1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine P20845
EM06M−03
P20847
SST
P20988
P20841
Magnetic Finger
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−37
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE CAMSHAFT HOUSING PLUGS
(a) Remove the bolt, nut, cylinder head rear plate and ground
strap.
(b) Remove the 2 bolts and camshaft bearing cap.
(c) Remove the housing plug.
2. REMOVE VALVE LIFTERS AND SHIMS
Pull out the valve lifter and shim by hand.
HINT:
Arrange the valve lifters and shims in correct order.
3. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202−70020 (09202−00010)
(b) Remove these parts:
Spring retainer
Valve spring
Valve
(c) Using needle−nose pliers, remove the oil seal.
(d) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in the correct order.

Downloaded from www.Manualslib.com manuals search engine P20505
EM1OQ−01
P20504
P20503
P20512
P20986
EM−38
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND
CYLINDER BLOCK
(a) Turn the crankshaft and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surfaces.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surfaces.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high−compressed air.
2. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
faces.
3. CLEAN COMBUSTION CHAMBERS
Using a wire brush, remove all the carbon from the combustion
chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
faces.
4. CLEAN VALVE GUIDE BUSHINGS
Using a valve guide bushing brush and solvent, clean all the
guide bushings.

Downloaded from www.Manualslib.com manuals search engine P20506
Z14652
P20514
EM0580
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−39
1996 TOYOTA T100 (RM449U)
5. CLEAN CYLINDER HEADS
Using a soft brush and solvent, thoroughly clean the cylinder
heads.
6. INSPECT FOR FLATNESS
Using precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder block and manifolds for war-
page.
Maximum warpage:
0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake
ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

Downloaded from www.Manualslib.com manuals search engine P21251
Z00052
A01572
Old Valve
Approx. 8 mm Towel
Tape
P20854
80 − 100°C (176 − 212°F) EM−40
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide busing.
Bushing inside diameter:
6.010 − 6.030 mm (0.2366 − 0.2374 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake5.970 − 5.985 mm (0.2350 − 0.2356 in.)
Exhaust5.965 − 5.980 mm (0.2348 − 0.2354 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Oil clearance:
Standard Intake
Exhaust0.025 − 0.060 mm (0.0010 − 0.0024 in.)
0.030 − 0.065 mm (0.0012 − 0.0026 in.)
Maximum Intake
Exhaust0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing.
10. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS
(a) w/ Snap ring:
Insert an old valve wrapped with tape into the valve guide
bushing, and break off the valve guide bushing by hitting
it with a hammer. Remove the snap ring.
HINT:
Wrap the tape approx. 8 mm (0.31 in.) from the valve stem end.
NOTICE:
Be careful not to damage the valve lifter hole.
(b) Gradually heat the cylinder head to 80 − 100°C (176 −
212°F).

Downloaded from www.Manualslib.com manuals search engine P20853
SST
P20510
P20984
Snap Ring
SST
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−41
1996 TOYOTA T100 (RM449U)
(c) Using SST and a hammer, tap out the guide bushing.
SST 09201−10000 (09201−01060),
09950−70010 (09951−07150)
(d) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
(e) Select a new guide bushing (STD size or O/S 0.05).
Both intake and exhaust
Bushing bore diameter mm (in.)Bushing size
10.985 − 11.027 (0.4325 − 0.4341)Use STD
11.050 − 11.077 (0.4350 − 0.4361)Use O/S 0.05
If the bushing bore diameter of the cylinder head is greater than
11.027 mm (0.4341 in.), machine the bushing bore to these di-
mension:
11.050 − 11.077 mm (0.4350 − 0.4361 in.)
If the bushing bore diameter of the cylinder head is greater than
11.077 mm (0.4361 in.), replace the cylinder head.
(f) Gradually heat the cylinder head to 80 − 100°C (176 −
212°F).
(g) Using SST and a hammer, tap in a new guide bushing un-
til the snap ring makes contact with the cylinder head.
SST 09201−10000 (09201−01060),
09950−70010 (09951−07150)

Downloaded from www.Manualslib.com manuals search engine P20985
Sharp 6 mm Reamer
Z00054
44.5°
EM0181
Margin Thickness
EM2534
Overall Length
EM0255
EM−42
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(h) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See step 9) be-
tween the guide bushing and valve stem.
11. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
1.0 mm (0.039 in.)
Minimum margin thickness:
0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.
(d) Check the valve overall length.
Overall length:
Standard Intake
Exhaust95.15 mm (3.7461 in.)
94.90 mm (3.7362 in.)
Minimum Intake
Exhaust94.60 mm (3.7244 in.)
94.40 mm (3.7165 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than the minimum.

Downloaded from www.Manualslib.com manuals search engine P20511
45° Carvide
Cutter
P12729
Width
Z11441
30°
45°
1.0 − 1.4 mm
Z00139
60°
45°
1.0 − 1.4 mm
P20513
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−43
1996 TOYOTA T100 (RM449U)
12. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats. Re-
move only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a thin coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate the valve.
(c) Check the valve face and seat for these:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with these width.
1.0 − 1.4 mm (0.039 − 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
(2) If the seating is too low on the valve face, use 60°
and 45° cutters to correct the seat.
(d) Hand−lap the valve and valve seat with an abrasive com-
pound.
(e) After hand−lapping, clean the valve and valve seat.

Downloaded from www.Manualslib.com manuals search engine EM0988
Deviation
EM0801
EM0281
EM1628
EM2011
EM−44
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
13. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the squareness of the
valve spring.
Maximum deviation:
2.0 mm (0.079 in.)
If deviation is greater than maximum, replace the valve spring.
(b) Using vernier calipers, measure the free length of the
valve spring.
Free length:
44.78 mm (1.7630 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186 − 206 N (19.0 − 21.0 kgf, 41.9 − 46.3 lbf)
at 33.3 mm (1.311 in.)
If the installed tension is not as specified, replace the valve
spring.
14. INSPECT CAMSHAFT FOR RUNOUT
(a) Place the camshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
15. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Cam lobe height:
Standard Intake
Exhaust42.31 − 42.41 mm (1.6657 − 1.6697 in.)
41.96 − 42.06 mm (1.6520 − 1.6559 in.)
Minimum Intake
Exhaust42.16 mm (1.6598 in.)
41.81 mm (1.6461 in.)
If the cam lobe height is greater than maximum, replace the
camshaft.