ESP TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine  DTC No.
Indicates the diagnostic trouble code.
 Page or Instructions
Indicates the page where the inspection procedure
for each circuit is to be found, or gives instructions
for checking and repairs.
 Detection Item
Indicates the system of the problem or
contents of the problem. Trouble Area
Indicates the suspect area of the
problem.
Mass Air Flow Circuit MalfunctionDetection Item
 Open or short in mass air flow meter circuit
 Mass air flow meter
 ECM DTC No.
(See page)Trouble AreaMIL*MemoryP0100
(DI − 26)
P0101
(DI − 31)Mass Air Flow Circuit
Range/Performance Problem Mass air flow meter
P0115
(DI − 37) Open or short in intake air temp. sensor circuit
 Intake air temp. sensor
 ECM Intake Air Temp. Circuit Malfunction P0110
(DI − 32)
Engine Coolant Temp. Circuit
Range/Performance Problem Open or short in engine coolant temp. sensor circuit
 Engine coolant temp. sensor
 ECM
P0120
(DI − 43)
Throttle/ Pedal Position Sensor/Switch
”A” Circuit Range/Performance
P0116
(DI − 41)
Throttle/Pedal Position Sensor/Switch
”A” Circuit Malfunction
Insufficient Coolant Temp. for Closed Engine coolant temp. sensor
 Cooling system Engine Coolant Temp. Circuit
Malfunction
 Open or short in throttle position sensor circuit
 Throttle position sensor
 ECM
 Throttle position sensor
 Open or short in heated oxygen sensor circuit
 Heated oxygen sensor
DTC CHART (SAE Controlled)
HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check mode, check the circuit for that code listed in the table
below. For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.”
in the DTC chart.
IN−22− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TOYOTA T100 (RM449U)
4. DIAGNOSTIC TROUBLE CODE CHART
The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot-
ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble-
shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the
diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.

Downloaded from www.Manualslib.com manuals search engine MA001−28
− MAINTENANCEOUTSIDE VEHICLE
MA−1
36 Author: Date:
1996 TOYOTA T100 (RM449U)
OUTSIDE VEHICLE
GENERAL MAINTENANCE
The owners are responsible for these maintenance and inspection items.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which
the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.
Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. TIRES
(a) Check the pressure with a gauge.
If necessary, adjust.
(b) Check for cuts, damage or excessive wear.
3. WHEEL NUTS
When checking the tires, check the nuts for looseness or for missing nuts.
If necessary, tighten them.
4. TIRE ROTATION
Check the owner’s manual supplement in which the maintenance schedule is shown.
5. WINDSHIELD WIPER BLADES
Check for wear or cracks whenever they do not wipe clean.
If necessary, replace.
6. FLUID LEAKS
(a) Check underneath for leaking fuel, oil, water or other fluid.
(b) If you smell gasoline fumes or notice any leak, have the cause found and corrected.
7. DOORS AND ENGINE HOOD
(a) Check that all doors and the tailgate operate smoothly, and that all latches lock securely.
(b) Check that the engine hood secondary latch secures the hood from opening when the primary latch
is released.

Downloaded from www.Manualslib.com manuals search engine MA002−05
MA−2
− MAINTENANCEINSIDE VEHICLE
37 Author: Date:
1996 TOYOTA T100 (RM449U)
INSIDE VEHICLE
GENERAL MAINTENANCE
These are maintenance and inspection items which are considered to be the owner’s responsibility.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which
the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.
Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD GLASS
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater or air conditioner.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and are mounted securely.
10. STEERING WHEEL
Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering,
excessive freeplay or strange noises.
11. SEATS
(a) Check that the seat adjusters operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the head restraints move up and down smoothly and that the locks hold securely in any
latch position.
(d) For fold−down seat backs, check that the latches lock securely.
12. SEAT BELTS
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.

Downloaded from www.Manualslib.com manuals search engine MA−14
− MAINTENANCECHASSIS
49 Author: Date:
1996 TOYOTA T100 (RM449U)
(c) Be sure to deliver a clean vehicle and especially check:
Steering wheel
Shift lever knob
All switch knobs
Door handles
Seats

Downloaded from www.Manualslib.com manuals search engine DI0T8−03
− DIAGNOSTICSENGINE (3RZ−FE)
DI−13
1996 TOYOTA T100 (RM449U)
DIAGNOSTIC TROUBLE CODE CHART
SAE CONTROLLED
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed
in the table below. For details of each code, turn to the page referred to under the ’’See Page ’’ for the respec-
tive ’’DTC No.’’ in the DTC chart.
DTC No.
(See Page)Detection ItemTrouble AreaMIL*Memory
P0100
(DI−22)Mass Air Flow Circuit
MalfunctionOpen or short in mass air flow meter circuit
Mass air flow meter
ECM

P0101
(DI−26)Mass Air Flow Circuit
Range/Performance
Problem
Mass air flow meter
P0110
(DI−27)Intake Air Temp. Circuit
MalfunctionOpen or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM

P0115
(DI−33)Engine Coolant Temp. Circuit
MalfunctionOpen or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM

P0116
(DI−38)Engine Coolant Temp. Circuit
Range/Performance ProblemEngine coolant temp. sensor
Cooling system
P0120
(DI−39)Throttle/Pedal Position
Sensor/Switch ”A” Circuit
MalfunctionOpen or short in throttle position sensor circuit
Throttle position sensor
ECM

P0121
(DI−43)Throttle/Pedal Position
Sensor/Switch ”A” Circuit
Range/Performance Problem
Throttle position sensor
P0125
(DI−44)Insufficient Coolant Temp. for
Closed Loop Fuel ControlOpen or short in heated oxygen sensor (bank 1 sensor 1)
circuit
Heated oxygen sensor (bank 1 sensor 1)

P0130
(DI−47)Heated Oxygen Sensor Circuit
Malfunction (Bank 1 Sensor 1)Heated oxygen sensor
Fuel trim malfunction
P0133
(DI−50)Heated Oxygen Sensor Circuit
Slow Response
(Bank 1 Sensor 1)
Heated oxygen sensor
P0135
(DI−51)Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 1)Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater
 ECM

P0136
(DI−53)Heated Oxygen Sensor Circuit
Malfunction
(Bank 1 Sensor 2)
Heated oxygen sensor
P0141
(DI−51)Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 2)
Same as DTC No. P0135
*:  MIL lights up

Downloaded from www.Manualslib.com manuals search engine DI−50
− DIAGNOSTICSENGINE (3RZ−FE)
1996 TOYOTA T100 (RM449U)
DTC P0133 Heated Oxygen Sensor Circuit Slow
Response (Bank 1 Sensor 1)
CIRCUIT DESCRIPTION
Refer to DTC P0125 on page DI−44.
DTC No.DTC Detecting ConditionTrouble Area
P0133
Response time for heated oxygen sensor’s voltage output to
change from rich to lean, or from lean to rich, is 1 sec. or
more during idling after engine is warmed up
(2 trip detection logic)
Heated oxygen sensor
HINT:
Sensor 1 refers to the sensor closer to the engine body.
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P0133) being output?
YES Go to relevant DTC chart.
NO
Replace heated oxygen sensor.
DI0TL−01

Downloaded from www.Manualslib.com manuals search engine A00652
ECM VSV for EVAP
Throttle
Valve
Fuel Tank Charcoal
CanisterFig 1
A00647
IG Switch
(M/T)(A/T)
23W−G
2
1
EFI
EFI Relay
VSV for
ECM From From
Battery
22
2
2
223 2
E7 E5
EA
W−B
IE2W−G1 R/B No.2
PRG
E01 4EVAP5
EA1
W−RW−R
921
B−W
DI−88
− DIAGNOSTICSENGINE (3RZ−FE)
1996 TOYOTA T100 (RM449U)
DTC P0441 Evaporative Emission Control System
Incorrect Purge Flow
CIRCUIT DESCRIPTION
To reduce HC emissions, evaporated fuel from the fuel tank is
routed through the charcoal canister to the intake manifold for
combustion in the cylinders.
The ECM changes the duty signal to the VSV for EVAP so that
the intake quantity of HC emissions is appropriate for the driving
conditions (engine load, engine speed, vehicle speed, etc.) af-
ter the engine is warmed up.
DTC No.DTC Detecting ConditionTrouble Area
P0441Proper response to computer command does not occur
(2 trip detection logic)
Open or short in VSV circuit for EVAP
VSV for EVAP
ECM
Vacuum hose cracks, hole, blocked, damaged or
disconnected
Charcoal canister
WIRING DIAGRAM
DI0TX−03

Downloaded from www.Manualslib.com manuals search engine DI0UC−02
DI−140
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
DIAGNOSTIC TROUBLE CODE CHART
SAE CONTROLLED
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed
in the table below. For details of each code, turn to the page referred to under the ’’See Page ’’ for the respec-
tive ’’DTC No.’’ in the DTC chart.
DTC No.
(See Page)Detection ItemTrouble AreaMIL*Memory
P0100
(DI−149)Mass Air Flow Circuit
MalfunctionOpen or short in mass air flow meter circuit
Mass air flow meter
ECM

P0101
(DI−153)Mass Air Flow Circuit
Range/Performance
Problem
Mass air flow meter
P0110
(DI−154)Intake Air Temp. Circuit
MalfunctionOpen or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM

P0115
(DI−158)Engine Coolant Temp. Circuit
MalfunctionOpen or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM

P0116
(DI−162)Engine Coolant Temp. Circuit
Range/Performance ProblemEngine coolant temp. sensor
Cooling system
P0120
(DI−163)Throttle/Pedal Position
Sensor/Switch ”A” Circuit
MalfunctionOpen or short in throttle position sensor circuit
Throttle position sensor
ECM

P0121
(DI−168)Throttle/Pedal Position
Sensor/Switch ”A” Circuit
Range/Performance Problem
Throttle position sensor
P0125
(DI−169)Insufficient Coolant Temp. for
Closed Loop Fuel ControlOpen or short in heated oxygen sensor (bank 1 sensor 1)
circuit
Heated oxygen sensor (bank 1 sensor 1)

P0130
(DI−172)Heated Oxygen Sensor Circuit
Malfunction (Bank 1 Sensor 1)Heated oxygen sensor
Fuel trim malfunction
P0133
(DI−175)Heated Oxygen Sensor Circuit
Slow Response
(Bank 1 Sensor 1)
Heated oxygen sensor
P0135
(DI−176)Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 1)Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor
ECM

P0136
(DI−178)Heated Oxygen Sensor Circuit
Malfunction
(Bank 1 Sensor 2)
Heated oxygen sensor
P0141
(DI−176)Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 2)
Same as DTC No. P0135
*:  MIL lights up

Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSENGINE (5VZ−FE)
DI−175
1996 TOYOTA T100 (RM449U)
DTC P0133 Heated Oxygen Sensor Circuit Slow
Response (Bank 1 Sensor 1)
CIRCUIT DESCRIPTION
Refer to DTC P0125 on page DI−169.
DTC No.DTC Detecting ConditionTrouble Area
P0133
Response time for heated oxygen sensor’s voltage output to
change from rich to lean, or from lean to rich, is 1 sec. or
more during idling after engine is warmed up
(2 trip detection logic)
Heated oxygen sensor
HINT:
Sensor 1 refers to the sensor closer to the engine body.
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P0133) being output?
YES Go to relevant DTC chart.
NO
Replace heated oxygen sensor.
DI0UP−01

Downloaded from www.Manualslib.com manuals search engine Q05336
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−275
1996 TOYOTA T100 (RM449U)
8. MANUAL SHIFTING TEST
HINT:
With this test, it can be determined whether the trouble is within
the electrical circuit or is a mechanical problem in the transmis-
sion.
(a) Disconnect the solenoid wire.
(b) Inspect the manual driving operation.
Check that the shift and gear positions correspond
with the table below.
While driving, shift through the L, 2 and D positions.
Check that the gear change corresponds to the shift
position.
Shift PositionGear Position
DO/D
23rd
L1st
RReverse
PPawl Lock
HINT:
If the L, 2 and D position gear positions are difficult to positions
are difficult to distinguish, do the following road test.
If any abnormality is found in the above test, the problem is in
the transmission itself.
(c) Connect the solenoid wire.
(d) Cancel out DTC. (See page DI−265).