1996 TOYOTA T100 fuel pump

Downloaded from www.Manualslib.com manuals search engine P14925
P15085
P15086
P15094
EM−66
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
14. w/ A/C:
DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Disconnect the A/C compressor connector.
(b) Remove the 4 mounting bolts, and disconnect the com-
pressor from the bracket.
HINT:
Put a side the compressor, and suspend it.
(c) Remove the 4 bolts and A/C compressor bracket.
15. DISCONNECT HEATER HOSES
16. DISCONNECT HOSES
Disconnect these hoses:
Brake booster vacuum hose
EVAP hose
2 PS air hoses
Fuel return hose
Fuel inlet hose
17. DISCONNECT PS PUMP
(a) Using SST, remove the nut and PS pump pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Remove the 2 bolts, and disconnect the PS pump.
HINT:
Put aside the pump, and suspend it.
18. DISCONNECT GENERATOR WIRE
(a) Disconnect the generator connector.
(b) Remove the nut, and disconnect the generator wire and
wire clip.

Downloaded from www.Manualslib.com manuals search engine P15739
P15094
P15086
EM−72
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
13. CONNECT WIRES AND CONNECTORS
(a) Push in the engine wire through the cowl panel.
(b) Connect the 4 engine wire clamps
(c) Connect these wires and connectors:
Ground strap to cowl top panel
Igniter connector
(d) Connect 2 connectors to cowl wire.
(e) Connect 4 connectors to the ECM.
(f) Install the ECM with the 3 bolts.
14. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
(a) Install the cowl side trim with the clip.
(b) Install the front door scuff plate with the 4 screws.
15. CONNECT GENERATOR WIRE
(a) Connect the generator connector.
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
16. CONNECT PS PUMP
(a) Connect the PS pump to the bracket with the 2 bolts.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(b) Using SST, install the PS pump pulley with the nut.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
17. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose

Downloaded from www.Manualslib.com manuals search engine S05155
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−31
1996 TOYOTA T100 (RM449U)
21. w/ EGR:
REMOVE EGR PIPE
Remove the 6 nuts, EGR pipe and 2 gaskets.
22. REMOVE INTAKE CHAMBER STAY
(a) A/T:
Remove the bolt, 2 nuts, oil filler tube and No.1 throttle
cable clamp.
(b) Remove the 2 bolts and intake chamber stay.
23. REMOVE AIR INTAKE CHAMBER ASSEMBLY
(a) Disconnect these connectors:
VSV connector for fuel pressure control
Throttle position sensor connector
IAC valve connector
w/ EGR:
EGR gas temperature sensor connector
VSV connector for EGR
(b) Disconnect these hoses:
(1) 2 PCV hoses
(2) 2 water bypass hoses
(3) Air assist hose from throttle body
(4) 2 Vacuum sensing hoses from VSV
w/ A/C
Air hose from A/C idle−up valve
(5) EVAP hose
(6) Air hose from PS pump
(c) Remove the 4 bolts, 2 nuts, the air intake chamber as-
sembly and gasket.
24. REMOVE INTAKE AIR CONNECTOR
(a) Remove the bolt, and disconnect the engine wire.
(b) Disconnect the 2 fuel return hoses.
(c) Disconnect the brake booster vacuum hose from the in-
take air connector.
(d) Remove the bolt, and disconnect the ground strap from
the intake air connector.
(e) Disconnect the DLC1 from the bracket.
(f) w/ A/C
Disconnect the A/C idle−up valve connector.
(g) Remove the 3 bolts, 2 nuts, intake air connector and gas-
ket.

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P21193
P21192
P21195
EM−32
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
25. DISCONNECT ENGINE WIRE
(a) Disconnect these connectors:
Oil pressure sensor connector
Crankshaft position sensor connector
6 Injector connectors
ECT sender gauge connector
ECT sensor connector
Knock sensor connector
Camshaft position sensor connector
(b) Disconnect the 3 engine wire clamps.
(c) Remove the 3 bolts, and disconnect the engine wire from
the cylinder head.
26. REMOVE CAMSHAFT POSITION SENSOR
27. REMOVE NO.3 TIMING BELT COVER
Remove the 6 bolts and timing belt cover.
28. REMOVE FUEL PRESSURE REGULATOR
29. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the fuel inlet hose.
(b) Remove the 2 bolts and the intake manifold stay.
(c) Remove the 8 bolts, 4 nuts, 4 plate washers, intake man-
ifold, delivery pipes and injectors assembly and 2 gas-
kets.
30. REMOVE PS PUMP BRACKET
31. REMOVE OIL DIPSTICK AND GUIDE
(a) Remove the 2 bolts holding the dipstick guide to the gen-
erator bracket.
(b) Pull out the dipstick guide together with the dipstick from
the oil pan.
(c) Remove the O−ring from the dipstick guide.
32. REMOVE GENERATOR BRACKET
33. REMOVE EXHAUST CROSSOVER PIPE
Remove the 6 nuts, crossover pipe and 2 gaskets.
34. REMOVE LH AND RH EXHAUST MANIFOLDS
(a) Remove the 6 nuts and exhaust manifold heat insulators.
(b) Remove the 12 nuts, LH, RH exhaust manifolds and gas-
ket.

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 Z19131
EM−60
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
23. INSTALL AIR INTAKE CHAMBER ASSEMBLY
(a) Install a new gasket and the air intake chamber assembly
with the 4 bolts and 2 nuts.
Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
(b) Connect these hoses:
2 PCV hoses
2 water bypass hoses
Air assist hose to throttle body
w/ EGR:
Water bypass hose
EVAP hose
Air hose to PS pump
w/ A/C
Air hose to A/C idle−up valve
(c) Connect these connectors:
VSV connector for fuel pressure control
Throttle position sensor connector
IAC valve connector
w/ EGR:
EGR gas temperature sensor connector
VSV connector for EGR
24. INSTALL AIR INTAKE CHAMBER STAY
(a) Install the air intake chamber stay with the 2 bolts.
Torque:
14 mm head bolt: 40 N·m (400 kgf·cm, 30 ft·lbf)
12 mm head bolt: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
(b) A/T:
Install a new O−ring to the oil filler tube.
(c) Apply soapy water to the O−ring.
(d) Push in the oil filler tube end into the tube hole of the oil
pan.
(e) Install the oil filler tube and No.1 throttle cable clamp with
the 2 nuts, bolt.
(f) Install the dipstick.
25. w/ EGR:
INSTALL EGR PIPE
Install 2 new gaskets and the EGR pipe with the 6 nuts.
Torque:
Nut A: 18.5 N·m (185 kgf·cm, 13 ft·lbf)
Nut B: 8 N·m (80 kgf·cm, 71 in.·lbf)
26. TEMPORARILY INSTALL GENERATOR

Downloaded from www.Manualslib.com manuals search engine P20501
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
EM−71
1996 TOYOTA T100 (RM449U)
13. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
14. CONNECT GENERATOR WIRE
(a) Connect the generator connector.
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
15. CONNECT STARTER WIRE AND CONNECTOR
(a) Connect the 2 starter wire clamps and connector.
(b) Install the 2 nuts, and connect the positive (+) terminal
cable to battery.
(c) Install the bolt, and connect the ground strap.
16. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose
Brake booster vacuum hose
EVAP hose
A.D.D. Vacuum hose
17. CONNECT HEATER HOSES
18. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
19. INSTALL AIR CLEANER CASE AND AIR FILTER
20. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP
21. w/ A/C:
CONNECT A/C COMPRESSOR
22. CONNECT PS PUMP
23. INSTALL FAN WITH FLUID COUPLING AND FAN
PULLEYS(See page EM−19)
24. INSTALL DRIVE BELT FOR GENERATOR (See page
CH−1)

Downloaded from www.Manualslib.com manuals search engine P21443
EM−80
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
1996 TOYOTA T100 (RM449U)
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
6. CONNECT STARTER WIRE AND CONNECTORS
(a) Connect the 3 starter wire clamps and connector.
(b) Install the 2 nuts, and connect the positive (+) terminal
cable to battery.
(c) Connect the A.D.D. indicator switch connector.
(d) Install the bolt, and connect the ground strap.
7. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose
Brake booster vacuum hose
EVAP hose
A.D.D. vacuum hose
8. CONNECT HEATER HOSES
9. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
10. INSTALL AIR CLEANER CASE AND AIR FILTER
11. INSTALL MAF METER, RESONATOR AND AIR
CLEANER CAP
12. w/ A/C:
CONNECT A/C COMPRESSOR
13. CONNECT PS PUMP
14. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS (See page EM−19)
15. INSTALL DRIVE BELT FOR GENERATOR (See page
CH−1)