torque 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:

Downloaded from www.Manualslib.com manuals search engine Illustration:
what to do and where21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a) Place SST and a dial indicator onto the overdrive brake
piston as shown in the illustration.
Task heading : what to do
SST 09350−30020 (09350−06120)
Set part No.Component part No.
Detailed text : how to do task
(b) Measure the stroke applying and releasing the compressed
Piston stroke: 1.40  1.70 mm (0.0551  0.0669 in.)
Specification air (392 − 785 kPa, 4 − 8 kgf.cm2 or 57 − 114 psi) as
shown in the illustration. IN−2
− INTRODUCTIONHOW TO USE THIS MANUAL
2 Author: Date:
1996 TOYOTA T100 (RM449U)
The procedures are presented in a step−by−step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section for quick ref-
erence.
8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
Abbreviation Part Name Symbol Illustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKERFUSE
M−FUSE
H−FUSE
FL
CB
− INTRODUCTIONREPAIR INSTRUCTIONS
IN−5
5 Author: Date:
1996 TOYOTA T100 (RM449U)
(3) Precoated parts are indicated in the component il-
lustrations by the ”” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in the preparation part at the front
of each section in this manual.
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.

Downloaded from www.Manualslib.com manuals search engine IN−34
− INTRODUCTIONTERMS
1996 TOYOTA T100 (RM449U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module−
IFIIndirect Fuel InjectionIndirect Injection
IFSInertia Fuel−Shutoff−
ISCIdle Speed Control−
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure−
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface Temperature−
MVZManifold Vacuum Zone−
NVRAMNon−Volatile Random Access Memory−
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn−Board DiagnosticOn−Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module−
PNPPark/Neutral Position−
PROMProgrammable Read Only Memory−
PSPPower Steering Pressure−
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module−
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass−
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter−
SRIService Reminder Indicator−
SRTSystem Readiness Test−
STScan Tool−
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

Downloaded from www.Manualslib.com manuals search engine MA0568
B02099
B02100
− MAINTENANCECHASSIS
MA−13
48 Author: Date:
1996 TOYOTA T100 (RM449U)
12. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
(a) Tighten these parts:
Seat mounting bolts
Torque:
37 N·m (375 kgf·cm, 27 ft·lbf)

2WD:
Strut bar bracket−to−frame mounting bolts
Torque: 52 N·m (530 kgf·cm, 38 ft·lbf)
Leaf spring U−bolt mounting nuts
Torque: 133 N·m (1,350 kgf·cm, 98 ft·lbf )
(b) Under Severe Conditions:
In addition to the above maintenance items, check for
loose or missing bolts and nuts on the following.
Steering system
Drive train
Suspension system
Fuel tank mounts
Engine mounts, etc.
13. FINAL INSPECTION
(a) Check operation of body parts:
Hood:
Auxiliary catch operates properly
Hood locks securely when closed
Doors:
Door locks operate properly
Doors close properly
Seats:
Seat adjusts easily and locks securely in any
positions
Seat backs lock securely at any angle
Fold−down seat backs lock securely
(b) Road test:
Engine and chassis parts do not have abnormal
noises.
Vehicle does not wander or pull to one side.
Brakes work properly and do not drag.

Downloaded from www.Manualslib.com manuals search engine PP0G5−01
− PREPARATIONMAINTENANCE
PP−1
50 Author: Date:
1996 TOYOTA T100 (RM449U)
MAINTENANCE
EQUIPMENT
MirrorBrake hose
Torque wrench

Downloaded from www.Manualslib.com manuals search engine PP0G8−01
PP−6
− PREPARATIONENGINE MECHANICAL (3RZ−FE)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Engine tune−up tester
Heater
Magnetic finger
Micrometer
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring testerValve spring
Steel squareValve spring
Thermometer
Torque wrench
V−block
Valve seat cutter
Vernier calipers

Downloaded from www.Manualslib.com manuals search engine PP018−03
PP−12
− PREPARATIONENGINE MECHANICAL (5VZ−FE)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Timing lightIgnition timing
OBDII scan toolEngine speed
Heater
Magnetic finger
Micrometer
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring testerValve spring
Steel squareValve spring
Thermometer
Torque wrench
Valve seat cutter
Vernier calipers

Downloaded from www.Manualslib.com manuals search engine PP0GB−01
− PREPARATIONEMISSION CONTROL (3RZ−FE)
PP−15
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Tachometer
Torque wrench
Vacuum gauge

Downloaded from www.Manualslib.com manuals search engine PP018−04
PP−18
− PREPARATIONEMISSION CONTROL (5VZ−FE)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
OBDII scan toolEngine speed
Torque wrench
Vacuum gauge