TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine EM1OO−01
P20830
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−13
1996 TOYOTA T100 (RM449U)
REMOVAL
1. 4WD:
REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT UPPER RADIATOR HOSE
4. REMOVE DRIVE BELT FOR PS PUMP
5. w/ A/C:
REMOVE DRIVE BELT FOR A/C COMPRESSOR
6. REMOVE DRIVE BELT FOR GENERATOR
7. REMOVE NO. 2 FAN SHROUD
8. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
9. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
10. w/ A/C:
DISCONNECT A/C COMPRESSOR FROM ENGINE
HINT:
Put aside the compressor, and suspend it.
11. w/ A/C:
REMOVE A/C COMPRESSOR BRACKET
12. REMOVE NO.2 TIMING BELT COVER
(a) Disconnect the camshaft position sensor connector from
the No.2 timing belt cover.
(b) Disconnect the 3 high−tension cord clamps from the No.2
timing belt cover.
(c) Remove the 6 bolts, and timing belt cover.
13. REMOVE FAN BRACKET
(a) Remove the nut and PS pump adjusting strut.
(b) Remove the bolt, nut, and fan bracket.

Downloaded from www.Manualslib.com manuals search engine P20829
P20826
P20818
P20831
P20833
EM−14
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
14. SET NO.1 CYLINDER AT TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with timing
mark ”0” of the No.1 timing belt cover.
(b) Check that the timing marks of the camshaft timing pul-
leys and No.3 timing belt cover are aligned.
If not, turn the crankshaft pulley 1 revolution (360°).
HINT:
When re−using timing belt: Place the matchmarks on the timing
belt and camshaft timing pulleys, and place matchmark on tim-
ing belt to match the end of the No.1 timing belt cover.
15. REMOVE TIMING BELT TENSIONER
Alternately loosen the 2 bolts, and remove them, the belt ten-
sioner and dust boot.
16. REMOVE RH CAMSHAFT TIMING PULLEY WITH TIM-
ING BELT
(a) Using SST, loosen the pulley bolt.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the bolt, knock pin and camshaft timing pulley
with timing belt.

Downloaded from www.Manualslib.com manuals search engine P20825
P20516
SST
SST
P20515
SST
P20500
P20499
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−15
1996 TOYOTA T100 (RM449U)
17. REMOVE LH CAMSHAFT TIMING PULLEY
(a) Using SST, loosen the pulley bolt.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the bolt, knock pin and camshaft timing pulley.
18. REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the pulley bolt.
SST 09213−54015 (90119−08216),
09330−00021
(b) Remove the SST, pulley bolt and pulley.
HINT:
If necessary, remove the pulley with SST and service bolt.
SST 09950−50010 (09551−05010, 09552−05010,
09553−05020, 09554−05030)
19. REMOVE STARTER WIRE BRACKET AND NO.1 TIM-
ING BELT COVER
(a) Remove the 2 bolts, starter wire bracket.
(b) Remove the 4 bolts, timing belt cover.
20. REMOVE TIMING BELT GUIDE
21. REMOVE TIMING BELT
HINT:
When re−using timing belt: If the installation marks have disap-
peared, place a new installation mark on the timing belt to
match the drilled mark of the crankshaft timing pulley.
22. REMOVE NO.2 IDLER PULLEY AND NO.1 IDLER
PULLEY
(a) Remove the bolt and No.2 idler pulley.
(b) Using a 10 mm hexagon wrench, remove the pivot bolt,
No.1 idler pulley and plate washer.

Downloaded from www.Manualslib.com manuals search engine P20816
SST
EM−16
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
23. REMOVE CRANKSHAFT TIMING PULLEY
Remove crankshaft timing pulley.
HINT:
If the pulley cannot be removed by hand, use SST and service
bolt to remove the crankshaft timing pulley.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05020, 09954−05010)

Downloaded from www.Manualslib.com manuals search engine EM06I−06
A01568
No!
OIL
P20043
P12604
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−17
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.Do not
allow the timing belt to come into contact with oil, water or
steam. Do not utilize timing belt tension when installing or
removing the mount bolt of the camshaft timing pulley.
If there are any defects, as shown in the illustrations, check
these points:
(a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check to see if there are nicks on the side of the idler
pulley lock and water pump.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check timing
cover for damage and check gasket has been installed
correctly and for foreign material on the pulley teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS
(a) Visually check the seal portion of the idler pulley for oil
leakage.
If leakage is found, replace the idler pulley.
(b) Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.

Downloaded from www.Manualslib.com manuals search engine P18782
P18764
P18770
Protrusion EM−18
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
3. INSPECT TIMING BELT TENSIONER
(a) Visually check the seal portion of the tensioner for oil leak-
age.
HINT:
If there is only the faintest trace of oil on the seal on the push
rod side, the tensioner is all right.
If leakage is found, replace the tensioner.
(b) Hold the tensioner with both hands and push the push rod
strongly as shown to check that it doesn’t move.
If the push rod moves, replace the tensioner.
NOTICE:
Never hold the tensioner push rod facing downward.
(c) Measure the protrusion of the push rod from the housing
end.
Protrusion:
10.0 − 10.8 mm (0.394 − 0.425 in.)
If the protrusion is not as specified, replace the tensioner.

Downloaded from www.Manualslib.com manuals search engine P20822
Inward
Sensor
EM06J−03
P20821
P20499
P20823
Front
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−19
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the timing
pulley and slide on the timing pulley.
(b) Slide on the timing pulley, facing the flange side inward.
2. INSTALL NO. 1 IDLER PULLEY AND NO.2 IDLER
PULLEY
(a) Using a 10 mm hexagon wrench, install the No.1 idler
pulley with the plate washer and bolt.
Torque: 35 N·m (350 kgf·cm, 26 ft·lbf)
(b) Check that the pulley bracket moves smoothly.
(c) Install the No.2 idler pulley with the bolt.
Torque: 40 N·m (400 kgf·cm, 30 ft·lbf)
(d) Check that the pulley moves smoothly.
3. TEMPORARILY INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Use the crankshaft pulley bolt to turn the crankshaft and
align the timing marks on the crankshaft timing pulley and
on the oil pump body.
(b) Remove any oil or water on the crankshaft timing pulley,
idler pulley and water pump pulley, and keep them clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(c) Align the installation mark on the timing belt with the
drilled mark of the crankshaft timing pulley.
(d) Install the timing belt on the crankshaft timing pulley, No.1
idler and water pump pulleys.
4. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.

Downloaded from www.Manualslib.com manuals search engine P20918
Length = 425 mm
(16.73 in.)
P21686
length = 145 mm
(5.71 in.)
P20516
SST SST
P20828
P20827
EM−20
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
5. INSTALL NO.1 TIMING BELT COVER AND STARTER
WIRE BRACKET
(a) Check that the timing belt cover gaskets have cracks or
peeling, etc.
If the gasket does have cracks or peeling, etc., replace it using
following steps.peeling, etc., replace them 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 back in the illustration.
(b) Install the timing belt cover with the 4 bolts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
(c) Install the starter wire bracket with the 2 bolts.
6. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide the pulley.
(b) Using SST, install and torque the bolt.
SST 09213−54015 (90119−08216),
09330−00021
Torque: 250 N·m (2,500 kgf·cm, 184 ft·lbf)
7. INSTALL LH CAMSHAFT TIMING PULLEY
(a) Slide the timing pulley, facing the flange side outward.
(b) Align the knock pin hole of the camshaft with the knock pin
groove of the timing pulley as shown.
(c) Install the knock pin.
(d) Using SST, install and torque the bolt.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 110 N·m (1,100 kgf·cm, 81 ft·lbf)
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Crankshaft Position:
Turn the crankshaft pulley, and align its groove with the
”O” timing mark of the No.1 timing belt cover.

Downloaded from www.Manualslib.com manuals search engine P20820
P20826
P20834
P20836
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−21
1996 TOYOTA T100 (RM449U)
(b) RH Camshaft Position:
Turn the camshaft, align the knock pin hole of the cam-
shaft with the timing mark of the No.3 timing belt cover.
(c) LH Camshaft Pulley Position:
Turn the camshaft timing pulley, align the timing marks of
the camshaft timing pulley and No.3 timing belt cover.
9. INSTALL TIMING BELT TO LH CAMSHAFT TIMING
PULLEY
(a) HINT (When re−using timing belt):
Check that the installation mark on the timing belt
matches the end of the No.1 timing belt cover.
If the installation mark do not align, shift the meshing of the tim-
ing belt and crankshaft timing pulley until they align.
(b) Remove any oil or water on the LH camshaft timing pulley,
and keep it clean.
(c) Using SST, slightly turn the LH camshaft timing pulley
clockwise. Align the installation mark on the timing belt
with the timing mark of the camshaft timing pulley, and
hang the timing belt on the LH camshaft timing pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(d) Using SST, align the timing marks of the LH camshaft
pulley and No.3 timing belt cover.
SST 09960−10010 (09962−01000, 09963−01000)
(e) Check that the timing belt has tension between the crank-
shaft timing and LH camshaft timing pulleys.

Downloaded from www.Manualslib.com manuals search engine P20839
P20832
P08325
P10221
EM−22
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
10. INSTALL RH CAMSHAFT TIMING PULLEY AND TIM-
ING BELT
(a) Remove any oil or water on the RH camshaft timing and
No.2 idler pulleys, and keep them clean.
(b) Align the installation mark on the timing belt with the tim-
ing mark of the RH camshaft timing pulley as shown.
(c) Hang the timing belt on the RH camshaft timing pulley.
(d) Align the timing marks of the RH camshaft timing pulley
and No.3 timing belt cover.
(e) Slide the RH camshaft timing pulley on the camshaft.
(f) Using SST, align the knock pin hole of the camshaft with
the knock pin groove marked R of the pulley and install the
knock pin.
SST 09960−10010 (09962−01000, 09963−01000)
(g) Using SST, install and torque the bolt.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 110 N·m (1,100 kgf·cm, 81 ft·lbf)
11. SET TIMING BELT TENSIONER
(a) Using a press, slowly press in the push rod using 100 −
1,000 kg (220 − 2,205 lb, 981 − 9,807 N) of pressure.
(b) Align the holes of the push rod and housing, pass a 1.5
mm hexagon wrench through the holes to keep the set-
ting position of the push rod.
(c) Release the press.
(d) Install the dust boot to the tensioner.