TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−63
882 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine Z18855
EM−64
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
883 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine EM06W−02
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−65
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DRAIN ENGINE OIL
3. DRAIN TRANSMISSION OIL
4. REMOVE HOOD
5. REMOVE RADIATOR ASSEMBLY
(See page CO−16)
6. REMOVE DRIVE BELT FOR PS PUMP
7. w/ A/C:
REMOVE DRIVE BELT FOR A/C COMPRESSOR
8. REMOVE DRIVE BELT FOR GENERATOR
9. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
(See page CO−5)
10. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
11. w/ A/C:
REMOVE A/C COMPRESSOR FROM ENGINE
HINT:
Put aside the compressor, and suspend it.
12. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
13. REMOVE AIR CLEANER CASE AND FILTER
14. DISCONNECT THESE CABLES:
(a) w/ Cruise control:
Cruise control actuator cable
(b) Accelerator cable
(c) A/T:
Throttle cable
15. DISCONNECT HEATER HOSES
16. DISCONNECT HOSES
Disconnect these hoses:
(1) Brake booster vacuum hose
(2) EVAP hose

Downloaded from www.Manualslib.com manuals search engine Z14701
P20501
P21435
P21441
P21437
EM−66
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
(3) Fuel return hose
(4) Fuel inlet hose
17. DISCONNECT STARTER WIRE AND CONNECTOR
(a) Remove the bolt, and disconnect the ground strap.
(b) Remove the 2 nuts, disconnect the positive (+) terminal
cable from battery.
(c) Disconnect the 2 starter wire clamps and connector.
18. DISCONNECT GENERATOR WIRE
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire and
wire clip.
19. REMOVE FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
20. DISCONNECT ENGINE WIRE AND CONNECTORS
(a) Remove the 3 bolts and ECM.
(b) M/T:
Disconnect the 3 ECM connectors.
(c) A/T:
Disconnect the 4 ECM connectors.
(d) Disconnect the 2 connectors from the cowl wire.
(e) Disconnect these wires and connectors:
Igniter connector
Ground strap
(f) Disconnect the 6 engine wire clamps.
(g) Pull out the engine wire from the cabin.
21. M/T:
REMOVE SHIFT LEVER
(a) Remove the shift lever knob.
(b) Remove the 4 screws and shift lever boot.
(c) Remove the shift lever.
22. REMOVE STABILIZER BAR
(See page SA−16)
23. REMOVE PROPELLER SHAFT
(See page PR−3)
24. DISCONNECT SPEEDOMETER CABLE
NOTICE:
Do not lose the felt protector and washers.
25. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the 2 heated oxygen sensor connectors.
(b) Remove the 2 bolts, and retainer holding the front ex-
haust pipe to the center exhaust pipe.

Downloaded from www.Manualslib.com manuals search engine P21436
P15099
P21444
Engine Hanger No. 2
P21459
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−67
1996 TOYOTA T100 (RM449U)
(c) Remove the 3 bolts and support bracket.
(d) Remove the 3 nuts, front exhaust pipe and 3 gaskets.
26. M/T:
REMOVE CLUTCH RELEASE CYLINDER
(a) Remove the 3 bolts and disconnect the clutch line.
(b) Remove the 2 bolts and disconnect the clutch release cyl-
inder.
27. A/T:
REMOVE CROSS SHAFT
(a) Remove the clip and disconnect the shifting rod.
(b) Remove the nut, 4 bolts and the cross shaft.
28. PLACE JACK UNDER TRANSMISSION
29. REMOVE ENGINE REAR MOUNTING BRACKET
Remove the 8 bolts holding the mounting bracket to the mount-
ing insulator and cross member.
30. REMOVE ENGINE WITH TRANSMISSION
(a) w/ A/C:
Remove the bolt and disconnect the A/C compressor wire
clamp.
(b) Install a engine hanger No.2 in the correct direction.
Part No.:
Engine hanger No.2 12282−62030
Bolt 91512−61020
Torque:40 N·m (400 kgf·cm, 30 ft·lbf)
(c) Attach the engine hoist chain to the 2 engine hangers.

Downloaded from www.Manualslib.com manuals search engine P23911
P21458
EM−68
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
(d) Remove the 4 bolts and nuts holding the engine front
mounting insulators to the frame.
(e) Lift the engine with transmission out of the vehicle slowly
and carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(f) Place the engine and transmission assembly onto the
stand.
31. SEPARATE ENGINE AND TRANSMISSION

Downloaded from www.Manualslib.com manuals search engine EM1OS−01
P21457
P21459
P21444
Engine Hanger No.2
P15099
P23911
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−69
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL TRANSMISSION TO ENGINE
(See page AT−26)
2. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
IN VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the en-
gine compartment.
(c) Keep the engine level, and align the RH and LH mount-
ings and body mountings.
(d) Attach the RH and LH mounting insulators to the body
mountings, and temporarily install the 4 bolts and nuts.
(e) Jack up and put the transmission onto the frame.
(f) Remove the engine chain hoist from the engine.
(g) Remove the 2 bolts and engine hanger No.2.
(h) w/ A/C:
Install the bolt, and connect the A/C compressor wire.
3. INSTALL ENGINE REAR MOUNTING BRACKET
(a) Raise the transmission slightly by raising the engine with
a jack and a wooden block under the transmission.
(b) Install the engine rear mounting bracket to the frame.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(c) Lower the transmission and rest it on the extension hous-
ing.
(d) Install the mounting bracket to the mounting insulator.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
4. TIGHTEN RH AND LH ENGINE MOUNTING
INSULATOR BOLTS AND NUTS
Tighten the 4 bolts and nuts holding the mounting insulators to
the body mountings.
Torque: 38 N·m (387 kgf·cm, 28 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P21436
P21441
P21435
EM−70
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
5. A/T:
INSTALL CROSS SHAFT
(a) Install the cross shaft with the 4 bolts and nut.
(b) Connect the shifting rod with the clip.
6. M/T:
INSTALL CLUTCH RELEASE CYLINDER
(a) Install the clutch release cylinder with the 2 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Connect the clutch line with the 3 bolts.
7. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with new 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 3 bolts.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
(c) Connect a new gasket and the front exhaust pipe assem-
bly to the center exhaust pipe with the 2 bolts and retainer.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(d) Connect the 2 heated oxygen sensor connectors.
8. CONNECT SPEEDOMETER CABLE
9. INSTALL PROPELLER SHAFT
(See page PR−9)
10. INSTALL STABILIZER BAR (See page SA−125)
11. M/T:
INSTALL SHIFT LEVER
(a) Install the shift lever.
(b) Install the shift lever boot with the 4 screws.
(c) Install the shift lever knob.
12. CONNECT ENGINE WIRE AND CONNECTORS
(a) Push in the engine wire through the cowl panel.
(b) Connect the 6 engine wire clamps
(c) Connect these wire and connectors:
Ground strap
Igniter connector
(d) Connect 2 connectors to cowl wire.
(e) M/T:
Connect 3 connectors to the ECM.
(f) A/T:
Connect 4 connectors to the ECM.
(g) Install the ECM with the 3 bolts.

Downloaded from www.Manualslib.com manuals search engine P20501
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−71
1996 TOYOTA T100 (RM449U)
13. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
14. CONNECT GENERATOR WIRE
(a) Connect the generator connector.
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
15. CONNECT STARTER WIRE AND CONNECTOR
(a) Connect the 2 starter wire clamps and connector.
(b) Install the 2 nuts, and connect the positive (+) terminal
cable to battery.
(c) Install the bolt, and connect the ground strap.
16. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose
Brake booster vacuum hose
EVAP hose
A.D.D. Vacuum hose
17. CONNECT HEATER HOSES
18. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
19. INSTALL AIR CLEANER CASE AND AIR FILTER
20. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP
21. w/ A/C:
CONNECT A/C COMPRESSOR
22. CONNECT PS PUMP
23. INSTALL FAN WITH FLUID COUPLING AND FAN
PULLEYS(See page EM−19)
24. INSTALL DRIVE BELT FOR GENERATOR (See page
CH−1)

Downloaded from www.Manualslib.com manuals search engine EM−72
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
25. w/ A/C:
INSTALL DRIVE BELT FOR A/C COMPRESSOR
26. INSTALL DRIVE BELT FOR PS PUMP
27. INSTALL RADIATOR ASSEMBLY
(See page CO−19)
28. FILL WITH ENGINE OIL
29. FILL WITH ENGINE COOLANT
30. FILL TRANSMISSION OIL
31. START ENGINE AND CHECK FOR LEAKS
32. CHECK IGNITION TIMING
(See page EM−9)
33. INSTALL HOOD
34. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
35. RECHECK ENGINE COOLANT AND OIL LEVELS