Lock assembly TOYOTA T100 1996 Factory Service Manual

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IN0IL−01
Z11554
Seal Lock Adhesive
IN−4
− INTRODUCTIONREPAIR INSTRUCTIONS
4 Author: Date:
1996 TOYOTA T100 (RM449U)
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Observe the following operations:
(1) Before performing electrical work, disconnect the
negative (−) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, always disconnect the negative
(−) terminal cable which is grounded to the vehicle
body.
(3) To prevent damage to the battery terminal, loosen
the cable nut and raise the cable straight up without
twisting or prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals with
the nut loose, and tighten the nut after installation.
Do not use a hammer to tap the cable ends onto the
terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are secure and correct.
(e) Non−reusable parts
(1) Always replace cotter pins, gaskets, O−rings and oil
seals etc. with new ones.
(2) Non−reusable parts are indicated in the component
illustrations by the ”” symbol.
(f) Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.

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Front IN−10
− INTRODUCTIONFOR ALL OF VEHICLES
10 Author: Date:
1996 TOYOTA T100 (RM449U)
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the center airbag sensor if
shocks are likely to be applied to the sensor during
repairs.
(6) Never disassemble and repair the center airbag
sensor assembly, steering wheel pad in order to re-
use it.
(7) If the center airbag sensor assembly, steering
wheel pad have been dropped, or if there are
cracks, dents or other defects in the case, bracket
or connector, replace them with new ones.
(8) Do not expose the center airbag sensor assembly,
steering wheel pad directly to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kΩ/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work on the supplemental restraint system is
completed, check the SRS warning light (See page
DI−365).
(c) FRONT AIRBAG SENSOR
(1) Never reuse the front airbag sensors involved in a
collision that activated the supplemental restraint
system. (Replace both left and right airbag sen-
sors.)
(2) Install the front airbag sensor with the arrow on the
sensor facing toward the front of the vehicle.
The front airbag sensor set bolts have been anti−
rust treated. When the sensor is removed, always
replace the set bolts with new ones.
(3) The front airbag sensor is equipped with an electri-
cal connection check mechanism. Be sure to lock
this mechanism securely when connecting the con-
nector.
(4) If connector is not securely locked, a malfunction
code will be the diagnosis system (See page
RS−2).

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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.

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− PREPARATIONCOOLING (3RZ−FE)
PP−25
74 Author: Date:
1996 TOYOTA T100 (RM449U)
COOLING (3RZ−FE)
SST (Special Service Tools)
09230−00010Radiator Service Tool Set
(09231−00010)Lock Plate Bender
(09231−00020)Lock Plate Bender
(09231−00030)Plug Handle
(09231−00040)No.1 Plug
(09231−00050)No.2 Plug
09230−01010Radiator Service Tool Set
(09231−01010)Overhaul Handle
(09231−01020)Punch Assembly
(09231−01030)Claw
(09231−00060)No.3 Plug

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SS−18
− SERVICE SPECIFICATIONSMFI (3RZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Fuel line (Union bolt type)2930022
Fuel line (Flare nut type)3031022
Fuel pump bracket assembly x Fuel tank3.94035 in.·lbf
Fuel filter x Cylinder block2020015
Fuel pressure regulator x Delivery pipe8.89078 in.·lbf
Delivery pipe x Cylinder head2121015
Fuel inlet tube x Fuel filter2930022
Fuel inlet tube x Delivery pipe2930022
Air intake chamber x Intake manifold2121015
Throttle body x Air intake chamber2020014
Fuel evaporation tube x Fuel tank1.51513 in.·lbf
Fuel tank filler pipe x Fuel tank3.53531 in.·lbf
Fuel inlet pipe x Body5.45547 in.·lbf
Fuel tank band x Body3940029
MAF meter x Air cleaner cap101007
ECT sensor x Cylinder head2020014
Knock sensor x Cylinder block4445033

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SS−20
− SERVICE SPECIFICATIONSSFI (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Fuel line (Union bolt type)34.335025
Fuel line (Flare nut type)34.335025
Fuel line (Flare nut type) using SST2828521
No. 2 timing belt cover x No. 3 timing belt cover99080 in.·lbf
Fuel inlet pipe x Intake manifold88071 in.·lbf
Delivery pipe x Intake manifold1313010
Fuel pump bracket assembly x Fuel tank3.94035 in.·lbf
Fuel tank band x Body4344032
Fuel tank filler pipe x Fuel tank3.94035 in.·lbf
Fuel evaporation vent tube x Fuel tank1.51513 in.·lbf
Fuel pressure regulator x LH delivery pipe88071 in.·lbf
MAF meter x Air cleaner cap6.97261 in.·lbf
VSV assembly x Air intake connector88071 in.·lbf
A/C idle−up valve x Intake air connector2020014
ECT sensor x Intake manifold2020014
Knock sensor x Cylinder block3940029
EGR gas temperature sensor x EGR valve2020014
Heated oxygen sensor x Front exhaust pipe, Center exhaust pipe2020014

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− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
SS−51
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Valve body x Transmission case101007
Oil strainer x Valve body (A340E)5.45548 in.·lbf
Oil strainer case x Valve body (A340F)101007
Oil strainer x Valve body (A340F)6.97061 in.·lbf
Oil pan7.47565 in.·lbf
Drain plug2020515
Parking lock pawl bracket x Transmission case7.47565 in.·lbf
Extension housing x Transmission case (A340E)3637027
Extension housing x Rear mounting insulator2525018
Rear support member x Rear mounting insulator (A340F)1818013
Rear support member x Body (A340F)9597070
Rear mounting insulator x Rear mounting bracket (A340E)1818013
Rear mounting bracket x Frame (A340E)5859042
Propeller shaft x Rear differential (A340E)7475054
Front propeller shaft x Front differential (A340F)7475054
Front propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Rear differential (A340F)7475054
Center support bearing x Body3637027
Drive plate x Crankshaft8385061
Torque converter clutch x Drive plate4142030
Stiffener plate x Engine (A340F)3738027
Stiffener plate x Transmission3738027
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x TWC4849035
Rear support member x Dynamic damper6162044
Oil cooler pipe3435025
Transmission x Engine7173053
Rear end plate x Transmission3738027
Rear support member x Transfer under cover2930021
Cross shaft x Frame2829021
Cross shaft x Transmission131309
Cross shaft x No.1 gear shifting rod131309
Exhaust pipe clamp(3RZ−FE)1919514
Exhaust pipe support bracket x Transmission (3RZ−FE)7173053
Exhaust pipe support bracket x Transmission (5VZ−FE)4445033
Exhaust pipe support bracket x Exhaust pipe (5VZ−FE)4445033
Park/neutral position switch (Nut)3.94035 in.·lbf
Park/neutral position switch (Bolt)131309
No.2 vehicle speed sensor5.45548 in.·lbf
Speedometer driven gear sleeve x Locking plate1616012
ATF temperature sensor x Transmission1515011
Shift lever assembly x Steering column assembly2930022

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− SERVICE SPECIFICATIONSTRANSFER
SS−55
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transfer x Dynamic damper3738027
Transfer adaptor x Transfer3738027
Engine rear mounting2526019
Indicator switch3738027
L4 position switch3738027
Transfer assembly x Transmission3738027
Front retainer1111 58
Control retainer or upper cover1818513
Companion flange lock nut11 81,20087
Extension housing1111 58
Front case x Rear case3738027
Straight screw plug for shift fork shaft1919014
Separator with oil strainer1818513
Oil pump body x Front case1111 58
Straight screw plug for ring gear1919014
Straight screw plug for oil pump body2930021
Oil pump plate x Oil pump body7.47565 in.·lbf

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− 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

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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