check engine light TOYOTA T100 1996 Factory Owners Manual

Downloaded from www.Manualslib.com manuals search engine FI7231
TOYOTA Hand−Held Tester
DLC3EM06E−05
P19970
SSTDLC1
TE1 E1
DLC1
P21121
− ENGINE MECHANICAL (5VZ−FE)IGNITION TIMING
EM−9
828 Author: Date:
1996 TOYOTA T100 (RM449U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND−HELD TESTER OR
OBDII SCAN TOOL
(a) Connect the TOYOTA hand−held tester or OBDII scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand−held tester or OBDII
scan tool operator’s manual for further details.
3. CONNECT TIMING LIGHT TO ENGINE
4. CHECK IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 se-
conds.
(b) Check the idle speed.
Idle speed:
700 ± 50 rpm
5. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the
DLC1.
SST 09843−18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
8 − 12° BTDC @ idle
(Transmission in neutral position)
(c) Remove the SST from the DLC1.
SST 09843−18020
6. FURTHER CHECK IGNITION TIMING
Ignition timing:
12.5 − 22° BTDC @ idle
(Transmission in neutral position)
HINT:
The timing mark moves in a range between
12.5° and 22°.
7. DISCONNECT TIMING LIGHT FROM ENGINE
8. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBDII SCAN TOOL

Downloaded from www.Manualslib.com manuals search engine P20820
P20826
P20834
P20836
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−21
1996 TOYOTA T100 (RM449U)
(b) RH Camshaft Position:
Turn the camshaft, align the knock pin hole of the cam-
shaft with the timing mark of the No.3 timing belt cover.
(c) LH Camshaft Pulley Position:
Turn the camshaft timing pulley, align the timing marks of
the camshaft timing pulley and No.3 timing belt cover.
9. INSTALL TIMING BELT TO LH CAMSHAFT TIMING
PULLEY
(a) HINT (When re−using timing belt):
Check that the installation mark on the timing belt
matches the end of the No.1 timing belt cover.
If the installation mark do not align, shift the meshing of the tim-
ing belt and crankshaft timing pulley until they align.
(b) Remove any oil or water on the LH camshaft timing pulley,
and keep it clean.
(c) Using SST, slightly turn the LH camshaft timing pulley
clockwise. Align the installation mark on the timing belt
with the timing mark of the camshaft timing pulley, and
hang the timing belt on the LH camshaft timing pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(d) Using SST, align the timing marks of the LH camshaft
pulley and No.3 timing belt cover.
SST 09960−10010 (09962−01000, 09963−01000)
(e) Check that the timing belt has tension between the crank-
shaft timing and LH camshaft timing pulleys.

Downloaded from www.Manualslib.com manuals search engine P20511
45° Carvide
Cutter
P12729
Width
Z11441
30°
45°
1.0 − 1.4 mm
Z00139
60°
45°
1.0 − 1.4 mm
P20513
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−43
1996 TOYOTA T100 (RM449U)
12. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats. Re-
move only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a thin coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate the valve.
(c) Check the valve face and seat for these:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with these width.
1.0 − 1.4 mm (0.039 − 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
(2) If the seating is too low on the valve face, use 60°
and 45° cutters to correct the seat.
(d) Hand−lap the valve and valve seat with an abrasive com-
pound.
(e) After hand−lapping, clean the valve and valve seat.

Downloaded from www.Manualslib.com manuals search engine P20989
P20847
SST
P20848
P12390
Seal
Packing
P20844
EM−50
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(b) Install these parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020 (09202−00010)
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to ensure a proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
4. INSTALL CAMSHAFT HOUSING PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the bearing cap as shown.
Seal packing:
Part No. 08826−00080 or equivalent
(c) Place a new housing plug in position on the cylinder head,
facing the cap side inward.
(d) Install the camshaft bearing cap with the 2 bolts.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(e) Install the cylinder head rear plate, ground strap with the
bolt and nut.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P21247
Front
RH
LH
EM1OR−01
Z14657
12 Pointed Head Bolt
Front
P21151
Painted Mark
Front
P00868
90°
90°
90°90°
Painted
Mark
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−51
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place 2 new cylinder head gaskets in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(b) Place the 2 cylinder heads in position on the cylinder head
gaskets.
2. INSTALL 12 POINTED HEAD CYLINDER HEAD BOLTS
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b), (d) and (e)).
If any bolt is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install and uniformly tighten the cylinder head bolts on
each cylinder head, in several passes, in the sequence
shown, then repeat for the other side, as shown.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts by 90° in the numerical
order shown.
(e) Retighten the cylinder head bolts by an additional 90°.
(f) Check that the painted mark is now facing rearward.

Downloaded from www.Manualslib.com manuals search engine P21158
P21162
P21159
P13274Seal Packing EM−56
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
8. Exhaust:
INSTALL CAMSHAFTS OF LH CYLINDER HEAD
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b) Align the timing marks (1 dot mark) of the camshaft drive
and driven gears.
(c) Place the exhaust camshaft on the cylinder head.
(d) Install the 4 bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under
the heads of bearing cap bolts.
(f) Install and uniformly tighten the 8 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(g) Remove the service bolt.
9. CHECK AND ADJUST VALVE CLEARANCE
10. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi−circular plug grooves.
Seal packing:
Part No. 08826−00080 or equivalent

Downloaded from www.Manualslib.com manuals search engine P20865
P20864
EM5345
EM−86
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−101).
Torque:
1st 25 N·m (250 kgf·cm, 18 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).

Downloaded from www.Manualslib.com manuals search engine P20861
Front Mark
(Arrow)
Z14732
EM5369
FrontPainted
Mark
EM5370
Painted Mark
90°
90°
P00591
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
(b) Install the main bearing cap with the front mark facing for-
ward.
8. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any main bearing cap bolt is broken or deformed, re-
place it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 8 main bearing cap bolts,
in several passes, in the sequence shown.
Torque: 61 N·m (625 kgf·cm, 45 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance (See page
EM−92).
9. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.

Downloaded from www.Manualslib.com manuals search engine SF0AF−04
− MFI (3RZ−FE)MFI SYSTEM
MF−1
953 Author: Date:
1996 TOYOTA T100 (RM449U)
MFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCON-
NECT NEGATIVE (−) TERMINAL CABLE FROM BAT-
TERY
HINT:
Any diagnostic trouble code retained by the ECM will be erased
when the battery negative (−) terminal cable is removed from
the battery.
Therefore, if necessary, read the diagnostic trouble code(s) be-
fore removing the negative (−) terminal cable from the battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME
WHEN WORKING ON FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATH-
ER PARTS
4. MAINTENANCE PRECAUTIONS
(a) Precaution when the connecting gauge.
Use battery as the power source for the timing light, etc.
(b) In the event of engine misfire, these precautions should
be taken.
(1) Check proper connection of battery terminals, etc.
(2) Handle high−tension cords carefully.
(3) After repair work, check that the ignition coil termi-
nals and all other ignition system lines are recon-
nected securely.
(4) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(c) Precautions when the handling heated oxygen sensors.
(1) Do not allow oxygen sensor to drop or hit against an
object.
(2) Do not allow the sensor to come into contact with
water.
If Vehicle is Equipped with Mobile Radio System (ham, cb, etc.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
5. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV
hose, etc. may cause the engine to run out of tune.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will cause air suction and cause the engine to run
out of tune.

Downloaded from www.Manualslib.com manuals search engine FI2553
SST
MF−2
− MFI (3RZ−FE)MFI SYSTEM
954 Author: Date:
1996 TOYOTA T100 (RM449U)
6. ELECTRONIC CONTROL SYSTEM
(a) Before removing SFI wiring connectors, terminals, etc.,
first disconnect the power by either turning the ignition
switch to LOCK or disconnecting the negative (−) terminal
cable from the battery.
HINT:
Always check the diagnostic trouble code before disconnecting
the battery terminal cable.
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (−) cable
terminals.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all SFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and even slight terminal con-
tact can further troubles.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent entry of water. Also, when washing the engine
compartment, prevent water from getting on the SFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(1) Release the lock and pull out the connector, pulling
on the connectors.
(2) Fully insert the connector and check that it is locked.
(i) When inspecting a connector with a volt/ohmmeter.
(1) Carefully take out the water−proofing rubber if it is
a water−proof type connector.
(2) Insert the test probe into the connector from wiring
side when checking the continuity, amperage or
voltage.
(3) Do not apply unnecessary force to the terminal.
(4) After checking, install the water−proofing rubber on
the connector securely.
(5) Use SST for inspection or test of the injector or its
wiring connector.
SST 09842−30070