Page 912 of 2062
Downloaded from www.Manualslib.com manuals search engine P21463
EM1OW−01
P21465
P21464
P21466
EM−84
− 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
Page 933 of 2062
Downloaded from www.Manualslib.com manuals search engine P02238
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)
Page 945 of 2062
Downloaded from www.Manualslib.com manuals search engine P23029
Cap
Filter
EC0JU−01
P15107
P22300
TOYOTA Hand−Held Tester
DLC3
− EMISSION CONTROL (3RZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−7
935 Author: Date:
1996 TOYOTA T100 (RM449U)
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM
INSPECTION
1. INSPECT AND CLEAN FILTER IN EGR VACUUM MOD-
ULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Install the filter and cap.
HINT:
Install the filter with the coarser surface facing the atmospheric
side (outward).
2. INSTALL VACUUM GAUGE
Using a 3−way connector, connect a vacuum gauge to the hose
between the EGR valve and EGR vacuum modulator.
3. INSPECT SEATING OF EGR VALVE
Start the engine and check that the engine starts and runs at
idle.
4. CONNECT TOYOTA HAND−HELD TESTER OR OBDII
SCAN TOOL
(a) Connect the TOYOTA hand−held tester or OBDII scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand−held tester or OBDII
scan tool operators manual for further details.
5. INSPECT VSV OPERATION WITH COLD ENGINE
(a) The engine coolant temperature should be below 50°C
(122°F).
(b) Check that the vacuum gauge indicates zero at 3,500
rpm.
(c) Check that the EGR pipe is not hot.
6. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR
(a) Select the active test mode on the TOYOTA hand−held
tester (VSV is closed.).
Page 958 of 2062
Downloaded from www.Manualslib.com manuals search engine EC02Z−03
S05202
EC−8
− EMISSION CONTROL (5VZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE EGR PIPE
Remove the 6 nuts, EGR pipe and 2 gaskets.
HINT:
At the time of installation, please refer to the following item.Ins-
tall 2 new gaskets.
Torque:
Nut A: 18.5 N·m (185 kgf·cm, 14 ft·lbf)
Nut B: 8.0 N·m (80 kgf·cm, 71 in.·lbf)
3. REMOVE EGR GAS TEMPERATURE SENSOR
4. REMOVE EGR VALVE
(a) Disconnect these hoses from the EGR valve:
Vacuum hose (from VSV for EGR)
EGR hose (from EGR vacuum modulator)
Water hose (from water bypass pipe)
Water bypass hose (from IAC valve)
(b) Remove the 2 nuts, EGR valve and gasket.
Torque: 18.5 N·m (185 kgf·cm, 14 ft·lbf)
HINT:
Use a new gasket.
At the time of installation, please refer to the following item.
(c) Check for sticking and heavy carbon deposits. If problem
is found, replace the EGR valve.
Page 959 of 2062
Downloaded from www.Manualslib.com manuals search engine P23552
P23553
EC02W−02
P19970
DLC1
DLC1 TE1E1SST
P19945
P23554
− EMISSION CONTROL (5VZ−FE)EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−9
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CHECK AND CLEAN FILTER IN EGR VACUUM MOD-
ULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Reinstall the filter and cap.
HINT:
Install the filter with the coarser surface facing out to the atmo-
spheric side.
2. INSTALL VACUUM GAUGE
Using a 3−way connector, connect a vacuum gauge to the hose
between the EGR valve and VSV.
3. INSPECT SEATING OF EGR VALVE
Check that the engine starts and runs at idle.
4. CONNECT TERMINALS TE1 AND E1
Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
5. INSPECT VSV OPERATION WITH COLD ENGINE
(a) The engine coolant temperature should be below 45°C
(113°F).
(b) Check that the vacuum gauge indicates zero at 2,800
rpm.
(c) Check that the EGR pipe is not hot.
6. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR WITH HOT ENGINE
(a) Warm up the engine to above 80°C (176°F).
(b) Check that the vacuum gauge indicates low vacuum at
2,800 rpm.
(c) Disconnect the vacuum hose from port R of the EGR vac-
uum modulator and connect port R directly to the intake
manifold with another hose.
Page 964 of 2062
Downloaded from www.Manualslib.com manuals search engine MF – MFI SYSTEM (3RZ-FE)
MFI SYSTEM MF-1
FUEL PUMP MF-5
FUEL PRESSURE REGULATOR MF-13
INJECTOR MF-16
FUEL TANK AND LINE MF-23
THROTTLE BODY MF-25
IDLE AIR CONTROL (IAC) VALVE MF-31
MASS AIR FLOW (MAF) METER MF-36
EFI MAIN RELAY MF-40
CIRCUIT OPENING RELAY MF-41
VSV FOR EVAPORATIVE EMISSION
(EVAP) MF-43
VSV FOR EXHAUST GAS
RECIRCULATION (EGR) MF-44
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR MF-45
INTAKE AIR TEMPERATURE (IAT)
SENSOR MF-46
KNOCK SENSOR MF-47
EXHAUST GAS RECIRCULATION
(EGR) GAS TEMPERATURE SENSOR MF-48
HEATED OXYGEN SENSOR MF-49
ENGINE CONTROL MODULE (ECM) MF-50
FUEL CUT RPM MF-54
Page 982 of 2062
Downloaded from www.Manualslib.com manuals search engine SF1QI−01
MF−18
− MFI (3RZ−FE)INJECTOR
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
(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 THROTTLE AND ACCELERATOR
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. DISCONNECT HIGH−TENSION CORDS FROM SPARK
PLUGS
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
Disconnect the distributor connector.
8. REMOVE THROTTLE BODY (See page MF−28)
9. REMOVE DELIVERY PIPE AND INJECTORS
Page 986 of 2062
Downloaded from www.Manualslib.com manuals search engine MF−22
− MFI (3RZ−FE)INJECTOR
1996 TOYOTA T100 (RM449U)
9. INSTALL MAF METER, RESONATOR AND AIR
CLEANER CAP
10. FILL WITH ENGINE COOLANT
11. RECHECK ENGINE COOLANT LEVEL
