TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P20511
45° Carvide
Cutter
P12729
Width
Z11441
30°
45°
1.0 − 1.4 mm
Z00139
60°
45°
1.0 − 1.4 mm
P20513
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−43
1996 TOYOTA T100 (RM449U)
12. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats. Re-
move only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a thin coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate the valve.
(c) Check the valve face and seat for these:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with these width.
1.0 − 1.4 mm (0.039 − 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
(2) If the seating is too low on the valve face, use 60°
and 45° cutters to correct the seat.
(d) Hand−lap the valve and valve seat with an abrasive com-
pound.
(e) After hand−lapping, clean the valve and valve seat.

Downloaded from www.Manualslib.com manuals search engine EM0988
Deviation
EM0801
EM0281
EM1628
EM2011
EM−44
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
13. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the squareness of the
valve spring.
Maximum deviation:
2.0 mm (0.079 in.)
If deviation is greater than maximum, replace the valve spring.
(b) Using vernier calipers, measure the free length of the
valve spring.
Free length:
44.78 mm (1.7630 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186 − 206 N (19.0 − 21.0 kgf, 41.9 − 46.3 lbf)
at 33.3 mm (1.311 in.)
If the installed tension is not as specified, replace the valve
spring.
14. INSPECT CAMSHAFT FOR RUNOUT
(a) Place the camshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
15. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Cam lobe height:
Standard Intake
Exhaust42.31 − 42.41 mm (1.6657 − 1.6697 in.)
41.96 − 42.06 mm (1.6520 − 1.6559 in.)
Minimum Intake
Exhaust42.16 mm (1.6598 in.)
41.81 mm (1.6461 in.)
If the cam lobe height is greater than maximum, replace the
camshaft.

Downloaded from www.Manualslib.com manuals search engine EM2538
EM3322
Free Distance
P20858Plastigage
P20852
P20855
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−45
1996 TOYOTA T100 (RM449U)
16. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.949 − 26.965 mm (1.0610 − 1.0616 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
17. INSPECT CAMSHAFT BEARINGS
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
18. INSPECT CAMSHAFT GEAR SPRING
Using vernier calipers, measure the free distance between the
spring ends.
Free distance:
18.2 − 18.8 mm (0.712 − 0.740 in.)
If the free distance is not as specified, replace the gear spring.
19. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps (See page EM−51).
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
0.035 − 0.072 mm (0.0014 − 0.0028 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the plastigage.
20. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts (See page EM−51).
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.033 − 0.080 mm (0.0013 − 0.0031 in.)
Maximum thrust clearance:
0.12 mm (0.0047 in.)

Downloaded from www.Manualslib.com manuals search engine P20856
P20509
EM2196
EM−46
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
21. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshafts without installing the exhaust cam-
shaft sub−gear (See page EM−51).
(b) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
Maximum backlash:
0.30 mm (0.0188 in.)
If the backlash is greater than maximum, replace the cam-
shafts.
22. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.000 − 31.018 mm (1.2205 − 1.2212 in.)
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 − 30.976 mm (1.2191 − 1.2195 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.024 − 0.052 mm (0.0009 − 0.0020 in.)
Maximum oil clearance:
0.08 mm (0.0031 in.)

Downloaded from www.Manualslib.com manuals search engine Z14655
Cylinder Head Side
Intake Air Connector Side
Z14656
LH Side
RH Side
P21621
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−47
1996 TOYOTA T100 (RM449U)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
23. INSPECT INTAKE MANIFOLD, EXHAUST MAN-
IFOLDS, AIR INTAKE CHAMBER AND INTAKE AIR
CONNECTOR
(a) Intake Manifold:
Using precision straight edge and thickness gauge, mea-
sure the surfaces contacting the cylinder head and intake
air connector for warpage.
Maximum warpage:
0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the intake man-
ifold.
(b) Exhaust Manifolds:
Measure the surfaces contacting the cylinder head for
warpage.
Maximum warpage:
1.00 mm (0.0394 in.)
If warpage is greater than maximum, replace the exhaust man-
ifold.
(c) Air Intake Chamber and intake air connector:
Measure the surfaces contacting the intake manifold and
intake air connector for warpage.
Maximum warpage:
0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the air intake
chamber or intake air connector.

Downloaded from www.Manualslib.com manuals search engine P20843
P20987
P24420
EM−48
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
24. IF NECESSARY, REPLACE SPARK PLUG TUBE GAS-
KETS
(a) Bend up the tab on the ventilation baffle plate which pre-
vents the gasket from the slipping out.
(b) Using a screwdriver and hammer, tap out the gasket.
NOTICE:
Do not scratch or damage the joint of the cylinder head cov-
er.
(c) Using needle−nose pliers, pry out the gasket.
(d) Using a 32 mm socket wrench and hammer, tap in a new
gasket until its surface is flush with the upper edge of the
cylinder head cover.
(e) Apply a light coat of MP grease to the gasket lip.
(f) Return the ventilation plate tab to its original position.

Downloaded from www.Manualslib.com manuals search engine EM06O−03
P11511
Adhesive
10 − 15 mm (0.39 − 0.59 in.)
P20850
Protrusion
P20842SST
Z09175
Silver Rubber Black Rubber
Plain Surface Coated Surface Intake Exhaust
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−49
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Apply adhesive to the end of the spark plug tube.
Adhesive:
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent
(b) Using a press, press in a new spark plug tube until there
is 49.0 − 49.4 mm (1.929 − 1.945 in.) protruding from the
camshaft bearing cap installation surface of the cylinder
head.
NOTICE:
Avoid pressing a new spark plug tube in too far by measur-
ing the amount of the protrusion while pressing.
2. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201−41020
HINT:
The intake valve oil seal is silver and the exhaust valve oil seal
is black.

Downloaded from www.Manualslib.com manuals search engine P20989
P20847
SST
P20848
P12390
Seal
Packing
P20844
EM−50
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(b) Install these parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020 (09202−00010)
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to ensure a proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
4. INSTALL CAMSHAFT HOUSING PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the bearing cap as shown.
Seal packing:
Part No. 08826−00080 or equivalent
(c) Place a new housing plug in position on the cylinder head,
facing the cap side inward.
(d) Install the camshaft bearing cap with the 2 bolts.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(e) Install the cylinder head rear plate, ground strap with the
bolt and nut.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P21247
Front
RH
LH
EM1OR−01
Z14657
12 Pointed Head Bolt
Front
P21151
Painted Mark
Front
P00868
90°
90°
90°90°
Painted
Mark
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−51
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place 2 new cylinder head gaskets in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(b) Place the 2 cylinder heads in position on the cylinder head
gaskets.
2. INSTALL 12 POINTED HEAD CYLINDER HEAD BOLTS
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b), (d) and (e)).
If any bolt is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install and uniformly tighten the cylinder head bolts on
each cylinder head, in several passes, in the sequence
shown, then repeat for the other side, as shown.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts by 90° in the numerical
order shown.
(e) Retighten the cylinder head bolts by an additional 90°.
(f) Check that the painted mark is now facing rearward.

Downloaded from www.Manualslib.com manuals search engine Z14658
Recessed Head Bolt
8 mm Hexagon
Wrench
Front
P21041
P21037
EM−52
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
3. INSTALL RECESSED HEAD CYLINDER HEAD BOLTS
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Using an 8 mm hexagon wrench, install the cylinder head
bolt on each cylinder head, then repeat for the other side,
as shown.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
4. CONNECT GROUND STRAP
Install the bolt, and connect the ground strap.
5. ASSEMBLE 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) Install these parts:
(1) Camshaft gear spring
(2) Camshaft sub−gear
HINT:
Attach the pins on the gears to the gear spring ends.
(3) Wave washer
(c) Using snap ring pliers, install the snap ring.