engine TOYOTA T100 1996 Factory Service Manual

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− DIAGNOSTICSENGINE (5VZ−FE)
DI−137
1996 TOYOTA T100 (RM449U)
8 Check for spark.
PREPARATION:
(a) Remove the ignition coil or disconnect the high−tension
cord from the spark plug.
(b) Remove the spark plug.
(c) Install the spark plug to the ignition coil or high−tension
cord.
(d) Disconnect the injector connector.
(e) Hold the end about 12.5 mm (0.61 in.) from the ground.
CHECK:
Check if the spark occurs while engine is being cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, don’t crank the engine for more than 5 − 10
seconds at a time.
NG Proceed to page IG−1 and continue to trouble-
shoot.
OK
Proceed to problem symptoms table on page
DI−148.

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− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
7. ENGINE OPERATING CONDITION
NOTICE:
The values given below for ”Normal Condition” are representative values, so a vehicle may still be
normal even if its value varies from those listed here. So do not decide whether a part is faulty or
not solely according to the ”Normal Condition” here.
(a) CARB mandated signals.
TOYOTA hand−held tester displayMeasurement ItemNormal Condition*
FUEL SYS #1
Fuel System Bank 1
OPEN: Air−fuel ratio feedback stopped
CLOSED: Air−fuel ratio feedback operating
Idling after warming up: CLOSED
CALC LOAD
Calculator Load:
Current intake air volume as a proportion of max.
intake air volumeIdling: 14.9 − 21.3 %
Racing without load (2,500rpm): 16.5 ∼ 23.5%
COOLANT TEMP.Engine Coolant Temp. Sensor ValueAfter warming up: 80 − 95°C (176 − 203°F)
SHORT FT #1Short−term Fuel Trim Bank 10 ± 20 %
LONG FT #1Long−term Fuel Trim Bank 10 ± 20 %
ENGINE SPDEngine SpeedIdling: 650 − 750 rpm
VEHICLE SPDVehicle SpeedVehicle stopped: 0 km/h (0 mph)
IGN ADVANCEIgnition Advance:
Ignition Timing of Cylinder No.1Idling: BTDC 12.5 − 22.0°
INTAKE AIRIntake Air Temp. Sensor ValueEquivalent to Ambient Temp.
MAFAir Flow Rate Through Mass Air Flow Meter
Idling: 3.2 − 4.6 gm/sec.
Racing without load (2,500 rpm):
12.9 − 18.3 gm/sec.
THROTTLE POS
Voltage Output of Throttle Position Sensor
Calculated as a percentage:
0 V →0 %, 5 V →100 %Throttle valve fully closed: 7 − 11 %
Throttle valve fully open: 65 − 75 %
O2S B1, S1Voltage Output of Oxygen Sensor
Bank 1, Sensor 1Idling: 0.1 − 0.9 V
O2FT B1, S1Oxygen Sensor Fuel Trim Bank 1, Sensor 1
(Same as SHORT FT #1)0 ± 20 %
O2S B1, S2Voltage Output of Oxygen Sensor
Bank 1, Sensor 2Driving 50 km/h (31 mph): 0.1 − 0.9 V
*: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch
is OFF and all accessory switches are OFF.

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DI−139
1996 TOYOTA T100 (RM449U)
(b) TOYOTA Enhanced Signals.
TOYOTA hand−held tester displayMeasurement ItemNormal Condition*1
MISFIRE RPMEngine RPM for first misfire rangeMisfire 0: 0 rpm
MISFIRE LOADEngine load for first misfire rangeMisfire 0: 0 g/r
INJECTORFuel injection time for cylinder No.1Idling: 1.82 − 3.15 ms
IAC DUTY RATIOIntake Air Control Valve Duty Ratio
Opening ratio rotary solenoid type IAC valveIdling: 22 − 46 %
STARTER SIGStarter SignalCranking: ON
A/C SIGA/C Switch SignalA/C ON: ON
PNP SWPark/Neutral Position Switch SignalP or N position: ON
STOP LIGHT SWStop Light Switch SignalStop light switch ON: ON
FC IDLFuel Cut Idle: Fuel cut when throttle valve fully
closed, during decelerationFuel cut operating: ON
FC TAUFuel Cut TAU: Fuel cut during very light loadFuel cut operating: ON
CYL #1 − CYL #6Abnormal revolution variation for each cylinder0 %
IGNITIONTotal number of ignition for every 1,000
revolutions0 − 3,000
EGRT GAS*2EGR Gas Temp. Sensor Value
EGR not operating:
Temp. between intake air temp. and engine
coolant temp.
EGR SYSTEM*2EGR System Operating ConditionIdling: OFF
A/C CUT SIGA/C Cut SignalA/C S/W OFF: ON
FUEL PUMPFuel Pump SignalIdling: ON
EVAP (PURGE) VSVEVAP VSV SignalVSV operating: ON
VAPOR PRESS VSVVapor Pressure VSV SignalVSV operating: ON
TOTAL FT B1Total Fuel Trim Bank 1: Average value for fuel
trim system of bank 1Idling: 0.8 − 1.2 V
O2 LR B1, S1
Oxygen Sensor Lean Rich Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from lean to rich
Idling after warming up: 0 − 1,000 msec.
O2 RL B1, S1
Oxygen Sensor Rich Lean Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from rich to lean
Idling after warming up: 0 − 1,000 msec.
*1: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C
switch is OFF and all accessory switches are OFF.
*2: Only for 2WD models with a load capacity of 0.5 ton and regular cab.

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DI−140
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
DIAGNOSTIC TROUBLE CODE CHART
SAE CONTROLLED
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed
in the table below. For details of each code, turn to the page referred to under the ’’See Page ’’ for the respec-
tive ’’DTC No.’’ in the DTC chart.
DTC No.
(See Page)Detection ItemTrouble AreaMIL*Memory
P0100
(DI−149)Mass Air Flow Circuit
MalfunctionOpen or short in mass air flow meter circuit
Mass air flow meter
ECM

P0101
(DI−153)Mass Air Flow Circuit
Range/Performance
Problem
Mass air flow meter
P0110
(DI−154)Intake Air Temp. Circuit
MalfunctionOpen or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM

P0115
(DI−158)Engine Coolant Temp. Circuit
MalfunctionOpen or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM

P0116
(DI−162)Engine Coolant Temp. Circuit
Range/Performance ProblemEngine coolant temp. sensor
Cooling system
P0120
(DI−163)Throttle/Pedal Position
Sensor/Switch ”A” Circuit
MalfunctionOpen or short in throttle position sensor circuit
Throttle position sensor
ECM

P0121
(DI−168)Throttle/Pedal Position
Sensor/Switch ”A” Circuit
Range/Performance Problem
Throttle position sensor
P0125
(DI−169)Insufficient Coolant Temp. for
Closed Loop Fuel ControlOpen or short in heated oxygen sensor (bank 1 sensor 1)
circuit
Heated oxygen sensor (bank 1 sensor 1)

P0130
(DI−172)Heated Oxygen Sensor Circuit
Malfunction (Bank 1 Sensor 1)Heated oxygen sensor
Fuel trim malfunction
P0133
(DI−175)Heated Oxygen Sensor Circuit
Slow Response
(Bank 1 Sensor 1)
Heated oxygen sensor
P0135
(DI−176)Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 1)Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor
ECM

P0136
(DI−178)Heated Oxygen Sensor Circuit
Malfunction
(Bank 1 Sensor 2)
Heated oxygen sensor
P0141
(DI−176)Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 2)
Same as DTC No. P0135
*:  MIL lights up

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DI−141
1996 TOYOTA T100 (RM449U) DTC No.
(See Page)
Detection ItemTrouble AreaMILMemory
P0171
(DI−180)System too Lean
(Fuel Trim)
Air intake (hose loose)
Fuel line pressure
Injector blockage
Heated oxygen sensor (bank 1 sensor 1) malfunction
Mass air flow meter
Engine coolant temp. sensor
*1
P0172
(DI−180)System too Rich
(Fuel Trim)
Fuel line pressure
Injector leak, blockage
Heated oxygen sensor (bank 1 sensor 1) malfunction
Mass air flow meter
Engine coolant temp. sensor
*1
P0300
(DI−183)Random/Multiple Cylinder
Misfire DetectedIgnition system
Injector
Fuel line pressure
EGR*3
Compression pressure
Valve clearance not to specification
Valve timing
Mass air flow meter
Engine coolant temp. sensor*2
P0301
P0302
P0303
P0304
P0305
P0306
(DI−183)Misfire Detected
− Cylinder 1
− Cylinder 2
− Cylinder 3
− Cylinder 4
− Cylinder 5
− Cylinder 6
*2
P0325
(DI−188)Knock Sensor 1 Circuit
MalfunctionOpen or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM
*1
P0330
(DI−188)Knock Sensor 2 Circuit
MalfunctionOpen or short in knock sensor 2 circuit
Knock sensor 2 (looseness)
ECM
*1
P0335
(DI−191)Crankshaft Position Sensor
”A” Circuit Malfunction
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Starter
ECM
*1 
P0340
(DI−194)Camshaft Position Sensor
Circuit Malfunction
Open or short in camshaft position sensor circuit
Camshaft position sensor
Starter
ECM
*1 
P0401*3
(DI−196)Exhaust Gas Recirculation
Flow Insufficient Detected
EGR valve stuck closed
Short in VSV circuit for EGR
Open in EGR gas temp. sensor circuit
EGR hose disconnected
ECM
*1 
P0402*3
(DI−206)Exhaust Gas Recirculation
Flow Excessive Detected
EGR valve stuck open
EGR VSV open malfunction
Open in VSV circuit for EGR
Short in EGR gas temp. sensor circuit
ECM
*1
P0420
(DI−210)Catalyst System Efficiency
Below Threshold
Three−way catalytic converter
Open or short in heated oxygen sensor (bank 1 sensor 1, 2)
circuit
Heated oxygen sensor (bank 1 sensor 1, 2)
*1
*1: MIL lights up
*2: MIL lights up or blinking
*3: Only for 2WD models with a load capacity of 0.5 ton and regular cab.

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− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U) DTC No.
(See Page)
Detection ItemTrouble AreaMIL*Memory
P0441
(DI−212)Evaporative Emission Control
System Incorrect Purge Flow
Open or short in VSV circuit for EVAP
VSV for EVAP
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
Open or short in VSV circuit for vapor pressure sensor
VSV for vapor pressure sensor
Vacuum hose cracked, holed, blocked, damaged or
disconnected
Charcoal canister cracked, holed or damaged

P0500
(DI−226)Vehicle Speed Sensor
Malfunction
Open or short in No.1 vehicle speed sensor circuit
No.1 vehicle speed sensor
ECM
Speedometer cable

P0505
(DI−228)Idle Control System
Malfunction
IAC valve is stuck or closed
Open or short in IAC valve circuit
Open or short in A/C signal circuit
Air intake (hose loose)

P0510
(DI−231)Closed Throttle Position Switch
MalfunctionOpen in closed throttle position switch circuit
Closed throttle position switch
ECM

*:  MIL lights up
MANUFACTURER CONTROLLED
DTC No.
(See Page)Detection ItemTrouble AreaMIL*Memory
P1300
(DI−235)Igniter Circuit Malfunction
Open or short in IGF or IGT circuit from igniter to ECM
Igniter
ECM

P1335
(DI−241)Crankshaft Position Sensor
Circuit Malfunction
(during engine running)Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Starter
ECM
−
P1500
(DI−242)Starter Signal Circuit Malfunction
Open or short in starter signal circuit
Open or short in ignition switch or starter relay circuit
ECM
−
P1600
(DI−244)ECM BATT MalfunctionOpen in back up power source circuit
ECM
P1605
(DI−246)Knock Control CPU MalfunctionECM
P1780
(DI−247)Park/Neutral Position Switch
MalfunctionShort in park/neutral position switch circuit
Park/neutral position switch
ECM

*: −  MIL does not light up,   MIL lights up

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A00783
DLC3
EGR Gas Temp. Sensor*
A/C Amplifier
Circuit Opening Replay
ECM
Throttle Position Sensor
IAC Valve
Igniter
Mass Air
Flow MeterHeated Oxygen Sensor (Bank 1 Sensor 1)
Combination Meter
Heated Oxygen
Sensor (Bank 1
Sensor 2)
Park/Neutral
Position Switch
Fuel Pump
Ignition Switch
VSV for EGR*
Stop Light Switch
VSV for Vapor Pressure Sensor
VSV for EVAP
EFI Main Relay
(Marking : EFI)
DLC1 Knock Sensor 2 Knock Sensor 1Injector Ignition Coil Injector
Camshaft
Position Sensor
Engine Coolant
Temp. Sensor
Crankshaft Position
Sensor
*: Only for 2WD models with a load capacity of 0.5 ton and regular cab.
− DIAGNOSTICSENGINE (5VZ−FE)
DI−143
1996 TOYOTA T100 (RM449U)
PARTS LOCATION

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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
E5 E6
E7
ECM Terminals
E4 DI−144
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TERMINALS OF ECM
For M/T
Symbols (Terminals No.)Wiring ColorConditionSTD Voltage (V)
BATT (E4−2) − E1 (E7−24)B−G ↔BRAlways9 − 14
+B (E4−12) − E1 (E7−24)W−R ↔ BRIG switch ON9 − 14
VCC (E6−1) − E2 (E6−9)G−B ↔ BR−BIG switch ON4.5 − 5.5
VG (E6−2) − E3 (E6−8)GR−R ↔BR−WIdling, N position, A/C switch OFF1.1 − 1.5
THA (E6−12) − E2 (E6−9)Y−G ↔BR−BIdling, Intake air temp. 20°C (68°F)0.5 − 3.4
THW (E6−4) − E2 (E6−9)G−Y ↔BR−BIdling, Engine coolant temp. 80°C (176°F) 0.2 − 1.0
IDL (E6−11) − E2 (E6−9)Y−L ↔ BR−B
IG switch ON and apply vacuum to the throttle opener/Throttle
valve fully closed0 − 3
IG switch ON
Throttle valve fully open9 − 14
VTA (E6−10) − E2 (E6−9)Y−B ↔ BR−B
IG switch ON
Throttle valve fully closed0.3 − 0.8
IG switch ON
Throttle valve fully open3.2 − 4.9
STA (E4−11) − E1 (E7−24)B−W ↔ BRCranking6.0 or more
#10 (E7−12) − E01 (E7−13)W−R ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#20 (E7−11) − E01 (E7−13)W ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#30 (E7−25) − E01 (E7−13)W−G ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#40 (E7−10) − E01 (E7−13)Y−K ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#50 (E7−9) − E01 (E7−13)W−L ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#60 (E7−8) − E01 (E7−13)Y−B ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
IGT1 (E7−23) − E1 (E7−24)B−L ↔BRIdlingPulse generation
(See page DI−235)

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DI−145
1996 TOYOTA T100 (RM449U) Symbols (Terminals No.)
Wiring ColorConditionSTD Voltage (V)
IGT2 (E7− 22) − E1 (E7−24)BR−B ↔BRIdlingPulse generation
(See page DI−235)
IGT3 (E7−31) − E1 (E7−24)B−W ↔BRIdlingPulse generation
(See page DI−235)
IGF (E7−17) − E1 (E7−24)B−Y ↔BR
IG switch ON, Disconnect igniter connector4.5 − 5.5
IdlingPulse generation
(See page DI−235)
G (E5−11) − G− (E5−5)B ↔WIdlingPulse generation
(See page DI−191)
NE (E5−12) − NE− (E5−6)G ↔LIdlingPulse generation
(See page DI−191)
FPU (E7−19) − E1 (E7−24)R−B ↔BRIG switch ON9 − 14
Idling0 − 3.0
EGR* (E7−18) − E1 (E7−24)R−W ↔BRIG switch ON9 − 14
THG* (E6−14) −E2( E6−9)P ↔BR−BIG switch ON4.5 − 5.5
EVP1 (E7−5) − E1 (E7−24)W−G ↔BRIG switch ON9 − 14
RSC (E7−6) − E1 (E7−24)B−R ↔BRIG switch ON, Disconnect E7 of ECM connector9 − 14
RSO (E7−7) − E1 (E7−24)BR−R ↔BRIG switch ON, Disconnect E7 of ECM connector9 − 14
ACV (E7−2) − E1 (7−24)B−R ↔ BRIdling, A/C switch ON0 − 3
Idling, A/C switch OFF9 − 14
FC (E7−14) − E1 (E7−24)G−Y ↔ BRIG switch ON9 − 14
Idling0 − 3
OX1 (E6−5) − E1 (E7−24)W ↔BRMaintain engine speed at 2,500 rpm for 2 min. after
warming upPulse generation
(See page DI−172)
OX2 (E6−13) − E1 (E7−24)R ↔BRMaintain engine speed at 2,500 rpm for 2 min. after
warming upPulse generation
(See page DI−172)
HT1 (E5−3) − E03 (E5−7)P−G ↔BRIdlingBelow 3.0
IG switch ON9 − 14
HT2 (E5−9) − E03 (E5−7)R−G ↔BRIdlingBelow 3.0
IG switch ON9 − 14
KNK1 (E6−6) − E1 (E7−24)B ↔BRIdlingPulse generation
(See page DI−188)
KNK2 (E6−3) − E1 (E7−24)GR ↔BRIdlingPulse generation
(See page DI−188)
SP1 (E4−8) − E1 (E7−24)G ↔BRIG switch ON
Rotate driving wheel slowlyPulse generation
(See page DI−226)
TE1 (E6−7) − E1 (E7−24)V−W ↔BRIG switch ON9 − 14
W (E4−4) − E1 (E7−24)V ↔BRIdling9 − 14
IG switch ONBelow 3.0
ACT (E4−6) − E1 (E7−24)L−B ↔BRA/C switch OFF at IdlingBelow 2.0
A/C switch ON at idling5 or more
AC1 (E4−7) − E1 (E7−24)B−R ↔BRA/C switch ON at idlingBelow 2.0
A/C switch OFF at Idling9 − 14
SDL (E4−19) − E1 (E7−24)W ↔BRDuring transmissionPulse generation
*: Only for 2WD models with a load capacity of 0.5 ton and regular cab.

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E7E6 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−146
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
For A/T
Symbols (Terminals No.)Wiring ColorConditionSTD Voltage (V)
BATT (E4−14) − E1 (E5−16)B−G ↔BRAlways9 − 14
+B (E4−22) − E1 (E5−16)W−R ↔ BRIG switch ON9 − 14
VCC (E6−1) − E2 (E6−22)G−B ↔ BR−BIG switch ON4.5 − 5.5
VG (E6−8) − E3 (E6−18)GR−R ↔BR−WIdling, P or N position, A/C switch OFF1.1 − 1.5
THA (E6−14) − E2 (E6−22)Y−G ↔BR−BIdling, Intake air temp. 20°C (68°F)0.5 − 3.4
THW (E6−20) − E2 (E6−22)G−Y ↔BR−BIdling, Engine coolant temp. 80°C (176°F) 0.2 − 1.0
STA (E7−13) − E1 (E5−16)B−W ↔ BRCranking6.0 or more
#10 (E7−10) − E01 (E7−34)W−R ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#20 (E7−9) − E01 (E7−34)W ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#30 (E7−8) − E01 (E7−34)W−G ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#40 (E7−7) − E01 (E7−34)Y−R ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#50 (E7−6) − E01 (E7−34)W−L ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
#60 (E7−5) − E01 (E7−34)Y−B ↔BR
IG switch ON9 − 14
IdlingPulse generation
(See page DI−183)
IGT1 (E7−24) − E1 (E5−16)B−L ↔BRIdlingPulse generation
(See page DI−235)
IGT2 (E7−25) − E1 (E5−16)BR−B ↔BRIdlingPulse generation
(See page DI−235)
IGT3 (E7−26) − E1 (E5−16)B−W ↔BRIdlingPulse generation
(See page DI−235)
IGF (E7−12) − E1 (E5−16)B−Y ↔BR
IG switch ON, Disconnect igniter connector4.5 − 5.5
IdlingPulse generation
(See page DI−235)
IDL (E7−32) − E2 (E6−22)Y−L ↔ BR−B
IG switch ON and apply vacuum to the throttle opener/THrottle
valve fully closed0 − 3
IG switch ON
Throttle valve fully open9 − 14