1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine SR07Z−01
R15251
SST
Fulcum Length
− STEERINGPOWER STEERING GEAR (2WD)
SR−71
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
Torque the 2 gear assembly set bolts and nut.
2. INSTALL MOUNT BRACKET AND GROMMET
(a) Install the grommet and mount bracket to the PS gear as-
sembly.
(b) Torque the 2 bolts.
Torque: 88 N·m (900 kgf·cm, 65 ft·lbf)
3. CONNECT PRESSURE FEED TUBE AND INSTALL
RETRUN TUBE
(a) Coat a new O−ring with power steering fluid and install it
to the tube.
(b) Using SST, connect the pressure feed tube and install the
return tube.
SST 09631−22020
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 250 mm
(9.84 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT RETURN HOSE
5. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
6. CONNECT RH AND LH TIE ROD ENDS
Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
7. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
8. CENTER SPIRAL CABLE
(See page SR−20)
9. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering column
main shaft.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
10. BLEED POWER STEERING SYSTEM
(See page SR−4)
11. CHECK STEERING WHEEL CENTER POINT
12. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
13. INSTALL STEERING WHEEL PAD
(See page SR−20)
14. CHECK FRONT WHEEL ALIGNMENT
(See page SA−7)

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Z14503
Dial Indicator
30 mm
(1.18 in.)
Z14504
Dial
Indicator
R01297
R01283
SST
Z06211 SR3019 SR3020
SR−76
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT BALL CLEARANCE
Using a dial indicator, check the ball clearance. Move the power
piston nut up and down.
Maximum clearance: 0.15 mm (0.0059 in.)
2. INSPECT SECTOR SHAFT ADJUSTING SCREW
THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.03 − 0.05 mm (0.0012 − 0.0020 in.)
Maximum clearance: 0.05 mm (0.0020 in.)
3. IF NECESSARY, ADJUST SECTOR SHAFT
ADJUSTING SCREW THRUST CLEARANCE
(a) Using a chisel and hammer, unstake the No.1 lock nut.
(b) Using SST, remove the No.1 lock nut.
SST 09630−00014 (09631−00051)
(c) Using a screwdriver, adjust the adjusting screw for the
correct thrust clearance.
(d) Tighten a new lock nut.
(e) Stake the lock nut.
4. IF NECESSARY, REPLACE 2 NEEDLE ROLLER
BEARINGS
(a) Using a screwdriver, pry out the oil seal from the gear
housing.
(b) Using snap ring pliers, remove the snap ring from the gear
housing.
(c) Remove the metal spacer, teflon ring and O−ring from the
gear housing.

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R15586
R15587
SST
R12202
Hexagon
Wrench SR−80
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH POWER STEERING FLUID OR MOLYBDE-
NUM DISULFIDE LITHIUM BASE GREASE (See page
SR−72)
2. INSTALL WORM GEAR VALVE BODY ASSEMBLY
(a) Coat 2 new O−rings with power steering fluid and install
them to the gear housing.
(b) Install the valve body assembly into the gear housing.
NOTICE:
Ensure that the power piston nut does not come off
the worm shaft.
Be careful not to damage the teflon ring.
(c) Torque the 4 bolts.
Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
(d) Using SST and a torque wrench, check the valve body as-
sembly rotating torque.
SST 09616−00010
Rotating torque:
0.3 − 0.5 N·m (3 − 5.5 kgf·cm, 2.6 − 4.8 in.·lbf)
HINT:
Hold the worm gear to prevent it from turning.
If rotating torque is not correct, replace the worm gear valve
body assembly.
3. INSTALL POWER PISTON PLUNGER GUIDE, POWER
PISTON PLUNGER, COMPRESSION SPRING AND
POWER PISTON PLUNGER GUIDE NUT
(a) Coat a new O−ring with power steering fluid and install it
to the plunger guide nut.
(b) Install the plunger guide nut with a hexagon wrench (10
mm).
Torque: 20 N·m (205 kgf·cm, 15 ft·lbf)

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SST SR−82
− STEERINGPOWER STEERING GEAR (4WD)
1996 TOYOTA T100 (RM449U)
9. CHECK TOTAL PRELOAD
Using SST and a torque wrench, check total preload.
SST 09616−00010
Total preload (Turning):
0.5 − 0.9 N·m (5 − 9.5 kgf·cm, 4.3 − 8.3 in.·lbf)

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R15509
Fulcrum
Length
SST
SR2922
Alignment Marks
− STEERINGPOWER STEERING GEAR (4WD)
SR−83
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Install the 3 bolts, washers and nuts.
Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf)
2. CONNECT INTERMEDIATE SHAFT ASSEMBLY
(See page SR−20)
3. CONNECT PRESSURE FEED TUBE AND RETURN
TUBE
Using SST, connect the tube.
SST 09631−22020
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).
This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT PITMAN ARM SUB−ASSEMBLY WITH
RELAY ROD
(a) Align the alignment marks on the pitman arm and sector
shaft, and connect the pitman arm.
(b) Install the spring washer and pitman arm set nut.
Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
5. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
HINT:
Do it with the front of the vehicle jacked up.
6. CENTER SPIRAL CABLE
(See page SR−20)
7. INSTALL STEERING WHEEL
(a) Align the matchmarks on the wheel and steering column
main shaft.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
8. BLEED POWER STEERING SYSTEM
(See page SR−4)
9. CHECK STEERING WHEEL CENTER POINT
10. TORQUE STEERING WHEEL SET NUT
Torque: 35 N·m (360 kgf·cm, 26 ft·lbf)
11. INSTALL STEERING WHEEL PAD
(See page SR−20)
12. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)

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Alignment
Marks SR−88
− STEERINGSTEERING LINKAGE
1996 TOYOTA T100 (RM449U)
5. INSTALL PITMAN ARM
(a) Align the alignment marks on the pitman arm and the
cross shaft.
(b) Install the spring washer and pitman arm set nut.
Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf)
(c) Connect the pitman arm to the relay rod.
(d) Install the nut and a new cotter pin.
Torque: 90 N·m (920 kgf·cm, 67 ft·lbf)
6. INSTALL ENGINE UNDER COVER
Tighten the 4 bolts.
7. CHECK FRONT WHEEL ALIGNMENT
(See page SA−10)

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SR1279
SR1287
R04472
− STEERINGIDLER ARM
SR−91
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE IDLER ARM BRACKET CAP
Using a screwdriver and a hammer, remove the idler arm brack-
et cap.
NOTICE:
Be careful not to damage the idler arm bracket.
2. MEASURE IDLER ARM ROTATING TORQUE
(a) Check that the arm rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the arm rotating torque.
Rotating torque:
0.5 − 2.9 N·m (5 − 30 kgf·cm, 5 − 26 in.·lbf)
3. REMOVE IDLER ARM
Remove the nut and plate washer, and pull the idler arm off the
idler arm bracket.
4. REMOVE OIL SEAL
5. REMOVE 2 BUSHINGS
Using a screwdriver, remove the bushing.
NOTICE:
Be careful not to damage the idler arm bracket.

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− SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS−1
1768 Author: Date:
1996 TOYOTA T100 (RM449U)
SRS AIRBAG
PRECAUTION
NOTICE:
The TOYOTA T100 is equipped with SRS, which comprises a driver airbag. Failure to carry out
service operations in the correct sequence could cause the SRS to unexpectedly deploy during
servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the
SRS, it is possible that the SRS may fail to operate when required. Before performing servicing
(including removal or installation of parts, inspection or replacement), be sure to read the fol-
lowing items carefully, then follow the correct procedures described in the repair manual.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting. When troubleshooting the SRS, always in-
spect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, air-
bag sensor assembly and front airbag sensor should be inspected (See page RS−9, RS−23 and
RS−28).
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, airbag sensor assembly or front airbag
sensor in order to reuse it.
If the steering wheel pad, airbag sensor assembly or front airbag sensor has been dropped, or
if there are cracks, dents or other defects in the case, bracket or connector, replace them with
new ones.
Use a volt/ohmmeter with high impedance ( 10 kΩ/V minimum) for troubleshooting the system’s
electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions on the notices.
After work on the SRS is completed, perform the SRS warning light check or SRS side airbag
warning light check (See page DI−365).
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
CAUTION:
Work must be started after 90 seconds from when the ignition switch is turned to the ”LOCK”
position and the negative (−) terminal cable is disconnected from the battery.
(The SRS is equipped with a back−up power source so that if work is started within 90 seconds
from disconnecting the negative (−) terminal cable of the battery, the SRS may be deployed.)
When the negative (−) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as they
were before and adjust the clock. To avoid erasing the memory in each memory system, never
use a back− up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.
Do not expose the steering wheel pad, airbag sensor assembly or front airbag sensor directly
to hot air or flames.