heater TOYOTA T100 1996 Factory Owner's Manual

Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSENGINE (5VZ−FE)
DI−177
1996 TOYOTA T100 (RM449U)
2 Check resistance of heated oxygen sensor heater (See page SF−60).
NG Replace heated oxygen sensor.
OK
Check and repair harness or connector
between EFI main relay, heated oxygen
sensor and ECM (See page IN−26).

Downloaded from www.Manualslib.com manuals search engine H18114
ONAirbag Sensor Assembly
IG
2Acc
(+) (−)
AB0119AB0234H00351
ON
− DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
DI−397
1996 TOYOTA T100 (RM449U)
INSPECTION PROCEDURE
1 Preparation.
PREPARATION:
(a) Turn ignition switch to LOCK.
(b) Disconnect center airbag sensor assembly connector.
(c) Turn ignition switch ON. But do not start engine.
(d) Measure voltage between terminal IG
2 or ACC on con-
nector wire harness side of center airbag sensor assem-
bly and body ground, and operate electric system (defog-
ger, wiper, headlight, heater blower, etc.).
Voltage: 6 V − 11.5 V at IG
2 and ACC
(e) Turn electric system switch OFF.
(f) Turn ignition switch to LOCK.
(g) Remove voltmeter and connect center airbag sensor as-
sembly connector.
2 Does SRS warning light turn off?
PREPARATION:
(a) Turn ignition switch to LOCK.
(b) Connect steering wheel pad connector.
(c) Connect center airbag sensor assembly connector.
(d) Turn ignition switch ON.
CHECK:
Operate electric system (defogger, wiper, headlight, heater
blower, etc.), and check that SRS warning light goes off.
NO Check for DTCs. If a DTC is output, perform trou-
bleshooting for DTC. If a normal code is output,
replace center airbag sensor assembly.
YES
From results of above inspection, malfunctioning part can now be considered normal. To make
sure of this, use simulation method to check.

Downloaded from www.Manualslib.com manuals search engine P15813A03782
P14635A03783
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−29
1996 TOYOTA T100 (RM449U)
8. REMOVE DISTRIBUTOR
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(a) Disconnect the distributor connector.
(b) Remove the hold−down bolts and distributor.
(c) Remove the O−ring.
9. REMOVE WATER OUTLET
(a) Disconnect the radiator inlet hose.
(b) Disconnect the ECT sender gauge connector.
(c) Remove the 2 bolts, water outlet and gasket.
10. REMOVE THROTTLE BODY (See page MF−28)
11. DISCONNECT ENGINE WIRE
(a) Disconnect these connectors:
w/ A/C:
A/C compressor connector
Oil pressure sensor connector
ECT sensor connector
EGR gas temperature sensor connector
EGR VSV connector
(b) Remove the 2 bolts and disconnect engine wire from the
intake chamber.
(c) Disconnect the 5 engine wire clamps and engine wire.
(d) Disconnect these connectors:
Knock sensor connector
Crankshaft position sensor connector
Fuel pressure control VSV connector
(e) Disconnect the DLC1 from the bracket.
(f) Disconnect the 2 engine wire clamps.
(g) Remove the bolt and disconnect the engine wire.
12. DISCONNECT INJECTOR CONNECTORS
13. REMOVE CYLINDER HEAD REAR COVER
(a) Disconnect the heater water bypass hose.
(b) Remove the 3 bolts and the rear cover and gasket.

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P14628
Z15935
P14635
EM−58
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
22. INSTALL FUEL RETURN PIPE
(a) Install the fuel return pipe with the 2 bolts.
(b) Connect these hoses:
Fuel return hose to fuel pressure regulator
Fuel return hose to fuel return pipe
23. INSTALL INTAKE CHAMBER STAY
Install the intake chamber stay with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
24. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket, EGR valve and vacuum modulator
with the bolt and 2 nuts.
Torque:
Bolt: 8.5 N·m (85 kgf·cm, 74 in.·lbf)
Nut: 19 N·m (195 kgf·cm, 14 ft·lbf)
(b) Connect these hoses:
2 vacuum hoses to EGR VSV (with clamp)
Water bypass hose to water bypass pipe
(c) Install 2 new gaskets and EGR pipe with the bolt and 4
nuts.
Torque:
Bolt: 18 N·m (185 kgf·cm, 14 ft·lbf)
Nut A: 19 N·m (195 kgf·cm, 14 ft·lbf)
Nut B: 20 N·m (200 kgf·cm, 15 ft·lbf)
25. INSTALL CYLINDER HEAD REAR COVER
(a) Install a new gasket and rear cover with the 3 bolts.
Torque: 13.5 N·m (135 kgf·cm, 10 ft·lbf)
(b) Connect the heater water bypass pipe.
26. CONNECT INJECTOR CONNECTORS
27. CONNECT ENGINE WIRE
(a) Connect the engine wire to the intake manifold with the
bolt.
(b) Connect the 2 engine wire clamps.
(c) Connect the DLC1 to the bracket.
(d) Connect these connectors:
Fuel pressure control VSV connector
Knock sensor connector
Crankshaft position sensor connector
(e) Connect the 5 engine wire clamps.
(f) Connect the engine wire to the intake chamber with the
2 bolts.
(g) Connect these connectors:
EGR VSV connector
EGR gas temperature sensor connector

Downloaded from www.Manualslib.com manuals search engine P14925
P15085
P15086
P15094
EM−66
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
14. w/ A/C:
DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Disconnect the A/C compressor connector.
(b) Remove the 4 mounting bolts, and disconnect the com-
pressor from the bracket.
HINT:
Put a side the compressor, and suspend it.
(c) Remove the 4 bolts and A/C compressor bracket.
15. DISCONNECT HEATER HOSES
16. DISCONNECT HOSES
Disconnect these hoses:
Brake booster vacuum hose
EVAP hose
2 PS air hoses
Fuel return hose
Fuel inlet hose
17. DISCONNECT PS PUMP
(a) Using SST, remove the nut and PS pump pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the 2 bolts, and disconnect the PS pump.
HINT:
Put aside the pump, and suspend it.
18. DISCONNECT GENERATOR WIRE
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire and
wire clip.

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P14935
P24651
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−73
1996 TOYOTA T100 (RM449U)
Brake booster vacuum hose
EVAP hose
2 PS hoses
18. CONNECT HEATER HOSES
19. 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)
(c) Connect the A/C compressor connector.
20. INSTALL INTAKE AIR CONNECTOR
(a) Install the intake air connector with the 2 bolts and hose
clamp.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Connect the 2 air hoses.
21. M/T:
CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
22. A/T:
CONNECT ACCELERATOR AND THROTTLE CABLES
TO THROTTLE BODY

Downloaded from www.Manualslib.com manuals search engine EM1OP−01
EM−30
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
REMOVAL
1. 4WD:
REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT EXHAUST PIPE (See page EM−108)
4. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
5. DISCONNECT THESE CABLES:
(a) w/ Cruise control:
Cruise control actuator cable
(b) Accelerator cable
(c) A/T:
Throttle cable
6. DISCONNECT HEATER HOSE
7. DISCONNECT UPPER RADIATOR HOSE
8. REMOVE DRIVE BELT FOR PS PUMP
(a) Stretch the belt and loosen the fan pulley mounting nuts.
9. w/ A/C:
REMOVE DRIVE BELT FOR A/C COMPRESSOR
10. REMOVE DRIVE BELT FOR GENERATOR
11. REMOVE NO. 2 FAN SHROUD
12. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
13. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
14. w/ A/C:
DISCONNECT A/C COMPRESSOR FROM ENGINE
HINT:
Put aside the compressor, and suspend it.
15. w/ A/C:
REMOVE A/C COMPRESSOR BRACKET
16. REMOVE HIGH−TENSION CORDS WITH IGNITION
COILS
17. REMOVE SPARK PLUGS
18. REMOVE TIMING BELT AND CAMSHAFT TIMING
PULLEYS (See page EM−13)
19. REMOVE TIMING BELT IDLER NO. 2 (See page
EM−13)
20. REMOVE GENERATOR

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−61
1996 TOYOTA T100 (RM449U)
27. INSTALL TIMING BELT IDLER NO. 2 (See page
EM−19)
28. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING
BELT (See page EM−19)
29. INSTALL SPARK PLUGS
30. INSTALL HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−1)
31. w/ A/C:
INSTALL A/C COMPRESSOR BRACKET
32. w/ A/C:
CONNECT A/C COMPRESSOR
33. CONNECT PS PUMP
34. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
Torque: 5.4 N·m (54 kgf·cm, 48 in.·lbf)
35. INSTALL NO. 2 FAN SHROUD
36. INSTALL AND ADJUST DRIVE BELT FOR GENERA-
TOR (See page CH−1)
37. w/ A/C:
INSTALL AND ADJUST DRIVE BELT FOR A/C COM-
PRESSOR
38. INSTALL AND ADJUST DRIVE BELT FOR PS PUMP
39. CONNECT HEATER HOSE AND UPPER RADIATOR
HOSE
40. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
41. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP ASSEMBLY
42. INSTALL FRONT EXHAUST PIPE (See page EM−108)
43. FILL WITH ENGINE COOLANT
44. START ENGINE AND CHECK FOR LEAKS
45. CHECK IGNITION TIMING (See page EM−9)
46. 4WD:
INSTALL ENGINE UNDER COVER
47. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
48. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM06W−02
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−65
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DRAIN ENGINE OIL
3. DRAIN TRANSMISSION OIL
4. REMOVE HOOD
5. REMOVE RADIATOR ASSEMBLY
(See page CO−16)
6. REMOVE DRIVE BELT FOR PS PUMP
7. w/ A/C:
REMOVE DRIVE BELT FOR A/C COMPRESSOR
8. REMOVE DRIVE BELT FOR GENERATOR
9. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
(See page CO−5)
10. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
11. w/ A/C:
REMOVE A/C COMPRESSOR FROM ENGINE
HINT:
Put aside the compressor, and suspend it.
12. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
13. REMOVE AIR CLEANER CASE AND FILTER
14. DISCONNECT THESE CABLES:
(a) w/ Cruise control:
Cruise control actuator cable
(b) Accelerator cable
(c) A/T:
Throttle cable
15. DISCONNECT HEATER HOSES
16. DISCONNECT HOSES
Disconnect these hoses:
(1) Brake booster vacuum hose
(2) EVAP hose

Downloaded from www.Manualslib.com manuals search engine P20501
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−71
1996 TOYOTA T100 (RM449U)
13. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
14. CONNECT GENERATOR WIRE
(a) Connect the generator connector.
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
15. CONNECT STARTER WIRE AND CONNECTOR
(a) Connect the 2 starter wire clamps and connector.
(b) Install the 2 nuts, and connect the positive (+) terminal
cable to battery.
(c) Install the bolt, and connect the ground strap.
16. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose
Brake booster vacuum hose
EVAP hose
A.D.D. Vacuum hose
17. CONNECT HEATER HOSES
18. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
19. INSTALL AIR CLEANER CASE AND AIR FILTER
20. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP
21. w/ A/C:
CONNECT A/C COMPRESSOR
22. CONNECT PS PUMP
23. INSTALL FAN WITH FLUID COUPLING AND FAN
PULLEYS(See page EM−19)
24. INSTALL DRIVE BELT FOR GENERATOR (See page
CH−1)