timing belt TOYOTA T100 1996 Factory Owner's Manual

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 EM−24
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
16. w/ A/C:
INSTALL A/C COMPRESSOR BRACKET
17. w/ A/C:
CONNECT A/C COMPRESSOR TO ENGINE
18. CONNECT PS PUMP TO ENGINE
19. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
Torque:5.4 N·m (54 kgf·cm, 48 in.·lbf)
20. INSTALL NO.2 FAN SHROUD
21. INSTALL AND ADJUST DRIVE BELT FOR GENERA-
TOR (See page CH−1)
22. w/ A/C:
INSTALL AND ADJUST DRIVE BELT FOR A/C COM-
PRESSOR
23. INSTALL AND ADJUST DRIVE BELT FOR PS PUMP
24. CONNECT UPPER RADIATOR HOSE
25. FILL ENGINE WITH COOLANT
26. START ENGINE CHECK FOR LEAKS
27. 4WD:
INSTALL ENGINE UNDER COVER
28. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
29. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM1OP−01
EM−30
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
REMOVAL
1. 4WD:
REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT EXHAUST PIPE (See page EM−108)
4. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
5. DISCONNECT THESE CABLES:
(a) w/ Cruise control:
Cruise control actuator cable
(b) Accelerator cable
(c) A/T:
Throttle cable
6. DISCONNECT HEATER HOSE
7. DISCONNECT UPPER RADIATOR HOSE
8. REMOVE DRIVE BELT FOR PS PUMP
(a) Stretch the belt and loosen the fan pulley mounting nuts.
9. w/ A/C:
REMOVE DRIVE BELT FOR A/C COMPRESSOR
10. REMOVE DRIVE BELT FOR GENERATOR
11. REMOVE NO. 2 FAN SHROUD
12. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
13. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
14. w/ A/C:
DISCONNECT A/C COMPRESSOR FROM ENGINE
HINT:
Put aside the compressor, and suspend it.
15. w/ A/C:
REMOVE A/C COMPRESSOR BRACKET
16. REMOVE HIGH−TENSION CORDS WITH IGNITION
COILS
17. REMOVE SPARK PLUGS
18. REMOVE TIMING BELT AND CAMSHAFT TIMING
PULLEYS (See page EM−13)
19. REMOVE TIMING BELT IDLER NO. 2 (See page
EM−13)
20. REMOVE GENERATOR

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P21193
P21192
P21195
EM−32
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
25. DISCONNECT ENGINE WIRE
(a) Disconnect these connectors:
Oil pressure sensor connector
Crankshaft position sensor connector
6 Injector connectors
ECT sender gauge connector
ECT sensor connector
Knock sensor connector
Camshaft position sensor connector
(b) Disconnect the 3 engine wire clamps.
(c) Remove the 3 bolts, and disconnect the engine wire from
the cylinder head.
26. REMOVE CAMSHAFT POSITION SENSOR
27. REMOVE NO.3 TIMING BELT COVER
Remove the 6 bolts and timing belt cover.
28. REMOVE FUEL PRESSURE REGULATOR
29. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the fuel inlet hose.
(b) Remove the 2 bolts and the intake manifold stay.
(c) Remove the 8 bolts, 4 nuts, 4 plate washers, intake man-
ifold, delivery pipes and injectors assembly and 2 gas-
kets.
30. REMOVE PS PUMP BRACKET
31. REMOVE OIL DIPSTICK AND GUIDE
(a) Remove the 2 bolts holding the dipstick guide to the gen-
erator bracket.
(b) Pull out the dipstick guide together with the dipstick from
the oil pan.
(c) Remove the O−ring from the dipstick guide.
32. REMOVE GENERATOR BRACKET
33. REMOVE EXHAUST CROSSOVER PIPE
Remove the 6 nuts, crossover pipe and 2 gaskets.
34. REMOVE LH AND RH EXHAUST MANIFOLDS
(a) Remove the 6 nuts and exhaust manifold heat insulators.
(b) Remove the 12 nuts, LH, RH exhaust manifolds and gas-
ket.

Downloaded from www.Manualslib.com manuals search engine P21192
P21198
L = 165 mm (6.50 in.) L = 165 mm (6.50 in.)
Join Line
L = 130 mm
(5.12 in.)
L = 265 mm
(10.43 in.)L = 145 mm
(5.71 in.)
L = Length
Join Line
EM−58
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(d) Install the dipstick guide with the 2 bolts.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)
(e) Install the dipstick.
16. INSTALL PS PUMP BRACKET
Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
17. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Install 2 new gaskets and the intake manifold, delivery
pipe and injectors assembly with the 8 bolts, 4 plate wash-
ers and 4 nuts.
Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)
(b) Install the intake manifold stay with the 2 bolts.
Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
(c) Connect the fuel inlet hose.
18. INSTALL FUEL PRESSURE REGULATOR
(See page SF−16)
19. INSTALL NO.3 TIMING BELT COVER
(a) Check that the timing belt cover gaskets have no cracks
or peeling, etc.
If the gaskets do have cracks or peeling etc., replace them us-
ing these 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 timing belt
cover shaded black in the illustration.
(b) Install the timing belt cover with the 6 bolts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
20. INSTALL CAMSHAFT POSITION SENSOR
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−61
1996 TOYOTA T100 (RM449U)
27. INSTALL TIMING BELT IDLER NO. 2 (See page
EM−19)
28. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING
BELT (See page EM−19)
29. INSTALL SPARK PLUGS
30. INSTALL HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−1)
31. w/ A/C:
INSTALL A/C COMPRESSOR BRACKET
32. w/ A/C:
CONNECT A/C COMPRESSOR
33. CONNECT PS PUMP
34. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
Torque: 5.4 N·m (54 kgf·cm, 48 in.·lbf)
35. INSTALL NO. 2 FAN SHROUD
36. INSTALL AND ADJUST DRIVE BELT FOR GENERA-
TOR (See page CH−1)
37. w/ A/C:
INSTALL AND ADJUST DRIVE BELT FOR A/C COM-
PRESSOR
38. INSTALL AND ADJUST DRIVE BELT FOR PS PUMP
39. CONNECT HEATER HOSE AND UPPER RADIATOR
HOSE
40. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
41. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP ASSEMBLY
42. INSTALL FRONT EXHAUST PIPE (See page EM−108)
43. FILL WITH ENGINE COOLANT
44. START ENGINE AND CHECK FOR LEAKS
45. CHECK IGNITION TIMING (See page EM−9)
46. 4WD:
INSTALL ENGINE UNDER COVER
47. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
48. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM−72
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
25. w/ A/C:
INSTALL DRIVE BELT FOR A/C COMPRESSOR
26. INSTALL DRIVE BELT FOR PS PUMP
27. INSTALL RADIATOR ASSEMBLY
(See page CO−19)
28. FILL WITH ENGINE OIL
29. FILL WITH ENGINE COOLANT
30. FILL TRANSMISSION OIL
31. START ENGINE AND CHECK FOR LEAKS
32. CHECK IGNITION TIMING
(See page EM−9)
33. INSTALL HOOD
34. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
35. RECHECK ENGINE COOLANT AND OIL LEVELS

Downloaded from www.Manualslib.com manuals search engine P21463
EM1OW−01
P21465
P21464
P21466
EM−84
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. M/T:
REMOVE FLYWHEEL
2. A/T:
REMOVE DRIVE PLATE
3. REMOVE REAR END PLATE
Remove the bolt and end plate.
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE TIMING BELT AND PULLEYS (See page
EM−13)
6. REMOVE CYLINDER HEADS (See page EM−30)
7. REMOVE WATER BYPASS PIPE WITH KNOCK SEN-
SOR WIRE
(a) Disconnect the 2 knock sensor connectors.
(b) Remove the 2 bolts, nut and water bypass pipe.
8. REMOVE NO.2 IDLER PULLEY BRACKET
Remove the 3 bolts and idler pulley bracket.
9. REMOVE KNOCK SENSORS
Using SST, remove the 2 knock sensors.
SST 09816−30010
10. REMOVE WATER PUMP (See page CO−5)
11. REMOVE GENERATOR ADJUSTING BAR
12. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816−30010
13. REMOVE OIL FILTER AND OIL FILTER UNION
(a) Using SST, remove the oil filter.
SST 09228−07501
(b) Using 12 mm hexagon wrench, remove the union.
14. REMOVE RH AND LH ENGINE MOUNTING BRACKET
15. REMOVE COOLANT DRAIN COCK
16. w/o OIL COOLER:
REMOVE OIL HOLE COVER PLATE

Downloaded from www.Manualslib.com manuals search engine P00601
Adhesive
P21461
1
5
3
7
2 68
4
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−107
1996 TOYOTA T100 (RM449U)
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 bypass pipe with the 2 bolts and nut.
Torque: 8.5 N·m (85 kgf·cm, 75 in.·lbf)
(d) Connect the 2 knock sensor connectors.
29. INSTALL CYLINDER HEADS
30. INSTALL PULLEYS AND TIMING BELT
(See page EM−19)
31. REMOVE ENGINE STAND
32. INSTALL REAR END PLATE
Torque: 7.5 N·m (75 kgf·cm, 66 in.·lbf)
33. A/T:
INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)
34. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine FI7231
TOYOTA Hand−Held Tester
DLC3
P21057
SF0BT−02
P21210
− SFI (5VZ−FE)FUEL PUMP
SF−5
1011 Author: Date:
1996 TOYOTA T100 (RM449U)
FUEL PUMP
ON−VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and push the TOYOTA hand−
held tester main switch ON.
NOTICE:
Do not start the engine.
(c) Select the active test mode on the TOYOTA hand−held
tester.
(d) Please refer to the TOYOTA hand−held tester operator’s
manual for further details.
(e) If you have no TOYOTA hand−held tester, connect the
positive (+) and negative (−) leads from the battery to the
fuel pump connector.
(f) Check that there is pressure in the fuel inlet hose from the
fuel filter.
HINT:
If there is fuel pressure, you will hear the sound of fuel flowing.
If there is no pressure, check these parts:
H−fuse (ALT 80A)
M−fuses (AM1 40A, AM2 30A)
Fuses (EFI 15A, IGN 7.5A)
EFI main relay
Circuit opening relay
Fuel pump
ECM
Wiring connections
(g) Turn the ignition switch to LOCK.
(h) Disconnect the TOYOTA hand−held tester from the
DLC3.
2. CHECK FUEL PRESSURE
(a) Check the battery positive voltage is above 12 V.
(b) Disconnect the negative (−) terminal cable from the bat-
tery.
(c) Remove the 6 bolts, and disconnect the No.2 timing belt
cover.
(d) Remove the union bolt holding the fuel pipe to the delivery
pipe and gasket.
CAUTION:
Put a shop towel under the delivery pipe. Slowly loosen the
union bolt.