1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine N21245
(Rear seat belt)
Rear Seat Belt
Shoulder Anchor
Rear Seat
Outer Belt
Inner Belt Rear Seat
N·m (kgf·cm, ft·lbf): Specified torque
43 (440, 32)
43 (440, 32)
43 (440, 32)43 (440, 32)
Extra cab
− BODYSEAT BELT
BO−49
1933 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine BO0FD−02
BO0632
BO0633
15°
45°
N15359
BO−50
− BODYSEAT BELT
1996 TOYOTA T100 (RM449U)
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts
or nuts and sill−bar) if it has been used in a severe impact.
The entire assembly should be replaced even if damage is
not obvious.
1. All seat belts:
RUNNING TEST (IN SAFE AREA)
(a) Fasten the seat belts.
(b) Drive the car at 10 mph (16 km/h) and make a very hard
stop.
(c) Check that the seat belt is locked and cannot be extended
at this time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. All seat belts:
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.
3. Except driver’s seat belt:
STATIC TEST
(a) Pull out the whole belt, release it slightly and then pull it
out again.
(b) Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.
4. Manual type seat belt:
TEST
(a) Adjust the belt to the proper length.
(b) Apply a firm load to the belt.
(c) Make sure that the belt does not extend.

Downloaded from www.Manualslib.com manuals search engine AC – AIR CONDITIONING

AIR CONDITIONING SYSTEM AC-1
DRIVE BELT AC-14
MANIFOLD GAUGE SET AC-17
REFRIGERANT LINE AC-19
COOLING UNIT AC-22
HEATER UNIT AC-27
BLOWER UNIT AC-33
COMPRESSOR AND MAGNETIC
CLUTCH AC-38
RECEIVER AC-46
CONDENSER AC-49
EVAPORATOR AC-53
HEATER RADIATOR AC-56
EXPANSION VALVE AC-59
WATER VALVE AC-62
BLOWER MOTOR AC-65
BLOWER RESISTOR AC-68
THERMISTOR AC-71
PRESSURE SWITCH AC-75
HEATER MAIN RELAY AC-78
AIR CONDITIONING AMPLIFIER AC-79
AIR CONDITIONING SWITCH AC-82
HEATER CONTROL ASSEMBLY AC-85

Downloaded from www.Manualslib.com manuals search engine AC2810
AC0EV−02
AC2811
N11084
Wrong Okay
HI LO HILO
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC−1
1935 Author: Date:
1996 TOYOTA T100 (RM449U)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR WEAR EYE PROTECTION
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional
treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERATION SYS-
TEM
If there is not enough refrigerant in the refrigerant system oil lu-
brication will be insufficient and compressor burnout may occur,
so that care to avoid this, necessary care should be taken.
7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE
COMPRESSOR IS OPERATE
If the high pressure valve is opened, refrigerant flows in the re-
verse direction and could cause the charging cylinder to rup-
ture, so open and close the only low pressure valve.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.

Downloaded from www.Manualslib.com manuals search engine AC−2
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
1936 Author: Date:
1996 TOYOTA T100 (RM449U)
9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
The TOYOTA T100 is equipped with an SRS (Supplemental
Restraint System) such as the driver airbag and passenger air-
bag. Failure to carry out service operations the correct se-
quence could cause the SRS to unexpectedly deployed during
servicing, possible the SRS may fail to operate when required.
Before servicing (including removal or installation of parts, in-
spection or replacement), be sure to read the following item
carefully, then follow the correct procedure described in the re-
pair manual.

Downloaded from www.Manualslib.com manuals search engine N06110
Sight Glass
AC0EX−02
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC−3
1996 TOYOTA T100 (RM449U)
ON−VEHICLE INSPECTION
1. INSPECT REFRIGERANT VOLUME
Observe the sight glass on the liquid tube.
Test conditions:
Running engine at 1,500 rpm
Blower speed control switch on ”HI” position
A/C switch ON
Temperature control dial on ”COOL” position
Fully open the doors
ItemSymptomAmount of refrigerantRemedy
1Bubbles present in sight glassInsufficient*
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
2No bubbles present in sight glassNone, sufficient or too muchRefer item 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
4Temperature between compressor inlet and
outlet is noticeably differentCorrect or too muchRefer to items 5 and 6
5Immediately after air conditioning is turned
off, refrigerant in sight glass stays clearToo much
(1) Discharge refrigerant
(2) Evacuate air and charge proper amount
of purified refrigerant
6When air conditioning is turned off, refriger-
ant foams and then stays clearCorrect−
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.

Downloaded from www.Manualslib.com manuals search engine I01386
I01387
Condition : Periodically cools and then fails to cool AC−4
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TOYOTA T100 (RM449U)
2. INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
This is a method in which the trouble is located by using a man-
ifold gauge set. Read the manifold gauge pressure when these
conditions are established.
Test conditions:
Temperature at the air inlet with the switch set
at RECURC is 30 − 35 °C (86 − 95 °F)
Engine running at 1500 rpm
Blower speed control switch on ”HI” position
Temperature control dial on ”COOL” position
HINT:
It should be noted that the gauge indications may vary slightly
due to ambient temperature conditions.
(1) Normally functioning refrigeration system.
Gauge reading:
Low pressure side:
0.15 − 0.25 MPa (1.5 − 2.5 kgf/cm
2)
High pressure side:
1.37 − 1.57 MPa (14 − 16 kgf/cm
2)
(2) Moisture present in refrigeration system.
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side sometimes become
a vacuum and sometime normal
Moisture entered in refrigeration
system freezes at expansion valve
orifice and temporarily stops cycle,
but normal state is restored after a
time when the ice melts Drier in oversaturated state
 Moisture in refrigeration system
freezes at expansion valve orifice
and blocks circulation of refriger-
ant(1) Replace receiver
(2) Remove moisture in cycle
through repeatedly evacuating air
(3) Charge proper amount of new
refrigerant

Downloaded from www.Manualslib.com manuals search engine I01388
Condition: Insufficient cooling
I01389
Condition: Insufficient cooling
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC−5
1996 TOYOTA T100 (RM449U)
(3) Insufficient cooling
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure low on both low and
high pressure sides
 Bubbles seen in sight glass con-
tinuously
 Insufficient cooling performance
Gas leakage at some place in re-
frigeration system Insufficient refrigerant in system
 Refrigerant leaking
(1) Check for gas leakage with gas
leak detector and repair if neces-
sary
(2) Charge Proper amount of re-
frigerant
(3) If indicated pressure value is
near 0 when connected to gauge,
create the vacuum after inspecting
and repairing the location of the
leak
(4) Poor circulation of refrigerant
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure low in both low and
high pressure sides
 Frost on tube from receiver to
unit
Refrigerant flow obstructed by dirt
in receiverReceiver cloggedReplace receiver