radiator TOYOTA T100 1996 Factory Service Manual

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HEAT METHOD: When the problem seems to occur when the suspect area is heated. 2
NOTICE:
(1) Do not heat to more than 60 °C (140 °F). (Temperature
is limited not to damage the components.)
(2) Do not apply heat directly to parts in the ECU.
3 WATER SPRINKLING METHOD:
NOTICE:
(1) Never sprinkle water directly into the engine
compartment, but indirectly change the temperature and
humidity by applying water spray onto the radiator front
surface.
(2) Never apply water directly onto the electronic
components.
4 OTHER: When a malfunction seems to occur when electrical load is excessive.When the malfunction seems to occur on a rainy day or in a
high−humidity condition. Heat the component that is the likely cause of the malfunction
with a hair dryer or similar object. Check to see if the malfunction
occurs.
Sprinkle water onto the vehicle and check to see if the malfunc-
tion occurs.
Turn on all electrical loads including the heater blower, head
lights, rear window defogger, etc. and check to see if the mal-
function occurs.ON (Service hint)
If a vehicle is subject to water leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, special caution must be taken.
Malfunc-
tion
− INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−21
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine MA003−05
MA−4
− MAINTENANCEUNDER HOOD
39 Author: Date:
1996 TOYOTA T100 (RM449U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which
the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.
Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. WINDSHIELD WASHER FLUID
Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
Check that the coolant level is between the FULL and LOW lines on the see−through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
5. BATTERY ELECTROLYTE LEVEL
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case.
6. BRAKE AND CLUTCH FLUID LEVELS
Check that the brake and clutch fluid levels are near the upper level line on the see−through reservoirs.
7. ENGINE DRIVE BELTS
Check all drive belts for fraying, cracks, wear or oiliness.
8. ENGINE OIL LEVEL
Check the level on the dipstick with the engine turned off.
9. POWER STEERING FLUID LEVEL
(a) Check the level on the dipstick.
(b) The level should be in the HOT or COLD range depending on the fluid temperature.
10. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking brake applied, shift the selector into all positions from the P to
L, and then shift into the P position.
(c) Pull out the dipstick and wipe off the fluid with a clean rag. Re−insert the dipstick and check that the
fluid level is in the HOT range.
(d) Do this check with the fluid at normal driving temperature (70 − 80°C, 158 − 176°F).
HINT:
Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at
high speeds, in hot weather, in heavy traffic or pulling a trailer.
11. EXHAUST SYSTEM
(a) Visually inspect for cracks, holes or loose supports.
(b) If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause
located and corrected.

Downloaded from www.Manualslib.com manuals search engine PP3MA−01
− PREPARATIONCOOLING (3RZ−FE)
PP−25
74 Author: Date:
1996 TOYOTA T100 (RM449U)
COOLING (3RZ−FE)
SST (Special Service Tools)
09230−00010Radiator Service Tool Set
(09231−00010)Lock Plate Bender
(09231−00020)Lock Plate Bender
(09231−00030)Plug Handle
(09231−00040)No.1 Plug
(09231−00050)No.2 Plug
09230−01010Radiator Service Tool Set
(09231−01010)Overhaul Handle
(09231−01020)Punch Assembly
(09231−01030)Claw
(09231−00060)No.3 Plug

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PP−26
− PREPARATIONCOOLING (3RZ−FE)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
HeaterThermostat
Radiator cap tester
ThermometerThermostat
Torque wrench

Downloaded from www.Manualslib.com manuals search engine PP01J−02
PP−30
− PREPARATIONCOOLING (5VZ−FE)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Heater
Radiator cap tester
Thermometer
Torque wrench

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 SS098−01
− SERVICE SPECIFICATIONSCOOLING (3RZ−FE)
SS−21
195 Author: Date:
1996 TOYOTA T100 (RM449U)
COOLING (3RZ−FE)
SERVICE DATA
Thermostat
Valve opening temperature
Valve lift at 95°C (203°F)80 − 84°C (176 − 183°F)
8 mm (0.31 in.) or more
Radiator capRelief valve opening pressure STD
Minimum74 − 103 kPa (0.75 − 1.05 kgf/cm2, 10.7 − 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.5 psi)

Downloaded from www.Manualslib.com manuals search engine SS099−01
SS−22
− SERVICE SPECIFICATIONSCOOLING (3RZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Cylinder block x Drain plug2425018
Fluid coupling x Fan5.55549 in.·lbf
Water pump x Cylinder block expect bolt A
for bolt A8.9
24.590
25078 in.·lbf
18
Water inlet x Water inlet housing2020015
Radiator support x Radiator tank M/T
A/T13
5.5130
569
49 in.·lbf
Radiator mounting bolt3131023

Downloaded from www.Manualslib.com manuals search engine SS00Y−03
− SERVICE SPECIFICATIONSCOOLING (5VZ−FE)
SS−23
197 Author: Date:
1996 TOYOTA T100 (RM449U)
COOLING (5VZ−FE)
SERVICE DATA
ThermostatValve opening pressure
Valve lift at 95°C (203°F)80 − 84°C (176 − 183°F)
8.5 mm (0.335 in .) or more
Radiator capRelief valve opening pressure STD
Minimum74 − 103 kPa (0.75 − 1.05 kgf/cm2, 10.7 − 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.5 psi)

Downloaded from www.Manualslib.com manuals search engine SS00Z−06
SS−24
− SERVICE SPECIFICATIONSCOOLING (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Fan x Fan pulley bracket5.45548 in.·lbf
Water pump x Cylinder block − Short bolt2020014
Water inlet x Water pump2020014
Radiator support x Body121208.7