1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine EM1EK−02
P21452
P21462
Front Mark(Cavity) Front Mark
(Mold)
Z14706
No.1 Code Mark
No.2 Code Mark
P21438
ExpanderFront Mark
(Cavity) Upper Side
RailCompression
Ring No.1
Compression
Ring No.2Lower Side
Rail
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−101
1996 TOYOTA T100 (RM449U)
INSTALLATION
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets, O−rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.
(b) Gradually heat the piston to about 60°C (140°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.
(e) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark:
No.1: 1R or T
No.2: 2R or T
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.

Downloaded from www.Manualslib.com manuals search engine P00592
P10205
No. 1
Others
22 mm20 mm
P10214
P10215
EM5354
EM−102
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
HINT:
Main bearings come in widths of 20 mm (0.79 in.) and 22
mm (0.87 in.). Install the 22 mm (0.87 in.) bearings in the
No.1 cylinder block journal position with the main bearing
caps. Install the 20 mm (0.79 in.) bearings in the other
positions.
Upper bearings have an oil holes lower bearings do not.
(a) Align the bearing claw with the claw groove of the main
bearing cap or cylinder block.
(b) Install the bearings in the cylinder block and main bearing
cap.
5. INSTALL UPPER THRUST WASHERS
Install the thrust washers under the No.2 journal position of the
cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. PLACE MAIN BEARING CAP AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the thrust washers on the No.2 journal position of
the bearing cap with the grooves facing outward.

Downloaded from www.Manualslib.com manuals search engine P20861
Front Mark
(Arrow)
Z14732
EM5369
FrontPainted
Mark
EM5370
Painted Mark
90°
90°
P00591
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
(b) Install the main bearing cap with the front mark facing for-
ward.
8. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any main bearing cap bolt is broken or deformed, re-
place it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 8 main bearing cap bolts,
in several passes, in the sequence shown.
Torque: 61 N·m (625 kgf·cm, 45 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance (See page
EM−92).
9. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.

Downloaded from www.Manualslib.com manuals search engine Z14819
FrontFront
Mark
(Cavity)
P00655
Front Mark
(Protrusion)
EM5345
P02237
Painted
MarkFront EM−104
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
10. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
11. INSTALL CONNECTING ROD CAP NUTS
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed, replace
it.
(a) Apply a light of engine oil on the threads and under the
nuts of the connecting rod cap.
(b) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
If any one of the connecting rod cap nuts does not meet the
torque specification, replace the cap nut.
(c) Mark the front of the connecting rod cap nut and bolt with
paint.

Downloaded from www.Manualslib.com manuals search engine P02238
Painted Mark
90°90°
EM5292
A
A B
B Seal Width
2 − 3 mm
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−105
1996 TOYOTA T100 (RM449U)
(d) Retighten the connecting rod cap nuts 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance (See page
EM−92).
12. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the retainer
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing:
Part No.08826−00080 or equivalent
 Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil seal retainer with the 6 bolts.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)
13. INSTALL OIL PUMP (See page LU−14)
14. INSTALL OIL PAN BAFFLE PLATE
15. INSTALL OIL STRAINER (See page LU−14)
16. INSTALL OIL PAN (See page LU−14)
17. w/ OIL COOLER:
INSTALL OIL COOLER WITH WATER BYPASS HOSE
AND OIL COOLER UNION (See page LU−20)
18. w/o OIL COOLER:
INSTALL OIL HOLE COVER PLATE
Torque: 60 N·m (600 kgf·cm, 44 ft·lbf)
19. INSTALL COOLANT DRAIN COCK
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
20. INSTALL RH AND LH ENGINE MOUNTING BRACKETS
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
21. INSTALL OIL FILTER UNION
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P00496
Adhesive
P10226
Seal Width
2 − 3 mm EM−106
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
22. INSTALL OIL FILTER (See page LU−3 )
23. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833 − 00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using SST, install the oil pressure switch.
SST 09816−30010
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
24. INSTALL GENERATOR ADJUSTING BAR
Torque: 42 N·m (420 kgf·cm, 31 ft·lbf)
25. INSTALL WATER PUMP (See page CO−7)
26. INSTALL KNOCK SENSORS
Using SST, install the 2 knock sensors.
SST 09816−30010
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
27. INSTALL NO.2 IDLER PULLEY BRACKET
Torque: 38 N·m (380 kgf·cm, 28 ft·lbf)
28. INSTALL WATER BYPASS PIPE WITH KNOCK SEN-
SOR WIRE
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the bypass
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the groove of the bypass pipe.
Seal packing:
Part No. 08826 − 00100 or equivalent
Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Downloaded from www.Manualslib.com manuals search engine P00601
Adhesive
P21461
1
5
3
7
2 68
4
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−107
1996 TOYOTA T100 (RM449U)
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the bypass pipe with the 2 bolts and nut.
Torque: 8.5 N·m (85 kgf·cm, 75 in.·lbf)
(d) Connect the 2 knock sensor connectors.
29. INSTALL CYLINDER HEADS
30. INSTALL PULLEYS AND TIMING BELT
(See page EM−19)
31. REMOVE ENGINE STAND
32. INSTALL REAR END PLATE
Torque: 7.5 N·m (75 kgf·cm, 66 in.·lbf)
33. A/T:
INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)
34. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the mount bolt end.
Adhesive:
Part No. 08833 − 00070, THREE BOND 1324 or equiva-
lent
(b) Install the drive plate on the crankshaft.
(c) Install and uniformly tighten the 8 mount bolts in several
passes, in the sequence shown.
Torque: 85 N·m (850 kgf·cm, 63 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine EM07F−01
P24419
EM−108
− ENGINE MECHANICAL (5VZ−FE)EXHAUST SYSTEM
927 Author: Date:
1996 TOYOTA T100 (RM449U)
EXHAUST SYSTEM
COMPONENTS