1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine P20839
P20832
P08325
P10221
EM−22
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
10. INSTALL RH CAMSHAFT TIMING PULLEY AND TIM-
ING BELT
(a) Remove any oil or water on the RH camshaft timing and
No.2 idler pulleys, and keep them clean.
(b) Align the installation mark on the timing belt with the tim-
ing mark of the RH camshaft timing pulley as shown.
(c) Hang the timing belt on the RH camshaft timing pulley.
(d) Align the timing marks of the RH camshaft timing pulley
and No.3 timing belt cover.
(e) Slide the RH camshaft timing pulley on the camshaft.
(f) Using SST, align the knock pin hole of the camshaft with
the knock pin groove marked R of the pulley and install the
knock pin.
SST 09960−10010 (09962−01000, 09963−01000)
(g) Using SST, install and torque the bolt.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 110 N·m (1,100 kgf·cm, 81 ft·lbf)
11. SET TIMING BELT TENSIONER
(a) Using a press, slowly press in the push rod using 100 −
1,000 kg (220 − 2,205 lb, 981 − 9,807 N) of pressure.
(b) Align the holes of the push rod and housing, pass a 1.5
mm hexagon wrench through the holes to keep the set-
ting position of the push rod.
(c) Release the press.
(d) Install the dust boot to the tensioner.

Downloaded from www.Manualslib.com manuals search engine P20817
P20819
P20830
P20837
Length = 955 mm (37.60 in.)
Length = 270 mm (10.63 in.)
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−23
1996 TOYOTA T100 (RM449U)
12. INSTALL TIMING BELT TENSIONER
(a) Install the tensioner with the 2 bolts.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)
(b) Remove the 1.5 mm hexagon wrench from the tensioner.
13. CHECK VALVE TIMING
(a) Turn the crankshaft pulley 2 revolutions from TDC to TDC.
HINT:
Always turn the crankshaft clockwise.
(b) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
14. INSTALL FAN BRACKET
(a) Install the fan bracket with the bolt and nut.
(b) Install the PS pump adjusting strut with the nut.
15. INSTALL NO.2 TIMING BELT COVER
(a) Check that the timing belt cover gasket has no cracks or
peeling, etc.
If the gasket does have cracks or peeling, etc., replace it using
following steps.
Using a screwdriver and gasket scraper, remove all
the old gasket material.
Thoroughly clean all components to remove all the
loose material.
Remove the backing paper from a new gasket and
install the gasket evenly to the part of the belt cover
shaded black in the illustration.
(b) Install the belt cover with the 6 bolts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
(c) Connect the 3 high−tension cord clamps to the No.2 tim-
ing belt cover.
(d) Connect the camshaft position sensor connector to the
No.2 timing belt cover.

Downloaded from www.Manualslib.com manuals search engine EM−24
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
16. w/ A/C:
INSTALL A/C COMPRESSOR BRACKET
17. w/ A/C:
CONNECT A/C COMPRESSOR TO ENGINE
18. CONNECT PS PUMP TO ENGINE
19. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
Torque:5.4 N·m (54 kgf·cm, 48 in.·lbf)
20. INSTALL NO.2 FAN SHROUD
21. INSTALL AND ADJUST DRIVE BELT FOR GENERA-
TOR (See page CH−1)
22. w/ A/C:
INSTALL AND ADJUST DRIVE BELT FOR A/C COM-
PRESSOR
23. INSTALL AND ADJUST DRIVE BELT FOR PS PUMP
24. CONNECT UPPER RADIATOR HOSE
25. FILL ENGINE WITH COOLANT
26. START ENGINE CHECK FOR LEAKS
27. 4WD:
INSTALL ENGINE UNDER COVER
28. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
29. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM2538
EM3322
Free Distance
P20858Plastigage
P20852
P20855
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−45
1996 TOYOTA T100 (RM449U)
16. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.949 − 26.965 mm (1.0610 − 1.0616 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
17. INSPECT CAMSHAFT BEARINGS
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
18. INSPECT CAMSHAFT GEAR SPRING
Using vernier calipers, measure the free distance between the
spring ends.
Free distance:
18.2 − 18.8 mm (0.712 − 0.740 in.)
If the free distance is not as specified, replace the gear spring.
19. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps (See page EM−51).
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
0.035 − 0.072 mm (0.0014 − 0.0028 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the plastigage.
20. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts (See page EM−51).
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.033 − 0.080 mm (0.0013 − 0.0031 in.)
Maximum thrust clearance:
0.12 mm (0.0047 in.)

Downloaded from www.Manualslib.com manuals search engine P20989
P20847
SST
P20848
P12390
Seal
Packing
P20844
EM−50
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(b) Install these parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020 (09202−00010)
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to ensure a proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
4. INSTALL CAMSHAFT HOUSING PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the bearing cap as shown.
Seal packing:
Part No. 08826−00080 or equivalent
(c) Place a new housing plug in position on the cylinder head,
facing the cap side inward.
(d) Install the camshaft bearing cap with the 2 bolts.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(e) Install the cylinder head rear plate, ground strap with the
bolt and nut.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P21247
Front
RH
LH
EM1OR−01
Z14657
12 Pointed Head Bolt
Front
P21151
Painted Mark
Front
P00868
90°
90°
90°90°
Painted
Mark
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−51
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place 2 new cylinder head gaskets in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(b) Place the 2 cylinder heads in position on the cylinder head
gaskets.
2. INSTALL 12 POINTED HEAD CYLINDER HEAD BOLTS
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b), (d) and (e)).
If any bolt is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install and uniformly tighten the cylinder head bolts on
each cylinder head, in several passes, in the sequence
shown, then repeat for the other side, as shown.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts by 90° in the numerical
order shown.
(e) Retighten the cylinder head bolts by an additional 90°.
(f) Check that the painted mark is now facing rearward.

Downloaded from www.Manualslib.com manuals search engine Z14658
Recessed Head Bolt
8 mm Hexagon
Wrench
Front
P21041
P21037
EM−52
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
3. INSTALL RECESSED HEAD CYLINDER HEAD BOLTS
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Using an 8 mm hexagon wrench, install the cylinder head
bolt on each cylinder head, then repeat for the other side,
as shown.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
4. CONNECT GROUND STRAP
Install the bolt, and connect the ground strap.
5. ASSEMBLE EXHAUST CAMSHAFTS
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install these parts:
(1) Camshaft gear spring
(2) Camshaft sub−gear
HINT:
Attach the pins on the gears to the gear spring ends.
(3) Wave washer
(c) Using snap ring pliers, install the snap ring.

Downloaded from www.Manualslib.com manuals search engine P21203
P21197
P21142
P21204
P21205
EM−54
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(f) Install the 5 bearing caps in their proper locations.
(g) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(h) Install and uniformly tighten the 10 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(i) Install the exhaust camshaft.
(j) Apply new engine oil to the thrust portion and journal of
the camshaft.
(k) Align the timing marks (2 dot marks) of the camshaft drive
and driven gears.
(l) Place the exhaust camshaft on the cylinder head.
(m) Install the 4 bearing caps in their proper locations.
(n) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(o) Install and uniformly tighten the 8 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(p) Remove the service bolt.