1996 TOYOTA T100 battery

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EM−80
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
1996 TOYOTA T100 (RM449U)
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
6. CONNECT STARTER WIRE AND CONNECTORS
(a) Connect the 3 starter wire clamps and connector.
(b) Install the 2 nuts, and connect the positive (+) terminal
cable to battery.
(c) Connect the A.D.D. indicator switch connector.
(d) Install the bolt, and connect the ground strap.
7. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose
Brake booster vacuum hose
EVAP hose
A.D.D. vacuum hose
8. CONNECT HEATER HOSES
9. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
10. INSTALL AIR CLEANER CASE AND AIR FILTER
11. INSTALL MAF METER, RESONATOR AND AIR
CLEANER CAP
12. w/ A/C:
CONNECT A/C COMPRESSOR
13. CONNECT PS PUMP
14. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS (See page EM−19)
15. INSTALL DRIVE BELT FOR GENERATOR (See page
CH−1)

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.

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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

Downloaded from www.Manualslib.com manuals search engine FI7231
TOYOTA Hand−Held Tester
DLC3SF0AG−03
P24761
− MFI (3RZ−FE)FUEL PUMP
MF−5
957 Author: Date:
1996 TOYOTA T100 (RM449U)
FUEL PUMP
ON−VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(c) Select the active test mode on the TOYOTA hand−held
tester.
(d) Please refer to the TOYOTA hand−held tester
operator ’s manual for further details.
(e) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector.
(See page MF−10)
(f) Check that there is pressure in the hose from the fuel filter.
HINT:
At this time, you will hear fuel return noise.
If there is no pressure, check these parts:
Fusible links (AM1 40A, AM2 30A, ALT 80A)
Fuses (EFI 15A, IGN 7.5A)
EFI main relay
Fuel pump
ECM
Wiring connections
(g) Turn the ignition switch to LOCK.
(h) Remove the TOYOTA hand−held tester.
2. CHECK FUEL PRESSURE
(a) Check that the battery voltage is above 12 volts.
(b) Disconnect the negative (−) terminal cable from the bat-
tery.
(c) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet pipe from the delivery pipe.
HINT:
Put a suitable container or shop rag under the delivery
pipe.
Slowly loosen the union bolt.

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FI7231
TOYOTA Hand−Held Tester
DLC3
MF−6
− MFI (3RZ−FE)FUEL PUMP
958 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Install the fuel inlet pipe and SST (pressure gauge) to the
delivery pipe with 3 gaskets and SST (union bolt).
SST 09268−45012
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(e) Wipe off any splattered gasoline.
(f) Connect the TOYOTA hand−held tester to the DLC3.
(g) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(h) Select the active test mode on the TOYOTA hand−held
tester.
(i) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(j) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector.
(See page MF−10)
(k) Reconnect the negative (−) terminal cable to the battery.
(l) Turn the ignition switch ON.
(m) Measure the fuel pressure.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
Fuel hoses and connections
Fuel pump
Fuel filter
Fuel pressure regulator
Injectors
(n) Remove the TOYOTA hand−held tester.
(o) Start the engine.
(p) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator, and plug the hose end.
(q) Measure the fuel pressure at idle.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
(r) Reconnect the vacuum sensing hose to the fuel pressure
regulator.
(s) Measure the fuel pressure at idle.
Fuel pressure:
206 − 255 kPa (2.1 − 2.6 kgf/cm
2, 31 − 37 psi)
If pressure is not as specified, check the vacuum sensing hose
and fuel pressure regulator.
(t) Stop the engine.

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− MFI (3RZ−FE)FUEL PUMP
MF−7
959 Author: Date:
1996 TOYOTA T100 (RM449U)
(u) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injector.
(v) After checking fuel pressure, disconnect the negative (−)
terminal cable from the battery and carefully remove SST
to prevent gasoline from splashing.
SST 09268−45012
(w) Reconnect the fuel inlet pipe to the delivery pipe with 2
new gaskets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(x) Reconnect the negative (−) terminal cable to the battery.
(y) Check for fuel leakage.

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P15055
P15059
MF−10
− MFI (3RZ−FE)FUEL PUMP
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. INSPECT FUEL PUMP RESISTANCE
Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance: 0.2 − 3.0 Ω at 20°C (68°F)
If the resistance is not as specified, replace the fuel pump and/
or set plate.
2. INSPECT FUEL PUMP OPERATION
Connect the positive (+) lead from the battery to terminal 1 of
the connector, and the negative (−) lead to terminal 2. Check
that the fuel pump operates.
NOTICE:
These tests must be done quickly (within 10 seconds) to
prevent the coil from burning out. Keep the fuel pump as far
away from the battery as possible. Always do the switching
at the battery side.
If operation is not as specified, replace the fuel pump and/or
plate.
3. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
(a) Disconnect the fuel pump connector.
(b) Pull off the lower side of the fuel pump from the pump
bracket.
(c) Disconnect the fuel hose from the fuel pump, and remove
the fuel pump.
(d) Remove the rubber cushion from the fuel pump.
4. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
(a) Using a small screwdriver, remove the clip.
(b) Pull out the pump filter.

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B02509
MF−20
− MFI (3RZ−FE)INJECTOR
1996 TOYOTA T100 (RM449U)
(j) Connect SST (wire) to the injector and battery for 15 se-
conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842−30070
Volume:
69 − 88 cm
3 (4.2 − 5.3 cu in.) per 15 seconds
Difference between each injector:
5 cm
3 (0.3 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of SST
(wire) from the battery and check the fuel leakage from
the injector.
SST 09842−30070
Fuel drop:
1 drop or less per 3 minutes
(b) Turn the ignition switch to LOCK.
(c) Disconnect the negative (−) terminal cable from battery.
(d) Remove SST and TOYOTA hand−held tester.
SST 09268−41046
(e) Reinstall the fuel pressure regulator to the delivery pipe.