TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)COMPRESSION
EM−3
822 Author: Date:
1996 TOYOTA T100 (RM449U)
6. REINSTALL HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−1)

Downloaded from www.Manualslib.com manuals search engine EM06D−03
P21120
P21152
Dot Mark
P01269
RH EX
12
36
LH EX LH IN RH IN
P01270
RH EX
34
5
LH EX LH IN RH IN
2 EM−4
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
823 Author: Date:
1996 TOYOTA T100 (RM449U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DRAIN ENGINE COOLANT
2. REMOVE INTAKE AIR CONNECTOR
(See page EM−65)
3. REMOVE CYLINDER HEAD COVERS
(See page EM−30)
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark ”0” of the No.1 timing belt cover.
(b) Check that the timing marks (1 dot) of the camshaft drive
and driven gears are in straight line on the cylinder heads
surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated in the illustration.
Using a thickness gauge, measure the clearance
between the valve lifter and camshaft.
Record out of specification valve clearance mea-
surements. They will be used later to determine the
required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.13 − 0.23 mm (0.006 − 0.009 in.)
Exhaust 0.27 − 0.37 mm (0.011 − 0.014 in.)
(b) Turn the crankshaft 2/3 of a revolution (240°), and check
only the valves indicated in the illustration. Measure the
valve clearance. (See procedure step (a))

Downloaded from www.Manualslib.com manuals search engine P01268
RH EX
6 4
5
LH EX LH IN RH IN
1
P21221
Upward
Cam Lobe
Notch
P21225
Front of No.1 and Rear of No.6 Cylinders
Others
SST (A) SST (B)SST (B)SST (A)
P21222
SST (B)
Magnetic Finger
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
EM−5
824 Author: Date:
1996 TOYOTA T100 (RM449U)
(c) Turn the crankshaft a further 2/3 of a revolution (240°),
and check only the valves indicated in the illustration.
Measure the valve clearance (See procedure step (a)).
6. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the camshaft so that the cam lobe for the valve
to be adjusted faces up.
Turn the valve lifter with a screwdriver so that the
notches are perpendicular to the camshaft.
Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248−55040 (09248−05410, 09248−05420)
HINT:
Apply SST (B) at a slight angle on the side marked with
”9” or ”7”, at the position shown in the illustration.
When SST (B) is inserted too deeply, it will get pinched by
the shim. To prevent it from being stuck, insert it gently
from the intake side, at a slight angle.
Using a small screwdriver and magnetic finger, re-
move the adjusting shim.

Downloaded from www.Manualslib.com manuals search engine EM0494
P21223
SST (B)
SST (A)
EM−6
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
825 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) Determine the replacement adjusting shim size according
to these Formula or Charts:
Using a micrometer, measure the thickness of the
removed shim.
Calculate the thickness of a new shim so the valve
clearance comes within the specified value.
T .......... Thickness of used shim
A .......... Measured valve clearance
N .......... Thickness of new shim
Intake
N = T + (A − 0.18 mm (0.007 in.))
Exhaust
N = T + (A − 0.32 mm (0.013 in.))
Select a new shim with a thickness as close as pos-
sible to the calculated values.
HINT:
Shims are available in 17 sizes in increments of 0.050 mm
(0.0020 in.), from 2.500 mm (0.0984 in.) to 3.300 mm (0.1299
in.).
(c) Install a new adjusting shim.
Place a new adjusting shim on the valve lifter, with
imprinted numbers facing down.
Press down the valve lifter with SST (A), and re-
move SST (B).
SST 09248−55040 (09248−05410, 09248−05420)
(d) Recheck the valve clearance.
7. REINSTALL CYLINDER HEAD COVERS (See page
EM−51)
8. REINSTALL INTAKE AIR CONNECTOR
(See page EM−69)
9. REFILL WITH ENGINE COOLANT
10. START ENGINE AND CHECK FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine V06208
Adjusting Shim Selection Chart (Intake)
mm (in.) Installed shim thickness
mm (in.) Measured clearance
Intake valve clearance (Cold):
0.13 − 0.23 mm (0.006 − 0.009 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is
installed and measured clearance is 0.450 mm
(0.0177 in.). Replace the 2.800 mm (0.1102 in.)
shim with a No. 12 shim.New shim thickness mm (in.)
HINT: New shims have the thickness in
millimeters imprinted on the face. Shim
No.Shim
No. Thickness Thickness
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
EM−7
826 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine V06209
Adjusting Shim Selection Chart (Exhaust)
mm (in.) Installed shim thickness
mm (in.) Measured clearance
Exhaust valve clearance (Cold):
0.27 − 0.37 mm (0.011 − 0.014 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is
installed and measured clearance is 0.450 mm
(0.0177 in.). Replace the 2.800 mm (0.1102 in.)
shim with a No. 12 shim.New shim thickness mm (in.)
Shim
No.
Thickness Thickness
Shim
No.
HINT: New shims have the thickness in
millimeters imprinted on the face.
EM−8
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
827 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine FI7231
TOYOTA Hand−Held Tester
DLC3EM06E−05
P19970
SSTDLC1
TE1 E1
DLC1
P21121
− ENGINE MECHANICAL (5VZ−FE)IGNITION TIMING
EM−9
828 Author: Date:
1996 TOYOTA T100 (RM449U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND−HELD TESTER OR
OBDII SCAN TOOL
(a) Connect the TOYOTA hand−held tester or OBDII scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand−held tester or OBDII
scan tool operator’s manual for further details.
3. CONNECT TIMING LIGHT TO ENGINE
4. CHECK IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 se-
conds.
(b) Check the idle speed.
Idle speed:
700 ± 50 rpm
5. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the
DLC1.
SST 09843−18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
8 − 12° BTDC @ idle
(Transmission in neutral position)
(c) Remove the SST from the DLC1.
SST 09843−18020
6. FURTHER CHECK IGNITION TIMING
Ignition timing:
12.5 − 22° BTDC @ idle
(Transmission in neutral position)
HINT:
The timing mark moves in a range between
12.5° and 22°.
7. DISCONNECT TIMING LIGHT FROM ENGINE
8. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBDII SCAN TOOL

Downloaded from www.Manualslib.com manuals search engine EM06F−01
EM−10
− ENGINE MECHANICAL (5VZ−FE)IDLE SPEED
829 Author: Date:
1996 TOYOTA T100 (RM449U)
IDLE SPEED
INSPECTION
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
w/ EGR: All vacuum hoses for EGR system, etc. should be
properly connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing check correctly
(h) Transmission in neutral position
2. CONNECT TOYOTA HAND−HELD TESTER OR OBD II
SCAN TOOL (See page EM−9)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 se-
conds.
(b) Check the idle speed.
Idle speed:
700 ± 50 rpm
If the idle speed is not as specified, check the IAC valve and air
intake system.
4. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBD II SCAN TOOL

Downloaded from www.Manualslib.com manuals search engine EM06G−03
P20840
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−11
830 Author: Date:
1996 TOYOTA T100 (RM449U)
TIMING BELT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine EM−12
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
831 Author: Date:
1996 TOYOTA T100 (RM449U)