TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SS016−04
− SERVICE SPECIFICATIONSIGNITION (5VZ−FE)
SS−31
205 Author: Date:
1996 TOYOTA T100 (RM449U)
IGNITION (5VZ−FE)
SERVICE DATA
Firing order−1 − 2 − 3 − 4 − 5 − 6
Spark plugRecommended spark plug ND
NGK
Correct electrode gap for new plugK16TR11
BKR5EKB−11
1.1 mm (0.043 in.)
Ignition coilPrimary coil resistance Cold
Hot
Secondary coil resistance Cold
Hot0.67 − 1.05 Ω
0.85 − 1.23 Ω
9.3 −16.0 kΩ
11.7 − 18.8 kΩ
Camshaft position
sensorResistance Cold
Hot835 − 1,400 Ω
1,060 − 1,645 Ω
Crankshaft posi-
tion sensorResistance Cold
Hot1,630 − 2,740 Ω
2,065 − 3,225 Ω

Downloaded from www.Manualslib.com manuals search engine SS017−01
SS−32
− SERVICE SPECIFICATIONSIGNITION (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Spark plug x Cylinder head1818013
Ignition coil x Cylinder head7.88069 in.·lbf
Camshaft position sensor x Cylinder head7.88069 in.·lbf
Crankshaft position sensor x Oil pump7.88069 in.·lbf

Downloaded from www.Manualslib.com manuals search engine SS09E−02
− SERVICE SPECIFICATIONSSTARTING (3RZ−FE)
SS−33
207 Author: Date:
1996 TOYOTA T100 (RM449U)
STARTING (3RZ−FE)
SERVICE DATA
Starter
(1.2 kW,
1.4 kW type)Rated voltage and output power
No−load characteristicsCurrent
rpm
Brush length STD
Minimum
Spring installed load
1.2 kW type STD
Minimum
1.4 kW type STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runoutMaximum
Magnetic switch
Contact plate for wearMaximum12 V 1.2 kW, 1.4 kW
90 A or less at 11.5 V
3,000 rpm or more
15.5 mm (0.610 in.)
10.0 mm (0.394 in.)
13.7 − 19.6 N (1.40 − 2.00 kgf, 3.1 − 4.4 lbf)
9.8 N (1.00 kgf, 2.2 lbf)
17.6 − 23.5 N (1.80 − 2.40 kgf, 4.0 − 5.3 lbf)
11.8 N (1.20 kgf, 2.6 lbf)
30.0 mm (1.18 in.)
29.0 mm (1.14 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)
Starter
(1.8 kW,
2.0 kW type)
Rated voltage and output power
No−load characteristicsCurrent
rpm
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runoutMaximum
Magnetic switch
Contact plate for wearMaximum12 V 1.8 kW, 2.0 kW
100 A or less at 11.5 V
2,500 rpm or more
15.0 mm (0.591 in.)
9.0 mm (0.354 in.)
21.5 − 27.5 N (2.20 − 2.80 kgf, 4.9 − 6.2 lbf)
12.7 N (1.30 kgf, 2.7 lbf)
35.0 mm (1.38 in.)
34.0 mm (1.34 in.)
0.7 mm (0.028 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)

Downloaded from www.Manualslib.com manuals search engine SS09F−02
SS−34
− SERVICE SPECIFICATIONSSTARTING (3RZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Starter mounting bolt3940029
Starter wire mounting nut8.89078 in.·lbf
Lead wire x Terminal C of starter5.96052 in.·lbf
Field frame x Starter housing 1.2 kW, 1.4 kW type
1.8 kW, 2.0 kW type5.9
9.360
9552 in.·lbf
82 in.·lbf
Starter housing x Magnetic switch 1.2 kW, 1.4 kW type
1.8 kW, 2.0 kW type5.9
9.360
9552 in.·lbf
82 in.·lbf
End cover x Field frame 1.2 kW, 1.4 kW type
1.8 kW, 2.0 kW type1.5
3.815
3913 in.·lbf
34 in.·lbf
Terminal nut x Terminal 30 of starter1717012
Terminal nut x Terminal C of starter1717012
Magnetic switch end cover x Magnetic switch 1.2 kW, 1.4 kW type
1.8 kW, 2.0 kW type2.5
3.625
3522
30

Downloaded from www.Manualslib.com manuals search engine SS01A−11
− SERVICE SPECIFICATIONSSTARTING (5VZ−FE)
SS−35
209 Author: Date:
1996 TOYOTA T100 (RM449U)
STARTING (5VZ−FE)
SERVICE DATA
Starter
(1.4 kW type)
Rated voltage and output power
No−load characteristicsCurrent
rpm
Brush length STD
Minimum
Spring installed load
1.2 kW type STD
Minimum
1.4 kW type STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runoutMaximum
Magnetic switch
Contact plate for wearMaximum12 V 1.2 kW 1.4 kW
90 A or less at 11.5 V
3,000 rpm or more
15.5 mm (0.610 in.)
10.0 mm (0.394 in.)
13.7 − 19.6 N (1.40 − 2.00 kgf, 3.1 − 4.4 lbf)
9.8 N (1.00 kgf, 2.2 lbf)
17.6 − 23.5 N (1.80 − 2.40 kgf, 4.0 − 5.3 lbf)
11.8 N (1.20 kgf, 2.6 lbf)
30 mm (1.180 in.)
29 mm (1.140 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)
Starter
(1.8 kW type)Rated voltage and output power
No−load characteristicsCurrent
rpm
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runoutMaximum
Magnetic switch
Contact plate for wearMaximum12 V 1.8 kW
100 A or less at 11.5 V
2,500 rpm or more
15.0 mm (0.591 in.)
9.0 mm (0.354 in.)
21.5 − 27.5 N (2.20 − 2.80 kgf, 4.9 − 6.2 lbf)
12.7 N (1.30 kgf, 2.7 lbf)
35 mm (1.380 in.)
34 mm (1.340 in.)
0.7 mm (0.028 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)

Downloaded from www.Manualslib.com manuals search engine SS01B−08
SS−36
− SERVICE SPECIFICATIONSSTARTING (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Starter wire mounting nut8.89078 in.·lbf
Starter mounting bolt3940029
Lead wire x Terminal C of starter5.96052 in.·lbf
Field frame, Magnetic switch x Starter housing 1.2 kW, 1.4 kW type
1.8 kW type5.9
9.360
9552 in.·lbf
82 in.·lbf
End cover x Field frame 1.2 kW, 1.4 kW type
1.8 kW type1.5
3.815
3913 in.·lbf
34 in.·lbf
Terminal nut x Terminal C of starter, Terminal 30 of starter1717012
Magnetic switch end cover x Magnetic switch 1.2 kW, 1.4 kW type
1.8 kW type2.5
3.625
3522 in.·lbf
30 in.·lbf

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 SS09H−02
SS−38
− SERVICE SPECIFICATIONSCHARGING (3RZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Drive end frame x Rectifier end frame4.54640 in.·lbf
Generator pulley x Rotor11 01,12581
Rectifier holder x Coil lead on rectifier end frame2.02017 in.·lbf
Rear end cover x Rectifier holder4.54640 in.·lbf
Terminal insulator x Rectifier holder4.141.536 in.·lbf
Pivot bolt (For generator) Generator x Generator bracket5960043
Lock bolt (For generator) Generator x Adjusting bar2930021
Bearing retainer x Drive end frame2.62723 in.·lbf
Voltage regulator and brush holder x Rectifier end frame2.02017 in.·lbf

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 SS01B−09
SS−40
− SERVICE SPECIFICATIONSCHARGING (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Bearing retainer x Drive end frame2.62723 in.·lbf
Rectifier end frame x Drive end frame4.54640 in.·lbf
Generator pulley x Rotor11 01,12581
Rectifier holder x Coil lead on rectifier end frame2.02017 in.·lbf
Voltage regulator and brush holder x Rectifier end frame2.02017 in.·lbf
Rear end cover x Rectifier holder4.54640 in.·lbf
Terminal insulator x Rectifier holder4.141.536 in.·lbf
Generator x Generator bracket (3RZ−FE)5960043
Generator x Adjusting bar (3RZ−FE)2930021
Generator x Generator bracket (5VZ−FE)5152038
Generator x Adjusting bar (5VZ−FE)18.518514