1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−61
1996 TOYOTA T100 (RM449U)
27. INSTALL TIMING BELT IDLER NO. 2 (See page
EM−19)
28. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING
BELT (See page EM−19)
29. INSTALL SPARK PLUGS
30. INSTALL HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−1)
31. w/ A/C:
INSTALL A/C COMPRESSOR BRACKET
32. w/ A/C:
CONNECT A/C COMPRESSOR
33. CONNECT PS PUMP
34. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
Torque: 5.4 N·m (54 kgf·cm, 48 in.·lbf)
35. INSTALL NO. 2 FAN SHROUD
36. INSTALL AND ADJUST DRIVE BELT FOR GENERA-
TOR (See page CH−1)
37. w/ A/C:
INSTALL AND ADJUST DRIVE BELT FOR A/C COM-
PRESSOR
38. INSTALL AND ADJUST DRIVE BELT FOR PS PUMP
39. CONNECT HEATER HOSE AND UPPER RADIATOR
HOSE
40. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
41. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP ASSEMBLY
42. INSTALL FRONT EXHAUST PIPE (See page EM−108)
43. FILL WITH ENGINE COOLANT
44. START ENGINE AND CHECK FOR LEAKS
45. CHECK IGNITION TIMING (See page EM−9)
46. 4WD:
INSTALL ENGINE UNDER COVER
47. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
48. RECHECK ENGINE COOLANT LEVEL

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EM−62
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
881 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE UNIT (2WD)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−63
882 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine Z18855
EM−64
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
883 Author: Date:
1996 TOYOTA T100 (RM449U)

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− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−65
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DRAIN ENGINE OIL
3. DRAIN TRANSMISSION OIL
4. REMOVE HOOD
5. REMOVE RADIATOR ASSEMBLY
(See page CO−16)
6. REMOVE DRIVE BELT FOR PS PUMP
7. w/ A/C:
REMOVE DRIVE BELT FOR A/C COMPRESSOR
8. REMOVE DRIVE BELT FOR GENERATOR
9. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
(See page CO−5)
10. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
11. w/ A/C:
REMOVE A/C COMPRESSOR FROM ENGINE
HINT:
Put aside the compressor, and suspend it.
12. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
13. REMOVE AIR CLEANER CASE AND FILTER
14. DISCONNECT THESE CABLES:
(a) w/ Cruise control:
Cruise control actuator cable
(b) Accelerator cable
(c) A/T:
Throttle cable
15. DISCONNECT HEATER HOSES
16. DISCONNECT HOSES
Disconnect these hoses:
(1) Brake booster vacuum hose
(2) EVAP hose

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− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
(3) Fuel return hose
(4) Fuel inlet hose
17. DISCONNECT STARTER WIRE AND CONNECTOR
(a) Remove the bolt, and disconnect the ground strap.
(b) Remove the 2 nuts, disconnect the positive (+) terminal
cable from battery.
(c) Disconnect the 2 starter wire clamps and connector.
18. DISCONNECT GENERATOR WIRE
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire and
wire clip.
19. REMOVE FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
20. DISCONNECT ENGINE WIRE AND CONNECTORS
(a) Remove the 3 bolts and ECM.
(b) M/T:
Disconnect the 3 ECM connectors.
(c) A/T:
Disconnect the 4 ECM connectors.
(d) Disconnect the 2 connectors from the cowl wire.
(e) Disconnect these wires and connectors:
Igniter connector
Ground strap
(f) Disconnect the 6 engine wire clamps.
(g) Pull out the engine wire from the cabin.
21. M/T:
REMOVE SHIFT LEVER
(a) Remove the shift lever knob.
(b) Remove the 4 screws and shift lever boot.
(c) Remove the shift lever.
22. REMOVE STABILIZER BAR
(See page SA−16)
23. REMOVE PROPELLER SHAFT
(See page PR−3)
24. DISCONNECT SPEEDOMETER CABLE
NOTICE:
Do not lose the felt protector and washers.
25. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the 2 heated oxygen sensor connectors.
(b) Remove the 2 bolts, and retainer holding the front ex-
haust pipe to the center exhaust pipe.

Downloaded from www.Manualslib.com manuals search engine P21436
P15099
P21444
Engine Hanger No. 2
P21459
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−67
1996 TOYOTA T100 (RM449U)
(c) Remove the 3 bolts and support bracket.
(d) Remove the 3 nuts, front exhaust pipe and 3 gaskets.
26. M/T:
REMOVE CLUTCH RELEASE CYLINDER
(a) Remove the 3 bolts and disconnect the clutch line.
(b) Remove the 2 bolts and disconnect the clutch release cyl-
inder.
27. A/T:
REMOVE CROSS SHAFT
(a) Remove the clip and disconnect the shifting rod.
(b) Remove the nut, 4 bolts and the cross shaft.
28. PLACE JACK UNDER TRANSMISSION
29. REMOVE ENGINE REAR MOUNTING BRACKET
Remove the 8 bolts holding the mounting bracket to the mount-
ing insulator and cross member.
30. REMOVE ENGINE WITH TRANSMISSION
(a) w/ A/C:
Remove the bolt and disconnect the A/C compressor wire
clamp.
(b) Install a engine hanger No.2 in the correct direction.
Part No.:
Engine hanger No.2 12282−62030
Bolt 91512−61020
Torque:40 N·m (400 kgf·cm, 30 ft·lbf)
(c) Attach the engine hoist chain to the 2 engine hangers.

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− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
(d) Remove the 4 bolts and nuts holding the engine front
mounting insulators to the frame.
(e) Lift the engine with transmission out of the vehicle slowly
and carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(f) Place the engine and transmission assembly onto the
stand.
31. SEPARATE ENGINE AND TRANSMISSION