light TOYOTA T100 1996 Factory Workshop Manual

Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSENGINE (5VZ−FE)
DI−183
1996 TOYOTA T100 (RM449U)
DTC P0300 Random/Multiple Cylinder Misfire Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
DTC P0305 Cylinder 5 Misfire Detected
DTC P0306 Cylinder 6 Misfire Detected
CIRCUIT DESCRIPTION
Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in
the crankshaft rotation for each cylinder.
The ECM counts the number of times the engine speed change rate indicates that misfire has occur-
red.When the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated,
the MIL lights up.
If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks
when misfiring occurs.
DTC No.DTC Detecting ConditionTrouble Area
P0300Misfiring of random cylinders is detected during any
particular 200 or 1,000 revolutionsIgnition system
Injector
Fuel line pressure
EGR*
Compression pressure
Valve clearance not to specification
Valve timing
Mass air flow meter
Engine coolant temp. sensor
P0301
P0302
P0303
P0304
P0305
P0306For any particular 200 revolutions for engine, misfiring is
detected which can cause catalyst overheating
(This causes MIL to blink)
For any particular 1,000 revolutions of engine, misfiring is de-
tected which causes a deterioration in emission
(2 trip detection logic)
*: Only for 2WD models with a load capacity of 0.5 ton and regular cab.
HINT:
When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no Random Misfire
code is
recorded, it indicates that the misfires were detected and recorded at different times.
DI0UT−01

Downloaded from www.Manualslib.com manuals search engine FI4825
EGR
Vacuum
Modulator ECM
VSV EGR Valve Throttle Body
Throttle
Valve
Intake Air
Chamber
Exhaust Gas
P19921
R/B No.2 IG Switch
E4 E5
(M/T)(A/T)
E01
E1 ECM
E2 EGR
THG
E6 E6
E6 E6
18 8
21 14
922 1
BR−B P2
2
1 9 9
EA
W−R W−R
IE1W−REA1
W−B
2 3
2
2 2
2 2
2
2
1 1
5 B−W
EFIEFI Relay
VSV for EGR
EGR Gas
Temp. SensorB−YEA14B−Y
1C17
1A3
W−R IGNJ/B
No.1FromFrom Battery
R−W
5 V DI−196
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
DTC P0401 Exhaust Gas Recirculation Flow Insufficient
Detected*
*: Only for 2WD models with a load capacity of 0.5 ton and regular cab.
CIRCUIT DESCRIPTION
The EGR system recirculates exhaust gas which is controlled to the proper quantity to suit the driving condi-
tions, into the intake air mixture to slow down combustion, reduce the combustion temp. and reduce NOx
emissions. The amount of EGR is regulated by the EGR vacuum modulator according to the engine load.
If even one of the following conditions is fulfilled, the VSV is
turned ON by a signal from the ECM.
This results in atmospheric air acting on the EGR valve, closing
the EGR valve and shutting off the exhaust gas (EGR cut−off).
Under the following conditions, EGR is cut to maintain
driveability:
Before the engine is warmed up
During deceleration (throttle valve closed)
Light engine load (amount of intake air very small)
Engine racing
DTC No.DTC Detecting ConditionTrouble Area
P0401
After engine is warmed up and run at 80 km/h (50 mph)
for 3 to 5 min., EGR gas temp. sensor valve does not
exceed 60°C (140°F) above ambient air temp.
(2 trip detection logic)EGR valve stuck closed
Short in VSV circuit for EGR
Open in EGR gas temp. sensor circuit
EGR hose disconnected
ECM
WIRING DIAGRAM
DI0UX−01

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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.

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OX Signal Waveform (Oscilloscope)
1.0 V
0 V
200 msec./Division
− DIAGNOSTICSENGINE (5VZ−FE)
DI−211
1996 TOYOTA T100 (RM449U)
(1) Connect the TOYOTA hand−held tester to the DLC3, or connect the probe of the oscilloscope between
terminals OX1, OX2 and E1 of ECM.
(2) Start engine and warm it up with all accessories switched OFF until water temp. is stable.
(3) Race the engine at 2500 − 3000 rpm for about 3 min.
(4) After confirming that the waveform of the heated oxygen sensor, bank 1 sensor 1 (OX1), oscillate around
0.5 V during feedback to the ECM, check the waveform of the heated oxygen sensor bank 1 sensor 2 (OX2).
HINT:
If there is a malfunction in the system, the waveform of the
heated oxygen sensor bank 1 sensor 2 (OX2) is almost the
same as that of the heated oxygen sensor bank 1 sensor 1
(OX1) on the left.
There are some cases where, even though a malfunction
exists, the MIL may either light up or not light up.
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P0420) being output?
YES Go to relevant DTC chart.
NO
2 Check heated oxygen sensor (bank 1 sensor 1) (See page DI−172).
NG Repair or replace.
OK
3 Check heated oxygen sensor (bank 1 sensor 2) (See page DI−178).
NG Repair or replace.
OK
Replace center exhaust pipe (TWC: catalyst)
(See page EM−108).

Downloaded from www.Manualslib.com manuals search engine DI0VD−02
Vehicle Brought to Workshop
Customer Problem Analysis
Check DTC and Freezes Frame Data (Precheck)
Record or Print DTC and Freezed Frame Data P.
DI−265
Clear DTC and Freezed Frame Data P. DI−265
Visual Inspection
Setting the Check Mode Diagnosis P.
DI−265
1
Items insideare titles of pages in this manual, with the
page number indicated in the bottom portion. See the indicated
pages for detailed explanations.
P.
DI−264
Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3
If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the
scan tool/TOYOTA hand−held tester, inspect DLC3 P.
DI−265
2
3
4
5
6
symptom does not occur
Problem Symptom Confirmation8
7Symptom Simulation
P.
IN−16symptom occur
DTC Check
P. DI−265OK Code
11Preliminary Check
P.
DI−265
DTC Chart
P.
DI−276
Mechanical System Tests
P.
DI−265
Manual Shifting Test
P.
DI−265 OK
OK
Chapter 1
(Electronic)Chapter 2
(On−Vehicle)OKChapter 3
(Off−Vehicle)OK Problem Symptoms table
P. DI−282
Circuit
Inspection O/D Cancel Signal Check
 Stop Light Signal Check
NG
Parts Inspection
NG
NGNG
Identification of ProblemRepairConfirmation TestEnd
NG
NG
12
NG13
14
1516
17 9
10
P. DI−282
P. DI−286 to DI−316
18
P. DI−282P. DI−282
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−263
520 Author: Date:
1996 TOYOTA T100 (RM449U)
AUTOMATIC TRANSMISSION
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following page.

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w/o Tachometer
w/ Tachometer
DI0VF−02
Q08498
TOYOTA Hand−Held Tester
DLC3
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−265
1996 TOYOTA T100 (RM449U)
PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Description
When troubleshooting OBD II vehicles, the only dif-
ference from the usual troubleshooting procedure
is that you connect to the vehicle an OBD II scan
tool complying with SAE J1978 or TOYOTA hand−
held tester, and read off various data output from
the vehicle’s ECM.
OBD II regulations require that the vehicle’s on−
board computer lights up the Malfunction Indicator
Lamp (MIL) on the instrument panel when the com-
puter detects a malfunction in the computer itself or
in drive system components which affect vehicle
emissions. In addition to the MIL lighting up when
a malfunction is detected, the applicable DTCs pre-
scribed by SAE J2012 are recorded in the ECM
memory.
(3RZ−FE: See page DI−13)
(5VZ−FE: See page DI−140)
If the malfunction only occurs in 3 trips, the MIL goes off but the
DTCs remain recorded in the ECM memory.
To check the DTCs, connect an OBD II scan tool or
TOYOTA hand−held tester to DLC3 on the vehicle.
The OBD II scan tool or TOYOTA hand−held tester
also enables you to erase the DTCs and check
freeze frame data and various forms of engine data
(For instruction book).
DTCs include SAE controlled codes and Manufac-
turer controlled codes.
SAE controlled codes must be set as prescribed by
the SAE, while Manufacturer controlled codes can
be set freely by the manufacturer within the pre-
scribed limits (See DTC chart on page DI−276).

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DI−266
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
The diagnosis system operates in normal mode
during normal vehicle use, and also has a check
mode for technicians to simulate malfunction symp-
toms and perform troubleshooting. Most DTCs use
2 trip detection logic(*) to prevent erroneous detec-
tion. By switching the ECM to check mode when
troubleshooting, the technician can cause the MIL
to light up and for a malfunction that is only detected
once or momentarily (TOYOTA hand−held tester)
(See page DI−265).
*2 trip detection logic:
When a logic malfunction is first detected, the mal-
function is temporarily stored in the ECM memory.
If the same malfunction is detected again during the
2nd test drive, this 2nd detection causes the MIL to
light up.
(b) Inspect the DLC3.
The vehicle’s ECM uses the V.P.W. (Variable Pulse Width)
for communication to comply with SAE J1850. The termi-
nal arrangement of DLC3 complies with SAE J1962 and
matches the V.P.W. format.
Terminal No.Connection / Voltage or ResistanceCondition
2Bus  Line / Pulse generationDuring communication
4Chassis Ground ↔ Body / 1 Ω or lessAlways
5Signal Ground ↔ Body / 1 Ω or lessAlways
16Battery Positive ↔ Body / 9 − 14 VAlways
HINT:
If your display shows ”UNABLE TO CONNECT TO VEHICLE”
when you have connected the cable of OBD II scan tool or TOY-
OTA hand−held tester to DLC3, turned the ignition switch ON
and operated the scan tool, there is a problem on the vehicle
side or tool side.
If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tool’s instruction manual.

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w/o Tachometer
w/ Tachometer
Q08498
TOYOTA Hand−Held Tester
DLC3
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−267
1996 TOYOTA T100 (RM449U)
2. INSPECT DIAGNOSIS (NORMAL MODE)
(a) Check the MIL.
(1) The MIL comes on when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter
(See page BE−38).
(2) When the engine is started, the MIL should go off.
If the lamp remains on, the diagnosis system has
detected a malfunction or abnormality in the sys-
tem.
(b) Check the DTC.
NOTICE:
TOYOTA hand−held tester only: When the diagnostic sys-
tem is switched from normal mode to check mode, it erases
all DTCs and freezed frame data recorded in normal mode.
So before switching modes, always check the DTCs and
freezed frame data, and note them down.
(1) Prepare an OBD II scan tool (complying with SAE
J1978) or TOYOTA hand−held tester.
(2) Connect the OBD II scan tool or TOYOTA hand−
held tester to DLC3 at the lower of the instrument
panel.
(3) Turn the ignition switch ON and turn the OBD II scan
tool or TOYOTA hand−held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand−held
tester to check the DTCs and freezed frame data
and note them down (For operating instructions,
see the OBD II scan tool’s instruction book).
(5) See page DI−276 to confirm the details of the
DTCs.
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand−held tester) to check the DTCs, use
normal mode. For codes on the DTCs chart subject to ”2
trip detection logic”, turn the ignition switch off after the
symptoms have been simulated the 1st time. Then repeat
the simulation process again. When the program has been
simulated twice, the MIL lights up and the DTCs are re-
corded in the ECM.

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DI−269
1996 TOYOTA T100 (RM449U)
4. ROAD TEST
NOTICE:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
(a) D position test
Shift into the D position and fully depress the accelerator pedal and and check the following points:
(1) Check up−shift operation.
1 → 2, 2 → 3 and 3 → O/D up−shift takes place, at the shift point shown in the automatic shift
schedule (See page SS−49).
HINT:
There is no O/D up−shift or lock−up when the coolant temperature is below 60°C (140°F).
Evaluation:
ProblemPossible cause
If there is no 1→2 up−shiftShift solenoid valve No.2 is stuck
1−2 shift valve is stuck
If there is no 2 →3 up−shiftShift solenoid valve No.1 is stuck
2−3 shift valve is stuck
If there is no 3 →O/D up−shift3−4 shift valve is stuck
If the shift point is defectiveThrottle valve, 1−2 shift valve, 2−3 shift valve, etc. are defective
If the lock up is defectiveShift solenoid valve SL is stuck
Lock−up relay valve is stuck
(2) Check for shift shock and slip.
Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up−shifts.
Evaluation:
ProblemPossible cause
If the shock is excessive
Line pressure is too high
Accumulator is defective
Check ball is defective
(3) Check for abnormal noises and vibration.
Run at the D position lock−up or O/D gear and check for abnormal noises and vibration.
HINT:
The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be
due to loss of balance in the differential torque converter clutch, etc.
(4) Check kick−down operation.
While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick−down
vehicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick−downs conform to those indicated on
the automatic shift schedule (See page SS−49).
(5) Check abnormal shock and slip at kick−down.
(6) Check the lock−up mechanism.
Drive in D position, O/D gear, at a steady speed (lock−up ON).
Lightly depress the accelerator pedal and check that there is lock−up.
If there is a big jump in engine speed, there is no lock−up.
(b) 2 position test
Shift into the 2 position and fully depress the accelerator pedal and check the following points:
(1) Check up−shift operation.
Check to see that the 1 → 2 up−shift takes place and that the shift point conforms to the automatic
shift schedule (See page SS−49).

Downloaded from www.Manualslib.com manuals search engine Q06793
N
R
P
AT5115
Neutral Basic line
Bolt
Groove
DI−272
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
(3) Return the No.1 gear shifting rod 2 notches to N
position.
(4) Set the shift lever to N position.
(5) While holding the shift lever lightly toward the R
position side, adjust the No.1 gear shifting rod nut.
(6) Tighten the No.1 gear shifting rod nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(7) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust the park/neutral position.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.If it
is not as stated above, carry out the following adjustment
procedure.
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)
(h) Check the idle speed.
Idle speed (In N position and air conditioner OFF):
3RZ−FE: 700 ± 50 rpm
5VZ−FE: 700 ± 50 rpm
6. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transmission and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the that at normal operating fluid temperature 50 − 80°C (122 − 176°F)
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm
(7) Do the same test in R position.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm