1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine EM1OS−01
P21457
P21459
P21444
Engine Hanger No.2
P15099
P23911
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−69
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL TRANSMISSION TO ENGINE
(See page AT−26)
2. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
IN VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the en-
gine compartment.
(c) Keep the engine level, and align the RH and LH mount-
ings and body mountings.
(d) Attach the RH and LH mounting insulators to the body
mountings, and temporarily install the 4 bolts and nuts.
(e) Jack up and put the transmission onto the frame.
(f) Remove the engine chain hoist from the engine.
(g) Remove the 2 bolts and engine hanger No.2.
(h) w/ A/C:
Install the bolt, and connect the A/C compressor wire.
3. INSTALL ENGINE REAR MOUNTING BRACKET
(a) Raise the transmission slightly by raising the engine with
a jack and a wooden block under the transmission.
(b) Install the engine rear mounting bracket to the frame.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(c) Lower the transmission and rest it on the extension hous-
ing.
(d) Install the mounting bracket to the mounting insulator.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
4. TIGHTEN RH AND LH ENGINE MOUNTING
INSULATOR BOLTS AND NUTS
Tighten the 4 bolts and nuts holding the mounting insulators to
the body mountings.
Torque: 38 N·m (387 kgf·cm, 28 ft·lbf)

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P21441
P21435
EM−70
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
5. A/T:
INSTALL CROSS SHAFT
(a) Install the cross shaft with the 4 bolts and nut.
(b) Connect the shifting rod with the clip.
6. M/T:
INSTALL CLUTCH RELEASE CYLINDER
(a) Install the clutch release cylinder with the 2 bolts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Connect the clutch line with the 3 bolts.
7. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with new 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 3 bolts.
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
(c) Connect a new gasket and the front exhaust pipe assem-
bly to the center exhaust pipe with the 2 bolts and retainer.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
(d) Connect the 2 heated oxygen sensor connectors.
8. CONNECT SPEEDOMETER CABLE
9. INSTALL PROPELLER SHAFT
(See page PR−9)
10. INSTALL STABILIZER BAR (See page SA−125)
11. M/T:
INSTALL SHIFT LEVER
(a) Install the shift lever.
(b) Install the shift lever boot with the 4 screws.
(c) Install the shift lever knob.
12. CONNECT ENGINE WIRE AND CONNECTORS
(a) Push in the engine wire through the cowl panel.
(b) Connect the 6 engine wire clamps
(c) Connect these wire and connectors:
Ground strap
Igniter connector
(d) Connect 2 connectors to cowl wire.
(e) M/T:
Connect 3 connectors to the ECM.
(f) A/T:
Connect 4 connectors to the ECM.
(g) Install the ECM with the 3 bolts.

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− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−71
1996 TOYOTA T100 (RM449U)
13. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
14. CONNECT GENERATOR WIRE
(a) Connect the generator connector.
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
15. CONNECT STARTER WIRE AND CONNECTOR
(a) Connect the 2 starter wire clamps and connector.
(b) Install the 2 nuts, and connect the positive (+) terminal
cable to battery.
(c) Install the bolt, and connect the ground strap.
16. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose
Brake booster vacuum hose
EVAP hose
A.D.D. Vacuum hose
17. CONNECT HEATER HOSES
18. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
19. INSTALL AIR CLEANER CASE AND AIR FILTER
20. 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
21. w/ A/C:
CONNECT A/C COMPRESSOR
22. CONNECT PS PUMP
23. INSTALL FAN WITH FLUID COUPLING AND FAN
PULLEYS(See page EM−19)
24. INSTALL DRIVE BELT FOR GENERATOR (See page
CH−1)

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− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
25. w/ A/C:
INSTALL DRIVE BELT FOR A/C COMPRESSOR
26. INSTALL DRIVE BELT FOR PS PUMP
27. INSTALL RADIATOR ASSEMBLY
(See page CO−19)
28. FILL WITH ENGINE OIL
29. FILL WITH ENGINE COOLANT
30. FILL TRANSMISSION OIL
31. START ENGINE AND CHECK FOR LEAKS
32. CHECK IGNITION TIMING
(See page EM−9)
33. INSTALL HOOD
34. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
35. RECHECK ENGINE COOLANT AND OIL LEVELS

Downloaded from www.Manualslib.com manuals search engine EM1OT−01
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
EM−73
892 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE UNIT (4WD)
COMPONENTS

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− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
893 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
EM−75
894 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine EM1OU−01
EM−76
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DRAIN ENGINE 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 FOR A/C COMPRESSOR
8. REMOVE DRIVE BELT FOR GENERATOR
9. REMOVE FAN WITH FLUID COUPLING AND FAN PUL-
LEYS (See page EM−13)
10. DISCONNECT PS PUMP FROM ENGINE
HINT:
Put aside the pump, and suspend it.
11. w/ A/C:
DISCONNECT A/C COMPRESSOR
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
(3) A.D.D. vacuum hose