1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine IG0IZ−01
IG−10
− IGNITION (3RZ−FE)DISTRIBUTOR
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT SHAFT
Turn the shaft and check that it is not rough or worn.
If it feels rough or worn, replace the distributor housing assem-
bly.

Downloaded from www.Manualslib.com manuals search engine IG0LB−01
IG−12
− IGNITION (3RZ−FE)DISTRIBUTOR
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. CHECK NO. 1 CYLINDER TO TDC/COMPORESSION
If necessary, remove the cylinder head cover, and check these
conditions:
Turn the crankshaft pulley clockwise and align its
groove with the timing mark ”0” of the oil pump cov-
er.
Verify that the timing marks with 1 and 2 dots are in
straight line on the cylinder head surface as shown
in the illustration.
If not, turn the crankshaft 1 revolition (360 °) and align the mark
as above.
2. INSTALL DISTRIBUTOR
(a) Install a new O−ring to the distributor.
HINT:
Always use a new O−ring when installing the distributor.
(b) Align the protrusion of the distributor housing with the
groove on the driven gear.
(c) Apply a light coat of engine oil on the O−ring.
(d) Install the distributor with the 2 bolts.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
3. INSTALL DISTRIBUTOR CAP
4. RECONECT HIGH−TENSION CORDS TO DISTRIBU-
TOR CAP
5. CONNECT DISTRIBUTOR CONNECTOR
6. CHECK IGNITION TIMING (See page EM−11)

Downloaded from www.Manualslib.com manuals search engine IG03Z−04
SPARK TEST
CHECK CONNECTION OF IGNITION COIL AND
CHECK RESISTANCE OF HIGH−TENSION
TRY ANOTHER IGNITER Maximum resistance; 25 kΩ per cord CORD (See step 2.)
CHECK POWER SUPPLY TO IGNITION COIL
AND IGNITER
1. Turn ignition switch to ON.
2. Check that there is battery voltage at
ignition coil positive (+) terminal.
Check wiring between ECM, distributor
CHECK RESISTANSE OF IGNITION COIL
(See step 4.)
Resistance: Cold
PrimaryHot
0.67 − 1.05 Ω0.85 − 1.23 Ω
POSITION SENSOR
(See step 5)
Resistance: Cold
G and GHot
835 − 1,400 Ω1,060 − 1,645 Ω CHECK RESISTANSE OF CAMSHAFT
POSITION SENSOR
(See page IG−13)
Resistance: Cold
NE and NEHot
1,630 − 2,740 Ω2,065 − 3,225 Ω CHECK RESISTANSE OF CRANKSHAFT
CHECK IGT SIGNAL FROM ECM
(See page DI−144)
OK NO
BAD
OK
OK
OK
OK
OK
Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
Replace the ignition coil.
Replace the camshaft position sensor.
Replace the crankshaft position sensor.
and igniter, and then try another ECM.
BAD
BAD
BAD
BAD
BAD
BAD
IGNITER
Secondary 9.3 − 16.0 kΩ11.7 − 18.8 kΩ
− IGNITION (5VZ−FE)IGNITION SYSTEM
IG−1
1156 Author: Date:
1996 TOYOTA T100 (RM449U)
IGNITION SYSTEM
ON−VEHICLE INSPECTION
NOTICE:
”Cold” and ”Hot” in the following sentences express the
temperature of the coils themselves. ”Cold” is from −10°C
(14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F)
to 100°C (212°F).
1. INSPECT SPARK TEST
Check that the spark occurs.
(1) Disconnect the high−tension cords from the spark
plug.
(2) Remove the spark plug.
(3) Install the spark plug to each high−tension cord.
(4) Ground the spark plug.
(5) Check if spark occurs while engine is being
cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more 1 − 2 se-
conds at a time.
If the spark does not occur, perform the test as follows:

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P20581
P20439
Ohmmeter IG−2
− IGNITION (5VZ−FE)IGNITION SYSTEM
1157 Author: Date:
1996 TOYOTA T100 (RM449U)
2. INSPECT HIGH−TENSION CORDS
(a) Remove the air cleaner cap and MAF meter assembly.
(b) Disconnect the high−tension cords from the spark plugs.
Disconnect the high−tension cords at the rubber boot.
DO NOT pull on the cords.
NOTICE:
Pulling on or bending the cords may damage the conduc-
tor inside.
(c) Disconnect the high−tension cords from the ignition coils.
(1) Using a screwdriver, lift up the lock claw and discon-
nect the holder from the ignition coils.
(2) Disconnect the high−tension cord at the grommet.
DO NOT pull on the cord.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.Do not wipe any of the oil from the grommet after the
high−tension cord is disconnected.
(d) Inspect the high−tension cord resistance.
Using an ohmmeter, measure the resistance.
Maximum resistance:
25 kΩ per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high−tension cord.

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Push
P04690
CORRECT
WRONG
− IGNITION (5VZ−FE)IGNITION SYSTEM
IG−3
1158 Author: Date:
1996 TOYOTA T100 (RM449U)
(e) Reconnect the high−tension cords to ignition coils.
(1) Assemble the holder and grommet.
(2) Align the spline of the ignition coil with the spline of
the holder, and push in the cord.
NOTICE:
Check that the holder is correctly installed to the grommet
and distributor cap as shown in the illustration.
(3) Check that the lock claw of the holder is engaged by
lightly pulling the holder.
(f) Reconnect the high−tension cords to spark plugs.
(g) Reinstall the air cleaner cap and MAF meter assembly.

Downloaded from www.Manualslib.com manuals search engine P20430
16 mm Plug Wrench
IG0152
P20433
P20584
IG−4
− IGNITION (5VZ−FE)IGNITION SYSTEM
1159 Author: Date:
1996 TOYOTA T100 (RM449U)
3. INSPECT SPARK PLUGS
(a) Remove the high−tension cords and ignition coils.
(b) Remove the spark plugs.
Using a 16 mm plug wrench, remove the 6 spark plugs
from the RH and LH cylinder heads.
(c) Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry
and then clean with a spark plug cleaner.
Air pressure:
Below 588 kPa (6 kgf/cm
2, 85 psi)
Duration:
20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
(d) Visually inspect the spark plugs.
Check the spark plug for thread damage and insulator
damage.
If abnormal, replace the spark plug.
Recommended spark plug:
ND: K16TR11
NGK: BKR5EKB−11
(e) Adjust the electrode gap.
Carefully bend the outer electrode to obtain the correct
electrode gap.
Correct electrode gap:
1.1 mm (0.043 in.)
(f) Reinstall the spark plugs.
Torque:18 N·m (180 kgf·cm, 13 ft·lbf)
(g) Reinstall the ignition coils. (See page IG−8)
(h) Reconnect the high−tension cords.
4. INSPECT IGNITION COIL
(a) Remove the air cleaner cap and MAF meter assembly.
(b) Disconnect the high−tension cords from the ignition coils.
(c) Disconnect the ignition coil connectors.

Downloaded from www.Manualslib.com manuals search engine P10584
Ohmmeter
Continuity
ST0NJ−01
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
ST−6
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
2. INSPECT COMMUTATOR FOR GROUNDED
Using an ohmmeter, check that there is no continuity between
the commutator and armature coil core.
If there is continuity, replace the armature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACES
If the surface is dirty or burnt, clean it with sandpaper (No.400)
or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V−blocks.
(b) Using a dial indicator, measure the circle runout.
Maximum circle runout:
0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
5. INSPECT COMMUTATOR DIAMETER
Using vernier calipers, measure the commutator diameter.
Standard diameter:
1.2 kW, 1.4 kW type: 30 mm (1.18 in.)
1.8 kW, 2.0 kW type: 35 mm (1.38 in.)
Minimum diameter:
1.2 kW, 1.4 kW type: 29 mm (1.14 in.)
1.8 kW, 2.0 kW type: 34 mm (1.34 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH OF SEGMENT
Check that the undercut depth is clean and free of foreign mate-
rial. Smooth out the edge.
Standard undercut depth:
1.2 kW, 1.4 kW type: 0.6 mm (0.024 in.)
1.8 kW, 2.0 kW type: 0.7 mm (0.028 in.)
Minimum undercut depth:
0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

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OhmmeterContinuity
P00299
OhmmeterNo Continuity
Z10079
Brush Holder Side
Field Frame SideLength
Length
ST0019
− STARTING (3RZ−FE)STARTER
ST−7
1996 TOYOTA T100 (RM449U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT THAT FIELD COIL IS NOT GROUNDED
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, repair or replace the field frame.
9. INSPECT BRUSH LENGTH
Using vernier calipers, measure the brush length.
Standard length:
1.2 kW, 1.4 kW type: 15.5 mm (0.610 in.)
1.8 kW, 2.0 kW type: 15.0 mm (0.591 in.)
Minimum length:
1.2 kW, 1.4 kW type: 10.0 mm (0.394 in.)
1.8 kW, 2.0 kW type: 9.0 mm (0.354 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard installed load:
1.2 kW type
13.7 − 19.6 N (1.40 − 2.00 kgf, 3.1 − 4.4 lbf)
1.4 kW type
17.6 − 23.5 N (1.80 − 2.40 kgf, 4.0 − 5.3 lbf)
1.8 kW, 2.0 kW type
21.5 − 27.5 N (2.20 − 2.80 kgf, 4.9 − 6.2 lbf)