TOYOTA T100 1996 Factory Service Manual

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− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
EM−73
892 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE UNIT (4WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine EM−74
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
893 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
EM−75
894 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine EM1OU−01
EM−76
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DRAIN ENGINE 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 FOR A/C COMPRESSOR
8. REMOVE DRIVE BELT FOR GENERATOR
9. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS (See page EM−13)
10. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
11. w/ A/C:
DISCONNECT A/C COMPRESSOR
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
(3) A.D.D. vacuum hose

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P21443
P21435
P21441
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
EM−77
1996 TOYOTA T100 (RM449U)
(4) Fuel return hose
(5) Fuel inlet hose
17. DISCONNECT STARTER WIRE AND CONNECTORS
(a) Remove the bolt, and disconnect the ground strap.
(b) Remove the 2 nut, and disconnect the positive (+) termi-
nal cable from battery.
(c) Disconnect the 3 starter wire clamps and connector.
(d) Disconnect the A.D.D. indicator switch 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.

Downloaded from www.Manualslib.com manuals search engine P21444
Engine Hanger No. 2
P21617
P21776
P21615
EM−78
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
1996 TOYOTA T100 (RM449U)
21. REMOVE ENGINE
(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.
(d) Remove the 4 bolts and nuts holding the engine front
mounting insulators to the frame.
(e) Lift the engine out of the vehicle slowly and carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(f) Place the engine assembly onto the stand.

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P21617
P21444
Engine Hanger No. 2
P21776
P21441
P21435
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
EM−79
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL ENGINE ASSEMBLY IN VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine assembly into the engine 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) Remove the engine chain hoist from the engine.
(f) Remove the 2 bolts and engine hanger No.2.
(g) w/ A/C:
Install the bolt, and connect the A/C compressor wire.
2. 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 (385 kgf·cm, 28 ft·lbf)
3. 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.
4. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
5. CONNECT GENERATOR WIRE
(a) Connect the generator connector.

Downloaded from www.Manualslib.com manuals search engine P21443
EM−80
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
1996 TOYOTA T100 (RM449U)
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
6. CONNECT STARTER WIRE AND CONNECTORS
(a) Connect the 3 starter wire clamps and connector.
(b) Install the 2 nuts, and connect the positive (+) terminal
cable to battery.
(c) Connect the A.D.D. indicator switch connector.
(d) Install the bolt, and connect the ground strap.
7. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose
Brake booster vacuum hose
EVAP hose
A.D.D. vacuum hose
8. CONNECT HEATER HOSES
9. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
10. INSTALL AIR CLEANER CASE AND AIR FILTER
11. INSTALL MAF METER, RESONATOR AND AIR
CLEANER CAP
12. w/ A/C:
CONNECT A/C COMPRESSOR
13. CONNECT PS PUMP
14. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS (See page EM−19)
15. INSTALL DRIVE BELT FOR GENERATOR (See page
CH−1)

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EM−81
1996 TOYOTA T100 (RM449U)
16. w/ A/C:
INSTALL DRIVE BELT FOR A/C COMPRESSOR
17. INSTALL DRIVE BELT FOR PS PUMP
18. INSTALL RADIATOR ASSEMBLY
(See page CO−19)
19. FILL WITH ENGINE OIL
20. FILL WITH ENGINE COOLANT
21. INSTALL ENGINE UNDER COVER
22. INSTALL TRANSMISSION
(See page MT−4)
23. INSTALL HOOD
24. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
25. RECHECK ENGINE COOLANT AND ENGINE OIL
LEVELS

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EM−82
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
901 Author: Date:
1996 TOYOTA T100 (RM449U)
CYLINDER BLOCK
COMPONENTS