1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine Z00145
(1)
Front(2)Thrust
Direction (1)
Axial
Direction (2)
10 mm
(0.39 in.)
Middle
10 mm
(0.39 in.)
P00884
P21450
P21455
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−93
1996 TOYOTA T100 (RM449U)
Using a cylinder gauge, measure the cylinder bore diameter at
positions A, B and C in the thrust and axial directions.
Standard diameter:
STD Mark ”1”93.500 − 93.510 mm (3.6811 − 3.6815 in.)
STD Mark ”2”93.510 − 93.520 mm (3.6815 − 3.6819 in.)
STD Mark ”3”93.520 − 93.530 mm (3.6819 − 3.6823 in.)
Maximum diameter:
STD93.730 mm (3.6902 in.)
O/S 0.5094.230 mm (3.7098 in.)
If the diameter is greater than maximum, rebore all the 6 cylin-
ders, If necessary, replace the cylinder block.
6. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
7. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.

Downloaded from www.Manualslib.com manuals search engine P21448
Z14705
Mark
26 mm 1, 2 or 3Front
Mark
(Cavity)
P21456
EM−94
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
8. INSPECT PISTON OIL CLEARANCE
HINT:
There are 3 sizes of the standard piston diameter, marked ”1”,
”2” and ”3” accordingly. The mark is stamped on the piston top.
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 26 mm (1.02 in.) from
the piston head.
Piston diameter:
STD Mark ”1”93.356 − 93.366 mm (3.6754 − 3.6758 in.)
STD Mark ”2”93.367 − 93.376 mm (3.6759 − 3.6762 in.)
STD Mark ”3”93.377 − 93.386 mm (3.6763 − 3.6766 in.)
O/S 0.5093.856 − 93.886 mm (3.6951 − 3.6963 in.)
(b) Measure the cylinder bore diameter in the thrust direc-
tions (See step 5.).
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.134 − 0.154 mm (0.0053 − 0.0060 in.)
Maximum oil clearance:
0.174 mm (0.0069 in.)
If the oil clearance is greater than maximum, replace all the 6
pistons. If necessary, rebore all the 6 cylinders or replace the
cylinder block.
HINT:
Use new cylinder block: Use a piston with the same number
mark as the standard bore diameter marked on the cylinder
block.
9. INSPECT PISTON RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between new pis-
ton ring and the wall of the piston ring groove.
Standard ring groove clearance:
No.10.040 − 0.080 mm (0.0016 − 0.0031 in.)
No.20.030 − 0.070 mm (0.0012 − 0.0028 in.)
If the clearance not as specified, replace the piston.

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11 5 m m
EM7639
P21449
Z00064
Z00065
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−95
1996 TOYOTA T100 (RM449U)
10. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 115 mm (4.53 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the ring end gap.
Standard ring end gap:
No.10.300 − 0.500 mm (0.0118 − 0.0197 in.)
No.20.400 − 0.600 mm (0.0157 − 0.0236 in.)
Oil (Side rail)0.150 − 0.550 mm (0.0059 − 0.0217 in.)
Maximum ring end gap:
No.11.100 mm (0.0433 in.)
No.21.200 mm (0.0472 in.)
Oil (Side rail)1.150 mm (0.0453 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, rebore all the 6 cylinders or replace the cylinder block.
11. INSPECT PISTON PIN FIT
At 60°C (140°F), you should be able to push the piston pin into
the piston pin hole with your thumb.
12. INSPECT CONNECTING ROD ALIGNMENT
Using a rod aligner and feeler gauge, check the connecting rod
alignment.
Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.
Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.

Downloaded from www.Manualslib.com manuals search engine P00325
EM0227
P00331
SST
P00330
Oil Hole
P01038
EM−96
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
13. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 − 22.017 mm (0.8663 − 0.8668 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 − 22.009 mm (0.8660 − 0.8665 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 − 0.011 mm (0.0002 − 0.0004 in.)
Maximum oil clearance:0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set.
14. IF NECESSARY, REPLACE CONNECTING ROD
BUSHING
(a) Using SST and a press, press out the bushing.
SST 09222−30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222−30010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (see step 13 above) be-
tween the bushing and piston pin.

Downloaded from www.Manualslib.com manuals search engine P00326
P00593
P00603
15 mm (0.59 in.)
Compressed Thread
P21447
26 mm
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−97
1996 TOYOTA T100 (RM449U)
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
15. INSPECT CONNECTING ROD BOLTS
(a) Install the cap nut to the connecting rod bolt. Check that
the rod cap nut can be turned easily by hand to the end
of the thread.
(b) If the cap nut cannot be turned easily, measure the outer
diameter of the compressed thread with vernier calipers.
Standard outer diameter:
7.860 − 8.000 mm (0.3094 − 0.3150 in.)
Minimum outer diameter: 7.600 mm (0.2992 in.)
HINT:
If the location of this area cannot be judged by visual inspection,
measure the outer diameter at the location shown in the illustra-
tion.
If the outer diameter is less than minimum, replace the connect-
ing rod and rod cap nut as a set.
16. CYLINDER BORING
HINT:
Bore all the 6 cylinders for the oversized piston outside di-
ameter.
Replace all the piston rings with ones to match the over-
sized pistons.
(a) Keep the oversized pistons.
Oversized piston diameter:
O/S 0.50: 93.856 − 93.886 mm (3.6951 − 3.6963 in.)
(b) Calculate amount to the bore cylinders.
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 26 mm
(1.02 in.) from the piston head.

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Z00149
EM−98
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(2) Calculate the amount of each cylinder is to be re-
bored as follows:
Size to be rebored = P + C − H
P = Piston diameter
C = Piston oil clearance
0.134 − 0.154 mm (0.0053 − 0.0060 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
(3) C.Bore and hone cylinder to calculated dimensions
Maximum honing:
0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
17. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
No.2 and No.3 journals.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
18. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
STD63.985 − 64.000 mm (2.5191 − 2.5197 in.)
U/S 0.2563.745 − 63.755 mm (2.5096 − 2.5100 in.)
Crank pin diameter:
STD54.987 − 55.000 mm (2.1648 − 2.1654 in.)
U/S 0.2554.745 − 54.755 mm (2.1553 − 2.1557 in.)
If the diameter is not as specified, check the oil clearance (See
page EM−84).
(b) Check each main journal and crank pin for taper and out−
of−round as shown.
Maximum taper and out−of−round:
0.02 mm (0.0008 in.)
If the taper or out−of−round is greater than maximum, grind or
replace the crankshaft.

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−99
1996 TOYOTA T100 (RM449U)
19. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
(a) Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure step 18).
(b) Install new main journal and/or crank pin undersized
bearings.

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EM5252
EM5251
SST
Z04104
Cut Position
EM7574
SST EM−100
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REPLACE CRANKSHAFT FRONT OIL SEAL
(See page EM−100)
2. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
There are 2 methods (A and B) to replace the oil seal which are
as follows:
(a) If rear oil seal retainer is removed from cylinder block.
(1) Using a screwdriver and hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223−15030, 09950−70010 (09951−07150)
(3) Apply MP grease to the oil seal lip.
(b) If rear oil seal retainer is installed to cylinder block.
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223−15030, 09950−70010 (09951−07150)