TOYOTA T100 1996 Factory Service Manual

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Vehicle Speed
70 ∼ 90 km/h
(43 ∼ 56 km/h)
Idling
IG SW OFF(2)
(1)(3)
(4)(5)
(6)
Warm up 3 ∼ 5 min. 3 ∼ 5 min. 2 min. 2 min.
Time
− DIAGNOSTICSENGINE (5VZ−FE)
DI−197
1996 TOYOTA T100 (RM449U)
SYSTEM CHECK DRIVING PATTERN
(1) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3.
(2) Start and warm up the engine with all the accessories switched OFF.
(3) Run the vehicle at 70 − 90 km/h (43 − 56 mph) for 3 min. or more.
(4) Idle the engine for about 2 min.
(5) Do steps (3) and (4) again.
(6) Check the ”READINESS TESTS” mode on the OBD II scan tool or TOYOTA hand−held tester.
If ”COMPL” is displayed and the MIL does not light up, the system is normal.
If ”INCMPL” is displayed and the MIL does not light up, run the vehicle step (5) from some time and check
it.
HINT:
”INCMPL” is displayed when either condition (a) or (b) exists:
(a) The system check is incomplete.
(b) There is a malfunction in the system.
If there is a malfunction in the system, the MIL will light up after steps (2) to (5) above are done.

Downloaded from www.Manualslib.com manuals search engine BE6653
P19555
A00046
ECM ON
2
1922
(M/T)(A/T)THG
E25 V
E1 E6 E6
E6 E6
EGR Gas Temp.
Sensor
14 21
DI−198
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
INSPECTION PROCEDURE
TOYOTA hand−held tester:
1 Connect TOYOTA hand−held tester and read value of EGR gas temp. value.
PREPARATION:
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and push the TOYOTA hand−held tester main switch ON.
CHECK:
Read EGR gas temp. on the TOYOTA hand−held tester.
OK:
EGR gas temp.: 10°C (50°F) or more
HINT:
If there is an open circuit, the TOYOTA hand−held tester indicates 3.1°C (37.6°F).
OK Go to step 4.
NG
2 Check for open in harness or ECM.
PREPARATION:
(a) Disconnect the EGR gas temp. sensor connector.
(b) Connect the sensor wire harness terminals together.
(c) Turn the ignition switch ON.
CHECK:
Read EGR gas temp. on the TOYOTA hand−held tester.
OK:
EGR gas temp.: 159°C (318.2°F)
OK Confirm good connection at sensor.
If OK, replace EGR gas temp. sensor.
NG

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A00780
EGR Gas Temp.
Sensor
2
114 3
922
E6 E6
E6 E6
(M/T)(A/T)THG5 V
E2
E1
For M/T
For A/TTHG E2
E2 THG
ON
− DIAGNOSTICSENGINE (5VZ−FE)
DI−199
1996 TOYOTA T100 (RM449U)
3 Check for open in harness or ECM.
PREPARATION:
(a) Remove the right cowl side trim (See page SF−61).
(b) Connect between terminals THG and E2 of the ECM con-
nector.
HINT:
The EGR gas temp. sensor connector is disconnected.
Before checking, do a visual check and contact pressure check
for the ECM connector (See page IN−26).
CHECK:
Read EGR gas temp. on the TOYOTA hand−held tester.
OK:
EGR gas temp.: 159°C (318.2°F)
OK Open in harness between terminals E2 or THG.
Repair or replace harness.
NG
Confirm connection at ECM.
If OK, replace ECM.

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ON
System is OFF System is ON
Air
FilterAir
EG
E Air
DI−200
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
4 Check connection of vacuum hose and EGR hose (See page EC−9).
NG Repair or replace.
OK
5 Check VSV for EGR.
PREPARATION:
Select the ”ACTIVE TEST” mode on the TOYOTA hand−held
tester.
CHECK:
Check operation of VSV when it is operated by the TOYOTA
hand−held tester.
OK:
EGR system is OFF:
Air flows from port E to the air filter.
EGR system is ON:
Air flows from port E to port G.
OK Go to step 7.
NG
6 Check operation of VSV for EGR (See page EC−9).
NG Replace VSV for EGR.
OK
Check for open in harness and connector be-
tween VSV and ECM (See page IN−26).

Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSENGINE (5VZ−FE)
DI−201
1996 TOYOTA T100 (RM449U)
7 Check EGR vacuum modulator (See page EC−9).
NG Repair or replace.
OK
8 Check EGR valve (See page EC−9).
NG Repair or replace.
OK
9 Check value of EGR gas temp. sensor.
PREPARATION:
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and push the TOYOTA hand−held tester main switch ON.
(c) Select the ”ACTIVE TEST” mode on the TOYOTA hand−held tester (EGR system ON).
(d) Race the engine at 4,000 rpm for 3 min.
CHECK:
Measure EGR gas temp. while racing engine at 4,000 rpm.
OK:
EGR gas temp. after 3 min.: 140°C (284°F) or more
NG Replace EGR gas temp. sensor.
OK
Check and replace ECM (See page IN−26 ).

Downloaded from www.Manualslib.com manuals search engine P24322
EGR Gas Temp. Sensor
Connector
BE6653
P24204
A00072
ON
Wire Harness Side
1 (−)2 (+)
DI−202
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
OBD II scan tool (excluding TOYOTA hand−held tester):
1 Check resistance of EGR gas temp. sensor.
PREPARATION:
Disconnect the EGR gas temp. sensor connector.
CHECK:
Measure resistance between terminals of EGR gas temp. sen-
sor connector.
OK:
Resistance: 600 kΩ or less
HINT:
If there is open circuit, ohmmeter indicates 720 kΩ or more.
NG Check and replace EGR gas temp. sensor (See
page SF−59).
OK
2 Check for open in harness or ECM.
PREPARATION:
(a) Disconnect the EGR gas temp. sensor connector.
(b) Turn the ignition switch ON.
CHECK:
Measure voltage between terminals of EGR gas temp. sensor
wire harness side connector.
OK:
4.5 − 5.5 V
OK Go to step 4.
NG

Downloaded from www.Manualslib.com manuals search engine BE6653P24203P24323A00804
ON
For M/T
For A/TTHG (+)
THG (+)E2 (−)
E2 (−)
− DIAGNOSTICSENGINE (5VZ−FE)
DI−203
1996 TOYOTA T100 (RM449U)
3 Check for open in harness or ECM.
PREPARATION:
(a) Remove the right cowl side trim (See page SF−61).
(b) Turn the ignition switch ON.
CHECK:
Measure voltage between terminals of THG and E2 of ECM
connector.
HINT:
The EGR gas temp. sensor connector is disconnected.
OK:
4.5 − 5.5 V
OK Open in harness between terminals E2 or THG.
Repair or replace harness.
NG
Confirm connection at ECM.
If OK, replace ECM.
4 Check connection of vacuum hose and EGR hose (See page EC−2).
NG Repair or replace.
OK

Downloaded from www.Manualslib.com manuals search engine P21116BE6653
P21117A00774A00775
A00782
ON
For M/T
For A/TOFF
ONEGR
OFF
ONEGR E7 Connector
E5 Connector
VSV is ON VSV is OFF
Air
FilterAir
EG
E Air
DI−204
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
5 Check VSV for EGR.
PREPARATION:
(a) Remove the right cowl side trim (See page SF−61).
(b) Disconnect the E7 or E5 connector of the ECM.
(c) Turn the ignition switch ON.
CHECK:
Check VSV function:
(1) Connect between terminal EGR of ECM connector
and body ground (ON).
(2) Disconnect between terminal EGR of ECM connec-
tor and body ground (OFF).
OK:
(1) VSV is ON:
Air flows from port E to the air filter.
(2) VSV is OFF:
Air flows from port E to port G.
OK Go to step 7.
NG
6 Check operation for VSV for EGR (See page SF−49).
NG Replace VSV for EGR.
OK
Check for open in harness and connector be-
tween R/B No.2 and ECM (See page
EC−1).

Downloaded from www.Manualslib.com manuals search engine P24227
EGR Gas
Temp.
Sensor
Connector
− DIAGNOSTICSENGINE (5VZ−FE)
DI−205
1996 TOYOTA T100 (RM449U)
7 Check EGR vacuum modulator (See page EC−9).
NG Repair or replace.
OK
8 Check EGR valve (See page EC−9).
NG Repair or replace.
OK
9 Check resistance of EGR gas temp. sensor.
PREPARATION:
(a) Disconnect the EGR gas temp. sensor connector.
(b) Start the engine and warm it up.
(c) Disconnect the VSV connector for EGR.
(d) Race the engine at 4,000 rpm or 3 min.
CHECK:
Measure resistance of the EGR gas temp. sensor while racing
the engine at 4,000 rpm.
OK:
Resistance of EGR gas temp. sensor after 3 min.:
4.3 kΩ or less
HINT:
Resistance: 188.6 ∼ 439.0 kΩ at 20°C (68°F)
NG Replace EGR gas temp. sensor.
OK
Check and replace ECM (See page IN−26).

Downloaded from www.Manualslib.com manuals search engine DI−206
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
DTC P0402 Exhaust Gas Recirculation Flow Excessive
Detected*
*: Only for 2WD models with a load capacity of 0.5 ton and regular cab.
CIRCUIT DESCRIPTION
Refer to DTC P0401 on page DI−196.
DTC No.Detection ItemDTC Detecting ConditionTrouble AreaTrouble Area
P0402
EGR gas temp. sensor value is high during EGR cut−off
when engine is cold (Race engine at about 4,000 rpm
without load so that vacuum is applied to port E)
(2 trip detection logic)EGR valve stuck open
VSV for EGR open malfunction
Open in VSV circuit for EGR
Short in EGR gas temp. sensor circuit
ECM
P0402EGR valve is always open (2 trip detection logic)
WIRING DIAGRAM
Refer to DTC P0401 on page DI−196.
SYSTEM CHECK DRIVING PATTERN
Refer to DTC P0401 on page DI−196.
INSPECTION PROCEDURE
TOYOTA hand−held tester:
1 Connect TOYOTA hand−held tester and read EGR gas temp. value.
PREPARATION:
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and push the TOYOTA hand−held tester main switch ON.
CHECK:
Read EGR gas temp. on the TOYOTA hand−held tester.
OK:
EGR gas temp.: 159°C (318.2°F) or less (Not immediately after driving)
HINT:
If there is a short circuit, the TOYOTA hand−held tester indicates 159.3°C (318.7°F).
OK Go to step 4.
NG
DI0UY−01