TOYOTA T100 1996 Factory Service Manual

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− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−83
902 Author: Date:
1996 TOYOTA T100 (RM449U)

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− 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

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− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−85
1996 TOYOTA T100 (RM449U)
17. w/ OIL COOLER:
REMOVE OIL COOLER WITH WATER BYPASS HOSE
AND OIL COOLER UNION (See page LU−18)
18. REMOVE OIL PAN (See page LU−9)
19. REMOVE OIL STRAINER (See page LU−9)
20. REMOVE OIL PAN BAFFLE PLATE (See page
LU−9)
21. REMOVE OIL PUMP (See page LU−9)
22. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
23. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.150 − 0.330 mm (0.0059 − 0.0130 in.)
Maximum thrust clearance:
0.38 mm (0.0150 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
24. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Using a punch or numbering stamp, mark the connecting
rod and cap to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.

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− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−101).
Torque:
1st 25 N·m (250 kgf·cm, 18 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).

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1, 2 or 3
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1, 2 or 3
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− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
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1996 TOYOTA T100 (RM449U)
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD
0.024 − 0.053 mm (0.0009 − 0.0021 in.)
U/S 0.25
0.023 − 0.069 mm (0.0009 − 0.0027 in.)
Maximum oil clearance:
0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number marked on the connecting rod cap. There are 3 sizes
of standard bearings, marked ”1”, ”2” and ”3” accordingly.
Reference:
Standard bearing center wall thickness
Mark ”1”1.484 − 1.488 mm (0.0584 − 0.0586 in.)
Mark ”2”1.488 − 1.492 mm (0.0586 − 0.0587 in.)
Mark ”3”1.492 − 1.496 mm (0.0587 − 0.0589 in.)
(k) Completely remove the Plastigage.
25. R E M O V E P I S TO N A N D C O N N E C T I N G R O D A S-
SEMBLIES
(a) Using a ridge reamer, remove the all carbon from the top
of the cylinder.
(b) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(c) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in cor-
rect order.

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− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
26. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
2.440 − 2.490 mm (0.0961 − 0.0980 in.)
27. REMOVE MAIN BEARING CAP AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts,
in several passes, in the sequence shown.
(b) Using a screwdriver, pry up the main bearing cap, and re-
move the main bearing cap, lower main bearings and low-
er thrust washers (No.2 journal position of main bearing
cap only).
HINT:
Keep the lower main bearings and lower thrust washers togeth-
er with the main bearing cap.
(c) Lift out the crankshaft.
HINT:
Keep the upper main bearings and upper thrust washers to-
gether with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing cap with the 8 bolts (See page
EM−101).
Torque:
1st 61 N·m (625 kgf·cm, 45 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 8 bolts and main bearing cap (See procedure
(a) and (b) above).
(j) Measure the Plastigage at its widest point.

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Mark
1, 2 or 3
Mark
1, 2, 3, 4 or 5 No. 1
No. 2
No. 3
No. 4
Mark 0, 1 or 2Mark F
No. 1
No. 2
No. 3
No. 4
No. 4
Crank Pin
No. 3 Crank Pin
5 Cylinder block
Crankshaft
Use bearingNumber marked
1
1
111
000 2
2
2
222 3
333
44
EXAMPLE: Cylinder block ”2” + Crankshaft ”1”
= Total number 3 (Use bearing ”3”)
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−89
1996 TOYOTA T100 (RM449U)
Standard clearance:
No.1
STD0.020 − 0.038 mm (0.0008 − 0.0015 in.)
U/S 0.250.019 − 0.059 mm (0.0007 − 0.0023 in.)
Others
STD0.024 − 0.042 mm (0.0009 − 0.0017 in.)
U/S 0.250.023 − 0.063 mm (0.0009 − 0.0025 in.)
Maximum clearance:
0.08 mm (0.0031 in.)
HINT:
If replacing the cylinder block subassembly, the bearing stan-
dard clearance will be:
No.1
0.010 − 0.049 mm (0.0004 − 0.0020 in.)
Others
0.014 − 0.053 mm (0.0006 − 0.0021 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then selecting the
bearing with the same number as the total. There are 5 sizes
of standard bearings, marked ”1”, ”2”, ”3”, ”4” and ”5” according-
ly.
Reference:
Standard sized bearing center wall thickness:
No.1
Mark ”1”1.991 − 1.994 mm (0.0784 − 0.0785 in.)
Mark ”2”1.994 − 1.997 mm (0.0785 − 0.0786 in.)
Mark ”3”1.997 − 2.000 mm (0.0786 − 0.0787 in.)
Mark ”4”2.000 − 2.003 mm (0.0787 − 0.0789 in.)
Mark ”5”2.003 − 2.006 mm (0.0789 − 0.0790 in.)

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− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
Others
Mark ”1”1.989 − 1.992 mm (0.0783 − 0.0784 in.)
Mark ”2”1.992 − 1.995 mm (0.0784 − 0.0785 in.)
Mark ”3”1.995 − 1.998 mm (0.0785 − 0.0787 in.)
Mark ”4”1.998 − 2.001 mm (0.0787 − 0.0788 in.)
Mark ”5”2.001 − 2.004 mm (0.0788 − 0.0789 in.)
Cylinder block main journal bore diameter:
Mark ”1”68.010 − 68.016 mm (2.6776 − 2.6778 in.)
Mark ”2”68.016 − 68.022 mm (2.6778 − 2.6780 in.)
Mark ”3”68.022 − 68.028 mm (2.6780 − 2.6783 in.)
Crankshaft main journal diameter:
Mark ”0”63.996 − 64.000 mm (2.5195 − 2.5197 in.)
Mark ”1”63.990 − 63.996 mm (2.5193 − 2.5195 in.)
Mark ”2”63.985 − 63.990 mm (2.5191 − 2.5193 in.)
(k) Completely remove the Plastigage.
28. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust wash-
ers from the cylinder block.
HINT:
Arrange the main bearings and thrust washers in correct order.
29. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
30. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the piston rings in the correct order only.

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− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
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1996 TOYOTA T100 (RM449U)
31. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to about 60°C (140°F).
(c) Using a plastic−faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

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Mark 1, 2 or 3
No.6 Front
No.1
No.3No.5
No.2 No.4 EM−92
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
INSPECTION
1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
top surface of the cylinder block.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, thoroughly clean the cylinder
block.
3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder head gasket for warpage.
Maximum warpage:
0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
4. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 6 cylinders. If nec-
essary, replace the cylinder block.
5. INSPECT CYLINDER BORE DIAMETER
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the
top of the cylinder block.