1996 TOYOTA T100 brake sensor

Downloaded from www.Manualslib.com manuals search engine DI34Z−02
− DIAGNOSTICSCRUISE CONTROL SYSTEM
DI−419
1996 TOYOTA T100 (RM449U)
PROBLEM SYMPTOMS TABLE
SymptomSuspect AreaSee page
SET not occourring or CANCEL occurring.
(DTC is Normal)
1. Main Switch Circuit
(Cruise control switch)
2. Vehicle Speed Sensor
3. Control Switch Circuit
(Cruise control switch)
4. Stop Light Switch Circuit
5. Park/Neutral Position Switch Circuit
6. Actuator Motor Circuit
7. Cruise Control Cable
8. Cruise Control ECU
DI−454
DI−428
DI−431
DI−434
DI−443
DI−420
DI−458
IN−26
SET not occurring or CANCEL occurring.
(DTC is not output)1. ECU Power Source Circuit
2. Cruise Control ECUDI−449
IN−26
Actual vehicle speed deviates above or below the set speed.
1. Cruise Control Cable
2. Vehicle Speed Signal Abnormal
3. Electronically Controlled Transmission
Communication Circuit
4. Actuator Motor Circuit
5. Idle Signal Circuit
(Main throttle position sensor)
6. Cruise Control ECUDI−458
DI−428
DI−440
DI−420
DI−437
IN−26
Gear shifting frequent between 3rd and O/D when driving on uphill
road. (Hurting)1. Electronically Controlled Transmission
Communication Circuit
2. Cruise Control ECUDI−440
IN−26
Cruise control not cancelled, even when brake pedal is de-
pressed.
1. Cruise Control Cable
2. Stop Light Switch Circuit
3. Actuator Motor Circuit
4. Cruise Control ECUDI−458
DI−434
DI−420
IN−26
Cruise control not cancelled, even when transmission is shifted to
”N” postion.
1. Cruise Control Cable
2. Park/Neutral Position Switch Circuit
3. Actuator Motor Circuit
4. Cruise Control ECUDI−458
DI−443
DI−420
IN−26
Control switch does not operate.
(SET/COAST, ACC/RES, CANCEL not possible)
1. Cruise Control Cable
2. Control Switch Circuit
3. Actuator Motor Circuit
4. Cruise Control ECUDI−458
DI−431
DI−420
IN−26
SET possible at 40 km/h (25 mph) or less, or CANCEL does not
operate at 40 km/h (25 mph) or less.
1. Cruise Control Cable
2. Vehicle Speed Signal Abnormal
3. Actuator Motor Circuit
4. Cruise Control ECUDI−458
DI−428
DI−420
IN−26
Poor response in ACCEL and RESUME modes.
1. Cruise Control Cable
2. Electronically Controlled Transmission
Communication Circuit
3. Actuator Motor Circuit
4. Cruise Control ECUDI−458
DI−440
DI−420
IN−26
O/D does not resume, even though the road is not uphill.
1. Electronically Controlled Transmission
Communication Circuit
2. Cruise Control ECU
DI−440
IN−26
DTC memory is erased.1. Back−up Power Source Circuit
2. Cruise Control ECUDI−452
IN−26
DTC is not output, or is output when it should not be.1. Tc Circuit
2. Cruise Control ECUDI−456
IN−26
Cruise MAIN indicator light remains ON or fails to light up.1. Cruise MAIN Indicator Light Switch Circuit−

Downloaded from www.Manualslib.com manuals search engine I22681
DI−422
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 TOYOTA T100 (RM449U)
DTC 12 Actuator Magnetic Clutch Circuit
CIRCUIT DESCRIPTION
This circuit turns on the magnetic clutch inside the actuator during cruise control operation according to the
signal from the ECU. If a malfunction occurs in the actuator or speed sensor, etc. during cruise control opera-
tion, the rotor shaft between the motor and control plate is released.
When the brake pedal is depressed, the stop light switch turns ON, supplying electrical power to the stop
light. Power supply to the magnetic clutch is mechanically cut and the magnetic clutch is turned OFF.
When driving downhill, if the vehicle speed exceeds the set speed by 15 km/h (9 mph), the ECU turns the
safety magnet clutch OFF. If the vehicle speed later drops to within 10 km/h (6 mph) above the set speed,
then cruise control at the set speed is resumed.
DTC No.Detection ItemTrouble Area
12Short in actuator magnetic clutch circuit.
Open (0.8 sec.) in actuator magnetic clutch circuit.
Actuator
Stop light switch
Wire harness
Cruise control ECU
WIRING DIAGRAM
DI351−02

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 S05155
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−31
1996 TOYOTA T100 (RM449U)
21. w/ EGR:
REMOVE EGR PIPE
Remove the 6 nuts, EGR pipe and 2 gaskets.
22. REMOVE INTAKE CHAMBER STAY
(a) A/T:
Remove the bolt, 2 nuts, oil filler tube and No.1 throttle
cable clamp.
(b) Remove the 2 bolts and intake chamber stay.
23. REMOVE AIR INTAKE CHAMBER ASSEMBLY
(a) Disconnect these connectors:
VSV connector for fuel pressure control
Throttle position sensor connector
IAC valve connector
w/ EGR:
EGR gas temperature sensor connector
VSV connector for EGR
(b) Disconnect these hoses:
(1) 2 PCV hoses
(2) 2 water bypass hoses
(3) Air assist hose from throttle body
(4) 2 Vacuum sensing hoses from VSV
w/ A/C
Air hose from A/C idle−up valve
(5) EVAP hose
(6) Air hose from PS pump
(c) Remove the 4 bolts, 2 nuts, the air intake chamber as-
sembly and gasket.
24. REMOVE INTAKE AIR CONNECTOR
(a) Remove the bolt, and disconnect the engine wire.
(b) Disconnect the 2 fuel return hoses.
(c) Disconnect the brake booster vacuum hose from the in-
take air connector.
(d) Remove the bolt, and disconnect the ground strap from
the intake air connector.
(e) Disconnect the DLC1 from the bracket.
(f) w/ A/C
Disconnect the A/C idle−up valve connector.
(g) Remove the 3 bolts, 2 nuts, intake air connector and gas-
ket.

Downloaded from www.Manualslib.com manuals search engine P21245
S02073
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−59
1996 TOYOTA T100 (RM449U)
21. CONNECT ENGINE WIRE
(a) Install the engine wire with the 3 bolts.
(b) Connect the 3 engine wire clamps.
(c) Connect these connectors:
Oil pressure sensor connector
Crankshaft position sensor connector
6 Injector connectors
ECT sender gauge connector
ECT sensor connector
Knock sensor connector
Camshaft position sensor connector
22. INSTALL INTAKE AIR CONNECTOR
(a) Install a new gasket and the intake air connector with the
3 bolts and 2 nuts.
Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
(b) Connect the DLC1 to the bracket.
(c) Install the bolt, and connect the ground strap to the intake
air connector.
(d) Connect the brake booster vacuum hose to the intake air
connector.
(e) Connect the 2 fuel return hoses.
(f) Install the engine wire with the bolt.
(g) w/ A/C
Connect the A/C idle−up valve connector.

Downloaded from www.Manualslib.com manuals search engine SA0FI−01
W00397
R04268
FA0026
SST SA−16
− SUSPENSION AND AXLEFRONT AXLE HUB (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
2. w/ ABS:
DISCONNECT ABS SPEED SENSOR FROM
STEERING KNUCKLE
3. REMOVE BRAKE CALIPER
(a) Remove the 2 brake caliper set bolts.
(b) Support the brake caliper securely.
4. CHECK AXLE HUB BEARING BACKLASH
(a) Remove the cap, cotter pin and lock cap.
(b) Using a dial indicator near the center of the axle hub and
check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash is not within the specification replace the bear-
ing.
5. REMOVE AXLE HUB WITH DISC
(a) Using a 30 mm socket, remove the nut.
(b) Remove the axle hub with the disc together with the outer
bearing from the steering knuckle.
NOTICE:
Be careful not to drop the outer bearing.
6. REMOVE OIL SEAL AND INNER BEARING
(a) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
(b) Remove the inner bearing from the axle hub.
7. REMOVE DUST COVER
Remove the 3 bolts and dust cover.
8. DISCONNECT KNUCKLE ARM FROM STEERING
KNUCKLE
Remove the 2 bolts and disconnect the knuckle arm from the
steering knuckle.
9. REMOVE STEERING KNUCKLE
(a) Support the lower suspension arm with a jack.
(b) Remove the upper and lower cotter pins.
(c) Remove the upper and lower nuts.
(d) Using SST, disconnect the steering knuckle from the up-
per and lower ball joints.
SST 09628−62011
(e) Remove the steering knuckle.

Downloaded from www.Manualslib.com manuals search engine R04258
− SUSPENSION AND AXLEFRONT AXLE HUB (2WD)
SA−21
1996 TOYOTA T100 (RM449U)
(f) Using a dial indicator, measure the hub bearing backlash.
Maximum: 0.05 mm (0.0020 in.)
9. INSTALL LOCK CAP, COTTER PIN AND GREASE CAP
(a) Install the lock cap and a new cotter pin.
(b) Install the grease cap.
10. INSTALL BRAKE CALIPER
Install the 2 brake caliper set bolts.
Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf)
11. w/ ABS:
CONNECT ABS SPEED SENSOR TO STEERING
KNUCKLE
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
12. INSTALL FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
13. CHECK FRONT WHEEL ALIGNMENT
(See page SA−7)
14. w/ ABS:
CHECK ABS SPEED SENSOR SIGNAL
(See page DI−321)

Downloaded from www.Manualslib.com manuals search engine SA0FN−01
W00399
SA0326
R04292
SST
− SUSPENSION AND AXLEFRONT AXLE HUB (4WD)
SA−23
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE FRONT WHEEL
2. w/ ABS:
DISCONNECT ABS SPEED SENSOR FROM
STEERING KNUCKLE
3. REMOVE BRAKE CALIPER
(a) Remove the 2 bolts and disconnect the knuckle arm with
brake line bracket from the steering knuckle.
(b) Remove the 2 brake caliper set bolts.
(c) Support the brake caliper securely.
4. REMOVE FLANGE
(a) Remove the grease cap from the flange.
(b) Remove the bolt.
(c) Remove the 6 mounting nuts and washers.
(d) Using a brass bar and hammer, tap on the bolts head and
remove the 6 cone washers.
(e) Install and tighten the 2 bolts and remove the flange.
(f) Remove the gasket.
5. REMOVE AXLE HUB WITH DISC
(a) Using a screwdriver, release the lock washer.
(b) Using SST, remove the lock nut.
SST 09607−60020
(c) Remove the lock washer and adjusting nut.
(d) Remove the claw washer.
(e) Remove the axle hub with the disc together with the outer
bearing.
NOTICE:
Be careful not to damage the ABS speed sensor rotor.
6. REMOVE OIL SEAL AND INNER BEARING
(a) Using a screwdriver, pry out the oil seal.
(b) Remove the inner bearing from the hub.