air condition TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine INDEX
IN Introduction
MA Maintenance
PP Preparation
SS Service Specifications
DI Diagnostics
EM Engine Mechanical (3RZ-FE)
Engine Mechanical (5VZ-FE)
EC Emissions Control (3RZ-FE)
Emissions Control (5VZ-FE)
MF MFI System (3RZ-FE)
SF SFI System (5VZ-FE)
CO Cooling (3RZ-FE)
Cooling (5VZ-FE)
LU Lubrication (3RZ-FE)
Lubrication (5VZ-FE)
IG Ignition (3RZ-FE)
Ignition (5VZ-FE)
ST Starting (3RZ-FE)
Starting (5VZ-FE)
CH Charging (3RZ-FE)
Charging (5VZ-FE)
CL Clutch
MT Manual Transmission (R150, R150F)
Manual Transmission (W59)
AT Automatic Transmission
TR Transfer
PR Propeller Shaft
SA Suspension and Axle
BR Brake
SR Steering
RS Supplemental Restraint System
BE Body Electrical
BO Body
AC Air Conditioning

Downloaded from www.Manualslib.com manuals search engine IN02J−03
Vehicle Brought Workshop
Customer Problem
Analysis
Symptom Confirmation
and Diagnostic Trouble
Code Check
Symptom Simulation
Diagnostic Trouble
Code Chart
Matrix Chart of Problem
Symptoms
Circuit Inspection or Parts
Inspection
Repair
Confirmation Test
End 1
2
43
5
6
7
8Ask the customer about the conditions and the
environment when the problem occurred.1
Confirm the symptoms and the problem conditions,
and check the diagnostic trouble codes.
(When the problem symptoms do not appear
during confirmation, use the symptom simulation
method described later on.)2, 3
Check the results obtained in Step 2, then confirm
the inspection procedure for the system or the part
which should be checked using the diagnostic
trouble code chart or the matrix chart of problem
symptoms.4, 5, 6
Check and repair the affected system or part in
accordance with the instructions in Step 6. 7
After completing repairs, confirm that the problem
has been eliminated.
(If the problem is not reproduced, perform the
confirmation test under the same conditions and
in the same environment as when it occurred for
the first time.)8
IN−16− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TOYOTA T100 (RM449U)
HOW TO PROCEED WITH TROUBLESHOOTING
Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro-
cedure is shown. Details are provided in each section, showing the most effective methods for each circuit.
Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that
circuit.

Downloaded from www.Manualslib.com manuals search engine Important Points in the Customer Problem Analysis
 What −−−−− Vehicle model, system name
 When −−−−− Date, time, occurrence frequency
 Where −−−−− Road conditions
 Under what conditions? −−−−− Running conditions, driving conditions, weather conditions
 How did it happen? −−−−− Problem symptoms
(Sample) Engine control system check sheet.
ENGINE CONTROL SYSTEM Check Sheet
Customer’s Name
Driver’s Name
Data Vehicle
Brought in
License No.
Model and Model
Year
Frame No.
Engine Model
Odometer Reading
km
miles
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Drive ability
Engine Stall
Others
Engine does not crankNo initial combustionNo complete combustion
Engine cranks slowly
Other
Incorrect first idleIdling rpm is abnormalHigh ( rpm)Low ( rpm)
Rough idling
Other
HesitationBack fireMuffler explosion (after−fire)Surging
Knocking
Other
Soon after startingAfter accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D
Other
Datas Problem
ConstantSometimes ( times per day/month)
Inspector’s
Name
CUSTOMER PROBLEM ANALYSIS CHECK
− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−17
1996 TOYOTA T100 (RM449U)
1. CUSTOMER PROBLEM ANALYSIS
In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be
cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it
is extremely important to ask the customer about the problem and the conditions at the time it occurred.
Important Point in the Problem Analysis:
The following 5 items are important points in the problem analysis. Past problems which are thought to be
unrelated and the repair history, etc. may also help in some cases, so as much information as possible should
be gathered and its relationship with the problem symptoms should be correctly ascertained for reference
in troubleshooting. A customer problem analysis table is provided in the troubleshooting section for each
system for your use.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE
Diagnostic Trouble
Code Check (Make a
note of and then clear)Confirmation
of SymptomsDiagnostic Trouble
Code CheckProblem Condition
Diagnostic Trouble
Code DisplayProblem symptoms
existSame diagnostic
trouble code is
displayedProblem is still occurring in the diagnostic
circuit.
Normal code is
displayedThe problem is still occurring in a place
other than in the diagnostic circuit.
(The diagnostic trouble code displayed
first is either for a past problem or it is a
secondary problem.)
No problem
symptoms existThe problem occurred in the diagnostic
circuit in the past.
Normal Code DisplayProblem symptoms
existNormal code is
displayedThe problem is still occurring in a place
other than in the diagnostic circuit.
No problem
symptoms existNormal code is
displayedThe problem occurred in a place other
than in the diagnostic circuit in the past.
IN−18− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TOYOTA T100 (RM449U)
2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK
The diagnostic system in the TOYOTA T100 fulfills various functions. The first function is the Diagnostic
Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU
memory at the time of occurrence, to be output by the technician during troubleshooting. Another function
is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly.
By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can
be performed effectively. Diagnostic functions are incorporated in the following systems in the TOYOTA
T100.
SystemDiagnostic Trouble
Code CheckInput Signal Check
(Sensor Check)Other Diagnosis
Function
Engine (3RZ−FE, 5VZ−FE)
Automatic Transmission
Anti−Lock Brake system
Supplemental Restraint System
Cruise Control (with Test Mode)
 (with Test Mode)






Cancel Signal
Check
In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diag-
nostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition,
it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic
trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes
should be checked before and after the symptom confirmation to determine the current conditions, as shown
in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting
for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent
to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble
code check.

Downloaded from www.Manualslib.com manuals search engine V07268
VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
WIRE HARNESS
PARTS AND SENSOR1
Slightly shake the connector vertically and horizontally.
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough-
ly.
Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check if the
malfunction occurs.Shake Slightly
Swing Slightly
Vibrate Slightly
HINT: Applying strong vibration to relays may result in open
relays. IN−20
− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TOYOTA T100 (RM449U)
3. SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customer’s vehicle. No matter how much experience a
technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem
symptoms he will tend to overlook something important in the repair operation and make a wrong guess
somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the en-
gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the prob-
lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the
vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which
is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex-
ternal causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-
toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the problem symp-
toms at the same time. Refer to the matrix chart of problem symptoms for each system to narrow down the
possible causes of the symptom.

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HEAT METHOD: When the problem seems to occur when the suspect area is heated. 2
NOTICE:
(1) Do not heat to more than 60 °C (140 °F). (Temperature
is limited not to damage the components.)
(2) Do not apply heat directly to parts in the ECU.
3 WATER SPRINKLING METHOD:
NOTICE:
(1) Never sprinkle water directly into the engine
compartment, but indirectly change the temperature and
humidity by applying water spray onto the radiator front
surface.
(2) Never apply water directly onto the electronic
components.
4 OTHER: When a malfunction seems to occur when electrical load is excessive.When the malfunction seems to occur on a rainy day or in a
high−humidity condition. Heat the component that is the likely cause of the malfunction
with a hair dryer or similar object. Check to see if the malfunction
occurs.
Sprinkle water onto the vehicle and check to see if the malfunc-
tion occurs.
Turn on all electrical loads including the heater blower, head
lights, rear window defogger, etc. and check to see if the mal-
function occurs.ON (Service hint)
If a vehicle is subject to water leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, special caution must be taken.
Malfunc-
tion
− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−21
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine IN02M−01
− INTRODUCTIONTERMS
IN−33
1996 TOYOTA T100 (RM449U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE−J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their Toyota equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )−−ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal−
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric Pressure−
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection−
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position−
CTOXContinuous Trap Oxidizer−
CTPClosed Throttle Position−
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition−
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode−
ECLEngine Control Level−
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control−
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory−
FEPROMFlash Erasable Programmable Read Only Memory−
FFFlexible Fuel−
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

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.

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MAINTENANCE PP-1
ENGINE MECHANICAL (3RZ-FE) PP-2
ENGINE MECHANICAL (5VZ-FE) PP-8
EMISSION CONTROL (3RZ-FE) PP-14
EMISSION CONTROL (5VZ-FE) PP-16
MFI (3RZ-FE) PP-19
SFI (5VZ-FE) PP-22
COOLING (3RZ-FE) PP-25
COOLING (5VZ-FE) PP-28
LUBRICATION (3RZ-FE) PP-33
LUBRICATION (5VZ-FE) PP-38
IGNITION (3RZ-FE) PP-43
IGNITION (5VZ-FE) PP-46
STARTING (3RZ-FE) PP-48
STARTING (5VZ-FE) PP-51
CHARGING (3RZ-FE) PP-54
CHARGING (5VZ-FE) PP-57
CLUTCH PP-60
MANUAL TRANSMISSION (R150,
R150F) PP-63
MANUAL TRANSMISSION (W59) PP-69
AUTOMATIC TRANSMISSION PP-75
TRANSFER PP-80
PROPELLER SHAFT PP-86
SUSPENSION AND AXLE PP-88
BRAKE PP-98
STEERING PP-103
SUPPLEMENTAL RESTRAINT SYSTEM PP-113
BODY ELECTRICAL PP-116
BODY PP-119
AIR CONDITIONING PP-122

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PP−122
− PREPARATIONAIR CONDITIONING
171 Author: Date:
1996 TOYOTA T100 (RM449U)
AIR CONDITIONING
SST (Special Service Tools)
07110−58060Air Conditioner Service Tool Set
(07117−58060)Refrigerant Drain Service Valve
(07117−58070)T−Joint
(07117−58080)Quick Disconnect AdapterDischarge (diam. 16 mm)
(07117−58090)Quick Disconnect AdapterSuction (diam. 13 mm)
(07117−78050)Refrigerant Charging Gauge
(07117−88060)Refrigerant Charging HoseDischarge (Red)
(07117−88070)Refrigerant Charging HoseSuction (Blue)
(07117−88080)Refrigerant Charging HoseUtility (Green)
07112−66040Magnetic Clutch Remover
07112−76060Magnetic Clutch Stopper
07116−38360Gas Leak Detector Assembly