width TOYOTA T100 1996 Factory User Guide

Downloaded from www.Manualslib.com manuals search engine P00592
P10205
No. 1
Others
22 mm20 mm
P10214
P10215
EM5354
EM−102
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
HINT:
Main bearings come in widths of 20 mm (0.79 in.) and 22
mm (0.87 in.). Install the 22 mm (0.87 in.) bearings in the
No.1 cylinder block journal position with the main bearing
caps. Install the 20 mm (0.79 in.) bearings in the other
positions.
Upper bearings have an oil holes lower bearings do not.
(a) Align the bearing claw with the claw groove of the main
bearing cap or cylinder block.
(b) Install the bearings in the cylinder block and main bearing
cap.
5. INSTALL UPPER THRUST WASHERS
Install the thrust washers under the No.2 journal position of the
cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. PLACE MAIN BEARING CAP AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the thrust washers on the No.2 journal position of
the bearing cap with the grooves facing outward.

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Painted Mark
90°90°
EM5292
A
A B
B Seal Width
2 − 3 mm
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−105
1996 TOYOTA T100 (RM449U)
(d) Retighten the connecting rod cap nuts 90° as 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 connecting rod thrust clearance (See page
EM−92).
12. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the retainer
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing:
Part No.08826−00080 or equivalent
 Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil seal retainer with the 6 bolts.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)
13. INSTALL OIL PUMP (See page LU−14)
14. INSTALL OIL PAN BAFFLE PLATE
15. INSTALL OIL STRAINER (See page LU−14)
16. INSTALL OIL PAN (See page LU−14)
17. w/ OIL COOLER:
INSTALL OIL COOLER WITH WATER BYPASS HOSE
AND OIL COOLER UNION (See page LU−20)
18. w/o OIL COOLER:
INSTALL OIL HOLE COVER PLATE
Torque: 60 N·m (600 kgf·cm, 44 ft·lbf)
19. INSTALL COOLANT DRAIN COCK
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
20. INSTALL RH AND LH ENGINE MOUNTING BRACKETS
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
21. INSTALL OIL FILTER UNION
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

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Adhesive
P10226
Seal Width
2 − 3 mm EM−106
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
22. INSTALL OIL FILTER (See page LU−3 )
23. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833 − 00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, install the oil pressure switch.
SST 09816−30010
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
24. INSTALL GENERATOR ADJUSTING BAR
Torque: 42 N·m (420 kgf·cm, 31 ft·lbf)
25. INSTALL WATER PUMP (See page CO−7)
26. INSTALL KNOCK SENSORS
Using SST, install the 2 knock sensors.
SST 09816−30010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
27. INSTALL NO.2 IDLER PULLEY BRACKET
Torque: 38 N·m (380 kgf·cm, 28 ft·lbf)
28. INSTALL WATER BYPASS PIPE WITH KNOCK SEN-
SOR WIRE
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the bypass
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the groove of the bypass pipe.
Seal packing:
Part No. 08826 − 00100 or equivalent
Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Downloaded from www.Manualslib.com manuals search engine LU03B−04
P20937
Seal Width
A
B2 − 3 mm
A
B
P20930
New O−Ring
P20971
Mark
Key
LU−14
− LUBRICATION (5VZ−FE)OIL PUMP
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pump
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pump, as shown in the il-
lustration.
Seal packing:
Part No. 08826−00080 or equivalent
Install nozzle that has been cut out to a 2 − 3 mm
(0.08 − 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Place a new O−ring into the groove of the cylinder block.
(d) Install the oil pump to the crankshaft with the spline teeth
of the drive rotor engaged with the large teeth of the
crankshaft.

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SST
Z10062
B
A
N00414
CL−18
− CLUTCHCLUTCH UNIT
1996 TOYOTA T100 (RM449U)
(b) Using SST, install a new pilot bearing.
SST 09304−30012
HINT:
After assembling the pilot bearing to the hub, install sure that
it rotates smoothly.
6. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum
Depth A: 0.6 mm (0.024 in.)
Width B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If necessary, replace the release bearing.

Downloaded from www.Manualslib.com manuals search engine R04421
Color
Bearing
CapDrill Mark
Drill MarkYoke
Z00735
PR0027
SST
PR0028
R16052
− PROPELLER SHAFTSPIDER BEARING
PR−19
1437 Author: Date:
1996 TOYOTA T100 (RM449U)
4. SELECT SPIDER BEARING
Select the appropriate bearing according to the existence of
drill mark on the yoke.
YokeBearing
With drill markWith color mark (Red)
No drill markNo color mark
5. INSTALL SPIDER BEARING
(a) Apply MP grease to the spider and bearings.
HINT:
Be careful not to apply too much grease.
(b) Align the matchmarks on the yoke and shaft.
(c) Fit a new spider into the yoke.
(d) Using SST, install a new bearing on the spider.
SST 09332−25010
(e) Using SST, adjust both bearings so that the snap ring
grooves are at maximum and equal in width.
6. INSTALL SNAP RINGS
(a) Install 2 new snap rings of equal thickness which will allow
0 − 0.05 mm (0 − 0.0020 in.) axial play.
HINT:
Do not reuse the snap rings.

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FIPG
Seal Width Approx.
1 − 2 mm (0.04 − 0.08 in.)
R11762
FIPG
− SUSPENSION AND AXLEFRONT DIFFERENTIAL CARRIER (4WD)
SA−67
1996 TOYOTA T100 (RM449U)
31. INSTALL DIFFERENTIAL CARRIER COVER
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the differential carrier and
carrier cover.
(b) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(c) Apply FIPG to the carrier cover, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the carrier cover within 10 minutes after applying FIPG.
(d) Install the differential carrier cover with the 8 bolts.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
32. INSTALL A.D.D. ACTUATOR
(a) Remove any old FIPG material and be careful not to drop
oil on the contact surfaces of the actuator and clutch case.
(b) Clean surfaces with FIPG material attached to using gas-
oline or alcohol.
(c) Apply FIPG to the clutch case, as shown.
FIPG:
Part No. 08826−00090, THREE BOND 1281 or equiva-
lent
HINT:
Install the actuator within 10 minutes after applying FIPG.
(d) Torque the 4 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine AB0158
Battery
SST
R05752
SST
H00401Weighty
y
x
RS−16
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 TOYOTA T100 (RM449U)
(d) Check functioning of SST.
SST 09082−00700
(e) Install the SST
CAUTION:
Place the disc wheel on the level ground.
(1) Connect the SST connector to the steering wheel
pad connector.
SST 09082−00700
NOTICE:
To avoid damaging the SST connector and wire harness,
do not lock the secondary lock of the twin lock. Also, se-
cure some slack for the SST wire harness inside the disc
wheel.
(2) Move the SST to at least 10 m (33 ft) away from
steering wheel pad tied down on the disc wheel.
(f) Cover steering wheel pad with cardboard box or tires.
Covering method using cardboard box:
Cover the steering wheel pad with the cardboard
box and weight the cardboard box down in 4 places
with at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
x=460 mm (18.11 in.)
When dimension of the cardboard box exceeds the di-
ameter of the disc wheel with the tire which the steer-
ing wheel pad is tied to−
x=460 mm (18.11 in.) + width of tire
y= 650 mm (25.59 in.)
NOTICE:
If a cardboard box smaller than the specified size is used,
the cardboard box will be broken by the shock from the air-
bag deployment.

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Inner Diam.
Tires
(3 or More)Width
H00400
10 m (33 ft) or more
AB0166
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−17
1996 TOYOTA T100 (RM449U)
Covering method using tires:
Place at least 3 tires without disc wheel on top of the
disc wheel with the tire to which the steering wheel
pad is tied.
Tire size: Must exceed the following dimensions−
Width: 185 mm (7.87 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.
NOTICE:
The tires may be marked by the airbag deployment, so use
the redundant tires.
(g) Deploy the airbag.
(1) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the battery negative
(−) terminal.
(2) Check that no one is within 10 m (33 ft) area around
the disc wheel which the steering wheel pad is tied
to.
(3) Press the SST activation switch and deploy the air-
bag.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
(h) Dispose of the steering wheel pad (with airbag)
CAUTION:
The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.
Use gloves and safety glasses when handling a steer-
ing wheel pad with deployed airbag.
Always wash your hands with water after completing
the operation.