warning TOYOTA T100 1996 Factory Service Manual

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)

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Front IN−10
− INTRODUCTIONFOR ALL OF VEHICLES
10 Author: Date:
1996 TOYOTA T100 (RM449U)
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the center airbag sensor if
shocks are likely to be applied to the sensor during
repairs.
(6) Never disassemble and repair the center airbag
sensor assembly, steering wheel pad in order to re-
use it.
(7) If the center airbag sensor assembly, steering
wheel pad have been dropped, or if there are
cracks, dents or other defects in the case, bracket
or connector, replace them with new ones.
(8) Do not expose the center airbag sensor assembly,
steering wheel pad directly to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kΩ/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work on the supplemental restraint system is
completed, check the SRS warning light (See page
DI−365).
(c) FRONT AIRBAG SENSOR
(1) Never reuse the front airbag sensors involved in a
collision that activated the supplemental restraint
system. (Replace both left and right airbag sen-
sors.)
(2) Install the front airbag sensor with the arrow on the
sensor facing toward the front of the vehicle.
The front airbag sensor set bolts have been anti−
rust treated. When the sensor is removed, always
replace the set bolts with new ones.
(3) The front airbag sensor is equipped with an electri-
cal connection check mechanism. Be sure to lock
this mechanism securely when connecting the con-
nector.
(4) If connector is not securely locked, a malfunction
code will be the diagnosis system (See page
RS−2).

Downloaded from www.Manualslib.com manuals search engine MA002−05
MA−2
− MAINTENANCEINSIDE VEHICLE
37 Author: Date:
1996 TOYOTA T100 (RM449U)
INSIDE VEHICLE
GENERAL MAINTENANCE
These are maintenance and inspection items which are considered to be the owner’s responsibility.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
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. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD GLASS
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater or air conditioner.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and are mounted securely.
10. STEERING WHEEL
Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering,
excessive freeplay or strange noises.
11. SEATS
(a) Check that the seat adjusters operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the head restraints move up and down smoothly and that the locks hold securely in any
latch position.
(d) For fold−down seat backs, check that the latches lock securely.
12. SEAT BELTS
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.

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PP−11 8
− PREPARATIONBODY ELECTRICAL
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Voltmeter
Ammeter
Ohmmeter
Test lead
SyphonBrake fluid level warning switch
Bulb (3W)Fuel sender gauge
Bulb (3.4W)Seat belt warning relay
Bulb (21W)Turn signal flasher relay
Dry cell batteryFuel sender gauge
Torque wrench

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 DI0ZI−01
ABS Check SheetInspector ’s
Name:
Customer ’s Name
Date Vehicle
Brought InRegistration YearRegistration No.
Frame No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs/ /
ContinuousIntermittent ( times a day)
ABS does not operate.
ABS does not operate efficiently.
ABS Warning Light
AbnormalRemains ONDoes not Light Up
DTC Check1st Time
2nd TimeNormal Code
Malfunction Code (Code )
Normal CodeMalfunction Code (Code )
Symptomskm
miles DI−320
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 TOYOTA T100 (RM449U)
CUSTOMER PROBLEM ANALYSIS CHECK

Downloaded from www.Manualslib.com manuals search engine R12019
DI0ZM−03
A00778DLC1 E
1Tc
F00006
DLC1Short Pin
R01346
Normal Code
0.25 sec.
0.25 sec. 2 sec.
ON
OFF
ON
OFF0.5 sec.0.5 sec.
Code 11 and 21
4 sec.1.5 sec.
2.5 sec.
Code 11 Code 21
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−321
1996 TOYOTA T100 (RM449U)
PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Check the indicator light.
When the ignition switch is turned ON, check that the ABS
warning light goes on for 3 seconds.
HINT:
If the indicator check result is not normal, proceed to trouble-
shooting for the ABS warning light circuit (See page DI−354).
(b) Check the DTC.
(1) Using SST, connect terminals Tc and E
1 of the
DLC1.
SST 09843−18020
(2) Disconnect the short pin from the DLC1.
(3) Turn the ignition switch ON.
(4) Read the DTC from the ABS warning light on the
combination meter.
HINT:
If no code appears, inspect the diagnostic circuit or ABS
warning light circuit (See page DI−354 or DI−358).
As an example, the blinking patterns for normal code and
codes 11 and 21 are shown on the left.
(5) Code are explained in the code table on page
DI−326.
(6) After completing the check, disconnect terminals Tc
and E
1, and turn off the display.
If 2 or more malfunctions are indicated at the same time the low-
est numbered DTC will be displayed 1st.

Downloaded from www.Manualslib.com manuals search engine BR3890
F00006DLC1Short Pin
N09348
TOYOTA
hand−held tester
TOYOTA
brake−out−box ECU
A00778DLC1 E
1Tc
Ts DI−322
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 TOYOTA T100 (RM449U)
(c) Clear the DTC.
(1) Using SST, connect terminals Tc and E
1 of the
DLC1 and remove the short pin from the DLC1.
SST 09843−18020
(2) Turn the ignition switch ON.
(3) Clear the DTC stored in ECU by depressing the
brake pedal 8 or more times within 3 seconds.
(4) Check that the warning light shows the normal
code.
(5) Remove the SST from the terminals of the DLC1.
SST 09843−18020
(6) Connect the short pin to the DLC1.
HINT:
Cancellation can also be done by removing the ECU−B fuse,
but in this case, other memory systems will also be cancelled
out.
(d) Using TOYOTA brake−out−box and TOYOTA hand−held
tester, measure the ECU terminal value.
(1) Hook up the TOYOTA hand−held tester and
TOYOTA break−out−box to the vehicle.
(2) Read the ECU input/output values by following the
prompts on the tester screen.
HINT:
TOYOTA hand−held tester has a ”Snapshot” function. This re-
cords the measured values and is effective in the diagnosis of
intermittent problems.
Please refer to the TOYOTA hand−held tester/TOYOTA break−
out−box operator’s manual for further details.
2. SPEED SENSOR SIGNAL AND DECELERATION SEN-
SOR CHECK
(a) Check the speed sensor signal.
(1) Turn the ignition switch OFF.
(2) Using SST, connect terminals Ts and E
1 of the
DLC1.
SST 09843−18020
(3) Start the engine.

Downloaded from www.Manualslib.com manuals search engine BR3904
0.13 sec. 0.13 sec.
ON
OFF
BR3893
Malfunction Code (Example Code 72, 76)
7
26
7
ON
OFF
0.5 sec. 0.5 sec. 0.5 sec. 0.5 sec.1.5 sec. 2.5 sec.4 sec.
Repeat
A00778DLC1 E
1
Ts
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
DI−323
1996 TOYOTA T100 (RM449U)
(4) Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit (See page DI−354).
(5) Drive vehicle straight forward.
HINT:
Drive vehicle faster than 45 km/h (28 mph) for several seconds.
(6) Stop the vehicle.
(7) Using SST, connect terminals Tc and E
1 of the
DLC1.
SST 09843−18020
(8) Read the number of blinks of the ABS warning light.
HINT:
See the list of DTC on page DI−326.
If every sensor is normal, a normal code is output (A cycle
of 0.25 sec. ON and 0.25 sec. OFF is repeated).
If 2 or more malfunction are indicated at the same time,
the lowest numbered code will be displayed 1st.
(9) After doing the check, disconnect terminals Ts and
E
1, Tc and E1 of the DLC1, and ignition switch
turned OFF.
(b) Check the deceleration sensor detection point.
(1) Turn the ignition switch OFF.
(2) Using SST, connect terminals Ts and E
1 of the
DLC1.
SST 09843−18020
(3) Start the engine.

Downloaded from www.Manualslib.com manuals search engine R05599
0.13 sec.
0.13 sec. 3 sec. ON
OFF
R12881
1,100 ± 30 mm
(43.31 ± 1.18 in.)
R12882
830 ± 30 mm
(32.68 ± 1.18 in.)
BR1865
0.13 sec.
0.13 sec. ON
OFF
R05596
0.13 sec. Braking0.13 sec. DI−324
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 TOYOTA T100 (RM449U)
(4) Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit (See page DI−354).
(5) Jack up the rear side of the vehicle slowly.
HINT:
When measuring the height, measure at the center of the lower
body of the vehicle.
(6) Check that the warning light blinks.
If the warning light turns on, inspect the deceleration sensor
installation. If the sensor installation is OK, replace the decel-
eration sensor.
(7) Jack down the vehicle slowly.
(8) Jack up the front side of the vehicle slowly, as
shown.
HINT:
When measuring the height, measure at the center of the lower
body of the vehicle.
(9) Check that the warning light blinks.
If the warning light turns on, inspect the deceleration sensor
installation. If the sensor installation is OK, replace the decel-
eration sensor.
(10) Jack down the vehicle slowly.
(c) Check the deceleration sensor operation.
(1) Drive the vehicle straight ahead at about 20 km/h
(12.4 mph) or more, lightly depress the brake pedal.
(2) Check that there is no change in the warning light
pattern.
(3) Drive the vehicle straight ahead at about 20 km/h
(12.4 mph) or more, and depress the brake pedal
moderately.
(4) Check that the warning light turns on while braking.