1996 TOYOTA T100 clock

Downloaded from www.Manualslib.com manuals search engine P03789
P14695
P14687
P14686
EM−56
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
12. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head installation sur-
face of the semi−circular plugs.
Seal packing:
Part No. 08826−00080 or equivalent
(c) Install the semi−circular plug to the cylinder head.
13. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise, and align its groove
with the timing mark ”0” of the timing chain cover.
(b) Check that the timing marks with 1 and 2 dots are in
straight line on the cylinder head surface as shown in the
illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
mark as above.
14. INSTALL CYLINDER HEAD COVER
(a) Install the gasket to the cylinder head cover.
(b) Install the cylinder head cover with the 10 bolts.
Install the No.2 engine hanger and ground strap with the
bolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)
15. INSTALL NO.1 ENGINE HANGER
Install the No.1 engine hanger with the bolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)
16. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and exhaust manifold with the 6 nuts.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Install the heat insulator with the 2 bolts and 2 nuts.
Torque: 5.5 N·m (55 kgf·cm, 48 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P20820
P20826
P20834
P20836
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−21
1996 TOYOTA T100 (RM449U)
(b) RH Camshaft Position:
Turn the camshaft, align the knock pin hole of the cam-
shaft with the timing mark of the No.3 timing belt cover.
(c) LH Camshaft Pulley Position:
Turn the camshaft timing pulley, align the timing marks of
the camshaft timing pulley and No.3 timing belt cover.
9. INSTALL TIMING BELT TO LH CAMSHAFT TIMING
PULLEY
(a) HINT (When re−using timing belt):
Check that the installation mark on the timing belt
matches the end of the No.1 timing belt cover.
If the installation mark do not align, shift the meshing of the tim-
ing belt and crankshaft timing pulley until they align.
(b) Remove any oil or water on the LH camshaft timing pulley,
and keep it clean.
(c) Using SST, slightly turn the LH camshaft timing pulley
clockwise. Align the installation mark on the timing belt
with the timing mark of the camshaft timing pulley, and
hang the timing belt on the LH camshaft timing pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(d) Using SST, align the timing marks of the LH camshaft
pulley and No.3 timing belt cover.
SST 09960−10010 (09962−01000, 09963−01000)
(e) Check that the timing belt has tension between the crank-
shaft timing and LH camshaft timing pulleys.

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.

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P21037
Z13745
8 mm Hexagon
FrontRecessed Head BoltWrench
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−35
1996 TOYOTA T100 (RM449U)
41. DISASSEMBLE 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) Using SST, turn the sub−gear clockwise, and remove the
service bolt.
SST 09960−10010 (09962−01000, 09963−00600)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove these parts:
Wave washer
Camshaft sub−gear
Camshaft gear spring
HINT:
Arrange the camshaft sub−gears and gear springs (RH and LH
side).
42. REMOVE CYLINDER HEADS
(a) Remove the bolt, and disconnect the ground strap.
(b) Using an 8 mm hexagon wrench, remove the cylinder
head (recessed head) bolt on each cylinder head, then re-
peat for the other side, as shown.

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SST
Turn
Z17650
RH
90°
P21199
P12390Seal Packing
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−53
1996 TOYOTA T100 (RM449U)
(d) Using SST, align the holes of the camshaft main gear and
sub−gear by turning camshaft sub−gear clockwise, and
temporarily install a service bolt.
SST 09960−10010 (09962−01000, 09963−00600)
(e) Align the gear teeth of the main gear and sub−gear, and
tighten the service bolt.
6. INSTALL CAMSHAFTS OF RH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be held level while it is being installed. If the
camshaft is not level, the portion of the cylinder head re-
ceiving the shaft thrust may crack or be damaged, causing
the camshaft to seize or break. To avoid this, these steps
should be carried out.
(a) Install the intake camshaft.
(1) Apply new engine oil to the thrust portion and jour-
nal of the camshaft.
(2) Place the intake camshaft at 90° angle of timing
mark (2 dot marks) on the cylinder head.
(b) Apply MP grease to a new oil seal lip.
(c) Install the oil seal to the camshaft.
(d) Remove any old packing (FIPG) material.
(e) Apply seal packing to the No.1 bearing cap as shown.
Seal packing:
Part No. 08826−00080 or equivalent

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P10889
New Grommet
New O−Ring
New GrommetNew O−Ring
P21185
Push
Turn
Connector
P21208
P21216
RotateOutward
P21207
− SFI (5VZ−FE)INJECTOR
SF−23
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. TEMPORARILY INSTALL INJECTORS AND
DELIVERY PIPES
(a) Install 2 new grommets to each injector.
(b) Apply a light coat of spindle oil or gasoline to 2 new O−
rings and install them to each injector.
(c) While turning the injector clockwise and counterclock-
wise, push it to the delivery pipes. Install the 6 injectors.
(d) Position the injector connector outward.
(e) Place the 4 spacers in position on the intake manifold.
(f) Place the delivery pipes with the 6 injectors in position on
the intake manifold.
(g) Temporarily install the 4 bolts holding the delivery pipes
to the intake manifold.
(h) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O−rings. Replace the O−rings.
(i) Position the injector connector outward.
2. CONNECT INJECTOR CONNECTORS
3. INSTALL FUEL PIPE AND TIGHTENING
DELIVERY PIPE HOLDING BOLTS
(a) Install the fuel pipe with 4 new gaskets and the 2 union
bolts.
Torque: 34.3 N·m (350 kgf·cm, 25 ft·lbf)
(b) Tighten the 4 bolts holding the delivery pipes to the intake
manifold.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)

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P19935
P20011
Throttle Lever
No Clearance
Throttle Stop Screw Vacuum
SF−36
− SFI (5VZ−FE)THROTTLE BODY
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CLEAN THROTTLE BODY
(a) Using a soft brush and carburetor cleaner, clean the cast
parts.
(b) Using compressed air, clean all the passages and aper-
tures.
NOTICE:
To prevent deterioration, do not clean the throttle position
sensor and IAC valve.
2. INSPECT THROTTLE VALVE
(a) Apply vacuum to the throttle opener.
(b) Check that there is no clearance between the throttle stop
screw and throttle lever when the throttle valve is fully
closed.
Throttle valve fully closed angle: 10°
3. INSPECT THROTTLE POSITION SENSOR
(a) Apply vacuum to the throttle opener.
(b) Insert a thickness gauge between the throttle stop screw
and stop lever.
(c) Using an ohmmeter, measure the resistance between
each terminal.
Clearance between
lever and stop screwBetween
terminalsResistance
0 mm (0 in.)VTA − E20.28 − 6.4 kΩ
0.32 mm (0.013 in.)IDL − E20.5 kΩ or less
0.54 mm (0.021 in.)IDL − E2Infinity
Throttle valve fully
openVTA − E22.0 − 11.6 kΩ
−VC − E22.7 − 7.7 kΩ
4. IF NECESSARY, ADJUST THROTTLE POSITION SEN-
SOR
(a) Loosen the 2 set screws of the sensor.
(b) Apply vacuum to the throttle opener.
(c) Insert a 0.43 mm (0.017 in.) thickness gauge, between
the throttle stop screw and stop lever.
(d) Connect the test probe of an ohmmeter to the terminals
IDL and E2 of the sensor.
(e) Gradually turn the sensor clockwise until the ohmmeter
deflects, and secure it with the 2 set screws.

Downloaded from www.Manualslib.com manuals search engine IG0IX−01
− IGNITION (3RZ−FE)DISTRIBUTOR
IG−7
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCONNECT DISTRIBUTOR CONNECTOR
2. DISCONNECT HIGH−TENSION CORDS FROM DIS-
TRIBUTOR CAP (See page IG−1)
3. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise until the timing mark
is aligned with ”0” mark on the oil pump cover.
(b) Remove the 3 bolts and distributor cap.
(c) Check that distributor rotor direction is as shown. If not,
turn the crankshaft pulley one complete revolution.
4. REMOVE DISTRIBUTOR
(a) Remove the 2 mounting bolts, and pull out the distributor.
(b) Remove the O−ring from the distributor housing.