VALVE BODY ASSEMBLY TOYOTA T100 1996 Factory Service Manual

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SS−20
− SERVICE SPECIFICATIONSSFI (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Fuel line (Union bolt type)34.335025
Fuel line (Flare nut type)34.335025
Fuel line (Flare nut type) using SST2828521
No. 2 timing belt cover x No. 3 timing belt cover99080 in.·lbf
Fuel inlet pipe x Intake manifold88071 in.·lbf
Delivery pipe x Intake manifold1313010
Fuel pump bracket assembly x Fuel tank3.94035 in.·lbf
Fuel tank band x Body4344032
Fuel tank filler pipe x Fuel tank3.94035 in.·lbf
Fuel evaporation vent tube x Fuel tank1.51513 in.·lbf
Fuel pressure regulator x LH delivery pipe88071 in.·lbf
MAF meter x Air cleaner cap6.97261 in.·lbf
VSV assembly x Air intake connector88071 in.·lbf
A/C idle−up valve x Intake air connector2020014
ECT sensor x Intake manifold2020014
Knock sensor x Cylinder block3940029
EGR gas temperature sensor x EGR valve2020014
Heated oxygen sensor x Front exhaust pipe, Center exhaust pipe2020014

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− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
SS−51
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Valve body x Transmission case101007
Oil strainer x Valve body (A340E)5.45548 in.·lbf
Oil strainer case x Valve body (A340F)101007
Oil strainer x Valve body (A340F)6.97061 in.·lbf
Oil pan7.47565 in.·lbf
Drain plug2020515
Parking lock pawl bracket x Transmission case7.47565 in.·lbf
Extension housing x Transmission case (A340E)3637027
Extension housing x Rear mounting insulator2525018
Rear support member x Rear mounting insulator (A340F)1818013
Rear support member x Body (A340F)9597070
Rear mounting insulator x Rear mounting bracket (A340E)1818013
Rear mounting bracket x Frame (A340E)5859042
Propeller shaft x Rear differential (A340E)7475054
Front propeller shaft x Front differential (A340F)7475054
Front propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Rear differential (A340F)7475054
Center support bearing x Body3637027
Drive plate x Crankshaft8385061
Torque converter clutch x Drive plate4142030
Stiffener plate x Engine (A340F)3738027
Stiffener plate x Transmission3738027
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x TWC4849035
Rear support member x Dynamic damper6162044
Oil cooler pipe3435025
Transmission x Engine7173053
Rear end plate x Transmission3738027
Rear support member x Transfer under cover2930021
Cross shaft x Frame2829021
Cross shaft x Transmission131309
Cross shaft x No.1 gear shifting rod131309
Exhaust pipe clamp(3RZ−FE)1919514
Exhaust pipe support bracket x Transmission (3RZ−FE)7173053
Exhaust pipe support bracket x Transmission (5VZ−FE)4445033
Exhaust pipe support bracket x Exhaust pipe (5VZ−FE)4445033
Park/neutral position switch (Nut)3.94035 in.·lbf
Park/neutral position switch (Bolt)131309
No.2 vehicle speed sensor5.45548 in.·lbf
Speedometer driven gear sleeve x Locking plate1616012
ATF temperature sensor x Transmission1515011
Shift lever assembly x Steering column assembly2930022

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− SERVICE SPECIFICATIONSSTEERING
1996 TOYOTA T100 (RM449U) Tie rod end lock nut
5657041
Turn pressure tube union nut10 (13)102 (130)7 (9)
PS gear assembly set bolt and nut8890065
Mount bracket x Suspension crossmember8890065
Control valve shaft x Intermediate shaft3536026
Pressure feed tube x Control valve housing19 (25)195 (250)14 (18)
Return tube x Control valve housing19 (25)195 (250)14 (18)
Tie rod end x Steering knuckle9092067
4WD:
Pressure feed tube x PS gear assembly36 (44)365 (450)26 (33)
Return tube x PS gear assembly36 (44)365 (450)26 (33)
PS gear assembly x Body1421450105
Pitman arm x Cross shaft1771800130
Cross shaft adjusting screw set nut4647034
Side cover x Gear housing6162045
Plunger guide nut2020515
Worm gear valve body assembly x Gear housing6162045
Worm gear valve body assembly x Intermediate shaft3536026
STEERING LINKAGE
Pitman arm x Cross shaft1771800130
Pitman arm x Relay rod9092067
Tie rod clamp bolt2222516
Tie rod assembly x Relay rod9092067
Tie rod assembly x Knuckle arm9092067
Idler arm assembly x Frame1421450105
Relay rod x Idler arm assembly5960043
Steering damper set bolt and nut2526019
Relay rod x Steering damper5960043
IDLER ARM
Idler arm x Idler arm bracket7880058
( ): For use without SST

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− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−31
1996 TOYOTA T100 (RM449U)
21. w/ EGR:
REMOVE EGR PIPE
Remove the 6 nuts, EGR pipe and 2 gaskets.
22. REMOVE INTAKE CHAMBER STAY
(a) A/T:
Remove the bolt, 2 nuts, oil filler tube and No.1 throttle
cable clamp.
(b) Remove the 2 bolts and intake chamber stay.
23. REMOVE AIR INTAKE CHAMBER ASSEMBLY
(a) Disconnect 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
(b) Disconnect these hoses:
(1) 2 PCV hoses
(2) 2 water bypass hoses
(3) Air assist hose from throttle body
(4) 2 Vacuum sensing hoses from VSV
w/ A/C
Air hose from A/C idle−up valve
(5) EVAP hose
(6) Air hose from PS pump
(c) Remove the 4 bolts, 2 nuts, the air intake chamber as-
sembly and gasket.
24. REMOVE INTAKE AIR CONNECTOR
(a) Remove the bolt, and disconnect the engine wire.
(b) Disconnect the 2 fuel return hoses.
(c) Disconnect the brake booster vacuum hose from the in-
take air connector.
(d) Remove the bolt, and disconnect the ground strap from
the intake air connector.
(e) Disconnect the DLC1 from the bracket.
(f) w/ A/C
Disconnect the A/C idle−up valve connector.
(g) Remove the 3 bolts, 2 nuts, intake air connector and gas-
ket.

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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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P24769
P21655
P21654
MF−28
− MFI (3RZ−FE)THROTTLE BODY
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP, MAF METER AND
RESONATOR
(a) Disconnect the MAF meter connector, IAT sensor con-
nector and wire clamp.
(b) Loosen the air cleaner hose clamp.
(c) Loosen the 4 clips, and remove the air cleaner cap, MAF
meter and resonator.
3. M/T:
DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
4. A/T:
DISCONNECT ACCELERATOR AND THROTTLE
CABLES FROM THROTTLE BODY
5. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the 2 air hoses.
(b) Remove the 2 bolts, hose clamp and intake air connector.
6. REMOVE NO.1 AND NO.2 PCV HOSES
7. REMOVE THROTTLE BODY
(a) Disconnect the throttle position sensor connector.
(b) Disconnect the IAC valve connector.
(c) Disconnect the EVAP hose.
(d) Disconnect the 3 vacuum hoses.
(e) Remove the 2 bolts, 2 nuts and disconnect the throttle
body from the air intake chamber.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(f) Remove the throttle body gasket.
HINT:
At the time assembly please refer to the following items.
Install the throttle body with a new gasket.
(g) Disconnect the No.1 and No.2 water bypass hoses from
the throttle body, and remove the throttle body.

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P14867
P14873
P14872
P14874
− LUBRICATION (3RZ−FE)OIL PUMP
LU−9
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls smoothly
into the valve hole by its own weight.
If it does not, replace the relief valve. If necessary, replace the
oil pump assembly.
2. INSPECT ROTOR BODY CLEARANCE
Using a thickness gauge, measure the clearance between the
driven rotor and body.
Standard body clearance:
0.100 − 0.175 mm (0.0039 − 0.0069 in.)
Maximum body clearance:
0.30 mm (0.0118 in.)
If the body clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
3. INSPECT ROTOR SIDE CLEARANCE
Using a thickness gauge and precision straight edge, measure
the clearance between the rotors and precision straight edge.
Standard side clearance:
0.030 − 0.090 mm (0.0012 − 0.0035 in.)
Maximum side clearance:
0.15 mm (0.0059 in.)
If the side clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
4. INSPECT ROTOR TIP CLEARANCE
Using a thickness gauge, measure the clearance between the
drive and driven rotor tips.
Standard tip clearance:
0.110 − 0.240 mm (0.0043 − 0.0094 in.)
Maximum tip clearance:
0.25 mm (0.0098 in.)
If the tip clearance is greater than maximum, replace the rotors
as a set.

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Z11072
P14912
P14866
New O−Ring
− LUBRICATION (3RZ−FE)OIL PUMP
LU−11
1996 TOYOTA T100 (RM449U)
REASSEMBLY
1. INSTALL RELIEF VALVE
(a) Install these parts:
(1) Relief valve
(2) Spring(s)
(3) Retainer
(b) Using snap ring pliers, install the snap ring.
2. INSTALL DRIVE AND DRIVEN ROTORS
(a) Place the drive and driven rotors into the pump body.
(b) Place a new O−ring to the pump body.
(c) Install the pump cover with the 9 screws.

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P20933
Mark
P20970
LU−10
− LUBRICATION (5VZ−FE)OIL PUMP
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE DRIVEN AND DRIVE ROTORS
(a) Remove the 8 screws and pump body cover.
Torque:10 N·m (105 kgf·cm, 8 ft·lbf)
(b) Remove the drive and driven rotors.
HINT:
Place the drive and driven rotor into pump body with the marks
facing the pump body cover side.
2. REMOVE RELIEF VALVE
(a) Unscrew the relief valve plug and gasket.
(b) Remove the spring and relief valve.

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P20968
Relief Valve
P20934
P20935
P20936
− LUBRICATION (5VZ−FE)OIL PUMP
LU−11
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls smoothly
into the valve hole by its own weight.
If the valve does not fall smoothly, replace the valve. If neces-
sary, replace the oil pump assembly.
2. INSPECT ROTOR BODY CIEARANCE
Using a thickness gauge, measure the clearance between the
driven rotor and pump body.
Standard body clearance:
0.10 − 0.18 mm (0.0039 − 0.0069 in.)
Maximum body clearance:
0.30 mm (0.0118 in.)
If the body clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.
3. INSPECT ROTOR TIP CLEARANCE
Using a thickness gauge, measure the clearance between the
drive and driven rotor tips.
Standard tip clearance:
0.11 − 0.24 mm (0.0043 − 0.0094 in.)
Maximum tip clearance:
0.35 mm (0.0138 in.)
If the tip clearance is greater than maximum, replace the rotors
as a set.
4. INSPECT ROTOR SIDE CLEARANCE
Using a thickness gauge and precision straight edge, measure
the clearance between the rotors and precision straight edge.
Standard side clearance:
0.03 − 0.09 mm (0.0012 − 0.0035 in.)
Maximum side clearance:
0.15 mm (0.0059 in.)
If the side clearance is greater than maximum, replace the ro-
tors as a set. If necessary, replace the oil pump assembly.