1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine P20430
16 mm Plug Wrench
IG0152
P20433
P20584
IG−4
− IGNITION (5VZ−FE)IGNITION SYSTEM
1159 Author: Date:
1996 TOYOTA T100 (RM449U)
3. INSPECT SPARK PLUGS
(a) Remove the high−tension cords and ignition coils.
(b) Remove the spark plugs.
Using a 16 mm plug wrench, remove the 6 spark plugs
from the RH and LH cylinder heads.
(c) Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry
and then clean with a spark plug cleaner.
Air pressure:
Below 588 kPa (6 kgf/cm
2, 85 psi)
Duration:
20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
(d) Visually inspect the spark plugs.
Check the spark plug for thread damage and insulator
damage.
If abnormal, replace the spark plug.
Recommended spark plug:
ND: K16TR11
NGK: BKR5EKB−11
(e) Adjust the electrode gap.
Carefully bend the outer electrode to obtain the correct
electrode gap.
Correct electrode gap:
1.1 mm (0.043 in.)
(f) Reinstall the spark plugs.
Torque:18 N·m (180 kgf·cm, 13 ft·lbf)
(g) Reinstall the ignition coils. (See page IG−8)
(h) Reconnect the high−tension cords.
4. INSPECT IGNITION COIL
(a) Remove the air cleaner cap and MAF meter assembly.
(b) Disconnect the high−tension cords from the ignition coils.
(c) Disconnect the ignition coil connectors.

Downloaded from www.Manualslib.com manuals search engine IG03Q−03
− IGNITION (5VZ−FE)IGNITION COIL
IG−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE AIR CLEANER CAP AND MAF METER AS-
SEMBLY
2. DISCONNECT HIGH−TENSION CORDS FROM
IGNITION COILS
(See page IG−1)
3. REMOVE IGNITION COILS
(a) Disconnect the 3 connectors from the ignition coils.
(b) Remove the 3 bolts and 3 ignition coils from the LH cylin-
der head.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)
HINT:
Arrange the ignition coils in correct order.

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P20432
IG−10
− IGNITION (5VZ−FE)CAMSHAFT POSITION SENSOR
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE UPPER RADIATOR HOSE
2. REMOVE NO. 2 TIMING BELT COVER
(a) Remove the high−tension cord clamps from the No. 2 tim-
ing belt cover.
(b) Remove the PS pump hose from the No. 2 timing belt cov-
er clamp.
(c) Remove the 6 bolts and No. 2 timing belt cover.
3. REMOVE CAMSHAFT POSITION SENSOR
(a) Disconnect the camshaft position sensor connector.
(b) Remove the bolts and camshaft position sensor.
Torque:7.8 N·m (80 kgf·cm, 69 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P20434
IG03V−03
IG−12
− IGNITION (5VZ−FE)CRANKSHAFT POSITION SENSOR
1167 Author: Date:
1996 TOYOTA T100 (RM449U)
CRANKSHAFT POSITION SENSOR
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. REMOVE CRANKSHAFT POSITION SENSOR
(a) Disconnect the crankshaft position sensor connector.
(b) Remove the bolt crankshaft position sensor.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

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P14944
− STARTING (3RZ−FE)STARTER
ST−3
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT STARTER CONNECTOR
2. REMOVE NUT, AND DISCONNECT STARTER WIRE
Torque: 8.8 N·m (90 kgf·cm, 70 in.·lbf)
3. REMOVE 2 BOLTS AND STARTER
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

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P14884
P14885
P14893
P14886
P14887
(1) (2)
(3) (4)(5)
ST−4
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE FIELD FRAME AND ARMATURE
(a) Remove the nut, and disconnect the lead wire from the
magnetic switch terminal.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(b) Remove the 2 through bolts.
Torque:
1.2 kW, 1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
1.8 kW, 2.0 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
(c) Pull out the field frame with the armature from the magnet-
ic switch assembly.
NOTICE:
At the time of notice, please refer to the following items.
Align the protrusion of the field frame with cutout of the
magnetic switch.
(d) Remove the O−ring.
HINT:
At the time of assembly, please refer to the following items.
Use a new O−ring.
2. REMOVE STARTER HOUSING, CLUTCH
ASSEMBLY AND GEAR
(a) Remove the 2 screws.
Torque:
1.2 kW, 1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
1.8 kW, 2.0 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf)
(b) Remove these parts from the magnetic switch assembly:
(1) Starter housing
(2) Return spring
(3) Bearing
(4) Idler Gear
(5) Clutch assembly

Downloaded from www.Manualslib.com manuals search engine P04515
Magnetic Finger
P14945
P04525
− STARTING (3RZ−FE)STARTER
ST−5
1996 TOYOTA T100 (RM449U)
3. REMOVE STEEL BALL
Using a magnetic finger, remove the steel ball from the clutch
shaft hole.
4. REMOVE BRUSH HOLDER
(a) Remove the 2 screws, 2 O−rings and end cover from the
field frame.
Torque:
1.2 kW, 1.4 kW type: 1.5 N·m (15 kgf·cm, 13 in.·lbf)
1.8 kW, 2.0 kW type: 3.8 N·m (39 kgf·cm, 34 in.·lbf)
(b) Remove the O−ring from the field frame.
HINT:
At the time of assembly, please refer to the following items.
Use a new O−ring.
(c) Using a screwdriver hold the spring back and disconnect
the brush from the brush holder.
Disconnect the 4 brushes, and remove the brush holder.
5. REMOVE ARMATURE FROM FIELD FRAME

Downloaded from www.Manualslib.com manuals search engine P25593
(1)
(2)
(3)
(4) (5) (6) (7)
Long
Short
Lead Terminal
P25597
40 mm
37 mm
20 mm Wooden Block
Contact
Plate
(kgf/cm2)
=
100 kgf
Ram diameter (cm)
2
2
2Ram diameter (in.) (psi)
=
x 3.14 (π) x 3.14 (π)
2
(kPa) = (kgf/cm
2) x 98.1
(kPa) = (psi) x 6.9221 lbf
P25596
SST
ST−12
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
(b) Terminal C:
Install these new parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O−ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulator (inside) in the
correct direction.
(c) Temporarily tighten the terminal nuts.
5. TIGHTEN TERMINAL NUT
(a) Put a wooden block on the contact plate and press it down
with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:
Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (173 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.