light TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine Z14658
Recessed Head Bolt
8 mm Hexagon
Wrench
Front
P21041
P21037
EM−52
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
3. INSTALL RECESSED HEAD CYLINDER HEAD BOLTS
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Using an 8 mm hexagon wrench, install the cylinder head
bolt on each cylinder head, then repeat for the other side,
as shown.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
4. CONNECT GROUND STRAP
Install the bolt, and connect the ground strap.
5. ASSEMBLE 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) Install these parts:
(1) Camshaft gear spring
(2) Camshaft sub−gear
HINT:
Attach the pins on the gears to the gear spring ends.
(3) Wave washer
(c) Using snap ring pliers, install the snap ring.

Downloaded from www.Manualslib.com manuals search engine P21203
P21197
P21142
P21204
P21205
EM−54
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(f) Install the 5 bearing caps in their proper locations.
(g) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(h) Install and uniformly tighten the 10 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(i) Install the exhaust camshaft.
(j) Apply new engine oil to the thrust portion and journal of
the camshaft.
(k) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears.
(l) Place the exhaust camshaft on the cylinder head.
(m) Install the 4 bearing caps in their proper locations.
(n) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(o) Install and uniformly tighten the 8 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(p) Remove the service bolt.

Downloaded from www.Manualslib.com manuals search engine P21249
P21200
P21202
P21201
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−55
1996 TOYOTA T100 (RM449U)
7. Intake:
INSTALL 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 installed. If the
camshaft is not level, the portion of the cylinder head re-
ceiving the shaft thrust may crack or be damaged, causing
the camshaft to seize or break. To avoid this, these steps
should be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b) Place the intake camshaft at 90° angle of timing mark (1
dot mark) on the cylinder head.
(c) Apply MP grease to a new oil seal lip.
(d) Install the oil seal to the camshaft.
(e) Remove any old packing (FIPG) material.
(f) Apply seal packing to the No.1 bearing cap.
Seal packing:
Part No. 08826−00080 or equivalent
(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(i) Install and uniformly tighten the 10 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P21158
P21162
P21159
P13274Seal Packing EM−56
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
8. Exhaust:
INSTALL CAMSHAFTS OF LH CYLINDER HEAD
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b) Align the timing marks (1 dot mark) of the camshaft drive
and driven gears.
(c) Place the exhaust camshaft on the cylinder head.
(d) Install the 4 bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under
the heads of bearing cap bolts.
(f) Install and uniformly tighten the 8 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(g) Remove the service bolt.
9. CHECK AND ADJUST VALVE CLEARANCE
10. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi−circular plug grooves.
Seal packing:
Part No. 08826−00080 or equivalent

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 P20865
P20864
EM5345
EM−86
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−101).
Torque:
1st 25 N·m (250 kgf·cm, 18 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).

Downloaded from www.Manualslib.com manuals search engine P21451
P01030
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−91
1996 TOYOTA T100 (RM449U)
31. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to about 60°C (140°F).
(c) Using a plastic−faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

Downloaded from www.Manualslib.com manuals search engine P20861
Front Mark
(Arrow)
Z14732
EM5369
FrontPainted
Mark
EM5370
Painted Mark
90°
90°
P00591
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
(b) Install the main bearing cap with the front mark facing for-
ward.
8. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any main bearing cap bolt is broken or deformed, re-
place it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 8 main bearing cap bolts,
in several passes, in the sequence shown.
Torque: 61 N·m (625 kgf·cm, 45 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order 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 crankshaft thrust clearance (See page
EM−92).
9. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.

Downloaded from www.Manualslib.com manuals search engine Z14819
FrontFront
Mark
(Cavity)
P00655
Front Mark
(Protrusion)
EM5345
P02237
Painted
MarkFront EM−104
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
10. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
11. INSTALL CONNECTING ROD CAP NUTS
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed, replace
it.
(a) Apply a light of engine oil on the threads and under the
nuts of the connecting rod cap.
(b) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
If any one of the connecting rod cap nuts does not meet the
torque specification, replace the cap nut.
(c) Mark the front of the connecting rod cap nut and bolt with
paint.

Downloaded from www.Manualslib.com manuals search engine SF0AF−04
− MFI (3RZ−FE)MFI SYSTEM
MF−1
953 Author: Date:
1996 TOYOTA T100 (RM449U)
MFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCON-
NECT NEGATIVE (−) TERMINAL CABLE FROM BAT-
TERY
HINT:
Any diagnostic trouble code retained by the ECM will be erased
when the battery negative (−) terminal cable is removed from
the battery.
Therefore, if necessary, read the diagnostic trouble code(s) be-
fore removing the negative (−) terminal cable from the battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME
WHEN WORKING ON FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATH-
ER PARTS
4. MAINTENANCE PRECAUTIONS
(a) Precaution when the connecting gauge.
Use battery as the power source for the timing light, etc.
(b) In the event of engine misfire, these precautions should
be taken.
(1) Check proper connection of battery terminals, etc.
(2) Handle high−tension cords carefully.
(3) After repair work, check that the ignition coil termi-
nals and all other ignition system lines are recon-
nected securely.
(4) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(c) Precautions when the handling heated oxygen sensors.
(1) Do not allow oxygen sensor to drop or hit against an
object.
(2) Do not allow the sensor to come into contact with
water.
If Vehicle is Equipped with Mobile Radio System (ham, cb, etc.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
5. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV
hose, etc. may cause the engine to run out of tune.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will cause air suction and cause the engine to run
out of tune.