1996 TOYOTA T100 air conditioning

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SS−82
− SERVICE SPECIFICATIONSAIR CONDITIONING
256 Author: Date:
1996 TOYOTA T100 (RM449U)
AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume650 ± 50 g (22.92 ± 1.76 oz.)
Drive belt tension−
New belt160 ± 25 lbf
Used belt100 ± 20 lbf
Idle−up speed−
3RZ − FE900 rpm
5VZ − FE850 rpm
Magnetic clutch clearance 0.5 ± 0.15 mm (0.020 ± 0.0059 in.)

Downloaded from www.Manualslib.com manuals search engine SS08C−03
− SERVICE SPECIFICATIONSAIR CONDITIONING
SS−83
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Compressor x Compressor Bracket2525018
Compressor bracket x Engine4747534
Idle pulley lock nut3940029
Compressor x Discharge hose101007
Compressor x Suction hose101007
Cooling unit x Suction tube3233024
Cooling unit x Liquid tube1414010
Expansion valve x Evaporator2222516
Expansion valve x Liquid tube1414010
Receiver x Liquied tube5.45548 in.·lbf
Condenser x Liquid tube101007
Condenser x Discharge hose101007
Pressure switch x Liquied tube101007
Pressure plate x Compressor13.21359

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ON
OFFFlashing
0.13 Second
DI−6
− DIAGNOSTICSENGINE (3RZ−FE)
1996 TOYOTA T100 (RM449U)
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand−held tester) to check the DTCs, use
normal mode. For code on the DTC chart subject to ”2 trip
detection logic”, turn the ignition switch OFF after the
symptom is simulated the 1st time. Then repeat the simula-
tion process again. When the problem has been simulated
twice, the MIL lights up and the DTCs are recorded in the
ECM.
3. INSPECT DIAGNOSIS (Check Mode)
HINT:
TOYOTA hand−held tester only:
Compared to the normal mode, the check mode has an in-
creased sensitivity to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Initial conditions
Battery positive voltage 11 V or more
Throttle valve fully closed
Transmission in ”P” or ”N” position
Air conditioning switched OFF
(2) Turn the ignition switch OFF.
(3) Prepare the TOYOTA hand−held tester.
(4) Connect the TOYOTA hand−held tester to DLC3 at
the lower of the instrument panel.
(5) Turn the ignition switch ON and switch the TOYOTA
hand−held tester ON.
(6) Switch the TOYOTA hand−held tester normal mode
to check mode (Check that the MIL flashes.).
(7) Start the engine (The MIL goes out after the engine
start.).
(8) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(9) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTCs and freezed frame data, etc.
HINT:
Take care not to turn the ignition switch OFF. Turning the ignition
switch OFF switches the diagnosis system from check mode to
normal mode. so all DTCs, etc. are erased.
(10) After checking the DTC, inspect the applicable cir-
cuit.

Downloaded from www.Manualslib.com manuals search engine A00654
DLC1 E1
TE1
SST
− DIAGNOSTICSENGINE (3RZ−FE)
DI−9
1996 TOYOTA T100 (RM449U)
5 Check idle speed.
PREPARATION:
(a) Warm up the engine to normal operating temperature.
(b) Switch off all the accessories.
(c) Switch off the air conditioning.
(d) Shift the transmission into ”N” position.
(e) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3 on the vehicle.
CHECK:
Use CURRENT DATA to check the idle speed.
OK:
Idle speed: 750 ± 50 rpm
NG Proceed to problem symptoms table on page
DI−21.
OK
6 Check ignition timing.
PREPARATION:
(a) Warm up the engine to normal operating temperature.
(b) Shift the transmission into ”N” position.
(c) Keep the engine speed at idle.
(d) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
(e) Using a timing light, connect the tester to the No.1 high−
tension cord.
CHECK:
Check the ignition timing.
OK:
Ignition timing: Approx. 5° BTDC at idle
NG Proceed to IGNITION and continue to trouble-
shoot.
OK
Proceed to problem symptoms table on page
DI−21.

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Flashing
ON
OFF
0.13 Seconds
DI−132
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand−held tester) to check the DTCs, use
normal mode. For code on the DTC chart subject to ”2 trip
detection logic”, turn the ignition switch OFF after the
symptom is simulated the 1st time. Then repeat the simula-
tion process again. When the problem has been simulated
twice, the MIL lights up and the DTCs are recorded in the
ECM.
3. INSPECT DIAGNOSIS (Check Mode)
HINT:
TOYOTA hand−held tester only:
Compared to the normal mode, the check mode has an in-
creased sensitivity to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Initial conditions
Battery positive voltage 11 V or more
Throttle valve fully closed
Transmission in ”P” or ”N” position
Air conditioning switched OFF
(2) Turn the ignition switch OFF.
(3) Prepare the TOYOTA hand−held tester.
(4) Connect the TOYOTA hand−held tester to DLC3 at
the lower of the instrument panel.
(5) Turn the ignition switch ON and push the TOYOTA
hand−held tester switch ON.
(6) Switch the TOYOTA hand−held tester normal mode
to check mode (Check that the MIL flashes.).
(7) Start the engine. (The MIL goes out after the engine
start.)
(8) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(9) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTCs and freezed frame data, etc.
HINT:
Take care not to turn the ignition switch OFF. Turning the ignition
switch OFF switches the diagnosis system from check mode to
normal mode. so all DTCs, etc. are erased.
(10) After checking the DTC, inspect the applicable cir-
cuit.

Downloaded from www.Manualslib.com manuals search engine P19970
P21121
A00097
SST
DLC1 E1
TE1
DLC1
− DIAGNOSTICSENGINE (5VZ−FE)
DI−135
1996 TOYOTA T100 (RM449U)
5 Check idle speed.
PREPARATION:
(a) Warm up the engine to normal operating temperature.
(b) Switch off all the accessories.
(c) Switch off air conditioning.
(d) Shift the transmission into ”N” position.
(e) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3 on the vehicle.
CHECK:
Use ”CURRENT DATA” to check the idle speed.
OK:
Idle speed: 650 − 750 rpm
NG Proceed to problem symptoms table on page
DI−148.
OK
6 Check ignition timing.
PREPARATION:
(a) Warm up the engine to normal operating temperature.
(b) Shift the transmission into ”N” position.
(c) Keep the engine speed at idle.
(d) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
(e) Using a timing light, connect the tester to the No.1 high−
tension cord.
CHECK:
Check the ignition timing.
OK:
Ignition timing: 8 − 12° BTDC at idle
NG Proceed to page Ignition system and continue
to troubleshoot.
OK
Proceed to problem symptoms table on page
DI−148.

Downloaded from www.Manualslib.com manuals search engine P01559
Throttle Valve
From
Air
Cleaner
Signal
ECM
ValveIAC Valve
To Cylinders Intake Air Chamber
P19957
ECM
RSC
RSOE01
E01 B−R
BR−R6
7 E7 E7
E7 E7
(M/T)(A/T)
3
1 IAC
Valve
W−R IG Switch FromFrom Battery
R/B No.2EFI Relay
EFI2
IE1
EA1
W−R
9
9
EA
W−R
W−B 2
2
2 3 B−W
22 2
5 1
1 2
2 B−YEA1
W−R
B−Y
4
IGNJ/B
No.11A
1C 3
1722
23 DI−228
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
DTC P0505 Idle Control System Malfunction
CIRCUIT DESCRIPTION
The rotary solenoid type IAC valve is located in front of the in-
take air chamber and intake air bypassing the throttle valve is
directed to the IAC valve through a passage.
In this way the intake air volume bypassing the throttle valve is
regulated, controlling the engine speed.
The ECM operates only the IAC valve to perform idle−up and
provide feedback for the target idling speed and a VSV for idle−
up control is also added (for air conditioning).
DTC No.DTC Detecting ConditionTrouble Area
P0505Idle speed continues to vary greatly from target speed
(2 trip detection logic)
IAC valve is stuck or closed
Open or short in IAC valve circuit
Open or short in A/C signal circuit
Air intake (hose loose)
WIRING DIAGRAM
DI0V4−01

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ON
OFFFlashing
0.13 Second
DI−268
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
3. INSPECT DIAGNOSIS (CHECK MODE)
HINT:
TOYOTA hand−held tester only: Compared to the normal
mode, the check mode has high sensing ability to detect mal-
functions. Furthermore, the same diagnostic items which are
detected in Normal mode can also be detected in Check mode.
(a) Check the DTC.
(1) Check the initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transmission in P position
Air conditioning switched off
(2) Turn the ignition switch OFF.
(3) Prepare a TOYOTA hand−held tester.
(4) Connect the TOYOTA hand−held tester to DLC3 at
the lower of the instrument panel.
(5) Turn the ignition switch ON and switch the TOYOTA
hand−held tester ON.
(6) Switch the TOYOTA hand−held tester from Normal
mode to Check mode (Check that the MIL flashes).
(7) Start the engine (MIL goes out after the engine
starts).
(8) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(9) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTCs and freeze frame data, etc.
HINT:
Take care not to turn the ignition switch OFF, as turning it off
switches the diagnosis system from Check mode to Normal
mode, so all DTCs, etc. are erased.
(10) After checking the DTC, inspect the applicable cir-
cuit.
(b) Clear the DTC.
The following actions will erase the DTC and freezed
frame data. Operating an OBD II scan tool (complying
with SAE J1978) or TOYOTA hand−held tester to erase
the codes (See the OBD II scan tool’s instruction book for
operating instructions.).
NOTICE:
If the TOYOTA hand−held tester switches the ECM from
normal mode to check mode or vice−versa, or if the ignition
switch is turned from ON to ACC or OFF during check
mode, the DTCs and freezed frame data will be erased.