TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P21040
SST
Turn
Z17650
RH
90°
P21199
P12390Seal Packing
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−53
1996 TOYOTA T100 (RM449U)
(d) Using SST, align the holes of the camshaft main gear and
sub−gear by turning camshaft sub−gear clockwise, and
temporarily install a service bolt.
SST 09960−10010 (09962−01000, 09963−00600)
(e) Align the gear teeth of the main gear and sub−gear, and
tighten the service bolt.
6. INSTALL CAMSHAFTS OF RH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be held level while it is being installed. If the
camshaft is not level, the portion of the cylinder head re-
ceiving the shaft thrust may crack or be damaged, causing
the camshaft to seize or break. To avoid this, these steps
should be carried out.
(a) Install the intake camshaft.
(1) Apply new engine oil to the thrust portion and jour-
nal of the camshaft.
(2) Place the intake camshaft at 90° angle of timing
mark (2 dot marks) on the cylinder head.
(b) Apply MP grease to a new oil seal lip.
(c) Install the oil seal to the camshaft.
(d) Remove any old packing (FIPG) material.
(e) Apply seal packing to the No.1 bearing cap as shown.
Seal packing:
Part No. 08826−00080 or equivalent

Downloaded from www.Manualslib.com manuals search engine P21203
P21197
P21142
P21204
P21205
EM−54
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(f) Install the 5 bearing caps in their proper locations.
(g) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(h) Install and uniformly tighten the 10 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(i) Install the exhaust camshaft.
(j) Apply new engine oil to the thrust portion and journal of
the camshaft.
(k) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears.
(l) Place the exhaust camshaft on the cylinder head.
(m) Install the 4 bearing caps in their proper locations.
(n) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(o) Install and uniformly tighten the 8 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(p) Remove the service bolt.

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P21200
P21202
P21201
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−55
1996 TOYOTA T100 (RM449U)
7. Intake:
INSTALL CAMSHAFTS OF LH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be held level while it is being installed. If the
camshaft is not level, the portion of the cylinder head re-
ceiving the shaft thrust may crack or be damaged, causing
the camshaft to seize or break. To avoid this, these steps
should be carried out.
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b) Place the intake camshaft at 90° angle of timing mark (1
dot mark) on the cylinder head.
(c) Apply MP grease to a new oil seal lip.
(d) Install the oil seal to the camshaft.
(e) Remove any old packing (FIPG) material.
(f) Apply seal packing to the No.1 bearing cap.
Seal packing:
Part No. 08826−00080 or equivalent
(g) Install the 5 bearing caps in their proper locations.
(h) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(i) Install and uniformly tighten the 10 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)

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P21162
P21159
P13274Seal Packing EM−56
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
8. Exhaust:
INSTALL CAMSHAFTS OF LH CYLINDER HEAD
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b) Align the timing marks (1 dot mark) of the camshaft drive
and driven gears.
(c) Place the exhaust camshaft on the cylinder head.
(d) Install the 4 bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under
the heads of bearing cap bolts.
(f) Install and uniformly tighten the 8 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(g) Remove the service bolt.
9. CHECK AND ADJUST VALVE CLEARANCE
10. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi−circular plug grooves.
Seal packing:
Part No. 08826−00080 or equivalent

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: Semi−Circular Plug
Front
P00827
Front: Seal Packing
P21195
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−57
1996 TOYOTA T100 (RM449U)
(c) Install the 4 semi−circular plugs to the cylinder heads.
11. INSTALL CYLINDER HEAD COVERS
(a) Apply seal packing to the cylinder heads as shown in the
illustration.
Seal packing:
Part No. 08826−00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the 8 bolts. Uniformly
tighten the bolts in several passes. Install the 2 cylinder
head covers.
Torque: 6 N·m (60 kgf·cm, 53 in.·lbf)
12. INSTALL RH AND LH EXHAUST MANIFOLDS
(a) Install 2 new gaskets, the RH and LH exhaust manifolds
with the 12 nuts.
Torque: 40 N·m (400 kgf·cm, 30 ft·lbf)
(b) Install the exhaust manifold heat insulators with the 6
nuts.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)
13. INSTALL EXHAUST CROSSOVER PIPE
Install 2 new gaskets and the crossover pipe with the 6 nuts.
Torque: 45 N·m (450 kgf·cm, 33 ft·lbf)
14. INSTALL GENERATOR BRACKET
Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
15. INSTALL OIL DIPSTICK AND GUIDE
(a) Install a new O−ring to the dipstick guide.
(b) Apply soapy water to the O−ring.
(c) Push in the dipstick guide end into the guide hole of the
oil pan.

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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)

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S02073
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−59
1996 TOYOTA T100 (RM449U)
21. CONNECT ENGINE WIRE
(a) Install the engine wire with the 3 bolts.
(b) Connect the 3 engine wire clamps.
(c) Connect 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
22. INSTALL INTAKE AIR CONNECTOR
(a) Install a new gasket and the intake air connector with the
3 bolts and 2 nuts.
Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
(b) Connect the DLC1 to the bracket.
(c) Install the bolt, and connect the ground strap to the intake
air connector.
(d) Connect the brake booster vacuum hose to the intake air
connector.
(e) Connect the 2 fuel return hoses.
(f) Install the engine wire with the bolt.
(g) w/ A/C
Connect the A/C idle−up valve connector.

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EM−60
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
23. INSTALL AIR INTAKE CHAMBER ASSEMBLY
(a) Install a new gasket and the air intake chamber assembly
with the 4 bolts and 2 nuts.
Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
(b) Connect these hoses:
2 PCV hoses
2 water bypass hoses
Air assist hose to throttle body
w/ EGR:
Water bypass hose
EVAP hose
Air hose to PS pump
w/ A/C
Air hose to A/C idle−up valve
(c) Connect these connectors:
VSV connector for fuel pressure control
Throttle position sensor connector
IAC valve connector
w/ EGR:
EGR gas temperature sensor connector
VSV connector for EGR
24. INSTALL AIR INTAKE CHAMBER STAY
(a) Install the air intake chamber stay with the 2 bolts.
Torque:
14 mm head bolt: 40 N·m (400 kgf·cm, 30 ft·lbf)
12 mm head bolt: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
(b) A/T:
Install a new O−ring to the oil filler tube.
(c) Apply soapy water to the O−ring.
(d) Push in the oil filler tube end into the tube hole of the oil
pan.
(e) Install the oil filler tube and No.1 throttle cable clamp with
the 2 nuts, bolt.
(f) Install the dipstick.
25. w/ EGR:
INSTALL EGR PIPE
Install 2 new gaskets and the EGR pipe with the 6 nuts.
Torque:
Nut A: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
Nut B: 8 N·m (80 kgf·cm, 71 in.·lbf)
26. TEMPORARILY INSTALL GENERATOR

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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

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EM−62
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
881 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE UNIT (2WD)
COMPONENTS