TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P21141
P00867
P21146
P21145
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−33
1996 TOYOTA T100 (RM449U)
35. REMOVE CYLINDER HEAD COVERS
Remove the 8 bolts, seal washers, cylinder head cover and
gasket. Remove the 2 cylinder head covers.
36. REMOVE SEMI−CIRCULAR PLUGS
37. Exhaust:
REMOVE CAMSHAFTS OF RH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be held level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, these
steps should be carried out.
(a) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub−gear to the main gear
with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 − 20 mm
HINT:
When removing the camshaft, mark certain that the torsional
spring force of the sub−gear has been eliminated by the above
operation.
(c) Uniformly loosen and remove the 8 bearing cap bolts, in
several passes, in the sequence shown.
(d) Remove the 4 bearing caps and exhaust camshaft.
38. Intake:
REMOVE CAMSHAFTS OF RH CYLINDER HEAD
(a) Uniformly loosen and remove the 10 bearing cap bolts, in
several passes, in the sequence shown.
(b) Remove the 5 bearing caps, oil seal and intake camshaft.

Downloaded from www.Manualslib.com manuals search engine P21160
P00897
P21144
P21143
EM−34
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
39. Exhaust:
REMOVE CAMSHAFTS OF LH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be held level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, these
steps should be carried out.
(a) Align the timing marks (1 dot mark) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub−gear to the main gear
with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 − 20 mm
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub−gear has been eliminated by the above
operation.
(c) Uniformly loosen and remove the 8 bearing cap bolts, in
several passes, in the sequence shown.
(d) Remove the 4 bearing caps and exhaust camshaft.
40. Intake:
REMOVE CAMSHAFTS OF LH CYLINDER HEAD
(a) Uniformly loosen and remove the 10 bearing cap bolts, in
several passes, in the sequence shown.
(b) Remove the 5 bearing caps, oil seal and intake camshaft.
HINT:
Arrange the camshafts in the correct order.
Arrange the bearing caps in the correct order.

Downloaded from www.Manualslib.com manuals search engine P24268
P21037
Z13745
8 mm Hexagon
FrontRecessed Head BoltWrench
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−35
1996 TOYOTA T100 (RM449U)
41. DISASSEMBLE EXHAUST CAMSHAFTS
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using SST, turn the sub−gear clockwise, and remove the
service bolt.
SST 09960−10010 (09962−01000, 09963−00600)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove these parts:
Wave washer
Camshaft sub−gear
Camshaft gear spring
HINT:
Arrange the camshaft sub−gears and gear springs (RH and LH
side).
42. REMOVE CYLINDER HEADS
(a) Remove the bolt, and disconnect the ground strap.
(b) Using an 8 mm hexagon wrench, remove the cylinder
head (recessed head) bolt on each cylinder head, then re-
peat for the other side, as shown.

Downloaded from www.Manualslib.com manuals search engine Z14651
12 Pointed Head Bolt
Front
P00828
EM−36
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(c) Uniformly loosen and remove the 8 cylinder head (12
pointed head) bolts on each cylinder head, in several
passes, in the sequence shown, then repeat for the other
side, as shown. Remove the 16 cylinder head bolts and
plate washers.
NOTICE:
Head warpage or cracking could result from removing
bolts in an incorrect order.
(d) Lift the cylinder head from the dowels on the cylinder
block and place the 2 cylinder heads on wooden blocks
on a bench.
HINT:
If the cylinder head is difficult to lift off, pry between the cyl-
inder head and cylinder block with a screwdriver.
Arrange the cylinder heads in the correct order.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.

Downloaded from www.Manualslib.com manuals search engine P20845
EM06M−03
P20847
SST
P20988
P20841
Magnetic Finger
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−37
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE CAMSHAFT HOUSING PLUGS
(a) Remove the bolt, nut, cylinder head rear plate and ground
strap.
(b) Remove the 2 bolts and camshaft bearing cap.
(c) Remove the housing plug.
2. REMOVE VALVE LIFTERS AND SHIMS
Pull out the valve lifter and shim by hand.
HINT:
Arrange the valve lifters and shims in correct order.
3. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202−70020 (09202−00010)
(b) Remove these parts:
Spring retainer
Valve spring
Valve
(c) Using needle−nose pliers, remove the oil seal.
(d) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in the correct order.

Downloaded from www.Manualslib.com manuals search engine P20505
EM1OQ−01
P20504
P20503
P20512
P20986
EM−38
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND
CYLINDER BLOCK
(a) Turn the crankshaft and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surfaces.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surfaces.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high−compressed air.
2. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
faces.
3. CLEAN COMBUSTION CHAMBERS
Using a wire brush, remove all the carbon from the combustion
chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
faces.
4. CLEAN VALVE GUIDE BUSHINGS
Using a valve guide bushing brush and solvent, clean all the
guide bushings.

Downloaded from www.Manualslib.com manuals search engine P20506
Z14652
P20514
EM0580
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−39
1996 TOYOTA T100 (RM449U)
5. CLEAN CYLINDER HEADS
Using a soft brush and solvent, thoroughly clean the cylinder
heads.
6. INSPECT FOR FLATNESS
Using precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder block and manifolds for war-
page.
Maximum warpage:
0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake
ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

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).

Downloaded from www.Manualslib.com manuals search engine P20853
SST
P20510
P20984
Snap Ring
SST
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−41
1996 TOYOTA T100 (RM449U)
(c) Using SST and a hammer, tap out the guide bushing.
SST 09201−10000 (09201−01060),
09950−70010 (09951−07150)
(d) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
(e) Select a new guide bushing (STD size or O/S 0.05).
Both intake and exhaust
Bushing bore diameter mm (in.)Bushing size
10.985 − 11.027 (0.4325 − 0.4341)Use STD
11.050 − 11.077 (0.4350 − 0.4361)Use O/S 0.05
If the bushing bore diameter of the cylinder head is greater than
11.027 mm (0.4341 in.), machine the bushing bore to these di-
mension:
11.050 − 11.077 mm (0.4350 − 0.4361 in.)
If the bushing bore diameter of the cylinder head is greater than
11.077 mm (0.4361 in.), replace the cylinder head.
(f) Gradually heat the cylinder head to 80 − 100°C (176 −
212°F).
(g) Using SST and a hammer, tap in a new guide bushing un-
til the snap ring makes contact with the cylinder head.
SST 09201−10000 (09201−01060),
09950−70010 (09951−07150)

Downloaded from www.Manualslib.com manuals search engine P20985
Sharp 6 mm Reamer
Z00054
44.5°
EM0181
Margin Thickness
EM2534
Overall Length
EM0255
EM−42
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(h) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See step 9) be-
tween the guide bushing and valve stem.
11. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
1.0 mm (0.039 in.)
Minimum margin thickness:
0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.
(d) Check the valve overall length.
Overall length:
Standard Intake
Exhaust95.15 mm (3.7461 in.)
94.90 mm (3.7362 in.)
Minimum Intake
Exhaust94.60 mm (3.7244 in.)
94.40 mm (3.7165 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than the minimum.