1996 TOYOTA T100 stop start

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 SR072−01
R07281
Normal Abnormal SR−4
− STEERINGPOWER STEERING FLUID
1678 Author: Date:
1996 TOYOTA T100 (RM449U)
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL (See page SR−5)
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock
several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the wheel to left or right full
lock and keep it there for 2 − 3 seconds, then turn the
wheel to the opposite full lock and keep it there for 2 − 3
seconds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL (See page SR−5)

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SR073−04
R07281
Normal Abnormal
R11361
5 mm (0.2 in.)
or less
Engine Idling Engine Stopped
− STEERINGPOWER STEERING FLUID
SR−5
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON®II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir cap dipstick. If the fluid is cold, check that it is within
the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem.
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system.
(i) Check the fluid level.

Downloaded from www.Manualslib.com manuals search engine R07653
SR0097
SR075−01
R09732
− STEERINGSTEERING WHEEL
SR−9
1683 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING WHEEL
INSPECTION
1. CHECK THAT STEERING WHEEL FREEPLAY IS COR-
RECT
With the vehicle stopped and tires pointed straight ahead, rock
the steering wheel gently back and forth with light finger pres-
sure.
Freeplay should not exceed the maximum.
Maimum freeplay: 30 mm (1.18 in.)
4WD:
If the freeplay exceeds the maximum, adjust it in the following
procedure.
2. 4WD:
ADJUST STEERING GEAR
(a) Point the front wheels straight ahead.
(b) Loosen the adjusting screw lock nut.
(c) Turn the sector shaft adjusting screw clockwise to de-
crease steering wheel freeplay and counterclockwise to
increase it.
HINT:
Turn the adjusting screw in small increments and check the
freeplay between each adjustment.
(d) Turn the steering wheel half way around in both direc-
tions.
Check the the freeplay is correct and steering is smooth
and without rough spots.
(e) Torque the adjusting screw lock nut (See page SR−80).
3. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b) Remove the steering wheel pad (See page SR−13).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Reference: 8.3 N·m (85 kgf·cm, 73 in.·lbf)
HINT:
Be sure to consider the tire type, pressure and contact surface
before making your diagnosis.
(e) Torque the steering wheel set nut.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
(f) Install the steering wheel pad (See page SR−20).

Downloaded from www.Manualslib.com manuals search engine Z08520
BE02X−03
Z14244
OFF
ON
N12605
N12606
BE−12− BODY ELECTRICALIGNITION SWITCH AND KEY UNLOCK WARNING
SWITCH
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT IGNITION SWITCH CONTINUITY
Switch positionTester connectionSpecified condition
LOCK−No continuity
ACC2 − 3Continuity
ON1 − 2 − 3
7 − 8Continuity
START1 − 3 − 6
7 − 8Continuity
If continuity is not as specified, replace the switch.
2. INSPECT KEY UNLOCK WARNING SWITCH CONTI-
NUITY
Switch positionTester connectionSpecified condition
OFF (Key removed) −No continuity
ON (Key set)4 − 5Continuity
If continuity is not as specified, replace the switch.
3. Key Unlock Warning System:
INSPECT INTEGRATION RELAY OPERATION
(a) Connect the positive (+) lead from the battery to terminal
2 and 3.
(b) Connect the negative (−) lead from the battery to terminal
7 and 10.
(c) Check the buzzer sounds.
(d) Disconnect the positive (+) lead from the battery to termi-
nal 3.
(e) Check that the buzzer stops sounding.

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From Back Side
17
Z08559
1
2
3
41
2
3
4
− BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
BE−19
1996 TOYOTA T100 (RM449U) Tester connection
ConditionSpecified condition
5 − GroundLight control switch OFF or TAILNo continuity
5 − GroundLight control switch HEADContinuity
7 − Ground
16 − GroundHeadlight dimmer switch
Low beamNo continuity
7 − Ground
16 − GroundHeadlight dimmer switch
High beam or FlashContinuity
8 − GroundParking brake switch OFF
(Parking brake lever released)No continuity
8 − GroundParing brake switch ON
(Parking brake lever pulled up)Continuity
12 − GroundConstantContinuity
13 − GroundConstantContinuity
2 − GroundIgnition switch LOCK or ACCNo voltage
2 − GroundIgnition switch ON or STARTBattery positive voltage
6 − GroundConstantBattery positive voltage
11 − GroundEngine StopNo voltage
11 − GroundEngine RunningBattery positive voltage
If circuit is as specified, perform inspections.
8. Connector Connected:
INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT
Connect the wire harness side connector to the relay and in-
spect wire harness side connector from the back side, as
shown.
Tester connectionConditionSpecified condition
17 − GroundHeadlight dimmer switch
Low beamNo voltage
17 − GroundHeadlight dimmer switch
High beam or FlashBattery positive voltage
If circuit is as specified, trying replacing the relay with a new
one.
9. INSPECT DAYTIME RUNNING LIGHT RELAY NO.4
CONTINUITY
ConditionTester connectionSpecified condition
Constant3 − 4Continuity
Apply B+ between
terminals 3 and 4.1 − 2Continuity
If continuity is not as specified, replace the relay.

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N13080
AC−38
− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
1972 Author: Date:
1996 TOYOTA T100 (RM449U)
COMPRESSOR AND MAGNETIC
CLUTCH
ON−VEHICLE INSPECTION
1. SET ON MANIFOLD GAUGE SET
(See page AC−17)
2. START ENGINE
3. INSPECT COMPRESSOR FOR METALLIC SOUND
Check if there is an abnormal metallic sound from the compres-
sor when the A/C switch is on.
If abnormal metallic sound is heard, replace the compressor as-
sembly.
4. INSPECT REFRIGERANT PRESSURE
See ”ON−VEHICLE INSPECTION” of AIR CONDITIONING
SYSTEM on page AC−3.
5. STOP ENGINE
6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGER-
ANT FROM SAFETY SEAL
Using a gas leak detector, check for leakage of refrigerant.
If there is any leakage, replace the compressor assembly.
7. SET OFF MANIFOLD GAUGE SET
(See page AC−18)
8. MAKE THESE VISUAL CHECK:
(a) Leakage of grease from the clutch bearing.
(b) Signs of oil on the pressure plate
If necessary, repair or replace.
9. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE
(a) Start engine.
(b) Check for abnormal noise from near the compressor
when the A/C switch is OFF.
If abnormal noise is being emitted, replace the magnetic clutch.
10. INSPECT MAGNETIC CLUTCH OPERATION
(a) Disconnect the connector.
(b) Connect the positive (+) lead from the battery to terminal
on the magnetic clutch connector and the negative (−)
lead to the body ground.
(c) Check that the magnetic clutch is energized.
If operation is not as specified, replace the magnetic clutch.