key TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SS−78
− SERVICE SPECIFICATIONSBODY ELECTRICAL
252 Author: Date:
1996 TOYOTA T100 (RM449U)B − C
Approx. 55.0 Ω
FUEL SENDER GAUGE
Float position mm (in.)Resistance (Ω)
F: Approx. 95 mmApprox. 3.0 Ω
1/2: Approx. 188.0 mmApprox. 32.5 Ω
E: Approx. 283.0 mmApprox. 110.0 Ω
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (w/ Tachometer)Resistance (Ω)
A − BApprox. 150.0 Ω
A − CApprox. 54.0 Ω
B − CApprox. 138.0 Ω
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (w/ o Tachometer)
A − BApprox. 25.0 Ω
OIL PRESSURE RECEIVER GAUGE
A − BApprox. 25.0 Ω
DOOR LOCK CONTROL RELAY (Wire Harness Side)
2 − Ground (Constant)Battery positive voltage
8 − Ground (Ignition Switch LOCK or ACC)No voltage
8 − Ground (Ignition Switch ON)Battery positive voltage
13 − Ground (Key unlock warning switch OFF (Ignition key removed))No voltage
13 − Ground (Key unlock warning switch ON (Ignition key set))Battery positive voltage
CRUISE CONTROL ECU (wire harness side)
24 − 26 (constant)Approx. 2.0 kΩ
25 − 26 (Actuator arm turned)Resistance change even
10 − Ground (Brake pedal position: Released)Approx. 38.0 Ω
10 − Ground (Brake pedal position: Depressed)No continuity
CRUISE CONTROL SWITCH
18 − Ground (Control switch position: OFF)No continuity
18 − Ground (Control switch position: RESUME/ACCEL)Approx. 68.0 Ω
18 − Ground (Control switch position: SET/COAST)Approx. 198.0 Ω
18 − Ground (Control switch position: CANCEL)Approx. 418.0 Ω
14 − Ground (Ignition switch position: LOCK or ACC)No voltage
14 − Ground (Ignition switch position: ON)Battery positive voltage
15 − Ground (Constant)Battery positive voltage
1 − Ground (Constant)Battery positive voltage
16 − Ground (Brake pedal position: Released)No voltage
16 − Ground (Brake pedal position: Depressed)Battery positive voltage
20 − Ground (With ignition switch ON, Speedsensor shaft turned)Valtage changes repeatedly
CRUISE CONTROL ACTUATOR
1 − 3Approx. 2.0 kΩ
2 − 3 (The arm is moving from the closed to open position)Approx. 0.5 to 1.8 kΩ
ANTENNA MOTOR CONTROL RELAY (Wire harness side)
3 − Ground (Constant)Battery positive voltage
5 − Ground (Ignition Switch position: LOCK)No voltage
5 − Ground (Ignition switch position: ACC)Battery positive voltage
7 − Ground (Ignition switch position: LOCK)No voltage

Downloaded from www.Manualslib.com manuals search engine P14986A03762
P15097A03763
P14954A03764
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−23
1996 TOYOTA T100 (RM449U)
(d) Install the 2 timing chain cover mounting bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(e) Install the 2 No.1 water bypass pipe mounting nuts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
8. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST, install and torque the pulley bolt.
SST 09213−54015, 09330−00021
Torque: 260 N·m (2,650 kgf·cm, 193 ft·lbf)
(c) w/ A/C:
Install the No.3 and No.2 crankshaft pulleies with the 4
bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
9. INSTALL OIL STRAINER
Install a new gasket and oil strainer with the 2 bolts and 2 nuts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P14744
P14748
No.1
Balance Shaft
No.2
Balance Shaft
P14753
Z11075
P14818
EM−82
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
25. REMOVE NO.1 AND NO.2 BALANCE SHAFTS
(a) Remove the 1 bolt from the No.1 balance shaft.
(b) Remove the 2 bolts from the No.2 balance shaft.
(c) Remove the balance shafts.
NOTICE:
When removing the balance shaft make sure you support
the balance shaft with both hands and avoid scratching the
balance shaft bearing on the cylinder block side.
HINT:
No.1 balance shaft (RH):
Has indentations.
No.2 balance shaft (LH):
Has no indentations.
26. DISASSEMBLE NO.1 BALANCE SHAFT
(a) Mount the hexagon wrench head portion of the balance
shaft in a vise.
NOTICE:
Be careful not to damage the balance shaft.
(b) Remove these parts from balance shaft assembly:
(1) No.1 balance shaft
(2) No.1 balance shaft thrust plate
(3) Balance shaft thrust spacer.
(4) Balance shaft timing gear.
(5) Key
27. DISASSEMBLE NO.2 BALANCE SHAFT
(a) Mount the hexagon wrench head portion of the balance
shaft in a vise.
NOTICE:
Be careful not to damage the balance shaft.

Downloaded from www.Manualslib.com manuals search engine P15016
No.1 Compression
Ring Upper Side
Rail
Front Mark
(Carirty)
No.2 Compression Ring ExpanderLower Side
Rail
P14796
P14748
No.1
Balanceshaft
No.2
Balanceshaft
Z11075
Z11076
EM−96
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting rod cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL CYLINDER BLOCK ORIFICE
5. INSTALL NO.1 AND NO.2 BALANCE SHAFTS
(a) No.1 balance shaft (RH):
Has indentations.
(b) No.2 balance shaft (LH):
Has no indentations.
6. ASSEMBLY NO.1 BALANCE SHAFT
(a) Mount the hexagon wrench head portion of the balance
shaft in a vise.
NOTICE:
Be careful not to damage the balance shaft.
(b) Install these parts to the balance shaft:
(1) No.1 balance shaft
(2) No.1 balance shaft thrust plate
(3) Balance shaft thrust spacer
(4) Balance shaft timing gear
(5) Key
(c) Install and torque the bolt.
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
7. ASSEMBLY NO.2 BALANCE SHAFT
(a) Mount the hexagon wrench head portion of the balance
shaft in a vise.
NOTICE:
Be careful not to damage the balance shaft.
(b) Install these parts to the balance shaft:
(1) No.2 balance shaft
(2) No.2 balance shaft thrust plate
(3) Balance shaft timing sprocket
(c) Install and torque the bolt.
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P20822
Inward
Sensor
EM06J−03
P20821
P20499
P20823
Front
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−19
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the timing
pulley and slide on the timing pulley.
(b) Slide on the timing pulley, facing the flange side inward.
2. INSTALL NO. 1 IDLER PULLEY AND NO.2 IDLER
PULLEY
(a) Using a 10 mm hexagon wrench, install the No.1 idler
pulley with the plate washer and bolt.
Torque: 35 N·m (350 kgf·cm, 26 ft·lbf)
(b) Check that the pulley bracket moves smoothly.
(c) Install the No.2 idler pulley with the bolt.
Torque: 40 N·m (400 kgf·cm, 30 ft·lbf)
(d) Check that the pulley moves smoothly.
3. TEMPORARILY INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Use the crankshaft pulley bolt to turn the crankshaft and
align the timing marks on the crankshaft timing pulley and
on the oil pump body.
(b) Remove any oil or water on the crankshaft timing pulley,
idler pulley and water pump pulley, and keep them clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(c) Align the installation mark on the timing belt with the
drilled mark of the crankshaft timing pulley.
(d) Install the timing belt on the crankshaft timing pulley, No.1
idler and water pump pulleys.
4. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.

Downloaded from www.Manualslib.com manuals search engine P20918
Length = 425 mm
(16.73 in.)
P21686
length = 145 mm
(5.71 in.)
P20516
SST SST
P20828
P20827
EM−20
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
5. INSTALL NO.1 TIMING BELT COVER AND STARTER
WIRE BRACKET
(a) Check that the timing belt cover gaskets have cracks or
peeling, etc.
If the gasket does have cracks or peeling, etc., replace it using
following steps.peeling, etc., replace them using following
steps.
Using a screwdriver and gasket scraper, remove all
the old gasket material.
Thoroughly clean all components to remove all the
loose material.
Remove the backing paper from a new gasket and
install the gasket evenly to the part of the belt cover
shaded back in the illustration.
(b) Install the timing belt cover with the 4 bolts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
(c) Install the starter wire bracket with the 2 bolts.
6. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide the pulley.
(b) Using SST, install and torque the bolt.
SST 09213−54015 (90119−08216),
09330−00021
Torque: 250 N·m (2,500 kgf·cm, 184 ft·lbf)
7. INSTALL LH CAMSHAFT TIMING PULLEY
(a) Slide the timing pulley, facing the flange side outward.
(b) Align the knock pin hole of the camshaft with the knock pin
groove of the timing pulley as shown.
(c) Install the knock pin.
(d) 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)
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Crankshaft Position:
Turn the crankshaft pulley, and align its groove with the
”O” timing mark of the No.1 timing belt cover.

Downloaded from www.Manualslib.com manuals search engine LU03B−04
P20937
Seal Width
A
B2 − 3 mm
A
B
P20930
New O−Ring
P20971
Mark
Key
LU−14
− LUBRICATION (5VZ−FE)OIL PUMP
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pump
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pump, as shown in the il-
lustration.
Seal packing:
Part No. 08826−00080 or equivalent
Install nozzle that has been cut out to a 2 − 3 mm
(0.08 − 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Place a new O−ring into the groove of the cylinder block.
(d) Install the oil pump to the crankshaft with the spline teeth
of the drive rotor engaged with the large teeth of the
crankshaft.

Downloaded from www.Manualslib.com manuals search engine MT04J−01
MT−2
− MANUAL TRANSMISSION (R150, R150F)TROUBLESHOOTING
1257 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Noise
1. Oil (Level low) 2WD
4WD
2. Oil (Wrong) 2WD
4WD
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−4
MT−7
MT−4
MT−7
MT−11
MT−11
Oil leakage
1. Oil (Level too high) 2WD
4WD
2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. O−Ring (Worn or damaged)MT−4
MT−7
MT−11
MT−11
MT−11
Hard to shift or will not shift
1. Synchronizer ring (Worn or damaged)
2. Shift key spring (Damaged)MT−22
MT−25
MT−34
MT−25
MT−34
Jumps out of gear
1. Locking ball spring (Damaged)
2. Shift fork (Worn)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)MT−11
MT−11
MT−11
MT−11

Downloaded from www.Manualslib.com manuals search engine Z15461
Output Shaft Assembly
Speedometer Drive Gear
Snap Ring Ball Bearing
Spacer
 Bearing Input Shaft
Synchronizer Ring
Rear Bearing Retainer
Gear Spline Piece No.5
Synchronizer Cone Ring
Hub Sleeve No.3 Reverse Idler Gear
Shifting Key SpringShaft
BallShifting Key
Counter 5th Gear
Reverse Synchronizer
Pull Ring
5th Synchronizer Ring
Reverse Synchronizer Ring Thrust Washer
Counter Gear Rear Bearing
Shift Fork Shaft No.2Needle Roller Bearing
Straight Pin Intermediate Plate
Counter Gear
 Front Bearing
Interlock Pin
Straight Pin
Shift Fork Shaft No.1
Slotted Spring Pin
Shift Fork No.3
2WD: 2WD:
Shift Fork No.1 Reverse Idler GearMagnet
Shift Fork Shaft No.3Shift Lever Housing
Shift and Select Lever
Shift Lever Housing
Shift and Select Lever4WD:
 Reverse Shift Arm Bracket
Reverse Shift Arm
E−Ring Reverse Shift Fork Shift Fork Shaft
No.4
 Non−reusable part
 Precoated part Bearing
Snap Ring
Snap Ring Snap RingSnap Ring
Snap Ring
Snap Ring
Snap Ring
 
Spring
Shift Fork No.2


Interlock Pin Snap Ring
Interlock Pin Snap Ring
Snap Ring
MT−12
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
1267 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine Q06688
Q06605
SST
RM0024
SST
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION ASSEMBLY
MT−19
1996 TOYOTA T100 (RM449U)
27. REMOVE GEAR SPLINE PIECE NO.5, SYNCHRONIZ-
ER RING, NEEDLE ROLLER BEARING AND COUNT-
ER 5TH GEAR WITH HUB SLEEVE NO.3
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
At the time of reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)
A2.80 − 2.85 (0.1102 − 0.1122)
B2.85 − 2.90 (0.1122 − 0.1142)
C2.90 − 2.95 (0.1142 − 0.1161)
D2.95 − 3.00 (0.1161 − 0.1181)
E3.00 − 3.05 (0.1181 − 0.1201)
F3.05 − 3.10 (0.1201 − 0.1220)
G3.10 − 3.15 (0.1220 − 0.1240)
(b) Using SST, remove the gear spline piece No.5.
SST 09950−50010
(c) Remove the counter 5th gear with the hub sleeve No.3.
HINT:
At the time of reassembly, please refer to the following items.
Using SST and a hammer, drive in the gear spline piece
No.5 with the synchronizer ring slots aligned with the shift-
ing keys.
SST 09316−60011 (09316−00011)
When installing the gear spline piece No.5, support the
counter gear in front with a 1.4 − 2.3 kg (3 − 5 lb) hammer
or equivalent.
28. REMOVE THRUST WASHER AND BALL FROM
COUNTER GEAR
29. REMOVE REAR BEARING RETAINER
Remove the 4 bolts and rear bearing retainer.
HINT:
At the time of reassembly, please refer to the following item.
Align the rear bearing retainer to the reverse idler gear shaft
groove.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)