boot TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine IN02D−02
N17080
Filler Cap
Float
Reservoir Tank
 Grommet
Clip
Slotted Spring Pin
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot
 Gasket
Lock Nut
Clevis Pin
Clevis
12 ( 120, 9)
15 ( 155, 11)
− INTRODUCTIONHOW TO USE THIS MANUAL
IN−1
1 Author: Date:
1996 TOYOTA T100 (RM449U)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the Section Title and major heading are given at the top of every
page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN−16.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:

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− MAINTENANCECHASSIS
43 Author: Date:
1996 TOYOTA T100 (RM449U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay (See page SR−9).
(b) Check the steering linkage for looseness or damage.
Check that:
Tie rod ends and relay rod ends do not have exces-
sive play.
Dust seals are not damaged.
2WD:
Boot clamps are not loose.
2. INSPECT SRS AIRBAG (See page RS−2)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leaks.
If leakage is found, check for cause and repair.
4. 4WD:
INSPECT DRIVE SHAFT BOOTS
Inspect the drive shaft boots for clamp looseness, grease leak-
age or damage.
5. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.
(b) Inspect the dust cover for damage.

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− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
SS−49
223 Author: Date:
1996 TOYOTA T100 (RM449U)
AUTOMATIC TRANSMISSION
SERVICE DATA
Line pressure (Wheel locked)
(3RZ−FE)
Engine idling
D position
R position
at stall (Throttle valve fully opened)
D position
R position
(5VZ−FE)
Engine idling
D position
R position
at stall (Throttle valve fully opened)
D position
R position
363 − 422 kPa (3.7 − 4.2 kgf/cm2, 53 − 61 psi)
490 − 588 kPa (5.0 − 6.0 kgf/cm2, 71 − 85 psi)
932 − 1,177 kPa (9.5 − 12.0 kgf/cm
2, 135 − 171 psi)
1,294 − 1,638 kPa (13.2 − 16.7 kgf/cm2, 188 − 238 psi)
363 − 422 kPa (3.7 − 4.2 kgf/cm
2, 53 − 61 psi)
608 − 696 kPa (6.2 − 7.1 kgf/cm2, 88 − 101 psi)
902 − 1,147 kPa (9.2 − 11.7 kgf/cm
2, 131 − 166 psi)
1,432 − 1,942 kPa (14.6 − 19.8 kgf/cm2, 208 − 282 psi)
Engine stall revolution (D and R positions) 3RZ−FE
5VZ−FE1,950 ± 150 rpm
2,150 ± 150 rpm
Time lag N → D position
N → R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed
(A/C OFF and N position)
700 ± 50 rpm
Throttle cable adjustment
(Throttle valve fully opened)Between boot end face and inner cable stopper
0 − 1 mm (0 − 0.04 in.)
Drive plate runoutMax.
Torque converter runoutMax.
Torque converter installation distance 3R−FE
5VZ−FE0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
More than 31.75 mm (1.2500 in.)
More than 17.95 mm (0.7067 in.)
Speedometer driven gear oil seal drive in depth 3RZ−FE
5VZ−FE20 mm (0.79 in.)
20 mm (0.79 in.)
Lock−up point
(3RZ−FE / A340E)
D position
(Throttle valve opening 5%) Lock−up ON
Lock−up OFF
(5VZ−FE / A340E)
D position
(Throttle valve opening 5%) Lock−up ON
Lock−up OFF
(5VZ−FE / A340F)
(Throttle valve opening 5%) Lock−up ON
Lock−up OFF
83 − 88 km/h (52 − 55 mph)
70 − 75 km/h (44 − 47 mph)
79 − 84 km/h (49 − 52 mph)
72 − 77 km/h (45 − 48 mph)
75 − 80 km/h (47 − 50 mph)
68 − 73 km/h (42 − 45 mph)

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− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−67
1996 TOYOTA T100 (RM449U)
19. REMOVE FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
(a) Remove the 4 screws and front door scuff plate.
(b) Remove the clip and cowl side trim.
20. DISCONNECT ENGINE WIRE AND CONNECTORS
(a) Remove the 3 bolts and ECM.
(b) Disconnect the 4 ECM connectors.
(c) Disconnect the 2 connectors from the cowl wire.
(d) Disconnect these wires and connectors:
Igniter connector
Ground strap from cowl top panel
(e) Disconnect the 4 engine wire clamps.
(f) Pull out the engine wire from the cabin.
21. M/T:
REMOVE SHIFT LEVER ASSEMBLY
(a) Remove the shift lever knob.
(b) Remove the 4 screws and shift lever boot.
(c) Remove the 6 bolts, shift lever assembly and baffle.
NOTICE:
Do not lose the washers.
22. REMOVE STABILIZER BAR
(a) Remove the nuts and cushions holding both sides of the
stabilizer bar to the lower arms, and disconnect the stabi-
lizer bar.
(b) Remove both stabilizer bar bushings and brackets, and
remove the stabilizer bar.
23. REMOVE PROPELLER SHAFT (See page PR−3)
24. DISCONNECT SPEED METER CABLE
NOTICE:
Do not lose the felt protector and washers.

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− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−71
1996 TOYOTA T100 (RM449U)
8. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with new 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 2 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect a new gasket and the front exhaust pipe assem-
bly to the TWC with the 2 bolts and retainer.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(e) Connect the 2 heated oxygen sensor connectors.
9. CONNECT SPEEDOMETER CABLE
10. INSTALL PROPELLER SHAFT (See page PR−9)
11. INSTALL STABILIZER BAR
(a) Place the stabilizer bar in position and install both stabiliz-
er bar bushings and brackets to the frame.
(b) Torque the stabilizer bar mounting bolts.
Torque: 30 N·m (306 kgf·cm, 22 ft·lbf)
(c) Connect the stabilizer bar on both sides to the lower arms
with brackets, cushions and new nuts as shown.
(d) Torque the nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
12. M/T:
INSTALL SHIFT LEVER ASSEMBLY
(a) Install baffle and shift lever assembly with the 6 bolts.
(b) Install the shift lever boot with the 4 screws.
(c) Install the shift lever knob.

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EM−14
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
14. SET NO.1 CYLINDER AT TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with timing
mark ”0” of the No.1 timing belt cover.
(b) Check that the timing marks of the camshaft timing pul-
leys and No.3 timing belt cover are aligned.
If not, turn the crankshaft pulley 1 revolution (360°).
HINT:
When re−using timing belt: Place the matchmarks on the timing
belt and camshaft timing pulleys, and place matchmark on tim-
ing belt to match the end of the No.1 timing belt cover.
15. REMOVE TIMING BELT TENSIONER
Alternately loosen the 2 bolts, and remove them, the belt ten-
sioner and dust boot.
16. REMOVE RH CAMSHAFT TIMING PULLEY WITH TIM-
ING BELT
(a) Using SST, loosen the pulley bolt.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the bolt, knock pin and camshaft timing pulley
with timing belt.

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EM−22
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
10. INSTALL RH CAMSHAFT TIMING PULLEY AND TIM-
ING BELT
(a) Remove any oil or water on the RH camshaft timing and
No.2 idler pulleys, and keep them clean.
(b) Align the installation mark on the timing belt with the tim-
ing mark of the RH camshaft timing pulley as shown.
(c) Hang the timing belt on the RH camshaft timing pulley.
(d) Align the timing marks of the RH camshaft timing pulley
and No.3 timing belt cover.
(e) Slide the RH camshaft timing pulley on the camshaft.
(f) Using SST, align the knock pin hole of the camshaft with
the knock pin groove marked R of the pulley and install the
knock pin.
SST 09960−10010 (09962−01000, 09963−01000)
(g) Using SST, install and torque the bolt.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 110 N·m (1,100 kgf·cm, 81 ft·lbf)
11. SET TIMING BELT TENSIONER
(a) Using a press, slowly press in the push rod using 100 −
1,000 kg (220 − 2,205 lb, 981 − 9,807 N) of pressure.
(b) Align the holes of the push rod and housing, pass a 1.5
mm hexagon wrench through the holes to keep the set-
ting position of the push rod.
(c) Release the press.
(d) Install the dust boot to the tensioner.

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− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
(3) Fuel return hose
(4) Fuel inlet hose
17. DISCONNECT STARTER WIRE AND CONNECTOR
(a) Remove the bolt, and disconnect the ground strap.
(b) Remove the 2 nuts, disconnect the positive (+) terminal
cable from battery.
(c) Disconnect the 2 starter wire clamps and connector.
18. DISCONNECT GENERATOR WIRE
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire and
wire clip.
19. REMOVE FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
20. DISCONNECT ENGINE WIRE AND CONNECTORS
(a) Remove the 3 bolts and ECM.
(b) M/T:
Disconnect the 3 ECM connectors.
(c) A/T:
Disconnect the 4 ECM connectors.
(d) Disconnect the 2 connectors from the cowl wire.
(e) Disconnect these wires and connectors:
Igniter connector
Ground strap
(f) Disconnect the 6 engine wire clamps.
(g) Pull out the engine wire from the cabin.
21. M/T:
REMOVE SHIFT LEVER
(a) Remove the shift lever knob.
(b) Remove the 4 screws and shift lever boot.
(c) Remove the shift lever.
22. REMOVE STABILIZER BAR
(See page SA−16)
23. REMOVE PROPELLER SHAFT
(See page PR−3)
24. DISCONNECT SPEEDOMETER CABLE
NOTICE:
Do not lose the felt protector and washers.
25. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the 2 heated oxygen sensor connectors.
(b) Remove the 2 bolts, and retainer holding the front ex-
haust pipe to the center exhaust pipe.

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EM−70
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
5. A/T:
INSTALL CROSS SHAFT
(a) Install the cross shaft with the 4 bolts and nut.
(b) Connect the shifting rod with the clip.
6. M/T:
INSTALL CLUTCH RELEASE CYLINDER
(a) Install the clutch release cylinder with the 2 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Connect the clutch line with the 3 bolts.
7. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with new 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 3 bolts.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
(c) Connect a new gasket and the front exhaust pipe assem-
bly to the center exhaust pipe with the 2 bolts and retainer.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(d) Connect the 2 heated oxygen sensor connectors.
8. CONNECT SPEEDOMETER CABLE
9. INSTALL PROPELLER SHAFT
(See page PR−9)
10. INSTALL STABILIZER BAR (See page SA−125)
11. M/T:
INSTALL SHIFT LEVER
(a) Install the shift lever.
(b) Install the shift lever boot with the 4 screws.
(c) Install the shift lever knob.
12. CONNECT ENGINE WIRE AND CONNECTORS
(a) Push in the engine wire through the cowl panel.
(b) Connect the 6 engine wire clamps
(c) Connect these wire and connectors:
Ground strap
Igniter connector
(d) Connect 2 connectors to cowl wire.
(e) M/T:
Connect 3 connectors to the ECM.
(f) A/T:
Connect 4 connectors to the ECM.
(g) Install the ECM with the 3 bolts.

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Ohmmeter IG−2
− IGNITION (5VZ−FE)IGNITION SYSTEM
1157 Author: Date:
1996 TOYOTA T100 (RM449U)
2. INSPECT HIGH−TENSION CORDS
(a) Remove the air cleaner cap and MAF meter assembly.
(b) Disconnect the high−tension cords from the spark plugs.
Disconnect the high−tension cords at the rubber boot.
DO NOT pull on the cords.
NOTICE:
Pulling on or bending the cords may damage the conduc-
tor inside.
(c) Disconnect the high−tension cords from the ignition coils.
(1) Using a screwdriver, lift up the lock claw and discon-
nect the holder from the ignition coils.
(2) Disconnect the high−tension cord at the grommet.
DO NOT pull on the cord.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.Do not wipe any of the oil from the grommet after the
high−tension cord is disconnected.
(d) Inspect the high−tension cord resistance.
Using an ohmmeter, measure the resistance.
Maximum resistance:
25 kΩ per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high−tension cord.