brake TOYOTA T100 1996 Factory Owner's Guide

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FI6526
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 261 2 3 4 5 6 7 8
9 10 11 12 13 14 15 161 2 3 4 5 6
7 8 9 10 11 121 2 3 4 5 6 7 8 9 10 11
14 15 16 17 18 19 20 21 22 1213
EE6
E
ECM Terminals
E
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−279
1996 TOYOTA T100 (RM449U)
TERMINALS OF ECM
3RZ−FE:
Symbols (Terminals No.)Wiring ColorConditionSTD Voltage (V)
SP1 − E1 (E4, 8 − E7, 24)G ↔ BR
IG switch ON (Disconnect cruise control connector)Below 1.5 or 4 − 6
Turn one rear wheel slowly (Disconnect cruise control connec-
tor)Pulse signal is output
Below 1.5 ↔ 4 − 6

S1 − E1 (E7, 10 − E7, 24)

W ↔ BR
IG switch ON9 − 14
1st or 2nd gear9 − 14
3rd or O/D gearBelow 1.5
S2 − E1 (E7, 9 − E7, 24)B−W ↔ BR
IG switch ONBelow 1.5
2nd or 3rd gear9 − 14
1st or O/D gearBelow 1.5
SL − E1 (E7, 8 − E7, 24)Y−B ↔ BRIG switch ONBelow 1.5
Vehicle driving under lock−up position9 − 14
SP2+ − SP2− (E5, 10 − E5, 4)BR−R ↔ B−RVehicle is runningPulse signal is output
Below 1.5 ↔ 4 − 10
OD2 − E1 (E4, 5 − E7, 24)Y−G ↔ BRO/D main switch ON (Pushed in)9 − 14
O/D main switch OFF (Pushed once again)Below 3
OIL − E2 (E7, 21 − E6, 9)G−B ↔ BR−BATF temperature: 110°C (230°F) or moreBelow 1.5
L − E1 (E4, 15 − E7, 24)V−W ↔ BRIG switch ON, Shift lever L position7.5 − 14
IG switch ON, Shift lever other than L positionBelow 1.5
2 − E1 (E4, 16 − E7, 24)P−G ↔ BRIG switch ON, Shift lever 2 position7.5 − 14
IG switch ON, Shift lever other than 2 positionBelow 1.5
R − E1 (E4, 17 − E7, 24)R−B ↔ BRIG switch ON, Shift lever R position7.5 − 14
IG switch ON, Shift lever other than R positionBelow 1.5
NSW − E1 (E4, 22 − E7, 24)B−Y ↔ BRIG switch ON, Shift lever P or N positionBelow 3
IG switch ON, Shift lever other than P or N position9 − 14
B/K − E1 (E4, 21 − E7, 24)G−W ↔ BRIG switch ON, Brake pedal is depressed7.5 − 14
IG switch ON, Brake pedal is releasedBelow 1.5
THW − E2 (E6, 4 − E6, 9)G−Y ↔ BR−BEngine coolant temperature: 80°C (176°F)Below 1.5
IDL − E2 (E6, 11 − E6, 9)Y−L ↔ BR−BIG switch ON, Accel. pedal is releasedBelow 1.5
IG switch ON, Accel. pedal is depressed9 − 14
VTA − E2 (E6, 10 − E6, 9)Y−B ↔ BR−BIG switch ON, Accel. pedal is releasedBelow 0.3 − 0.8
IG switch ON, Accel. pedal is depressed3.2 − 4.9

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E7
E6 E5 E4
34 33 32 31 30 29 28 2717 18 19 20 21 22 23 24 25 2611 12 13 14 15 161 2 3 4 5 6 7 8 9 101 2 3 4 5 6 7 8
9 10 11 12 13
14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 1 2 3 4
5 6 7
8 9 10 11
12 13 14 15 16 1 2 3 4 5 6
7 8 9 10 11
12 13 14 15 16 17
18 19 20 21 22
ECM Terminals DI−280
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
5VZ−FE:
Symbols (Terminals No.)Wiring ColorConditionSTD Voltage (V)
SPD − E1 (E4, 12− E5, 16)G ↔ BR
IG switch ON (Disconnect cruise control connector)Below 1.5 or 4 − 6
Turn one rear wheel slowly (Disconnect cruise control connec-
tor)Pulse signal is output
Below 1.5 ↔ 4 − 6

S1 − E1 (E7, 11 − E5, 16)

W ↔ BR
IG switch ON9 − 14
1st or 2nd gear9 − 14
3rd or O/D gearBelow 1.5
S2 − E1 (E7, 17 − E5, 16)B−W ↔ BR
IG switch ONBelow 1.5
2nd or 3rd gear9 − 14
1st or O/D gearBelow 1.5
SL − E1 (E7, 27 − E5, 16)Y−B ↔ BRIG switch ONBelow 1.5
Vehicle driving under lock−up position9 − 14
SP2 − E1 (E6, 9 − E5, 16)BR−R ↔ BRTurn one rear wheel slowlyPulse signal is output
Below 1.5 ↔ 4 ∼ 6
OD1 − E1 (E4, 7 − E5, 16)Y−R ↔ BRIG switch ON9 − 14
OD2 − E1 (E4, 6 − E5, 16)Y−G ↔ BRO/D main switch ON (Pushed in)9 − 14
O/D main switch OFF (Pushed once again)Below 3
OIL − E2 (E6, 12 − E6, 22)G−B ↔ BR−BATF temperature: 110°C (230°F) or moreBelow 1.5
L − E1 (E4, 3 − E5, 16)V−W ↔ BRIG switch ON, Shift lever L position7.5 − 14
IG switch ON, Shift lever other than L positionBelow 1.5
2 − E1 (E4, 2 − E5, 16)P−G ↔ BRIG switch ON, Shift lever 2 position7.5 − 14
IG switch ON, Shift lever other than 2 positionBelow 1.5
R − E1 (E4, 1 − E5, 16)R−B ↔ BRIG switch ON, Shift lever R position7.5 − 14
IG switch ON, Shift lever other than R positionBelow 1.5
NSW − E1 (E7, 14 − E6, 22)B−O ↔ BRIG switch ON, Shift lever P or N positionBelow 3
IG switch ON, Shift lever other than P or N position9 − 14
B/K − E1 (E4, 25 − E5, 16)G−W ↔ BRIG switch ON, Brake pedal is depressed7.5 − 14
IG switch ON, Brake pedal is releasedBelow 1.5
THW − E2 (E6, 20 − E6, 22)G−Y ↔ BR−BEngine coolant temperature: 80°C (176°F)Below 1.5
IDL − E2 (E7, 32 − E6, 22)Y−L ↔ BR−BIG switch ON, Accel. pedal is releasedBelow 1.5
IG switch ON, Accel. pedal is depressed9 − 14
VTA − E2 (E6, 7 − E6, 22)Y−B ↔ BR−BIG switch ON, Accel. pedal is releasedBelow 0.3 − 0.8
IG switch ON, Accel. pedal is depressed3.2 − 4.9
TFN − E1 (E4, 17 − E5, 16)Y ↔ BRIG switch ON, Transfer N positionBelow 3
IG switch ON, Transfer other than N position9 − 14

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DI−285
1996 TOYOTA T100 (RM449U)
Chapter 3: Off−Vehicle Repair Matrix Chart
(: A340E, A340F, A340H AUTOMATIC TRANSMISSION Repair Manual Pub. No. RM391U)
(: A340F, A343F AUTOMATIC TRANSMISSION Repair Manual Pub. No. RM479U)
SymptomSuspect AreaSee page
Vehicle does not move in any forward position and reverse posi-
tion
1. O/D one−way clutch (F0)
2. O/D direct clutch (C
0)
3. O/D planetary gear unit
4. Torque converter clutch



AT−38
Vehicle does not move in R position
1. Front and rear planetary gear unit
2. Direct clutch (C
2)
3. 1st and reverse brake (B
3)
4. O/D direct clutch (C
0)




No up−shift (1st → 2nd)1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)


No up−shift (2nd → 3rd)1. Direct clutch (C2)
No up−shift (3rd → O/D)1. O/D brake (B0)
No lock−up or No lock−up off1. Torque converter clutchAT−38
Harsh engagement (N → D)
1. Forward clutch (C1)
2. O/D one−way clutch (F
0)
3. No. 2 one−way clutch (F
2)



Harsh engagement (N → R)
1. Direct clutch (C2)
2. 1st and reverse brake (B
3)
3. O/D one−way clutch (F
0)



Harsh engagement (N → 2)
1. Forward clutch (C1)
2. O/D one−way clutch (F
0)
3. No. 2 one−way clutch (F
2)



Harsh engagement (N → L)
1. Forward clutch (C1)
2. 1st and reverse brake (B
3)
3. O/D one−way clutch (F
0)
4. No. 2 one−way clutch (F
2)




Harsh engagement (Lock−up)1. Torque converter clutchAT−38
Slip or shudder (Forward and reverse: After warm−up)
1. Torque converter clutch
2. O/D one−way clutch (F
0)
3. O/D direct clutch (C
0)
AT−38


Slip or shudder (Particular position: Just after engine starts)1. Torque converter clutchAT−38
Slip or shudder (R position)1. Direct clutch (C2)
2. 1st and reverse brake (B
3)


Slip or shudder (1st)1. Forward clutch (C1)
2. No. 2 one−way clutch (F
2)


Slip or shudder (2nd)
1. 2nd brake (B2)
2. 2nd coast brake (B
1)
3. No. 1 one−way clutch (F
1)



Slip or shudder (3rd)1. Direct clutch (C2)
Slip or shudder (O/D)1. O/D brake (B0)
No engine braking (1st ∼ 3rd: D position)1. 2nd brake (B2)
No engine braking (1st: L position)1. 1st and reverse brake (B3)
No engine braking (2nd: 2 position)1. 2nd coast brake (B1)
Poor acceleration (All position)1. Torque converter clutchAT−38
Poor acceleration (O/D)1. O/D direct clutch (C0)
2. O/D planetary gear unit

Engine stalls when starting off or stopping1. Torque converter clutchAT−38

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DI−316
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
Stop Light Switch Circuit
CIRCUIT DESCRIPTION
The purpose of this circuit is to prevent the engine from stalling, while driving in lock−up condition, when
brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signals to the ECM. Then the ECM cancels operation
of the lock−up clutch while braking is in progress.
WIRING DIAGRAM
DI98I−01

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− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−317
1996 TOYOTA T100 (RM449U)
INSPECTION PROCEDURE
1 Check operation of stop light.
CHECK:
Check if the stop lights go on and off normally when the brake pedal is operated and released.
NG Check and repair stop light circuit.
OK
2 Check STP signal.
When using OBD II scan tool or TOYOTA hand−held tester:
PREPARATION:
(a) Connect an OBD II scan tool or TOYOTA hand−held tes-
ter to the DLC3.
(b) Turn the ignition switch ON and OBD II scan tool or TOY-
OTA hand−held tester main switch ON.
CHECK:
Read the STP signal on the TOYOTA hand−held tester.
OK:
Brake PedalSTP Signal
DepressedON
ReleaseOFF
When not using OBD II scan tool or TOYOTA hand−held tes-
ter:
PREPARATION:
Turn the ignition switch ON.
CHECK:
Check the voltage between terminal B/K of the ECM connector
and body ground.
OK:
Brake PedalVoltage
Depressed7.5 − 14 V
ReleaseBelow 1.5 V

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Vehicle Brought to Workshop
Customer Problem Analysis
P. DI−320
Check and Clear DTC (Precheck)
P.
DI−321
Items inside
are titles of pages in this manual,
with the page number in the bottom portion. See
the pages for detailed explanations.
Problem Symptom ConfirmationSymptom Simulation
P. IN−16
Symptom
does not occur
Symptom
occurs
DTC Check
P. DI−321
Sensor CheckCircuit Inspection
P. DI−332 ∼ DI−360
DTC Chart
P. DI−326 Malfunction codeProblem Symptoms Table
P. DI−331
Check for Fluid Leakage
P. DI−362
Identification of Problem
Normal code
Repair
Confirmation Test
End
1
2
3
4
5
67
89
10
11
Step 8 :Diagnostic steps permitting the use of the
TOYOTA hand−held tester or TOYOTA
break−out−box.
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−319
576 Author: Date:
1996 TOYOTA T100 (RM449U)
ANTI−LOCK BRAKE SYSTEM
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoooting in accordance with the procedure on the following pages.

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ABS Check SheetInspector ’s
Name:
Customer ’s Name
Date Vehicle
Brought InRegistration YearRegistration No.
Frame No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs/ /
ContinuousIntermittent ( times a day)
ABS does not operate.
ABS does not operate efficiently.
ABS Warning Light
AbnormalRemains ONDoes not Light Up
DTC Check1st Time
2nd TimeNormal Code
Malfunction Code (Code )
Normal CodeMalfunction Code (Code )
Symptomskm
miles DI−320
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 TOYOTA T100 (RM449U)
CUSTOMER PROBLEM ANALYSIS CHECK

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DI0ZM−03
A00778DLC1 E
1Tc
F00006
DLC1Short Pin
R01346
Normal Code
0.25 sec.
0.25 sec. 2 sec.
ON
OFF
ON
OFF0.5 sec.0.5 sec.
Code 11 and 21
4 sec.1.5 sec.
2.5 sec.
Code 11 Code 21
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−321
1996 TOYOTA T100 (RM449U)
PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Check the indicator light.
When the ignition switch is turned ON, check that the ABS
warning light goes on for 3 seconds.
HINT:
If the indicator check result is not normal, proceed to trouble-
shooting for the ABS warning light circuit (See page DI−354).
(b) Check the DTC.
(1) Using SST, connect terminals Tc and E
1 of the
DLC1.
SST 09843−18020
(2) Disconnect the short pin from the DLC1.
(3) Turn the ignition switch ON.
(4) Read the DTC from the ABS warning light on the
combination meter.
HINT:
If no code appears, inspect the diagnostic circuit or ABS
warning light circuit (See page DI−354 or DI−358).
As an example, the blinking patterns for normal code and
codes 11 and 21 are shown on the left.
(5) Code are explained in the code table on page
DI−326.
(6) After completing the check, disconnect terminals Tc
and E
1, and turn off the display.
If 2 or more malfunctions are indicated at the same time the low-
est numbered DTC will be displayed 1st.

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F00006DLC1Short Pin
N09348
TOYOTA
hand−held tester
TOYOTA
brake−out−box ECU
A00778DLC1 E
1Tc
Ts DI−322
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 TOYOTA T100 (RM449U)
(c) Clear the DTC.
(1) Using SST, connect terminals Tc and E
1 of the
DLC1 and remove the short pin from the DLC1.
SST 09843−18020
(2) Turn the ignition switch ON.
(3) Clear the DTC stored in ECU by depressing the
brake pedal 8 or more times within 3 seconds.
(4) Check that the warning light shows the normal
code.
(5) Remove the SST from the terminals of the DLC1.
SST 09843−18020
(6) Connect the short pin to the DLC1.
HINT:
Cancellation can also be done by removing the ECU−B fuse,
but in this case, other memory systems will also be cancelled
out.
(d) Using TOYOTA brake−out−box and TOYOTA hand−held
tester, measure the ECU terminal value.
(1) Hook up the TOYOTA hand−held tester and
TOYOTA break−out−box to the vehicle.
(2) Read the ECU input/output values by following the
prompts on the tester screen.
HINT:
TOYOTA hand−held tester has a ”Snapshot” function. This re-
cords the measured values and is effective in the diagnosis of
intermittent problems.
Please refer to the TOYOTA hand−held tester/TOYOTA break−
out−box operator’s manual for further details.
2. SPEED SENSOR SIGNAL AND DECELERATION SEN-
SOR CHECK
(a) Check the speed sensor signal.
(1) Turn the ignition switch OFF.
(2) Using SST, connect terminals Ts and E
1 of the
DLC1.
SST 09843−18020
(3) Start the engine.

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0.13 sec. 0.13 sec.
ON
OFF
BR3893
Malfunction Code (Example Code 72, 76)
7
26
7
ON
OFF
0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.1.5 sec. 2.5 sec.4 sec.
Repeat
A00778DLC1 E
1
Ts
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−323
1996 TOYOTA T100 (RM449U)
(4) Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit (See page DI−354).
(5) Drive vehicle straight forward.
HINT:
Drive vehicle faster than 45 km/h (28 mph) for several seconds.
(6) Stop the vehicle.
(7) Using SST, connect terminals Tc and E
1 of the
DLC1.
SST 09843−18020
(8) Read the number of blinks of the ABS warning light.
HINT:
See the list of DTC on page DI−326.
If every sensor is normal, a normal code is output (A cycle
of 0.25 sec. ON and 0.25 sec. OFF is repeated).
If 2 or more malfunction are indicated at the same time,
the lowest numbered code will be displayed 1st.
(9) After doing the check, disconnect terminals Ts and
E
1, Tc and E1 of the DLC1, and ignition switch
turned OFF.
(b) Check the deceleration sensor detection point.
(1) Turn the ignition switch OFF.
(2) Using SST, connect terminals Ts and E
1 of the
DLC1.
SST 09843−18020
(3) Start the engine.