1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine SR08C−01
R14326
SST
R04473
SR1285
SST SR−92
− STEERINGIDLER ARM
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM
BASE GREASE
(See page SR−89)
2. INSTALL 2 BUSHINGS
Using SST and a hammer, tap in a new bushing to the idler arm
braket.
SST 09950−60010 (09951−00300),
09950−70010 (09951−07200)
3. INSTALL OIL SEAL
(a) Coat a new oil seal lip with molybdenum disulfide lithium
base grease.
(b) Install the oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.
4. INSTALL IDLER ARM
(a) Install the idler arm to the bracket.
(b) Install the plate washer and nut.
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
5. MEASURE IDLER ARM ROTATING TORQUE
(See page SR−91)
6. INSTALL IDLER ARM BRACKET CAP
(a) Apply sealant to a new cap end.
Sealant: Part No.08826−00090, THREE BOND 1281 or
equivalent
(b) Using SST, tap in the idler arm bracket cap.
SST 09223−46011

Downloaded from www.Manualslib.com manuals search engine RS03T−03
− SUPPLEMENTAL RESTRAINT SYSTEMAIRBAG SENSOR ASSEMBLY
RS−25
1996 TOYOTA T100 (RM449U)
INSTALLATION
NOTICE:
Never use SRS parts from another vehicle. When re-
placing parts, replace with new ones.
Never reuse the airbag sensor assembly involved in
a collision when the airbag has deployed.
Never repair a sensor in order to reuse it.
1. INSTALL AIRBAG SENSOR ASSEMBLY
(a) Using a torx wrench, install the airbag sensor assembly
with 3 screws.
Torx wrench: T40 (Part No. 09042−0020 or locally
manufactured tool)
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(b) Connect the connector.
NOTICE:
Installation of the connector is done with the sensor
assembly installed. Make sure the sensor assembly
is installed to the specified torque.
If the sensor assembly has been dropped, or there are
cracks, dents or other defects in the case, bracket or
connector, replace the sensor assembly with a new
one.
When installing the sensor assembly, take care that
the SRS wiring does not interfere with other parts and
is not pinched between other parts.
After installing, shake the sensor assembly to check
that there is no looseness.
2. INSTALL REMOVED PARTS

Downloaded from www.Manualslib.com manuals search engine RS03Y−02
Z09743
Front RS−30
− SUPPLEMENTAL RESTRAINT SYSTEMFRONT AIRBAG SENSOR
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL FRONT AIRBAG SENSOR
(a) Install the sensor so that the arrow on the sensor faces
toward the front of the vehicle.
(b) Using a torx wrench, install the sensor with 2 screws.
Torx wrench: T40 (Part No. 09042−00020 or locally
manufactured tool)
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(c) Connect the connector.
NOTICE:
Make sure the sensor is installed to the specified
torque.
If the sensor has been dropped, or there are cracks,
dents or other defects in the case, brackets or con-
nector, replace the removed sensor, always replace
the set bolts with new ones.
The sensor set bolts which have been anti−rust
treated. When the sensor is removed, always replace
the set bolts with new ones.
After installation, shake the sensor to check that
there is no looseness.
The front sensor is equipped with an electrical con-
nection check mechanism. Be sure to lock this mech-
anism securely when connecting the connector . If
the connector is not securely locked, a malfunction
code will be detected by the diagnostic system.
2. INSTALL REMOVED PARTS

Downloaded from www.Manualslib.com manuals search engine BO0DV−02
H16111
Side Mounting Bracket
Bumper Arm
Front Bumper
Front Balance Panel
Turn Signal Light CushionSide Mounting BracketBumper Arm
Cushion
Turn Signal Light
61 (620,45)
61 (620,45)
N·m (kgf·cm,ft·lbf) : Specigied torque BO−4
− BODYFRONT BUMPER
1888 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT BUMPER
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine N03433
Centering Bolt Standard Bolt
BO0DW−02
N12588
BO3211
BO2553
− BODYHOOD
BO−5
1889 Author: Date:
1996 TOYOTA T100 (RM449U)
HOOD
ADJUSTMENT
HINT:
Since the centering bolt is used as the hood hinge and lock set
bolt, the hood and lock cannot be adjusted with it on. Substitute
the standard bolt for the centering bolt.
1. ADJUST HOOD IN FORWARD/REARWARD AND
LEFT/RIGHT DIRECTIONS
Adjust the hood by loosening the hood side hinge bolts.
Torque: 14 N·m (145 kgf·cm, 10 ft·lbf)
2. ADJUST FRONT EDGE OF HOOD IN VERTICAL
DIRECTIONS
Adjust the hood by turning the cushions.
3. ADJUST HOOD LOCK
Adjust the lock by loosening bolts.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine BO0DX−02
N12592
w/ Power door lock:
w/ Remote control
w/ Tweeter
w/ Power window:
w/ Tweeter speaker: Regulator HandleInner Weatherstrip Inside Handle BezelPull Handles Door Armrest Base Door Lock Striker
Rear Lower Frame
Window Regulator
Door HingeFront Lower FrameRear View Mirror Door Lock Remote Control
Door Lock
Snap Ring(Driver’s) Door Frame Moulding
Door LockOutside HandleDoor GlassDoor Glass Run
Door Belt Moulding
mirror:
speaker:
Cylinder
Link
Inside Handle
Armrest Panel
(Passenger’s)
Door TrimSpeaker
w/ Power window: Precoated part 
N·m (kgf·cm, ft·lbf) : Specified torque
5.9 (60, 52 in.·lbf)
25 (260, 19)
5.4 (55, 48 in.·lbf)
5.9 (60, 52 in.·lbf)

25 (260, 19)
5.4 (55, 48 in.·lbf)
BO−6
− BODYFRONT DOOR
1890 Author: Date:
1996 TOYOTA T100 (RM449U)
FRONT DOOR
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine BO0DY−02
BO0020
N0590513 Clips
BO2455
Cotton
TapePanel
Cover
N09263
− BODYFRONT DOOR
BO−7
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. w/o Power window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a shop rag and remove the regulator
handle and plate.
2. REMOVE INSIDE HANDLE BEZEL
Remove the screw and pull the inside handle bezel.
3. REMOVE POWER WINDOW SWITCH
4. REMOVE PULL HANDLE
5. REMOVE DOOR TRIM
6. REMOVE INSIDE HANDLE
7. w/ Tweeter speaker:
REMOVE SPEAKER AND TWEETER SPEAKER
8. REMOVE DOOR ARMREST BASE
9. REMOVE SERVICE HOLE COVER
HINT:
At the time of reassembly, please refer to the follwing item.
Bring out the links through the service hole cover.
10. REMOVE REAR VIEW MIRROR
11. REMOVE DOOR BELT MOULDING
12. REMOVE DOOR FRAME MOULDING
13. REMOVE DOOR GLASS RUN
14. REMOVE INNER WEATHERSTRIP
15. REMOVE DOOR GLASS
16. REMOVE WINDOW REGULATOR
(a) Remove the 5 bolts and regulator.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(b) Disconnect the connector.
HINT:
At the time of reassembly, please refer to the follwing item.
Apply MP grease to the window regulator rollers.

Downloaded from www.Manualslib.com manuals search engine N05928
BO−8
− BODYFRONT DOOR
1996 TOYOTA T100 (RM449U)
17. REMOVE DOOR LOCK
(a) Disconnect the 2 links to the door lock.
(b) Disconnect the 2 links to the outside handle and the door
lock cylinder.
(c) w/ Power door lock:
Disconnect the connector.
(d) Remove the 3 screws.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
HINT:
At the time of reassembly, please refer to the follwing items.
Apply adhesive to the 3 screws.
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent.
Apply MP grease to the sliding and rotating parts of the
door lock.
18. REMOVE FRONT LOWER FRAME
19. REMOVE OUTSIDE HANDLE
20. REMOVE REAR LOWER FRAME