gas type TOYOTA T100 1996 Factory Service Manual

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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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− DIAGNOSTICSENGINE (3RZ−FE)
1996 TOYOTA T100 (RM449U)
(b) TOYOTA Enhanced Signals.
TOYOTA hand−held tester displayMeasurement ItemNormal Condition*
MISFIRE RPMEngine RPM for first misfire rangeMisfire 0: 0 rpm
MISFIRE LOADEngine load for first misfire rangeMisfire 0: 0 g/r
INJECTORFuel injection time for cylinder No.1Idling: 2.5 − 4.3 ms
IAC DUTY RATIOIntake Air Control Valve Duty Ratio
Opening ratio rotary solenoid type IAC valveIdling: 24.8 − 50.0 %
STARTER SIGStarter SignalCranking: ON
CTP SWClosed Throttle Position Switch SignalThrottle Fully Closed: ON
A/C SIGA/C Switch SignalA/C ON: ON
STOP LIGHT SWStop Light Switch SignalStop light switch ON: ON
FC IDLFuel Cut Idle: Fuel cut when throttle valve fully
closed, during decelerationFuel cut operating: ON
FC TAUFuel Cut TAU: Fuel cut during very light loadFuel cut operating: ON
CYL #1, CYL #2, CYL #3, CYL #4Abnormal revolution variation for each cylinder0 %
IGNITIONTotal number of ignition for every 1,000
revolutions0 − 2,000
EGRT GASEGR Gas Temp. Sensor ValueEGR not operating: Temp. between intake air
temp. and engine coolant temp.
EGR SYSTEMEGR System Operating ConditionIdling: OFF
A/C CUT SIGA/C Cut SignalA/C S/W OFF: ON
FUEL PUMPFuel Pump SignalIdling: ON
EVAP (PURGE) VSVEVAP VSV SignalIdling: OFF
TOTAL FT B1Total Fuel Trim Bank 1: Average value for fuel
trim system of bank 1Idling: 0.8 − 1.2 V
O2 LR B1, S1
Oxygen Sensor Lean Rich Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from lean to rich
Idling after warming up: 0 − 1,000 msec.
O2 RL B1, S1
Oxygen Sensor Rich Lean Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from rich to lean
Idling after warming up: 0 − 1,000 msec.
*: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch
is OFF and all accessory switches are OFF.

Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSENGINE (5VZ−FE)
DI−139
1996 TOYOTA T100 (RM449U)
(b) TOYOTA Enhanced Signals.
TOYOTA hand−held tester displayMeasurement ItemNormal Condition*1
MISFIRE RPMEngine RPM for first misfire rangeMisfire 0: 0 rpm
MISFIRE LOADEngine load for first misfire rangeMisfire 0: 0 g/r
INJECTORFuel injection time for cylinder No.1Idling: 1.82 − 3.15 ms
IAC DUTY RATIOIntake Air Control Valve Duty Ratio
Opening ratio rotary solenoid type IAC valveIdling: 22 − 46 %
STARTER SIGStarter SignalCranking: ON
A/C SIGA/C Switch SignalA/C ON: ON
PNP SWPark/Neutral Position Switch SignalP or N position: ON
STOP LIGHT SWStop Light Switch SignalStop light switch ON: ON
FC IDLFuel Cut Idle: Fuel cut when throttle valve fully
closed, during decelerationFuel cut operating: ON
FC TAUFuel Cut TAU: Fuel cut during very light loadFuel cut operating: ON
CYL #1 − CYL #6Abnormal revolution variation for each cylinder0 %
IGNITIONTotal number of ignition for every 1,000
revolutions0 − 3,000
EGRT GAS*2EGR Gas Temp. Sensor Value
EGR not operating:
Temp. between intake air temp. and engine
coolant temp.
EGR SYSTEM*2EGR System Operating ConditionIdling: OFF
A/C CUT SIGA/C Cut SignalA/C S/W OFF: ON
FUEL PUMPFuel Pump SignalIdling: ON
EVAP (PURGE) VSVEVAP VSV SignalVSV operating: ON
VAPOR PRESS VSVVapor Pressure VSV SignalVSV operating: ON
TOTAL FT B1Total Fuel Trim Bank 1: Average value for fuel
trim system of bank 1Idling: 0.8 − 1.2 V
O2 LR B1, S1
Oxygen Sensor Lean Rich Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from lean to rich
Idling after warming up: 0 − 1,000 msec.
O2 RL B1, S1
Oxygen Sensor Rich Lean Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from rich to lean
Idling after warming up: 0 − 1,000 msec.
*1: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C
switch is OFF and all accessory switches are OFF.
*2: Only for 2WD models with a load capacity of 0.5 ton and regular cab.

Downloaded from www.Manualslib.com manuals search engine P15006
Plug
P15007
New Gasket
New
Gasket
FI1654
SST
Fulcrum Length
30 cm
P15750
Grommet
New O−Ring
Delivery PipeCORRECT
WRONG
P15128
Delivery Pipe
Injector
InsulatorO−Ring
Grommet
− MFI (3RZ−FE)MFI SYSTEM
MF−3
955 Author: Date:
1996 TOYOTA T100 (RM449U)
7. FUEL SYSTEM
(a) When disconnecting the high pressure fuel line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Put a container under the connection.
(2) Slowly loosen the connection.
(3) Disconnect the connection.
(4) Plug the connection with a rubber plug.
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe these procedures:
(1) (Union Bolt Type)
Always use a new gasket.
(2) (Union Bolt Type)
Tighten the union bolt by hand.
(3) (Union Bolt Type)
Tighten the union bolt to the specified torque.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(4) (Flare Nut Type)
Apply a light coat of engine oil to the flare and tight-
en the flare nut by hand.
(5) (Flare Nut Type)
Using SST, tighten the flare nut to the specified
torque.
SST 09631−22020
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(c) Observe these precautions when removing and installing
the injectors.
(1) Never reuse the O−ring.
(2) When placing a new O−ring on the injector, take
care not to damage it in any way.
(3) Coat a new O−ring with spindle oil or gasoline be-
fore installing−never use engine, gear or brake oil.
(d) Install the injector to the delivery pipe and cylinder head
as shown in the illustration.

Downloaded from www.Manualslib.com manuals search engine P21154
P19985
FI1654
30 cm
SST
Fulcrum Length
− SFI (5VZ−FE)SFI SYSTEM
SF−3
1009 Author: Date:
1996 TOYOTA T100 (RM449U)
7. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe these procedures:
(1) Union Bolt Type:
Always use 2 new gaskets.
(2) Union Bolt Type:
Tighten the union bolt by hand.
(3) Union Bolt Type:
Tighten the union bolt to the specified torque.
Torque: 34.3 N·m (350 kgf·cm, 25 ft·lbf)
(4) Flare Nut Type:
Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(5) Flare Nut Type:
Using SST, tighten the flare nut to specified torque.
SST 09631−22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque:
34.3 N·m (350 kgf·cm, 25 ft·lbf)
28 N·m (285 kgf·cm, 21 ft·lbf) for using SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Downloaded from www.Manualslib.com manuals search engine P25589
− STARTING (3RZ−FE)STARTER
ST−13
1996 TOYOTA T100 (RM449U)
6. CLEAN CONTACT SURFACES OF CONTACT PLATE
AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
7. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp with
the 3 bolts.
Torque:
1.2 kW, 1.4 kW type: 2.5 N·m (25 kgf·cm, 22 in.·lbf)
1.8 kW, 2.0 kW type: 3.6 N·m (35 kgf·cm, 30 in.·lbf)

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=
100 kgf
Ram diameter (cm)
2
2
2Ram diameter (in.) (psi)
=
x 3.14 (π) x 3.14 (π)
2
(kPa) = (kgf/cm
2) x 98.1
(kPa) = (psi) x 6.9221 lbf
P25601
SST
P25591
ST−12
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
NOTICE:
Check the diameter of the hand press ram. Then calculate
the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the specified pres-
sure, the contact plate may tilt due to coil deformation or the
tightening of the nut.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (173 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
6. CLEAN CONTACT SURFACES OF CONTACT PLATE
AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
7. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp (1.8
kW type) with the 3 bolts.
Torque:
1.2 kW, 1.4 kW type: 2.5 N·m (25 kgf·cm, 22 in.·lbf)
1.8 kW type: 3.6 N·m (35 kgf·cm, 30 in.·lbf)

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Q07625
AT3168SST
AT0103
AT−12
− AUTOMATIC TRANSMISSIONVALVE BODY ASSEMBLY
1353 Author: Date:
1996 TOYOTA T100 (RM449U)
VALVE BODY ASSEMBLY
ON−VEHICLE REPAIR
CAUTION:
When working with FIPG material, you must observe the
followings.
Using a razor blade and a gasket scraper, remove all
oil FIPG material from the gasket surfaces.
Remove all loose material to thoroughly clean all
components.
Clean both sealing surfaces with a non−residue sol-
vent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead
along the sealing surface.
Parts must be assembled within 10 minutes of ap-
plication. Otherwise, the FIPG material must be re-
moved and reapplied.
1. REMOVE DRAIN PLUG AND DRAIN ATF
Torque: 20 N·m (205 kgf·cm, 15 ft·lbf)
2. REMOVE OIL PAN
NOTICE:
Some fluid will remain in the oil pan.
(a) Remove the 19 bolts.
Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
(b) Install the blade of SST between the transmission case
and oil pan, cut off applied sealer, and remove the oil pan.
SST 09032−00100
NOTICE:
When removing the oil pan, be careful not to damage the oil
pan flange.
3. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect steel particles.
Carefully look at the foreign matter and particles in the pan and
on the magnets to anticipate the type of wear you will find in the
transmission.
Steel (magnetic)......bearing, gear and clutch plate wear
Brass (non−magnetic) ...... bushing wear

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RA10720 − 5 mm (0 − 0.20 in.) OilFiller Hole SA−154
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL NEW GASKET TO AXLE HOUSING
2. INSTALL DIFFERENTIAL CARRIER ASSEMBLY
Install the differential carrier assembly in the axle housing.
Torque: 73 N·m (740 kgf·cm, 54 ft·lbf)
3. INSTALL PROPELLER SHAFT
2WD: See page PR−9
4WD: See page PR−16
4. INSTALL REAR AXLE SHAFTS
(See page SA−135)
5. FILL DIFFERENTIAL WITH DIFFERENTIAL OIL
Torque:
Drain plug: 49 N·m (500 kgf·cm, 39 ft·lbf)
Filler plug: 39 N·m (400 kgf·cm, 29 ft·lbf)
Oil type: Hypoid gear oil API GL−5
Recommended oil viscosity:
Above −18°C (0°F) SAE 90
Below −18°C (0°F) SAE 80W or 80W − 90
Capacity: 2.35 liters (2.22 US qts, 2.67 lmp.qts)