1996 TOYOTA T100 length

Downloaded from www.Manualslib.com manuals search engine P20985
Sharp 6 mm Reamer
Z00054
44.5°
EM0181
Margin Thickness
EM2534
Overall Length
EM0255
EM−42
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(h) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See step 9) be-
tween the guide bushing and valve stem.
11. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
1.0 mm (0.039 in.)
Minimum margin thickness:
0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.
(d) Check the valve overall length.
Overall length:
Standard Intake
Exhaust95.15 mm (3.7461 in.)
94.90 mm (3.7362 in.)
Minimum Intake
Exhaust94.60 mm (3.7244 in.)
94.40 mm (3.7165 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 the minimum.

Downloaded from www.Manualslib.com manuals search engine EM0988
Deviation
EM0801
EM0281
EM1628
EM2011
EM−44
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
13. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the squareness of the
valve spring.
Maximum deviation:
2.0 mm (0.079 in.)
If deviation is greater than maximum, replace the valve spring.
(b) Using vernier calipers, measure the free length of the
valve spring.
Free length:
44.78 mm (1.7630 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186 − 206 N (19.0 − 21.0 kgf, 41.9 − 46.3 lbf)
at 33.3 mm (1.311 in.)
If the installed tension is not as specified, replace the valve
spring.
14. INSPECT CAMSHAFT FOR RUNOUT
(a) Place the camshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
15. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Cam lobe height:
Standard Intake
Exhaust42.31 − 42.41 mm (1.6657 − 1.6697 in.)
41.96 − 42.06 mm (1.6520 − 1.6559 in.)
Minimum Intake
Exhaust42.16 mm (1.6598 in.)
41.81 mm (1.6461 in.)
If the cam lobe height is greater than maximum, replace the
camshaft.

Downloaded from www.Manualslib.com manuals search engine P21192
P21198
L = 165 mm (6.50 in.) L = 165 mm (6.50 in.)
Join Line
L = 130 mm
(5.12 in.)
L = 265 mm
(10.43 in.)L = 145 mm
(5.71 in.)
L = Length
Join Line
EM−58
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(d) Install the dipstick guide with the 2 bolts.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)
(e) Install the dipstick.
16. INSTALL PS PUMP BRACKET
Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
17. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Install 2 new gaskets and the intake manifold, delivery
pipe and injectors assembly with the 8 bolts, 4 plate wash-
ers and 4 nuts.
Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)
(b) Install the intake manifold stay with the 2 bolts.
Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
(c) Connect the fuel inlet hose.
18. INSTALL FUEL PRESSURE REGULATOR
(See page SF−16)
19. INSTALL NO.3 TIMING BELT COVER
(a) Check that the timing belt cover gaskets have no cracks
or peeling, etc.
If the gaskets do have cracks or peeling etc., replace them us-
ing these 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 timing belt
cover shaded black in the illustration.
(b) Install the timing belt cover with the 6 bolts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
20. INSTALL CAMSHAFT POSITION SENSOR
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P15006
Plug
P15007
New Gasket
New
Gasket
FI1654
SST
Fulcrum Length
30 cm
P15750
Grommet
New O−Ring
Delivery PipeCORRECT
WRONG
P15128
Delivery Pipe
Injector
InsulatorO−Ring
Grommet
− MFI (3RZ−FE)MFI SYSTEM
MF−3
955 Author: Date:
1996 TOYOTA T100 (RM449U)
7. FUEL SYSTEM
(a) When disconnecting the high pressure fuel line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Put a container under the connection.
(2) Slowly loosen the connection.
(3) Disconnect the connection.
(4) Plug the connection with a rubber plug.
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe these procedures:
(1) (Union Bolt Type)
Always use a new gasket.
(2) (Union Bolt Type)
Tighten the union bolt by hand.
(3) (Union Bolt Type)
Tighten the union bolt to the specified torque.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(4) (Flare Nut Type)
Apply a light coat of engine oil to the flare and tight-
en the flare nut by hand.
(5) (Flare Nut Type)
Using SST, tighten the flare nut to the specified
torque.
SST 09631−22020
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(c) Observe these precautions when removing and installing
the injectors.
(1) Never reuse the O−ring.
(2) When placing a new O−ring on the injector, take
care not to damage it in any way.
(3) Coat a new O−ring with spindle oil or gasoline be-
fore installing−never use engine, gear or brake oil.
(d) Install the injector to the delivery pipe and cylinder head
as shown in the illustration.

Downloaded from www.Manualslib.com manuals search engine BO0919
Crack
Leakage
Deformation
Z10162
SST
SST: 09631−22020Use SST
30 N·m
(310 kgf·cm, 22 ft·lbf)
Fulcrum
Length
30 cm
(11.81 in.)
FU0041
Pipe
0 − 3 mm (0 − 0.12 in.) 2 − 5 mm (0.08 − 0.20 in.)
Hose
Clip
SF0AV−02
MF−24
− MFI (3RZ−FE)FUEL TANK AND LINE
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT FUEL TANK AND LINE
(a) Check the fuel lines for cracks or leakage, and all connec-
tions for deformation.
(b) Check the fuel tank vapor vent system hoses and connec-
tions for looseness, sharp bends or damage.
(c) Check the fuel tank for deformation, cracks, fuel leakage
or tank band looseness.
(d) Check the filler neck for damage or fuel leakage.
(e) Hose and tube connections are as shown in the illustra-
tion.
If a problem is found, repair or replace the part as necessary.

Downloaded from www.Manualslib.com manuals search engine P21154
P19985
FI1654
30 cm
SST
Fulcrum Length
− SFI (5VZ−FE)SFI SYSTEM
SF−3
1009 Author: Date:
1996 TOYOTA T100 (RM449U)
7. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch to LOCK.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.
(b) When connecting the flare nut or union bolt on the high
pressure pipe union, observe these procedures:
(1) Union Bolt Type:
Always use 2 new gaskets.
(2) Union Bolt Type:
Tighten the union bolt by hand.
(3) Union Bolt Type:
Tighten the union bolt to the specified torque.
Torque: 34.3 N·m (350 kgf·cm, 25 ft·lbf)
(4) Flare Nut Type:
Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(5) Flare Nut Type:
Using SST, tighten the flare nut to specified torque.
SST 09631−22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque:
34.3 N·m (350 kgf·cm, 25 ft·lbf)
28 N·m (285 kgf·cm, 21 ft·lbf) for using SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Downloaded from www.Manualslib.com manuals search engine SF0D2−01
BO0919
Crack
Leakage
Deformation
Z10162
SST
SST: 09631−22020Use SST
28 N·m
(285 kgf·cm, 21 ft·lbf)
Fulcrum
Length
30 cm
(11.81 in.)
FU0041
Pipe
0 − 3 mm (0 − 0.12 in.) 2 − 7 mm (0.08 − 0.28 in.)
Hose
Clip
− SFI (5VZ−FE)FUEL TANK AND LINE
SF−27
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT FUEL TANK AND LINE
(a) Check the fuel lines for cracks or leakage, and all connec-
tions for deformation.
(b) Check the fuel tank vapor vent system hoses and connec-
tions for looseness, sharp bends or damage.
(c) Check the fuel tank for deformation, cracks, fuel leakage
or tank band looseness.
(d) Check the filler neck for damage or fuel leakage.
(e) Hose and pipe connections are as shown in the illustra-
tion.
If a problem is found, repair or replace the parts as necessary.

Downloaded from www.Manualslib.com manuals search engine LU0O8−01
P15000
SST
− LUBRICATION (3RZ−FE)OIL AND FILTER
LU−3
1996 TOYOTA T100 (RM449U)
REPLACEMENT
CAUTION:
Prolonged and repeated contact with mineral oil will result
in the removal of natural fats from the skin, leading to dry-
ness, irritation and dermatitis. In addition, used engine oil
contains potentially harmful contaminants which may
cause skin cancer. Care should be taken, therefore, when
changing engine, oil to minimize the frequency and length
of time your skin is exposed to used engine oil. Protective
clothing and gloves that cannot be penetrated by oil should
be worn. The skin should be thoroughly washed with soap
and water, or use water−less hand cleaner, to remove any
used engine oil. Do not use gasoline, thinners, or solvents.
In order to preserve the environment, used oil and used oil
filters must be disposed of only at designated disposal
sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, and drain the oil into a contain-
er.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228−07501
(b) Check and clean the oil filter installation surface.
(c) Apply clean engine oil to the gasket of a new oil filter.
(d) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(e) Using SST, tighten it an additional 3/4 turn.
SST 09228−07501