engine TOYOTA T100 1996 Factory Service Manual

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 SS−72
− SERVICE SPECIFICATIONSSTEERING
246 Author: Date:
1996 TOYOTA T100 (RM449U) Total preload
0.5−1.4 N·m (5−14 kgf·cm, 4.3−12.2 in.·lbf)
4WD:
Worm gear valve body ball clearance0.15 mm (0.059 in.)
Cross shaft adjusting screw thrust clearance STD0.03−0.05 mm (0.0012−0.0020 in.)
Cross shaft adjusting screw thrust clearanceMaximum0.05 mm (0.0020 in.)
Worm gear preload0.3−0.5 N·m (3−5.5 kgf·cm, 2.6−4.8 in.·lbf)
Total preload0.5−0.9 N·m (5−9.5 kgf·cm, 4.3−8.3 in.·lbf)
STEERING LINKAGE
Tie rod lengthApproximately329.2 mm (12.961 in.)
Idler arm rotating torque0.5−2.9 N·m (5−30 kgf·cm, 5−26 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine SS08X−01
− SERVICE SPECIFICATIONSSTEERING
SS−73
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
STEERING COLUMN
NON−TILT STEERING COLUMN:
Steering wheel set nut3536026
Steering wheel pad set screw (Torx screw)9.09078 in.·lbf
Steering column assembly set bolt and nut2526019
Control shaft lever x Control shaft assembly AT3536026
Intermediate shaft x Control valve assembly 2WD3536026
Intermediate shaft x Worm gear valve assembly 4WD3536026
Sliding w/shaft york sub−assembly x Intermediate shaft3536026
Main shaft assembly x Sliding w/shaft york sub−assembly3536026
TILT STEERING COLUMN:
Steering wheel set nut3536026
Steering wheel pad set screw (Torx screw)9.09078 in.·lbf
Steering column assembly set bolt and nut2526019
Control shaft lever x Control shaft assembly AT3536026
Intermediate shaft x Control valve assembly 2WD3536026
Intermediate shaft x Worm gear valve assembly 4WD3536026
Sliding w/shaft york sub−assembly x Intermediate shaft3536026
Sliding york sub−assembly x Sliding w/shaft york sub−assembly3536026
Main shaft assembly x Sliding york sub−assembly3536026
Turn signal bracket set bolt7.88069 in.·lbf
Tilt lever assembly set bolt22017 in.·lbf
Tilt sub lever side pawl set bolt x nut5.96052 in.·lbf
Tilt lever retainer set nut1515011
Compression spring set bolt7.88069 in.·lbf
PS VANE PUMP
3RZ−FE and 5VZ−FE:
Union bolt x Pressure feed tube4747534
Pressure port union x Pump housing8385061
Bracket x Pump assembly 5VZ−FE4344032
Rear housing set bolt2424017
Oil reservoir set bolt Front131309
Rear2424017
Vane pump pulley set nut4344032
Vane pump assembly set bolt 3RZ−FE3940029
Vane pump assembly with bracket set bolt and nut 5VZ−FE3940029
PS GEAR
2WD:
Control valve housing x Rack housing1818513
Self−locking nut2525018
Rack housing cap6970051
Rack guide spring cap lock nut51 (60)521 (700)38 (51)
Rack x Rack end61 (83)618 (850)45 (62)

Downloaded from www.Manualslib.com manuals search engine SS−74
− SERVICE SPECIFICATIONSSTEERING
1996 TOYOTA T100 (RM449U) Tie rod end lock nut
5657041
Turn pressure tube union nut10 (13)102 (130)7 (9)
PS gear assembly set bolt and nut8890065
Mount bracket x Suspension crossmember8890065
Control valve shaft x Intermediate shaft3536026
Pressure feed tube x Control valve housing19 (25)195 (250)14 (18)
Return tube x Control valve housing19 (25)195 (250)14 (18)
Tie rod end x Steering knuckle9092067
4WD:
Pressure feed tube x PS gear assembly36 (44)365 (450)26 (33)
Return tube x PS gear assembly36 (44)365 (450)26 (33)
PS gear assembly x Body1421450105
Pitman arm x Cross shaft1771800130
Cross shaft adjusting screw set nut4647034
Side cover x Gear housing6162045
Plunger guide nut2020515
Worm gear valve body assembly x Gear housing6162045
Worm gear valve body assembly x Intermediate shaft3536026
STEERING LINKAGE
Pitman arm x Cross shaft1771800130
Pitman arm x Relay rod9092067
Tie rod clamp bolt2222516
Tie rod assembly x Relay rod9092067
Tie rod assembly x Knuckle arm9092067
Idler arm assembly x Frame1421450105
Relay rod x Idler arm assembly5960043
Steering damper set bolt and nut2526019
Relay rod x Steering damper5960043
IDLER ARM
Idler arm x Idler arm bracket7880058
( ): For use without SST

Downloaded from www.Manualslib.com manuals search engine SS08E−01
− SERVICE SPECIFICATIONSSUPPLEMENTAL RESTRAINT SYSTEM
SS−75
249 Author: Date:
1996 TOYOTA T100 (RM449U)
SUPPLEMENTAL RESTRAINT SYSTEM
SERVICE DATA
FRONT AIRBAG SENSOR
S − ALess then 1 Ω
S − S1 MΩ or Higher
S − A755 − 885 Ω

Downloaded from www.Manualslib.com manuals search engine SS08D−01
SS−76
− SERVICE SPECIFICATIONSSUPPLEMENTAL RESTRAINT SYSTEM
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Steering wheel3435025
Steering wheel pad8.89078 in.·lbf
Airbag sensor assembly2121015
Front airbag sensor2930022

Downloaded from www.Manualslib.com manuals search engine SS03A−03
− SERVICE SPECIFICATIONSBODY ELECTRICAL
SS−77
251 Author: Date:
1996 TOYOTA T100 (RM449U)
BODY ELECTRICAL
SERVICE DATA
DAYTIME RUNNING LIGHT MAIN RELAY (Wire Harness Side)
2 − Ground (Ignition Switch LOCK or ACC)No voltage
2 − Ground (Ignition Switch ON or START)Battery positive voltage
6 − Ground (Constant)Battery positive voltage
11 − Ground (Engine Stop)No voltage
11 − Ground (Engine Running)Battery positive voltage
DAYTIME RUNNING LIGHT MAIN RELAY (Connector connected)
17 − Ground (Headlight dimmer switch LOW beam)No voltage
17 − Ground (Headlight dimmer switch HIGH beam or Flash)Battery positive voltage
TURN SIGNAL FLASHER
Flashes/ Minute60 − 120
SPEEDOMETER (Using a speedmeter tester)
Standard indication (mph)Allowable range (mph)
2018 − 24
4038 − 44
6058 − 66
8078 − 88
10098 − 11 0
12011 8 − 132
Standard indication (km/h)Allowable range (km/h)
2017 − 24
4038 − 46
6057.5 − 67
8077 − 88
10096 − 109
12011 5 − 130
140134 − 151.5
160153 − 173
TACHOMETER (On−Vehicle) / DC 13.5 V 20 °C at (68 °F)
Standard indicationAllowable range
700610 − 750
3,0002,850 − 3,150
5,0004,850 − 5,150
7,0006,790 − 7,210
VOLT GAUGEResistance (Ω)
A − BApprox. 347.0 Ω
FUEL RECEIVER GAUGE (w/ Tachometer)Resistance (Ω)
A − BApprox. 137.0 Ω
A − CApprox. 123.0 Ω
B − CApprox. 260.0 Ω
FUEL RECEIVER GAUGE (w/o Tachometer)Resistance (Ω)
A − BApprox. 150.0 Ω
A − CApprox. 80.0 Ω

Downloaded from www.Manualslib.com manuals search engine SS−78
− SERVICE SPECIFICATIONSBODY ELECTRICAL
252 Author: Date:
1996 TOYOTA T100 (RM449U)B − C
Approx. 55.0 Ω
FUEL SENDER GAUGE
Float position mm (in.)Resistance (Ω)
F: Approx. 95 mmApprox. 3.0 Ω
1/2: Approx. 188.0 mmApprox. 32.5 Ω
E: Approx. 283.0 mmApprox. 110.0 Ω
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (w/ Tachometer)Resistance (Ω)
A − BApprox. 150.0 Ω
A − CApprox. 54.0 Ω
B − CApprox. 138.0 Ω
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (w/ o Tachometer)
A − BApprox. 25.0 Ω
OIL PRESSURE RECEIVER GAUGE
A − BApprox. 25.0 Ω
DOOR LOCK CONTROL RELAY (Wire Harness Side)
2 − Ground (Constant)Battery positive voltage
8 − Ground (Ignition Switch LOCK or ACC)No voltage
8 − Ground (Ignition Switch ON)Battery positive voltage
13 − Ground (Key unlock warning switch OFF (Ignition key removed))No voltage
13 − Ground (Key unlock warning switch ON (Ignition key set))Battery positive voltage
CRUISE CONTROL ECU (wire harness side)
24 − 26 (constant)Approx. 2.0 kΩ
25 − 26 (Actuator arm turned)Resistance change even
10 − Ground (Brake pedal position: Released)Approx. 38.0 Ω
10 − Ground (Brake pedal position: Depressed)No continuity
CRUISE CONTROL SWITCH
18 − Ground (Control switch position: OFF)No continuity
18 − Ground (Control switch position: RESUME/ACCEL)Approx. 68.0 Ω
18 − Ground (Control switch position: SET/COAST)Approx. 198.0 Ω
18 − Ground (Control switch position: CANCEL)Approx. 418.0 Ω
14 − Ground (Ignition switch position: LOCK or ACC)No voltage
14 − Ground (Ignition switch position: ON)Battery positive voltage
15 − Ground (Constant)Battery positive voltage
1 − Ground (Constant)Battery positive voltage
16 − Ground (Brake pedal position: Released)No voltage
16 − Ground (Brake pedal position: Depressed)Battery positive voltage
20 − Ground (With ignition switch ON, Speedsensor shaft turned)Valtage changes repeatedly
CRUISE CONTROL ACTUATOR
1 − 3Approx. 2.0 kΩ
2 − 3 (The arm is moving from the closed to open position)Approx. 0.5 to 1.8 kΩ
ANTENNA MOTOR CONTROL RELAY (Wire harness side)
3 − Ground (Constant)Battery positive voltage
5 − Ground (Ignition Switch position: LOCK)No voltage
5 − Ground (Ignition switch position: ACC)Battery positive voltage
7 − Ground (Ignition switch position: LOCK)No voltage

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSBODY ELECTRICAL
SS−79
253 Author: Date:
1996 TOYOTA T100 (RM449U) 7 − Ground (Ignition switch position: ACC or ON)
(Radio switch and cassette OFF)
No voltage
7 − Ground (Ignition switch position: ACC or ON)
(Radio switch and cassette ON)Battery positive voltage
8 − Ground (Ignition switch position: LOCK)No voltage
8 − Ground (Ignition switch position: ACC or ON)
(Radio switch ON and cassette ON)No voltage
8 − Ground (Ignition switch position: ACC or ON)
(Radio switch ON and cassette OFF)Battery positive voltage
4 − Ground (Ignition switch position: LOCK or ACC)No voltage
4 − Ground (Ignition switch position: ON)Battery positive voltage

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