VALVE BODY 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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− SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
SS−7
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Throttle body x Air intake chamber2020014
Spark plug x Cylinder head1920014
Cylinder head x Cylinder block 1st
2nd
3rd39
Turn 90°
Turn 90°
40029
Cylinder head x Timing chain cover2121015
Camshaft bearing cap x Cylinder head15.516012
Camshaft timing gear x Camshaft73.575054
Distributor gear x Camshaft4646534
Chain tensioner x Cylinder head2121015
Engine hanger x Cylinder head4242030
Exhaust manifold x Cylinder head4950036
Heat insulator x Exhaust manifold5.55548 in.·lbf
Front exhaust pipe x Exhaust manifold6263046
No.1 support bracket x Transmission3940029
No.1 support bracket clamp bolt1919514
Front exhaust pipe x TWC3940029
Intake manifold x Cylinder head2930022
Delivery pipe x Intake manifold2121015
Fuel inlet tube x Fuel filter2930022
Fuel inlet tube x Delivery pipe2930022
EGR valve x Air intake chamber, EGR pipe1919514
EGR vacuum modulator x Air intake chamber8.58574 in.·lbf
EGR pipe x Exhaust manifold2020015
EGR pipe x Cylinder head1818514
Cylinder head rear cover x Cylinder head13.513510
Water outlet x Cylinder head2020014
PS pump bracket x Cylinder head2020014
PS pump bracket x PS pump5859043
PS pump x PS pump pulley4344032
PS pump idler pulley x Cylinder head2020014
Balance shaft drive gear x Balance shaft2525018
No.2 chain tensioner, No.3 vibration damper x Cylinder block1818513
No.2 vibration damper x Cylinder block2727020
No.1 vibration damper x Cylinder block1818513
No.1 timing chain tensioner slipper x Cylinder block2727020
Timing chain cover x Cylinder block Bolt A
Bolt B
Bolt C
Nut D20
24.5
44
20200
250
440
20014
18
32
14
Timing chain cover mounting bolt1818513
No.1 water bypass pipe mounting nut2020014
Crankshaft pulley x Crankshaft2602,650193
No.2 and No.3 crankshaft pulley x Crankshaft pulley2525018

Downloaded from www.Manualslib.com manuals search engine SS096−02
− SERVICE SPECIFICATIONSMFI (3RZ−FE)
SS−17
191 Author: Date:
1996 TOYOTA T100 (RM449U)
MFI (3RZ−FE)
SERVICE DATA
Fuel pressure
regulatorFuel pressure at no vacuum265 − 304 kPa
(2.7 − 3.1 kgf/cm2, 38 − 44 psi)
Fuel pumpResistance at 20°C (68°F)0.2 − 3.0 Ω
InjectorResistance at 20°C (68°F)
Injection volume
Difference between each cylinder
Fuel leakage12 − 16 Ω
69 − 88 cm3 (4.2 − 5.3 cu in.) per 15 seconds
5 cm3 (0.3 cu in.) or less
One drop or less per minutes
Throttle bodyThrottle valve fully closed angle
Throttle opener setting speed6°
1,200 − 1,400 rpm
TP sensorClearance between stop screw and leverTerminalsResistance
0 mm (0 in.) VTA − E2
0.50 mm (0.020 in.) IDL − E2
0.75 mm (0.030 in.) IDL − E2
Throttle valve fully open VTA − E2
−VC − E20.2 − 5.7 kΩ
2.3 kΩ or less
Infinity
2.0 − 10.2 kΩ
2.5 − 5.9 kΩ
IAC valveResistance +B − RSC or RSO17.0 − 24.5 Ω (−10 − 50°C)
21.5 − 28.5 Ω ( 50 − 100°C)
VSV for EVAPResistance at 20°C (68°F)30 − 34 Ω
VSV for EGRResistance at 20°C (68°F)33 − 39 Ω
VSV for Vapor
pressure sensorResistance at 20°C (68°F)37 − 44 Ω
Vapor pressure
sensorPower source voltage4.5 − 5.5 V
ECT sensorResistance at −20°C (−4°F)
at 0°C (32°F)
at 20°C (68°F)
at 40°C (104°F)
at 60°C (140°F)
at 80°C (176°F)10 − 20 kΩ
4 − 7 kΩ
2 − 3 kΩ
0.9 − 1.3 kΩ
0.4 − 0.7 kΩ
0.2 − 0.4 kΩ
MAF meterResistance (THA − E2) at −20°C (−4°F)
at 0°C (32°F)
at 20°C (68°F)
at 40°C (104°F)
at 60°C (140°F)
at 80°C (176°F)10 − 20 kΩ
4 − 7 kΩ
2 − 3 kΩ
0.9 − 1.3 kΩ
0.4 − 0.7 kΩ
0.2 − 0.4 kΩ
EGR gas temp.
sensorResistance at 50°C (122°F)
at 100°C (212°F)
at 150°C (302°F)64 − 97 kΩ
11 − 16 kΩ
2 − 4 kΩ
Heated
oxygen sensorHeater coil resistance
Bank 1 sensor 1 at 20°C (68°F)
Bank 1 sensor 2 at 20°C (68°F)
11 − 16 Ω
11 − 16 Ω
Fuel cut RPMFuel return rpm M/T
A/T1,400 rpm
1,500 rpm

Downloaded from www.Manualslib.com manuals search engine SS00U−11
− SERVICE SPECIFICATIONSSFI (5VZ−FE)
SS−19
193 Author: Date:
1996 TOYOTA T100 (RM449U)
SFI (5VZ−FE)
SERVICE DATA
Fuel pressure
regulatorFuel pressure at no vacuum265 − 304 kPa (2.7 − 3.1 kgf/cm2, 38 − 44 psi)
Fuel pumpResistance at 20 °C (68 °F)0.2 − 3.0 Ω
InjectorResistance
Injection volume
Difference between each cylinder
Fuel leakageApprox. 13.8 Ω
56 − 69 cm3 (3.4 − 4.2 cu in.) per 15 sec.
6 cm3 (0.31 cu in.) or less
1 drop or less per minute
MAF meterResistance (THA − E2) at −20 °C (−4 °F)
at 0 °C (32 °F)
at 20 °C (68 °F)
at 40 °C (104 °F)
at 60 °C (140 °F)
at 80 °C (176 °F)10 − 20 kΩ
4 − 7 kΩ
2 − 3 kΩ
0.9 − 1.3 kΩ
0.4 − 0.7 kΩ
0.2 − 0.4 kΩ
Throttle bodyThrottle valve fully closed angle
DP setting speed (M/T)
Throttle opener setting speed10°
1,800 − 2,200 rpm
900 − 1,950 rpm
Throttle position
sensor
Clearance between stop screw and lever
0 mm (0 in.) VTA − E2
0.32 mm (0.013 in.) IDL − E2
0.54 mm (0.021 in.) IDL − E2
Throttle valve fully open VTA − E2
VC − E2
0.28 − 6.4 kΩ
0.5 kΩ or less
Infinity
2.0 − 11.6 kΩ
2.7 − 7.7 kΩ
IAC valveResistance (+B − RSO or RSC) at cold
at hot17.0 − 24.5 Ω
21.5 − 28.5 Ω
VSV for fuel pres-
sure controlResistance at 20 °C (68 °F)33 − 39 Ω
VSV for EGR
(2WD 0.5 ton)Resistance at 20 °C (68 °F)33 − 39 Ω
VSV for EVAPResistance at 20 °C (68 °F)29 − 33 Ω
A/C idle−up valve
(w/ A/C)Resistance at 20 °C (68 °F)30 − 34 Ω
ECT sensorResistance at −20 °C (−4 °F)
at 0 °C (32 °F)
at 20 °C (68 °F)
at 40 °C (104 °F)
at 60 °C (140 °F)
at 80 °C (176 °F)10 − 20 kΩ
4 − 7 kΩ
2 − 3 kΩ
0.9 − 1.3 kΩ
0.4 − 0.7 kΩ
0.2 − 0.4 kΩ
EGR gas temper-
ature sensor
(2WD 0.5 ton)Resistance at 50 °C (122 °F)
at 100 °C (212 °F)
at 150 °C (302 °F)64 − 97 kΩ
11 − 16 κΩ
2 − 4 kΩ
Heated oxygen
sensorHeater coil resistance
M/T Bank 1 Sensor 1 at 20 °C (68 °F)
Others at 20 °C (68 °F)
5 − 7 Ω
11 − 16 Ω
Fuel cut rpmFuel return rpm M/T
A/T1,000 rpm
1,200 rpm

Downloaded from www.Manualslib.com manuals search engine SS00V−11
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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SS−28
− SERVICE SPECIFICATIONSLUBRICATION (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Oil pressure switch x Cylinder block1515011
Oil pump x Oil pump body cover101058
Oil pump x Cylinder block Bolt A
Bolt B20
42200
42014
31
Oil pump x Relief valve3737527
Oil strainer x Cylinder block7.57666 in.·lbf
Oil pan x Cylinder block7.67867 in.·lbf
Oil cooler x Cylinder block5960043

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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

Downloaded from www.Manualslib.com manuals search engine SS−72
− SERVICE SPECIFICATIONSSTEERING
246 Author: Date:
1996 TOYOTA T100 (RM449U) Total preload
0.5−1.4 N·m (5−14 kgf·cm, 4.3−12.2 in.·lbf)
4WD:
Worm gear valve body ball clearance0.15 mm (0.059 in.)
Cross shaft adjusting screw thrust clearance STD0.03−0.05 mm (0.0012−0.0020 in.)
Cross shaft adjusting screw thrust clearanceMaximum0.05 mm (0.0020 in.)
Worm gear preload0.3−0.5 N·m (3−5.5 kgf·cm, 2.6−4.8 in.·lbf)
Total preload0.5−0.9 N·m (5−9.5 kgf·cm, 4.3−8.3 in.·lbf)
STEERING LINKAGE
Tie rod lengthApproximately329.2 mm (12.961 in.)
Idler arm rotating torque0.5−2.9 N·m (5−30 kgf·cm, 5−26 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine SS−74
− SERVICE SPECIFICATIONSSTEERING
1996 TOYOTA T100 (RM449U) Tie rod end lock nut
5657041
Turn pressure tube union nut10 (13)102 (130)7 (9)
PS gear assembly set bolt and nut8890065
Mount bracket x Suspension crossmember8890065
Control valve shaft x Intermediate shaft3536026
Pressure feed tube x Control valve housing19 (25)195 (250)14 (18)
Return tube x Control valve housing19 (25)195 (250)14 (18)
Tie rod end x Steering knuckle9092067
4WD:
Pressure feed tube x PS gear assembly36 (44)365 (450)26 (33)
Return tube x PS gear assembly36 (44)365 (450)26 (33)
PS gear assembly x Body1421450105
Pitman arm x Cross shaft1771800130
Cross shaft adjusting screw set nut4647034
Side cover x Gear housing6162045
Plunger guide nut2020515
Worm gear valve body assembly x Gear housing6162045
Worm gear valve body assembly x Intermediate shaft3536026
STEERING LINKAGE
Pitman arm x Cross shaft1771800130
Pitman arm x Relay rod9092067
Tie rod clamp bolt2222516
Tie rod assembly x Relay rod9092067
Tie rod assembly x Knuckle arm9092067
Idler arm assembly x Frame1421450105
Relay rod x Idler arm assembly5960043
Steering damper set bolt and nut2526019
Relay rod x Steering damper5960043
IDLER ARM
Idler arm x Idler arm bracket7880058
( ): For use without SST

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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