1996 TOYOTA T100 fuel filter

Downloaded from www.Manualslib.com manuals search engine BE6653
P24320
P24319A00111
ON
#10 #20
#30#40 #50 #60 (+) (+) (+) (+) (+)
(+)
#10 #20 #40 #50 #60#30(+) (+) (+) (+) (+) (+)
For M/T
For A/T
DI−186
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
2 Check voltage of ECM terminal for injector of failed cylinder.
PREPARATION:
(a) Remove the right cowl side trim (See page SF−61).
(b) Turn the ignition switch ON.
CHECK:
Measure voltage between applicable terminal of ECM connec-
tor and body ground.
OK:
Voltage: 9 − 14 V
OK Go to step 4.
NG
3 Check resistance of injector of misfiring cylinder (See page SF−21).
NG Replace injector.
OK
Check for open and short in harness and con-
nector between injector and ECM (See page
IN−26).
4 Check fuel pressure (See page SF−5).
NG Check and repair fuel pump, pressure regulator,
fuel pipe line and filter (See page SF−5).
OK

Downloaded from www.Manualslib.com manuals search engine EM−2
− ENGINE MECHANICAL (3RZ−FE)CO/HC
717 Author: Date:
1996 TOYOTA T100 (RM449U)
6. TROUBLESHOOTING
If the CO/HC concentration does not comply with regulations,
troubleshoot according to the table below.
(a) Check heated oxygen sensor operation.
(b) Check and correct the cause if necessary.
COHCSymptomCauses
NormalHighRough Idle
1. Faulty ignitions:
 Incorrect timing
 Fouled, shorted or improperly gapped plugs
 Open or crossed high−tension cords
 Cracked distributor cap
2. Incorrect valve clearance
3. Leaky EGR valves
4. Leaky exhaust valves
5. Leaky cylinder
LowHighRough Idle
(Fluctuating HC reading)
1. Vacuum leaks:
 Vacuum hose
 Intake manifold
 Intake chamber
 PCV line
 Throttle body
HighHighRough Idle
(Black smoke from exhaust)
1. Clogged air filter
2. Plugged PCV valve
3. Faulty SFI systems:
 Faulty fuel pressure regulator
 Clogged fuel return line
 Faulty MAF meter
 Defective ECT sensor
 Defective IAT sensor
 Faulty engine control module (ECM)
 Faulty injector

Downloaded from www.Manualslib.com manuals search engine P14653A03784
P14628A03785
P24689A03786
A02538
P24691A03787
EM−30
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
14. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Remove the bolt, 4 nuts, EGR pipe and 2 gaskets.
(b) Disconnect these hoses:
2 vacuum hoses from EGR VSV (with clamp)
Water bypass hose from water bypass pipe
(c) Remove the bolt, 2 nuts, EGR valve, vacuum modulator
and gasket.
15. REMOVE INTAKE CHAMBER STAY
Remove the 2 bolts and intake chamber stay.
16. REMOVE FUEL RETURN PIPE
(a) Disconnect these hoses:
Fuel return hose from fuel pressure regulator
Fuel return hose from fuel return pipe
(b) Remove the 2 bolts and fuel return pipe.
17. REMOVE AIR INTAKE CHAMBER
(a) Disconnect the vacuum hose from the gas filter.
(b) Disconnect the brake booster vacuum hose from intake
chamber.
(c) Remove the 3 bolts, 2 nuts, air intake chamber and gas-
ket.
18. REMOVE FUEL INLET TUBE
Remove the 2 union bolts, 4 gaskets and fuel inlet tube.

Downloaded from www.Manualslib.com manuals search engine P15073
P22272
P24691
A02538
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−57
1996 TOYOTA T100 (RM449U)
17. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with the 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 2 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect a new gasket and the front exhaust pipe assem-
bly to the TWC with the 2 bolts and retainer.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(e) Install camshaft position sensor.
18. INSTALL INTAKE MANIFOLD
Install a new gasket and intake manifold with the 3 bolts and 2
nuts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
19. INSTALL INJECTORS AND DELIVERY PIPE (See page
MF−21)
HINT:
When using a new cylinder head, spacers must be installed.
Apply a light coat of gasoline to a new O−ring a nd install it to
a new spacer.
20. INSTALL FUEL TUBE
Install the fuel inlet tube and 4 new gaskets with 2 union bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
21. INSTALL AIR INTAKE CHAMBER
(a) Install a new gasket and the air intake chamber with the
3 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(b) Connect the vacuum hose to the gas filter.
(c) Connect the brake booster vacuum hose to the intake
camber.

Downloaded from www.Manualslib.com manuals search engine EM07L−02
P14816
Knock
SensorSST
P15971
SST
Oil Pressure Switch
P14771
EM−76
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. M/T:
REMOVE FLYWHEEL
Remove the 10 bolts and flywheel.
2. A/T:
REMOVE DRIVE PLATE
Remove the 10 bolts, front spacer, drive plate and rear spacer.
3. REMOVE REAR END PLATE
Remove the 3 bolts and rear end plate.
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE CYLINDER HEAD (See page EM−28)
6. REMOVE TIMING CHAINS, GEARS AND SPROCKET
(See page EM−14)
7. REMOVE FUEL FILTER
Remove the 2 bolts and fuel filter.
8. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816−30010
9. REMOVE WATER BYPASS PIPE
Remove the bolt and water bypass pipe.
10. REMOVE OIL FILTER AND BRACKET
(a) Remove the oil filter (See page LU−3).
(b) Remove the 2 bolts, nut, oil filter bracket and O−ring.
11. REMOVE OIL FILTER BRACKET UNION
Using 14 mm hexagon wrench, remove the union and O−ring.
12. REMOVE ENGINE COOLANT DRAIN PLUG
13. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816−30010
14. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 4 bolts and bracket.
15. REMOVE LH ENGINE MOUNTING BRACKET
Remove the 5 bolts and bracket.
16. REMOVE REAR OIL SEAL RETAINER
Remove the 6 bolts and retainer.

Downloaded from www.Manualslib.com manuals search engine P15971
Oil Pressure Switch
SST
P14816
Knock
SensorSST
EM−102
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(b) Using SST, install the oil pressure switch.
SST 09816−30010
21. INSTALL ENGINE COOLANT DRAIN PLUG
(a) Apply adhesive to 2 or 3 threads of the engine coolant
drain plug.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the engine coolant drain plug.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
22. INSTALL OIL FILTER BRACKET UNION
(a) Install a new O−ring.
(b) Using 14 mm hexagon wrench, install the oil filter bracket
union.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
23. INSTALL OIL FILTER AND BRACKET
(a) Install a new O−ring and oil filter bracket with the 2 bolts
and nut.
Torque: 28 N·m (290 kgf·cm, 21 ft·lbf)
(b) Install the oil filter (See page LU−3).
24. INSTALL WATER BYPASS PIPE
Install the bolt and water bypass pipe.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
25. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816−30010
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
26. INSTALL FUEL FILTER
Install the 2 bolts and fuel filter.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
27. INSTALL TIMING CHAINS, GEARS AND SPROCKETS
(See page EM−20)
28. INSTALL CYLINDER HEAD (See page EM−50)
29. REMOVE ENGINE STAND

Downloaded from www.Manualslib.com manuals search engine P20501
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−71
1996 TOYOTA T100 (RM449U)
13. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
14. CONNECT GENERATOR WIRE
(a) Connect the generator connector.
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
15. CONNECT STARTER WIRE AND CONNECTOR
(a) Connect the 2 starter wire clamps and connector.
(b) Install the 2 nuts, and connect the positive (+) terminal
cable to battery.
(c) Install the bolt, and connect the ground strap.
16. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose
Brake booster vacuum hose
EVAP hose
A.D.D. Vacuum hose
17. CONNECT HEATER HOSES
18. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
19. INSTALL AIR CLEANER CASE AND AIR FILTER
20. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP
21. w/ A/C:
CONNECT A/C COMPRESSOR
22. CONNECT PS PUMP
23. INSTALL FAN WITH FLUID COUPLING AND FAN
PULLEYS(See page EM−19)
24. INSTALL DRIVE BELT FOR GENERATOR (See page
CH−1)

Downloaded from www.Manualslib.com manuals search engine P21443
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)