ABS TOYOTA T100 1996 Factory Service Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 1996, Model line: T100, Model: TOYOTA T100 1996Pages: 2062, PDF Size: 43.47 MB
Page 9 of 2062
Downloaded from www.Manualslib.com manuals search engine IN0253
WRONG CORRECT
IN0252
WRONG CORRECT
IN0002
Example IN−6
− INTRODUCTIONREPAIR INSTRUCTIONS
6 Author: Date:
1996 TOYOTA T100 (RM449U)
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN−8).
(1) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels at the opposite
end in order to ensure safety.
(2) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on a vehicle raised on a jack alone, even for a small
job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU, ECM,
PCM or TCM unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by
static electricity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission−related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step−down
adapter for adjustment. Once the hose has been
stretched, it may leak.
(m) Tag hoses before disconnecting them:
(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
Page 16 of 2062
Downloaded from www.Manualslib.com manuals search engine − INTRODUCTIONFOR ALL OF VEHICLES
IN−13
13 Author: Date:
1996 TOYOTA T100 (RM449U)
(f) CENTER AIRBAG SENSOR ASSEMBLY
(1) Never reuse the center airbag sensor assembly in-
volved in a collision when the SRS has deployed.
(2) The connectors to the center airbag sensor assem-
bly should be connected or disconnected with the
sensor mounted on the floor. If the connectors are
connected or disconnected while the center airbag
sensor assembly is not mounted to the floor, it could
cause undesired ignition of the supplemental re-
straint system.
(3) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative (−) terminal cable is discon-
nected from the battery, even if only loosening the
set bolts of the center airbag sensor assembly.
(g) WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the cowl wire har-
ness assembly and floor wire harness assembly. The
wires for the SRS wire harness are encased in a yellow
corrugated tube. All the connectors for the system are
also a standard yellow color. If the SRS wire harness be-
comes disconnected or the connector becomes broken
due to an accident, etc., repair or replace it.
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off and prolonged braking.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
Page 34 of 2062
Downloaded from www.Manualslib.com manuals search engine IN02L−01
− INTRODUCTIONTERMS
IN−31
31 Author: Date:
1996 TOYOTA T100 (RM449U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti−Lock Brake System
A.D.D.Automatic Disconnecting Differential
A/TAutomatic Transmission
AT FAutomatic Transmission Fluid
BTDCBefore Top Dead Center
Calif.California
CBCircuit Breaker
Diff.LockDifferential Locking System
DPDash Pot
ECUElectronic Control Unit
E/GEngine
ELREmergency Locking Retractor
ESAElectronic Spark Advance
EXExhaust (Manifold, Valve)
FIPGFormed in Place Gasket
FLFusible Link
FPUFuel Pressure Up
FrFront
IGIgnition
INIntake (Manifold, Valve)
J/BJunction Block
LHLeft−Hand
LLCLong Life Coolant (Year Around Coolant)
LSPVLoad Sensing Proportioning Valve
Max.Maximum
Min.Minimum
MPMultipurpose
M/TManual Transmission
O/D, ODOverdrive
OHCOver Head Camshaft
O/SOversize
PCVPositive Crankcase Ventilation
PSPower Steering
RHRight−Hand
RrRear
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
SWSwitch
TDCTop Dead Center
TEMP.Temperature
Page 37 of 2062
Downloaded from www.Manualslib.com manuals search engine IN−34
− INTRODUCTIONTERMS
1996 TOYOTA T100 (RM449U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module−
IFIIndirect Fuel InjectionIndirect Injection
IFSInertia Fuel−Shutoff−
ISCIdle Speed Control−
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure−
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface Temperature−
MVZManifold Vacuum Zone−
NVRAMNon−Volatile Random Access Memory−
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn−Board DiagnosticOn−Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module−
PNPPark/Neutral Position−
PROMProgrammable Read Only Memory−
PSPPower Steering Pressure−
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module−
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass−
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter−
SRIService Reminder Indicator−
SRTSystem Readiness Test−
STScan Tool−
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
Page 152 of 2062
Downloaded from www.Manualslib.com manuals search engine PP0FA−03
PP−98
− PREPARATIONBRAKE
147 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE
SST (Special Service Tools)
09023−00100Union Nut Wrench 10 mm
09703−30010Brake Shoe Return Spring Tool
09709−29017LSPV Gauge Set
09718−00010Shoe Hold Down Spring Driver
09737−00010Brake Booster Push Rod Gauge
09751−36011Brake Line Union Nut 10 x 12 mm
Wrench
09843−18020Diagnosis Check Wire
09990−00150ABS Actuator Checker and
Sub−harness
09990−00200ABS Actuator Checker Sub−harness
”C”
09990−00310ABS Actuator Checker Sub−harness
”J”
09990−00370ABS Actuator Checker Sheet ”L”
Page 247 of 2062
Downloaded from www.Manualslib.com manuals search engine SS083−02
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS−67
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Front (2WD)
Tie rod end lock nut5657041
Steering knuckle x Upper ball joint1081,10080
Steering knuckle x Lower ball joint1421,450105
Steering knuckle x Brake caliper1081,10080
Steering knuckle x Steering knuckle arm1831,870135
Dust cover x Steering knuckle1919514
Disc x Axle hub6465047
Upper suspension arm x Upper ball joint3132023
Lower suspension arm x Lower ball joint7576055
Torque arm x Lower suspension arm4950036
Shock absorber x Frame2525018
Lower suspension arm x Shock absorber1818513
Lower suspension arm x Stabilizer bar131309
Lower suspension arm shaft nut2062,100152
Upper suspension arm shaft x Frame9698071
Upper suspension arm shaft x Upper suspension arm1261,28093
Lower ball joint x Strut bar7576055
Strut bar x Frame1231,25090
Stabilizer bar link set nut131309
Stabilizer bar bracket x Frame3030622
Hub nut1031,05076
ABS speed sensor x Steering knuckle8.08271 in.·lbf
ABS Speed sensor wire harness x Upper suspension arm5.05144 in.·lbf
Front (4WD)
Knuckle stopper bolt lock nut4748035
Tie rod clamp bolt2222516
Steering knuckle x Upper ball joint1421,450105
Steering knuckle x Lower ball joint5859043
Steering knuckle x Brake caliper1231,25090
Flange x Axle hub3131523
Flange x Front drive shaft1818513
Axle hub bearing lock nut4748035
Oil seal x Dust cover1818513
Upper suspension arm x Upper ball joint3334025
Lower suspension arm x Lower ball joint1421,450105
Steering knuckle arm x Steering knuckle1831,870135
Upper suspension arm x Torque arm8789064
Upper suspension arm shaft lock nut2262,300166
Shock absorber x Frame2525018
Lower suspension arm x Shock absorber1371,400101
Lower suspension arm x Stabilizer bar2526019
Stabilizer bar bracket x Frame2930022
Page 248 of 2062
Downloaded from www.Manualslib.com manuals search engine SS−68
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
1996 TOYOTA T100 (RM449U)Part tightened
N·mkgf·cmft·lbf
Front drive shaft x Side gear shaft8384561
Lower suspension arm x Frame1962,000145
Upper suspension arm shaft x Frame1781,810131
Hub nut1031,05076
ABS speed sensor x Steering knuckle8.08271 in.·lbf
ABS speed sensor wire harness5.05144 in.·lbf
Companion flange x Front differential assembly1081,10080
Drain plug4950036
Filler plug3940029
Crossmember x Frame1261,28093
Front mounting bolt1471,500108
Rear mounting bolt1671,700123
Actuator x Clutch case cover2121015
Screw plug x Clutch case cover2020014
A.D.D. indicator switch x Clutch case cover4041030
Carrier cover x Oil deflector7.47565 in.·lbf
Ring gear x Differential case9798571
Differential carrier x Bearing cap7880058
Clutch case x Tube7880058
Clutch case x Differential carrier78800500
Differential x Front propeller shaft7475054
Clutch case cover x Clutch case2121015
Differential carrier cover x Differential carrier4747534
Tube x Bearing retainer121209
Rear
Ring gear x Differential case1251,27092
Bearing cap x Differential carrier11 31,15083
Differential carrier x Axle housing7374054
Rear axle housing x Rear brake assembly6970051
Rear shock absorber x Spring seat2626019
Rear shock absorber x Frame2626019
U−bolt x Spring seat1321,35097
Shackle pin x Leaf spring9193067
Differential x Propeller shaft7678056
Hanger pin x Leaf spring9193067
Hanger pin lock bolt2626019
Leaf spring center bolt4445033
Hub nut1031,05076
Spring bumper seat set bolt2930022
ABS speed sensor x Rear axle housing8.08271 in.·lbf
Brake line1515511
Parking brake set bolt2526019
Drain plug4950036
Filler plug3940029
Page 250 of 2062
Downloaded from www.Manualslib.com manuals search engine SS085−01
SS−70
− SERVICE SPECIFICATIONSBRAKE
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.·lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket131309
Front disc brake caliper installation bolt 2WD 1.0 ton3940029
2WD 0.5 ton3637027
4WD1231,25090
Bleeder plug1111 08
Front disc brake torque plate x Steering knuckle 2WD1081,10080
Front disc x Front axle hub6465047
Front disc brake caliper x Flexible hose1515511
Rear drum brake wheel cylinder x Backing plate101007
Parking brake bellcrank bracket x Backing plate131309
LSP & BV installation nut131309
LSP & BV x Load Sensing Spring Assembly1818513
Load Sensing Spring Assembly x Shackle No.11818513
Shackle No.1 x Shackle No.22525018
Shackle No.2 x Shackle Bracket131309
LSP & BV x Frame2930011
ABS actuator x ABS actuator bracket5.45548 in.·lbf
ABS actuator bracket x Body1919514
Speed sensor installation bolt8.08271 in.·lbf
Front speed sensor wire harness clamp5.05144 in.·lbf
Rear speed sensor wire harness clamp131309
Page 520 of 2062
Downloaded from www.Manualslib.com manuals search engine A00651
ECM
EFI AM2 ALT
Battery
IG Switch
Park/
Switch
StarterOpening Relay
Clutch
Start
Switch
E01 FC 4 14
E7 E5
(M/T)(A/T)
G−Y13
IE1 G−YL
1 4
6
Circuit
8
W−B
BJ1
W−B
IC
IC2 W−RW−R
EA19
EA
6
B−WB−R
Relay
(M/T)
3
B−O
WB−W
3
2
22
2 RelayEFI
2 22
51
2
22
2
22 5 R/B
1 2 2
2 3
1 W
W
B−YIA3
IGN
B (M/T)
B
Neutral
Position
(A/T)
Fuel
PumpW−BBJ1 BJ2
BJ2W−B(w/ ABS)
(w/o ABS)
11
(w/ ABS)
(w/o ABS)
10 16
Clutch
Start
Switch
(M/T)Cancel
No.2Starter
J/B No.1
B−R
B−WB−W
B−W B−W
B−W
B−O
B
B−R
W−B
W−RW
B−Y
W 2
2W−B
AM1
23
151 5
1 36 873 17 1113
IC
EB1
S1
EA1IA3
IA31C1A
1
IE1
IE1
B−Y
W−R
W−B
2
2 5 6 4
1
13A/T
DI−256
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
WIRING DIAGRAM
Page 584 of 2062
Downloaded from www.Manualslib.com manuals search engine DI0ZI−01
ABS Check SheetInspector ’s
Name:
Customer ’s Name
Date Vehicle
Brought InRegistration YearRegistration No.
Frame No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs/ /
ContinuousIntermittent ( times a day)
ABS does not operate.
ABS does not operate efficiently.
ABS Warning Light
AbnormalRemains ONDoes not Light Up
DTC Check1st Time
2nd TimeNormal Code
Malfunction Code (Code )
Normal CodeMalfunction Code (Code )
Symptomskm
miles DI−320
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 TOYOTA T100 (RM449U)
CUSTOMER PROBLEM ANALYSIS CHECK