1996 TOYOTA T100 torque

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)

Downloaded from www.Manualslib.com manuals search engine P21436
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.

Downloaded from www.Manualslib.com manuals search engine P21444
Engine Hanger No. 2
P21617
P21776
P21615
EM−78
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
1996 TOYOTA T100 (RM449U)
21. REMOVE ENGINE
(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.
(d) Remove the 4 bolts and nuts holding the engine front
mounting insulators to the frame.
(e) Lift the engine out of the vehicle slowly and carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(f) Place the engine assembly onto the stand.

Downloaded from www.Manualslib.com manuals search engine EM1OV−01
P21617
P21444
Engine Hanger No. 2
P21776
P21441
P21435
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
EM−79
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL ENGINE ASSEMBLY IN VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine assembly into the engine 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) Remove the engine chain hoist from the engine.
(f) Remove the 2 bolts and engine hanger No.2.
(g) w/ A/C:
Install the bolt, and connect the A/C compressor wire.
2. 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 (385 kgf·cm, 28 ft·lbf)
3. 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.
4. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
5. CONNECT GENERATOR WIRE
(a) Connect the generator connector.

Downloaded from www.Manualslib.com manuals search engine P20865
P20864
EM5345
EM−86
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−101).
Torque:
1st 25 N·m (250 kgf·cm, 18 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).

Downloaded from www.Manualslib.com manuals search engine P20860
EM5365
P21453
EM4968
Plastigauge
EM4969
EM−88
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
26. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
2.440 − 2.490 mm (0.0961 − 0.0980 in.)
27. REMOVE MAIN BEARING CAP AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts,
in several passes, in the sequence shown.
(b) Using a screwdriver, pry up the main bearing cap, and re-
move the main bearing cap, lower main bearings and low-
er thrust washers (No.2 journal position of main bearing
cap only).
HINT:
Keep the lower main bearings and lower thrust washers togeth-
er with the main bearing cap.
(c) Lift out the crankshaft.
HINT:
Keep the upper main bearings and upper thrust washers to-
gether with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing cap with the 8 bolts (See page
EM−101).
Torque:
1st 61 N·m (625 kgf·cm, 45 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 8 bolts and main bearing cap (See procedure
(a) and (b) above).
(j) Measure the Plastigage at its widest point.

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.