oil type TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P25779
P21163A00110
− DIAGNOSTICSENGINE (5VZ−FE)
DI−185
1996 TOYOTA T100 (RM449U)
INSPECTION PROCEDURE
1 Check spark plug and spark of misfiring cylinder.
PREPARATION:
(a) Remove the ignition coil and high−tension cord.
(b) Remove the spark plug.
CHECK:
(a) Check the spark plug type.
(b) Check for carbon deposits on electrode.
(c) Check the electrode gap.
OK:
(1) Twin ground electrodes type.
Recommended spark plug:
ND K16TR11
NGK BKR5EKB−11
(2) No large carbon deposit present. Not wet with
gosoline or oil.
(3) Electrode gap: 1.0 − 1.1 mm (0.039 − 0.043 in.)
PREPARATION:
(a) Install the spark plug to the ignition coil or high−tension
cord.
(b) Disconnect the injector connector.
(c) Ground the spark plug.
CHECK:
Check if the spark occurs while the engine is being cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, don’t crank the engine for more than 5 − 10
sec. at a time.
OK:
Spark jumps across electrode gap.
NG Replace or check ignition system (See page
IG−1).
OK

Downloaded from www.Manualslib.com manuals search engine AT1347
AT6683
AT3417
OK if hot
Add if hot
AT4252
0 − 1 mm (0 − 0.04 in.)
Q03104No.1 Gear Shifting Rod
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−271
1996 TOYOTA T100 (RM449U)
If the level is at the low side, add new fluid.
Fluid type: ATF DEXRON®II
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the ATF.
(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
(3) With the engine OFF, add new fluid through the oil
filler pipe.
Fluid type: ATF DEXRON®II
Capacity:
A340E: 1.6 liters (1.7 US qts, 1.4 Imp. qts)
A340F: 2.0 liters (2.1 US qts, 1.8 Imp. qts)
(4) Start the engine and shift the shift lever into all posi-
tions from P to L position and then shift into P posi-
tion.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature, 70 − 80°C (158 − 176°F), and add as nec-
essary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transmission.
If there are leaks, it is necessary to repair or replace O−
rings, FIPGs, oil seals, plugs or other parts.
(e) INSPECT AND ADJUST THROTTLE CABLE
(1) Check that the accelerator pedal is fully released.
(2) Check that the inner cable is not slack.
(3) Measure the distance between the outer cable end
and stopper on the cable.
Standard distance: 0 − 1 mm (0 − 0.04 in.)
If the distance is not standard, adjust the cable by the adjusting
nuts.
(f) Inspect and adjust the shift lever position.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator is not aligned with the correct position.
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures.
(1) Remove the nut on the No.1 gear shifting rod.
(2) Push the No.1 gear shifting rod fully downward.

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 P10584
Ohmmeter
Continuity
ST0NJ−01
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
ST−6
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
2. INSPECT COMMUTATOR FOR GROUNDED
Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt, clean it with sandpaper (No.400)
or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V−blocks.
(b) Using a dial indicator, measure the circle runout.
Maximum circle runout:
0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
5. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter.
Standard diameter:
1.2 kW, 1.4 kW type: 30 mm (1.18 in.)
1.8 kW, 2.0 kW type: 35 mm (1.38 in.)
Minimum diameter:
1.2 kW, 1.4 kW type: 29 mm (1.14 in.)
1.8 kW, 2.0 kW type: 34 mm (1.34 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH OF SEGMENT
Check that the undercut depth is clean and free of foreign mate-
rial. Smooth out the edge.
Standard undercut depth:
1.2 kW, 1.4 kW type: 0.6 mm (0.024 in.)
1.8 kW, 2.0 kW type: 0.7 mm (0.028 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

Downloaded from www.Manualslib.com manuals search engine P00300
OhmmeterContinuity
P00299
OhmmeterNo Continuity
Z10079
Brush Holder Side
Field Frame SideLength
Length
ST0019
− STARTING (3RZ−FE)STARTER
ST−7
1996 TOYOTA T100 (RM449U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT THAT FIELD COIL IS NOT GROUNDED
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, repair or replace the field frame.
9. INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
Standard length:
1.2 kW, 1.4 kW type: 15.5 mm (0.610 in.)
1.8 kW, 2.0 kW type: 15.0 mm (0.591 in.)
Minimum length:
1.2 kW, 1.4 kW type: 10.0 mm (0.394 in.)
1.8 kW, 2.0 kW type: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard installed load:
1.2 kW type
13.7 − 19.6 N (1.40 − 2.00 kgf, 3.1 − 4.4 lbf)
1.4 kW type
17.6 − 23.5 N (1.80 − 2.40 kgf, 4.0 − 5.3 lbf)
1.8 kW, 2.0 kW type
21.5 − 27.5 N (2.20 − 2.80 kgf, 4.9 − 6.2 lbf)

Downloaded from www.Manualslib.com manuals search engine ST032−02
P14894
Terminal 50
Terminal C
Battery
P14895
P14896
P14897
Terminal 30Ammeter
Battery
− STARTING (3RZ−FE)STARTER
ST−15
1996 TOYOTA T100 (RM449U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL−IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD−IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (−) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (−) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO−LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
reads the specified current.
Specified current:
1.2 kW, 1.4 kW type
90 A or less at 11.5 V
1.8 kW, 2.0 kW type
100 A or less at 11.5 V

Downloaded from www.Manualslib.com manuals search engine P10584
OhmmeterContinuity
ST0NK−01
P10585
OhmmeterNo Continuity
P10586
P10587
ST0040
ST−6
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
2. INSPECT COMMUTATOR FOR GROUNDED
Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt, clean it with sandpaper (No.400)
or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V−blocks.
(b) Using a dial indicator, measure the circle runout.
Maximum circle runout:
0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
5. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter.
Standard diameter:
1.2 kW, 1.4 kW type: 30 mm (1.18 in.)
1.8 kW type: 35 mm (1.38 in.)
Minimum diameter:
1.2 kW, 1.4 kW type: 29 mm (1.14 in.)
1.8 kW type: 34 mm (1.34 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH OF SEGMENT
Check that the undercut depth is clean and free of foreign mate-
rial. Smooth out the edge.
Standard undercut depth:
1.2 kW, 1.4 kW type: 0.6 mm (0.024 in.)
1.8 kW type: 0.7 mm (0.028 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

Downloaded from www.Manualslib.com manuals search engine P00300
OhmmeterContinuity
P00299
No continuity
Ohmmeter
Z10079
Length Brush Holder Side
Field Frame Side
Length
ST0019
− STARTING (5VZ−FE)STARTER
ST−7
1996 TOYOTA T100 (RM449U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT THAT FIELD COIL IS NOT GROUNDED
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, repair or replace the field frame.
9. INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
Standard length:
1.2 kW, 1.4 kW type: 15.5 mm (0.610 in.)
1.8 kW type: 15.0 mm (0.591 in.)
Minimum length:
1.2 kW, 1.4 kW type: 10.0 mm (0.394 in.)
1.8 kW type: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard installed load:
1.2 kW type
13.7 − 19.6 N (1.40 − 2.00 kgf, 3.1 − 4.4 lbf)
1.4 kW type
17.6 − 23.5 N (1.80 − 2.40 kgf, 4.0 − 5.3 lbf)
1.8 kW type
21.5 − 27.5 N (2.20 − 2.80 kgf, 4.9 − 6.2 lbf)

Downloaded from www.Manualslib.com manuals search engine (kgf/cm2)
=
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)