air filter TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine IN0253
WRONG CORRECT
IN0252
WRONG CORRECT
IN0002
Example IN−6
− INTRODUCTIONREPAIR INSTRUCTIONS
6 Author: Date:
1996 TOYOTA T100 (RM449U)
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN−8).
(1) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels at the opposite
end in order to ensure safety.
(2) After the vehicle is jacked up, be sure to support it
on stands. It is extremely dangerous to do any work
on a vehicle raised on a jack alone, even for a small
job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU, ECM,
PCM or TCM unless absolutely necessary. (If the IC
terminals are touched, the IC may be destroyed by
static electricity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission−related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step−down
adapter for adjustment. Once the hose has been
stretched, it may leak.
(m) Tag hoses before disconnecting them:
(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.

Downloaded from www.Manualslib.com manuals search engine IN−34
− 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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P08488
Back Front
− MAINTENANCEENGINE
MA−5
40 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE
INSPECTION
HINT:
Inspect these items when the engine is cold.
1. (5VZ−FE ENGINE)
REPLACE TIMING BELT
(See page EM−11 )
2. INSPECT DRIVE BELTS
GENERATOR:
(3RZ−FE: See page CH−2)
(5VZ−FE: See page CH−1)
PS:
(3RZ−FE: See page SR−3)
(5VZ−FE: See page SR−3)
A/C:
(3RZ−FE: See page AC−14)
(5VZ−FE: See page AC−14)
3. REPLACE SPARK PLUGS
(3RZ−FE: See page IG−1)
(5VZ−FE: See page IG−1)
4. INSPECT AIR FILTER
(a) Visually check that the air cleaner element is not exces-
sively dirty, damaged or oily.
HINT:
Oiliness may indicate a stuck PCV valve.
If necessary, replace the air cleaner element.
(b) Clean the element with compressed air.
First blow from back side thoroughly, then blow off the
front side of the element.
5. REPLACE AIR FILTER
Replace the used air cleaner element with a new one.
6. REPLACE ENGINE OIL AND OIL FILTER
(3RZ−FE: See page LU−3)
(5VZ−FE: See page LU−3)
7. REPLACE ENGINE COOLANT
(3RZ−FE: See page CO−2)
(5VZ−FE: See page CO−
2)
8. CALIFORNIA, MASSACHUSETTS, MAIN, VERMONT,
RHODE ISLAND and NEW HAMPSHIRE:
INSPECT CHARCOAL CANISTER
(3RZ−FE: See page EC−5)
(5VZ−FE: See page EC−5)
9. REPLACE GASKET IN FUEL TANK CAP
(3RZ−FE: See page EC−5)
(5VZ−FE: See page EC−5)

Downloaded from www.Manualslib.com manuals search engine SS093−02
− 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 SS−8
− SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
1996 TOYOTA T100 (RM449U) Oil strainer x Cylinder block
1818513
Oil pan x Cylinder block12.51309
Crankshaft position sensor x Timing chain cover8.58574 in.·lbf
Generator bracket x Cylinder block74.576055
Generator bracket x Timing chain cover1818513
Generator adjusting bar x Timing chain cover63.565047
A/C compressor bracket x Cylinder block4444032
A/C compressor x A/C compressor bracket2525018
Water pump pulley x Water pump2121016
Connecting rod cap x Connecting rod 1st
2nd45
Turn 90°46033
Main bearing cap x Cylinder block 1st
2nd39
Turn 90°40029
No.1 balance shaft x Timing gear3636526
No.2 balance shaft x Timing sprocket3636526
Balance shaft x Cylinder block1818513.4
Rear oil seal retainer x Cylinder block13.51359.7
RH, LH engine mounting bracket x Cylinder block4545034
Oil dipstick guide x LH engine mounting bracket2020014
Oil filter bracket union, Engine coolant drain plug x Cylinder block2525018
Oil filter bracket x Cylinder block2829021
Water bypass pipe x Cylinder block2020014
Knock sensor x Cylinder block3738027
Fuel filter x Cylinder block2020014
Rear end plate x Cylinder block1818513
Rear end plate x Water bypass pipe2020014
Flywheel x Crankshaft 1st
2nd26.5
Turn 90°27019
Front crossmember x Engine rear mounting bracket2526019
Front exhaust pipe clamp x Exhaust manifold6263046
Exhaust support bracket x Transmission3940029
Front exhaust pipe clamp1919514
Front exhaust pipe x TWC3940029
Engine rear mounting bracket x Engine rear mounting insulator1818313
Engine front mounting insulator x Frame3838728
Clutch release cylinder bracket x Transmission3940029
Clutch release cylinder x Transmission131309
Stabilizer bar bracket mounting bolt3030622
Stabilizer bar x Lower suspension arm131309
Intake air connector x Cylinder head1818513
Radiator x Body1818513

Downloaded from www.Manualslib.com manuals search engine SS097−02
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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Outside
Inside
DI−8
− DIAGNOSTICSENGINE (3RZ−FE)
1996 TOYOTA T100 (RM449U)
6. BASIC INSPECTION
When the malfunction code is not confirmed in the DTC check, troubleshooting should be performed in the
order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying
out the basic engine check shown in the following flow chart, the location causing the problem can be found
quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting.
1 Is battery positive voltage 11 V or more when engine is stopped?
NO Charge or replace battery.
YES
2 Is engine cranked?
NO Proceed to page ST−15 and continue to trouble-
shoot.
YES
3 Does engine start?
NO Go to step 7.
YES
4 Check air filter.
PREPARATION:
Remove the air filter.
CHECK:
Visual check that the air filter is not dirty or excessive oily.
HINT:
If necessary, clean the filter with compressed air. First blow from
inside thoroughly, then blow from outside of the filter.
NG Repair or replace.
OK

Downloaded from www.Manualslib.com manuals search engine DI−56
− DIAGNOSTICSENGINE (3RZ−FE)
1996 TOYOTA T100 (RM449U)
2 Check for heated oxygen sensor (bank 1 sensor 1 ) data.
PREPARATION:
(a) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3.
(b) Warm up the engine to normal operating temp.
CHECK:
Read heated oxygen sensor output voltage and short−term fuel trim.
RESULT:
PatternHeated oxygen sensor output voltageShort−term fuel trim
1Lean condition (Changes at 0.55 V or less)Changes at about + 20 %
2Rich condition (Changes at 0.4 V or more)Changes at about − 20 %
3Except 1 and 2
3 Check for heated oxygen sensor (bank 1 sensor
1) (See page MF−49).
1, 2
3 Check fuel pressure (See page MF−5).
NG Check and repair fuel pump, pressure regulator,
fuel pipe line and filter (See page MF−10).
OK
4 Check injector injection (See page MF−16).
NG Replace injector.
OK

Downloaded from www.Manualslib.com manuals search engine BE6653
P23816
P23817
A00066
For M/T
#10 (+) #20 (+)
#10 (+) #20 (+)
For A/T
− DIAGNOSTICSENGINE (3RZ−FE)
DI−61
1996 TOYOTA T100 (RM449U)
2 Check voltage of ECM terminal for injector of failed cylinder.
PREPARATION:
(a) Remove the right cowl side trim (See page MF−50).
(b) Turn the ignition switch ON.
CHECK:
Measure voltage between applicable terminal of ECM connec-
tor and body ground.
OK:
Voltage: 9 − 14 V
OK Go to step 4.
NG
3 Check resistance of injector of misfiring cylinder (See page MF−16).
NG Replace injector.
OK
Check for open and short in harness and con-
nector between injector and ECM (See page
IN−26).
4 Check fuel pressure (See page MF−5).
NG Check and repair fuel pump, pressure regulator,
fuel pipe line and filter (See page MF−10).
OK

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Outside
Inside
DI−134
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
YES
2 Is engine cranked?
NO Proceed to page ST−6 and continue to trouble-
shoot.
YES
3 Does engine start?
NO Go to step 7.
YES
4 Check air filter.
PREPARATION:
Remove the air filter.
CHECK:
Visual check that the air filter is not dirty or excessive oily.
HINT:
If necessary, clean the filter with compressed air. First blow from
inside thoroughly, then blow from outside of the filter.
NG Repair or replace.
OK