Page 779 of 2062
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)
Page 832 of 2062
Downloaded from www.Manualslib.com manuals search engine EM06D−03
P21120
P21152
Dot Mark
P01269
RH EX
12
36
LH EX LH IN RH IN
P01270
RH EX
34
5
LH EX LH IN RH IN
2 EM−4
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
823 Author: Date:
1996 TOYOTA T100 (RM449U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DRAIN ENGINE COOLANT
2. REMOVE INTAKE AIR CONNECTOR
(See page EM−65)
3. REMOVE CYLINDER HEAD COVERS
(See page EM−30)
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark ”0” of the No.1 timing belt cover.
(b) Check that the timing marks (1 dot) of the camshaft drive
and driven gears are in straight line on the cylinder heads
surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated in the illustration.
Using a thickness gauge, measure the clearance
between the valve lifter and camshaft.
Record out of specification valve clearance mea-
surements. They will be used later to determine the
required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.13 − 0.23 mm (0.006 − 0.009 in.)
Exhaust 0.27 − 0.37 mm (0.011 − 0.014 in.)
(b) Turn the crankshaft 2/3 of a revolution (240°), and check
only the valves indicated in the illustration. Measure the
valve clearance. (See procedure step (a))
Page 848 of 2062
Downloaded from www.Manualslib.com manuals search engine P20918
Length = 425 mm
(16.73 in.)
P21686
length = 145 mm
(5.71 in.)
P20516
SST SST
P20828
P20827
EM−20
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
5. INSTALL NO.1 TIMING BELT COVER AND STARTER
WIRE BRACKET
(a) Check that the timing belt cover gaskets have cracks or
peeling, etc.
If the gasket does have cracks or peeling, etc., replace it using
following steps.peeling, etc., replace them 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 back in the illustration.
(b) Install the timing belt cover with the 4 bolts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
(c) Install the starter wire bracket with the 2 bolts.
6. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide the pulley.
(b) Using SST, install and torque the bolt.
SST 09213−54015 (90119−08216),
09330−00021
Torque: 250 N·m (2,500 kgf·cm, 184 ft·lbf)
7. INSTALL LH CAMSHAFT TIMING PULLEY
(a) Slide the timing pulley, facing the flange side outward.
(b) Align the knock pin hole of the camshaft with the knock pin
groove of the timing pulley as shown.
(c) Install the knock pin.
(d) 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)
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Crankshaft Position:
Turn the crankshaft pulley, and align its groove with the
”O” timing mark of the No.1 timing belt cover.
Page 1734 of 2062
Downloaded from www.Manualslib.com manuals search engine SR07E−01
R15245
Matchmarks
R11947
Screw Extractor
R15212
SSTBolt
SST Nut Tilt No.2 Bolt
Plate Washer
− STEERINGTILT STEERING COLUMN
SR−27
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE SLIDING YOKE SUB−ASSEMBLY
(a) Remove the bolt.
(b) Shift the yoke.
(c) Place matchmarks on the sliding yoke and main shaft.
2. REMOVE COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Using a centering punch, mark the center of the 2 ta-
pered−head bolts.
(b) Using a 3 − 4 mm (0.12 − 0.16 in.) drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts.
3. REMOVE 3 TENSION SPRINGS
4. REMOVE COMPRESSION SPRING
(a) Remove the bolt with the spring.
(b) Remove the 2 bushings from the spring.
5. REMOVE 2 TILT LEVER RETAINERS
(a) Remove the E−ring from the tilt lever lock shaft.
(b) Remove the nut and retainer.
6. REMOVE 2 TILT PAWL STOPPERS
7. REMOVE 2 TILT PAWLS
(a) Remove the tilt lever assembly set bolt.
(b) Remove the nut and bolt.
(c) Remove the washer.
8. REMOVE TILT LEVER ASSEMBLY, TILT SUB LEVER,
TILT LEVER AND TILT LEVER LOCK SHAFT
9. REMOVE COLUMN UPPER TUBE WITH MAIN SHAFT
ASSEMBLY
(a) Set SST, the nut (10 mm nominal diameter, 1.25 mm
pitch), plate washer (36 mm outer diameter) and bolt (10
mm nominal diameter, 1.25 mm pitch, 50 mm length), as
shown in the illustration.
SST 09910−00015 (09911−00011, 09912−00010)
Reference
Nut: 90170−10004
Plate washer: 90201−10201
Bolt: 91111−51050
(b) Remove the 2 tilt No.2 bolts by using the sliding hammer
on SST.
(c) Remove the upper tube with the shaft assembly from the
lower tube.
(d) Remove the collar and stopper from the shaft assembly.
10. REMOVE TURN SIGNAL BRACKET
Remove the 2 bolts.
Page 1979 of 2062
Downloaded from www.Manualslib.com manuals search engine I01393
Condition : Does not cool AC−8
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TOYOTA T100 (RM449U)
(9) Defective compression compressor
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
Pressure too high on low and
high pressure sides
Pressure too low on high pres-
sure side
Internal leak in compressor
Compression defective
Valve leaking or broken sliding
parts
Repair or replace compressor
3. INSPECT IDLE−UP SPEED
(a) Warm up engine.
(b) Inspect idle−up speed when the these conditions are es-
tablished.
Warm up engine
Blower speed control switch at ”HI” position
A/C switch ON
Temperature control dial at ”COOL” position
Magnetic clutch conditionIdle−up speed
3RZ−FE Engine−
Magnetic clutch not engaged700 ± 50 rpm
Magnetic clutch engaged900 ± 50 rpm
5VZ−FE Engine−
Magnetic clutch not engaged700 ± 50 rpm
Magnetic clutch engaged850 ± 50 rpm
If idle speed is not as specified, check idle control system.
4. INSPECT FOR LEAKAGE OF REFRIGERANT
(a) Perform in these conditions:
Stop engine.
Secure good ventilation (If the gas leak detector
may not react to volatile gases which are not refrig-
erant, such as evaporated gasoline and exhaust
gas.)
Repeat the test 2 or 3 times.
Make sure that there is some refrigerant remaining
in the refrigeration system.
When compressor is OFF: approx. 392 − 588 kPa
(4 − 6 kgf/ cm
2, 57 − 85 psi)