1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine SR074−04
SR−8
− STEERINGAIR CONTROL VALVE
1682 Author: Date:
1996 TOYOTA T100 (RM449U)
AIR CONTROL VALVE
INSPECTION
1. TURN AIR CONDITIONING SWITCH OFF
2. CHECK IDLE−UP
(a) Start the engine and run it at idle.
(b) Fully turn the steering wheel.
(c) Check that the engine rpm decreases when the vacuum
hose is pinched.
(d) Check that the engine rpm increases when the hose is re-
leased.

Downloaded from www.Manualslib.com manuals search engine R07653
SR0097
SR075−01
R09732
− STEERINGSTEERING WHEEL
SR−9
1683 Author: Date:
1996 TOYOTA T100 (RM449U)
STEERING WHEEL
INSPECTION
1. CHECK THAT STEERING WHEEL FREEPLAY IS COR-
RECT
With the vehicle stopped and tires pointed straight ahead, rock
the steering wheel gently back and forth with light finger pres-
sure.
Freeplay should not exceed the maximum.
Maimum freeplay: 30 mm (1.18 in.)
4WD:
If the freeplay exceeds the maximum, adjust it in the following
procedure.
2. 4WD:
ADJUST STEERING GEAR
(a) Point the front wheels straight ahead.
(b) Loosen the adjusting screw lock nut.
(c) Turn the sector shaft adjusting screw clockwise to de-
crease steering wheel freeplay and counterclockwise to
increase it.
HINT:
Turn the adjusting screw in small increments and check the
freeplay between each adjustment.
(d) Turn the steering wheel half way around in both direc-
tions.
Check the the freeplay is correct and steering is smooth
and without rough spots.
(e) Torque the adjusting screw lock nut (See page SR−80).
3. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b) Remove the steering wheel pad (See page SR−13).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Reference: 8.3 N·m (85 kgf·cm, 73 in.·lbf)
HINT:
Be sure to consider the tire type, pressure and contact surface
before making your diagnosis.
(e) Torque the steering wheel set nut.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
(f) Install the steering wheel pad (See page SR−20).

Downloaded from www.Manualslib.com manuals search engine R04668
SR079−01
R04670
R11778
R01835
− STEERINGNON−TILT STEERING COLUMN
SR−17
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT COLUMN UPPER BRACKET
Check that the steering lock mechanism operates properly.
2. IF NECESSARY, REPLACE KEY CYLINDER
(a) Place the ignition key at the ACC position.
(b) Push down the stop pin with a thin rod, and pull out the
key cylinder.
(c) Install a new key cylinder.
HINT:
Make sure the ignition key is at the ACC position.
3. INSPECT IGNITION SWITCH AND KEY UNLOCK
WARNING SWITCH (See page BE−12)
4. IF NECESSARY, REPLACE IGNITION SWITCH AND
KEY UNLOCK WARNING SWITCH
(a) Remove the 3 screws.
(b) Install a new switches with the 3 screws.
5. INSPECT BEARING
Check the bearing rotation condition and check for abnormal
noise.
If the bearing is worn or damaged, replace the column tube/col-
umn upper tube.
6. IF NECESSARY, REPLACE BUSHING
(a) TILT STEERING COLUMN:
Remove the snap ring from the column lower tube.
(b) Using a screwdriver, remove the bushing from the column
tube/column lower tube.
NOTICE:
Be careful not to damage the column tube.
(c) Coat the inside of new bushing with molybdenum disul-
fide lithium base grease.

Downloaded from www.Manualslib.com manuals search engine R07644Red Mark
R07660
Torx ScrewScrew Case
− STEERINGNON−TILT STEERING COLUMN
SR−21
1996 TOYOTA T100 (RM449U)
9. INSTALL COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Install the 4 screws.
(b) Connect the airbag connector.
(c) Connect the connectors.
(d) Install the 2 screws.
10. INSTALL DUCT HEATER TO REGISTER NO.2
Install the screw.
11. INSTALL LOWER FINISH PANEL NO.1
(a) Install the lock nuts and light control rheostat.
(b) Tighten the 4 panel set bolts.
(c) Install the cowl side trim and clip.
(d) Install the front door scuff plate with the 4 screws.
(e) Install the engine hood release lever with the 2 screws.
12. A/T:
INSTALL UPPER AND LOWER COLUMN COVERS
Install the 6 screws.
13. M/T:
INSTALL UPPER AND LOWER COLUMN COVERS
Install the 7 screws.
14. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the spiral counterclockwise by hand until it becomes
harder to turn the cable.
(c) Then turn the spiral cable clockwise about 3 turns to align
the red mark.
HINT:
The spiral cable turns clockwise about 3 turns to either left or
right of the center.
15. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and main shaft.
(b) Torque the set nut.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
(c) Connect the connector.
16. INSTALL STEERING WHEEL PAD
NOTICE:
Make sure the wheel pad is installed to the specified
torque.
If the wheel pad has been dropped, or there are
cracks, dents in the case or connector, replace the
wheel pad with a new one.
When installing the wheel pad, take care that the wir-
ings do not interfere with other parts and are not
pinched between other parts.

Downloaded from www.Manualslib.com manuals search engine SR−22
− STEERINGNON−TILT STEERING COLUMN
1996 TOYOTA T100 (RM449U)
(a) Connect the airbag connector.
(b) Install the wheel pad after confirming that the circumfer-
ence groove of the torx screws is caught on the screw
case.
(c) Using a torx wrench, torque the 2 screws.
Torque: 9.0 N·m (90 kgf·cm, 78 in.·lbf)
17. CHECK STEERING WHEEL CENTER POINT

Downloaded from www.Manualslib.com manuals search engine W03535
R15213
Tilt Pawl
Alignment Mark
Tilt Pawl Stopper
SR3128
”A” ”A”
Mark
− STEERINGTILT STEERING COLUMN
SR−31
1996 TOYOTA T100 (RM449U)
7. INSTALL 2 TILT PAWLS
Install the pawl to the column upper tube and temporarily install
the washer with the bolt and nut.
HINT:
Install the pawl pin into the long hole of the tilt lever/tilt sub lever.
8. ENGAGE AND ADJUST 2 TILT PAWLS
(a) Engage the tilt sub lever side pawl to the center of the
ratchet.
(b) While turning the tilt lever side collar, engage the tilt lever
side pawl to the ratchet completely.
(c) Torque the nut.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
(d) Check that the pawls rotate smoothly.
9. SELECT 2 TILT PAWL STOPPERS
(a) With the tilt pawl and ratchet engaged, install the 2 pawl
stoppers.
(b) Check that the alignment marks on the stopper and pawl
align when the stopper is lightly rotated to the pawl side.
(c) If the alignment marks are not align, select pawl stopper
according to the following table.
Right pawl stopperLeft pawl stopperDimension ”A”
mm (in.)
1A12.68 − 12.74
(0.4992 − 0.5016)
2B12.61 − 12.67
(0.4965 − 0.4988)
3C12.54 − 12.60
(0.4937 − 0.4961)
4D12.47 − 12.53
(0.4909 − 0.4933)
5E12.40 − 12.46
(0.4882 − 0.4906)
6F12.33 − 12.39
(0.4854 − 0.4878)
7G12.26 − 12.32
(0.4827 − 0.4850)
(d) After selecting the stoppers, check that the pawl and
ratchet are fully engaged.
10. INSTALL 2 TILT PAWL STOPPERS
11. INSTALL 2 TILT LEVER RETAINERS
(a) Install the tilt lever retainer and torque the nut.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
(b) Install a new E−ring.
12. INSTALL COMPRESSION SPRING
(a) Install the 2 bushings to the compression spring.
(b) Install the spring with the bolt.
Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine R04531
SR−32
− STEERINGTILT STEERING COLUMN
1996 TOYOTA T100 (RM449U)
13. INSTALL 3 TENSION SPRINGS
14. INSTALL COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Install the bracket with 2 new tapered−head bolts.
(b) Tighten the tapered−head bolts until the bolt heads break
off.
15. INSTALL SLIDING YORK SUB−ASSEMBLY
(a) Align the matchmarks on the sliding york and main shaft.
(b) Torque the bolt.
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
16. CHECK TILT STEERING OPERATION
(a) Check that there is no axial play at the end of the main
shaft.
(b) With the main shaft in the neutral position, pull the tilt lever
and check that the main shaft rises to the uppermost posi-
tion.
(c) Lower the main shaft, and check that it locks in the lower-
most position.

Downloaded from www.Manualslib.com manuals search engine SR07K−01
R12065
R09248
SST
Z14482
Vinyl Tape
Oil Seal
Bearing
− STEERINGPOWER STEERING VANE PUMP (3RZ−FE)
SR−37
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.25 N·m (2.5 kgf·cm, 2.2 in.·lbf) or less
2. REMOVE VANE PUMP PULLEY
Using SST to stop the pulley rotating, remove the pulley set nut.
SST 09960−10010 (09962−01000, 09963−01000)
3. REMOVE OIL RESERVOIR
(a) Remove the 3 bolts and oil reservoir.
(b) Remove the O−ring from the oil reservoir.
4. REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND SPRING
Remove the O−ring from the union.
5. REMOVE REAR HOUSING
(a) Remove the 2 bolts and rear housing.
(b) Remove the 2 O−rings from the housing.
6. REMOVE WAVE WASHER
7. REMOVE SIDE PLATE
8. REMOVE CAM RING, VANE PLATES AND VANE
PUMP ROTOR
(a) Remove the 10 plates.
NOTICE:
Take care not to drop the plate.
(b) Using a screwdriver, remove the snap ring from the vane
pump shaft.
9. REMOVE STRAIGHT PINS
Remove the 2 pins from the front housing.
10. REMOVE GASKET
11. REMOVE VANE PUMP SHAFT WITH BEARING
(a) Using snap ring pliers, remove the snap ring from the front
housing.
(b) Wind vinyl tape on the serrated part of the vane pump
shaft.
(c) Using a press, press out the shaft with the bearing.
NOTICE:
Be careful not to damage the oil seal lip.