1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine BR09O−01
BR1134
BR3116
BR0966
SST
BR0967
SST
BR0968
SST
− BRAKEREAR DRUM BRAKE (4WD)
BR−45
1996 TOYOTA T100 (RM449U)
REMOVAL
1. INSPECT SHOE LINING THICKNESS
Remove the inspection hole plug, and check the shoe lining
thickness through the hole.
If it is less than the minimum, replace the shoes.
Minimum thickness: 1.0 mm (0.03. in.)
2. REMOVE REAR WHEEL
3. REMOVE BRAKE DRUM
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(a) Remove the adjusting hole plug in the backing plate.
(b) Insert a screwdriver through the hole in the backing plate,
and hold the automatic adjusting lever away from the ad-
justing bolt.
(c) Using another screwdriver, reduce the brake shoe adjust-
ment by turning the adjusting bolt.
4. REMOVE REAR SHOE
(a) Using SST, disconnect the return spring.
SST 09703−30010
(b) Using SST, remove the shoe hold−down spring, cups and
pin.
SST 09718−00010
(c) Disconnect the anchor spring from the rear shoe and re-
move the rear shoe.
(d) Remove the anchor spring from the front shoe.
5. REMOVE FRONT SHOE
(a) Using SST, remove the shoe hold−down spring, cups and
pin.
SST 09718−00010
(b) Remove the return spring from the front shoe.
(c) Disconnect the parking brake cable No.1 from the parking
brake bellcrank No.3.
(d) Remove the front shoe with adjuster.
(e) Disconnect the parking brake cable from the front shoe.

Downloaded from www.Manualslib.com manuals search engine BR09Q−01
BR0122
C
A
BAdjusting Bolt
BR0973
Z03640
Z03659
− BRAKEREAR DRUM BRAKE (4WD)
BR−49
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page
BR−45).
NOTICE:
Apply lithium soap base glycol grease and high tempera-
ture grease to the parts indicated by the arrows (See page
BR−44).
1. ADJUST BELLCRANK
(a) Lightly pull the bellcrank in direction A until there is no
slack at part B.
(b) In this condition, turn the adjusting bolt so that dimension
C will be 0.4 − 0.8 mm (0.016 − 0.031 in.).
(c) Lock the adjusting bolt with the lock nut.
(d) Connect the parking brake cable to the parking brake bell-
crank and install the clip.
(e) Install the tension spring.
2. CHECK OPERATION OF AUTOMATIC ADJUSTING
MECHANISM
(a) Move the parking brake lever of the front shoe back and
forth. Check that the adjuster turns.
If the adjuster does not turn, check for incorrect installation of
the rear brakes.
(b) Adjust the adjuster length as short as possible.
(c) Install the brake drum.
(d) Pull the parking brake lever all the way up until a clicking
sound can no longer be heard.
3. CHECK CLEARANCE BETWEEN BRAKE SHOES AND
DRUM (See page BR−43)
Shoe clearance: 0.6 mm (0.024 in.)
4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See Page BR−4)
5. CHECK FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine BR0060
BR09R−11
BR0061
SST
BR0062
80 kg/cm2
BR−50− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)
1655 Author: Date:
1996 TOYOTA T100 (RM449U)
LOAD SENSING PROPORTIONING
AND BY−PASS VALVE (LSP & BV)
ON−VEHICLE INSPECTION
1. SET REAR AXLE LOAD
Rear axle load (includes vehicle weight):
2WD:
1 ton: 850 kg (1,874 lb)
0.5 ton std: 800 kg (1,764 lb)
0.5 ton opt (soft ride): 850 kg (1,874 lb)
4WD: 1,050 kg (2,315 lb)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR
SST 09709−29017
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80
kgf/cm
2, 1,138 psi) AND CHECK REAR BRAKE PRES-
SURE
Rear brake pressure:
5,325 ± 490 kPa (54.3 ± 5 kgf/cm
2, 772 ± 71 psi)
HINT:
The brake pedal should not be depressed twice and/or returned
while setting to the specified pressure. Read the value of rear
brake pressure after holding the specified fluid pressure for 2
seconds. If the brake pressure is incorrect, adjust the fluid pres-
sure.

Downloaded from www.Manualslib.com manuals search engine BR3278
R09580
Z11334
Z03643
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)BR−51
1656 Author: Date:
1996 TOYOTA T100 (RM449U)
4. IF NECESSARY, ADJUST FLUID PRESSURE
(a) Loosen the lock nut.
(b) Adjust the length of the No.2 shackle.
Low pressure: Lengthen A
High pressure: Shorten A
Initial set: 120 mm (4.72 in.)
Adjustment range: 114 − 126 mm (4.49 − 4.96 in.)
HINT:
One turn of the nut changes the fluid pressure as shown in the
following specification.
7.5 kPa (0.77 kgf/cm, 11 psi)
(c) Torque the lock nut.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(d) If the pressure cannot be adjusted by the No.2 shackle,
raise or lower the valve body. (2WD shown, for 4WD refer
to component illustration on next page.)
Low pressure−Lower body
High pressure−Raise body
(e) Torque the nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(f) Adjust the length of the No.2 shackle again.
If it cannot be adjusted, inspect the valve housing.
5. IF NECESSARY, CHECK VALVE BODY
(a) Assemble the valve body in the uppermost position.
HINT:
When the brakes are applied, the piston will move down about
0.8 mm (0.03 in.). Even at this time, the piston should not make
contact with or move the load sensing spring.
(b) In this position, check the rear brake pressure.
Front brake pressure
kPa (kgf/cm2, psi)
Rear brake pressure
kPa (kgf/cm2, psi)
1,960 (20, 285)1,960 (20, 285)
3,920 (40, 570)2,352 ± 196 (24 ± 2, 342 ± 28.5)
6,860 (70, 997.5)2,940 ± 343 (30 ± 3.5, 427.5 ± 50)
If the measured value is not within the standard, replace the
valve body.

Downloaded from www.Manualslib.com manuals search engine BR09X−01
Z11332
SST
Z11333
A
BR0218
BR0061
SST
− BRAKELOAD SENSING PROPORTIONING AND BY−PASS
VALVE (LSP & BV)BR−57
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL LSP & BV ASSEMBLY TO FRAME
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
2. CONNECT BRAKE LINE
Using SST, connect the brake lines.
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
SST 09751−36011
3. CONNECT SHACKLE NO.2 BRACKET
(a) Install the shackle No.2 to the load sensing spring.
(b) Set dimension A and torque the lock nut.
Initial set: 120 mm (4.72 in.)
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Connect the shackle No.2 to the shackle bracket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install a new cotter pin.
4. SET REAR AXLE LOAD
(See page BR−50)
5. SET VALVE BODY
(a) When pulling down the load sensing spring, check that
the valve piston moves down smoothly.
(b) Position the valve body so that the valve piston lightly
contacts with the load sensing spring.
(c) Tighten the valve body mounting nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. BLEED BRAKE LINE (See page BR−4)
7. CHECK AND ADJUST LSP & BV FLUID PRESSURE
(See page BR−50)
8. APPLY SEALANT TO SHACKLE No.2
Apply sealant to the top portion of the shackle No.2 bolt threads
not to lose the upper lock nut.
Sealant:
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent

Downloaded from www.Manualslib.com manuals search engine F14857
BR1NW−01
R07778
BR−58
− BRAKEABS ACTUATOR
1663 Author: Date:
1996 TOYOTA T100 (RM449U)
ABS ACTUATOR
ON−VEHICLE INSPECTION
1. INSPECT BATTERY POSITIVE VOLTAGE
Battery positive voltage: 10 − 14 V
2. DISCONNECT CONNECTORS
(a) Disconnect the 2 connectors from the control relay.
(b) Disconnect the connector from the actuator.
3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA-
TOR
(a) Connect the actuator checker (SST) to the actuator, con-
trol relay and body side wire harness through the sub−
wire harness C and E (SST) as shown in the illustration.
SST 09990−00150, 09990−00200, 09990−00210
(b) Connect the red cable of the checker to the battery posi-
tive (+) terminal and black cable to the negative (−) termi-
nal. Connect the black cable of the sub−wire harnesses
to the battery negative (−) terminal or body ground.
(c) Place the ”SHEET L” (SST) on the actuator checker.
SST 09990−00370
4. INSPECT BRAKE ACTUATOR OPERATION
(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker in
”FRONT” position.
(c) Push and hold in the MOTOR switch for a few seconds.
Make sure that you can hear the motor running.

Downloaded from www.Manualslib.com manuals search engine R07779
R07780
R07781
R07782
− BRAKEABS ACTUATOR
BR−59
1664 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Depress the brake pedal and hold it until the step (g) is
completed.
(e) Push the POWER SWITCH, and check that the brake
pedal does not go down.
NOTICE:
Do not keep the POWER SWITCH pushed down for more
than 10 seconds.
(f) Release the switch, and check that the pedal goes down.
(g) Push and hold in the MOTOR switch for a few seconds,
and check that the pedal returns.
(h) Release the brake pedal.
(i) Push and hold in the MOTOR switch for a few seconds.
(j) Depress the brake pedal and hold it for about 15 seconds.
As you hold the pedal down, push the MOTOR switch for
a few seconds. Check that the brake pedal does not pul-
sate.
(k) Release the brake pedal.
5. INSPECT FOR OTHER WHEELS
(a) Change the connection of the actuator checker (SST) to
the sub − wire harness E (SST) − from the sub − wire har-
ness MAIN connector to the SUB connector, or vice ver-
sa.
(b) Repeating (c) to (i) of the step 4, check the actuator opera-
tion same way.
6. INSPECT FOR REAR WHEEL
(a) Turn the selector switch to the ”REAR” position.
(b) Push and hold in the MOTOR switch for a few seconds.
(c) Depress the brake pedal and hold it until the step (g) is
completed.

Downloaded from www.Manualslib.com manuals search engine R07783
R07784
R07785
R07782
BR−60
− BRAKEABS ACTUATOR
1665 Author: Date:
1996 TOYOTA T100 (RM449U)
(d) Push the REAR switch while pressing the POWER
SWITCH, and check that the brake pedal cannot be de-
pressed.
NOTICE:
Do not keep the POWER SWITCH pushed down for more
than 10 seconds.
(e) Release the REAR switch then the POWER SWITCH,
and check that the brake pedal can be depressed.
(f) Push and hold in the MOTOR switch for a few seconds,
and check that the pedal returns.
(g) Release the brake pedal.
(h) Push and hold in the MOTOR switch for a few seconds.
(i) Depress the brake pedal and hold it for about 15 seconds.
As you hold the pedal down, push the MOTOR switch for
a few seconds. Check that the brake pedal does not pul-
sate.
(j) Release the brake pedal.
7. PUSH MOTOR SWITCH
(a) Push and hold on the MOTOR switch for a few seconds.
(b) Stop the engine.
8. DISCONNECT ACTUATOR CHECKER (SST) FROM
ACTUATOR
Remove the ”SHEET L” (SST) and disconnect the actuator
checker (SST) and sub−wire harness (SST) from the actuator,
control relay and body side wire harness.
SST 09990−00150, 09990−00200, 09990−00210,
09990−00370
9. CONNECT CONNECTOR TO ACTUATOR
10. CLEAR DTC (See page DI−321)