TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine EC02P−02
− EMISSION CONTROL (3RZ−FE)PARTS LAYOUT AND SCHEMATIC DRAWING
EC−3
1996 TOYOTA T100 (RM449U)
DRAWING

Downloaded from www.Manualslib.com manuals search engine P05445
Cylinder Head Cover Side
Clean Hose
P05444
Air Intake Chamber Side
EC02Q−01
P15871
EC−4− EMISSION CONTROL (3RZ−FE)POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM
932 Author: Date:
1996 TOYOTA T100 (RM449U)
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM
INSPECTION
1. REMOVE PCV VALVE
2. INSTALL CLEAN HOSE TO PCV VALVE
3. INSPECT PCV VALVE OPERATION
(a) Blow into the cylinder head cover side, and check that air
passes through easily.
CAUTION:
Do not suck air through the valve. Petroleum substances
inside the valve are harmful.
(b) Blow air into the air intake chamber side, and check that
air passes through with difficulty.
If operation is not as specified, replace the PCV valve.
4. REMOVE CLEAN HOSE FROM PCV VALVE
5. REINSTALL PCV VALVE
6. VISUALLY INSPECT HOSES AND CONNECTIONS
Check for cracks, leaks or damage.

Downloaded from www.Manualslib.com manuals search engine EC0GF−01
EC3069Check Valve (Vacuum Valve)
Gasket
− EMISSION CONTROL (3RZ−FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC−5
933 Author: Date:
1996 TOYOTA T100 (RM449U)
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM
INSPECTION
1. VISUALLY INSPECT LINES AND CONNECTIONS
Look for loosen connections, sharp bends or damage.
2. VISUALLY INSPECT FUEL TANK
Look for deformation, cracks or fuel leakage.
3. VISUALLY INSPECT FUEL TANK CAP
Check if the cap and/or gasket are deformed or damaged.
If necessary, repair or replace the cap.
4. REMOVE VSV
Remove the screw from the charcoal canister.
5. REMOVE CHARCOAL CANISTER
6. REMOVE CAP FROM CHARCOAL CANISTER
7. VISUALLY INSPECT CHARCOAL CANISTER
Look for cracks or damage.
8. INSPECT FOR CLOGGED FILTER AND STUCK
CHECK VALVE
(a) Using low pressure compressed air (4.71 kPa, 48 gf/cm
2,
0.68 psi), blow into tank pipe and check that air flows with-
out resistance from the other pipes.
(b) Blow air (4.71 kPa, 48 gf/cm
2, 0.68 psi) into purge pipe
and check that air does not flow from the tank pipe and air
flows without resistance from the other pipe.
If a problem is found, replace the charcoal canister.

Downloaded from www.Manualslib.com manuals search engine EC−6
− EMISSION CONTROL (3RZ−FE)EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
934 Author: Date:
1996 TOYOTA T100 (RM449U)
9. CLEAN FILTER IN CANISTER
Clean the filter by blowing 294 kPa (3 kgf·cm
2, 43 psi) of com-
pressed air into tank pipe while holding purge pipe closed
NOTICE:
Do not attempt to wash the canister.
No activated carbon should come out.
10. REINSTALL CAP TO CHARCOAL CANISTER
11. RECONNECT CHARCOAL CANISTER
Torque: 31 N·m (310 kgf·cm, 23 ft·lbf)
12. REINSTALL VSV

Downloaded from www.Manualslib.com manuals search engine P23029
Cap
Filter
EC0JU−01
P15107
P22300
TOYOTA Hand−Held Tester
DLC3
− EMISSION CONTROL (3RZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−7
935 Author: Date:
1996 TOYOTA T100 (RM449U)
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM
INSPECTION
1. INSPECT AND CLEAN FILTER IN EGR VACUUM MOD-
ULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Install the filter and cap.
HINT:
Install the filter with the coarser surface facing the atmospheric
side (outward).
2. INSTALL VACUUM GAUGE
Using a 3−way connector, connect a vacuum gauge to the hose
between the EGR valve and EGR vacuum modulator.
3. INSPECT SEATING OF EGR VALVE
Start the engine and check that the engine starts and runs at
idle.
4. CONNECT TOYOTA HAND−HELD TESTER OR OBDII
SCAN TOOL
(a) Connect the TOYOTA hand−held tester or OBDII scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand−held tester or OBDII
scan tool operators manual for further details.
5. INSPECT VSV OPERATION WITH COLD ENGINE
(a) The engine coolant temperature should be below 50°C
(122°F).
(b) Check that the vacuum gauge indicates zero at 3,500
rpm.
(c) Check that the EGR pipe is not hot.
6. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR
(a) Select the active test mode on the TOYOTA hand−held
tester (VSV is closed.).

Downloaded from www.Manualslib.com manuals search engine P23481
3−Wa y
Plug
Port Q
Low Vacuum
Z15471
B A
AB
EC−8
− EMISSION CONTROL (3RZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
936 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) If you have no TOYOTA hand−held tester, check these
procedures:
(1) Remove the 3−way connector with the vacuum
hose.
(2) Connect the vacuum hose (from port Q of EGR vac-
uum modulator) to the EGR valve.
(3) Plug the vacuum hose (from VSV for EGR).
(c) Check that the vacuum gauge indicates low vacuum at
3,500 rpm.
7. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBDII SCAN TOOL
8. REMOVE VACUUM GAUGE
Remove the vacuum gauge, and reconnect the vacuum hoses
to the proper locations.
9. INSPECT EGR VALVE
(a) Apply vacuum directly to the EGR valve with the engine
idling.
(b) Check that the engine runs rough or dies.
(c) Reconnect the vacuum hoses to the proper locations.
If no problem is found with this inspection, system is normal;
otherwise inspect each part.
10. REMOVE EGR PIPE
Remove the bolt, 4 nuts, EGR pipe and 2 gaskets.
HINT:
Install 2 new gaskets.
Torque:
Bolt: 18 N·m (185 kgf·cm, 13 ft·lbf)
Nut A: 19 N·m (195 kgf·cm, 14 ft·lbf)
Nut B: 20 N·m (200 kgf·cm, 15 ft·lbf)
11. REMOVE EGR VALVE
(a) Disconnect these hoses:
2 Vacuum hoses
2 Water bypass hoses
(b) Remove the 2 nuts, EGR valve and gasket.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine EC0107
Orange Pipe
Black Pipe
− EMISSION CONTROL (3RZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−9
937 Author: Date:
1996 TOYOTA T100 (RM449U)
12. DISCONNECT VACUUM HOSES FROM EGR VACUUM
MODULATOR
13. INSPECT EGR VACUUM MODULATOR OPERATION
(a) Block ports P and R with your finger.
(b) Blow air into port Q, and check that the air passes through
to the air filter side freely.
(c) Start the engine, and maintain speed at 3,500 rpm.
(d) Repeat the above test. Check that there is a strong resis-
tance to air flow.
If operation is not as specified, replace the EGR vacuum modu-
lator.
14. RECONNECT VACUUM HOSES TO EGR VACUUM
MODULATOR
15. REMOVE CHECK VALVE
16. INSPECT CHECK VALVE
(a) Check that air flows from the orange pipe to the black
pipe.
(b) Check that air does not flow from the black pipe to the
orange pipe.
If operation is not as specified, replace the check valve.
17. INSTALL CHECK VALVE
HINT:
Install the check valve with the orange pipe facing the EGR vac-
uum modulator side.
18. INSPECT VSV FOR EGR (See page MF−44)

Downloaded from www.Manualslib.com manuals search engine EC02T−01
EC−10− EMISSION CONTROL (3RZ−FE)THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEM
938 Author: Date:
1996 TOYOTA T100 (RM449U)
THREE−WAY CATALYTIC CONVERTER (TWC) SYSTEM
INSPECTION
1. CHECK TWC FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented to the extent that it touches the three−way catalytic convert-
er, repair or replace it.
2. CHECK EXHAUST PIPE CONNECTIONS FOR
LOOSENESS OR DAMAGE
3. CHECK EXHAUST PIPE CLUMPS FOR WEAKNESS,CRACKS OR DAMAGE
4. CHECK HEAT INSULATOR FOR DAMAGE
5. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSU-
LATOR

Downloaded from www.Manualslib.com manuals search engine EC02U−03
P21187
P21181
− EMISSION CONTROL (3RZ−FE)THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEMEC−11
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE CENTER EXHAUST PIPE
(a) Disconnect the 2 rings from the support bracket.
(b) Remove the 2 nuts and gasket, and disconnect the
heated oxygen sensor (bank 1 sensor 2).
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
HINT:
At the time of assembly please refer to the following item.
Install the heated oxygen sensor with a new gasket.
(c) Remove the 4 bolts, TWC joint retainer, center exhaust
pipe and 2 gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
HINT:
At the time of assembly please refer to the following item.
Place 2 new gaskets on the front exhaust and tail pipes, and
temporarily install the center exhaust pipe.
2. REINSTALL CENTER EXHAUST PIPE

Downloaded from www.Manualslib.com manuals search engine EC – EMISSIONS CONTROL (5VZ-FE)

EMISSION CONTROL SYSTEM EC-1
PARTS LAYOUT AND SCHEMATIC
DRAWING EC-2
POSITIVE CRANKCASE VENTILATION
(PCV) SYSTEM EC-4
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM EC-5
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM EC-7
THREE-WAY CATALYTIC CONVERTER
(TWC) SYSTEM EC-12