1996 TOYOTA T100 stop start

Downloaded from www.Manualslib.com manuals search engine BE6443
1
12
No.Operation MethodCRUISE MAIN Indicator LIght
Blinking PatternDiagnosis
1
2
3
4Drive approx. 40 km/h
(25 mph) or over
Drive approx 40 km/h
(25 mph) or below
LightON
OFF
LightON
OFF
ON
OFFSET/COAST switch circuit
is normal
RES/ACC switch circuit
is normal
LightON
OFF LightON
OFF
1sec.
0.25 sec. 0.25 sec.Push the speed control switch
SET/COAT on.
Push the speed control switch
RESUME/ACCEL on.
Each cancel switch turned
ON.
 Speed control switch (to
CANCEL)
 Stop light switch
 Park/Neutral position switch
(to N or O Position)
 Clutch start switch
 Parking brake switch
Speed sensor circuit is
normal
Speed sensor circuit is
normalEach cancel switch is
normal
5 DI−414
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 TOYOTA T100 (RM449U)
5. INPUT SIGNAL CHECK
HINT:
For check No.1 ∼ No.3
Turn ignition switch ON.
For check No.4
Jack up the vehicle.
Start the engine.
Shift to D position.
(a) Press the control switch to SET/COAST or RES/ACC
position and hold it down or hold it up ”(1)”.
(b) Push the main switch ON ”(2)”.
(c) Check that the CRUISE MAIN indicator light blinks twice
or 3 times repeatedly after 3 seconds.
(d) Turn the SET/COAST or RES/ACC switch OFF.
(e) Operate each switch as listed in the table below.
(f) Read the blinking pattern of the CRUISE MAIN indicator
light.
(g) After performing the check, turn the main switch OFF.
HINT:
When 2 or more signals are input to the ECU, the lowest num-
bered code will be displayed first.

Downloaded from www.Manualslib.com manuals search engine P24762
FI7231
TOYOTA Hand−Held Tester
DLC3
MF−6
− MFI (3RZ−FE)FUEL PUMP
958 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Install the fuel inlet pipe and SST (pressure gauge) to the
delivery pipe with 3 gaskets and SST (union bolt).
SST 09268−45012
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(e) Wipe off any splattered gasoline.
(f) Connect the TOYOTA hand−held tester to the DLC3.
(g) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(h) Select the active test mode on the TOYOTA hand−held
tester.
(i) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(j) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector.
(See page MF−10)
(k) Reconnect the negative (−) terminal cable to the battery.
(l) Turn the ignition switch ON.
(m) Measure the fuel pressure.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
Fuel hoses and connections
Fuel pump
Fuel filter
Fuel pressure regulator
Injectors
(n) Remove the TOYOTA hand−held tester.
(o) Start the engine.
(p) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator, and plug the hose end.
(q) Measure the fuel pressure at idle.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
(r) Reconnect the vacuum sensing hose to the fuel pressure
regulator.
(s) Measure the fuel pressure at idle.
Fuel pressure:
206 − 255 kPa (2.1 − 2.6 kgf/cm
2, 31 − 37 psi)
If pressure is not as specified, check the vacuum sensing hose
and fuel pressure regulator.
(t) Stop the engine.

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− MFI (3RZ−FE)THROTTLE BODY
978 Author: Date:
1996 TOYOTA T100 (RM449U)
(e) Check the throttle opener setting speed.
Throttle opener setting speed: 1,200 − 1,400 rpm
If the throttle opener setting is not as specified, replace the
throttle body.
(f) Stop the engine.
(g) Connect the vacuum hose to the throttle opener.
(h) Start the engine, and check that the idle speed returns to
the correct speed.
(i) Disconnect TOYOTA hand−held tester or OBDII scan
tool.

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P19985
FI1654
30 cm
SST
Fulcrum Length
− SFI (5VZ−FE)SFI SYSTEM
SF−3
1009 Author: Date:
1996 TOYOTA T100 (RM449U)
7. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe these procedures:
(1) Union Bolt Type:
Always use 2 new gaskets.
(2) Union Bolt Type:
Tighten the union bolt by hand.
(3) Union Bolt Type:
Tighten the union bolt to the specified torque.
Torque: 34.3 N·m (350 kgf·cm, 25 ft·lbf)
(4) Flare Nut Type:
Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(5) Flare Nut Type:
Using SST, tighten the flare nut to specified torque.
SST 09631−22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque:
34.3 N·m (350 kgf·cm, 25 ft·lbf)
28 N·m (285 kgf·cm, 21 ft·lbf) for using SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Downloaded from www.Manualslib.com manuals search engine P21220
SST (Union)
SST
(Union Bolt) Gasket
P21224
SF−6
− SFI (5VZ−FE)FUEL PUMP
1012 Author: Date:
1996 TOYOTA T100 (RM449U)
(e) Install SST (pressure gauge) to the delivery pipe with the
2 gaskets and SST (union and union bolt).
SST 09268−45012
Torque:34.3 N·m (350 kgf·cm, 25 ft·lbf)
(f) Wipe off any splattered gasoline.
(g) Connect the TOYOTA hand−held tester to the DLC3.
(See on−vehicle inspection in fuel pump)
(h) Reconnect the negative (−) terminal cable to the battery.
(i) Turn the ignition switch ON.
(j) Measure the fuel pressure.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
If pressure is high, replace the fuel pressure regulator.
If pressure is low, check these parts:
Fuel hoses and connections
Fuel pump
Fuel filter
Fuel pressure regulator
VSV for fuel pressure control
(k) Disconnect the TOYOTA hand−held tester from the
DLC3.
(l) Reinstall the No.2 timing belt cover with the 6 bolts.
(m) Start the engine.
(n) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator, and plug the hose end.
(o) Measure the fuel pressure at idle.
Fuel pressure:
265 − 304 kPa (2.7 − 3.1 kgf/cm
2, 38 − 44 psi)
(p) Reconnect the vacuum sensing hose to the fuel
pressure regulator.
(q) Measure the fuel pressure at idle.
Fuel pressure:
226 − 265 kPa (2.3 − 2.7 kgf/cm
2, 33 − 38 psi)
If pressure is not as specified, check the vacuum sensing hose
and fuel pressure regulator.
(r) Stop the engine.
(s) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injectors.
(t) After checking fuel pressure, disconnect the negative (−)
terminal cable from the battery and carefully remove the
SST to prevent gasoline from splashing.
SST 09268−45012
(u) Remove the other union bolt, 3 gaskets and fuel pipe
from the delivery pipes.

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SST
TE1 E1DLC1
P21055Plug Air Assist Hose
Disconnect
SF−40
− SFI (5VZ−FE)IDLE AIR CONTROL (IAC) VALVE
1046 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) Using SST, connect terminals TE1 and E1 of the
DLC1.
SST 09843−18020
(c) After engine speed is kept at 900 − 1,300 rpm for 10 se-
conds, check that it returns to idle speed.
(d) Stop the engine.
(e) Disconnect the air assist hose from the IAC valve, and
plug it.
(f) Start the engine and check that the idle speed reaches
500 rpm or below (the engine may stall).
If the idle does not reach 500 rpm or below, check for a
leak between the air assist hoses, pipe and injectors.
(g) Remove the SST from the DLC1.
SST 09843−18020
(h) Reconnect the air assist hose to the IAC valve.

Downloaded from www.Manualslib.com manuals search engine Q02464
Push Rod Play Adjust Point
Pedal Height
Adjust Point
Pedal Height
Push Rod
PlayCL027−01
CL0102Pedal Freeplay CL−2
− CLUTCHCLUTCH PEDAL
1237 Author: Date:
1996 TOYOTA T100 (RM449U)
CLUTCH PEDAL
INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from floor panel:
154.6 − 164.6 mm (6.087 − 6.480 in.)
Pedal height from asphalt sheet:
Extra Cab (4WD): 150.1 − 160.1 mm (5.909 − 6.303 in.)
Others: 153.1 − 163.1 mm (6.027 − 6.421 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD
PLAY ARE CORRECT
Push in on the pedal until the beginning of clutch resis-
tance is felt.
Pedal freeplay: 5.0 − 15.0 mm (0.197 − 0.591 in.)
Gently push on the pedal until the resistance begins to in-
crease a little.
Push rod play at pedal top:
1.0 − 5.0 mm (0.039 − 0.197 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. CHECK CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start the engine and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears contact.

Downloaded from www.Manualslib.com manuals search engine CL0512
25 mm (0.98 in.) or more
Release
Point
Full Stroke
End Position
Q02465
Clutch
Start Switch
Q00617
8 ± 0.5 mm
(0.31 ± 0.020 in.)
− CLUTCHCLUTCH PEDAL
CL−3
1238 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (re-
lease point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance not as specified, perform the following operation.
Check pedal height.
Check push rod play and pedal freeplay.
Bleed the clutch line.
Check the clutch cover and disc.
6. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch ped-
al is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, replace the clutch start switch.
7. CHECK CONTINUITY OF CLUTCH START SWITCH
Check the continuity between terminals when the switch is ON
and OFF.
Switch positionCondition
ON (pushed)Continuity
OFF (free)No Continuity
If continuity is not as specified, replace the switch.