1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine P25589
− STARTING (3RZ−FE)STARTER
ST−13
1996 TOYOTA T100 (RM449U)
6. CLEAN CONTACT SURFACES OF CONTACT PLATE
AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
7. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp with
the 3 bolts.
Torque:
1.2 kW, 1.4 kW type: 2.5 N·m (25 kgf·cm, 22 in.·lbf)
1.8 kW, 2.0 kW type: 3.6 N·m (35 kgf·cm, 30 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine ST037−04
P20440
− STARTING (5VZ−FE)STARTER
ST−3
1996 TOYOTA T100 (RM449U)
REMOVAL
REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(c) Remove the 2 bolts and starter.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P20446
ST038−04
P20444
P20443
P20441
ST−4
− STARTING (5VZ−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 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 reassembly, please refer to the following
item.
Align the protrusion of the field frame with cutout of the
magnetic switch.
(d) Remove the O−ring.
HINT:
At the ime of reassembly, please refer to the following item.
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 type: 9.3 N·m (95 kgf·cm, 82 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P25577
P04515
Magnetic Finger
P20445
P04525
− STARTING (5VZ−FE)STARTER
ST−5
1996 TOYOTA T100 (RM449U)
(b) Remove these parts from the magnetic switch assembly:
(1) Starter housing
(2) Return spring
(3) Bearing
(4) Idler Gear
(5) Clutch assembly
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 type: 3.8 N·m (38 kgf·cm, 34 in.·lbf)
(b) Remove the O−ring from the field frame.
HINT:
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 (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
P25601
SST
P25591
ST−12
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
NOTICE:
Check the diameter of the hand press ram. Then calculate
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 specified pres-
sure, 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.
6. CLEAN CONTACT SURFACES OF CONTACT PLATE
AND PLUNGER
Clean the contact surfaces of the remaining contact plate and
plunger with a dry shop rag.
7. REINSTALL MAGNETIC SWITCH END COVER
Install the plunger, new gasket, end cover and lead clamp (1.8
kW type) with the 3 bolts.
Torque:
1.2 kW, 1.4 kW type: 2.5 N·m (25 kgf·cm, 22 in.·lbf)
1.8 kW type: 3.6 N·m (35 kgf·cm, 30 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine CH02D−03
P14842Pivot BoltLock Bolt
Adjust Bolt
P14830
− CHARGING (3RZ−FE)GENERATOR
CH−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE DRIVE BELT
(a) Loosen the lock bolt, pivot bolt, nut and adjusting bolt.
(b) Remove the drive belt.
2. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire.
(c) Disconnect the wire harness with the clip.
(d) Remove the lock bolt, pivot bolt, nut and generator.
Torque:
Pivot bolt: 59 N·m (600 kgf·cm, 43 ft·lbf)
Lock bolt: 29 N·m (300 kgf·cm, 21 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine CH0ES−02
P13397
P13398
P13396
P20344
CH0213
SST (B)SST (A)
CH−8
− CHARGING (3RZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the 3 nuts and end cover.
2. REMOVE BRUSH HOLDER
(a) Remove the 2 screws, brush holder and cover.
(b) Remove the brush holder cover from the brush holder.
3. REMOVE VOLTAGE REGULATOR
Remove the 3 screws and voltage regulator.
4. REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
5. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.

Downloaded from www.Manualslib.com manuals search engine CH0827
P22368
SST
P22369
SST
N00581
SST
CH−12
− CHARGING (3RZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
10. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
11. IF NECESSARY, REPLACE FRONT BEARING
(a) Remove the 4 screws and bearing retainer.
(b) Using SST and a press, press out the bearing.
SST 09950−60010 (09951−00260, 09952−06010)
(c) Using SST and a press, press in a new bearing.
SST 09950−60010 (09951−00500)
(d) Install the bearing retainer with the 4 screws.
Torque: 2.6 N·m (27 kgf·cm, 23 in.·lbf)
12. INSPECT REAR BEARING
Check that the bearing is not rough or worn.
13. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing cover and bearing.
SST 09820−00021
(b) Remove the bearing cover (inside).