1996 TOYOTA T100 engine

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− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−29
848 Author: Date:
1996 TOYOTA T100 (RM449U)

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EM−30
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
REMOVAL
1. 4WD:
REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT EXHAUST PIPE (See page EM−108)
4. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
5. DISCONNECT THESE CABLES:
(a) w/ Cruise control:
Cruise control actuator cable
(b) Accelerator cable
(c) A/T:
Throttle cable
6. DISCONNECT HEATER HOSE
7. DISCONNECT UPPER RADIATOR HOSE
8. REMOVE DRIVE BELT FOR PS PUMP
(a) Stretch the belt and loosen the fan pulley mounting nuts.
9. w/ A/C:
REMOVE DRIVE BELT FOR A/C COMPRESSOR
10. REMOVE DRIVE BELT FOR GENERATOR
11. REMOVE NO. 2 FAN SHROUD
12. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
13. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
14. w/ A/C:
DISCONNECT A/C COMPRESSOR FROM ENGINE
HINT:
Put aside the compressor, and suspend it.
15. w/ A/C:
REMOVE A/C COMPRESSOR BRACKET
16. REMOVE HIGH−TENSION CORDS WITH IGNITION
COILS
17. REMOVE SPARK PLUGS
18. REMOVE TIMING BELT AND CAMSHAFT TIMING
PULLEYS (See page EM−13)
19. REMOVE TIMING BELT IDLER NO. 2 (See page
EM−13)
20. REMOVE GENERATOR

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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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P21193
P21192
P21195
EM−32
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
25. DISCONNECT ENGINE WIRE
(a) Disconnect 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
(b) Disconnect the 3 engine wire clamps.
(c) Remove the 3 bolts, and disconnect the engine wire from
the cylinder head.
26. REMOVE CAMSHAFT POSITION SENSOR
27. REMOVE NO.3 TIMING BELT COVER
Remove the 6 bolts and timing belt cover.
28. REMOVE FUEL PRESSURE REGULATOR
29. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the fuel inlet hose.
(b) Remove the 2 bolts and the intake manifold stay.
(c) Remove the 8 bolts, 4 nuts, 4 plate washers, intake man-
ifold, delivery pipes and injectors assembly and 2 gas-
kets.
30. REMOVE PS PUMP BRACKET
31. REMOVE OIL DIPSTICK AND GUIDE
(a) Remove the 2 bolts holding the dipstick guide to the gen-
erator bracket.
(b) Pull out the dipstick guide together with the dipstick from
the oil pan.
(c) Remove the O−ring from the dipstick guide.
32. REMOVE GENERATOR BRACKET
33. REMOVE EXHAUST CROSSOVER PIPE
Remove the 6 nuts, crossover pipe and 2 gaskets.
34. REMOVE LH AND RH EXHAUST MANIFOLDS
(a) Remove the 6 nuts and exhaust manifold heat insulators.
(b) Remove the 12 nuts, LH, RH exhaust manifolds and gas-
ket.

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P00867
P21146
P21145
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−33
1996 TOYOTA T100 (RM449U)
35. REMOVE CYLINDER HEAD COVERS
Remove the 8 bolts, seal washers, cylinder head cover and
gasket. Remove the 2 cylinder head covers.
36. REMOVE SEMI−CIRCULAR PLUGS
37. Exhaust:
REMOVE 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 removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, these
steps should be carried out.
(a) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub−gear to the main gear
with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 − 20 mm
HINT:
When removing the camshaft, mark certain that the torsional
spring force of the sub−gear has been eliminated by the above
operation.
(c) Uniformly loosen and remove the 8 bearing cap bolts, in
several passes, in the sequence shown.
(d) Remove the 4 bearing caps and exhaust camshaft.
38. Intake:
REMOVE CAMSHAFTS OF RH CYLINDER HEAD
(a) Uniformly loosen and remove the 10 bearing cap bolts, in
several passes, in the sequence shown.
(b) Remove the 5 bearing caps, oil seal and intake camshaft.

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P00897
P21144
P21143
EM−34
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
39. Exhaust:
REMOVE 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 removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, these
steps should be carried out.
(a) Align the timing marks (1 dot mark) of the camshaft drive
and driven gears by turning the camshaft with a wrench.
(b) Secure the exhaust camshaft sub−gear to the main gear
with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 − 20 mm
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub−gear has been eliminated by the above
operation.
(c) Uniformly loosen and remove the 8 bearing cap bolts, in
several passes, in the sequence shown.
(d) Remove the 4 bearing caps and exhaust camshaft.
40. Intake:
REMOVE CAMSHAFTS OF LH CYLINDER HEAD
(a) Uniformly loosen and remove the 10 bearing cap bolts, in
several passes, in the sequence shown.
(b) Remove the 5 bearing caps, oil seal and intake camshaft.
HINT:
Arrange the camshafts in the correct order.
Arrange the bearing caps in the correct order.

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P21037
Z13745
8 mm Hexagon
FrontRecessed Head BoltWrench
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−35
1996 TOYOTA T100 (RM449U)
41. DISASSEMBLE EXHAUST CAMSHAFTS
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using SST, turn the sub−gear clockwise, and remove the
service bolt.
SST 09960−10010 (09962−01000, 09963−00600)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove these parts:
Wave washer
Camshaft sub−gear
Camshaft gear spring
HINT:
Arrange the camshaft sub−gears and gear springs (RH and LH
side).
42. REMOVE CYLINDER HEADS
(a) Remove the bolt, and disconnect the ground strap.
(b) Using an 8 mm hexagon wrench, remove the cylinder
head (recessed head) bolt on each cylinder head, then re-
peat for the other side, as shown.

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12 Pointed Head Bolt
Front
P00828
EM−36
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(c) Uniformly loosen and remove the 8 cylinder head (12
pointed head) bolts on each cylinder head, in several
passes, in the sequence shown, then repeat for the other
side, as shown. Remove the 16 cylinder head bolts and
plate washers.
NOTICE:
Head warpage or cracking could result from removing
bolts in an incorrect order.
(d) Lift the cylinder head from the dowels on the cylinder
block and place the 2 cylinder heads on wooden blocks
on a bench.
HINT:
If the cylinder head is difficult to lift off, pry between the cyl-
inder head and cylinder block with a screwdriver.
Arrange the cylinder heads in the correct order.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.