1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine P00303
OhmmeterNo Continuity
P04514
LockFree
B01309
ST−8
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
Minimum installed load:
1.2 kW type: 9.8 N (1.00 kgf, 2.2 lbf)
1.4 kW type: 11.8 N (1.20 kgf, 2.6 lbf)
1.8 kW, 2.0 kW type: 12.7 N (1.30 kgf, 2.7 lbf)
If the installed load is less than minimum, replace the brush
springs.
HINT:
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
11. INSPECT INSULATION OF BRUSH HOLDER
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (−) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel or drive plate ring gear for
wear or damage.
13. INSPECT CLUTCH
Hold the starter clutch and rotate the clutch pinion gear clock-
wise and check that it turns freely. Try to rotate the clutch pinion
counterclockwise and check that it locks. If necessary, replace
the clutch assembly.
14. INSPECT REAR BEARING
Turn the bearing by hand while applying inward force.
If the resistance is felt or if the bearing sticks, replace the bear-
ing.

Downloaded from www.Manualslib.com manuals search engine P14888
Ohmmeter
Terminal CTerminal 50
Continuity
P14889
Ohmmeter
Terminal 50
Continuity Switch
Body
ST−10
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
18. DO PULL−IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
19. DO HOLD−IN COIL CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, replace the magnetic switch assembly.

Downloaded from www.Manualslib.com manuals search engine P25593
(1)
(2)
(3)
(4) (5) (6) (7)
Long
Short
Lead Terminal
P25597
40 mm
37 mm
20 mm Wooden Block
Contact
Plate
(kgf/cm2)
=
100 kgf
Ram diameter (cm)
2
2
2Ram diameter (in.) (psi)
=
x 3.14 (π) x 3.14 (π)
2
(kPa) = (kgf/cm
2) x 98.1
(kPa) = (psi) x 6.9221 lbf
P25596
SST
ST−12
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
(b) Terminal C:
Install these new parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O−ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulator (inside) in the
correct direction.
(c) Temporarily tighten the terminal nuts.
5. TIGHTEN TERMINAL NUT
(a) Put a wooden block on the contact plate and press it down
with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:
Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (173 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.

Downloaded from www.Manualslib.com manuals search engine ST032−02
P14894
Terminal 50
Terminal C
Battery
P14895
P14896
P14897
Terminal 30Ammeter
Battery
− STARTING (3RZ−FE)STARTER
ST−15
1996 TOYOTA T100 (RM449U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL−IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD−IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (−) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (−) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO−LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
reads the specified current.
Specified current:
1.2 kW, 1.4 kW type
90 A or less at 11.5 V
1.8 kW, 2.0 kW type
100 A or less at 11.5 V

Downloaded from www.Manualslib.com manuals search engine P07170
Ohmmeter
No
ContinuityContinuity
Ohmmeter 1
3
25ST034−02
P07171
Ohmmeter
Continuity
Battery 1
2 35
− STARTING (3RZ−FE)STARTER RELAY
ST−17
1186 Author: Date:
1996 TOYOTA T100 (RM449U)
STARTER RELAY
INSPECTION
1. REMOVE STARTER RELAY (Marking: ST)
HINT:
The relay is located in the No. 1 junction block on the driver’s
side.
2. INSPECT STARTER RELAY CONTINUITY
(a) Using an ohmmeter, check that there is continuity be-
tween terminals 1 and 2.
If there is no continuity, replace the relay.
(b) Check that there is no continuity between terminals 3 and
5.
If there is continuity, replace the relay.
3. INSPECT STARTER RELAY OPERATION
(a) Apply battery voltage across terminals 1 and 2.
(b) Using an ohmmeter, check that there is continuity be-
tween terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY

Downloaded from www.Manualslib.com manuals search engine P10584
OhmmeterContinuity
ST0NK−01
P10585
OhmmeterNo Continuity
P10586
P10587
ST0040
ST−6
− STARTING (5VZ−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 type: 35 mm (1.38 in.)
Minimum diameter:
1.2 kW, 1.4 kW type: 29 mm (1.14 in.)
1.8 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 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.

Downloaded from www.Manualslib.com manuals search engine P00300
OhmmeterContinuity
P00299
No continuity
Ohmmeter
Z10079
Length Brush Holder Side
Field Frame Side
Length
ST0019
− STARTING (5VZ−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 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 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 type
21.5 − 27.5 N (2.20 − 2.80 kgf, 4.9 − 6.2 lbf)

Downloaded from www.Manualslib.com manuals search engine P00303
No continuity
Ohmmeter
P04514
Free
Lock
P10593
SST
ST−8
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
Minimum installed load:
1.2 kw type: 9.8 N (1.00 kgf, 2.2 lbf)
1.4 kw type: 11.8 N (1.20 kgf, 2.6 lbf)
1.8 kw type: 12.7 N (1.30 kgf, 2.7 lbf)
If the installed load is less than minimum, replace the brush
springs.
HINT:
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
11. INSPECT INSULATION OF BRUSH HOLDER
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (−) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel or drive plate ring gear for
wear or damage.
13. INSPECT CLUTCH
Hold the starter clutch and rotate the clutch pinion gear clock-
wise and check that it turns freely. Try to rotate the clutch pinion
counterclockwise and check that it locks. If necessary, replace
the clutch assembly.
14. INSPECT REAR BEARING
Turn the bearing by hand while applying inward force.
If the resistance is felt or if the bearing sticks, replace the bear-
ing.
15. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286−46011