1996 TOYOTA T100 check engine

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.

Downloaded from www.Manualslib.com manuals search engine EM−24
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
16. w/ A/C:
INSTALL A/C COMPRESSOR BRACKET
17. w/ A/C:
CONNECT A/C COMPRESSOR TO ENGINE
18. CONNECT PS PUMP TO ENGINE
19. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
Torque:5.4 N·m (54 kgf·cm, 48 in.·lbf)
20. INSTALL NO.2 FAN SHROUD
21. INSTALL AND ADJUST DRIVE BELT FOR GENERA-
TOR (See page CH−1)
22. w/ A/C:
INSTALL AND ADJUST DRIVE BELT FOR A/C COM-
PRESSOR
23. INSTALL AND ADJUST DRIVE BELT FOR PS PUMP
24. CONNECT UPPER RADIATOR HOSE
25. FILL ENGINE WITH COOLANT
26. START ENGINE CHECK FOR LEAKS
27. 4WD:
INSTALL ENGINE UNDER COVER
28. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
29. RECHECK ENGINE COOLANT LEVEL

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Z14652
P20514
EM0580
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−39
1996 TOYOTA T100 (RM449U)
5. CLEAN CYLINDER HEADS
Using a soft brush and solvent, thoroughly clean the cylinder
heads.
6. INSPECT FOR FLATNESS
Using precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder block and manifolds for war-
page.
Maximum warpage:
0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake
ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

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.

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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 EM2538
EM3322
Free Distance
P20858Plastigage
P20852
P20855
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−45
1996 TOYOTA T100 (RM449U)
16. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.949 − 26.965 mm (1.0610 − 1.0616 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
17. INSPECT CAMSHAFT BEARINGS
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
18. INSPECT CAMSHAFT GEAR SPRING
Using vernier calipers, measure the free distance between the
spring ends.
Free distance:
18.2 − 18.8 mm (0.712 − 0.740 in.)
If the free distance is not as specified, replace the gear spring.
19. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps (See page EM−51).
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
0.035 − 0.072 mm (0.0014 − 0.0028 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the plastigage.
20. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts (See page EM−51).
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.033 − 0.080 mm (0.0013 − 0.0031 in.)
Maximum thrust clearance:
0.12 mm (0.0047 in.)

Downloaded from www.Manualslib.com manuals search engine P20989
P20847
SST
P20848
P12390
Seal
Packing
P20844
EM−50
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(b) Install these parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020 (09202−00010)
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to ensure a proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
4. INSTALL CAMSHAFT HOUSING PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the bearing cap as shown.
Seal packing:
Part No. 08826−00080 or equivalent
(c) Place a new housing plug in position on the cylinder head,
facing the cap side inward.
(d) Install the camshaft bearing cap with the 2 bolts.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(e) Install the cylinder head rear plate, ground strap with the
bolt and nut.
Torque: 8 N·m (80 kgf·cm, 71 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P21247
Front
RH
LH
EM1OR−01
Z14657
12 Pointed Head Bolt
Front
P21151
Painted Mark
Front
P00868
90°
90°
90°90°
Painted
Mark
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
EM−51
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place 2 new cylinder head gaskets in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(b) Place the 2 cylinder heads in position on the cylinder head
gaskets.
2. INSTALL 12 POINTED HEAD CYLINDER HEAD BOLTS
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b), (d) and (e)).
If any bolt is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install and uniformly tighten the cylinder head bolts on
each cylinder head, in several passes, in the sequence
shown, then repeat for the other side, as shown.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts by 90° in the numerical
order shown.
(e) Retighten the cylinder head bolts by an additional 90°.
(f) Check that the painted mark is now facing rearward.