OBD port TOYOTA T100 1996 Factory Service Manual

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− 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

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Vehicle Brought to Workshop
Customer Problem Analysis P. DI−2
Problem Symptom Confirmation
If the engine does not start perform steps 10 and 12 firstConnect the OBD II scan tool or TOYOTA hand−held tester to DLC3 P. DI−3
If the display indicates a communication fault in the tool, inspect DLC3 P. DI−3
Check DTC and Freezed Frame Data (Precheck)
Record or Print DTC and Freezed Frame Data P. DI−3
Clear DTC and Freezed Frame Data P. DI−3
Visual Inspection
Setting the Check Mode Diagnosis P. DI−3
Symptom Simulation P.IN−16
Basic Inspection P. DI−3DTC Chart P. DI−13
Problem Symptoms Table P. DI−21
Circuit Inspection P. DI−22
Adjustment, Repair
DTC Check P. DI−3
Titles insideare titles of pages in
in the bottom portion. See the indicated
pages for detailed explanations.this manual with the page number indicated
Malfunction
occurs.Malfunction does not occur.
Parts Inspection
Check for Intermittent Problems P. DI−3
Identification of Problem
Confirmation Test
End 1
2
3
4
5
6
7
108
9
11
12
13
15 14
16
Normal Malfunction code.
17
− DIAGNOSTICSENGINE (3RZ−FE)
DI−1
258 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE (3RZ−FE)
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following page.

Downloaded from www.Manualslib.com manuals search engine FI6571
Throttle Position
SensorECM
VCC
VTA
IDL
E25 V
B+
− DIAGNOSTICSENGINE (3RZ−FE)
DI−39
1996 TOYOTA T100 (RM449U)
DTC P0120 Throttle/Pedal Position Sensor/Switch ”A”
Circuit Malfunction
CIRCUIT DESCRIPTION
The throttle position sensor is mounted in the throttle body and
detects the throttle valve opening angle. When the throttle valve
is fully closed, the IDL contacts in the throttle position sensor
are on, so the voltage at terminal IDL of the ECM becomes
0 V. At this time, a voltage of approximately 0.3 − 0.8 V is applied
to terminal VTA of the ECM. When the throttle valve is opened,
the IDL contacts go off and thus the power source voltage of
approximately 12 V in the ECM is applied to terminal IDL of the
ECM. The voltage applied to terminal VTA of the ECM in-
creases in proportion to the opening angle of the throttle valve
and becomes approximately 3.2 − 4.9 V when the throttle valve
is fully opened. The ECM judges the vehicle driving conditions
from these signals input from terminals VTA and IDL, and uses
them as one of the conditions for deciding the air−fuel ratio
correction, power increase correction and fuel−cut control etc.
DTC No.DTC Detecting ConditionTrouble Area
P0120
Condition (a) or (b) continues:
(a) VTA < 0.1 V, and closed throttle position switch is OFF
(b) VTA > 4.9 VOpen or short in throttle position sensor circuit
Throttle position sensor
ECM
HINT:
If there is open circuit in IDL line, DTC P0120 does not indicate.
After confirming DTC P0120 use the OBD II scan tool or TOYOTA hand−held tester to confirm the
throttle valve opening percentage and closed throttle position switch condition.
Throttle valve opening position
expressed as percentage
Trouble Area
Throttle valve fully closedThrottle valve fully open
0 %0 %VCC line open
VTA line open or short
100 %100 %E2 line open
DI0TH−03

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Vehicle Brought to Workshop
Customer Problem Analysis P. DI−128
Problem Symptom Confirmation
If the engine does not start, perform steps 10 and 12 firstConnect the OBD II scan tool or TOYOTA hand−held tester to DLC3 P. DI−129
If the display indicates a communication fault in the tool, inspect DLC3 P. DI−129
Check DTC and Freezed Frame Data (Precheck)
Record or Print DTC and Freezed Frame Data P. DI−129
Clear DTC and Freezed Frame Data P. DI−129
Visual Inspection
Setting the Check Mode Diagnosis P. DI−129
Symptom Simulation P. IN−16
DTC Chart P. DI−140
Problem Symptoms Table P. DI−148
Circuit Inspection P. DI−149
Adjustment, Repair
DTC Check P. DI−129
Titles insideare titles of pages in
in the bottom portion. See the indicated
pages for detailed explanations.this manual with the page number indicated
Malfunction
occurs.Malfunction does not occur.
Parts Inspection
Check for Intermittent Problems P. DI−129
Identification of Problem
Confirmation Test
End 1
2
3
4
5
6
7
108
9
11
12
13
15 14
16
Normal Malfunction code.
17Basic Inspection P. DI−129
− DIAGNOSTICSENGINE (5VZ−FE)
DI−127
384 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE (5VZ−FE)
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following page.

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ECM
Throttle Position
Sensor
VCC
VTA
E2
− DIAGNOSTICSENGINE (5VZ−FE)
DI−163
1996 TOYOTA T100 (RM449U)
DTC P0120 Throttle/Pedal position Sensor/Switch ”A”
Circuit Malfunction
CIRCUIT DESCRIPTION
The throttle position sensor is mounted in the throttle body and
detects the throttle valve opening angle. When the throttle valve
is fully closed, a voltage of approximately 0.7 V is applied to ter-
minal VTA of the ECM. The voltage applied to the terminals VTA
of the ECM increases in proportion to the opening angle of the
throttle valve and becomes approximately 2.7 ∼ 5.2 V when the
throttle valve is fully opened. The ECM judges the vehicle driv-
ing conditions from these signals input from terminals VTA and
uses them as one of the conditions for deciding the air−fuel ratio
correction, power increase correction and fuel−cut control etc.
DTC No.DTC Detecting ConditionTrouble Area
P0120
Condition (a) or (b) continues:
(a) VTA
0.1 V
(b) VTA
4.9 V
Open or short in throttle position sensor circuit
Throttle position sensor
ECM
HINT:
After confirming DTC P0120 use the OBD II scan tool or TOYOTA hand−held tester to confirm the throttle
valve opening percentage and closed throttle position switch condition.
Throttle valve opening position
expressed as percentageTrouble Area
Throttle valve fully closedThrottle valve fully openTrouble Area
0 %0 %VCC line open
VTA line open or short
Approx. 99 %Approx. 100 %E2 line open
DI0UL−01

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Vehicle Brought to Workshop
Customer Problem Analysis
Check DTC and Freezes Frame Data (Precheck)
Record or Print DTC and Freezed Frame Data P.
DI−265
Clear DTC and Freezed Frame Data P. DI−265
Visual Inspection
Setting the Check Mode Diagnosis P.
DI−265
1
Items insideare titles of pages in this manual, with the
page number indicated in the bottom portion. See the indicated
pages for detailed explanations.
P.
DI−264
Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3
If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the
scan tool/TOYOTA hand−held tester, inspect DLC3 P.
DI−265
2
3
4
5
6
symptom does not occur
Problem Symptom Confirmation8
7Symptom Simulation
P.
IN−16symptom occur
DTC Check
P. DI−265OK Code
11Preliminary Check
P.
DI−265
DTC Chart
P.
DI−276
Mechanical System Tests
P.
DI−265
Manual Shifting Test
P.
DI−265 OK
OK
Chapter 1
(Electronic)Chapter 2
(On−Vehicle)OKChapter 3
(Off−Vehicle)OK Problem Symptoms table
P. DI−282
Circuit
Inspection O/D Cancel Signal Check
 Stop Light Signal Check
NG
Parts Inspection
NG
NGNG
Identification of ProblemRepairConfirmation TestEnd
NG
NG
12
NG13
14
1516
17 9
10
P. DI−282
P. DI−286 to DI−316
18
P. DI−282P. DI−282
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−263
520 Author: Date:
1996 TOYOTA T100 (RM449U)
AUTOMATIC TRANSMISSION
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following page.

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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)

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SF1QK−01
− MFI (3RZ−FE)THROTTLE BODY
MF−25
977 Author: Date:
1996 TOYOTA T100 (RM449U)
THROTTLE BODY
ON−VEHICLE INSPECTION
1. INSPECT THROTTLE BODY
(a) Check that the throttle linkage moves smoothly.
(b) Check the vacuum at each port.
(1) Start the engine.
(2) Check the vacuum with your finger.
Port nameAt idleAt 3,500 rpm
PNo vacuumVacuum
ENo vacuumVacuum
RNo vacuumVacuum
2. INSPECT THROTTLE POSITION SENSOR
(a) Disconnect the sensor connector.
(b) Apply vacuum to the throttle opener.
(c) Using an ohmmeter, measure the resistance between
each terminal.
Throttle valve
conditionBetween
terminalsResistance
Fully closedVTA − E20.2 − 5.7 kΩ
Fully closedIDL − E22.3 kΩ or less
OpenIDL − E2Infinity
Fully openVTA − E22.0 − 10.2 kΩ
−VC − E22.5 − 5.9 kΩ
(d) Connect the sensor connector.
3. INSPECT THROTTLE OPENER
(a) Warm up engine
Allow the engine to warm up to normal operating tempera-
ture.
(b) Connect TOYOTA hand−held tester or OBD II scan tool.
(c) Check idle speed
Idle speed: 700 rpm
(d) Disconnect the vacuum hose from the throttle opener,
and plug the hose end.