Toyota T100 (1996) manual

1996 TOYOTA T100 Factory Service Manual[...]

INDEX IN Introduction MA Maintenance PP Preparation SS Service Specifications DI Diagnostics EM Engine Mechanical (3RZ-FE) Engine Mechanical (5VZ-FE) EC Emissions Control (3RZ-FE) Emissions Control (5VZ-FE) MF MFI System (3RZ-FE) SF SFI System (5VZ-FE) CO Cooling (3RZ-FE) Cooling (5VZ-FE) LU Lubrication (3RZ-FE) Lubrication (5VZ-FE) IG Ignition (3R[...]

IN – INTRODUCTION HOW TO USE THIS MANUAL IN-1 IDENTIFICATION INFORMATION IN-3 REPAIR INSTRUCTIONS IN-4 FOR ALL OF VEHICLES IN-9 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN-15 TERMS IN-31[...]

IN02D − 02 N17080 Filler Cap Float Reservoir T ank z Grommet Clip Slotted Spring Pin N·m (kgf·cm, ft·lbf) : Specified torque z Non − reusable part Cylinder Piston Push Ro d W asher Snap Ring Boot z Gasket Lock Nu t Clevis P i n Clevis 12 ( 120, 9) 15 ( 155, 1 1) − INTRODUCTION HOW T O USE THIS MANUAL IN − 1 1 A uthor: Date: 1996 T [...]

Illustration: what to do and where 21 . CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. T a s k 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 releasin[...]

IN02E − 02 A B13830 − INTRODUCTION IDENTIFICA TION INFORMA TION IN − 3 3 A uthor: Date: 1996 T OYOT A T100 (RM449U) IDENTIFICA TION INFORMA TION VEHICLE IDENTIFICA TION AND ENGINE SERIAL NUMBER 1. VEHICLE IDENTIFICA TION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification labe[...]

FI1066 IN0IL − 01 Z1 1554 Seal Lock Adhesive IN − 4 − INTRODUCTION REP AIR INSTRUCTIONS 4 A uthor: Date: 1996 TOYOT A T100 (RM449U) REP AIR INSTRUCTIONS GENERAL INFORMA TION BASIC REP AIR HINT (a) Use fender , seat and floor covers to keep the vehicle clean and prevent damage. (b) During disassembly , keep parts in the appropriate order[...]

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 BREAKER FUSE M − FUSE H − FUSE FL CB − INTRODUCTION REP AIR INSTRUCTIONS IN − 5 5 A uthor: Date: 1996 TOYOT A T100 (RM449U) (3) Precoated parts are ind[...]

IN0253 WRONG CORRECT IN0252 WRONG CORRECT IN0002 Example IN − 6 − INTRODUCTION REP AIR INSTRUCTIONS 6 A uthor: Date: 1996 TOYOT A T100 (RM449U) (k) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the prop- er locations (See page IN − 8 ). (1) If the vehicle is to be jacked up onl[...]

− INTRODUCTION REP AIR INSTRUCTIONS IN − 7 7 A uthor: Date: 1996 TOYOT A T100 (RM449U) (n) Unless otherwise stated, all resistance is measured at an ambient temperature of 20 ° C (68 ° F). Because the resis- tance may be outside specifications if measured at high temperatures immediately after the vehicle has been run- ning, measurement[...]

IN02G − 02 B01 123 [2WD] [4WD] JACK POSITION SUPPORT POSITION Front Center of crossmember Rear Under the rear dif ferential Safety stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

IN02H − 03 BO41 1 1 Negative Cable − INTRODUCTION FOR AL L OF VEHICLES IN − 9 9 A uthor: Date: 1996 T OYOT A T100 (RM449U) FOR ALL OF VEHICLES PRECAUTION 1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG (a) The T OYOT A T100 is equipped with an SRS (Supple- mental Restraint System), such as the driver airbag. Failure to carry out service operat[...]

B01 124 Front IN − 10 − INTRODUCTION FOR AL L OF VEHICLES 10 A uthor: Date: 1996 TOYOT A 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 a[...]

R1 1910 Red Mark − INTRODUCTION FOR AL L OF VEHICLES IN − 11 11 A uthor: Date: 1996 TOYOT A T100 (RM449U) (d) SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, other- wise cable disconnection and other troubles may result. Refer to SR − [...]

Z13953 Example: Correct Wrong Z13950 Example: IN − 12 − INTRODUCTION FOR AL L OF VEHICLES 12 A uthor: Date: 1996 TOYOT A T100 (RM449U) (e) STEERING WHEEL P AD (with Airbag) (1) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. In this case, the twin − lock [...]

− INTRODUCTION FOR AL L OF VEHICLES IN − 13 13 A uthor: Date: 1996 TOYOT A T100 (RM449U) (f) CENTER AIRBAG SENSOR ASSEMBL Y (1) Never reuse the center airbag sensor assembly in- volved in a collision when the SRS has deployed. (2) The connectors to the center airbag sensor assem- bly should be connected or disconnected with the sensor mou[...]

IN − 14 − INTRODUCTION FOR AL L OF VEHICLES 14 A uthor: Date: 1996 TOYOT A T100 (RM449U) 3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICA TION SYSTEM For vehicles with mobile communication systems such as two − way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away from the [...]

IN02I − 02 − INTRODUCTION HOW T O TROUBLESHOOT ECU CONTROLLED SYSTEMS IN − 15 15 A uthor: Date: 1996 T OYOT A T100 (RM449U) HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMA TION A large number of ECU controlled systems are used in the TOYOT A T100. In general, the ECU controlled system is considered to be a very intricate syst[...]

IN02J − 03 V ehicle Brought Workshop Customer Problem Analysis Symptom Confirmation and Diagnostic T rouble Code Check Symptom Simulation Diagnostic T rouble Code Chart Matrix Chart of Problem Symptoms Circuit Inspection or Parts Inspection Repair Confirmation T est End 1 2 4 3 5 6 7 8 Ask the customer about the conditions and the environment whe[...]

Important Points in the Customer Problem Analysis D What −−−−− V ehicle model, system name D When −−−−− Date, time, occurrence frequency D Where −−−−− Road conditions D Under what conditions? −−−−− Running conditions, driving conditions, weather conditions D How did it happen? −−−−− Problem symptoms[...]

DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic T rouble Cod e Check (Make a note of and then clear) Conf irmation of Symptoms Diagnostic T rouble Code Check Problem Condition Diagnostic T rouble Code Display Problem symptoms exist Same diagnostic trouble code is displayed Problem is still occurring in the diagnostic circuit. Normal code is disp[...]

Diagnostic trouble code check Making a note of and clearing of the diagnostic trouble codes displayed Symptom confirmation No problem symptoms exist Problem symptoms exist Simulation test using the symptom simulation methods D Normal code displayed D Problem symptoms exist D Normal code displayed D No problem symptoms exist Diagnostic trouble code [...]

V07268 VIBRA TION METHOD: When vibration seems to be the major cause. CONNECTORS WIRE HARNESS P ARTS AND SENSOR 1 Slightly shake the connector vertically and horizontally . Slightly shake the wire harness vertically and horizontally . The connect or joint, fulcrum of the vibration, and body through portion are the major areas to be checked thorough[...]

V07469 HEA T 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). (T emperature is limited not to damage the components.) (2) Do not apply heat directly to parts in the ECU. 3 W A TER SPRINKLING METHOD: NOTICE: (1) Never sprinkle water directly into the engine compartmen[...]

D DTC No. Indicates the diagnostic trouble code. D Page or Instructions Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs. D Detection Item Indicates the system of the problem or contents of the problem. D T rouble Area Indicates the suspect area of the problem. Mass Ai[...]

− INTRODUCTION HOW T O TROUBLESHOOT ECU CONTROLLED SYSTEMS IN − 23 1996 TOYOT A T100 (RM449U) 5. PROBLEM SYMPTOMS T ABLE The suspect circuits or parts for each problem symptom are shown in the table below . Use this table to trou- bleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the prob- lem i[...]

V08423 Knock Sensor 1 GR ECM KNK E1 12 E6 WIRING DIAGRAM D Wiring Diagram DTC P0325 Knock Sensor 1 Circuit Malfunction CIRCUIT DESCRIPTION Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibra[...]

V08425 LOCK KNK E6 Connector (a) Remove the glove compartment (See page SF − 37). (b) Disconnect the E6 connector of ECM. INSPECTION PROCEDURE Replace knock sensor . 1 Check continuity between terminal KNK of ECM connector and body ground. OK: Check knock sensor (See page SF − 34). Measure resistance between terminal KNK of ECM connector and bo[...]

FI0046 FI0047 FI0048 IN02K − 03 IN − 26 − INTRODUCTION HOW T O TROUBLESHOOT ECU CONTROLLED SYSTEMS 1996 T OYOT A T100 (RM449U) HOW T O USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1 . CONNECTOR CONNECTI ON AND TE RMINAL IN - SPECTION S For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circ[...]

IN0379 Sensor Side ECU Side IN0378 Sensor Side ECU Side IN0380 Sensor Side ECU Side IN0381 Pull Lightly Looseness of Crimping − INTRODUCTION HOW T O TROUBLESHOOT ECU CONTROLLED SYSTEMS IN − 27 1996 TOYOT A T100 (RM449U) 2. CONTINUITY CHECK (OPEN CIRCUIT CHECK) ( a ) Disc onnect the connector s at both ECU and sens or sides. (b) Measure the resi[...]

FI7187 Z17004 C B A OPEN Sensor Fig. 1 ECU 1 2 1 2 1 22 1 Z17005 Fig. 2 Sensor ECU C B A 1 2 1 2 1 2 B04722 Fig. 3 ECU Sensor 2 1 A B1 C 1 1 22 1 2 B2 IN − 28 − INTRODUCTION HOW T O TROUBLESHOOT ECU CONTROLLED SYSTEMS 1996 TOYOT A T100 (RM449U) 5. CONNECTOR HANDLING When inserting tester probes into a connector , insert them from the rear of th[...]

Z17007 Fig. 4 Sensor C A 1 2 1 2 1 2 ECU B 5 V 5 V 0 V 5 V Z17008 CB A SHORT Fig. 5 1 2 1 2 2 1 Z17009 Fig. 6 Sensor ECU C B A 1 2 1 2 1 2 − INTRODUCTION HOW T O TROUBLESHOOT ECU CONTROLLED SYSTEMS IN − 29 1996 TOYOT A T100 (RM449U) (b) Check the voltage. In a circuit in which voltage is applied (to the ECU connec- tor terminal), an open circui[...]

Z17808 Fig. 7 Sensor ECU C A 1 2 1 2 1 22 1 B2 B1 IN0383 Example Ground IN0384 EC U Side Ground W/H Side Ground IN − 30 − INTRODUCTION HOW T O TROUBLESHOOT ECU CONTROLLED SYSTEMS 1996 TOYOT A T100 (RM449U) (2) Disconnect connector ”B” and measure the resis- tance bet wee n terminal 1 of connector ”A” and body ground, and terminal 1 of c[...]

IN02L − 01 − INTRODUCTION TERMS IN − 31 31 A uthor: Date: 1996 T OYOT A T100 (RM449U) TERMS ABBREVIA TIONS USED IN THIS MANUAL Abbreviations Meaning ABS Anti − Lock Brake System A.D.D. Automatic Disconnecting Dif ferential A/T Aut omati c T ransmission AT F Automatic Transmission Fluid BTDC Before T op Dead Center Calif. California CB[...]

IN − 32 − INTRODUCTION TERMS 32 A uthor: Date: 1996 T OYOT A T100 (RM449U) T/M T ransmission U/S Undersize VCV V acuum Control V alve VSV V acuum Switching V alve VTV V acuum Transmitting V alve w/ With w/o Without 2WD T wo Wheel Drive V ehicles (4x2) 4WD Four Wheel Drive V ehicles (2x2)[...]

IN02M − 01 − INTRODUCTION TERMS IN − 33 1996 T OYOT A T100 (RM449U) GLOSSARY OF SAE AND T OYOT A TERMS This glossary lists all SAE − J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their T oyota equivalents. SAE ABBREVIA TIONS SAE TERMS T OYOT A TERMS ( ) −− ABBREVIA TIONS A/C Air C[...]

IN − 34 − INTRODUCTION TERMS 1996 T OYOT A T100 (RM449U) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IA T Intake Air T emperature Intake or Inlet Air T emperature ICM Ignition Control Module − IFI Indirect Fuel Injection Indirect Injection IFS Inertia Fuel − Shutof f − ISC Idle Speed[...]

− INTRODUCTION TERMS IN − 35 1996 T OYOT A T100 (RM449U) TCM Transmission Control Module T ransmission ECU (Electronic Control Unit) TP Throttle Position Throttle Position TR T ransmission Range − TVV Thermal V acuum V alve Bimetallic V acuum Switching V alve (BVSV) Thermostatic V acuum Switching V alve (TVSV) TWC Three − W ay Catalytic Con[...]

MA – MAINTENANCE OUTSIDE VEHICLE MA-1 INSIDE VEHICLE MA-2 UNDER HOOD MA-4 ENGINE MA-5 BRAKE MA-7 CHASSIS MA-8[...]

MA001 − 28 − MAINTENANCE OUTSIDE VEHICLE MA − 1 36 A uthor: Date: 1996 T OYOT A T100 (RM449U) OUTSIDE VEHICLE GENERAL MAINTENANCE The owners are responsible for these maintenance and inspection items. 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 [...]

MA002 − 05 MA − 2 − MAINTENANCE INSIDE VEHICLE 37 A uthor: Date: 1996 T OYOT A 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[...]

− MAINTENANCE INSIDE VEHICLE MA − 3 38 A uthor: Date: 1996 TOYOT A T100 (RM449U) 13. ACCELERA TOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. 14. CLUTCH PEDAL (See page CL − 2 ) (a) Check the pedal for smooth operation. (b) Check that the pedal has the proper freeplay . 15. BRAKE PEDAL (See page BR ?[...]

MA003 − 05 MA − 4 − MAINTENANCE UNDER HOOD 39 A uthor: Date: 1996 T OYOT A T100 (RM449U) UNDER HOOD GENERAL MAINTENANCE 1. GENERAL NOTES S Maintenance items may vary from country to country . Check the owner ’ s manual supplement in which the maintenance schedule is shown. S Every service item in the periodic maintenance schedule must[...]

MA004 − 03 P08488 Back Front − MAINTENANCE ENGINE MA − 5 40 A uthor: Date: 1996 T OYOT A T100 (RM449U) ENGINE INSPECTION HINT : Inspect these items when the engine is cold. 1. (5VZ − FE ENGINE) REPLACE TIMING BEL T (See page EM − 11 ) 2. INSPECT DRIVE BEL TS GENERA TOR: (3RZ − FE: See page CH − 2 ) (5VZ − FE: See page CH − 1[...]

MA − 6 − MAINTENANCE ENGINE 41 A uthor: Date: 1996 TOYOT A T100 (RM449U) 10. INSPECT FUEL LINES AND CONNECTIONS Visually inspect the fuel lines for cracks, leakage loose connec- tions, deformation or tank band looseness. 1 1. INSPECT EXHAUST PIPES AND MOUNTINGS Visually inspect the p ipes, hangers and connections for severe corrosion, lea[...]