1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine P21454
P21446
EM−90
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
Others
Mark ”1”1.989 − 1.992 mm (0.0783 − 0.0784 in.)
Mark ”2”1.992 − 1.995 mm (0.0784 − 0.0785 in.)
Mark ”3”1.995 − 1.998 mm (0.0785 − 0.0787 in.)
Mark ”4”1.998 − 2.001 mm (0.0787 − 0.0788 in.)
Mark ”5”2.001 − 2.004 mm (0.0788 − 0.0789 in.)
Cylinder block main journal bore diameter:
Mark ”1”68.010 − 68.016 mm (2.6776 − 2.6778 in.)
Mark ”2”68.016 − 68.022 mm (2.6778 − 2.6780 in.)
Mark ”3”68.022 − 68.028 mm (2.6780 − 2.6783 in.)
Crankshaft main journal diameter:
Mark ”0”63.996 − 64.000 mm (2.5195 − 2.5197 in.)
Mark ”1”63.990 − 63.996 mm (2.5193 − 2.5195 in.)
Mark ”2”63.985 − 63.990 mm (2.5191 − 2.5193 in.)
(k) Completely remove the Plastigage.
28. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust wash-
ers from the cylinder block.
HINT:
Arrange the main bearings and thrust washers in correct order.
29. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
30. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the piston rings in the correct order only.

Downloaded from www.Manualslib.com manuals search engine P21512
EM07A−03
Z14704
P21514
EM6290
Mark 1, 2 or 3
No.6 Front
No.1
No.3No.5
No.2 No.4 EM−92
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
INSPECTION
1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
top surface of the cylinder block.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, thoroughly clean the cylinder
block.
3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder head gasket for warpage.
Maximum warpage:
0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
4. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 6 cylinders. If nec-
essary, replace the cylinder block.
5. INSPECT CYLINDER BORE DIAMETER
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the
top of the cylinder block.

Downloaded from www.Manualslib.com manuals search engine Z14733
11 5 m m
EM7639
P21449
Z00064
Z00065
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−95
1996 TOYOTA T100 (RM449U)
10. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 115 mm (4.53 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the ring end gap.
Standard ring end gap:
No.10.300 − 0.500 mm (0.0118 − 0.0197 in.)
No.20.400 − 0.600 mm (0.0157 − 0.0236 in.)
Oil (Side rail)0.150 − 0.550 mm (0.0059 − 0.0217 in.)
Maximum ring end gap:
No.11.100 mm (0.0433 in.)
No.21.200 mm (0.0472 in.)
Oil (Side rail)1.150 mm (0.0453 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, rebore all the 6 cylinders or replace the cylinder block.
11. INSPECT PISTON PIN FIT
At 60°C (140°F), you should be able to push the piston pin into
the piston pin hole with your thumb.
12. INSPECT CONNECTING ROD ALIGNMENT
Using a rod aligner and feeler gauge, check the connecting rod
alignment.
Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.
Check for twist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.

Downloaded from www.Manualslib.com manuals search engine P00326
P00593
P00603
15 mm (0.59 in.)
Compressed Thread
P21447
26 mm
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−97
1996 TOYOTA T100 (RM449U)
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
15. INSPECT CONNECTING ROD BOLTS
(a) Install the cap nut to the connecting rod bolt. Check that
the rod cap nut can be turned easily by hand to the end
of the thread.
(b) If the cap nut cannot be turned easily, measure the outer
diameter of the compressed thread with vernier calipers.
Standard outer diameter:
7.860 − 8.000 mm (0.3094 − 0.3150 in.)
Minimum outer diameter: 7.600 mm (0.2992 in.)
HINT:
If the location of this area cannot be judged by visual inspection,
measure the outer diameter at the location shown in the illustra-
tion.
If the outer diameter is less than minimum, replace the connect-
ing rod and rod cap nut as a set.
16. CYLINDER BORING
HINT:
Bore all the 6 cylinders for the oversized piston outside di-
ameter.
Replace all the piston rings with ones to match the over-
sized pistons.
(a) Keep the oversized pistons.
Oversized piston diameter:
O/S 0.50: 93.856 − 93.886 mm (3.6951 − 3.6963 in.)
(b) Calculate amount to the bore cylinders.
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 26 mm
(1.02 in.) from the piston head.

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Z00149
EM−98
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(2) Calculate the amount of each cylinder is to be re-
bored as follows:
Size to be rebored = P + C − H
P = Piston diameter
C = Piston oil clearance
0.134 − 0.154 mm (0.0053 − 0.0060 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
(3) C.Bore and hone cylinder to calculated dimensions
Maximum honing:
0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
17. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
No.2 and No.3 journals.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
18. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
STD63.985 − 64.000 mm (2.5191 − 2.5197 in.)
U/S 0.2563.745 − 63.755 mm (2.5096 − 2.5100 in.)
Crank pin diameter:
STD54.987 − 55.000 mm (2.1648 − 2.1654 in.)
U/S 0.2554.745 − 54.755 mm (2.1553 − 2.1557 in.)
If the diameter is not as specified, check the oil clearance (See
page EM−84).
(b) Check each main journal and crank pin for taper and out−
of−round as shown.
Maximum taper and out−of−round:
0.02 mm (0.0008 in.)
If the taper or out−of−round is greater than maximum, grind or
replace the crankshaft.

Downloaded from www.Manualslib.com manuals search engine P20861
Front Mark
(Arrow)
Z14732
EM5369
FrontPainted
Mark
EM5370
Painted Mark
90°
90°
P00591
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
(b) Install the main bearing cap with the front mark facing for-
ward.
8. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any main bearing cap bolt is broken or deformed, re-
place it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 8 main bearing cap bolts,
in several passes, in the sequence shown.
Torque: 61 N·m (625 kgf·cm, 45 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the cap bolt.
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order 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 crankshaft thrust clearance (See page
EM−92).
9. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.

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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 P05445
Cylinder Head Cover Side
Clean Hose
P05444
Air Intake Chamber Side
EC02Q−01
P15871
EC−4− EMISSION CONTROL (3RZ−FE)POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM
932 Author: Date:
1996 TOYOTA T100 (RM449U)
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM
INSPECTION
1. REMOVE PCV VALVE
2. INSTALL CLEAN HOSE TO PCV VALVE
3. INSPECT PCV VALVE OPERATION
(a) Blow into the cylinder head cover side, and check that air
passes through easily.
CAUTION:
Do not suck air through the valve. Petroleum substances
inside the valve are harmful.
(b) Blow air into the air intake chamber side, and check that
air passes through with difficulty.
If operation is not as specified, replace the PCV valve.
4. REMOVE CLEAN HOSE FROM PCV VALVE
5. REINSTALL PCV VALVE
6. VISUALLY INSPECT HOSES AND CONNECTIONS
Check for cracks, leaks or damage.