1996 TOYOTA T100 engine

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− EMISSION CONTROL (5VZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−11
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page EC−8).

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EC−12− EMISSION CONTROL (5VZ−FE)THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEM
951 Author: Date:
1996 TOYOTA T100 (RM449U)
THREE−WAY CATALYTIC
CONVERTER (TWC) SYSTEM
INSPECTION
1. CHECK TWC FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented to the extent
that it contacts the three−way catalytic converter, repair or re-
place it.
2. CHECK CONNECTIONS EXHAUST PIPE FOR
LOOSENESS OR DAMAGE
3. CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS,
CRACKS OR DAMAGE
4. CHECK HEAT INSULATOR FOR DAMAGE
5. CHECK FOR ADEQUATE CLEARANCE BETWEEN
CATALYTIC CONVERTER AND HEAT INSULATOR

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P21187
P21181
− EMISSION CONTROL (5VZ−FE)THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEMEC−13
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE CENTER EXHAUST PIPE
(a) 2WD:
Disconnect the 2 rings from the support bracket.
(b) Remove the 2 nuts and gasket, and disconnect the
heated oxygen sensor (bank 1 sensor 2).
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
HINT:
Use a new gasket.
(c) Remove the 4 bolts, TWC joint retainer, center exhaust
pipe and 2 gasket.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
2. REINSTALL CENTER EXHAUST PIPE
HINT:
Place 2 new gaskets on the front exhaust and tail pipes, and
temporarily install the center exhaust pipe.

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MFI SYSTEM MF-1
FUEL PUMP MF-5
FUEL PRESSURE REGULATOR MF-13
INJECTOR MF-16
FUEL TANK AND LINE MF-23
THROTTLE BODY MF-25
IDLE AIR CONTROL (IAC) VALVE MF-31
MASS AIR FLOW (MAF) METER MF-36
EFI MAIN RELAY MF-40
CIRCUIT OPENING RELAY MF-41
VSV FOR EVAPORATIVE EMISSION
(EVAP) MF-43
VSV FOR EXHAUST GAS
RECIRCULATION (EGR) MF-44
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR MF-45
INTAKE AIR TEMPERATURE (IAT)
SENSOR MF-46
KNOCK SENSOR MF-47
EXHAUST GAS RECIRCULATION
(EGR) GAS TEMPERATURE SENSOR MF-48
HEATED OXYGEN SENSOR MF-49
ENGINE CONTROL MODULE (ECM) MF-50
FUEL CUT RPM MF-54

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− MFI (3RZ−FE)MFI SYSTEM
MF−1
953 Author: Date:
1996 TOYOTA T100 (RM449U)
MFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCON-
NECT NEGATIVE (−) TERMINAL CABLE FROM BAT-
TERY
HINT:
Any diagnostic trouble code retained by the ECM will be erased
when the battery negative (−) terminal cable is removed from
the battery.
Therefore, if necessary, read the diagnostic trouble code(s) be-
fore removing the negative (−) terminal cable from the battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME
WHEN WORKING ON FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATH-
ER PARTS
4. MAINTENANCE PRECAUTIONS
(a) Precaution when the connecting gauge.
Use battery as the power source for the timing light, etc.
(b) In the event of engine misfire, these precautions should
be taken.
(1) Check proper connection of battery terminals, etc.
(2) Handle high−tension cords carefully.
(3) After repair work, check that the ignition coil termi-
nals and all other ignition system lines are recon-
nected securely.
(4) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(c) Precautions when the handling heated oxygen sensors.
(1) Do not allow oxygen sensor to drop or hit against an
object.
(2) Do not allow the sensor to come into contact with
water.
If Vehicle is Equipped with Mobile Radio System (ham, cb, etc.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
5. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV
hose, etc. may cause the engine to run out of tune.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will cause air suction and cause the engine to run
out of tune.

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SST
MF−2
− MFI (3RZ−FE)MFI SYSTEM
954 Author: Date:
1996 TOYOTA T100 (RM449U)
6. ELECTRONIC CONTROL SYSTEM
(a) Before removing SFI wiring connectors, terminals, etc.,
first disconnect the power by either turning the ignition
switch to LOCK or disconnecting the negative (−) terminal
cable from the battery.
HINT:
Always check the diagnostic trouble code before disconnecting
the battery terminal cable.
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (−) cable
terminals.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and even slight terminal con-
tact can further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(1) Release the lock and pull out the connector, pulling
on the connectors.
(2) Fully insert the connector and check that it is locked.
(i) When inspecting a connector with a volt/ohmmeter.
(1) Carefully take out the water−proofing rubber if it is
a water−proof type connector.
(2) Insert the test probe into the connector from wiring
side when checking the continuity, amperage or
voltage.
(3) Do not apply unnecessary force to the terminal.
(4) After checking, install the water−proofing rubber on
the connector securely.
(5) Use SST for inspection or test of the injector or its
wiring connector.
SST 09842−30070

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Plug
P15007
New Gasket
New
Gasket
FI1654
SST
Fulcrum Length
30 cm
P15750
Grommet
New O−Ring
Delivery PipeCORRECT
WRONG
P15128
Delivery Pipe
Injector
InsulatorO−Ring
Grommet
− MFI (3RZ−FE)MFI SYSTEM
MF−3
955 Author: Date:
1996 TOYOTA T100 (RM449U)
7. FUEL SYSTEM
(a) When disconnecting the high pressure fuel line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Put a container under the connection.
(2) Slowly loosen the connection.
(3) Disconnect the connection.
(4) Plug the connection with a rubber plug.
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe these procedures:
(1) (Union Bolt Type)
Always use a new gasket.
(2) (Union Bolt Type)
Tighten the union bolt by hand.
(3) (Union Bolt Type)
Tighten the union bolt to the specified torque.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(4) (Flare Nut Type)
Apply a light coat of engine oil to the flare and tight-
en the flare nut by hand.
(5) (Flare Nut Type)
Using SST, tighten the flare nut to the specified
torque.
SST 09631−22020
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(c) Observe these precautions when removing and installing
the injectors.
(1) Never reuse the O−ring.
(2) When placing a new O−ring on the injector, take
care not to damage it in any way.
(3) Coat a new O−ring with spindle oil or gasoline be-
fore installing−never use engine, gear or brake oil.
(d) Install the injector to the delivery pipe and cylinder head
as shown in the illustration.

Downloaded from www.Manualslib.com manuals search engine FI7231
TOYOTA Hand−Held Tester
DLC3
MF−4
− MFI (3RZ−FE)MFI SYSTEM
956 Author: Date:
1996 TOYOTA T100 (RM449U)
(e) Check that there are no fuel leaks after doing mainte-
nance anywhere on the fuel system.
(1) Connect the TOYOTA hand−held tester to the
DLC3.
(2) Turn ignition switch ON and TOYOTA hand−held
tester main switch ON.
NOTICE:
Do not start the engine
(3) Select the active test mode on the TOYOTA hand−
held tester.
(4) Please refer to the TOYOTA hand−held tester oper-
ator ’s manual for further details.
(5) If you have no TOYOTA hand−held tester, connect
the positive (+) and negative (−) leads from the bat-
tery to the fuel pump connector.
(See page MF−10)
(6) Pinch the fuel return hose. The pressure in high
pressure line will rise to approx. 400 kPa (4 kgf/cm
2,
57 psi). In this state, check to see that there are no
leaks from any part of the fuel system.
NOTICE:
Always pinch the hose. Avoid bending as it may cause to
hose to crack.
(7) Turn the ignition switch to LOCK.
(8) Disconnect the TOYOTA hand−held tester from the
DLC3.