TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P24689
P14628
Z15935
P14635
EM−58
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
22. INSTALL FUEL RETURN PIPE
(a) Install the fuel return pipe with the 2 bolts.
(b) Connect these hoses:
Fuel return hose to fuel pressure regulator
Fuel return hose to fuel return pipe
23. INSTALL INTAKE CHAMBER STAY
Install the intake chamber stay with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
24. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket, EGR valve and vacuum modulator
with the bolt and 2 nuts.
Torque:
Bolt: 8.5 N·m (85 kgf·cm, 74 in.·lbf)
Nut: 19 N·m (195 kgf·cm, 14 ft·lbf)
(b) Connect these hoses:
2 vacuum hoses to EGR VSV (with clamp)
Water bypass hose to water bypass pipe
(c) Install 2 new gaskets and EGR pipe with the bolt and 4
nuts.
Torque:
Bolt: 18 N·m (185 kgf·cm, 14 ft·lbf)
Nut A: 19 N·m (195 kgf·cm, 14 ft·lbf)
Nut B: 20 N·m (200 kgf·cm, 15 ft·lbf)
25. INSTALL CYLINDER HEAD REAR COVER
(a) Install a new gasket and rear cover with the 3 bolts.
Torque: 13.5 N·m (135 kgf·cm, 10 ft·lbf)
(b) Connect the heater water bypass pipe.
26. CONNECT INJECTOR CONNECTORS
27. CONNECT ENGINE WIRE
(a) Connect the engine wire to the intake manifold with the
bolt.
(b) Connect the 2 engine wire clamps.
(c) Connect the DLC1 to the bracket.
(d) Connect these connectors:
Fuel pressure control VSV connector
Knock sensor connector
Crankshaft position sensor connector
(e) Connect the 5 engine wire clamps.
(f) Connect the engine wire to the intake chamber with the
2 bolts.
(g) Connect these connectors:
EGR VSV connector
EGR gas temperature sensor connector

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P15755SST
P14841
Adjusting Bolt
Look Bolt
P24651
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−59
1996 TOYOTA T100 (RM449U)
ECT sensor connector
Oil pressure sensor connector
w/ A/C:
A/C compressor connector
28. INSTALL THROTTLE BODY (See page MF−30)
29. INSTALL WATER OUTLET
(a) Install a new gasket and water outlet with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Connect the ECT sender gauge connector.
(c) Connect the radiator inlet hose.
30. INSTALL IGNITION COIL.
31. INSTALL NO.1 AND NO.2 PCV HOSES
32. INSTALL PS PUMP AND BRACKET
(a) Install the PS pump bracket with the 4 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Connect the PS pump to the bracket with the 2 bolts.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(c) Connect the 2 air hoses to the intake chamber.
(d) Using SST, install the PS pump pulley with the nut.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
33. INSTALL PS PUMP DRIVE BELT AND IDLER
PULLEY
(a) Install the idler pulley with the 3 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Install and adjust drive belt (See page CH−2).
34. INSTALL AIR INTAKE CONNECTOR
(a) Install the air intake connector with the 2 bolts and hose
clamp.
(b) Connect the 2 air hoses.
35. M/T:
CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
36. A/T:
CONNECT THROTTLE AND ACCELERATOR CABLES
TO THROTTLE BODY

Downloaded from www.Manualslib.com manuals search engine P15087
EM−60
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
37. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP
(a) Connect the air cleaner hose clamp.
(b) Install the air cleaner cap, MAF meter and resonator with
the 4 clips.
(c) Connect the MAF meter connector, IAT sensor connector
and wire clamp.
38. FILL WITH ENGINE COOLANT
39. START ENGINE AND CHECK FOR LEAKS
40. CHECK IGNITION TIMING (See page EM−11)
41. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
42. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM07H−03
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−61
776 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE UNIT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine A02533
(w/AC)
A/C Compressor
Front Exhaust PipeRetainer
 Gasket
Rear Mounting
Bracket
(M/T)
Clutch Release Cylinder
PS Pump Stabilizer Bar(w/AC)
A/C Compressor Bracket
Drive Belt
Bracket
Cushion
Rropeller Shaft
 Gasket
Drive Belt
Drive Belt
PS Pump Pulley
Bracket
Cushion
62 (630, 46)
39 (400, 29)
N·m (kgf·cm, ft·lbf): Specified torque
 Non − reusable part EM−62
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
777 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine P21702
P21922
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−63
778 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine Z14987
EM−64
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
779 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine EM07I−03
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−65
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. DRAIN TRANSMISSION OIL
6. REMOVE HOOD
7. REMOVE RADIATOR RESERVOIR TANK
8. REMOVE RADIATOR (See page CO−15)
9. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
(a) Disconnect the MAF meter connector, IAT sensor con-
nector and wire clamp.
(b) Loosen the air cleaner hose clamp.
(c) Loosen the 4 clips, and remove the air cleaner cap, MAF
meter and resonator.
10. REMOVE AIR CLEANER CASE
(a) Remove the air cleaner element.
(b) Remove the 3 bolts and air cleaner case.
11. M/T:
DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
12. A/T:
DISCONNECT ACCELERATOR AND THROTTLE
CABLES FROM THROTTLE BODY
13. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the 2 air hoses and vs hose.
(b) Remove the 2 bolts, hose clamp and intake air connector.

Downloaded from www.Manualslib.com manuals search engine P14925
P15085
P15086
P15094
EM−66
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
14. w/ A/C:
DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Disconnect the A/C compressor connector.
(b) Remove the 4 mounting bolts, and disconnect the com-
pressor from the bracket.
HINT:
Put a side the compressor, and suspend it.
(c) Remove the 4 bolts and A/C compressor bracket.
15. DISCONNECT HEATER HOSES
16. DISCONNECT HOSES
Disconnect these hoses:
Brake booster vacuum hose
EVAP hose
2 PS air hoses
Fuel return hose
Fuel inlet hose
17. DISCONNECT PS PUMP
(a) Using SST, remove the nut and PS pump pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the 2 bolts, and disconnect the PS pump.
HINT:
Put aside the pump, and suspend it.
18. DISCONNECT GENERATOR WIRE
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire and
wire clip.

Downloaded from www.Manualslib.com manuals search engine P15739
P15078
P15089
P15072
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−67
1996 TOYOTA T100 (RM449U)
19. REMOVE FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
(a) Remove the 4 screws and front door scuff plate.
(b) Remove the clip and cowl side trim.
20. DISCONNECT ENGINE WIRE AND CONNECTORS
(a) Remove the 3 bolts and ECM.
(b) Disconnect the 4 ECM connectors.
(c) Disconnect the 2 connectors from the cowl wire.
(d) Disconnect these wires and connectors:
Igniter connector
Ground strap from cowl top panel
(e) Disconnect the 4 engine wire clamps.
(f) Pull out the engine wire from the cabin.
21. M/T:
REMOVE SHIFT LEVER ASSEMBLY
(a) Remove the shift lever knob.
(b) Remove the 4 screws and shift lever boot.
(c) Remove the 6 bolts, shift lever assembly and baffle.
NOTICE:
Do not lose the washers.
22. REMOVE STABILIZER BAR
(a) Remove the nuts and cushions holding both sides of the
stabilizer bar to the lower arms, and disconnect the stabi-
lizer bar.
(b) Remove both stabilizer bar bushings and brackets, and
remove the stabilizer bar.
23. REMOVE PROPELLER SHAFT (See page PR−3)
24. DISCONNECT SPEED METER CABLE
NOTICE:
Do not lose the felt protector and washers.