1996 TOYOTA T100 check oil

Downloaded from www.Manualslib.com manuals search engine P20820
P20826
P20834
P20836
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−21
1996 TOYOTA T100 (RM449U)
(b) RH Camshaft Position:
Turn the camshaft, align the knock pin hole of the cam-
shaft with the timing mark of the No.3 timing belt cover.
(c) LH Camshaft Pulley Position:
Turn the camshaft timing pulley, align the timing marks of
the camshaft timing pulley and No.3 timing belt cover.
9. INSTALL TIMING BELT TO LH CAMSHAFT TIMING
PULLEY
(a) HINT (When re−using timing belt):
Check that the installation mark on the timing belt
matches the end of the No.1 timing belt cover.
If the installation mark do not align, shift the meshing of the tim-
ing belt and crankshaft timing pulley until they align.
(b) Remove any oil or water on the LH camshaft timing pulley,
and keep it clean.
(c) Using SST, slightly turn the LH camshaft timing pulley
clockwise. Align the installation mark on the timing belt
with the timing mark of the camshaft timing pulley, and
hang the timing belt on the LH camshaft timing pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(d) Using SST, align the timing marks of the LH camshaft
pulley and No.3 timing belt cover.
SST 09960−10010 (09962−01000, 09963−01000)
(e) Check that the timing belt has tension between the crank-
shaft timing and LH camshaft timing pulleys.

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 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.

Downloaded from www.Manualslib.com manuals search engine P21158
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

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)CYLINDER HEAD
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

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− 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

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)ENGINE UNIT (4WD)
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.