clock TOYOTA T100 1996 Factory User Guide

Downloaded from www.Manualslib.com manuals search engine P20817
P20819
P20830
P20837
Length = 955 mm (37.60 in.)
Length = 270 mm (10.63 in.)
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−23
1996 TOYOTA T100 (RM449U)
12. INSTALL TIMING BELT TENSIONER
(a) Install the tensioner with the 2 bolts.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)
(b) Remove the 1.5 mm hexagon wrench from the tensioner.
13. CHECK VALVE TIMING
(a) Turn the crankshaft pulley 2 revolutions from TDC to TDC.
HINT:
Always turn the crankshaft clockwise.
(b) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
14. INSTALL FAN BRACKET
(a) Install the fan bracket with the bolt and nut.
(b) Install the PS pump adjusting strut with the nut.
15. INSTALL NO.2 TIMING BELT COVER
(a) Check that the timing belt cover gasket has no cracks or
peeling, etc.
If the gasket does have cracks or peeling, etc., replace it using
following steps.
Using a screwdriver and gasket scraper, remove all
the old gasket material.
Thoroughly clean all components to remove all the
loose material.
Remove the backing paper from a new gasket and
install the gasket evenly to the part of the belt cover
shaded black in the illustration.
(b) Install the belt cover with the 6 bolts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
(c) Connect the 3 high−tension cord clamps to the No.2 tim-
ing belt cover.
(d) Connect the camshaft position sensor connector to the
No.2 timing belt cover.

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.

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SST
Turn
Z17650
RH
90°
P21199
P12390Seal Packing
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−53
1996 TOYOTA T100 (RM449U)
(d) Using SST, align the holes of the camshaft main gear and
sub−gear by turning camshaft sub−gear clockwise, and
temporarily install a service bolt.
SST 09960−10010 (09962−01000, 09963−00600)
(e) Align the gear teeth of the main gear and sub−gear, and
tighten the service bolt.
6. INSTALL 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 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) Install the intake camshaft.
(1) Apply new engine oil to the thrust portion and jour-
nal of the camshaft.
(2) Place the intake camshaft at 90° angle of timing
mark (2 dot marks) on the cylinder head.
(b) Apply MP grease to a new oil seal lip.
(c) Install the oil seal to the camshaft.
(d) Remove any old packing (FIPG) material.
(e) Apply seal packing to the No.1 bearing cap as shown.
Seal packing:
Part No. 08826−00080 or equivalent

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P10889
New Grommet
New O−Ring
New GrommetNew O−Ring
P21185
Push
Turn
Connector
P21208
P21216
RotateOutward
P21207
− SFI (5VZ−FE)INJECTOR
SF−23
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. TEMPORARILY INSTALL INJECTORS AND
DELIVERY PIPES
(a) Install 2 new grommets to each injector.
(b) Apply a light coat of spindle oil or gasoline to 2 new O−
rings and install them to each injector.
(c) While turning the injector clockwise and counterclock-
wise, push it to the delivery pipes. Install the 6 injectors.
(d) Position the injector connector outward.
(e) Place the 4 spacers in position on the intake manifold.
(f) Place the delivery pipes with the 6 injectors in position on
the intake manifold.
(g) Temporarily install the 4 bolts holding the delivery pipes
to the intake manifold.
(h) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O−rings. Replace the O−rings.
(i) Position the injector connector outward.
2. CONNECT INJECTOR CONNECTORS
3. INSTALL FUEL PIPE AND TIGHTENING
DELIVERY PIPE HOLDING BOLTS
(a) Install the fuel pipe with 4 new gaskets and the 2 union
bolts.
Torque: 34.3 N·m (350 kgf·cm, 25 ft·lbf)
(b) Tighten the 4 bolts holding the delivery pipes to the intake
manifold.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)

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P19935
P20011
Throttle Lever
No Clearance
Throttle Stop Screw Vacuum
SF−36
− SFI (5VZ−FE)THROTTLE BODY
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CLEAN THROTTLE BODY
(a) Using a soft brush and carburetor cleaner, clean the cast
parts.
(b) Using compressed air, clean all the passages and aper-
tures.
NOTICE:
To prevent deterioration, do not clean the throttle position
sensor and IAC valve.
2. INSPECT THROTTLE VALVE
(a) Apply vacuum to the throttle opener.
(b) Check that there is no clearance between the throttle stop
screw and throttle lever when the throttle valve is fully
closed.
Throttle valve fully closed angle: 10°
3. INSPECT THROTTLE POSITION SENSOR
(a) Apply vacuum to the throttle opener.
(b) Insert a thickness gauge between the throttle stop screw
and stop lever.
(c) Using an ohmmeter, measure the resistance between
each terminal.
Clearance between
lever and stop screwBetween
terminalsResistance
0 mm (0 in.)VTA − E20.28 − 6.4 kΩ
0.32 mm (0.013 in.)IDL − E20.5 kΩ or less
0.54 mm (0.021 in.)IDL − E2Infinity
Throttle valve fully
openVTA − E22.0 − 11.6 kΩ
−VC − E22.7 − 7.7 kΩ
4. IF NECESSARY, ADJUST THROTTLE POSITION SEN-
SOR
(a) Loosen the 2 set screws of the sensor.
(b) Apply vacuum to the throttle opener.
(c) Insert a 0.43 mm (0.017 in.) thickness gauge, between
the throttle stop screw and stop lever.
(d) Connect the test probe of an ohmmeter to the terminals
IDL and E2 of the sensor.
(e) Gradually turn the sensor clockwise until the ohmmeter
deflects, and secure it with the 2 set screws.

Downloaded from www.Manualslib.com manuals search engine IG0IX−01
− IGNITION (3RZ−FE)DISTRIBUTOR
IG−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT DISTRIBUTOR CONNECTOR
2. DISCONNECT HIGH−TENSION CORDS FROM DIS-
TRIBUTOR CAP (See page IG−1)
3. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise until the timing mark
is aligned with ”0” mark on the oil pump cover.
(b) Remove the 3 bolts and distributor cap.
(c) Check that distributor rotor direction is as shown. If not,
turn the crankshaft pulley one complete revolution.
4. REMOVE DISTRIBUTOR
(a) Remove the 2 mounting bolts, and pull out the distributor.
(b) Remove the O−ring from the distributor housing.

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IG−12
− IGNITION (3RZ−FE)DISTRIBUTOR
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. CHECK NO. 1 CYLINDER TO TDC/COMPORESSION
If necessary, remove the cylinder head cover, and check these
conditions:
Turn the crankshaft pulley clockwise and align its
groove with the timing mark ”0” of the oil pump cov-
er.
Verify that the timing marks with 1 and 2 dots are in
straight line on the cylinder head surface as shown
in the illustration.
If not, turn the crankshaft 1 revolition (360 °) and align the mark
as above.
2. INSTALL DISTRIBUTOR
(a) Install a new O−ring to the distributor.
HINT:
Always use a new O−ring when installing the distributor.
(b) Align the protrusion of the distributor housing with the
groove on the driven gear.
(c) Apply a light coat of engine oil on the O−ring.
(d) Install the distributor with the 2 bolts.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
3. INSTALL DISTRIBUTOR CAP
4. RECONECT HIGH−TENSION CORDS TO DISTRIBU-
TOR CAP
5. CONNECT DISTRIBUTOR CONNECTOR
6. CHECK IGNITION TIMING (See page EM−11)

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OhmmeterNo Continuity
P04514
LockFree
B01309
ST−8
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
Minimum installed load:
1.2 kW type: 9.8 N (1.00 kgf, 2.2 lbf)
1.4 kW type: 11.8 N (1.20 kgf, 2.6 lbf)
1.8 kW, 2.0 kW type: 12.7 N (1.30 kgf, 2.7 lbf)
If the installed load is less than minimum, replace the brush
springs.
HINT:
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
11. INSPECT INSULATION OF BRUSH HOLDER
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (−) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel or drive plate ring gear for
wear or damage.
13. INSPECT CLUTCH
Hold the starter clutch and rotate the clutch pinion gear clock-
wise and check that it turns freely. Try to rotate the clutch pinion
counterclockwise and check that it locks. If necessary, replace
the clutch assembly.
14. INSPECT REAR BEARING
Turn the bearing by hand while applying inward force.
If the resistance is felt or if the bearing sticks, replace the bear-
ing.

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No continuity
Ohmmeter
P04514
Free
Lock
P10593
SST
ST−8
− STARTING (5VZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
Minimum installed load:
1.2 kw type: 9.8 N (1.00 kgf, 2.2 lbf)
1.4 kw type: 11.8 N (1.20 kgf, 2.6 lbf)
1.8 kw type: 12.7 N (1.30 kgf, 2.7 lbf)
If the installed load is less than minimum, replace the brush
springs.
HINT:
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
11. INSPECT INSULATION OF BRUSH HOLDER
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (−) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idler gear and clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the flywheel or drive plate ring gear for
wear or damage.
13. INSPECT CLUTCH
Hold the starter clutch and rotate the clutch pinion gear clock-
wise and check that it turns freely. Try to rotate the clutch pinion
counterclockwise and check that it locks. If necessary, replace
the clutch assembly.
14. INSPECT REAR BEARING
Turn the bearing by hand while applying inward force.
If the resistance is felt or if the bearing sticks, replace the bear-
ing.
15. IF NECESSARY, REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286−46011

Downloaded from www.Manualslib.com manuals search engine CH0ES−02
P13397
P13398
P13396
P20344
CH0213
SST (B)SST (A)
CH−8
− CHARGING (3RZ−FE)GENERATOR
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE REAR END COVER
(a) Remove the nut and terminal insulator.
(b) Remove the 3 nuts and end cover.
2. REMOVE BRUSH HOLDER
(a) Remove the 2 screws, brush holder and cover.
(b) Remove the brush holder cover from the brush holder.
3. REMOVE VOLTAGE REGULATOR
Remove the 3 screws and voltage regulator.
4. REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
5. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820−63010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Check that SST (A) is secured to the rotor shaft.