1996 TOYOTA T100 clock

Downloaded from www.Manualslib.com manuals search engine IG0LB−01
IG−12
− IGNITION (3RZ−FE)DISTRIBUTOR
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. CHECK NO. 1 CYLINDER TO TDC/COMPORESSION
If necessary, remove the cylinder head cover, and check these
conditions:
Turn the crankshaft pulley clockwise and align its
groove with the timing mark ”0” of the oil pump cov-
er.
Verify that the timing marks with 1 and 2 dots are in
straight line on the cylinder head surface as shown
in the illustration.
If not, turn the crankshaft 1 revolition (360 °) and align the mark
as above.
2. INSTALL DISTRIBUTOR
(a) Install a new O−ring to the distributor.
HINT:
Always use a new O−ring when installing the distributor.
(b) Align the protrusion of the distributor housing with the
groove on the driven gear.
(c) Apply a light coat of engine oil on the O−ring.
(d) Install the distributor with the 2 bolts.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
3. INSTALL DISTRIBUTOR CAP
4. RECONECT HIGH−TENSION CORDS TO DISTRIBU-
TOR CAP
5. CONNECT DISTRIBUTOR CONNECTOR
6. CHECK IGNITION TIMING (See page EM−11)

Downloaded from www.Manualslib.com manuals search engine P00303
OhmmeterNo Continuity
P04514
LockFree
B01309
ST−8
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
Minimum installed load:
1.2 kW type: 9.8 N (1.00 kgf, 2.2 lbf)
1.4 kW type: 11.8 N (1.20 kgf, 2.6 lbf)
1.8 kW, 2.0 kW type: 12.7 N (1.30 kgf, 2.7 lbf)
If the installed load is less than minimum, replace the brush
springs.
HINT:
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
11. INSPECT INSULATION OF BRUSH HOLDER
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (−) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel or drive plate ring gear for
wear or damage.
13. INSPECT CLUTCH
Hold the starter clutch and rotate the clutch pinion gear clock-
wise and check that it turns freely. Try to rotate the clutch pinion
counterclockwise and check that it locks. If necessary, replace
the clutch assembly.
14. INSPECT REAR BEARING
Turn the bearing by hand while applying inward force.
If the resistance is felt or if the bearing sticks, replace the bear-
ing.

Downloaded from www.Manualslib.com manuals search engine P00303
No continuity
Ohmmeter
P04514
Free
Lock
P10593
SST
ST−8
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
Minimum installed load:
1.2 kw type: 9.8 N (1.00 kgf, 2.2 lbf)
1.4 kw type: 11.8 N (1.20 kgf, 2.6 lbf)
1.8 kw type: 12.7 N (1.30 kgf, 2.7 lbf)
If the installed load is less than minimum, replace the brush
springs.
HINT:
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
11. INSPECT INSULATION OF BRUSH HOLDER
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (−) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel or drive plate ring gear for
wear or damage.
13. INSPECT CLUTCH
Hold the starter clutch and rotate the clutch pinion gear clock-
wise and check that it turns freely. Try to rotate the clutch pinion
counterclockwise and check that it locks. If necessary, replace
the clutch assembly.
14. INSPECT REAR BEARING
Turn the bearing by hand while applying inward force.
If the resistance is felt or if the bearing sticks, replace the bear-
ing.
15. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286−46011

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 P13486
CH0HX−01
P13762
Upward
P13487
29 mm
Socket
Wrench
P13597
SST (A)
SST (B)TurnTurn
P10834
SST (C)SST (B)
Insert CH−14
− CHARGING (3RZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation directon.
4. INSTALL RECTIFIER END FRAME
(a) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(b) Install the 4 nuts.
Torque: 4.5 N·m (46 kgf·cm, 39 in.·lbf)
5. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) 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)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

Downloaded from www.Manualslib.com manuals search engine CH0HZ−01
P13397
P13398
P13396
P20344
CH0213
SST (A)SST (B)
− CHARGING (5VZ−FE)GENERATOR
CH−7
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 CH02N−03
P13486
P13762
Upward
P13487
Wrench Socket
29 mm
P13597
SST (B)SST (A)
P10834
SST (B)
SST (C)Insert
− CHARGING (5VZ−FE)GENERATOR
CH−13
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation direction.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Install the 4 nuts.
Torque:4.5 N·m (46 kgf·cm, 39 in.·lbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) 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)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

Downloaded from www.Manualslib.com manuals search engine MT0501
Down
ClothCounterclockwise
MT0ER−01
D10948
MT−4
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION WITH ENGINE (See page
EM−65)
2. REMOVE REAR END PLATE
Remove the 4 bolts, nuts and rear end plate.
Torque:37 N·m (380 kgf·cm, 27 ft·lbf)
3. REMOVE STARTER
Remove the 2 bolts and starter.
Torque:39 N·m (400 kgf·cm, 29 ft·lbf)
4. REMOVE TRANSMISSION FROM ENGINE
(a) Remove the 6 transmission mounting bolts from the en-
gine.
Torque:72 N·m (730 kgf·cm, 53 ft·lbf)
(b) Pull out the transmission toward the rear.
5. REMOVE ENGINE REAR MOUNTING
(a) Remove the 4 bolts and engine rear mounting.
Torque:25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Lower the front side of the transmission and remove it
from the front side of the vehicle.