1996 TOYOTA T100 check engine light

Downloaded from www.Manualslib.com manuals search engine P20865
P20864
EM5345
EM−86
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−101).
Torque:
1st 25 N·m (250 kgf·cm, 18 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).

Downloaded from www.Manualslib.com manuals search engine P20861
Front Mark
(Arrow)
Z14732
EM5369
FrontPainted
Mark
EM5370
Painted Mark
90°
90°
P00591
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
(b) Install the main bearing cap with the front mark facing for-
ward.
8. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any main bearing cap bolt is broken or deformed, re-
place it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 8 main bearing cap bolts,
in several passes, in the sequence shown.
Torque: 61 N·m (625 kgf·cm, 45 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance (See page
EM−92).
9. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.

Downloaded from www.Manualslib.com manuals search engine SF0AF−04
− 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.

Downloaded from www.Manualslib.com manuals search engine FI2553
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

Downloaded from www.Manualslib.com manuals search engine P14758
New
GrommetNew
O−Ring
SF0AT−03
P14756
Upward
Turn
Push
P14757
P24768
− MFI (3RZ−FE)INJECTOR
MF−21
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL INJECTORS TO DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to a new O−ring and install
it to the injector.
(c) While turning the injector left and right, install it to the de-
livery pipe. Install the 4 injectors.
(d) Position the injector connector upward.
2. INSTALL INJECTORS AND DELIVERY PIPE
(a) Place the 4 new insulators and in position on the spacers.
(b) Place the 4 injectors together with the delivery pipe in
position on the cylinder head.
(c) Temporarily install the 2 bolts holding the delivery pipe to
the cylinder head.
(d) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O−rings. Replace the O−rings.
(e) Position the injector connector upward.
(f) Tighten the 2 bolts holding the delivery pipe to the cylinder
head.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
3. INSTALL THROTTLE BODY (See page MF−30)
4. REINSTALL HIGH−TENSION CORDS TO SPARK
PLUGS
5. INSTALL NO.1 AND NO.2 PCV HOSES
6. INSTALL AIR INTAKE CONNECTOR
7. M/T:
CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
8. A/T:
CONNECT THROTTLE AND ACCELERATOR CABLES
TO THROTTLE BODY

Downloaded from www.Manualslib.com manuals search engine P03244Press Down Lock
P03245LockInsert
FI2553
SF−2
− SFI (5VZ−FE)SFI SYSTEM
1008 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 OFF or disconnecting the negative (−) terminal
cable from the battery.
HINT:
Always check the diagnostic trouble code before disconnecting
the negative (−) terminal cable from the battery.
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (−) cables.
(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 the wir-
ing 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

Downloaded from www.Manualslib.com manuals search engine SF0C2−03
P21125
New O−Ring
P21218
Delivery Pipe CORRECTNew O−Ring
Regulator
WRONG
− SFI (5VZ−FE)FUEL PRESSURE REGULATOR
SF−17
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR
(a) Apply a light coat of gasoline to a new O−ring, and install
it to the pressure regulator.
(b) Attach the pressure regulator to the LH delivery pipe.
(c) Check that the pressure regulator rotates smoothly.
NOTICE:
If it does not rotate smoothly, the O−ring may be pinched,
so remove the pressure regulator and repeat steps (a) to (c)
above.
(d) Install the pressure regulator with the 2 bolts.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)
(e) Install the engine wire with the bolt.
2. CONNECT FUEL RETURN HOSE TO FUEL
PRESSURE REGULATOR
NOTICE:
Be sure to insert the hose up to the stopper and clip it.
3. INSTALL INTAKE AIR CONNECTOR
(See page EM−69)
4. INSTALL AIR CLEANER HOSE
5. CHECK FOR FUEL LEAKS

Downloaded from www.Manualslib.com manuals search engine SF0C6−03
P10889
New Grommet
New O−Ring
New GrommetNew O−Ring
P21185
Push
Turn
Connector
P21208
P21216
RotateOutward
P21207
− SFI (5VZ−FE)INJECTOR
SF−23
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. TEMPORARILY INSTALL INJECTORS AND
DELIVERY PIPES
(a) Install 2 new grommets to each injector.
(b) Apply a light coat of spindle oil or gasoline to 2 new O−
rings and install them to each injector.
(c) While turning the injector clockwise and counterclock-
wise, push it to the delivery pipes. Install the 6 injectors.
(d) Position the injector connector outward.
(e) Place the 4 spacers in position on the intake manifold.
(f) Place the delivery pipes with the 6 injectors in position on
the intake manifold.
(g) Temporarily install the 4 bolts holding the delivery pipes
to the intake manifold.
(h) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O−rings. Replace the O−rings.
(i) Position the injector connector outward.
2. CONNECT INJECTOR CONNECTORS
3. INSTALL FUEL PIPE AND TIGHTENING
DELIVERY PIPE HOLDING BOLTS
(a) Install the fuel pipe with 4 new gaskets and the 2 union
bolts.
Torque: 34.3 N·m (350 kgf·cm, 25 ft·lbf)
(b) Tighten the 4 bolts holding the delivery pipes to the intake
manifold.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)