1996 TOYOTA T100 Factory Service Manual
Contents
1. problem Detection Item Indicates the system of the problem or contents of the problem Indicates the suspect area of the HINT Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors If a malfunction code is displayed during the DTC check mode check the circuit for that code listed in the table below For details of each code turn to the page referred to under the See for the respective DTC No in the DTC chart Ice Detection Item Trouble Area MIL Memory See page P0100 Open or short in mass air flow meter circuit Mass Air Flow Circuit Malfunction Mass air flow meter DI 26 e ECM P0101 Mass Air Flow Circuit DI 31 Range Performance Problem MASKAN O P0110 Open or short in intake air temp sensor circuit DI 32 Intake Air Temp Circuit Malfunction e Intake air temp sensor O O e ECM P0115 Engine Coolant Temp Circuit a or in engine coolant temp sensor circuit O DI 37 Malfunction Engine coolant temp sensor C e ECM P0116 Engine Coolant Temp Circuit e Engine coolant temp sensor DI 41 Range Performance Problem e Cooling system Open or short in throttle position sensor circuit P0120 Throttle Pedal Position Sensor Switch 7 Ma Throttle position sensor DI 43 A Circuit Malfunction SEC attle Pedal Position Sensor2. The diagnostic system in the TOYOTA T100 fulfills various functions The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence to be output by the technician during troubleshooting Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly By using these check functions the problem areas can be narrowed down quickly and troubleshooting can be performed effectively Diagnostic functions are incorporated in the following systems in the TOYOTA T100 Bod agnostic Trouble Input Signal Check Other Diagnosis stem y Code Check Sensor Check Function Di Engine SRZ FE 5VZ FE O with Test Mode Automatic Transmission with Test Mode Anti Lock Brake system supplemental Restraint System Cruise Control Cancel Signal Check In diagnostic trouble code check it is very important to determine whether the problem indicated by the diag nostic trouble code is still occurring or occurred in the past but returned to normal at present In addition it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not For this reason the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions as shown in
3. abnormal use it to determine whether 27 Ignition Switch START 27 Ignition Switch ACC the problem is located in the sensors actuators wire harness or ECU INSPECTION PROCEDURE Y 1 Check continuity between terminal of ECM connector and body ground Y LOCK PREPARATION a Remove the glove compartment See page SF 37 b Disconnect the E6 connector of ECM CHECK Measure resistance between terminal KNK of ECM connector and body ground OK Resistance 1 MO or higher D AEA E6 Connector AB0117 A00265 A00255 Go to step 3 Check knock sensor See page SF 34 Replace knock sensor B e Indicates the place to check the voltage or resistance e Indicates the connector position to checked from the front or back side Y E Check from the connector back side with harness Gg Check from the connector front side without harness Wire Harness e Indicates the condition of the connector of ECU during the check gop MEDERE ERTEN imt EE E6 Connector E6 Connector Connector being checked is connected Connector being checked is disconnected In this case care must be taken not to bend the terminals V08425 1996 TOYOTA T100 RM449U IN 26 INTRODUCTION HOW TO TROUBLE
4. all specifications for bolt tightening torques Always use a torque wrench _ Use of special service tools SST and special service ma terials SSM may be required depending on the nature of the repair Be sure to use SST and SSM where speci fied and follow the proper work procedure A list of SST and SSM can be found in the preparation part at the front of each section in this manual C nent Fuse When replacing fuses be sure the new fuse nas the cor Equal Amperage Rating rect amperage rating DO NOT exceed the rating or use TUS one with a lower rating 70 FUSE FUSE INO365 ERO MEDIUM CURRENT FUSE M FUSE INO366 oe Ao HIGH CURRENT FUSE H FUSE BE5596 INO367 ro FUSIBLE LINK FL BE5597 INO367 Axl CIRCUIT BREAKER CB BE5598 INO368 V00076 1996 TOYOTA T100 RM449U Author Date 5 INTRODUCTION REPAIR INSTRUCTIONS k must be taken when jacking up and supporting the vehicle Be sure to lift and support the vehicle at the prop er locations See page IN 8 1 Ifthe vehicle is to be jacked up only at the front or rear end be sure to block the wheels at the opposite end in order to ensure safety 2 After the vehicle is jacked up be sure to support it on stands It is extremely dangerous to do any work on a vehicle raised on a jack alone even for a small job that can be finished quickly Observe the following precautions to avoid damage to the following part
5. carry out the symptom simulation test judging whether the circuit being tested is defective or normal and also confirming the problem symp toms at the same time Refer to the matrix chart of problem symptoms for each system to narrow down the possible causes of the symptom m VIBRATION METHOD When vibration seems to be the major cause CONNECTORS olightly shake the connector vertically and horizontally WIRE HARNESS Slightly shake the wire harness vertically and horizontally The connector joint fulcrum of the vibration and body through portion are the major areas to be checked thorough ly PARTS AND SENSOR Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check if the malfunction occurs HINT Applying strong vibration to relays may result in open relays V07268 1996 TOYOTA T100 RM449U INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED IN 21 SYSTEMS I HEAT METHOD When the problem seems to occur when the suspect area is heated Heat the component that is the likely cause of the malfunction with a hair dryer or similar object Check to see if the malfunction occurs NOTICE 1 Do not heat to more than 60 140 F Temperature is limited not to damage the components 2 Do not apply heat directly to parts in the ECU WATER SPRINKLING METHOD When the malfunction seems to occur on a rainy day or ina high humidity condition Sprinkle water onto
6. the following items carefully then follow the cor rect procedure described in this manual GENERAL NOTICE 1 Malfunction symptoms of the supplemental re straint system are difficult to confirm so the diag nostic trouble codes become the most important source of information when troubleshooting When troubleshooting the supplemental restraint system always inspect the diagnostic trouble codes before disconnecting the battery See page 01 365 2 Work must be started after 90 seconds from the time the ignition switch is turned to the posi tion and the negative terminal cable is discon nected from the battery The supplemental restraint system is equipped with a back up power source so that if work is started within 90 seconds of disconnecting the neg ative terminal cable from the battery the SRS may deploy When the negative terminal cable is discon nected from the battery memory of the clock and audio systems will be cancelled So before starting work make a record of the contents memorized by the each memory system Then when work is fin ished reset the clock and audio systems as before To avoid erasing the memory of each memory sys tem never use a back up power supply from out side the vehicle 3 Even in cases of a minor collision where the SRS does not deploy the steering wheel pad should be inspected See page RS 9 Author Date 9 IN 10 1996 TOYOTA T100 RM449U INTROD
7. the owner to do Items and procedures for general maintenance are as follows 1 GENERAL NOTES Maintenance items may vary from country to country Check the owner s manual supplement in which the maintenance schedule is shown Every service item in the periodic maintenance schedule must be performed Periodic maintenance service must be performed according to whichever interval in the periodic main tenance schedule occurs first the odometer reading miles or the time interval months Maintenance service after the last period should be performed at the same interval as before unless otherwise noted Failure to do even one item can cause the engine to run poorly and increase exhaust emissions LIGHTS Check that the headlights stop lights taillights turn signal lights and other lights are all working Check the headlight aim WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly 4 HORN Check that it is working 5 WINDSHIELD GLASS Check for scratches pits or abrasions 6 WINDSHIELD WIPER AND WASHER a Check operation of the wipers and washer b Check that the wipers do not streak 7 WINDSHIELD DEFROSTER Check that air comes out from the defroster outlet when operating the heater or air conditioner 8 REAR VIEW MIRROR Check that it is mounted securely 9 SUN VISORS Check that they move freely and are mounted securely 10 STEERING WHEEL Check that it has t
8. these items when the engine is cold 1 5VZ FE ENGINE REPLACE TIMING BELT See page EM 11 2 INSPECT DRIVE BELTS GENERATOR SRZ FE See page CH 2 5VZ FE See page CH 1 PS SRZ FE See page SR 3 5VZ FE See page SR 3 A C SRZ FE See page AC 14 5VZ FE See page AC 14 3 REPLACE SPARK PLUGS SRZ FE See page IG 1 5VZ FE See page IG 1 4 INSPECT AIR FILTER a Visually check that the air cleaner element is not exces sively dirty damaged or oily HINT Oiliness may indicate a stuck PCV valve If necessary replace the air cleaner element MA004 03 b Clean the element with compressed air First blow from back side thoroughly then blow off the front side of the element 5 REPLACE AIR FILTER Replace the used air cleaner element with a new one 6 REPLACE ENGINE OIL AND OIL FILTER SRZ FE See page LU 3 5VZ FE See page LU 3 7 REPLACE ENGINE COOLANT SRZ FE See page CO 2 5VZ FE See page CO 2 8 CALIFORNIA MASSACHUSETTS MAIN VERMONT RHODE ISLAND and NEW HAMPSHIRE INSPECT CHARCOAL CANISTER SRZ FE See page EC 5 5VZ FE See page EC 5 9 REPLACE GASKET IN FUEL TANK CAP SRZ FE See page EC 5 5VZ FE See page EC 5 1996 TOYOTA T100 RM449U Author Date 40 6 1996 TOYOTA T100 RM449U MAINTENANCE ENGINE 10 INSPECT FUEL LINES AND CONNECTIONS Visually inspect the fuel lines for cracks leakage loose connec tions deformation or tank band looseness 11 INSPECT EXHA
9. wheel pad where the ambient temperature remains below 93 C 200 F without high humidity and away from electrical noise 5 When using electric welding first disconnect the air bag connector yellow color and 2 pins under the steering column near the combination switch con nector before starting work 6 When disposing of a vehicle or the steering wheel pad alone the airbag should be deployed using an SST before disposal See page RS 11 Carry out the operation in a safe place away from electrical noise Correct Example N01550 Example RO5643 RO6GS53 R06952 1996 TOYOTA T100 RM449U Author Date 12 2 IN 13 INTRODUCTION FORALLOF VEHICLES CENTER AIRBAG SENSOR ASSEMBLY 1 Never reuse the center airbag sensor assembly in volved in a collision when the SRS has deployed 2 The connectors to the center airbag sensor assem bly should be connected or disconnected with the sensor mounted on the floor If the connectors are connected or disconnected while the center airbag sensor assembly is not mounted to the floor it could cause undesired ignition of the supplemental re straint system 3 Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK posi tion and the negative terminal cable is discon nected from the battery even if only loosening the set bolts of the center airbag sensor assembly 9 WIRE HARNESS AND CONNECTOR The SRS wire harn
10. 1996 100 Factory Service Manual INDEX Introduction Maintenance Preparation Service Specifications Diagnostics Engine Mechanical SRZ FE Engine Mechanical 5VZ FE Emissions Control 3RZ FE Emissions Control 5VZ FE MFI System SRZ FE SFI System 5VZ FE Cooling 3RZ FE Cooling 5VZ FE Lubrication 3RZ FE Lubrication 5VZ FE Ignition 83RZ FE Ignition 5VZ FE Starting 3RZ FE Starting 5VZ FE Charging SRZ FE Charging 5VZ FE Clutch Manual Transmission R150 R150F Manual Transmission W59 Automatic Transmission Transfer Propeller Shaft Suspension and Axle Brake Steering Supplemental Restraint System Body Electrical Body Air Conditioning IN INTRODUCTION HOW TO USE THIS MANUAL IDENTIFICATION INFORMATION REPAIR INSTRUCTIONS FOR ALL OF VEHICLES HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS TERMS IN 1 IN 3 IN 4 IN 9 IN 15 IN 31 INTRODUCTION HOWTO USE THIS MANUAL HOW TO USE THIS MANUAL GENERAL INFORMATION 1 INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired To assist you in finding your way through the manual the Section Title and major heading are given at the top of every page 2 PRECAUTION At the beginning of each section a PRECAUTION is given that pertains to all repair operations contained in that section Read these precautions before starting any repair task 3 TROUBLESHOOTING TR
11. IMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring In such cases a thorough customer problem analysis must be carried out then simulate the same or similar conditions and environment in which the problem occurred in the customer s vehicle No matter how much experience a technician has or how skilled he may be if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere which will only lead to a standstill For example for a problem which only occurs when the en gine is cold or for a problem which occurs due to vibration caused by the road during driving etc the prob lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill Since vibration heat or water penetration moisture is likely cause for problem which is difficult to reproduce the symptom simulation tests introduced here are effective measures in that the ex ternal causes are applied to the vehicle in a stopped condition Important Points in the Symptom Simulation Test In the symptom simulation test the problem symptoms should of course be confirmed but the problem area or parts must also be found out To do this narrow down the possible problem circuits according to the symp toms before starting this test and connect a tester beforehand After that
12. M449U mim Im zZ IN 34 INTRODUCTION TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor HO2S Idle Air Control Idle Speed Control ISC Intake Air Temperature Intake or Inlet Air Temperature nion Contro Module ee Indirect Fuel Injection Indirect Injection IF I inertia Fuel Shutof pi dle Speed Contro Mass Air Flow Air Flow Meter MAF Manifold Pressure MAP Manifold Absolute Pressure Intake Vacuum Electric Bleed Air Control Valve EBCV MC Mixture Control Mixture Control Valve MCV Electric Air Control Valve EACV MDP Manifold Diferential Pressure MST Manifold Surface Temperature o m gt __ Manifold Vacuum Zone m EE O O O ST VZ OP Opniop 0 00 ParkiNeutral Position PROM PrgammaleReadOnyMemoy PSP PowerSteering Pressure ________ o Diesel Particulate Filter DPF Diesel Particulate Trap DPT Relay Module 00 NEN SCB Supercharger Bypass ________ m co Remi Throttle Body Throttle Body Single Point Injection Central Fuel Injection Ci Turbocharger Turbocharger Torque Converter Clutch Torque Converter 1996 TOYOTA T100 RM449U Throttle Body Fuel Injection IN 35 INTRODUCTION TERMS TCM Transmission Control Module Transmission ECU Electronic Control Unit Throttle Position Throttle Position TR Transmission Range ooo om TVV Th IV Val Bimetallic Vacuum Switching Valve BV
13. NIT The UNITS given in this manual are primarily expressed according to the SI UNIT International System of Unit and alternately expressed in the metric system and in the English System Example Torque 30 N m 310 kgf cm 22 ft Ibf 1996 TOYOTA T100 RM449U Author Date 2 INTRODUCTION IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER 1 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label as shown in the illustration A Vehicle Identification Number Plate B Certification Label 2 ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown in the illustration INO155 1996 TOYOTA T100 RM449U Author Date 3 INTRODUCTION REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS GENERAL INFORMATION BASIC REPAIR HINT a Use fender seat and floor covers to keep the vehicle clean and prevent damage b During disassembly keep parts in the appropriate order to facilitate reassembly c Observe the following operations 1 Before performing electrical work disconnect the negative terminal cable from the battery 2 If it is necessary to disconnect the battery for in spection or repair always disconnect the negative terminal cable which is grounded to the vehicle body 3 To prevent damage to the battery terminal loose
14. NSMISSION PARK MECHANISM Check the lock release button of the selector lever for proper and smooth operation On a safe incline check that the vehicle is held securely with the selector lever in P position and all brakes released 1996 TOYOTA T100 RM449U Author Date 38 4 MAINTENANCE UNDERHOOD UNDER HOOD GENERAL MAINTENANCE 1 GENERAL NOTES Maintenance items may vary from country to country Check the owner s manual supplement in which the maintenance schedule is shown Every service item in the periodic maintenance schedule must be performed Periodic maintenance service must be performed according to whichever interval in the periodic main tenance schedule occurs first the odometer reading miles or the time interval months Maintenance service after the last period should be performed at the same interval as before unless otherwise noted Failure to do even one item can cause the engine to run poorly and increase exhaust emissions 2 WINDSHIELD WASHER FLUID Check that there is sufficient fluid in the tank 3 ENGINE COOLANT LEVEL Check that the coolant level is between the FULL and LOW lines on the see through reservoir 4 RADIATOR AND HOSES a Check that the front of the radiator is clean and not blocked with leaves dirt or bugs b Check the hoses for cracks kinks rot or loose connections 5 BATTERY ELECTROLYTE LEVEL Check that the electrolyte level of all battery cells is between the up
15. OUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause The fundamentals of how to proceed with troubleshooting are described on page IN 16 Be sure to read this before performing troubleshooting 4 PREPARATION Preparation lists the SST Special Service Tools recommended tools equipment lubricant and SSM Spe cial Service Materials which should be prepared before beginning the operation and explains the purpose of each one 5 REPAIR PROCEDURES Most repair operations begin with an overview illustration It identifies the components and shows how the parts fit together Example D Filler Cap Float Clevis Pin Gasket Clip Reservoir Tank Boot S P j IN02D 02 5 Grommet Slotted Spring Pi y 12 120 9 15 155 11 e Clevis QV Ring Washer Lock Nut Push Rod Piston Cylinder N m kgf cm ft Ibf Specified torque Non reusable part 1996 TOYOTA T100 RM449U Author Date 1 IN 2 INTRODUCTION HOW TO USE THIS MANUAL The procedures are presented in a step by step format e illustration shows what to do and where to do it e task heading tells what to do e detailed text tells how to perform the task and gives other information such as specifications and warnings Example Task heading what do 21 CHECK PISTON STROKE OF OVERDRIVE BRAKE a Place SST and a dial indicator onto the ov
16. REPAIR INSTRUCTIONS n Unless otherwise stated all resistance is measured at an ambient temperature of 20 C 68 F Because the resis tance may be outside specifications if measured at high temperatures immediately after the vehicle has been run ning measurement should be made when the engine has cooled down Author Date 7 IN 8 INTRODUCTION REPAIR INSTRUCTIONS VEHICLE LIFT AND SUPPORT LOCATIONS INO2G 02 2WD La em d AWD JACK POSITION cece cee RR RR n n amp Front f Center of crossmember Reap Under the rear differential SUPPORT POSITION Safety stand a er ee ee ee ee ee ae ae ee a ee ae ee ee eee or NE B01123 1996 TOYOTA T100 RM449U 1996 TOYOTA T100 RM449U INTRODUCTION FORALLOF VEHICLES FOR ALL OF VEHICLES PRECAUTION BO4111 1 INO2H 03 FOR VEHICLES EQUIPPED WITH SRS AIRBAG The TOYOTA T100 is equipped with an SRS Supple mental Restraint System such as the driver airbag Failure to carry out service operations in the correct se quence could cause the supplemental restraint system to unexpectedly deploy during servicing possibly leading to a serious accident Further if a mistake is made in servicing the supplemental restraint system it is possible the SRS may fail to operate when required Before servicing including removal or installation of parts inspection or replacement be sure to read
17. SHOOT ECU CONTROLLED SYSTEMS INO2K 03 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1 CONNECTOR CONNECTION AND TERMINAL IN SPECTION For troubleshooting diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures on the following pages e When all the component parts wire harnesses and con nectors of each circuit except the ECU are found to be normal in troubleshooting then it is determined that the problem is in the ECU Accordingly if diagnosis is per formed without the problem symptoms occurring refer to step 8 to replace the ECU even if the problem is not in the ECU So always confirm that the problem symptoms are occurring or proceed with inspection while using the symptom simulation method e instructions Check wire harness and connector and Check and replace ECU which appear in the inspection procedure are common and applicable to all diagnostic trouble codes Follow the procedure outlined below whenever these instructions appear OPEN CIRCUIT This could be due to and a disconnected wire harness faulty contact in the connector a connector terminal pulled out etc HINT It is rarely the case that a wire is broken in the middle of it Most cases occur at the connector In particular care fully check the connectors of sensors and actuators Faulty contact could be due to rusting of the connector terminals to foreig
18. SV ermal Vacuum Valve x Thermostatic Vacuum Switching Valve TVSV Three Way Catalytic TWC TWC OC Three Way Oxidation Catalytic Converter CCo Volume Air Flow Air Flow Meter Three Way Catalytic Converter Vehicle Speed Sensor Vehicle Speed Sensor Read Switch Type wor woos 1 4GR 1996 TOYOTA T100 RM449U MAINTENANCE OUTSIDE VEHICLE INSIDE VEHICLE UNDER HOOD ENGINE BRAKE CHASSIS 1 MAINTENANCE OUTSIDE VEHICLE OUTSIDE VEHICLE GENERAL MAINTENANCE The owners are responsible for these maintenance and inspection items They can be done by the owner or they can have them done at a service shop These items include those which should be checked on a daily basis those which in most cases do not require Special tools and those which are considered to be reasonable for the owner to do ltems and procedures for general maintenance are as follows 1 GENERAL NOTES Maintenance items may vary from country to country Check the owner s manual supplement in which the maintenance schedule is shown Every service item in the periodic maintenance schedule must be performed Periodic maintenance service must be performed according to whichever interval in the periodic main tenance schedule occurs first the odometer reading miles or the time interval months Maintenance service after the last period should be performed at the same interval as be
19. Switch age Performance Throttle position sensor at Temp for Closed 1996 TOYOTA T100 RM449U e Open or short in heated oxygen sensor cirg e Heated oxygen sensor INTRODUCTION HOWTO TROUBLESHOOT ECU CONTROLLED IN 23 SYSTEMS 5 PROBLEM SYMPTOMS TABLE The suspect circuits or parts for each problem symptom are shown in the table below Use this table to trou bleshoot the problem when a Normal code is displayed in the diagnostic trouble code check but the prob lem is still occurring Numbers in the table indicate the inspection order in which the circuits or parts should be checked HINT When the problem is not detected by the diagnostic system even though the problem symptom is present it is considered that the problem is occurring outside the detection range of the diagnostic system or that the problem is occurring in a system other than the diagnostic system e Page Indicates the page where the flow chart for each circuit is located e Circuit Inspection Inspection Order Indicates the circuit which needs to be checked for each problem symptom Check in the order indicated by the numbers e Problem Symptom PROBLEM SYMPTOMS TABL Symptom Suspect Area See page Engine does not crank Does not start 1 Starter and starter relay ST 2 ST 17 ECM power source circuit DI 101 No initial combustion Does not start 2 Fuel pump control circuit DI 104 3 Engine control m
20. UCTION FOR ALL OF VEHICLES Never use SRS parts from another vehicle When replacing parts replace them with new parts Before repairs remove the center airbag sensor if shocks are likely to be applied to the sensor during repairs Never disassemble and repair the center airbag sensor assembly steering wheel pad in order to re use it 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 Do not expose the center airbag sensor assembly steering wheel pad directly to hot air or flames Use a volt ohmmeter with high impedance 10 minimum for troubleshooting of the electrical cir cuit Information labels are attached to the periphery of the SRS components Follow the instructions on the notices After work on the supplemental restraint system is completed check the SRS warning light See page DI 365 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 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 The front airbag sensor is equipped with an electri cal connection
21. UST PIPES AND MOUNTINGS Visually inspect the pipes hangers and connections for severe corrosion leaks or damage 12 ADJUST VALVE CLEARANCE SRZ FE See page EM 5 5VZ FE See page EM 4 Author Date 41
22. ance with SAE rec ommendations as well as their Toyota equivalents SAE SAE TERMS TOYOTA TERMS ABBREVIATIONS ABBREVIATIONS Air Conditioning Air Conditioner Battery Positive Voltage B Battery Voltage BARO BarometrioPressure _________ o CAC Intercooler CARB Carburetor Crank Angle Closed Loop M Cam Angle OPP K r U Ul CTOX Continuous Trap Oxidizer CTP Closed Throttle Position DFI Direct Fuel Injection Diesel Direct Injection DI Distributor Ignition DLC1 Data Link Connector 1 1 Check Connector DLC2 Data Link Connector 2 2 Total Diagnosis Comunication Link TDCL Data Link Connector 3 3 OBD II Diagnostic Connector Diagnostic Code EOL ECM Engine ECU Electronic Control Unit Coolant Temperature Water Temperature THW Electrically Erasable Programmable Read Only Memory EEPROM Electrically Erasable Programmable Read Only Memory EEPROM m Erasable Programmable Read Only Memory EPROM Cold Mixture Heater CMH Heat Control Valve HCV EGR Exhaust Gas Recirculation EGR Distributorless Ignition DI Engine Modification EM m TI m lt EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory PROM EVAP Evaporative Emission Control EVAP Flash Electrically Erasable Programmable FEEPROM Read Only Memory FEPROM Fuel Pump Alternator GND Ground GND 1996 TOYOTA T100 R
23. and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting A customer problem analysis table is provided in the troubleshooting section for each system for your use Important Points in the Customer Problem Analysis e What Vehicle model system name e When Date time occurrence frequency e Where Road conditions e Under what conditions Running conditions driving conditions weather conditions e How did it happen Problem symptoms Sample Engine control system check sheet CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Data Vehicle 1 le Engine does not crank No initial combustion No complete combustion Difficult to L Engine cranks slowly Start Other Incorrect first idle Idling rpm is abnormal L High rpm LiLow rpm L Rough idling Other License No Poor Idling O Poor Hesitation Back fire Muffler explosion after fire Surging Drive ability g Knocking Other Soon after starting After accelerator pedal depressed Engine Stall After accelerator pedal released During A C operation O Shifting from N to D Other o E E z o E Q us 1996 TOYOTA T100 RM449U IN 18 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK
24. check mechanism Be sure to lock this mechanism securely when connecting the con nector If connector is not securely locked a malfunction code will be the diagnosis system See page RS 2 Author Date 10 Red Mark 1996 TOYOTA T100 RM449U IN 11 INTRODUCTION FORALLOF VEHICLES SPIRAL CABLE in Combination Switch The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position other wise cable disconnection and other troubles may result Refer to SR 33 of this manual concerning correct steer ing wheel installation Author Date 11 IN 12 INTRODUCTION FORALL OF VEHICLES e STEERING WHEEL PAD with Airbag 1 When removing the steering wheel pad or handling a new steering wheel pad it should be placed with the pad top surface facing up In this case the twin lock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be dam aged In addition do not store a steering wheel pad on top of another one Storing the pad withits metal lic surface facing upward may lead to a serious acci dent if the airbag inflates for some reason 2 Never measure the resistance of the airbag squib This may cause the airbag to deploy which is very dangerous 3 Grease should not be applied to the steering wheel pad and the pad should not be cleaned with deter gents of any kind 4 Store the steering
25. erdrive brake piston as shown in the illustration SST 09350 30020 09350 06120 Illustration what where Set part No Component part No Detailed text howto do task b Measure the stroke applying and releasing the compressed air 392 785 kPa 4 8 kgf cm or 57 114 psi as shown in the illustration Piston stroke 1 40 1 70 mm 0 0551 0 0669 in Specification This format provides the experienced technician with a FAST TRACK to the information needed The upper case task heading can be read at a glance when necessary and the text below it provides detailed informa tion Important specifications and warnings always stand out in bold type 6 REFERENCES References have been kept to a minimum However when they are required you are given the page to refer to 7T SPECIFICATIONS Specifications are presented in bold type throughout the text where needed You never have to leave the procedure to look up your specifications They are also found in Service Specifications section for quick ref erence 8 CAUTIONS NOTICES HINTS CAUTIONS are presented in bold type and indicate there is a possibility of injury to you or other people e NOTICES are also presented in bold type and indicate the possibility of damage to the components being repaired HINTS are separated from the text but do not appear in bold They provide additional information to help you perform the repair efficiently 9 SI U
26. ess is integrated with the cowl wire har ness assembly and floor wire harness assembly The wires for the SRS wire harness are encased in a yellow corrugated tube All the connectors for the system are also a standard yellow color If the SRS wire harness be comes disconnected or the connector becomes broken due to an accident etc repair or replace it FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION If large amount of unburned gasoline flows into the converter it may overheat and create a fire haz ard To prevent this observe the following precautions and explain them to your customer b Use only unleaded gasoline Avoid prolonged idling Avoid running the engine at idle speed for more than 20 minutes Avoid spark jump test 1 Perform spark jump test only when absolutely necessary Perform this test as rapidly as possible 2 While testing never race the engine Avoid prolonged engine compression measurement Engine compression tests must be done as rapidly as possible Do not run engine when fuel tank is nearly empty This may cause the engine to misfire and create an extra load on the converter Avoid coasting with ignition turned off and prolonged braking Do not dispose of used catalyst along with parts contaminated with gasoline or oil 1996 TOYOTA T100 RM449U Author Date 13 IN 14 INTRODUCTION FORALLOF VEHICLES 3 IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles
27. fore unless otherwise noted Failure to do even one item can cause the engine to run poorly and increase exhaust emissions 2 TIRES a Check the pressure with a gauge If necessary adjust b Check for cuts damage or excessive wear 3 WHEEL NUTS When checking the tires check the nuts for looseness or for missing nuts If necessary tighten them 4 TIRE ROTATION Check the owner s manual supplement in which the maintenance schedule is shown 5 WINDSHIELD WIPER BLADES Check for wear or cracks whenever they do not wipe clean If necessary replace 6 FLUID LEAKS a Check underneath for leaking fuel oil water or other fluid b If you smell gasoline fumes or notice any leak have the cause found and corrected 7 DOORS AND ENGINE HOOD a Check that all doors and the tailgate operate smoothly and that all latches lock securely b Check that the engine hood secondary latch secures the hood from opening when the primary latch is released MAO01 28 Nee 1996 TOYOTA T100 RM449U Author Date 36 2 MAINTENANCE INSIDE VEHICLE INSIDE VEHICLE GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner s responsibility They can be done by the owner or they can have them done at a service shop These items include those which should be checked on a daily basis those which in most cases do not require special tools and those which are considered to be reasonable for
28. he specified freeplay Be alert for changes in steering condition such as hard steering excessive freeplay or strange noises 11 SEATS a Check that the seat adjusters operate smoothly b Check that all latches lock securely in any position c Check that the head restraints move up and down smoothly and that the locks hold securely in any latch position d For fold down seat backs check that the latches lock securely 12 SEAT BELTS a Check that the seat belt system such as the buckles retractors and anchors operate properly and smoothly b Check that the belt webbing is not cut frayed worn or damaged MA002 05 1996 TOYOTA T100 RM449U Author Date 37 13 MA 3 MAINTENANCE INSIDE VEHICLE ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching 14 5 20 At CLUTCH PEDAL See page CL 2 Check the pedal for smooth operation Check that the pedal has the proper freeplay BRAKE PEDAL See page BR 6 Check the pedal for smooth operation Check that the pedal has the proper reserve distance and freeplay Check the brake booster function BRAKES a safe place check that the brakes do not pull to one side when applied 17 PARKING BRAKE See page BR 8 Check that the lever has the proper travel On a safe incline check that the vehicle is held securely with only the parking brake applied AUTOMATIC TRA
29. hoot ing using the diagnostic trouble code check is shown below This flow chart shows how to utilize the diagnos tic trouble code check effectively then by carefully checking the results indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms Diagnostic trouble code check Making a note of and clearing of the diagnostic trouble codes displayed oymptom confirmation exist exist lt 7 Simulation test using the symptom simulation methods Diagnostic trouble code check Diagnostic trouble code displayed Normal code displayed Normal code displayed Problem symptoms exist Problem symptoms exist No problem symptoms exist Troubleshooting of problem indicated Troubleshooting of each system Normal Py Slane Ste OUDS code eee If a diagnostic trouble code was displayed in the initial diagnostic trouble code check it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past Therefore check the wire harness and con nectors See page IN 26 1996 TOYOTA T100 RM449U IN 20 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 3 SYMPTOM S
30. is designed through emphasis of the above standpoint to help service technicians perform ac curate and effective troubleshooting and is compiled for the following major ECU controlled systems ZE 5 Supplemental Restraint System DI 363 6 Cruise Control DI 408 The troubleshooting procedure and how to make use of it are described on the above pages 1996 TOYOTA T100 RM449U Author Date 15 IN 16 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS INO2J 03 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page Here only the basic pro cedure is shown Details are provided in each section showing the most effective methods for each circuit Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit Vehicle Brought Workshop d Customer Problem Analysis 1 Ask the customer about the conditions and the environment when the problem occurred 2 Symptom Confirmation 3 and Diagnostic Trouble Symptom Code Check Simulation 2 3 Confirm the symptoms and the problem conditions and check the diagnostic trouble codes When the problem symptoms do not appear during confirmation use the symptom simulation method described later on 4 Diag
31. isconnect the connectors on both ends Measure the resistance between the applicable terminals of the connectors and body ground Be sure to carry out this check on the connectors on both ends Resistance 1 MO or higher HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally 4 VISUAL CHECK AND CONTACT PRESSURE CHECK a Disconnect the connectors at both ends b Check for rust or foreign material etc in the terminals of the connectors Pull Lightly c Check crimped portions for looseness or damage and Looseness of Crimping check if the terminals are secured in lock portion HINT Es The terminals should not come out when pulled lightly d Prepare atest male terminal and insert it in the female ter minal then pull it out NOTICE When testing a gold plated female terminal always use a gold plated male terminal HINT When the test terminal is pulled out more easily than others there may be poor contact in that section 1996 TOYOTA T100 RM449U IN 28 Fig 1 Q OPEN B 1 i 4 X Sensor BE4063 BE4064 1996 TOYOTA T100 RM449U cel INTRODUCTION FI7187 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 5 CONNECTOR HANDLING When inserting tester probes into a connector insert them from the rear of the connector When necessary use mini test leads For water resistant connectors which cannot be accessed from behind take g
32. knocking occurs ignition timing is retarded to suppress it DTC No DTC Detecting Condition Trouble Area e Open or short in knoCk sensor1 circuit No knock sensor 1 signal to ECM with engine speed P0325 e Knock sensor 1 looseness e ECM 1 200 rpm or more If the ECM detects the above diagnosis conditions it operates the fall safe function in which the corrective retard angle value is set to the maximum value e Indicates the diagnostic trouble code diagnostic trouble code set parameter and suspect area of the problem WIRING DIAGRAM e Wiring Diagram This shows a wring diagram of the circuit Use the diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit Wiring colors are indicated by an alphabetical code Black L Blue R Red BR Brown LG Light Green V Violet Green Orange W White GR Gray P Pink Y Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe Knock Sensor 1 V08423 1996 TOYOTA T100 RM449U INTRODUCTION SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED IN 25 e Indicates the position of the ignition switch during the check LOCK ON amp Ignition Switch LOCK OFF 2 Ignition Switch ON START ACC Inspection Procedure Use the inspection procedure to determine if the circuit is normal or abnormal and if it is
33. n the cable nut and raise the cable straight up without twisting or prying it 4 Clean the battery terminals and cable ends with a clean shop rag Do not scrape them with a file or oth er abrasive objects 5 Install the cable ends to the battery terminals with the nut loose and tighten the nut after installation Do not use a hammer to tap the cable ends onto the terminals 6 Be sure the cover for the positive terminal is properly in place d Check hose and wiring connectors to make sure that they are secure and correct e Non reusable parts 1 Always replace cotter pins gaskets O rings and oil seals etc with new ones 2 Non reusable parts are indicated in the component illustrations by the symbol INOIL 01 f Precoated parts Precoated parts are bolts and nuts etc that are coated with a seal lock adhesive at the factory 1 lf a precoated part is retightened loosened or caused to move in any way it must be recoated with the specified adhesive Seal Lock Adhesive 2 When reusing precoated parts clean off the old adhesive and dry with compressed air Then apply the specified seal lock adhesive to the bolt nut or threads 1996 TOYOTA T100 RM449U Author Date 4 IN 5 INTRODUCTION REPAIR INSTRUCTIONS 3 Precoated parts are indicated in the component il lustrations by the X symbol g When necessary use a sealer on gaskets to prevent leaks h Carefully observe
34. n materials entering terminals or a de formation of connector terminals between the male and female terminals of the connector Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation Therefore in troubleshooting if no ab normality is found in the wire harness and connector check but the problem disappears after the check then the cause is considered to be in the wire harness or con nectors SHORT CIRCUIT This could be due to a connect between the wire harness and the body ground or to a short occurred inside the switch etc HINT When there is a short circuit between the wire harness and body ground check thoroughly whether the wire harness is caught in the body or is clamped properly 1996 TOYOTA T100 RM449U INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED IN 27 SYSTEMS Sensor Side CONTINUITY CHECK OPEN CIRCUIT CHECK Disconnect the connectors at both ECU and sensor sides Measure the resistance between the applicable terminals of the connectors Measure the resistance while lightly shaking the wire har ness vertically and horizontally When tester probes are inserted into a connector insert the probes from the back For waterproof connectors in which the probes cannot be inserted from the back be 0 n careful not to bend the terminals when inserting the tester probes mA RESISTANCE CHECK SHORT CIRCUIT CHECK D
35. nd out that there is a short circuit between terminal 1 of connector B2 and terminal 1 of connector C 8 CHECK AND REPLACE ECU First check the ECU ground circuit If it is faulty repair it If it is normal the ECU could be faulty so replace the ECU with a nor mal functioning one and check that the symptoms appear Example zn 1 Measure the resistance between the ECU ground TERRY terminal and the body ground Resistance 1 or less 2 Disconnect the ECU connector check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure W H Side Ground 1996 TOYOTA T100 RM449U IN 31 INTRODUCTION TERMS TERMS ABBREVIATIONS USED IN THIS MANUAL Anti Lock Brake System Automatic Disconnecting Differential Automatic Transmission Fluid California Differential Locking System oe ash ECU Electronic Control Unit INO2L 01 FPU Long Life Coolant Year Around Coolant Vin POV 106 1996 TOYOTA T100 RM449U Author Date 31 IN 32 INTRODUCTION TERMS T M Transmission Vacuum Control Valve Vacuum Switching Valve Vacuum Transmitting Valve 2WD Two Wheel Drive Vehicles 4x2 4WD Four Wheel Drive Vehicles 2x2 1996 TOYOTA T100 RM449U Author Date 32 IN 33 INTRODUCTION TERMS INO2M 01 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE J1930 terms and abbreviations used in this manual in compli
36. nostic Trouble Code Chart Matrix Chart of Problem Symptoms 6 Circuit Inspection or Parts Inspection Repair Confirmation Test End 1996 TOYOTA T100 RM449U 4 5 6 Check the results obtained in Step 2 then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the matrix chart of problem symptoms T Check and repair the affected system or part in accordance with the instructions in Step 6 8 After completing repairs confirm that the problem has been eliminated If the problem is not reproduced perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time INTRODUCTION HOWTO TROUBLESHOOT ECU CONTROLLED IN 17 SYSTEMS 1 CUSTOMER PROBLEM ANALYSIS In troubleshooting the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgement To ascertain just what the problem symptoms are it is extremely important to ask the customer about the problem and the conditions at the time it occurred Important Point in the Problem Analysis The following 5 items are important points in the problem analysis Past problems which are thought to be unrelated and the repair history etc may also help in some cases so as much information as possible should be gathered
37. odule ECM IN 28 No complete combustion Does not start 1 Fuel pump control circuit DI 104 1 Starter signal circuit DI 173 Engine cranks normally Difficult to start 2 Fuel pump control circuit DI 104 3 Compression EM 3 1 Starter signal circuit DI 178 Difficult to start Inque erste 2 Fuel pump control circuit DI 104 1 Starter signal circuit DI 173 Hot engine HM 2 Fuel pump control circuit DI 104 A C signal circuit Compressor circuit AC 85 High engine idle speed Poor idling ing 1996 TOYOTA T100 RM449U N N Circuit or Part Indicates the circuit or part which needs to be checked ECM power source circuit A C signal circuit Fuel pump control circuit Compression Fuel pump control circuit IN 24 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 6 CIRCUIT INSPECTION How to read and use each page is shown below Diagnostic Trouble Code No and Detection Circuit Description The major role and operation etc of the circuit and its component parts are explained Y DTC P0325 Knock Sensor 1 Circuit Malfunction CIRCUIT DESCRIPTION y Knock sensor is fitted to the cylinder block to detect engine knocking This sensor contains a piezoelectric element which generates a voltage when it becomes deformed which occurs when the cylinder block vibrates due to knocking If engine
38. ood care not to deform the connector terminals 6 CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig 1 perform a Continuity Check or b Voltage Check to locate the section a Check the continuity 1 Disconnect connectors A and C and measure the resistance between them In the case of Fig 2 Between terminal 1 of connector A and terminal 1 of connector C No continuity open Between terminal 2 of connector A and terminal 2 of connector C Continuity Therefore it is found out that there is an open circuit between terminal 1 of connector A and terminal 1 of connector C Disconnect connector B and measure the resis tance between the connectors In the case of Fig 3 Between terminal 1 of connector A and terminal 1 of connector B1 Continuity Between terminal 1 of connector B2 and terminal 1 of connector C No continuity open Therefore it is found out that there is an open circuit between terminal 1 of connector B2 and terminal 1 of connector C INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED IN 29 SYSTEMS b Check the voltage In a circuit in which voltage is applied to the ECU connec tor terminal an open circuit can be checked for by con ducting a voltage check As shown in Fig 4 with each connector still connected measure the voltage between body ground and terminal 1 of connector A at the ECU 5V output terminal terminal 1 1 of connec
39. per and lower level lines on the case 6 BRAKE AND CLUTCH FLUID LEVELS Check that the brake and clutch fluid levels are near the upper level line on the see through reservoirs 7 ENGINE DRIVE BELTS Check all drive belts for fraying cracks wear or oiliness 8 ENGINE OIL LEVEL Check the level on the dipstick with the engine turned off 9 POWER STEERING FLUID LEVEL a Check the level on the dipstick b The level should be in the HOT or COLD range depending on the fluid temperature 10 AUTOMATIC TRANSMISSION FLUID LEVEL a Park the vehicle on a level surface b With the engine idling and the parking brake applied shift the selector into all positions from the P to L and then shift into the P position c Pull out the dipstick and wipe off the fluid with a clean rag Re insert the dipstick and check that the fluid level is in the HOT range d Do this check with the fluid at normal driving temperature 70 80 C 158 176 HINT Wait until the engine cools down approx 30 min before checking the fluid level after extended driving at high speeds in hot weather in heavy traffic or pulling a trailer 11 EXHAUST SYSTEM a Visually inspect for cracks holes or loose supports b If any change in the sound of the exhaust or smell of the exhaust fumes is noticed have the cause located and corrected 05 1996 TOYOTA T100 RM449U Author Date 39 MA 5 MAINTENANCE ENGINE ENGINE INSPECTION HINT Inspect
40. s 1 Do not open the cover or case of the ECU ECM PCM or TCM unless absolutely necessary If the IC terminals are touched the IC may be destroyed by static electricity 2 To disconnect vacuum hoses pull off the end not the middle of the hose 3 To pull apart electrical connectors pull on the con nector itself not the wires 4 Be careful not to drop electrical components such as sensors or relays If they are dropped on a hard floor they should be replaced and not reused 5 When steam cleaning an engine protect the elec tronic components air filter and emission related components from water 6 Never use an impact wrench to remove or install temperature switches or temperature sensors 7 When checking continuity at the wire connector in sert the tester probe carefully to prevent terminals from bending 8 When using a vacuum gauge never force the hose onto a connector that is too large Use a step down adapter for adjustment Once the hose has been stretched it may leak Tag hoses before disconnecting them 1 When disconnecting vacuum hoses use tags to identify how they should be reconnected to 2 After completing a job double check that the vacu Exampl e VTV for TPa White Side um hoses are properly connected A label under the hood shows the proper layout alid Black Side 1996 TOYOTA T100 RM449U Author Date 6 1996 TOYOTA T100 RM449U IN 7 INTRODUCTION
41. the table below If this is not done it may depending on the case result in unnecessary troubleshooting for normally operating systems thus making it more difficult to locate the problem or in repairs not pertinent to the problem Therefore always follow the procedure in correct order and perform the diagnostic trouble code check DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check Make a note of and then clear Diagnostic Trouble Problem symptoms Same diagnostic Proplem is still occurring in the diagnostic Code Display exist trouble code iS circuit displayed Confirmation Diagnostic Trouble of Symptoms Code Check Problem Condition Normal code is The problem is still occurring in a place displayed other than in the diagnostic circuit The diagnostic trouble code displayed first is either for a past problem or it is a secondary problem No problem The problem occurred in the diagnostic Symptoms exist circuit in the past Normal Code Display Problem symptoms Normal code is The problem is still occurring in a place exist displayed other than in the diagnostic circuit No problem Normal code is The problem occurred in a place other symptoms exist displayed than in the diagnostic circuit in the past 1996 TOYOTA T100 RM449U INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED IN 19 SYSTEMS Taking into account the points on the previous page a flow chart showing how to proceed with troubles
42. the vehicle and check to see if the malfunc tion occurs NOTICE 1 Never sprinkle water directly into the engine compartment but indirectly change the temperature and humidity by applying water spray onto the radiator front surface 2 Never apply water directly onto the electronic components Service hint If a vehicle is subject to water leakage the leaked water may contaminate the ECU When testing a vehicle with a water leak age problem special caution must be taken Turn on all electrical loads including the heater blower head lights rear window defogger etc and check to see if the mal function occurs V07469 1996 TOYOTA T100 RM449U IN 22 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 4 DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below This table permits efficient and accurate troubleshoot ing using the diagnostic trouble codes displayed in the diagnostic trouble code check Proceed with trouble shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed The engine diagnostic trouble code chart is shown below as an example e DIC No Indicates the diagnostic trouble code Page or Instructions Indicates the page where the inspection procedure for each circuit is to be found or gives instructions for checking and repairs DTC CHART SAE Controlled Trouble Area
43. tor B and terminal 1 of connector in that If the results are 5V Between Terminal 1 of connector and Body Ground 5V Between Terminal 1 of connector B and Body Ground OV Between Terminal 1 of connector C and Body Ground Then it is found out that there is an open circuit in the wire har ness between terminal 1 of B and terminal 1 of C 7 CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig 5 locate the sec tion by conducting a continuity check with ground BE4067 Check the continuity with ground 1 Disconnect connectors A and C and measure the resistance between terminal 1 and 2 of connec tor A and body ground In the case of Fig 6 Between terminal 1 of connector A and body ground Continuity short Between terminal 2 of connector A and body BE4068 ground No continuity Therefore it is found out that there is a short circuit between terminal 1 of connector and terminal 1 of connector Sensor 1996 TOYOTA T100 RM449U IN 30 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2 Disconnect connector B and measure the resis tance between terminal 1 of connector A and body ground and terminal 1 of connector B2 and body ground Between terminal 1 of connector A and body ground No continuity Between terminal 1 of connector B2 and body ground Continuity short EAD Therefore it is fou
44. with mobile communication systems such as two way radios and cellular telephones observe the following precautions 1 Install the antenna as far as possible away from the ECU and sensors of the vehicle s electronic system 2 Install the antenna feeder at least 20 cm 7 87 in away from the ECU and sensors of the ve hicle s electronics systems For details about ECU and sensors locations refer to the section on the applicable component 3 Avoid winding the antenna feeder together with the other wiring as much as possible and also avoid running the antenna feeder parallel with other wire harnesses 4 Confirm that the antenna and feeder are correctly adjusted 5 Do not install powerful mobile communications system 1996 TOYOTA T100 RM449U Author Date 14 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED IN 15 SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION A large number of ECU controlled systems are used in the TOYOTA T100 In general the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot However the fact is that if you proceed to inspect the circuits one by one troubleshoot ing of these systems is not complex If you have adequate understanding of the system and a basic knowl edge of electricity accurate diagnosis and necessary repair can be performed to locate and fix the problem This manual
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