1996 TOYOTA T100 tow

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Front IN−10
− INTRODUCTIONFOR ALL OF VEHICLES
10 Author: Date:
1996 TOYOTA T100 (RM449U)
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the center airbag sensor if
shocks are likely to be applied to the sensor during
repairs.
(6) Never disassemble and repair the center airbag
sensor assembly, steering wheel pad in order to re-
use it.
(7) If the center airbag sensor assembly, steering
wheel pad have been dropped, or if there are
cracks, dents or other defects in the case, bracket
or connector, replace them with new ones.
(8) Do not expose the center airbag sensor assembly,
steering wheel pad directly to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kΩ/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work on the supplemental restraint system is
completed, check the SRS warning light (See page
DI−365).
(c) FRONT AIRBAG SENSOR
(1) Never reuse the front airbag sensors involved in a
collision that activated the supplemental restraint
system. (Replace both left and right airbag sen-
sors.)
(2) Install the front airbag sensor with the arrow on the
sensor facing toward the front of the vehicle.
The front airbag sensor set bolts have been anti−
rust treated. When the sensor is removed, always
replace the set bolts with new ones.
(3) The front airbag sensor is equipped with an electri-
cal connection check mechanism. Be sure to lock
this mechanism securely when connecting the con-
nector.
(4) If connector is not securely locked, a malfunction
code will be the diagnosis system (See page
RS−2).

Downloaded from www.Manualslib.com manuals search engine Q06793
N
R
P
AT5115
Neutral Basic line
Bolt
Groove
DI−272
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
(3) Return the No.1 gear shifting rod 2 notches to N
position.
(4) Set the shift lever to N position.
(5) While holding the shift lever lightly toward the R
position side, adjust the No.1 gear shifting rod nut.
(6) Tighten the No.1 gear shifting rod nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(7) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D position and reverses when shifting it to the R
position.
(g) Inspect and adjust the park/neutral position.
Check that the engine can be started with the shift lever
only in the N or P position, but not in other positions.If it
is not as stated above, carry out the following adjustment
procedure.
(1) Loosen the park/neutral position switch bolt and set
the shift lever to the N position.
(2) Align the groove and neutral basic line.
(3) Hold in position and tighten the bolt.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)
(h) Check the idle speed.
Idle speed (In N position and air conditioner OFF):
3RZ−FE: 700 ± 50 rpm
5VZ−FE: 700 ± 50 rpm
6. MECHANICAL SYSTEM TESTS
(a) Measure the stall speed.
The object of this test is to check the overall performance of the transmission and engine by measuring
the stall speeds in the D and R positions.
NOTICE:
Do the that at normal operating fluid temperature 50 − 80°C (122 − 176°F)
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear, level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the condi-
tions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressed firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm
(7) Do the same test in R position.
Stall speed:
3RZ−FE: 1,950 ± 150 rpm
5VZ−FE: 2,150 ± 150 rpm

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Dot Mark
P15017A03714
P15018A03715
P15045A03716
P15044
SST (A)
SST (B)
EM−6
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
721 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) Check that the timing marks (one and two dots) of the
camshaft drive and driven gears are in straight line on the
cylinder head surface as shown in the illustration. If not,
turn the crankshaft 1 revolution (360°) and align the
marks as above.
9. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
Using a thickness gauge, measure the clearance
between the valve lifter and camshaft.
Record the out−of−specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake
0.15 − 0.25 mm (0.006 − 0.010 in.)
Exhaust
0.25 − 0.35 mm (0.010 − 0.014 in.)
(b) Turn the crankshaft pulley 1 revolution (360°) and align
its groove with timing mark ”0” of the timing chain cover.
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
10. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the crankshaft to position the cam lobe of the
camshaft on the adjusting valve upward.
Position the notch of the valve lifter toward the spark
plug side.
Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter
flange. Remove SST (A).
SST 09248−55040 (09248−05410, 09248−05420)
HINT:
 Apply SST (B) at slight angle on the side marked with ”9”,
at the position shown in the illustration.
 When SST (B) is inserted too deeply, it will get pinched
by the shim. To prevent it from being stuck, insert it shal-
lowly from the outside of the cylinder head, at a slight
angle.

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P14685
Front Mark
P04668
Hook
Pin
P14683
Push EM−54
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(b) Hold the intake camshaft with a wrench, install and torque
the bolt.
Torque: 73.5 N·m (750 kgf·cm, 54 ft·lbf)
(c) Hold the exhaust camshaft with a wrench, install the bolt
and distributor gear.
Torque: 46 N·m (465 kgf·cm, 34 ft·lbf)
7. INSTALL CHAIN TENSIONER
(a) Place a new gasket so that the front mark is toward the
front side.
(b) Release the ratchet pawl, fully push in the plunger and ap-
ply the hook to the pin so that the plunger cannot spring
out.
(c) Turn the crankshaft pulley clockwise to provide some
slack for the chain on the tensioner side.
NOTICE:
Do not turn the pulley counterclockwise.
(d) Push the tensioner by hand until it touches the head
installation surface, then install the 2 nuts.
(e) Tighten the 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(f) Check that the hook of the tensioner is not released.
NOTICE:
If the plunger springs out during installation of the chain
tensioner, repeat the operation in step (b) before installing
the tensioner.

Downloaded from www.Manualslib.com manuals search engine P21251
Z00052
A01572
Old Valve
Approx. 8 mm Towel
Tape
P20854
80 − 100°C (176 − 212°F) EM−40
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide busing.
Bushing inside diameter:
6.010 − 6.030 mm (0.2366 − 0.2374 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake5.970 − 5.985 mm (0.2350 − 0.2356 in.)
Exhaust5.965 − 5.980 mm (0.2348 − 0.2354 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Oil clearance:
Standard Intake
Exhaust0.025 − 0.060 mm (0.0010 − 0.0024 in.)
0.030 − 0.065 mm (0.0012 − 0.0026 in.)
Maximum Intake
Exhaust0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing.
10. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS
(a) w/ Snap ring:
Insert an old valve wrapped with tape into the valve guide
bushing, and break off the valve guide bushing by hitting
it with a hammer. Remove the snap ring.
HINT:
Wrap the tape approx. 8 mm (0.31 in.) from the valve stem end.
NOTICE:
Be careful not to damage the valve lifter hole.
(b) Gradually heat the cylinder head to 80 − 100°C (176 −
212°F).

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P14968
MF−14
− MFI (3RZ−FE)FUEL PRESSURE REGULATOR
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT VACUUM SENSING HOSE FROM FUEL
PRESSURE REGULATOR
2. DISCONNECT FUEL RETURN HOSE FROM FUEL
PRESSURE REGULATOR
HINT:
Put a suitable container or shop towel under the pressure regu-
lator.
3. REMOVE FUEL PRESSURE REGULATOR
(a) Remove the 2 bolts and the fuel pressure regulator.
Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf)
(b) Remove the O−ring.
HINT:
At the time of installation please refer to the following items.
Install the pressure regulator with a new O−ring.

Downloaded from www.Manualslib.com manuals search engine FI7231
TOYOTA Hand−Held Tester
DLC3
P21057
SF0BT−02
P21210
− SFI (5VZ−FE)FUEL PUMP
SF−5
1011 Author: Date:
1996 TOYOTA T100 (RM449U)
FUEL PUMP
ON−VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and push the TOYOTA hand−
held tester main switch ON.
NOTICE:
Do not start the engine.
(c) Select the active test mode on the TOYOTA hand−held
tester.
(d) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(e) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector.
(f) Check that there is pressure in the fuel inlet hose from the
fuel filter.
HINT:
If there is fuel pressure, you will hear the sound of fuel flowing.
If there is no pressure, check these parts:
H−fuse (ALT 80A)
M−fuses (AM1 40A, AM2 30A)
Fuses (EFI 15A, IGN 7.5A)
EFI main relay
Circuit opening relay
Fuel pump
ECM
Wiring connections
(g) Turn the ignition switch to LOCK.
(h) Disconnect the TOYOTA hand−held tester from the
DLC3.
2. CHECK FUEL PRESSURE
(a) Check the battery positive voltage is above 12 V.
(b) Disconnect the negative (−) terminal cable from the bat-
tery.
(c) Remove the 6 bolts, and disconnect the No.2 timing belt
cover.
(d) Remove the union bolt holding the fuel pipe to the delivery
pipe and gasket.
CAUTION:
Put a shop towel under the delivery pipe. Slowly loosen the
union bolt.

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Down
ClothCounterclockwise
MT0ER−01
D10948
MT−4
− MANUAL TRANSMISSION (R150, R150F)MANUAL TRANSMISSION UNIT (2WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE TRANSMISSION WITH ENGINE (See page
EM−65)
2. REMOVE REAR END PLATE
Remove the 4 bolts, nuts and rear end plate.
Torque:37 N·m (380 kgf·cm, 27 ft·lbf)
3. REMOVE STARTER
Remove the 2 bolts and starter.
Torque:39 N·m (400 kgf·cm, 29 ft·lbf)
4. REMOVE TRANSMISSION FROM ENGINE
(a) Remove the 6 transmission mounting bolts from the en-
gine.
Torque:72 N·m (730 kgf·cm, 53 ft·lbf)
(b) Pull out the transmission toward the rear.
5. REMOVE ENGINE REAR MOUNTING
(a) Remove the 4 bolts and engine rear mounting.
Torque:25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Lower the front side of the transmission and remove it
from the front side of the vehicle.