TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P20861
Front Mark
(Arrow)
Z14732
EM5369
FrontPainted
Mark
EM5370
Painted Mark
90°
90°
P00591
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
(b) Install the main bearing cap with the front mark facing for-
ward.
8. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any main bearing cap bolt is broken or deformed, re-
place it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 8 main bearing cap bolts,
in several passes, in the sequence shown.
Torque: 61 N·m (625 kgf·cm, 45 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance (See page
EM−92).
9. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.

Downloaded from www.Manualslib.com manuals search engine Z14819
FrontFront
Mark
(Cavity)
P00655
Front Mark
(Protrusion)
EM5345
P02237
Painted
MarkFront EM−104
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
10. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
11. INSTALL CONNECTING ROD CAP NUTS
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed, replace
it.
(a) Apply a light of engine oil on the threads and under the
nuts of the connecting rod cap.
(b) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
If any one of the connecting rod cap nuts does not meet the
torque specification, replace the cap nut.
(c) Mark the front of the connecting rod cap nut and bolt with
paint.

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Painted Mark
90°90°
EM5292
A
A B
B Seal Width
2 − 3 mm
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−105
1996 TOYOTA T100 (RM449U)
(d) Retighten the connecting rod cap nuts 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance (See page
EM−92).
12. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the retainer
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing:
Part No.08826−00080 or equivalent
 Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil seal retainer with the 6 bolts.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)
13. INSTALL OIL PUMP (See page LU−14)
14. INSTALL OIL PAN BAFFLE PLATE
15. INSTALL OIL STRAINER (See page LU−14)
16. INSTALL OIL PAN (See page LU−14)
17. w/ OIL COOLER:
INSTALL OIL COOLER WITH WATER BYPASS HOSE
AND OIL COOLER UNION (See page LU−20)
18. w/o OIL COOLER:
INSTALL OIL HOLE COVER PLATE
Torque: 60 N·m (600 kgf·cm, 44 ft·lbf)
19. INSTALL COOLANT DRAIN COCK
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
20. INSTALL RH AND LH ENGINE MOUNTING BRACKETS
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
21. INSTALL OIL FILTER UNION
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P00496
Adhesive
P10226
Seal Width
2 − 3 mm EM−106
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
22. INSTALL OIL FILTER (See page LU−3 )
23. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833 − 00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, install the oil pressure switch.
SST 09816−30010
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
24. INSTALL GENERATOR ADJUSTING BAR
Torque: 42 N·m (420 kgf·cm, 31 ft·lbf)
25. INSTALL WATER PUMP (See page CO−7)
26. INSTALL KNOCK SENSORS
Using SST, install the 2 knock sensors.
SST 09816−30010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
27. INSTALL NO.2 IDLER PULLEY BRACKET
Torque: 38 N·m (380 kgf·cm, 28 ft·lbf)
28. INSTALL WATER BYPASS PIPE WITH KNOCK SEN-
SOR WIRE
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the bypass
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the groove of the bypass pipe.
Seal packing:
Part No. 08826 − 00100 or equivalent
Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Downloaded from www.Manualslib.com manuals search engine P00601
Adhesive
P21461
1
5
3
7
2 68
4
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−107
1996 TOYOTA T100 (RM449U)
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the bypass pipe with the 2 bolts and nut.
Torque: 8.5 N·m (85 kgf·cm, 75 in.·lbf)
(d) Connect the 2 knock sensor connectors.
29. INSTALL CYLINDER HEADS
30. INSTALL PULLEYS AND TIMING BELT
(See page EM−19)
31. REMOVE ENGINE STAND
32. INSTALL REAR END PLATE
Torque: 7.5 N·m (75 kgf·cm, 66 in.·lbf)
33. A/T:
INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)
34. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine EM07F−01
P24419
EM−108
− ENGINE MECHANICAL (5VZ−FE)EXHAUST SYSTEM
927 Author: Date:
1996 TOYOTA T100 (RM449U)
EXHAUST SYSTEM
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine P24450
− ENGINE MECHANICAL (5VZ−FE)EXHAUST SYSTEM
EM−109
928 Author: Date:
1996 TOYOTA T100 (RM449U)

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EMISSION CONTROL SYSTEM EC-1
PARTS LAYOUT AND SCHEMATIC
DRAWING EC-2
POSITIVE CRANKCASE VENTILATION
(PCV) SYSTEM EC-4
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM EC-5
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM EC-7
THREE-WAY CATALYTIC CONVERTER
(TWC) SYSTEM EC-10

Downloaded from www.Manualslib.com manuals search engine EC02N−02
− EMISSION CONTROL (3RZ−FE)EMISSION CONTROL SYSTEM
EC−1
929 Author: Date:
1996 TOYOTA T100 (RM449U)
EMISSION CONTROL SYSTEM
PURPOSE
The emission control systems are installed to reduce the amount of CO, HC and NOx exhausted from the
engine ((3), (4) and (5)), to prevent the atmospheric release of blow−by gas−containing HC (1) and evapo-
rated fuel containing HC being released from the fuel tank (2).
The function of each system is shown in these table.
SystemAbbreviationFunction
(1) Positive Crankcase Ventilation
(2) Evaporative Emission Control
(3) Exhaust Gas Recirculation
(4) Three−Way Catalytic Converter
(5) Multiport Fuel Injection *PCV
EVAP
EGR
TWC
MFIReduces HC
Reduces evaporated HC
Reduces NOx
Reduces CO, HC and NOx
Injects a precisely timed, optimum amount of fuel for reduced exhaust
emissions
Remark: * For inspection and repair of the MFI system, refer to the MF section this manual.

Downloaded from www.Manualslib.com manuals search engine EC02O−02
EC−2
− EMISSION CONTROL (3RZ−FE)PARTS LAYOUT AND SCHEMATIC DRAWING
930 Author: Date:
1996 TOYOTA T100 (RM449U)
PARTS LAYOUT AND SCHEMATIC DRAWING
LOCATION