1996 TOYOTA T100 Factory Service Manual

spark plugs engine oil capacity TPMS reset fuel ECO mode trailer

Load previous 8 pages

Page 529 of 2062

TOYOTA T100 1996 Factory Service Manual Downloaded from www.Manualslib.com manuals search engine A00653
w/o Tachometer
w/ Tachometer
DI0VF−02
Q08498
TOYOTA Hand−Held Tester
DLC3
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−265
1996 TOYOTA

Page 530 of 2062

TOYOTA T100 1996 Factory Service Manual Downloaded from www.Manualslib.com manuals search engine N09214
DI−266
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
The diagnosis system operates in normal mode
during normal v

Page 531 of 2062

TOYOTA T100 1996 Factory Service Manual Downloaded from www.Manualslib.com manuals search engine A00653
w/o Tachometer
w/ Tachometer
Q08498
TOYOTA Hand−Held Tester
DLC3
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−267
1996 TOYOTA T100 (RM

Page 532 of 2062

TOYOTA T100 1996 Factory Service Manual Downloaded from www.Manualslib.com manuals search engine FI3605
ON
OFFFlashing
0.13 Second
DI−268
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
3. INSPECT DIAGNOSIS (CHECK MODE)

Downloaded from www.Manualslib.com manuals search engine FI3605
ON
OFFFlashing
0.13 Second
DI−268
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
3. INSPECT DIAGNOSIS (CHECK MODE)
HINT:
TOYOTA hand−held tester only: Compared to the normal
mode, the check mode has high sensing ability to detect mal-
functions. Furthermore, the same diagnostic items which are
detected in Normal mode can also be detected in Check mode.
(a) Check the DTC.
(1) Check the initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transmission in P position
Air conditioning switched off
(2) Turn the ignition switch OFF.
(3) Prepare a TOYOTA hand−held tester.
(4) Connect the TOYOTA hand−held tester to DLC3 at
the lower of the instrument panel.
(5) Turn the ignition switch ON and switch the TOYOTA
hand−held tester ON.
(6) Switch the TOYOTA hand−held tester from Normal
mode to Check mode (Check that the MIL flashes).
(7) Start the engine (MIL goes out after the engine
starts).
(8) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(9) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTCs and freeze frame data, etc.
HINT:
Take care not to turn the ignition switch OFF, as turning it off
switches the diagnosis system from Check mode to Normal
mode, so all DTCs, etc. are erased.
(10) After checking the DTC, inspect the applicable cir-
cuit.
(b) Clear the DTC.
The following actions will erase the DTC and freezed
frame data. Operating an OBD II scan tool (complying
with SAE J1978) or TOYOTA hand−held tester to erase
the codes (See the OBD II scan tool’s instruction book for
operating instructions.).
NOTICE:
If the TOYOTA hand−held tester switches the ECM from
normal mode to check mode or vice−versa, or if the ignition
switch is turned from ON to ACC or OFF during check
mode, the DTCs and freezed frame data will be erased.

Page 533 of 2062

TOYOTA T100 1996 Factory Service Manual Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−269
1996 TOYOTA T100 (RM449U)
4. ROAD TEST
NOTICE:
Perform the test at normal operating ATF temper

Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−269
1996 TOYOTA T100 (RM449U)
4. ROAD TEST
NOTICE:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
(a) D position test
Shift into the D position and fully depress the accelerator pedal and and check the following points:
(1) Check up−shift operation.
1 → 2, 2 → 3 and 3 → O/D up−shift takes place, at the shift point shown in the automatic shift
schedule (See page SS−49).
HINT:
There is no O/D up−shift or lock−up when the coolant temperature is below 60°C (140°F).
Evaluation:
ProblemPossible cause
If there is no 1→2 up−shiftShift solenoid valve No.2 is stuck
1−2 shift valve is stuck
If there is no 2 →3 up−shiftShift solenoid valve No.1 is stuck
2−3 shift valve is stuck
If there is no 3 →O/D up−shift3−4 shift valve is stuck
If the shift point is defectiveThrottle valve, 1−2 shift valve, 2−3 shift valve, etc. are defective
If the lock up is defectiveShift solenoid valve SL is stuck
Lock−up relay valve is stuck
(2) Check for shift shock and slip.
Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up−shifts.
Evaluation:
ProblemPossible cause
If the shock is excessive
Line pressure is too high
Accumulator is defective
Check ball is defective
(3) Check for abnormal noises and vibration.
Run at the D position lock−up or O/D gear and check for abnormal noises and vibration.
HINT:
The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be
due to loss of balance in the differential torque converter clutch, etc.
(4) Check kick−down operation.
While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick−down
vehicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick−downs conform to those indicated on
the automatic shift schedule (See page SS−49).
(5) Check abnormal shock and slip at kick−down.
(6) Check the lock−up mechanism.
Drive in D position, O/D gear, at a steady speed (lock−up ON).
Lightly depress the accelerator pedal and check that there is lock−up.
If there is a big jump in engine speed, there is no lock−up.
(b) 2 position test
Shift into the 2 position and fully depress the accelerator pedal and check the following points:
(1) Check up−shift operation.
Check to see that the 1 → 2 up−shift takes place and that the shift point conforms to the automatic
shift schedule (See page SS−49).

Page 534 of 2062

TOYOTA T100 1996 Factory Service Manual Downloaded from www.Manualslib.com manuals search engine AT3417
OK if hot
Add if hot DI−270
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
HINT:
There is no O/D up−shift and loc

Downloaded from www.Manualslib.com manuals search engine AT3417
OK if hot
Add if hot DI−270
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
HINT:
There is no O/D up−shift and lock−up in the 2 position.
(2) Check engine braking.
While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine
braking effect.
Evaluation:
ProblemPossible cause
If there is no engine braking effect2nd coast brake defective
(3) Check for abnormal noises during acceleration and deceleration, and for shock at up−shift and
down−shift.
(c) L position test
Shift into the 2 position and fully depress the accelerator pedal and check the following points:
(1) Check no up−shift.
While running in the L position, check that there is no up−shift to 2nd gear.
(2) Check engine braking.
While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
Evaluation:
ProblemPossible cause
If there is no engine braking effect1st and reverse brake is defective
(3) Check for abnormal noises during acceleration and deceleration.
(d) R position test
Shift into the R position and fully depress the accelerator pedal and check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from personnel and obstruction.
(e) P position test
Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking
brake. Then, check to see that the parking lock pawl holds the vehicle in place.
5. BASIC INSPECTION
(a) Check the fluid level.
HINT:
Drive the vehicle so that the engine and transmission are
at normal operating temperature.
Fluid temp.: 70 − 80°C (158 − 176°F)
Only use the COOL range on the dipstick as a rough refer-
ence when the fluid is replaced or the engine does not
run.
(1) Park the vehicle on a level surface and set the park-
ing brake.
(2) With the engine idling and the brake pedal de-
pressed, shift the shift lever into all positions from P
to L position and return to P position.
(3) Pull out the dipstick and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range.

Page 535 of 2062

TOYOTA T100 1996 Factory Service Manual Downloaded from www.Manualslib.com manuals search engine AT1347
AT6683
AT3417
OK if hot
Add if hot
AT4252
0 − 1 mm (0 − 0.04 in.)
Q03104No.1 Gear Shifting Rod
− DIAGNOSTICSAUTOMATIC TRANSMISSION

Downloaded from www.Manualslib.com manuals search engine AT1347
AT6683
AT3417
OK if hot
Add if hot
AT4252
0 − 1 mm (0 − 0.04 in.)
Q03104No.1 Gear Shifting Rod
− DIAGNOSTICSAUTOMATIC TRANSMISSION
DI−271
1996 TOYOTA T100 (RM449U)
If the level is at the low side, add new fluid.
Fluid type: ATF DEXRON®II
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the ATF.
(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
(3) With the engine OFF, add new fluid through the oil
filler pipe.
Fluid type: ATF DEXRON®II
Capacity:
A340E: 1.6 liters (1.7 US qts, 1.4 Imp. qts)
A340F: 2.0 liters (2.1 US qts, 1.8 Imp. qts)
(4) Start the engine and shift the shift lever into all posi-
tions from P to L position and then shift into P posi-
tion.
(5) With the engine idling, check the fluid level. Add
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature, 70 − 80°C (158 − 176°F), and add as nec-
essary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transmission.
If there are leaks, it is necessary to repair or replace O−
rings, FIPGs, oil seals, plugs or other parts.
(e) INSPECT AND ADJUST THROTTLE CABLE
(1) Check that the accelerator pedal is fully released.
(2) Check that the inner cable is not slack.
(3) Measure the distance between the outer cable end
and stopper on the cable.
Standard distance: 0 − 1 mm (0 − 0.04 in.)
If the distance is not standard, adjust the cable by the adjusting
nuts.
(f) Inspect and adjust the shift lever position.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator is not aligned with the correct position.
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures.
(1) Remove the nut on the No.1 gear shifting rod.
(2) Push the No.1 gear shifting rod fully downward.

Page 536 of 2062

TOYOTA T100 1996 Factory Service Manual Downloaded from www.Manualslib.com manuals search engine Q06793
N
R
P
AT5115
Neutral Basic line
Bolt
Groove
DI−272
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
(3) Return the No

Downloaded from www.Manualslib.com manuals search engine Q06793
N
R
P
AT5115
Neutral Basic line
Bolt
Groove
DI−272
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
(3) Return the No.1 gear shifting rod 2 notches to N
position.
(4) Set the shift lever to N position.
(5) While holding the shift lever lightly toward the R
position side, adjust the No.1 gear shifting rod nut.
(6) Tighten the No.1 gear shifting rod nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(7) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust the park/neutral position.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.If it
is not as stated above, carry out the following adjustment
procedure.
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)
(h) Check the idle speed.
Idle speed (In N position and air conditioner OFF):
3RZ−FE: 700 ± 50 rpm
5VZ−FE: 700 ± 50 rpm
6. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transmission and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the that at normal operating fluid temperature 50 − 80°C (122 − 176°F)
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm
(7) Do the same test in R position.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm

Load next 8 pages

Page: < prev 1-10 ... 497-504 505-512 513-520 521-528 529-536 537-544 545-552 553-560 561-568 ... 2064 next >

tow bar open bonnet brake pads replacement battery capacity instrument cluster key battery