TOYOTA T100 1996 Factory Service Manual

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P20922
Seal Packing
− COOLING (5VZ−FE)WATER PUMP
CO−7
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL WATER PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
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 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 water pump groove.
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.
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 water pump with the 7 bolts.
Torque:20 N·m (200 kgf·cm, 14 ft·lbf)
2. w/ OIL COOLER:
CONNECT NO.2 OIL COOLER HOSE
3. INSTALL THERMOSTAT
(See page CO−11)
4. INSTALL TIMING BELT
(See page EM−19)

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S02352 Non−Reusable part: Specified torque
N·m(kgf·cm, ft·lbf)
20 (200, 14)Water Inlet
Thermostat
 Gasket
Wire Clamp
Lower Radiator Hose
CO−8
− COOLING (5VZ−FE)THERMOSTAT
1097 Author: Date:
1996 TOYOTA T100 (RM449U)
THERMOSTAT
COMPONENTS

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P20967Jiggle Valve
− COOLING (5VZ−FE)THERMOSTAT
CO−9
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DISCONNECT LOWER RADIATOR HOSE
3. REMOVE THERMOSTAT
(a) Remove the 3 nuts, water inlet and thermostat with gas-
ket from the water pump.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Remove the gasket from the thermostat.
HINT:
Use a new gasket.

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CO0600
8.5 mm CO−10
− COOLING (5VZ−FE)THERMOSTAT
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT THERMOSTAT
HINT:
Thermostat is numbered according to the valve opening tem-
perature.
(a) Immerse the thermostat in water and heat the water grad-
ually.
(b) Check the valve opening temperature and valve lift.
Valve opening temperature:
80 − 84°C (176 − 183°F)
Valve lift: At 95°C (203°F): 8.5 mm (0.335 in.) or more
If the valve opening temperature and valve lift are not within
specifications, replace the thermostat.
(c) Check that the valve is fully closed when the thermostat
is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.

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P20967Jiggle Valve
− COOLING (5VZ−FE)THERMOSTAT
CO−11
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL THERMOSTAT
(a) Place a new gasket to the thermostat.
(b) Install the thermostat with the jiggle valve downward.
(c) Install the water inlet with the 3 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
2. CONNECT LOWER RADIATOR HOSE
3. FILL WITH ENGINE COOLANT
4. START ENGINE AND CHECK FOR LEAKS

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CO−12
− COOLING (5VZ−FE)RADIATOR
1101 Author: Date:
1996 TOYOTA T100 (RM449U)
RADIATOR
ON−VEHICLE CLEANING
Using water or a steam cleaner, remove any mud or dirt from the
radiator core.
NOTICE:
If using a high pressure type cleaner, be careful not to de-
form the fins of the radiator core. (i.e. Maintain a distance
between the cleaner nozzle and radiator core.)

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Z02362
Radiator Cap Tester
Radiator Cap
P14264
− COOLING (5VZ−FE)RADIATOR
CO−13
1996 TOYOTA T100 (RM449U)
ON−VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:
If the radiator cap has contaminations, always rinse it with
water.
Using a radiator cap tester, pump the tester and measure the
relief valve opening pressure.
Standard opening pressure:
74 − 103 kPa
(0.75 − 1.05 kgf/cm
2, 10.7 − 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP

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Z15608
CO−14
− COOLING (5VZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)
COMPONENTS

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− COOLING (5VZ−FE)RADIATOR
CO−15
1996 TOYOTA T100 (RM449U)

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P20524
P20523
CO−16
− COOLING (5VZ−FE)RADIATOR
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE RADIATOR GRILLE
(a) Remove the 4 screws, and clearance lights.
(b) Remove the 4 screws, 11 clips and radiator grille.
3. DISCONNECT UPPER RADIATOR HOSE
4. DISCONNECT RADIATOR RESERVOIR HOSE
5. DISCONNECT LOWER RADIATOR HOSE
6. REMOVE RADIATOR NO.2 FAN SHROUD
7. A/T:
DISCONNECT OIL COOLER HOSES
8. REMOVE RADIATOR
Remove the 4 bolts and radiator.
Torque:12 N·m (120 kgf·cm, 8.7 ft·lbf)
HINT:
Insert the tabs of the radiator support through the radiator ser-
vice holes.