TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine N06219
DLC1
E1
TC
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−457
1996 TOYOTA T100 (RM449U)
INSPECTION PROCEDURE
1 Check voltage between terminals Tc and E1 of DLC1.
PREPARATION:
Turn ignition switch ON.
CHECK:
Measure voltage between terminals Tc and E1 of DLC1.
OK:
Voltage: 10 − 16 V
OK Proceed to next circuit inspection shown in
problem symptoms table (See page DI−419).
NG
2 Check harness and connector between cruise control ECU and DLC1, DLC1 and
body ground (See page IN−16).
NG Repair or replace harness or connector.
OK
Check and replace cruise control ECU (See
page IN−26).

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− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 TOYOTA T100 (RM449U)
Actuator Control Cable Inspection
INSPECTION PROCEDURE
1 Actuator control cable inspection.
CHECK:
(a) Check that the actuator and control cable throttle link are properly installed and that the cable and link
are connected correctly.
(b) Check that the actuator and bell crank are operating smoothly.
(c) Check that the cable is not loose or too tight.
OK:
Freeplay: less than 10 mm
HINT:
If the control cable is very loose, the vehicle’s loss of speed going uphill will be large.
If the control cable is too tight, the idle RPM will become high.
DI35E−01

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CO/HC EM-1
COMPRESSION EM-3
VALVE CLEARANCE EM-5
IGNITION TIMING EM-11
IDLE SPEED EM-12
TIMING CHAIN EM-13
CYLINDER HEAD EM-26
ENGINE UNIT EM-61
CYLINDER BLOCK EM-75
EXHAUST SYSTEM EM-104

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EM06Q−03
− ENGINE MECHANICAL (3RZ−FE)CO/HC
EM−1
716 Author: Date:
1996 TOYOTA T100 (RM449U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing set correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180
SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When doing the 2 mode (2,500 rpm and idle) test, follow the
measurement order prescribed by the applicable local regula-
tions.

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− ENGINE MECHANICAL (3RZ−FE)CO/HC
717 Author: Date:
1996 TOYOTA T100 (RM449U)
6. TROUBLESHOOTING
If the CO/HC concentration does not comply with regulations,
troubleshoot according to the table below.
(a) Check heated oxygen sensor operation.
(b) Check and correct the cause if necessary.
COHCSymptomCauses
NormalHighRough Idle
1. Faulty ignitions:
 Incorrect timing
 Fouled, shorted or improperly gapped plugs
 Open or crossed high−tension cords
 Cracked distributor cap
2. Incorrect valve clearance
3. Leaky EGR valves
4. Leaky exhaust valves
5. Leaky cylinder
LowHighRough Idle
(Fluctuating HC reading)
1. Vacuum leaks:
 Vacuum hose
 Intake manifold
 Intake chamber
 PCV line
 Throttle body
HighHighRough Idle
(Black smoke from exhaust)
1. Clogged air filter
2. Plugged PCV valve
3. Faulty SFI systems:
 Faulty fuel pressure regulator
 Clogged fuel return line
 Faulty MAF meter
 Defective ECT sensor
 Defective IAT sensor
 Faulty engine control module (ECM)
 Faulty injector

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P15972
Compression Gauge
− ENGINE MECHANICAL (3RZ−FE)COMPRESSION
EM−3
718 Author: Date:
1996 TOYOTA T100 (RM449U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
2. REMOVE INTAKE AIR CONNECTOR
(See page EM−65)
3. DISCONNECT HIGH−TENSION CORDS FROM
SPARK PLUGS
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
4. REMOVE SPARK PLUGS
5. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,230 kPa (12.5 kgf/cm
2, 178 psi) or more
Minimum pressure:
880 kPa (9.0 kgf/cm
2, 127 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damage.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.

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− ENGINE MECHANICAL (3RZ−FE)COMPRESSION
719 Author: Date:
1996 TOYOTA T100 (RM449U)
6. REINSTALL SPARK PLUGS
Torque:19 N·m (200 kgf·cm, 14 ft·lbf)
7. REINSTALL HIGH−TENSION CORDS TO SPARK
PLUGS
8. REINSTALL AIR INTAKE CONNECTOR
(See page EM−70)

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P24401A03713
P14695
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
EM−5
720 Author: Date:
1996 TOYOTA T100 (RM449U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR (See page EM−65)
3. REMOVE NO.1 AND NO.2 PCV HOSES
4. DISCONNECT HIGH−TENSION CORDS FROM SPARK
PLUGS
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
5. REMOVE THROTTLE BODY (See page MF−28)
6. DISCONNECT ENGINE WIRE
(a) Disconnect these connectors:
w/ A/C:
A/C compressor connector
Oil pressure sensor connector
ECT sensor connector
(b) Disconnect the 5 engine wire clamps and engine wire.
7. REMOVE CYLINDER HEAD COVER
Remove the 10 bolts, cylinder head cover and gasket.
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise and align its groove
with the ”0” mark on the timing chain cover.

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Dot Mark
P15017A03714
P15018A03715
P15045A03716
P15044
SST (A)
SST (B)
EM−6
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
721 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) Check that the timing marks (one and two dots) of the
camshaft drive and driven gears are in straight line on the
cylinder head surface as shown in the illustration. If not,
turn the crankshaft 1 revolution (360°) and align the
marks as above.
9. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
Using a thickness gauge, measure the clearance
between the valve lifter and camshaft.
Record the out−of−specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake
0.15 − 0.25 mm (0.006 − 0.010 in.)
Exhaust
0.25 − 0.35 mm (0.010 − 0.014 in.)
(b) Turn the crankshaft pulley 1 revolution (360°) and align
its groove with timing mark ”0” of the timing chain cover.
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
10. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the crankshaft to position the cam lobe of the
camshaft on the adjusting valve upward.
Position the notch of the valve lifter toward the spark
plug side.
Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter
flange. Remove SST (A).
SST 09248−55040 (09248−05410, 09248−05420)
HINT:
 Apply SST (B) at slight angle on the side marked with ”9”,
at the position shown in the illustration.
 When SST (B) is inserted too deeply, it will get pinched
by the shim. To prevent it from being stuck, insert it shal-
lowly from the outside of the cylinder head, at a slight
angle.

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EM0494
P15043
SST (A)
SST (B)
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
EM−7
722 Author: Date:
1996 TOYOTA T100 (RM449U)
Remove the adjusting shim with a small screwdriver and
magnetic finger.
(b) Determine the replacement adjusting shim size by follow-
ing the Formula or Charts:
Using a micrometer, measure the thickness of the
removed shim.
Calculate the thickness of a new shim so that the
valve clearance comes within the specified value.
T ....... Thickness of removed shim
A ....... Measured valve clearance
N ....... Thickness of new shim
Intake:
N=T + (A − 0.20 mm (0.008 in.))
Exhaust:
N=T + (A − 0.30 mm (0.012 in.))
Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 17 sized in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
Place a new adjusting shim on the valve lifter.
Using SST (A), press down the valve lifter and re-
move SST (B).
SST 09248−55040 (09248−05410, 09248−05420)
(d) Recheck the valve clearance.