light TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine W03156
Column UpperParking Lock Cable
Torx Screw
Steering Wheel Lower
No.2 Cover
Control Shaft AssemblySteering Wheel
Steering Wheel
Steering Wheel Lower
No.3 Cover
Torx Screw
Combination Switch
(w/ Spiral Cable)
Column lower Cover
Light Control Rheostat
Front Door Scuff Steering Column
Assembly Control Shaft
 Locking
Column Hole
Sliding w/ Shaft York
Sub−Assembly
Lower Finish Panel No.1
Engine Hood Release Intermediate
Shaft Assembly
Register No.2 Duct Heater toPlatePad
Lever Cover
Wire
Cover
Lever AT:
For 2WD
Intermediate
Shaft Assembly
Cowl Side Trimx6
Non−reusable part35 (360, 26)
9.0 (90, 78 in.·lbf)
35 (360, 26)
35 (360, 26)
35 (360, 26)
35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
25 (260, 19)
25 (260, 19)
9.0 (90, 78 in.·lbf)
SR07C−01
− STEERINGTILT STEERING COLUMN
SR−23
1697 Author: Date:
1996 TOYOTA T100 (RM449U)
TILT STEERING COLUMN
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine W03157
Cover
Pad
Plate
Lever MT:
For 2WDSteering Column AssemblySteering Wheel Steering Wheel
Steering Wheel Lower
No.3 Cover
Torx Screw
Combination Switch
(w/ Spiral Cable)
Column Lower Cover
Light Control Rheostat
Front Door Scuff x7
Sliding w/ Shaft York
Sub−Assembly
Lower Finish Panel No.1 Column Hole CoverColumn Upper
Torx Screw
Steering Wheel Lower
No.2 Cover
Intermediate
Engine Hood Release Shaft Assembly
Duct Heater to
Register No.2
Intermediate
Shaft Assembly
Cowl Side Trim 9.0 (90, 78 in.·lbf)
35 (360, 26)
: Specified torque
N·m (kgf·cm, ft·lbf)
25 (260, 19)
9.0 (90, 78 in.·lbf)
35 (360, 26)
35 (360, 26)
35 (360, 26)
SR−24
− STEERINGTILT STEERING COLUMN
1698 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine W03535
R15213
Tilt Pawl
Alignment Mark
Tilt Pawl Stopper
SR3128
”A” ”A”
Mark
− STEERINGTILT STEERING COLUMN
SR−31
1996 TOYOTA T100 (RM449U)
7. INSTALL 2 TILT PAWLS
Install the pawl to the column upper tube and temporarily install
the washer with the bolt and nut.
HINT:
Install the pawl pin into the long hole of the tilt lever/tilt sub lever.
8. ENGAGE AND ADJUST 2 TILT PAWLS
(a) Engage the tilt sub lever side pawl to the center of the
ratchet.
(b) While turning the tilt lever side collar, engage the tilt lever
side pawl to the ratchet completely.
(c) Torque the nut.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(d) Check that the pawls rotate smoothly.
9. SELECT 2 TILT PAWL STOPPERS
(a) With the tilt pawl and ratchet engaged, install the 2 pawl
stoppers.
(b) Check that the alignment marks on the stopper and pawl
align when the stopper is lightly rotated to the pawl side.
(c) If the alignment marks are not align, select pawl stopper
according to the following table.
Right pawl stopperLeft pawl stopperDimension ”A”
mm (in.)
1A12.68 − 12.74
(0.4992 − 0.5016)
2B12.61 − 12.67
(0.4965 − 0.4988)
3C12.54 − 12.60
(0.4937 − 0.4961)
4D12.47 − 12.53
(0.4909 − 0.4933)
5E12.40 − 12.46
(0.4882 − 0.4906)
6F12.33 − 12.39
(0.4854 − 0.4878)
7G12.26 − 12.32
(0.4827 − 0.4850)
(d) After selecting the stoppers, check that the pawl and
ratchet are fully engaged.
10. INSTALL 2 TILT PAWL STOPPERS
11. INSTALL 2 TILT LEVER RETAINERS
(a) Install the tilt lever retainer and torque the nut.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(b) Install a new E−ring.
12. INSTALL COMPRESSION SPRING
(a) Install the 2 bushings to the compression spring.
(b) Install the spring with the bolt.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine RS03H−01
− SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS−1
1768 Author: Date:
1996 TOYOTA T100 (RM449U)
SRS AIRBAG
PRECAUTION
NOTICE:
The TOYOTA T100 is equipped with SRS, which comprises a driver airbag. Failure to carry out
service operations in the correct sequence could cause the SRS to unexpectedly deploy during
servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the
SRS, it is possible that the SRS may fail to operate when required. Before performing servicing
(including removal or installation of parts, inspection or replacement), be sure to read the fol-
lowing items carefully, then follow the correct procedures described in the repair manual.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting. When troubleshooting the SRS, always in-
spect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, air-
bag sensor assembly and front airbag sensor should be inspected (See page RS−9, RS−23 and
RS−28).
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, airbag sensor assembly or front airbag
sensor in order to reuse it.
If the steering wheel pad, airbag sensor assembly or front airbag sensor has been dropped, or
if there are cracks, dents or other defects in the case, bracket or connector, replace them with
new ones.
Use a volt/ohmmeter with high impedance ( 10 kΩ/V minimum) for troubleshooting the system’s
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions on the notices.
After work on the SRS is completed, perform the SRS warning light check or SRS side airbag
warning light check (See page DI−365).
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
CAUTION:
Work must be started after 90 seconds from when the ignition switch is turned to the ”LOCK”
position and the negative (−) terminal cable is disconnected from the battery.
(The SRS is equipped with a back−up power source so that if work is started within 90 seconds
from disconnecting the negative (−) terminal cable of the battery, the SRS may be deployed.)
When the negative (−) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as they
were before and adjust the clock. To avoid erasing the memory in each memory system, never
use a back− up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Do not expose the steering wheel pad, airbag sensor assembly or front airbag sensor directly
to hot air or flames.

Downloaded from www.Manualslib.com manuals search engine RS03I−03
R07746
AB0250Spiral Cable
Z09709
w/ Tachometer:
w/o Tachometer:
R12497
RS−2
− SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
1996 TOYOTA T100 (RM449U)
OPERATION
1. STEERING WHEEL PAD (with AIRBAG)
The inflater and bag of the SRS are stored in the steering wheel
pad and cannot be disassembled. The inflater contains a squib,
igniter charge, gas generant, etc., and inflates the bag when
instructed by the airbag sensor assembly.
2. SPIRAL CABLE (in COMBINATION SWITCH)
A spiral cable is used as an electrical joint from the vehicle body
side to the steering wheel.
3. SRS WARNING LIGHT
The SRS warning light is located on the combination meter. It
goes on to alert the driver of trouble in the system when a mal-
function is detected in the airbag sensor assembly. In normal
operation conditions when the ignition switch is turned to the
ACC or ON position, the light goes on for about 6 seconds and
then goes off.
4. AIRBAG SENSOR ASSEMBLY
The airbag sensor assembly is mounted on the floor inside the
lower center cover. The airbag sensor assembly consists of an
airbag sensor, safing sensor, diagnosis circuit, ignition control,
drive and circuit, etc.
It receives signals from the airbag sensor and judges whether
the SRS must be activated or not.

Downloaded from www.Manualslib.com manuals search engine AB0158
Battery
SST
AB0152
SST
AB0158
Battery
SST
H01580
SST
RS−12
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 TOYOTA T100 (RM449U)
1. AIRBAG DEPLOYMENT WHEN SCRAPPING VE-
HICLE
HINT:
Have a battery ready as the power source to deploy the airbag.
(a) Check functioning of SST
CAUTION:
When deploying the airbag, always use the specified SST:
SRS Airbag Deployment Tool.
SST 09082−00700
(1) Connect the SST battery.
Connect the red clip of the SST to the battery posi-
tive (+) terminal and the black clip to the battery neg-
ative (−) terminal.
HINT:
Do not connect the yellow connector which will be connected
with the supplemental restraint system.
(2) Check functioning of SST.
Press the SST activation switch, and check that the
LED of the SST activation switch lights up.
CAUTION:
If the LED lights up when the activation switch is not being
pressed, SST malfunction is probable, so definitely do not
use the SST.
(b) Install the SST.
CAUTION:
Check that there is no looseness in the steering wheel and
steering wheel pad.
(1) Disconnect the airbag connector of the spiral cable.

Downloaded from www.Manualslib.com manuals search engine SST
R13455
SSTBattery
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−13
1996 TOYOTA T100 (RM449U)
(2) Connect the SST connector to the airbag connector
of the spiral cable.
SST 09082−00700
(3) Move the SST at least 10 m (33 ft) away from the
front of the vehicle.
(4) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST wire harness.
(5) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the negative (−) termi-
nal.
(c) Deploy the airbag.
(1) Check that no one is inside the vehicle or within 10
m (33 ft) area around the vehicle.
(2) Press the SST activation switch and deploy the air-
bag.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
(d) Dispose of steering wheel pad (with airbag).
CAUTION:
The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.
Use gloves and safety glasses when handling a steer-
ing wheel pad with deployed airbag.
Always wash your hands with water after completing
the operation.
Do not apply water, etc. to a steering wheel pad with
deployed airbag.
(1) When scrapping a vehicle, deploy the airbag and
scrap the vehicle with the steering wheel pad still
installed.
(2) When moving a vehicle for scrapping which has a
steering wheel pad with deployed airbag, use
gloves and safety glasses.

Downloaded from www.Manualslib.com manuals search engine R04211
Inner Diam.
Tires
(3 or More)Width
H00400
10 m (33 ft) or more
AB0166
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−17
1996 TOYOTA T100 (RM449U)
Covering method using tires:
Place at least 3 tires without disc wheel on top of the
disc wheel with the tire to which the steering wheel
pad is tied.
Tire size: Must exceed the following dimensions−
Width: 185 mm (7.87 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.
NOTICE:
The tires may be marked by the airbag deployment, so use
the redundant tires.
(g) Deploy the airbag.
(1) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the battery negative
(−) terminal.
(2) Check that no one is within 10 m (33 ft) area around
the disc wheel which the steering wheel pad is tied
to.
(3) Press the SST activation switch and deploy the air-
bag.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
(h) Dispose of the steering wheel pad (with airbag)
CAUTION:
The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.
Use gloves and safety glasses when handling a steer-
ing wheel pad with deployed airbag.
Always wash your hands with water after completing
the operation.

Downloaded from www.Manualslib.com manuals search engine RS03Z−02
R12498
SRS Warning Light
Steering Wheel Pad
(with Airbag) Front Airbag Sensor RH
Front Airbag Sensor LH
Spiral Cable
Center Airbag Sensor Assembly
− SUPPLEMENTAL RESTRAINT SYSTEMWIRE HARNESS AND CONNECTOR
RS−31
1798 Author: Date:
1996 TOYOTA T100 (RM449U)
WIRE HARNESS AND CONNECTOR
LOCATION

Downloaded from www.Manualslib.com manuals search engine BE – BODY ELECTRICAL

BODY ELECTRICAL SYSTEM BE-1
POWER SOURCE BE-10
IGNITION SWITCH AND KEY UNLOCK
WARNING SWITCH BE-11
HEADLIGHT AND TAILLIGHT SYSTEM BE-14
TURN SIGNAL AND HAZARD
WARNING SYSTEM BE-22
INTERIOR LIGHT SYSTEM BE-24
BACK-UP LIGHT SYSTEM BE-26
STOP LIGHT SYSTEM BE-29
WIPER AND WASHER SYSTEM BE-31
COMBINATION METER BE-35
POWER WINDOW CONTROL SYSTEM BE-46
POWER DOOR LOCK CONTROL
SYSTEM BE-50
POWER MIRROR CONTROL SYSTEM BE-56
AUDIO SYSTEM BE-59
ANTENNA BE-81
CLOCK BE-83