light TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine N06234
Oil Pressure Gauge
Ignition
Switch
BatteryTest Bulb
(3.4W)
Z09833
w/ TachometerAB
BE4917
Test LED
Battery
BE1217
Ignition
Switch
BatteryWarning Light
BE2570
ONOFF
− BODY ELECTRICALCOMBINATION METER
BE−43
1996 TOYOTA T100 (RM449U)
(c) Ground terminal on the wire harness side connector
through a 3.4 W test bulb.
(d) Turn the ignition ON, check that the bulb lights up and the
receiver gauge needle moves to the high side.
If resistance value is not as specified, replace the receiver
gauge.
16. INSPECT OIL PRESSURE RECEIVER GAUGE RESIS-
TANCE
Measure the resistance between terminals A and B.
Resistance: Approx. 25.0 Ω
If resistance value is not as specified, replace the receiver
gauge.
17. INSPECT OIL PRESSURE SENDER GAUGE OPERA-
TION
(a) Disconnect the connector from the sender gauge.
(b) Apply battery positive voltage to the sender gauge termi-
nal through a test LED.
(c) Check that the bulb does not light when the engine is
stopped.
(d) Check that the LED flashes when the engine is running.
The number of flashes should vary with the engine speed.
If operation is not as specified, replace the sender gauge.
18. INSPECT BRAKE WARNING LIGHT
(a) Disconnect the connectors from the level warning switch
and parking brake switch.
(b) Connect terminals on the wire harness side connector of
the level warning switch connector.
(c) Turn the ignition switch ON, check that the warning light
lights up.
If the warning light does not light up, test the bulb.
19. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
(a) Check that there is no continuity between terminals with
the switch OFF (float up).
(b) Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.

Downloaded from www.Manualslib.com manuals search engine N06136
ON
OFF
BE1217
Warning Light
Ignition
Switch
Battery
N07797
ONOFF
N13155
Warning Light
Ignition
Switch
Battery
N06137
ON
OFF BE−44
− BODY ELECTRICALCOMBINATION METER
1996 TOYOTA T100 (RM449U)
20. INSPECT PARKING BRAKE SWITCH
(a) Check that there is continuity between terminals with the
switch ON (switch pin released).
(b) Check that there is no continuity between terminals with
the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch.
21. INSPECT WASHER LEVEL WARNING LIGHT
(a) Disconnect the connectors from the level warning switch
and parking brake switch.
(b) Connect terminals on the wire harness side connector of
the level warning switch connector.
(c) Remove the CHARGE fuse and turn the ignition switch
ON, check that the warning light come on.
If the warning light does not light up, test the bulb.
22. INSPECT WASHER LEVEL SWITCH
(a) Check that there is no continuity between terminals with
the switch OFF (float up).
(b) Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.
23. INSPECT SEAT BELT WARNING LIGHT
(a) Remove the integration relay from the junction block
No.1.
(b) Ground terminal 9 on the junction block side connector.
(c) Turn the ignition switch ON, check that the warning light
lights up.
If the warning light does not light up, inspect the bulb or wire har-
ness.
24. INSPECT BUCKLE SWITCH CONTINUITY
(a) Check that there is continuity between terminals on the
switch side connector with the switch ON (belt unfas-
tened).
(b) Check that there is no continuity between terminals on the
switch side connector with the switch OFF (belt fastened).
If operation is not as specified, replace the seat belt inner.

Downloaded from www.Manualslib.com manuals search engine N12611
N12612
Z04393
4WD Indicator Light
(Wire Harness Side) Ignition
Switch
Battery
BE3241
OFF
ON
Z04394
Test Bulb
(3.4W)
Bright
Extinguished
Dark
− BODY ELECTRICALCOMBINATION METER
BE−45
1996 TOYOTA T100 (RM449U)
25. INSPECT INTEGRATION RELAY SEAT BELT WARN-
ING SYSTEM OPERATION
(a) Connect the positive (+) lead from the battery to terminals
3 and 9.
(b) Connect the terminal 8 to terminal 9 through the 3.4 W test
bulb.
(c) Connect the negative (−) lead from the battery to terminal
7.
(d) Check that the bulb lights and the buzzer sounds.
(e) Return to step (a), and operate the buzzer again.
(f) Connect the negative (−) lead from the battery to terminal
6.
(g) Check that the buzzer stops sounding.
HINT:
Check the buzzer within a period of 4 to 8 seconds.
If operation is not as specified, replace the relay.
26. INSPECT INTEGRATION RELAY CIRCUIT (See page
BE−12)
27. INSPECT 4WD INDICATOR LIGHT
(a) Disconnect the connector from the 4WD indicator switch.
Connect the switch terminal 2 and body ground.
(b) Turn the ignition switch on. Check that the bulb lights up.
If operation is not as specified, remove and test the bulb.
28. INSPECT 4WD INDICATOR SWITCH
(a) Check that the there is continuity when the switch pin is
pushed.
(b) Check that there is no continuity when the switch is free.
If operation is not as specified, replace the switch.
29. INSPECT LIGHT CONTROL RHEOSTAT
(a) Connect terminals 1 and 3 through a 3.4 W test bulb.
(b) Connect the positive (+) lead from the battery to terminal
1 and the negative (−) lead to terminal 2.
(c) Turn the rheostat knob fully counterclockwise, check that
the test bulb goes out.
(d) Gradually turn the rheostat knob clockwise, check that
the test bulb brightness changes from dark to bright.
If operation is not as specified, replace the rheostat.

Downloaded from www.Manualslib.com manuals search engine BE03H−03
Z09299
Left/Light
Adjustment
Switch
Control Switch
Z04379
Z04380
− BODY ELECTRICALPOWER MIRROR CONTROL SYSTEM
BE−57
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT MIRROR SWITCH CONTINUITY
Left side:
Switch positionTester connectionSpecified condition
UP3 − 4
1 − 8Continuity
DOWN1 − 3
4 − 8Continuity
LEFT3 − 4
1 − 7Continuity
RIGHT1 − 3
4 − 7Continuity
Right side:
Switch positionTester connectionSpecified condition
UP3 − 4
1 − 5Continuity
DOWN1 − 3
4 − 5Continuity
LEFT3 − 4
1 − 6Continuity
RIGHT1 − 3
4 − 6Continuity
If continuity is not as specified, replace the switch.
2. INSPECT MIRROR MOTOR OPERATION
(a) Connect the positive (+) lead from the battery to terminal
3 and negative (−) lead to terminal 1. Check that the mirror
turns to left side.
(b) Remove the polarity, check that the mirror turns to right
side.

Downloaded from www.Manualslib.com manuals search engine BO0DV−02
H16111
Side Mounting Bracket
Bumper Arm
Front Bumper
Front Balance Panel
Turn Signal Light CushionSide Mounting BracketBumper Arm
Cushion
Turn Signal Light
61 (620,45)
61 (620,45)
N·m (kgf·cm,ft·lbf) : Specigied torque BO−4
− BODYFRONT BUMPER
1888 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BUMPER
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BO0FD−02
BO0632
BO0633
15°
45°
N15359
BO−50
− BODYSEAT BELT
1996 TOYOTA T100 (RM449U)
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts
or nuts and sill−bar) if it has been used in a severe impact.
The entire assembly should be replaced even if damage is
not obvious.
1. All seat belts:
RUNNING TEST (IN SAFE AREA)
(a) Fasten the seat belts.
(b) Drive the car at 10 mph (16 km/h) and make a very hard
stop.
(c) Check that the seat belt is locked and cannot be extended
at this time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. All seat belts:
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.
3. Except driver’s seat belt:
STATIC TEST
(a) Pull out the whole belt, release it slightly and then pull it
out again.
(b) Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.
4. Manual type seat belt:
TEST
(a) Adjust the belt to the proper length.
(b) Apply a firm load to the belt.
(c) Make sure that the belt does not extend.

Downloaded from www.Manualslib.com manuals search engine I01386
I01387
Condition : Periodically cools and then fails to cool AC−4
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TOYOTA T100 (RM449U)
2. INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
This is a method in which the trouble is located by using a man-
ifold gauge set. Read the manifold gauge pressure when these
conditions are established.
Test conditions:
Temperature at the air inlet with the switch set
at RECURC is 30 − 35 °C (86 − 95 °F)
Engine running at 1500 rpm
Blower speed control switch on ”HI” position
Temperature control dial on ”COOL” position
HINT:
It should be noted that the gauge indications may vary slightly
due to ambient temperature conditions.
(1) Normally functioning refrigeration system.
Gauge reading:
Low pressure side:
0.15 − 0.25 MPa (1.5 − 2.5 kgf/cm
2)
High pressure side:
1.37 − 1.57 MPa (14 − 16 kgf/cm
2)
(2) Moisture present in refrigeration system.
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side sometimes become
a vacuum and sometime normal
Moisture entered in refrigeration
system freezes at expansion valve
orifice and temporarily stops cycle,
but normal state is restored after a
time when the ice melts Drier in oversaturated state
 Moisture in refrigeration system
freezes at expansion valve orifice
and blocks circulation of refriger-
ant(1) Replace receiver
(2) Remove moisture in cycle
through repeatedly evacuating air
(3) Charge proper amount of new
refrigerant

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I02282
OFF ON
64
I02283
OFF ON
6 4
3
Z07777
1
3 4 65
− AIR CONDITIONINGAIR CONDITIONING SWITCH
AC−83
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT A/C INDICATOR OPERATION
(a) Connect the positive (+) lead from the battery to terminal
6 and negative (−) lead to terminal 4 and check that the
indicator lights up, when A/C switch ON.
(b) Connect the positive (+) lead from the battery to terminal
3 and check that the indicator dims
If operations are not as specified, replace the A/C switch.
2. INSPECT A/C SWITCH CONTINUITY
Condition/ CircuitTester connectionSpecified condition
OFF−No continuity
ON4 − 5
4 − 6Continuity
Illumination circuit3 − 1Continuity
If continuity is not as specified, replace the A/C switch

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N05735
FRESH Clamp
RECIRC
N05736
Clamp
DEF
FACE
N05734
Clamp
COOL
WARM
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC−91
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page
AC−87).
1. AFTER INSTALLATION, INSPECT HEATER CONTROL
LEVER OPERATION
Move the control lever and dials left and right check for stiffness
and binding the full range of the lever.
If there is stiffness and binding, proceed next step.
2. ADJUST HEATER CONTROL CABLES
(a) Set heater control assembly in these conditions:
(1) Air inlet control lever in ”FRESH” position
(2) Mode control lever in ”FACE” position
(3) Temperature control lever in ”Max. WARM” position
(b) Adjust the air inlet control cable.
Set the air inlet damper control damper on ”FRESH” posi-
tion, install the control cable and lock the clamp.
HINT:
Lock the clamp during lightly pushing the outer cable in the
direction shown by arrow.
(c) Adjust mode control cable.
Set the air inlet damper control damper on ”FACE” posi-
tion, install the control cable and lock the clamp.
HINT:
Lock the clamp during lightly pulling the outer cable in the direc-
tion shown by arrow.
(d) Adjust air mix control cable.
Set the air inlet damper control damper on ”WARM” posi-
tion, install the control cable and lock the clamp.
HINT:
Lock the clamp during lightly pulling the outer cable in the direc-
tion shown by arrow.

Downloaded from www.Manualslib.com manuals search engine N05737Clamp COOL
WARM
AC−92
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
1996 TOYOTA T100 (RM449U)
(e) Adjust water valve control cable.
Set the air inlet damper control damper on ”WARM” posi-
tion, install the control cable and lock the clamp.
HINT:
Lock the clamp during lightly pulling the outer cable in the direc-
tion shown by arrow.