1996 TOYOTA T100 width

Downloaded from www.Manualslib.com manuals search engine P03849
Overall Length
EM0255
A03806
P04415
Width
Z11441
45°30°
1.0 − 1.4 mm EM−42
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(d) Check the valve overall length.
Standard overall length:
Intake
103.45 mm (4.0728 in.)
Exhaust
103.60 mm (4.0787 in.)
Minimum overall length:
Intake
102.95 mm (4.0531 in.)
Exhaust
103.10 mm (4.0590 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
12. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for these:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with these width:
1.0 − 1.4 mm (0.039 − 0.055 in.)
If not, correct the valve seats as follows:
Intake:
If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.

Downloaded from www.Manualslib.com manuals search engine P20511
45° Carvide
Cutter
P12729
Width
Z11441
30°
45°
1.0 − 1.4 mm
Z00139
60°
45°
1.0 − 1.4 mm
P20513
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−43
1996 TOYOTA T100 (RM449U)
12. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats. Re-
move only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a thin coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate the valve.
(c) Check the valve face and seat for these:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with these width.
1.0 − 1.4 mm (0.039 − 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
(2) If the seating is too low on the valve face, use 60°
and 45° cutters to correct the seat.
(d) Hand−lap the valve and valve seat with an abrasive com-
pound.
(e) After hand−lapping, clean the valve and valve seat.

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 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 LU03B−04
P20937
Seal Width
A
B2 − 3 mm
A
B
P20930
New O−Ring
P20971
Mark
Key
LU−14
− LUBRICATION (5VZ−FE)OIL PUMP
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pump
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
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 pump, as shown in the il-
lustration.
Seal packing:
Part No. 08826−00080 or equivalent
Install nozzle that has been cut out to a 2 − 3 mm
(0.08 − 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
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) Place a new O−ring into the groove of the cylinder block.
(d) Install the oil pump to the crankshaft with the spline teeth
of the drive rotor engaged with the large teeth of the
crankshaft.

Downloaded from www.Manualslib.com manuals search engine Q02483
SST
Z10062
B
A
N00414
CL−18
− CLUTCHCLUTCH UNIT
1996 TOYOTA T100 (RM449U)
(b) Using SST, install a new pilot bearing.
SST 09304−30012
HINT:
After assembling the pilot bearing to the hub, install sure that
it rotates smoothly.
6. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum
Depth A: 0.6 mm (0.024 in.)
Width B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
7. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If necessary, replace the release bearing.

Downloaded from www.Manualslib.com manuals search engine R04421
Color
Bearing
CapDrill Mark
Drill MarkYoke
Z00735
PR0027
SST
PR0028
R16052
− PROPELLER SHAFTSPIDER BEARING
PR−19
1437 Author: Date:
1996 TOYOTA T100 (RM449U)
4. SELECT SPIDER BEARING
Select the appropriate bearing according to the existence of
drill mark on the yoke.
YokeBearing
With drill markWith color mark (Red)
No drill markNo color mark
5. INSTALL SPIDER BEARING
(a) Apply MP grease to the spider and bearings.
HINT:
Be careful not to apply too much grease.
(b) Align the matchmarks on the yoke and shaft.
(c) Fit a new spider into the yoke.
(d) Using SST, install a new bearing on the spider.
SST 09332−25010
(e) Using SST, adjust both bearings so that the snap ring
grooves are at maximum and equal in width.
6. INSTALL SNAP RINGS
(a) Install 2 new snap rings of equal thickness which will allow
0 − 0.05 mm (0 − 0.0020 in.) axial play.
HINT:
Do not reuse the snap rings.