1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine P25592
ST0KV−02
P25599
Wear
P25600
SST
ST−10
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REMOVE MAGNETIC SWITCH END COVER
Remove the 3 bolts, lead clamp, end cover, gasket and plunger.
2. INSPECT CONTACT PLATE FOR WEAR
Using vernier calipers, measure the contact plate for depth of
wear.
Maximum wear:
0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
3. REMOVE TERMINAL KIT PARTS
(a) Using SST, loosen the terminal nuts.
SST 09810−38140
(b) Terminal C:
Remove the terminal nut, wave washer, terminal insulator
(outside), O−ring, terminal bolt, contact plate and terminal
insulator (inside).
(c) Terminal 30:
Remove the terminal nut, wave washer, terminal insulator
(outside), packing, O−ring, terminal bolt, contact plate,
terminal insulator (inside) and insulation paper.

Downloaded from www.Manualslib.com manuals search engine P25641
Long
Short
Indentation
Protrusion
P25598
Long
Short
Lead Terminal
P25602
40 mm
37 mm
20 mm Wooden Block
Contact
Plate
− STARTING (5VZ−FE)STARTER
ST−11
1996 TOYOTA T100 (RM449U)
4. REINSTALL TERMINAL KIT PARTS
(a) Terminal 30:
Install these new parts:
(1) Insulation paper
(2) Terminal insulator (inside)
NOTICE:
Be careful to install the terminal insulator in the correct
direction.
(3) Contact plate
(4) Terminal bolt
(5) O−ring
(6) Packing and terminal insulator (outside)
Install the packing to the terminal insulator, and
install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(7) Wave washer
(8) Terminal nut
(b) Terminal C:
Install these new parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O−ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulator (inside) in the
correct direction.
(c) Temporarily tighten the terminal nuts.
5. TIGHTEN TERMINAL NUT
(a) Put a wooden block on the contact plate and press it down
with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)

Downloaded from www.Manualslib.com manuals search engine (kgf/cm2)
=
100 kgf
Ram diameter (cm)
2
2
2Ram diameter (in.) (psi)
=
x 3.14 (π) x 3.14 (π)
2
(kPa) = (kgf/cm
2) x 98.1
(kPa) = (psi) x 6.9221 lbf
P25601
SST
P25591
ST−12
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
NOTICE:
Check the diameter of the hand press ram. Then calculate
the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the specified pres-
sure, the contact plate may tilt due to coil deformation or the
tightening of the nut.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (173 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
6. CLEAN CONTACT SURFACES OF CONTACT PLATE
AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
7. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp (1.8
kW type) with the 3 bolts.
Torque:
1.2 kW, 1.4 kW type: 2.5 N·m (25 kgf·cm, 22 in.·lbf)
1.8 kW type: 3.6 N·m (35 kgf·cm, 30 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine ST03B−03
− STARTING (5VZ−FE)STARTER
ST−13
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page ST−4).
HINT:
Use high−temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling
the starter.

Downloaded from www.Manualslib.com manuals search engine ST03C−03
P20438Battery
Terminal 50Terminal C
P20449
P20448
P20447
Terminal 30
Ammeter
ST−14
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL−IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD−IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (−) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (−) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO−LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
reads the specified current.
Specified current:
1.2 kW, 1.4 kW type
90 A or less at 11.5 V
1.8 kW type
100 A or less at 11.5 V

Downloaded from www.Manualslib.com manuals search engine ST03D−02
− STARTING (5VZ−FE)STARTER
ST−15
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page ST−3).

Downloaded from www.Manualslib.com manuals search engine ST03E−03
P02536
Continuity
No continuity
P02537
Ohmmeter
Battery Continuity ST−16
− STARTING (5VZ−FE)STARTER RELAY
1202 Author: Date:
1996 TOYOTA T100 (RM449U)
STARTER RELAY
INSPECTION
1. REMOVE STARTER RELAY (Marking: ”ST”)
LOCATION: The relay is located in the No.1 junction block on
the driver’s side.
2. INSPECT STARTER RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity be-
tween terminals 1 and 2.
If there is no continuity, replace the relay.
(b) Check that there is no continuity between terminals 3 and
5.
If there is continuity, replace the relay.
3. INSPECT STARTER RELAY OPERATION
(a) Apply battery voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is continuity be-
tween terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY

Downloaded from www.Manualslib.com manuals search engine CH – CHARGING (3RZ-FE)

CHARGING SYSTEM CH-1
GENERATOR CH-6