1996 TOYOTA T100 check engine

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P21162
P21159
P13274Seal Packing EM−56
− ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
8. Exhaust:
INSTALL CAMSHAFTS OF LH CYLINDER HEAD
(a) Apply new engine oil to the thrust portion and journal of
the camshaft.
(b) Align the timing marks (1 dot mark) of the camshaft drive
and driven gears.
(c) Place the exhaust camshaft on the cylinder head.
(d) Install the 4 bearing caps in their proper locations.
(e) Apply a light coat of engine oil on the threads and under
the heads of bearing cap bolts.
(f) Install and uniformly tighten the 8 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(g) Remove the service bolt.
9. CHECK AND ADJUST VALVE CLEARANCE
10. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi−circular plug grooves.
Seal packing:
Part No. 08826−00080 or equivalent

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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)

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EM−61
1996 TOYOTA T100 (RM449U)
27. INSTALL TIMING BELT IDLER NO. 2 (See page
EM−19)
28. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING
BELT (See page EM−19)
29. INSTALL SPARK PLUGS
30. INSTALL HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−1)
31. w/ A/C:
INSTALL A/C COMPRESSOR BRACKET
32. w/ A/C:
CONNECT A/C COMPRESSOR
33. CONNECT PS PUMP
34. INSTALL FAN WITH FLUID COUPLING AND FAN PUL-
LEYS
Torque: 5.4 N·m (54 kgf·cm, 48 in.·lbf)
35. INSTALL NO. 2 FAN SHROUD
36. INSTALL AND ADJUST DRIVE BELT FOR GENERA-
TOR (See page CH−1)
37. w/ A/C:
INSTALL AND ADJUST DRIVE BELT FOR A/C COM-
PRESSOR
38. INSTALL AND ADJUST DRIVE BELT FOR PS PUMP
39. CONNECT HEATER HOSE AND UPPER RADIATOR
HOSE
40. CONNECT THESE CABLES:
(a) A/T:
Throttle cable
(b) Accelerator cable
(c) w/ Cruise control:
Cruise control actuator cable
41. 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 ASSEMBLY
42. INSTALL FRONT EXHAUST PIPE (See page EM−108)
43. FILL WITH ENGINE COOLANT
44. START ENGINE AND CHECK FOR LEAKS
45. CHECK IGNITION TIMING (See page EM−9)
46. 4WD:
INSTALL ENGINE UNDER COVER
47. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
48. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM−72
− ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (2WD)
1996 TOYOTA T100 (RM449U)
25. w/ A/C:
INSTALL DRIVE BELT FOR A/C COMPRESSOR
26. INSTALL DRIVE BELT FOR PS PUMP
27. INSTALL RADIATOR ASSEMBLY
(See page CO−19)
28. FILL WITH ENGINE OIL
29. FILL WITH ENGINE COOLANT
30. FILL TRANSMISSION OIL
31. START ENGINE AND CHECK FOR LEAKS
32. CHECK IGNITION TIMING
(See page EM−9)
33. INSTALL HOOD
34. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
35. RECHECK ENGINE COOLANT AND OIL LEVELS

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EM−81
1996 TOYOTA T100 (RM449U)
16. w/ A/C:
INSTALL DRIVE BELT FOR A/C COMPRESSOR
17. INSTALL DRIVE BELT FOR PS PUMP
18. INSTALL RADIATOR ASSEMBLY
(See page CO−19)
19. FILL WITH ENGINE OIL
20. FILL WITH ENGINE COOLANT
21. INSTALL ENGINE UNDER COVER
22. INSTALL TRANSMISSION
(See page MT−4)
23. INSTALL HOOD
24. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
25. RECHECK ENGINE COOLANT AND ENGINE OIL
LEVELS

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P20859
P20862
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−85
1996 TOYOTA T100 (RM449U)
17. w/ OIL COOLER:
REMOVE OIL COOLER WITH WATER BYPASS HOSE
AND OIL COOLER UNION (See page LU−18)
18. REMOVE OIL PAN (See page LU−9)
19. REMOVE OIL STRAINER (See page LU−9)
20. REMOVE OIL PAN BAFFLE PLATE (See page
LU−9)
21. REMOVE OIL PUMP (See page LU−9)
22. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
23. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.150 − 0.330 mm (0.0059 − 0.0130 in.)
Maximum thrust clearance:
0.38 mm (0.0150 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
24. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Using a punch or numbering stamp, mark the connecting
rod and cap to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.

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P20864
EM5345
EM−86
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−101).
Torque:
1st 25 N·m (250 kgf·cm, 18 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).

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EM5365
P21453
EM4968
Plastigauge
EM4969
EM−88
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
26. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
2.440 − 2.490 mm (0.0961 − 0.0980 in.)
27. REMOVE MAIN BEARING CAP AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts,
in several passes, in the sequence shown.
(b) Using a screwdriver, pry up the main bearing cap, and re-
move the main bearing cap, lower main bearings and low-
er thrust washers (No.2 journal position of main bearing
cap only).
HINT:
Keep the lower main bearings and lower thrust washers togeth-
er with the main bearing cap.
(c) Lift out the crankshaft.
HINT:
Keep the upper main bearings and upper thrust washers to-
gether with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing cap with the 8 bolts (See page
EM−101).
Torque:
1st 61 N·m (625 kgf·cm, 45 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 8 bolts and main bearing cap (See procedure
(a) and (b) above).
(j) Measure the Plastigage at its widest point.