CHARGING (5VZ−FE)
SERVICE DATA
BatteryVoltage at 20 °C (68 °F)12.7 − 12.9 V
Drive beltTension
New belt 3RZ−FE
5VZ−FE
used belt 3RZ−FE
5VZ−FE
175 ± 5 lbf
160 ± 20 lbf
115 ± 20 lbf
100 ± 20 lbf
GeneratorRated output
Rotor coil resistance
Slip ring diameter STD
Minimum
Brush exposed length STD
Minimum12 V − 60 A
2.8 − 3.0 Ω
14.2 mm − 14.4 mm (0.559 − 0.567 in.)
12.8 mm (0.504 in.)
10.5 mm (0.413 in.)
1.5 mm (0.059 in.)
Voltage regulatorRegulating voltage at 25 °C (77 °F)
at 115 °C (239 °F)14.0 − 15.0 V
13.5 − 14.3 V

Downloaded from www.Manualslib.com manuals search engine SS08W−01
− SERVICE SPECIFICATIONSSTEERING
SS−71
245 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING
SERVICE DATA
ON−VEHICLE INSPECTION
Steering wheel freeplayMaximum30 mm (1.18 in.)
3RZ−FE:
Drive belt tension New belt135−185 lbf
Drive belt tension Used belt80−120 lbf
Oil level rise MaximumBelow 5 mm (0.20 in.)
5VZ−FE:
Drive belt tension New belt135−180 lbf
Drive belt tension Used belt85−120 lbf
Oil level rise MaximumBelow 5 mm (0.20 in.)
3RZ−FE and 5VZ−FE (2WD):
Oil pressure at idle speed with valve closedMinimum7,845 kPa (80 kgf/cm2, 1,138 psi)
5VZ−FE (4WD):
Oil pressure at idle speed with valve closedMinimum8,336 kPa (85 kgf/cm2, 1,209 psi)
Steering effort at idle speedMaximum8.3 N·m (85 kgf·cm, 73 in.·lbf)
TILT STEERING COLUMN
Pawl stopper
1 or A12.68 − 12.74 mm (0.4992 − 0.5016 in.)
2 or B12.61 − 12.67 mm (0.4965 − 0.4988 in.)
3 or C12.54 − 12.60 mm (0.4937 − 0.4961 in.)
4 or D12.47 − 12.53 mm (0.4909 − 0.4933 in.)
5 or E12.40 − 12.46 mm (0.4882 − 0.4906 in.)
6 or F12.33 − 12.39 mm (0.4854 − 0.4878 in.)
7 or G12.26 − 12.32 mm (0.4827 − 0.4850 in.)
PS VANE PUMP
3RZ−FE and 5VZ−FE:
Pump shaft and front housing bushing oil clearance STD0.03−0.05 mm (0.0012−0.0020 in.)
Pump shaft and front housing bushing oil clearanceMaximum0.07 mm (0.0028 in.)
Vane plate heightMinimum8.6 mm (0.339 in.)
Vane plate thicknessMinimum1.397 mm (0.0550 in.)
Vane plate lengthMinimum14.991 mm (0.5902 in.)
Vane plate and pump rotor groove clearanceMaximum0.035 mm (0.0014 in.)
Vane plate length Pump rotor and cam ring mark
None14.999−15.001 mm (0.59051−0.59059 in.)
114.997−14.999 mm (0.59043−0.59051 in.)
214.995−14.997 mm (0.59035−0.59043 in.)
314.993−14.995 mm (0.59027−0.59035 in.)
414.991−14.993 mm (0.59020−0.59027 in.)
Flow control valve spring lengthMinimum32.3 mm (1.272 in.)
Pump rotating torqueMaximum0.25 N·m (2.5 kgf·cm, 2.2 in.·lbf) or less
PS GEAR
2WD:
Steering rack runoutMaximum0.3 mm (0.0118 in.)

Downloaded from www.Manualslib.com manuals search engine SS08Y−02
SS−80
− SERVICE SPECIFICATIONSBODY
254 Author: Date:
1996 TOYOTA T100 (RM449U)
BODY
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
FRONT BUMPER−−−
Front bumper arm x Body6162045
Bumper side support x Bumper arm131309
HOOD−−−
Hood hinge x Hood1414510
Hood lock x Body1919514
FRONT DOOR−−−
Door hinge x Body2526019
Door hinge x Door panel2526019
Door lock x Door panel5.96052 in.·lbf
Window regulator x Door panel5.45548 in.·lbf
FRONT WIPER AND WASHER−−−
Wiper arm x Wiper link2020415
TAIL GATE−−−
Tail gate lock striker x Body121209
Tail gate lock x Tail gate121209
Tail gate hinge x Tail gate1818513
FRONT SEAT (Bench Type)−−−
Seat track x Body3737527
Seat track x Seatback1818513
Outer track x Seat cushion frame1818513
Inner track x Seat cushion frame1818513
FRONT SEAT (Split Bench Type)−−−
Seat track x Body3737527
Seat adjuster x Seatback1818513
Outer track x Seat cushion frame1818513
Inner track x Seat cushion frame1818513
Seat adjuster x Seat cushion frame1818513
Inner track x Seat back frame12.51309.5
REAR SEAT−−−
Back panel trim x Body9.81007
Seat cushion x Body9.81007
SEAT BELT−−−
Front Seat Belt−−−
Adjustable anchor x Body4344032
Shoulder anchor x Adjustable anchor4344032
ELR x Body4344032
Lap outer anchor x Body4344032
Inner belt x Body4344032
Rear Seat Belt−−−
Shoulder anchor x Body4344032
ELR x Body4344032

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSBODY
SS−81
255 Author: Date:
1996 TOYOTA T100 (RM449U)Part tightened
N·mkgf·cmft·lbf
Lap outer anchor x Body4344032
Inner belt x Body4344032

Downloaded from www.Manualslib.com manuals search engine SS08B−03
SS−82
− SERVICE SPECIFICATIONSAIR CONDITIONING
256 Author: Date:
1996 TOYOTA T100 (RM449U)
AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume650 ± 50 g (22.92 ± 1.76 oz.)
Drive belt tension−
New belt160 ± 25 lbf
Used belt100 ± 20 lbf
Idle−up speed−
3RZ − FE900 rpm
5VZ − FE850 rpm
Magnetic clutch clearance 0.5 ± 0.15 mm (0.020 ± 0.0059 in.)

Downloaded from www.Manualslib.com manuals search engine EM06Z−03
P14842
Adjusting Bolt
Lock Bolt
Pivot Bolt
P14935
P14907A03721
P14953
EM−14
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE OIL
2. DRAIN ENGINE COOLANT
3. REMOVE CYLINDER HEAD
(See page EM−28)
4. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
5. w/ A/C:
REMOVE A/C COMPRESSOR DRIVE BELT
Loosen the idler pulley nut and adjusting bolt, and remove the
drive belt.
6. REMOVE DRIVE BELT, FAN WITH FLUID
COUPLING, WATER PUMP PULLEY AND FAN
SHROUD
(a) Stretch the belt and loosen the water pump pulley mount-
ing nuts.
(b) Loosen the lock, pivot and adjusting bolts of the genera-
tor, and remove the drive belts.
(c) Remove the 4 water pump pulley mounting nuts.
(d) Pull out the fan with fluid coupling and water pump pulley.
(e) Remove the No.2 fan shroud.
(f) Remove the 4 bolts and No.1 fan shroud.
7. w/ A/C:
DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Remove the 4 mounting bolts, and disconnect the com-
pressor from the bracket.
HINT:
Put a side the compressor, and suspend it.
(b) Remove the 4 bolts and A/C compressor bracket.
8. REMOVE GENERATOR, ADJUSTING BAR AND
BRACKET
(a) Remove the lock, pivot bolts and the generator.
(b) Remove the bolt and adjusting bar.
(c) Remove the 3 bolts and bracket.
9. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts and crankshaft position sensor.
(b) Remove the O−ring from the crankshaft position sensor.

Downloaded from www.Manualslib.com manuals search engine P14907A03766
P14935
P14842
Adjusting Bolt
Lock Bolt
Pivot Bolt
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−25
1996 TOYOTA T100 (RM449U)
(c) Install the generator with the pivot bolt and lock bolt.
13. w/ A/C:
INSTALL A/C COMPRESSOR AND BRACKET
(a) Install the A/C compressor bracket with the 4 bolts.
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
(b) Install the A/C compressor with the 4 bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
14. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN
WITH FLUID COUPLING AND DRIVE BELT
(a) Place the fan with fluid coupling, water pump pulley and
fan shroud in position.
(b) Temporarily install the water pump pulley mounting nuts.
(c) Install the No.1 fan shroud with the 4 bolts.
(d) Install the No.2 fan shroud with the 2 clips.
(e) Install the drive belts with the adjusting bolt and pivot bolt.
(f) Stretch the belt tight and tighten the 4 water pump pulley
mounting nuts.
Torque: 21 N·m (210 kgf·cm, 16 ft·lbf)
(g) Adjust the drive belts.
15. w/ A/C:
INSTALL A/C COMPRESSOR DRIVE BELT
Install and adjust the drive belt (See page CH−2).
16. INSTALL ENGINE UNDER COVER
Install the engine under cover with the bolts.
17. INSTALL CYLINDER HEAD (See page EM−50)
18. START ENGINE AND CHECK FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine EM1OK−01
P14841
Adjust Bolt
Lock Bolt
P15755SST
EM−28
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
(a) Disconnect the MAF meter connector, IAT sensor con-
nector and wire clamp.
(b) Loosen the air cleaner hose clamp.
(c) Loosen the 4 clips, and remove the air cleaner cap, MAF
meter and resonator.
3. M/T:
DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
4. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the 2 air hoses and VS hose.
(b) Remove the 2 bolts, hose clamp and intake air connector.
5. REMOVE PS PUMP DRIVE BELT AND IDLER PULLEY
(a) Loosen the lock bolt and adjusting bolt and remove the
drive belt.
(b) Remove the 3 bolts and idler pulley.
6. REMOVE PS PUMP AND BRACKET
(a) Using SST, remove the nut and PS pump pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Disconnect the 2 air hoses from air intake chamber.
(c) Remove the 2 bolts, and disconnect the PS pump.
(d) Remove the 4 bolts and PS pump bracket.
7. REMOVE NO.1 AND NO.2 PCV HOSES

Downloaded from www.Manualslib.com manuals search engine P15813
P15755SST
P14841
Adjusting Bolt
Look Bolt
P24651
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−59
1996 TOYOTA T100 (RM449U)
ECT sensor connector
Oil pressure sensor connector
w/ A/C:
A/C compressor connector
28. INSTALL THROTTLE BODY (See page MF−30)
29. INSTALL WATER OUTLET
(a) Install a new gasket and water outlet with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Connect the ECT sender gauge connector.
(c) Connect the radiator inlet hose.
30. INSTALL IGNITION COIL.
31. INSTALL NO.1 AND NO.2 PCV HOSES
32. INSTALL PS PUMP AND BRACKET
(a) Install the PS pump bracket with the 4 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Connect the PS pump to the bracket with the 2 bolts.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(c) Connect the 2 air hoses to the intake chamber.
(d) Using SST, install the PS pump pulley with the nut.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
33. INSTALL PS PUMP DRIVE BELT AND IDLER
PULLEY
(a) Install the idler pulley with the 3 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Install and adjust drive belt (See page CH−2).
34. INSTALL AIR INTAKE CONNECTOR
(a) Install the air intake connector with the 2 bolts and hose
clamp.
(b) Connect the 2 air hoses.
35. M/T:
CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
36. A/T:
CONNECT THROTTLE AND ACCELERATOR CABLES
TO THROTTLE BODY