1996 TOYOTA T100 radiator cap

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−61
1996 TOYOTA T100 (RM449U)
27. INSTALL TIMING BELT IDLER NO. 2 (See page
EM−19)
28. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING
BELT (See page EM−19)
29. INSTALL SPARK PLUGS
30. INSTALL HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−1)
31. w/ A/C:
INSTALL A/C COMPRESSOR BRACKET
32. w/ A/C:
CONNECT A/C COMPRESSOR
33. CONNECT PS PUMP
34. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
Torque: 5.4 N·m (54 kgf·cm, 48 in.·lbf)
35. INSTALL NO. 2 FAN SHROUD
36. INSTALL AND ADJUST DRIVE BELT FOR GENERA-
TOR (See page CH−1)
37. w/ A/C:
INSTALL AND ADJUST DRIVE BELT FOR A/C COM-
PRESSOR
38. INSTALL AND ADJUST DRIVE BELT FOR PS PUMP
39. CONNECT HEATER HOSE AND UPPER RADIATOR
HOSE
40. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
41. 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 ASSEMBLY
42. INSTALL FRONT EXHAUST PIPE (See page EM−108)
43. FILL WITH ENGINE COOLANT
44. START ENGINE AND CHECK FOR LEAKS
45. CHECK IGNITION TIMING (See page EM−9)
46. 4WD:
INSTALL ENGINE UNDER COVER
47. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
48. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM06W−02
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−65
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DRAIN ENGINE OIL
3. DRAIN TRANSMISSION OIL
4. REMOVE HOOD
5. REMOVE RADIATOR ASSEMBLY
(See page CO−16)
6. REMOVE DRIVE BELT FOR PS PUMP
7. w/ A/C:
REMOVE DRIVE BELT FOR A/C COMPRESSOR
8. REMOVE DRIVE BELT FOR GENERATOR
9. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
(See page CO−5)
10. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
11. w/ A/C:
REMOVE A/C COMPRESSOR FROM ENGINE
HINT:
Put aside the compressor, and suspend it.
12. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
13. REMOVE AIR CLEANER CASE AND FILTER
14. DISCONNECT THESE CABLES:
(a) w/ Cruise control:
Cruise control actuator cable
(b) Accelerator cable
(c) A/T:
Throttle cable
15. DISCONNECT HEATER HOSES
16. DISCONNECT HOSES
Disconnect these hoses:
(1) Brake booster vacuum hose
(2) EVAP hose

Downloaded from www.Manualslib.com manuals search engine EM1OU−01
EM−76
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DRAIN ENGINE OIL
4. REMOVE HOOD
5. REMOVE RADIATOR ASSEMBLY
(See page CO−16)
6. REMOVE DRIVE BELT FOR PS PUMP
7. w/ A/C:
REMOVE DRIVE FOR A/C COMPRESSOR
8. REMOVE DRIVE BELT FOR GENERATOR
9. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS (See page EM−13)
10. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
11. w/ A/C:
DISCONNECT A/C COMPRESSOR
HINT:
Put aside the compressor, and suspend it.
12. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
13. REMOVE AIR CLEANER CASE AND FILTER
14. DISCONNECT THESE CABLES:
(a) w/ Cruise control:
Cruise control actuator cable
(b) Accelerator cable
(c) A/T:
Throttle cable
15. DISCONNECT HEATER HOSES
16. DISCONNECT HOSES
Disconnect these hoses:
(1) Brake booster vacuum hose
(2) EVAP hose
(3) A.D.D. vacuum hose

Downloaded from www.Manualslib.com manuals search engine CO056−02
− COOLING (3RZ−FE)COOLANT
CO−1
1070 Author: Date:
1996 TOYOTA T100 (RM449U)
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK
The coolant level should be between the ”LOW” and ”FULL” lines.
If low, check for leaks and add coolant up to the ”FULL” line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

Downloaded from www.Manualslib.com manuals search engine CO057−03
P14901Drain Plug
Drain Plug CO−2
− COOLING (3RZ−FE)COOLANT
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REPLACE ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove it while
the engine and radiator are still hot, as fluid and steam can
be blown out under pressure.
(b) Drain the coolant from the radiator drain plug and engine
drain plug. (Engine drain plug at the right of engine block.)
(c) Close the drain cock plug.
Torque:Torque (Engine drain plug):
24 N·m (250 kgf·cm, 18 ft·lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.
Use a good brand of ethylene−glycol base coolant
and mix it according to the manufacturer’s direc-
tions.
Using coolant which includes more than 50 % ethyl-
ene−glycol (but not more than 70 %) is recom-
mended.
NOTICE:
Do not use an alcohol type coolant. The coolant should be
mixed with demineralized water or distilled water.
Capacity (w/ Heater):
8.7 liters (9.2 US qts, 7.7 lmp. qts)
(b) Reinstall the radiator cap.
(c) Warm up the engine and check for leaks.
(d) Recheck the coolant level and refill as necessary.

Downloaded from www.Manualslib.com manuals search engine CO05H−02
Z02362
Radiator Cap Tester
Radiator Cap
P14849Radiator Cap Tester
CO−12
− COOLING (3RZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)
ON−VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:
If the radiator cap has contaminations,always rinse it with
water.
Using a radiator cap tester, pump the tester and measure the
relief valve opening pressure.
Standard opening pressure:
74 − 103 kPa (0.75 − 1.05 kgf/cm
2, 10.7 − 14.9 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than standard, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP

Downloaded from www.Manualslib.com manuals search engine P21703
Radiator Cap
Upper Tank
 Tank Plate
 O−Ring
 O−RingCore
 Tank Plate
Lower Tank
 O−Ring Drain Cock
 Non−reusable part CO−14
− COOLING (3RZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine P14899
P14860
CO0035
ClearanceTank
Core Plate
Tank Plate
O−Ring
− COOLING (3RZ−FE)RADIATOR
CO−19
1996 TOYOTA T100 (RM449U)
The points shown in the illustration cannot be staked with
the SST. Use pliers and be careful not to damage the core
plates.
6. M/T:
CHECK FOR WATER LEAKS
(a) Tighten the drain plug.
(b) Plug the inlet and outlet pipes of the radiator with SST
SST 09230 − 01010 (09231 − 00060, 09231 − 01010,
09231 − 01020, 09231 − 01030)
(c) Using a radiator cap tester, apply pressure to the radiator.
Test pressure:
147 kPa (1.5 kgf/cm
2, 21 psi)
(d) Check for water leaks.
HINT:
On radiators with resin tanks, these is a clearance between the
core plate and tank plate where a minute amount of air will re-
main, giving the appearance of an air leak when the radiator is
submerged in water. Therefore, before performing the water
leak test, first swirl the water around in the radiator until all air
bubbles disappear.
7. M/T:
PAINT TANK PLATE
HINT:
If the water leak test checks out okay, allow the radiator to dry
completely and then paint the tank plate.