1996 TOYOTA T100 height

Downloaded from www.Manualslib.com manuals search engine SS08W−01
− SERVICE SPECIFICATIONSSTEERING
SS−71
245 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING
SERVICE DATA
ON−VEHICLE INSPECTION
Steering wheel freeplayMaximum30 mm (1.18 in.)
3RZ−FE:
Drive belt tension New belt135−185 lbf
Drive belt tension Used belt80−120 lbf
Oil level rise MaximumBelow 5 mm (0.20 in.)
5VZ−FE:
Drive belt tension New belt135−180 lbf
Drive belt tension Used belt85−120 lbf
Oil level rise MaximumBelow 5 mm (0.20 in.)
3RZ−FE and 5VZ−FE (2WD):
Oil pressure at idle speed with valve closedMinimum7,845 kPa (80 kgf/cm2, 1,138 psi)
5VZ−FE (4WD):
Oil pressure at idle speed with valve closedMinimum8,336 kPa (85 kgf/cm2, 1,209 psi)
Steering effort at idle speedMaximum8.3 N·m (85 kgf·cm, 73 in.·lbf)
TILT STEERING COLUMN
Pawl stopper
1 or A12.68 − 12.74 mm (0.4992 − 0.5016 in.)
2 or B12.61 − 12.67 mm (0.4965 − 0.4988 in.)
3 or C12.54 − 12.60 mm (0.4937 − 0.4961 in.)
4 or D12.47 − 12.53 mm (0.4909 − 0.4933 in.)
5 or E12.40 − 12.46 mm (0.4882 − 0.4906 in.)
6 or F12.33 − 12.39 mm (0.4854 − 0.4878 in.)
7 or G12.26 − 12.32 mm (0.4827 − 0.4850 in.)
PS VANE PUMP
3RZ−FE and 5VZ−FE:
Pump shaft and front housing bushing oil clearance STD0.03−0.05 mm (0.0012−0.0020 in.)
Pump shaft and front housing bushing oil clearanceMaximum0.07 mm (0.0028 in.)
Vane plate heightMinimum8.6 mm (0.339 in.)
Vane plate thicknessMinimum1.397 mm (0.0550 in.)
Vane plate lengthMinimum14.991 mm (0.5902 in.)
Vane plate and pump rotor groove clearanceMaximum0.035 mm (0.0014 in.)
Vane plate length Pump rotor and cam ring mark
None14.999−15.001 mm (0.59051−0.59059 in.)
114.997−14.999 mm (0.59043−0.59051 in.)
214.995−14.997 mm (0.59035−0.59043 in.)
314.993−14.995 mm (0.59027−0.59035 in.)
414.991−14.993 mm (0.59020−0.59027 in.)
Flow control valve spring lengthMinimum32.3 mm (1.272 in.)
Pump rotating torqueMaximum0.25 N·m (2.5 kgf·cm, 2.2 in.·lbf) or less
PS GEAR
2WD:
Steering rack runoutMaximum0.3 mm (0.0118 in.)

Downloaded from www.Manualslib.com manuals search engine R05599
0.13 sec.
0.13 sec. 3 sec. ON
OFF
R12881
1,100 ± 30 mm
(43.31 ± 1.18 in.)
R12882
830 ± 30 mm
(32.68 ± 1.18 in.)
BR1865
0.13 sec.
0.13 sec. ON
OFF
R05596
0.13 sec. Braking0.13 sec. DI−324
− DIAGNOSTICSANTI−LOCK BRAKE SYSTEM
1996 TOYOTA T100 (RM449U)
(4) Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit (See page DI−354).
(5) Jack up the rear side of the vehicle slowly.
HINT:
When measuring the height, measure at the center of the lower
body of the vehicle.
(6) Check that the warning light blinks.
If the warning light turns on, inspect the deceleration sensor
installation. If the sensor installation is OK, replace the decel-
eration sensor.
(7) Jack down the vehicle slowly.
(8) Jack up the front side of the vehicle slowly, as
shown.
HINT:
When measuring the height, measure at the center of the lower
body of the vehicle.
(9) Check that the warning light blinks.
If the warning light turns on, inspect the deceleration sensor
installation. If the sensor installation is OK, replace the decel-
eration sensor.
(10) Jack down the vehicle slowly.
(c) Check the deceleration sensor operation.
(1) Drive the vehicle straight ahead at about 20 km/h
(12.4 mph) or more, lightly depress the brake pedal.
(2) Check that there is no change in the warning light
pattern.
(3) Drive the vehicle straight ahead at about 20 km/h
(12.4 mph) or more, and depress the brake pedal
moderately.
(4) Check that the warning light turns on while braking.

Downloaded from www.Manualslib.com manuals search engine P03976
P03977
EM3322
Free Distance
P14668
Plastigage
P14665
EM−44
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
15. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
45.31 − 45.41 mm (1.7839 − 1.7878 in.)
Exhaust
45.06 − 45.16 mm (1.7740 − 1.7779 in.)
If the cam lobe height is less than standard allowable, replace
the camshaft.
16. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
17. INSPECT CAMSHAFT BEARING
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
18. INSPECT CAMSHAFT GEAR SPRING
Using a vernier caliper, measure the free distance between the
spring ends.
Free distance:
22.5 − 22.9 mm (0.886 − 0.902 in.)
If the free distance is not as specified, replace the gear spring.
19. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps (See page EM−50).
Torque: 15.5 N·m (160 kgf·cm, 12 ft·lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
Maximum oil clearance:
0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the Plastigage.

Downloaded from www.Manualslib.com manuals search engine EM0988
Deviation
EM0801
EM0281
EM1628
EM2011
EM−44
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
13. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the squareness of the
valve spring.
Maximum deviation:
2.0 mm (0.079 in.)
If deviation is greater than maximum, replace the valve spring.
(b) Using vernier calipers, measure the free length of the
valve spring.
Free length:
44.78 mm (1.7630 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186 − 206 N (19.0 − 21.0 kgf, 41.9 − 46.3 lbf)
at 33.3 mm (1.311 in.)
If the installed tension is not as specified, replace the valve
spring.
14. INSPECT CAMSHAFT FOR RUNOUT
(a) Place the camshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
15. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Cam lobe height:
Standard Intake
Exhaust42.31 − 42.41 mm (1.6657 − 1.6697 in.)
41.96 − 42.06 mm (1.6520 − 1.6559 in.)
Minimum Intake
Exhaust42.16 mm (1.6598 in.)
41.81 mm (1.6461 in.)
If the cam lobe height is greater than maximum, replace the
camshaft.

Downloaded from www.Manualslib.com manuals search engine CO0373
SST
Punch
Shaft
Guide Block
P14898
8
5324
167
Z04269
PunchTank Plate
Tank
SST
Stopper Guide Book SST
P14858
P14859
CO−18
− COOLING (3RZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)
5. M/T:
STAKE CLAWS OF TANK PLATES
(a) Set the punch of SST to ”LOW”.
SST 09230 − 00010 (09231 − 00010, 09231 − 00020,
09231 − 00030, 09231 − 00040, 09231 − 00050)
(b) Stake the claws of the tank plates with SST in the numeri-
cal order shown in the illustration.
NOTICE:
If the bottom of the core plate is staked with the SST on the
guide block stopper, it may result in water leakage.
HINT:
Stake with just enough pressure to leave a mark on the
claw. The staked plate height (H) should be as follows.
Plate height (H):
9.2 − 9.6 mm (0.362 − 0.378 in.)
Do not stake the are as protruding around the pipes.

Downloaded from www.Manualslib.com manuals search engine Q02464
Push Rod Play Adjust Point
Pedal Height
Adjust Point
Pedal Height
Push Rod
PlayCL027−01
CL0102Pedal Freeplay CL−2
− CLUTCHCLUTCH PEDAL
1237 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH PEDAL
INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from floor panel:
154.6 − 164.6 mm (6.087 − 6.480 in.)
Pedal height from asphalt sheet:
Extra Cab (4WD): 150.1 − 160.1 mm (5.909 − 6.303 in.)
Others: 153.1 − 163.1 mm (6.027 − 6.421 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD
PLAY ARE CORRECT
Push in on the pedal until the beginning of clutch resis-
tance is felt.
Pedal freeplay: 5.0 − 15.0 mm (0.197 − 0.591 in.)
Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0 − 5.0 mm (0.039 − 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. CHECK CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears contact.

Downloaded from www.Manualslib.com manuals search engine CL0512
25 mm (0.98 in.) or more
Release
Point
Full Stroke
End Position
Q02465
Clutch
Start Switch
Q00617
8 ± 0.5 mm
(0.31 ± 0.020 in.)
− CLUTCHCLUTCH PEDAL
CL−3
1238 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance not as specified, perform the following operation.
Check pedal height.
Check push rod play and pedal freeplay.
Bleed the clutch line.
Check the clutch cover and disc.
6. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch ped-
al is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, replace the clutch start switch.
7. CHECK CONTINUITY OF CLUTCH START SWITCH
Check the continuity between terminals when the switch is ON
and OFF.
Switch positionCondition
ON (pushed)Continuity
OFF (free)No Continuity
If continuity is not as specified, replace the switch.

Downloaded from www.Manualslib.com manuals search engine R12919
R12268F01731
A
B
C
D Front
Rear
SA0FF−02
Z03382
− SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT (2WD)
SA−7
1446 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT WHEEL ALIGNMENT (2WD)
INSPECTION
HINT:
For the vehicle height of non−loaded vehidles for each model
and alighment standed values, refer to page SA−11 9.
1. MEASURE VEHICLE HEIGHT
Vehicle height: See page SS−58
Front: A − B = 74.0 mm (2.913 in.)
Rear: C − D = Standed cab
0.5 ton: 122.0 mm (4.803 in.)
1.0 ton: 107.0 mm (4.213 in.)
Extre cab: 115.5 mm (4.547 in.)
Measuring points:
A: Steering knuckle height measured at its center on
the outer edge.
B: Lower suspension arm front adjusting bolt height
measured at its center.
C: Rear axle shaft height measured at its center.
D: Rear leaf spring front bushing height measured at
its center.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to specification.
If the vehicle height is not standard, try to adjust it by pushing
down on or lifting the body.
2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR
ONTO WHEEL ALIGNMENT TESTER
Follow the specific instructions of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Camber
Left−right error0°00’ ± 45’ (0° ± 0.75°)
45’ (0.75°) or less
Caster
Left−right error4°00’ ± 45’ (4° ± 0.75°)
45’ (0.75°) or less
Steering axis inclination
Left−right error12°30’ ± 45’ (12.5° ± 0.75°)
45’ (0.75°) or less
If the steering axis inclination is not as specified, after camber
and caster have correctly adjusted, recheck the steering
knuckle front wheel for bearing or looseness.