weight TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P14962
EM073−03
P15101
Aligin
Aligin
Aligin
P15100
P15080A03755
EM−20
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
INSTALLATION
NOTICE:
Check that No.1 cylinder is at TDC and that the weights of
the No.1 and No.2 balance shafts are at the bottom side.
1. INSTALL NO.4 VIBRATION DAMPER
Install the No.4 damper with the 2 bolts.
2. INSTALL NO.2 TIMING CHAIN
(a) Install the No.2 timing chain by matching its mark links
with the timing marks on the No.2 crankshaft timing
sprocket and balance shaft timing sprocket.
(b) Fit the other mark link of No.2 timing chain onto the
sprocket behind the large timing mark of the balance shaft
drive gear.
(c) Insert the balance shaft drive gear shaft through the bal-
ance shaft drive gear so that it fits into the thrust plate
hole.
Then align the small timing mark of the balance shaft drive
gear with the timing mark of the balance shaft timing gear.
(d) Install the bolt to the balance shaft drive gear and tighten
it.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(e) Check that each timing mark is matched with the corre-
sponding mark link.
3. INSTALL NO.2, NO.3 VIBRATION DAMPERS AND
NO.2 CHAIN TENSIONER
NOTICE:
Assemble the chain tensioner with the pin installed, then
remove the pin after assembly.
When doing this, avoid pushing the No.2 vibration damper
against the chain.
(a) Install the No.2 chain tensioner with the nut.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine LU02Y−02
P14867
P14873
P14872
P14874
− LUBRICATION (3RZ−FE)OIL PUMP
LU−9
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls smoothly
into the valve hole by its own weight.
If it does not, replace the relief valve. If necessary, replace the
oil pump assembly.
2. INSPECT ROTOR BODY CLEARANCE
Using a thickness gauge, measure the clearance between the
driven rotor and body.
Standard body clearance:
0.100 − 0.175 mm (0.0039 − 0.0069 in.)
Maximum body clearance:
0.30 mm (0.0118 in.)
If the body clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
3. INSPECT ROTOR SIDE CLEARANCE
Using a thickness gauge and precision straight edge, measure
the clearance between the rotors and precision straight edge.
Standard side clearance:
0.030 − 0.090 mm (0.0012 − 0.0035 in.)
Maximum side clearance:
0.15 mm (0.0059 in.)
If the side clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
4. INSPECT ROTOR TIP CLEARANCE
Using a thickness gauge, measure the clearance between the
drive and driven rotor tips.
Standard tip clearance:
0.110 − 0.240 mm (0.0043 − 0.0094 in.)
Maximum tip clearance:
0.25 mm (0.0098 in.)
If the tip clearance is greater than maximum, replace the rotors
as a set.

Downloaded from www.Manualslib.com manuals search engine LU038−01
P20968
Relief Valve
P20934
P20935
P20936
− LUBRICATION (5VZ−FE)OIL PUMP
LU−11
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls smoothly
into the valve hole by its own weight.
If the valve does not fall smoothly, replace the valve. If neces-
sary, replace the oil pump assembly.
2. INSPECT ROTOR BODY CIEARANCE
Using a thickness gauge, measure the clearance between the
driven rotor and pump body.
Standard body clearance:
0.10 − 0.18 mm (0.0039 − 0.0069 in.)
Maximum body clearance:
0.30 mm (0.0118 in.)
If the body clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
3. INSPECT ROTOR TIP CLEARANCE
Using a thickness gauge, measure the clearance between the
drive and driven rotor tips.
Standard tip clearance:
0.11 − 0.24 mm (0.0043 − 0.0094 in.)
Maximum tip clearance:
0.35 mm (0.0138 in.)
If the tip clearance is greater than maximum, replace the rotors
as a set.
4. INSPECT ROTOR SIDE CLEARANCE
Using a thickness gauge and precision straight edge, measure
the clearance between the rotors and precision straight edge.
Standard side clearance:
0.03 − 0.09 mm (0.0012 − 0.0035 in.)
Maximum side clearance:
0.15 mm (0.0059 in.)
If the side clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.

Downloaded from www.Manualslib.com manuals search engine BR0060
BR09R−11
BR0061
SST
BR0062
80 kg/cm2
BR−50− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)
1655 Author: Date:
1996 TOYOTA T100 (RM449U)
LOAD SENSING PROPORTIONING
AND BY−PASS VALVE (LSP & BV)
ON−VEHICLE INSPECTION
1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight):
2WD:
1 ton: 850 kg (1,874 lb)
0.5 ton std: 800 kg (1,764 lb)
0.5 ton opt (soft ride): 850 kg (1,874 lb)
4WD: 1,050 kg (2,315 lb)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709−29017
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80
kgf/cm
2, 1,138 psi) AND CHECK REAR BRAKE PRES-
SURE
Rear brake pressure:
5,325 ± 490 kPa (54.3 ± 5 kgf/cm
2, 772 ± 71 psi)
HINT:
The brake pedal should not be depressed twice and/or returned
while setting to the specified pressure. Read the value of rear
brake pressure after holding the specified fluid pressure for 2
seconds. If the brake pressure is incorrect, adjust the fluid pres-
sure.

Downloaded from www.Manualslib.com manuals search engine Z14294
R09063
Compressed Air
R09064
Inscribed
Mark
R08702
Calipers
Z14483
SST
Oil Seal
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−39
1996 TOYOTA T100 (RM449U)
3. INSPECT FLOW CONTROL VALVE
(a) Coat the valve with power steering fluid and check that it
falls smoothly into the valve hole by its own weight.
(b) Check the flow control valve for leakage.
Close one of the holes and apply compressed air 392 −
490 kPa (4 − 5 kgf/cm
2, 57 − 71 psi) into the opposite side,
and confirm that air does not come out from the end hole.
If necessary, replace the valve with one having the same letter
on the front housing.
Inscribed mark: A, B, C, D, E or F
4. INSPECT SPRING
Using calipers, measure the free length of the spring.
Minimum free length: 32.3 mm(1.272 in.)
If it is not within the specification, replace the spring.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, tap out the oil seal from the front housing.
SST 09631−10030
NOTICE:
Be careful not to damage the bushing of the front housing.
(b) Coat a new oil seal lip with power steering fluid.

Downloaded from www.Manualslib.com manuals search engine R13897Inscribed Mark
R12184
R07591
Compressed Air
R12185Inscribed Mark
− STEERINGPOWER STEERING VANE PUMP (5VZ−FE)
SR−49
1996 TOYOTA T100 (RM449U)
If it is more than maximum, replace the plate and/or rotor with
one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None
HINT:
There are 5 vane plate lengths with the following rotor and cam
ring marks:
Rotor and
cam ring markVane plate
part numberVane plate length mm
(in.)
None44345−2601014.999 − 15.001
(0.59051 − 0.59059)
144345−2602014.997 − 14.999
(0.59043 − 0.59051)
244345−2603014.995 − 14.997
(0.59035 − 0.59043)
344345−2604014.993 − 14.995
(0.59027 − 0.59035)
444345−2605014.991 − 14.993
(0.59020 − 0.59027)
3. INSPECT FLOW CONTROL VALVE
(a) Coat the valve with power steering fluid and check that it
falls smoothly into the valve hole by its own weight.
(b) Check the flow control valve for leakage.
Close one of the holes and apply compressed air 392 −
490 kPa (4 − 5 kgf/cm
2, 57 − 71 psi) into the opposite side,
and confirm that air does not come out from the end holes.
If necessary, replace the valve with one having the same letter
as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F

Downloaded from www.Manualslib.com manuals search engine AB0158
Battery
SST
R05752
SST
H00401Weighty
y
x
RS−16
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 TOYOTA T100 (RM449U)
(d) Check functioning of SST.
SST 09082−00700
(e) Install the SST
CAUTION:
Place the disc wheel on the level ground.
(1) Connect the SST connector to the steering wheel
pad connector.
SST 09082−00700
NOTICE:
To avoid damaging the SST connector and wire harness,
do not lock the secondary lock of the twin lock. Also, se-
cure some slack for the SST wire harness inside the disc
wheel.
(2) Move the SST to at least 10 m (33 ft) away from
steering wheel pad tied down on the disc wheel.
(f) Cover steering wheel pad with cardboard box or tires.
Covering method using cardboard box:
Cover the steering wheel pad with the cardboard
box and weight the cardboard box down in 4 places
with at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
x=460 mm (18.11 in.)
When dimension of the cardboard box exceeds the di-
ameter of the disc wheel with the tire which the steer-
ing wheel pad is tied to−
x=460 mm (18.11 in.) + width of tire
y= 650 mm (25.59 in.)
NOTICE:
If a cardboard box smaller than the specified size is used,
the cardboard box will be broken by the shock from the air-
bag deployment.