TOYOTA T100 1996 Factory Service Manual

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SS−11
185 Author: Date:
1996 TOYOTA T100 (RM449U) Connecting
rod
Thrust clearance STD
Maximum
Connecting rod bearing center wall thickness
Reference Mark 1
Mark 2
Mark 3
Connecting rod oil clearance STD
O/S 0.25
Maximum
Rod bend Maximum per 100 mm (3.94 in.)
Rod twist Maximum per 100 mm (3.94 in.)
Bushing inside diameter
Piston pin diameter
Bushing oil clearance STD
Maximum
Connecting rod bolt outer diameter STD
Minimum0.150 − 0.330 mm (0.0059 − 0.0130 in.)
0.380 mm (0.0150 in.)
1.484 − 1.488 mm (0.0584 − 0.0586 in.)
1.488 − 1.492 mm (0.0586 − 0.0587 in.)
1.492 − 1.496 mm (0.0587 − 0.0589 in.)
0.024 − 0.053 mm (0.0009 − 0.0021 in.)
0.023 − 0.069 mm (0.0009 − 0.0027 in.)
0.08 mm (0.0031 in.)
0.05 mm (0.0020 in.)
0.15 mm (0.0059 in.)
22.005 − 22.017 mm (0.8663 − 0.8668 in.)
21.997 − 22.009 mm (0.8660 − 0.8665 in.)
0.005 − 0.011 mm (0.0002 − 0.0004 in)
0.05 mm (0.0020 in.)
7.860 − 8.000 mm (0.3094 − 0.3150 in.)
7.600 mm (0.2992 in.)
CrankshaftThrust clearance STD
Maximum
Thrust washer thickness
Main journal oil clearance No.1 STD
U/S 0.25
Others STD
U/S 0.25
Maximum
Main journal diameter STD
U/S 0.25
Main bearing center wall thickness
Reference No.1 Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Others Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Crank pin diameter STD
U/S 0.25
Circle runoutMaximum
Main journal taper and out−of−roundMaximum
Crank pin taper and out−of−roundMaximum0.020 − 0.220 mm (0.0008 − 0.0087 in.)
0.300 mm (0.0118 in.)
2.440 − 2.490 mm (0.0961 − 0.0980 in.)
0.020 − 0.038 mm (0.0008 − 0.0015 in.)
0.019 − 0.059 mm (0.0007 − 0.0023 in.)
0.024 − 0.042 mm (0.0009 − 0.0017 in.)
0.023 − 0.063 mm (0.0009 − 0.0025 in.)
0.08 mm (0.0031 in.)
63.985 − 64.000 mm (2.5191 − 2.5197 in.)
63.745 − 63.755 mm (2.5096 − 2.5100 in.)
1.991 − 1.994 mm (0.0784 − 0.0785 in.)
1.994 − 1.997 mm (0.0785 − 0.0786 in.)
1.997 − 2.000 mm (0.0786 − 0.0787 in.)
2.000 − 2.003 mm (0.0787 − 0.0789 in.)
2.003 − 2.006 mm (0.0789 − 0.0790 in.)
1.989 − 1.992 mm (0.0783 − 0.0784 in.)
1.992 − 1.995 mm (0.0784 − 0.0785 in.)
1.995 − 1.998 mm (0.0785 − 0.0787 in.)
1.998 − 2.001 mm (0.0787 − 0.0788 in.)
2.001 − 2.004 mm (0.0788 − 0.0789 in.)
54.987 − 55.000 mm (2.1648 − 2.1654 in.)
54.745 − 54.755 mm (2.1553 − 2.1557 in.)
0.06 mm (0.0024 in.)
0.02 mm (0.0008 in.)
0.02 mm (0.0008 in.)

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SS−12
− SERVICE SPECIFICATIONSENGINE MECHANICAL (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
No.1 idler pulley x Oil pump3535026
No.2 idler pulley x No.2 idler pulley bracket4040030
No.1 timing belt cover x Oil pump99080 in.·lbf
Crankshaft pulley x Crankshaft2502,500184
Camshaft timing pulley x Camshaft11 01,10081
Timing belt tensioner x Oil pump2727020
No.2 timing belt cover x No.3 timing belt cover99080 in.·lbf
Oil dipstick guide x Generator bracket88071 in.·lbf
Fluid coupling x Fan bracket5.45448 in.·lbf
Camshaft bearing cap x Cylinder head1616012
Rear plate x Cylinder head88071 in.·lbf
Cylinder head x Cylinder block 12 pointed head 1st
2nd
3rd
Recessed head34
Turn 90°
Turn 90°
18350
Turn 90°
Turn 90°
18525
Turn 90°
Turn 90°
13
Cylinder head cover x Cylinder head66053 in.·lbf
Exhaust manifold x Cylinder head4040030
Exhaust manifold heat insulator x Exhaust manifold88071 in.·lbf
Exhaust crossover pipe x Exhaust manifold4545033
Generator bracket x LH cylinder head18.518514
PS pump bracket x RH cylinder head4444032
Intake manifold x Cylinder head1818013
Intake manifold stay x Intake manifold18.518513
Intake manifold stay x No. 2 idler pulley bracket18.518513
No.3 timing belt cover x Cylinder head99080 in.·lbf
Camshaft position sensor x RH cylinder head88071 in.·lbf
Intake air connector x Intake manifold18.518513
Air intake chamber x Intake air connector18.518513
Air intake chamber stay x LH cylinder head, Air intake chamber4040030
EGR pipe x LH exhaust manifold18.518513
EGR pipe x EGR valve18.518513
EGR pipe x Cylinder head88071 in.·lbf
Engine hanger No.2 x RH cylinder head4040030
Frame crossmember x Engine rear mounting bracket5859043
Engine rear mounting bracket x Engine rear mounting insulator1818513
Engine front mounting insulator x Frame3838728
Connecting rod cap x Connecting rod 1st
2nd25
Turn 90°250
Turn 90°18
Turn 90°
Main bearing cap x Cylinder block 1st
2nd61
Turn 90°625
Turn 90°45
Turn 90°
Rear oil seal retainer x Cylinder block88071 in.·lbf
Oil cooler union x Cylinder block3030022
Oil hole cover plate x Cylinder block6060044
Engine coolant drain cock x Cylinder block3940029

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SS−13
1996 TOYOTA T100 (RM449U) Engine mounting bracket x Cylinder block
4444032
Oil filter union x Cylinder block2525018
Oil pressure switch x Cylinder block1515011
Generator adjusting bar x Cylinder block4242031
Knock sensor x Cylinder block3940029
No.2 idler pulley bracket x Cylinder block3838028
Water bypass pipe x Cylinder block8.58575 in.·lbf
Rear end plate x Cylinder block7.57566 in.·lbf
Drive plate x Crankshaft8385063
Flywheel x Crankshaft8585063
Clutch release cylinder x Transmission121209
Stabilizer bar bracket mounting bolt3030622
Stabilizer bar x Lower suspension arm131309
Front exhaust pipe x Exhaust crossover pipe6263046
Front exhaust pipe x Center exhaust pipe4849035
Front exhaust pipe support bracket x Front exhaust pipe4445033
Front exhaust pipe support bracket x Transmission4445033
Center exhaust pipe x Tailpipe4849035
Center exhaust pipe support bracket x Body2930021

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SS−14
− SERVICE SPECIFICATIONSEMISSION CONTROL (3RZ−FE)
188 Author: Date:
1996 TOYOTA T100 (RM449U)
EMISSION CONTROL (3RZ−FE)
SERVICE DATA
VSV for EVAPResistance at 20°C (68°F)30 − 34 Ω
VSV for EGRResistance at 20°C (68°F)33 − 39 Ω

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− SERVICE SPECIFICATIONSEMISSION CONTROL (3RZ−FE)
SS−15
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Charcoal canister x Charcoal canister bracket3131023
EGR valve x Air intake chamber1919514
EGR valve x EGR pipe1919514
EGR pipe x Exhaust manifold2020015
EGR pipe x Cylinder head1818513
Heated oxygen sensor x Center exhaust pipe2020014
Front exhaust pipe x Center pipe4849035
Center pipe x Tail pipe4849035

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SS−16
− SERVICE SPECIFICATIONSEMISSION CONTROL (5VZ−FE)
190 Author: Date:
1996 TOYOTA T100 (RM449U)
EMISSION CONTROL (5VZ−FE)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Charcoal canister x Charcoal canister bracket1818013
EGR valve x Air intake chamber18.518514
EGR valve x EGR pipe18.518514
EGR pipe x LH exhaust manifold18.518514
EGR pipe stay x Cylinder head8.08071 in.·lbf
Heated oxygen sensor x Center exhaust pipe2020014
Front exhaust pipe x Center exhaust pipe4849035
Center exhaust pipe x Tailpipe4849035

Downloaded from www.Manualslib.com manuals search engine SS096−02
− SERVICE SPECIFICATIONSMFI (3RZ−FE)
SS−17
191 Author: Date:
1996 TOYOTA T100 (RM449U)
MFI (3RZ−FE)
SERVICE DATA
Fuel pressure
regulatorFuel pressure at no vacuum265 − 304 kPa
(2.7 − 3.1 kgf/cm2, 38 − 44 psi)
Fuel pumpResistance at 20°C (68°F)0.2 − 3.0 Ω
InjectorResistance at 20°C (68°F)
Injection volume
Difference between each cylinder
Fuel leakage12 − 16 Ω
69 − 88 cm3 (4.2 − 5.3 cu in.) per 15 seconds
5 cm3 (0.3 cu in.) or less
One drop or less per minutes
Throttle bodyThrottle valve fully closed angle
Throttle opener setting speed6°
1,200 − 1,400 rpm
TP sensorClearance between stop screw and leverTerminalsResistance
0 mm (0 in.) VTA − E2
0.50 mm (0.020 in.) IDL − E2
0.75 mm (0.030 in.) IDL − E2
Throttle valve fully open VTA − E2
−VC − E20.2 − 5.7 kΩ
2.3 kΩ or less
Infinity
2.0 − 10.2 kΩ
2.5 − 5.9 kΩ
IAC valveResistance +B − RSC or RSO17.0 − 24.5 Ω (−10 − 50°C)
21.5 − 28.5 Ω ( 50 − 100°C)
VSV for EVAPResistance at 20°C (68°F)30 − 34 Ω
VSV for EGRResistance at 20°C (68°F)33 − 39 Ω
VSV for Vapor
pressure sensorResistance at 20°C (68°F)37 − 44 Ω
Vapor pressure
sensorPower source voltage4.5 − 5.5 V
ECT sensorResistance at −20°C (−4°F)
at 0°C (32°F)
at 20°C (68°F)
at 40°C (104°F)
at 60°C (140°F)
at 80°C (176°F)10 − 20 kΩ
4 − 7 kΩ
2 − 3 kΩ
0.9 − 1.3 kΩ
0.4 − 0.7 kΩ
0.2 − 0.4 kΩ
MAF meterResistance (THA − E2) at −20°C (−4°F)
at 0°C (32°F)
at 20°C (68°F)
at 40°C (104°F)
at 60°C (140°F)
at 80°C (176°F)10 − 20 kΩ
4 − 7 kΩ
2 − 3 kΩ
0.9 − 1.3 kΩ
0.4 − 0.7 kΩ
0.2 − 0.4 kΩ
EGR gas temp.
sensorResistance at 50°C (122°F)
at 100°C (212°F)
at 150°C (302°F)64 − 97 kΩ
11 − 16 kΩ
2 − 4 kΩ
Heated
oxygen sensorHeater coil resistance
Bank 1 sensor 1 at 20°C (68°F)
Bank 1 sensor 2 at 20°C (68°F)
11 − 16 Ω
11 − 16 Ω
Fuel cut RPMFuel return rpm M/T
A/T1,400 rpm
1,500 rpm

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SS−18
− SERVICE SPECIFICATIONSMFI (3RZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Fuel line (Union bolt type)2930022
Fuel line (Flare nut type)3031022
Fuel pump bracket assembly x Fuel tank3.94035 in.·lbf
Fuel filter x Cylinder block2020015
Fuel pressure regulator x Delivery pipe8.89078 in.·lbf
Delivery pipe x Cylinder head2121015
Fuel inlet tube x Fuel filter2930022
Fuel inlet tube x Delivery pipe2930022
Air intake chamber x Intake manifold2121015
Throttle body x Air intake chamber2020014
Fuel evaporation tube x Fuel tank1.51513 in.·lbf
Fuel tank filler pipe x Fuel tank3.53531 in.·lbf
Fuel inlet pipe x Body5.45547 in.·lbf
Fuel tank band x Body3940029
MAF meter x Air cleaner cap101007
ECT sensor x Cylinder head2020014
Knock sensor x Cylinder block4445033

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− SERVICE SPECIFICATIONSSFI (5VZ−FE)
SS−19
193 Author: Date:
1996 TOYOTA T100 (RM449U)
SFI (5VZ−FE)
SERVICE DATA
Fuel pressure
regulatorFuel pressure at no vacuum265 − 304 kPa (2.7 − 3.1 kgf/cm2, 38 − 44 psi)
Fuel pumpResistance at 20 °C (68 °F)0.2 − 3.0 Ω
InjectorResistance
Injection volume
Difference between each cylinder
Fuel leakageApprox. 13.8 Ω
56 − 69 cm3 (3.4 − 4.2 cu in.) per 15 sec.
6 cm3 (0.31 cu in.) or less
1 drop or less per minute
MAF meterResistance (THA − E2) at −20 °C (−4 °F)
at 0 °C (32 °F)
at 20 °C (68 °F)
at 40 °C (104 °F)
at 60 °C (140 °F)
at 80 °C (176 °F)10 − 20 kΩ
4 − 7 kΩ
2 − 3 kΩ
0.9 − 1.3 kΩ
0.4 − 0.7 kΩ
0.2 − 0.4 kΩ
Throttle bodyThrottle valve fully closed angle
DP setting speed (M/T)
Throttle opener setting speed10°
1,800 − 2,200 rpm
900 − 1,950 rpm
Throttle position
sensor
Clearance between stop screw and lever
0 mm (0 in.) VTA − E2
0.32 mm (0.013 in.) IDL − E2
0.54 mm (0.021 in.) IDL − E2
Throttle valve fully open VTA − E2
VC − E2
0.28 − 6.4 kΩ
0.5 kΩ or less
Infinity
2.0 − 11.6 kΩ
2.7 − 7.7 kΩ
IAC valveResistance (+B − RSO or RSC) at cold
at hot17.0 − 24.5 Ω
21.5 − 28.5 Ω
VSV for fuel pres-
sure controlResistance at 20 °C (68 °F)33 − 39 Ω
VSV for EGR
(2WD 0.5 ton)Resistance at 20 °C (68 °F)33 − 39 Ω
VSV for EVAPResistance at 20 °C (68 °F)29 − 33 Ω
A/C idle−up valve
(w/ A/C)Resistance at 20 °C (68 °F)30 − 34 Ω
ECT sensorResistance at −20 °C (−4 °F)
at 0 °C (32 °F)
at 20 °C (68 °F)
at 40 °C (104 °F)
at 60 °C (140 °F)
at 80 °C (176 °F)10 − 20 kΩ
4 − 7 kΩ
2 − 3 kΩ
0.9 − 1.3 kΩ
0.4 − 0.7 kΩ
0.2 − 0.4 kΩ
EGR gas temper-
ature sensor
(2WD 0.5 ton)Resistance at 50 °C (122 °F)
at 100 °C (212 °F)
at 150 °C (302 °F)64 − 97 kΩ
11 − 16 κΩ
2 − 4 kΩ
Heated oxygen
sensorHeater coil resistance
M/T Bank 1 Sensor 1 at 20 °C (68 °F)
Others at 20 °C (68 °F)
5 − 7 Ω
11 − 16 Ω
Fuel cut rpmFuel return rpm M/T
A/T1,000 rpm
1,200 rpm

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SS−20
− SERVICE SPECIFICATIONSSFI (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Fuel line (Union bolt type)34.335025
Fuel line (Flare nut type)34.335025
Fuel line (Flare nut type) using SST2828521
No. 2 timing belt cover x No. 3 timing belt cover99080 in.·lbf
Fuel inlet pipe x Intake manifold88071 in.·lbf
Delivery pipe x Intake manifold1313010
Fuel pump bracket assembly x Fuel tank3.94035 in.·lbf
Fuel tank band x Body4344032
Fuel tank filler pipe x Fuel tank3.94035 in.·lbf
Fuel evaporation vent tube x Fuel tank1.51513 in.·lbf
Fuel pressure regulator x LH delivery pipe88071 in.·lbf
MAF meter x Air cleaner cap6.97261 in.·lbf
VSV assembly x Air intake connector88071 in.·lbf
A/C idle−up valve x Intake air connector2020014
ECT sensor x Intake manifold2020014
Knock sensor x Cylinder block3940029
EGR gas temperature sensor x EGR valve2020014
Heated oxygen sensor x Front exhaust pipe, Center exhaust pipe2020014