1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine SR07G−01
R11780
SST
SST
R13024
1
2Hollow Tipped
Mark Position
R04528
R04529
SR−30
− STEERINGTILT STEERING COLUMN
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM
BASE GREASE
(See pages SR−23)
2. INSTALL MAIN SHAFT ASSEMBLY
(a) Install the bearing, bearing thrust collar and compression
spring to the main shaft.
(b) Install the main shaft into the column upper tube.
(c) Using SST, compress the compression spring.
SST 09950−40010 (09957−04010, 09958−04010)
NOTICE:
Do not bend the universal joint of the main shaft more than
20°.
(d) Using a snap ring expander, install a new snap ring.
3. INSTALL TURN SIGNAL BRACKET
Torque the 2 bolts.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)
4. SELECT 2 TILT NO.2 BOLTS
Select the bolt with the hollow−tipped thread end when the col-
umn upper tube mark is 1, and the bolt with the plain thread end
when the mark is 2.
NOTICE:
Select the bolt type to match each number marked in the
squares on the upper tube.
5. INSTALL COLUMN UPPER TUBE WITH MAIN SHAFT
ASSEMBLY
(a) Install the stopper and collar to the shaft assembly.
(b) Install the upper tube with the shaft assembly to the col-
umn lower tube.
(c) Using a plastic hammer, drive in the 2 tilt No.2 bolts.
6. INSTALL TILT LEVER LOCK SHAFT, TILT LEVER
ASSEMBLY AND TILT SUB LEVER, TILT LEVER
Torque the tilt lever assembly set bolt.
Torque: 2 N·m (20 kgf·cm, 17 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine W03535
R15213
Tilt Pawl
Alignment Mark
Tilt Pawl Stopper
SR3128
”A” ”A”
Mark
− STEERINGTILT STEERING COLUMN
SR−31
1996 TOYOTA T100 (RM449U)
7. INSTALL 2 TILT PAWLS
Install the pawl to the column upper tube and temporarily install
the washer with the bolt and nut.
HINT:
Install the pawl pin into the long hole of the tilt lever/tilt sub lever.
8. ENGAGE AND ADJUST 2 TILT PAWLS
(a) Engage the tilt sub lever side pawl to the center of the
ratchet.
(b) While turning the tilt lever side collar, engage the tilt lever
side pawl to the ratchet completely.
(c) Torque the nut.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(d) Check that the pawls rotate smoothly.
9. SELECT 2 TILT PAWL STOPPERS
(a) With the tilt pawl and ratchet engaged, install the 2 pawl
stoppers.
(b) Check that the alignment marks on the stopper and pawl
align when the stopper is lightly rotated to the pawl side.
(c) If the alignment marks are not align, select pawl stopper
according to the following table.
Right pawl stopperLeft pawl stopperDimension ”A”
mm (in.)
1A12.68 − 12.74
(0.4992 − 0.5016)
2B12.61 − 12.67
(0.4965 − 0.4988)
3C12.54 − 12.60
(0.4937 − 0.4961)
4D12.47 − 12.53
(0.4909 − 0.4933)
5E12.40 − 12.46
(0.4882 − 0.4906)
6F12.33 − 12.39
(0.4854 − 0.4878)
7G12.26 − 12.32
(0.4827 − 0.4850)
(d) After selecting the stoppers, check that the pawl and
ratchet are fully engaged.
10. INSTALL 2 TILT PAWL STOPPERS
11. INSTALL 2 TILT LEVER RETAINERS
(a) Install the tilt lever retainer and torque the nut.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(b) Install a new E−ring.
12. INSTALL COMPRESSION SPRING
(a) Install the 2 bushings to the compression spring.
(b) Install the spring with the bolt.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine R04531
SR−32
− STEERINGTILT STEERING COLUMN
1996 TOYOTA T100 (RM449U)
13. INSTALL 3 TENSION SPRINGS
14. INSTALL COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Install the bracket with 2 new tapered−head bolts.
(b) Tighten the tapered−head bolts until the bolt heads break
off.
15. INSTALL SLIDING YORK SUB−ASSEMBLY
(a) Align the matchmarks on the sliding york and main shaft.
(b) Torque the bolt.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
16. CHECK TILT STEERING OPERATION
(a) Check that there is no axial play at the end of the main
shaft.
(b) With the main shaft in the neutral position, pull the tilt lever
and check that the main shaft rises to the uppermost posi-
tion.
(c) Lower the main shaft, and check that it locks in the lower-
most position.

Downloaded from www.Manualslib.com manuals search engine SR07H−01
− STEERINGTILT STEERING COLUMN
SR−33
1996 TOYOTA T100 (RM449U)
INSTALLATION
(See page SR−20)

Downloaded from www.Manualslib.com manuals search engine R14723
PS Vane Pump Assembly
Vacuum Hose
Return Hose
Union Bolt Pressure Feed Tube  Gasket Belt Adjusting Bolt
Drive Belt
Power Steering
Idle Pulley
 Non−reusable part 39 (400, 29)
: Specified torque
N·m (kgf·cm, ft·lbf)
47 (475, 34)
39 (400, 29)
SR07I−01
SR−34
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1708 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING VANE PUMP (3RZ−FE)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine Z18935
Vane Pump Pulley Snap RingOil Reservoir
Spring
Front Housing
Flow Control Valve
Pressure Port
Union Vane Pump Shaft
Wave Washer
Rear Housing  Bearing
 Snap Ring Oil Seal O−Ring  O−Ring Gasket
 Straight Pin
Side Plate
Cam Ring
Vane Plate
Non−reusable part
Power Steering fluid O−Ring

Vane Pump Rotor
43 (440, 32)
13 (130, 9)
24 (240, 17)
83 (850, 61)
24 (240, 17)
: Specified torque
N·m (kgf·cm, ft·lbf)
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−35
1709 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine SR07J−01
R09245
R13844
SR−36
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE DRIVE BELT
(a) Loosen the power steering idle pulley set bolt.
(b) Loosen the belt adjusting bolt.
2. DISCONNECT PRESSURE FEED TUBE
Using a spanner (24 mm) to hold the pressure port union, re-
move the union bolt and the 2 gaskets.
3. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
4. REMOVE PS VANE PUMP ASSEMBLY
Remove the 2 pump assembly set bolts.

Downloaded from www.Manualslib.com manuals search engine SR07K−01
R12065
R09248
SST
Z14482
Vinyl Tape
Oil Seal
Bearing
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−37
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.25 N·m (2.5 kgf·cm, 2.2 in.·lbf) or less
2. REMOVE VANE PUMP PULLEY
Using SST to stop the pulley rotating, remove the pulley set nut.
SST 09960−10010 (09962−01000, 09963−01000)
3. REMOVE OIL RESERVOIR
(a) Remove the 3 bolts and oil reservoir.
(b) Remove the O−ring from the oil reservoir.
4. REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND SPRING
Remove the O−ring from the union.
5. REMOVE REAR HOUSING
(a) Remove the 2 bolts and rear housing.
(b) Remove the 2 O−rings from the housing.
6. REMOVE WAVE WASHER
7. REMOVE SIDE PLATE
8. REMOVE CAM RING, VANE PLATES AND VANE
PUMP ROTOR
(a) Remove the 10 plates.
NOTICE:
Take care not to drop the plate.
(b) Using a screwdriver, remove the snap ring from the vane
pump shaft.
9. REMOVE STRAIGHT PINS
Remove the 2 pins from the front housing.
10. REMOVE GASKET
11. REMOVE VANE PUMP SHAFT WITH BEARING
(a) Using snap ring pliers, remove the snap ring from the front
housing.
(b) Wind vinyl tape on the serrated part of the vane pump
shaft.
(c) Using a press, press out the shaft with the bearing.
NOTICE:
Be careful not to damage the oil seal lip.