1996 TOYOTA T100 brake light

Downloaded from www.Manualslib.com manuals search engine Input SignalIndicator Light
Blinking Pattern
Stop Light
switch ON
LightON
OFFSW OFF
SW ON
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−435
1996 TOYOTA T100 (RM449U)
INSPECTION PROCEDURE
1 Check operation of stop light.
CHECK:
Check that stop light comes on when brake pedal is depressed, and turns off when brake pedal is released.
NG Check stop light system (See page BE−30).
OK
2 Input signal check.
CHECK:
(a) See input signal check on DI−410.
(b) Check the indicator light when the brake pedal is de-
pressed.
OK:
The indicator light goes off when the brake pedal is
depressed.
OK Proceed to next circuit inspection shown in
problem symptoms table (See page DI−419).
NG

Downloaded from www.Manualslib.com manuals search engine AB0119
I00015I00024
ON
STP−
(−) (+)
DI−436
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 TOYOTA T100 (RM449U)
3 Check voltage between terminal STP− of cruise control ECU connector and
body ground.
PREPARATION:
(a) Remove the ECU with connectors still connected.
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminal STP− of cruise control ECU
connector and body ground, when the brake pedal is de-
pressed and released.
OK:
Depressed10 − 16 V
ReleasedBelow 1 V
OK Proceed to next circuit inspection shown in
problem symptoms table (See page DI−419).
NG
4 Check for open in harness and connectors between terminal STP− of cruise con-
trol ECU and stop light switch (See page IN−16).
NG Repair or replace harness or connector.
OK
Check and replace cruise control ECU (See
page IN−26).

Downloaded from www.Manualslib.com manuals search engine P15073
P22272
P24691
A02538
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−57
1996 TOYOTA T100 (RM449U)
17. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with the 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 2 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect a new gasket and the front exhaust pipe assem-
bly to the TWC with the 2 bolts and retainer.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(e) Install camshaft position sensor.
18. INSTALL INTAKE MANIFOLD
Install a new gasket and intake manifold with the 3 bolts and 2
nuts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
19. INSTALL INJECTORS AND DELIVERY PIPE (See page
MF−21)
HINT:
When using a new cylinder head, spacers must be installed.
Apply a light coat of gasoline to a new O−ring a nd install it to
a new spacer.
20. INSTALL FUEL TUBE
Install the fuel inlet tube and 4 new gaskets with 2 union bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
21. INSTALL AIR INTAKE CHAMBER
(a) Install a new gasket and the air intake chamber with the
3 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(b) Connect the vacuum hose to the gas filter.
(c) Connect the brake booster vacuum hose to the intake
camber.

Downloaded from www.Manualslib.com manuals search engine P15006
Plug
P15007
New Gasket
New
Gasket
FI1654
SST
Fulcrum Length
30 cm
P15750
Grommet
New O−Ring
Delivery PipeCORRECT
WRONG
P15128
Delivery Pipe
Injector
InsulatorO−Ring
Grommet
− MFI (3RZ−FE)MFI SYSTEM
MF−3
955 Author: Date:
1996 TOYOTA T100 (RM449U)
7. FUEL SYSTEM
(a) When disconnecting the high pressure fuel line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Put a container under the connection.
(2) Slowly loosen the connection.
(3) Disconnect the connection.
(4) 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 a new gasket.
(2) (Union Bolt Type)
Tighten the union bolt by hand.
(3) (Union Bolt Type)
Tighten the union bolt to the specified torque.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(4) (Flare Nut Type)
Apply a light coat of engine oil to the flare and tight-
en the flare nut by hand.
(5) (Flare Nut Type)
Using SST, tighten the flare nut to the specified
torque.
SST 09631−22020
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(c) Observe these precautions when removing and installing
the injectors.
(1) Never reuse the O−ring.
(2) When placing a new O−ring on the injector, take
care not to damage it in any way.
(3) Coat a new O−ring with spindle oil or gasoline be-
fore installing−never use engine, gear or brake oil.
(d) Install the injector to the delivery pipe and cylinder head
as shown in the illustration.

Downloaded from www.Manualslib.com manuals search engine BR3295
Stop Light Switch
Pedal Height Push RodBR08R−01
BR4980
A BR−6
− BRAKEBRAKE PEDAL
1611 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE PEDAL
ON−VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
Extra cab 4WD:
146.7 − 156.7 mm (5.776 − 6.169 in.)
Except extra cab 4WD:
149.7 − 159.7 mm (5.894 − 6.287 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 − 2.4 mm (0.020 − 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Check the stop lights come on when the brake pedal is de-
pressed, and go off when the brake pedal is released.
(k) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the pedal
stopper has been adjusted correctly, the pedal freeplay will
meet the specifications.

Downloaded from www.Manualslib.com manuals search engine R12236
A
− BRAKEBRAKE MASTER CYLINDER
BR−13
1996 TOYOTA T100 (RM449U)
(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No.2 piston drops out of cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).

Downloaded from www.Manualslib.com manuals search engine BR2237
BR08Z−01
BR2238
GOOD NO GOOD
1st2nd3rd
− BRAKEBRAKE BOOSTER ASSEMBLY
BR−17
1622 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE BOOSTER ASSEMBLY
ON−VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off,
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down furthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop it with the pedal depressed. If there is no change in
pedal reserve travel after holding the pedal for 30 se-
conds, the booster is air tight.

Downloaded from www.Manualslib.com manuals search engine BR092−01
BR3286
F03521
SST
Gasket
Z03607
SST BR−20
− BRAKEBRAKE BOOSTER ASSEMBLY
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install a new gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737−00010
(c) Turn the SST upside down, and set it on the booster.
SST 09737−00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod light-
ly touches the pin head.
3. INSTALL MASTER CYLINDER (See page BR−16)
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR−4)
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL
(See page BR−6)
Check and adjust the brake pedal, then tighten the clevis lock
nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
8. DO OPERATIONAL CHECK (See page BR−17)