belt TOYOTA T100 1996 Factory Workshop Manual

Downloaded from www.Manualslib.com manuals search engine P21220
SST (Union)
SST
(Union Bolt) Gasket
P21224
SF−6
− SFI (5VZ−FE)FUEL PUMP
1012 Author: Date:
1996 TOYOTA T100 (RM449U)
(e) Install SST (pressure gauge) to the delivery pipe with the
2 gaskets and SST (union and union bolt).
SST 09268−45012
Torque:34.3 N·m (350 kgf·cm, 25 ft·lbf)
(f) Wipe off any splattered gasoline.
(g) Connect the TOYOTA hand−held tester to the DLC3.
(See on−vehicle inspection in fuel pump)
(h) Reconnect the negative (−) terminal cable to the battery.
(i) Turn the ignition switch ON.
(j) Measure the fuel pressure.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
Fuel hoses and connections
Fuel pump
Fuel filter
Fuel pressure regulator
VSV for fuel pressure control
(k) Disconnect the TOYOTA hand−held tester from the
DLC3.
(l) Reinstall the No.2 timing belt cover with the 6 bolts.
(m) Start the engine.
(n) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator, and plug the hose end.
(o) Measure the fuel pressure at idle.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
(p) Reconnect the vacuum sensing hose to the fuel
pressure regulator.
(q) Measure the fuel pressure at idle.
Fuel pressure:
226 − 265 kPa (2.3 − 2.7 kgf/cm
2, 33 − 38 psi)
If pressure is not as specified, check the vacuum sensing hose
and fuel pressure regulator.
(r) Stop the engine.
(s) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injectors.
(t) After checking fuel pressure, disconnect the negative (−)
terminal cable from the battery and carefully remove the
SST to prevent gasoline from splashing.
SST 09268−45012
(u) Remove the other union bolt, 3 gaskets and fuel pipe
from the delivery pipes.

Downloaded from www.Manualslib.com manuals search engine SF0CS−03
P21183
SF−52
− SFI (5VZ−FE)ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1996 TOYOTA T100 (RM449U)
INSPECTION
1. DRAIN ENGINE COOLANT
2. DISCONNECT UPPER RADIATOR HOSE FROM WA-
TER OUTLET
3. REMOVE NO. 2 TIMING BELT COVER
(a) Disconnect the PS air hose from the clamp.
(b) Disconnect the 3 cord clamps of the high−tension cords
from the belt cover.
(c) Remove the 6 bolts, timing belt cover and gasket.
(d) Disconnect the camshaft position sensor connector.
4. REMOVE FUEL PIPE
5. REMOVE ECT SENSOR
(a) Disconnect the ECT sensor connector.
(b) Using a 19 mm deep socket wrench, remove the ECT
sensor and gasket.

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Ohmmeter
Acceptable
TEMPERATURE °C (°F)
RESISTANCE kΩ
− SFI (5VZ−FE)ENGINE COOLANT TEMPERATURE (ECT) SENSOR
SF−53
1996 TOYOTA T100 (RM449U)
6. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance:
Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
7. REINSTALL ECT SENSOR
(a) Install a new gasket to the ECT sensor.
(b) Using a 19 mm deep socket, install the ECT sensor.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(c) Connect the ECT sensor connector.
8. REINSTALL FUEL PIPE
Install the fuel pipe with 4 new gaskets and the 2 union bolts.
Torque: 34.3 N·m (350 kgf·cm, 25 ft·lbf)
9. REINSTALL NO.2 TIMING BELT COVER
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
10. RECONNECT UPPER RADIATOR HOSE TO WATER
OUTLET
11. REFILL WITH ENGINE COOLANT

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P21182
SSTKnock Sensor 1
Knock Sensor 2
P01630
Ohmmeter
− SFI (5VZ−FE)KNOCK SENSOR
SF−57
1996 TOYOTA T100 (RM449U)
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER HOSE
3. REMOVE INTAKE AIR CONNECTOR (See page
EM−30)
4. REMOVE HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−7)
5. REMOVE TIMING BELT AND CAMSHAFT TIMING
PULLEYS (See page EM−13)
6. REMOVE TIMING BELT IDLER NO. 2
7. REMOVE FUEL PRESSURE REGULATOR (See page
SF−16)
8. REMOVE INTAKE MANIFOLD ASSEMBLY (See page
EM−30)
9. REMOVE WATER BYPASS PIPE AND KNOCK SEN-
SOR WIRE (See page EM−84)
10. REMOVE KNOCK SENSORS
Using SST, remove the knock sensor.
SST 09816−30010
11. INSPECT KNOCK SENSORS
Using an ohmmeter, check that there is no continuity between
the terminal and body.
If there is continuity, replace the sensor.
12. INSTALL KNOCK SENSORS
Using SST, install the knock sensor.
SST 09816−30010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
13. INSTALL WATER BYPASS PIPE AND KNOCK SEN-
SOR WIRE (See page CO−5)
14. INSTALL INTAKE MANIFOLD ASSEMBLY (See page
EM−51)
15. INSTALL FUEL PRESSURE REGULATOR (See page
SF−17)
16. INSTALL TIMING BELT IDLER NO. 2 (See page
EM−19)
17. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING
BELT (See page EM−19)
18. INSTALL HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−8)

Downloaded from www.Manualslib.com manuals search engine CO059−03
P14842
Adjusting Bolt
Lock Bolt
Pivot Bolt
P14838
A CO−4
− COOLING (3RZ−FE)WATER PUMP
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DISCONNECT RADIATOR INLET HOSE
3. REMOVE PS DRIVE BELT
Loosen the lock bolt and adjusting bolt, and remove the drive
belt.
4. w/ A/C:
REMOVE A/C DRIVE BELT
Loosen the idler pulley nut and adjusting bolt, and remove the
drive belt.
5. REMOVE DRIVE BELT, FAN WITH FLUID
COUPLING, WATER PUMP PULLEY AND FAN
SHROUD
(a) Stretch the belt and loosen the water pump pulley nuts.
(b) Loosen the lock, pivot and adjusting bolts of the genera-
tor, and remove the drive belt.
(c) Remove the 4 water pump pulley nuts.
Torque: 21 N·m (210 kgf·cm, 16 ft·lbf)
(d) Pull out the fan with fluid coupling and water pump pulley.
(e) Remove the No.2 fan shroud.
(f) Remove the 4 bolts and No.1 fan shroud.
6. REMOVE WATER PUMP
Remove the 10 bolts, water pump and gasket.
Torque:
8.9 N·m (90 kgf·cm, 78 in.·lbf) except bolt A
24.5 N·m (250 kgf·cm, 18 ft·lbf) for bolt A
HINT:
Use a new gasket.

Downloaded from www.Manualslib.com manuals search engine CO18O−01
P14852
P14853
P20975
− COOLING (3RZ−FE)RADIATOR
CO−15
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE BATTERY
3. REMOVE RADIATOR GRILLE
(a) Remove the 4 screws, and clearance lights.
(b) Remove the 4 screws, 11 clips and radiator grille.
4. DISCONNECT RADIATOR INLET HOSE
5. DISCONNECT RADIATOR RESERVOIR HOSE
6. REMOVE PS DRIVE BELT
Loosen the lock bolt and adjusting bolt, and remove the drive
belt.
7. w/ A/C:
REMOVE A/C DRIVE BELT
Loosen the idler pulley nut and adjusting bolt, and remove the
drive belt.
8. REMOVE DRIVE BELT, FAN WITH FLUID COUPLING,
WATER PUMP PULLEY AND FAN SHROUD (See page
CO−4)
9. A/T:
DISCONNECT OIL COOLER HOSES
10. DISCONNECT RADIATOR OUTLET HOSE
11. REMOVE RADIATOR
Remove the 4 bolts and radiator.
12. REMOVE RADIATOR SUPPORTS
M/T:
Remove the 4 bolts and 2 radiator supports.
A/T:
Remove the 8 bolts and 2 radiator supports.

Downloaded from www.Manualslib.com manuals search engine P14853
CO18P−01
P20975
P14852
CO−20
− COOLING (3RZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL SUPPORTS
M/T:
Install the supports with the 4 bolts.
Torque:13 N·m (130 kgf·cm,9 ft·lbf)
A/T:
Install the supports with the 8 bolts.
2. INSTALL RADIATOR
(a) Insert the tabs of the radiator support through the radiator
service holes.
(b) Install the radiator with the 4 bolts.
Torque:31 N·m (310 kgf·cm, 23 ft·lbf)
3. CONNECT RADIATOR OUTLET HOSE
4. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN
WITH FLUID COUPLING AND DRIVE BELT (See page
CO−6)
5. w/ A/C:
INSTALL A/C COMPRESSOR DRIVE BELT
Install and adjust the A/C compressor drive belt (See page
AC−16).
6. INSTALL PS PUMP DRIVE BELT
Install and adjust the PS pump drive belt (See page SR−3).
7. CONNECT RADIATOR RESERVOIR HOSE
8. CONNECT RADIATOR INLET HOSE
9. INSTALL RADIATOR GRILLE
(a) Install the 4 screws, 11 clips and radiator grille.
(b) Install the 4 screws and clearance lights.
10. FILL WITH ENGINE COOLANT
11. START ENGINE AND CHECK FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine CO05R−03
− COOLING (5VZ−FE)WATER PUMP
CO−5
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TIMING BELT
(See page EM−13)
2. REMOVE WATER INLET AND THERMOSTAT
3. w/ Oil Cooler:
DISCONNECT NO.2 OIL COOLER HOSE FROM WA-
TER PUMP
4. REMOVE WATER PUMP
Remove the 7 bolts and water pump.

Downloaded from www.Manualslib.com manuals search engine CO05S−01
P20920
P21660
P21515
CO−6
− COOLING (5VZ−FE)WATER PUMP
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT WATER PUMP
(a) Visually check the air hole and water hole for coolant leak-
age.
If leakage is found, replace the water pump.
If engine coolant has leaked onto the timing belt, replace the
timing belt.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.
2. INSPECT FLUID COUPLING
(a) Remove the 4 nuts and fan from the fluid coupling.
(b) Check that the fluid coupling is not damaged and that no
silicon oil leaks.
If necessary, replace the fluid coupling.
3. INSPECT FAN PULLEY BRACKET
(a) Check the turning smoothness of the fan pulley.
If necessary, replace the pulley bracket.
(b) Reinstall the fan to the fluid coupling with the 4 nuts.
Torque:5.4 N·m (75 kgf·cm, 48 in.·lbf)
4. INSPECT TIMING BELT
(See page EM−17)

Downloaded from www.Manualslib.com manuals search engine CO05T−02
P20922
Seal Packing
− COOLING (5VZ−FE)WATER PUMP
CO−7
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL WATER PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the water pump groove.
Seal packing:
Part No. 08826−00100 or equivalent
Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the water pump with the 7 bolts.
Torque:20 N·m (200 kgf·cm, 14 ft·lbf)
2. w/ OIL COOLER:
CONNECT NO.2 OIL COOLER HOSE
3. INSTALL THERMOSTAT
(See page CO−11)
4. INSTALL TIMING BELT
(See page EM−19)