1996 TOYOTA T100 air suspension

Downloaded from www.Manualslib.com manuals search engine INDEX
IN Introduction
MA Maintenance
PP Preparation
SS Service Specifications
DI Diagnostics
EM Engine Mechanical (3RZ-FE)
Engine Mechanical (5VZ-FE)
EC Emissions Control (3RZ-FE)
Emissions Control (5VZ-FE)
MF MFI System (3RZ-FE)
SF SFI System (5VZ-FE)
CO Cooling (3RZ-FE)
Cooling (5VZ-FE)
LU Lubrication (3RZ-FE)
Lubrication (5VZ-FE)
IG Ignition (3RZ-FE)
Ignition (5VZ-FE)
ST Starting (3RZ-FE)
Starting (5VZ-FE)
CH Charging (3RZ-FE)
Charging (5VZ-FE)
CL Clutch
MT Manual Transmission (R150, R150F)
Manual Transmission (W59)
AT Automatic Transmission
TR Transfer
PR Propeller Shaft
SA Suspension and Axle
BR Brake
SR Steering
RS Supplemental Restraint System
BE Body Electrical
BO Body
AC Air Conditioning

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MAINTENANCE PP-1
ENGINE MECHANICAL (3RZ-FE) PP-2
ENGINE MECHANICAL (5VZ-FE) PP-8
EMISSION CONTROL (3RZ-FE) PP-14
EMISSION CONTROL (5VZ-FE) PP-16
MFI (3RZ-FE) PP-19
SFI (5VZ-FE) PP-22
COOLING (3RZ-FE) PP-25
COOLING (5VZ-FE) PP-28
LUBRICATION (3RZ-FE) PP-33
LUBRICATION (5VZ-FE) PP-38
IGNITION (3RZ-FE) PP-43
IGNITION (5VZ-FE) PP-46
STARTING (3RZ-FE) PP-48
STARTING (5VZ-FE) PP-51
CHARGING (3RZ-FE) PP-54
CHARGING (5VZ-FE) PP-57
CLUTCH PP-60
MANUAL TRANSMISSION (R150,
R150F) PP-63
MANUAL TRANSMISSION (W59) PP-69
AUTOMATIC TRANSMISSION PP-75
TRANSFER PP-80
PROPELLER SHAFT PP-86
SUSPENSION AND AXLE PP-88
BRAKE PP-98
STEERING PP-103
SUPPLEMENTAL RESTRAINT SYSTEM PP-113
BODY ELECTRICAL PP-116
BODY PP-119
AIR CONDITIONING PP-122

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STANDARD BOLT SS-1
MAINTENANCE SS-3
ENGINE MECHANICAL (3RZ-FE) SS-4
ENGINE MECHANICAL (5VZ-FE) SS-9
EMISSION CONTROL (3RZ-FE) SS-14
EMISSION CONTROL (5VZ-FE) SS-16
MFI (3RZ-FE) SS-17
SFI (5VZ-FE) SS-19
COOLING (3RZ-FE) SS-21
COOLING (5VZ-FE) SS-23
LUBRICATION (3RZ-FE) SS-25
LUBRICATION (5VZ-FE) SS-27
IGNITION (3RZ-FE) SS-29
IGNITION (5VZ-FE) SS-31
STARTING (3RZ-FE) SS-33
STARTING (5VZ-FE) SS-35
CHARGING (3RZ-FE) SS-37
CHARGING (5VZ-FE) SS-39
CLUTCH SS-41
MANUAL TRANSMISSION (R150,
R150F) SS-43
MANUAL TRANSMISSION (W59) SS-46
AUTOMATIC TRANSMISSION SS-49
TRANSFER SS-53
PROPELLER SHAFT SS-56
SUSPENSION AND AXLE SS-58
BRAKE SS-69
STEERING SS-71
SUPPLEMENTAL RESTRAINT SYSTEM SS-75
BODY ELECTRICAL SS-77
BODY SS-80
AIR CONDITIONING SS-82

Downloaded from www.Manualslib.com manuals search engine SS−8
− SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
1996 TOYOTA T100 (RM449U) Oil strainer x Cylinder block
1818513
Oil pan x Cylinder block12.51309
Crankshaft position sensor x Timing chain cover8.58574 in.·lbf
Generator bracket x Cylinder block74.576055
Generator bracket x Timing chain cover1818513
Generator adjusting bar x Timing chain cover63.565047
A/C compressor bracket x Cylinder block4444032
A/C compressor x A/C compressor bracket2525018
Water pump pulley x Water pump2121016
Connecting rod cap x Connecting rod 1st
2nd45
Turn 90°46033
Main bearing cap x Cylinder block 1st
2nd39
Turn 90°40029
No.1 balance shaft x Timing gear3636526
No.2 balance shaft x Timing sprocket3636526
Balance shaft x Cylinder block1818513.4
Rear oil seal retainer x Cylinder block13.51359.7
RH, LH engine mounting bracket x Cylinder block4545034
Oil dipstick guide x LH engine mounting bracket2020014
Oil filter bracket union, Engine coolant drain plug x Cylinder block2525018
Oil filter bracket x Cylinder block2829021
Water bypass pipe x Cylinder block2020014
Knock sensor x Cylinder block3738027
Fuel filter x Cylinder block2020014
Rear end plate x Cylinder block1818513
Rear end plate x Water bypass pipe2020014
Flywheel x Crankshaft 1st
2nd26.5
Turn 90°27019
Front crossmember x Engine rear mounting bracket2526019
Front exhaust pipe clamp x Exhaust manifold6263046
Exhaust support bracket x Transmission3940029
Front exhaust pipe clamp1919514
Front exhaust pipe x TWC3940029
Engine rear mounting bracket x Engine rear mounting insulator1818313
Engine front mounting insulator x Frame3838728
Clutch release cylinder bracket x Transmission3940029
Clutch release cylinder x Transmission131309
Stabilizer bar bracket mounting bolt3030622
Stabilizer bar x Lower suspension arm131309
Intake air connector x Cylinder head1818513
Radiator x Body1818513

Downloaded from www.Manualslib.com manuals search engine SA0384
Air FilterE
F
SA0385
Air FilterE
F
SA0375
1
2 3
4
61
23
4
6
Z04174
Z04175
− SUSPENSION AND AXLEA.D.D. CONTROL SYSTEM
SA−71
1996 TOYOTA T100 (RM449U)
(b) Connect the battery to the solenoid.
Check that air flows from the port E to port F.
Check that air does not flow from the port E to the air filter.
(c) Disconnect the battery positive voltage from the solenoid.
Check that air flows from the port E to the air filter.
Check that air does not flow from the port E to port F.
5. INSPECT A.D.D. RELAY
(a) Using an ohmmeter, check that continuity exists between
terminals 1 and 3.
(b) Using an ohmmeter, check that continuity exists between
terminals 2 and 6.
(c) Connect the positive (+) lead from the battery to terminal
6 and the negative (−) lead to terminal 2.
(d) Using an ohmmeter, check that continuity exists between
terminals 1 and 4.
6. INSPECT A.D.D. INDICATOR SWITCH
(a) Using an ohmmeter, check that continuity exists between
terminals when the switch when the switch is pushed (dif-
ferential connected position).
(b) Using an ohmmeter, check that continuity doesn’t exists
when the switch is free (differential disconnected posi-
tion).
7. INSPECT TRANSFER INDICATOR SWITCH
(a) Using an ohmmeter, check that there is continuity be-
tween terminals between terminals when the switch is
pushed (transfer 4WD position).
(b) Using an ohmmeter, check that there is continuity be-
tween terminals when switch is free (transfer H2 position).

Downloaded from www.Manualslib.com manuals search engine SA259−01
W00493
30 mm
(1.18 in.)
R04321
R04322
R04323
R04463
SA−140
− SUSPENSION AND AXLEREAR DIFFERENTIAL CARRIER
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the runout of the companion
flange vertical and lateral.
Maximum
Vertical runout: 0.09 mm (0.0035 in.)
Lateral runout: 0.09 mm (0.0035 in.)
If the runout is greater than the maximum, replace the compan-
ion flange.
2. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout.
Maximum runout: 0.05 mm (0.0020 in.)
3. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash:
2WD: 0.08 − 0.13 mm (0.0031 − 0.0051 in.)
4WD: 0.13 − 0.18 mm (0.0051 − 0.0071 in.)
If the backlash is not within specification, adjust the side bear-
ing preload or repair if necessary.
HINT:
Measure from 3 or more places on the circumference of the ring
gear.
4. CHECK TOOTH CONTACT BETWEEN RING GEAR
AND DRIVE PINION (See page SA−145)
5. CHECK SIDE GEAR BACKLASH
Using a dial indicator, measure the side gear backlash with
holding one pinion gear toward the case.
Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.)
If the backlash is not within the specification, install the side
gear thrust washers of differential thickness.

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SR−2
− STEERINGTROUBLESHOOTING
1676 Author: Date:
1996 TOYOTA T100 (RM449U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, repair or replace these parts.
SymptomSuspect AreaSee page
Hard steering
1. Tires (Improperly inflated)
2. Power steering fluid level (Low)
3. Drive belt (Loose)
4. Front wheel alignment (Incorrect)
5. Steering system joints (Worn)
6. Suspension arm ball joints
7. Steering column (Binding)
8.Power steering gearSA−3
SA−5
SR−5
SR−3
SA−7
SA−10
−
SA−109
SA−11 3
SA−11 7
SA−121
−
SR−54
SR−72
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gearSA−3
SA−5
SA−7
SA−10
−
SR−54
SR−72
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Universal joint, Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Power steering gear−
SA−109
SA−11 3
SA−11 7
SA−121
−
SA−16
SR−54
SR−72
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering gearSR−5
−
SR−54
SR−72