1996 TOYOTA T100 length

Downloaded from www.Manualslib.com manuals search engine MA0055
MA014−01
− MAINTENANCEBRAKE
MA−7
42 Author: Date:
1996 TOYOTA T100 (RM449U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Inspect in a well−lighted area. Inspect the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before inspecting the front
brake.
(a) Check all brake lines and hoses for:
Damage
Wear
Deformation
Cracks
Corrosion
Leaks
Bends
Twists
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS
(2WD: See page BR−22)
(4WD: See page BR−25)
HINT:
If a squealing or scraping noise occurs from the brake during
driving, check the pad wear indicator.
If there are traces of the indicator contacting the disc rotor, the
disc pad should be replaced.
3. INSPECT REAR BRAKE LININGS AND DRUMS
(2WD: See page BR−42)
(4WD: See page BR−48)

Downloaded from www.Manualslib.com manuals search engine PP0FT−01
− PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
PP−11 5
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Torque wrench
Bolt: Length: 35mm (1.38 in.) Pitch: 1.0 mm (0.039 in.)
Diam.: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam.: 360 mm (14.17 in.)Airbag disposal
vinyl bagAirbag disposal

Downloaded from www.Manualslib.com manuals search engine SS092−01
SS−4
− SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
178 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE MECHANICAL (3RZ−FE)
SERVICE DATA
Valve
clearance
(Cold)Intake
Exhaust0.15 − 0.25 mm (0.006 − 0.010 in.)
0.25 − 0.35 mm (0.010 − 0.014 in.)
Ignition timing3 − 7° BTDC @ idle
Idle speed650 − 750 rpm
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,230 kPa (12.5 kgf/cm2, 178 psi) or more
880 kPa (9.0 kgf/cm2, 127 psi)
98 kPa (1.0 kgf/cm2, 14 psi) or less
Cylinder headWarpage
Cylinder block side Maximum
Manifold sideMaximum
Valve seat
Refacing angleIntake
Exhaust
Contacting angle
Contacting width
Valve guide bushing bore diameter STD
O/S 0.05
Cylinder head bolt outside diameter STD
Minimum
0.05 mm (0.0020 in.)
0.10 mm (0.0039 in.)
30°, 45°, 60°
45°, 60°
45°
1.0 − 1.4 mm (0.039 − 0.055 in.)
11.000 − 11.027 mm (0.4331 − 0.4341 in.)
11.050 − 11.077 mm (0.4350 − 0.4361 in.)
10.76 − 10.97 mm (0.4236 − 0.4319 in.)
10.40 mm (0.4094 in.)
Valve guide
bushingInside diameter
Protrusion height
Replacing temperature (Cylinder head side)6.010 − 6.030 mm (0.2366 − 0.2374 in.)
8.2 − 8.6 mm (0.323 − 0.339 in.)
80 − 100°C (176 −212°F)
ValveValve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Minimum Intake
Exhaust
Margin thickness STD
Minimum103.45 mm (4.0728 in.)
103.60 mm (4.0787 in.)
102.95 mm (4.0531 in.)
103.10 mm (4.0590 in.)
44.5°
5.970 − 5.985 mm (0.2350 − 0.2356 in.)
5.965 − 5.980 mm (0.2348 − 0.2354 in.)
0.025 − 0.060 mm (0.0010 − 0.0024 in.)
0.030 − 0.065 mm (0.0012 − 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
1.0 mm (0.039 in.)
0.5 mm (0.020 in.)
Valve springDeviation Maximum
Installed tension at 37.5 mm (1.406 in.)2.0 mm (0.079 in.)
177 − 204 N (18.0 − 20.0 kgf, 45.9 − 39.7 lbf)
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum30.966 − 30.976 mm (1.1578 − 1.2195 in.)
31.000 − 31.016 mm (1.2205 − 1.2211 in.)
0.024 − 0.055 mm (0.0009 − 0.0022 in.)
0.07 mm (0.0028 in.)
ManifoldWarpageMaximum Intake
Exhaust0.20 mm (0.0078 in.)
0.50 mm (0.0197 in.)
Air intake
chamberWarpage Maximum0.20 mm (0.0078 in.)

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
SS−5
179 Author: Date:
1996 TOYOTA T100 (RM449U) Camshaft
Thrust clearance STD
Maximum
Journal oil clearance STD
Maximum
Journal diameter
Circle runoutMaximum
Cam lobe heightIntake
Exhaust
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.040 − 0.095 mm (0.0016 − 0.0037 in.)
0.12 mm (0.0047 in.)
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
0.08 mm (0.0031 in.)
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
0.06 mm (0.0024 in.)
45.31 − 45.41 mm (1.7839 − 1.7878 in.)
45.06 − 45.16 mm (1.7740 − 1.7779 in.)
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
0.30 mm (0.0188 in.)
22.5 − 22.9 mm (0.886 − 0.902 in.)
Spark plug
tubeProtrusion47.0 mm (1.850 in.)
Chain and
timing gearChain length at 16 links Maximum No.1
No.2
Crankshaft timing gear wearMinimum
Camshaft timing gear wearMinimum
Balance shaft drive gear wearMinimum
No.2 crankshaft timing
sprocket wear Maximum147.5 mm (5.807 in.)
123.6 mm (4.866 in.)
59.4 mm (2.339 in.)
113.8 mm (4.480 in.)
75.9 mm (2.988 in.)
96.7 mm (3.807 in.)
Chain
tensioner
slipper and
vibration
damperWear Maximum1.0 mm (0.039 in.)
Cylinder blockCylinder head surface warpageMaximum
Cylinder bore diameter STD
Maximum
Main bearing bolt outside diameter STD
Minimum
Cylinder block main journal bore diameter
STD Mark 1
Mark 2
Mark 3
U/S 0.250.05 mm (0.0020 in.)
94.990 − 95.003 mm (3.7398 − 3.7403 in.)
95.06 mm (3.7425 in.)
10.76 − 10.97 mm (0.4236 − 0.4319 in.)
10.40 mm (0.4094 in.)
64.004 − 64.010 mm (2.5198 − 2.5201 in.)
64.011 − 64.016 mm (2.5201 − 2.5203 in.)
64.017 − 64.022 mm (2.5203 − 2.5205 in.)
64.000 − 64.024 mm (2.5197 − 2.5206 in.)
Piston and
piston ringPiston diameter STD
O/S 0.50
Piston oil clearance
Piston ring groove clearanceNo.1
No.2
Piston ring end gap STD No.1
STD No.2 mark ”T”
”N”
Maximum No.1
No.2
Piston pin installing temperature94.933 − 94.943 mm (3.7375 − 3.7379 in.)
95.433 − 95.443 mm (3.7572 − 3.7575 in.)
0.047 − 0.070 mm (0.0019 − 0.0028 in.)
0.020 − 0.070 mm (0.0008 − 0.0028 in.)
0.030 − 0.070 mm (0.0012 − 0.0028 in.)
0.300 − 0.400 mm (0.0118 − 0.0157 in.)
0.400 − 0.500 mm (0.0157 − 0.0194 in.)
0.400 − 0.500 mm (0.0157 − 0.0194 in.)
0.40 mm (0.0157 in.)
0.50 mm (0.0196 in.)
80 − 90°C (176 − 194°F)

Downloaded from www.Manualslib.com manuals search engine SS00O−07
− SERVICE SPECIFICATIONSENGINE MECHANICAL (5VZ−FE)
SS−9
183 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE MECHANICAL (5VZ−FE)
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,200 kPa (12.2 kgf/cm2, 174 psi)
1,000 kPa (10.2 kgf/cm2, 145 psi)
100 kPa (1.0 kgf/cm2, 15 psi) or less
Valve
clearanceat cold Intake
Exhaust
Adjusting shim for repair part Mark 2.500
Mark 2.550
Mark 2.600
Mark 2.650
Mark 2.700
Mark 2.750
Mark 2.800
Mark 2.850
Mark 2.900
Mark 2.950
Mark 3.000
Mark 3.050
Mark 3.100
Mark 3.150
Mark 3.200
Mark 3.250
Mark 3.3000.13 − 0.23 mm (0.006 − 0.009 in.)
0.27 − 0.37 mm (0.011 − 0.014 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Ignition timingw/ Terminals TE1 and E1 connected of DLC18 − 12° BTDC @ idle
Idle speed−700 ± 50 rpm
Intake manifold
vacuumat idle speed60 kPa (450 mmHg, 17.7 in.Hg) or more
Timing belt
tensionerProtrusion from housing side10.0 − 10.8 mm (0.394 − 0.425 in.)
Cylinder headWarpage Maximum
Valve seat
Refacing angle
Contacting angle
Contacting width
Valve guide bushing bore diameter STD
O/S 0.050.10 mm (0.039 in.)
30°, 45°, 60°
45°
1.0 − 1.4 mm (0.039 − 0.055 in.)
10.985 − 11.027 mm (0.4325 − 0.4341 in.)
11.050 − 11.077 mm (0.4350 − 0.4361 in.)
Valve guide
bushingInside diameter
Outside diameter for repair part STD
O/S 0.056.010 − 6.030 mm (0.2366 − 0.2374 in.)
11.033 − 11.044 mm (0.4344 − 0.4348 in.)
11.083 − 11.094 mm (0.4363 − 0.4368 in.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum95.15 mm (3.7461 in.)
94.90 mm (3.7362 in.)
94.60 mm (3.7244 in.)
94.40 mm (3.7165 in.)
44.5°
5.970 − 5.985 mm (0.2350 − 0.2356 in.)
5.965 − 5.980 mm (0.2348 − 0.2354 in.)
0.025 − 0.060 mm (0.0010 − 0.0024 in.)
0.030 − 0.065 mm (0.0012 − 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
1.0 mm (0.039 in.)
0.5 mm (0.020 in.)

Downloaded from www.Manualslib.com manuals search engine SS−10
− SERVICE SPECIFICATIONSENGINE MECHANICAL (5VZ−FE)
184 Author: Date:
1996 TOYOTA T100 (RM449U) Valve spring
Deviation Maximum
Free length
Installed tension at 33.3 mm (1.311 in.)2.0 mm (0.079 in.)
44.78 mm (1.7630 in.)
186 − 206 N (19.0 − 21.0 kgf, 41.9 − 46.3 lbf)
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum30.966 − 30.976 mm (1.2191 − 2.2195 in.)
31.000 − 31.018 mm (1.2205 − 1.2212 in.)
0.024 − 0.052 mm (0.0009 − 0.0020 in.)
0.08 mm (0.0031 in.)
CamshaftThrust clearance STD
Maximum
Journal oil clearance STD
Maximum
Journal diameter
Circle runoutMaximum
Cam lobe height STD Intake
Exhaust
Minimum Intake
Exhaust
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.033 − 0.080 mm (0.0013 − 0.0031 in.)
0.12 mm (0.0047 in.)
0.035 − 0.072 mm (0.0014 − 0.0028 in.)
0.10 mm (0.0039 in.)
26.949 − 26.965 mm (1.0610 − 1.0616 in.)
0.06 mm (0.0024 in.)
42.31 − 42.41 mm (1.6657 − 1.6697 in.)
41.96 − 42.06 mm (1.6520 − 1.6559 in.)
42.16 mm (1.6598 in.)
41.81 mm (1.6461 in.)
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
0.30 mm (0.0188 in.)
18.2 − 18.8 mm (0.712 − 0.740 in.)
Air intake
chamberWarpage Maximum0.10 mm (0.0039 in.)
Intake air
connectorWarpage Maximum0.10 mm (0.0039 in.)
Intake
manifoldWarpage Maximum0.10 mm (0.0039 in.)
Exhaust
manifoldWarpage Maximum1.00 mm (0.0394 in.)
Cylinder blockCylinder head surface warpageMaximum
Cylinder bore diameter STD Mark 1
Mark 2
Mark 3
Maximum STD
O/S 0.500.05 mm (0.0020 in.)
93.500 − 93.510 mm (3.6811 − 3.6815 in.)
93.510 − 93.520 mm (3.6815 − 3.6819 in.)
93.520 − 93.530 mm (3.6819 − 3.6823 in.)
93.730 mm (3.6902 in.)
94.230 mm (3.7098 in.)
Piston and
piston ringPiston diameter STD Mark 1
Mark 2
Mark 3
O/S 0.50
Piston oil clearance STD
Maximum
Piston ring groove clearanceNo.1
No.2
Piston ring end gap STD No.1
No.2
Oil
Maximum No.1
No.2
Oil93.356 − 93.366 mm (3.6754 − 3.6758 in.)
93.367 − 93.376 mm (3.6759 − 3.6762 in.)
93.377 − 93.386 mm (3.6763 − 3.6766 in.)
93.856 − 93.886 mm (3.6951 − 3.6963 in.)
0.134 − 0.154 mm (0.0053 − 0.0060 in.)
0.174 mm (0.0069 in.)
0.040 − 0.080 mm (0.0016 − 0.0031 in.)
0.030 − 0.070 mm (0.0012 − 0.0028 in.)
0.300 − 0.500 mm (0.0118 − 0.0197 in.)
0.400 − 0.600 mm (0.0157 − 0.0236 in.)
0.150 − 0.550 mm (0.0059 − 0.0217 in.)
1.100 mm (0.0433 in.)
1.200 mm (0.0472 in.)
1.150 mm (0.0453 in.)

Downloaded from www.Manualslib.com manuals search engine SS09E−02
− SERVICE SPECIFICATIONSSTARTING (3RZ−FE)
SS−33
207 Author: Date:
1996 TOYOTA T100 (RM449U)
STARTING (3RZ−FE)
SERVICE DATA
Starter
(1.2 kW,
1.4 kW type)Rated voltage and output power
No−load characteristicsCurrent
rpm
Brush length STD
Minimum
Spring installed load
1.2 kW type STD
Minimum
1.4 kW type STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runoutMaximum
Magnetic switch
Contact plate for wearMaximum12 V 1.2 kW, 1.4 kW
90 A or less at 11.5 V
3,000 rpm or more
15.5 mm (0.610 in.)
10.0 mm (0.394 in.)
13.7 − 19.6 N (1.40 − 2.00 kgf, 3.1 − 4.4 lbf)
9.8 N (1.00 kgf, 2.2 lbf)
17.6 − 23.5 N (1.80 − 2.40 kgf, 4.0 − 5.3 lbf)
11.8 N (1.20 kgf, 2.6 lbf)
30.0 mm (1.18 in.)
29.0 mm (1.14 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)
Starter
(1.8 kW,
2.0 kW type)
Rated voltage and output power
No−load characteristicsCurrent
rpm
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runoutMaximum
Magnetic switch
Contact plate for wearMaximum12 V 1.8 kW, 2.0 kW
100 A or less at 11.5 V
2,500 rpm or more
15.0 mm (0.591 in.)
9.0 mm (0.354 in.)
21.5 − 27.5 N (2.20 − 2.80 kgf, 4.9 − 6.2 lbf)
12.7 N (1.30 kgf, 2.7 lbf)
35.0 mm (1.38 in.)
34.0 mm (1.34 in.)
0.7 mm (0.028 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)

Downloaded from www.Manualslib.com manuals search engine SS01A−11
− SERVICE SPECIFICATIONSSTARTING (5VZ−FE)
SS−35
209 Author: Date:
1996 TOYOTA T100 (RM449U)
STARTING (5VZ−FE)
SERVICE DATA
Starter
(1.4 kW type)
Rated voltage and output power
No−load characteristicsCurrent
rpm
Brush length STD
Minimum
Spring installed load
1.2 kW type STD
Minimum
1.4 kW type STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runoutMaximum
Magnetic switch
Contact plate for wearMaximum12 V 1.2 kW 1.4 kW
90 A or less at 11.5 V
3,000 rpm or more
15.5 mm (0.610 in.)
10.0 mm (0.394 in.)
13.7 − 19.6 N (1.40 − 2.00 kgf, 3.1 − 4.4 lbf)
9.8 N (1.00 kgf, 2.2 lbf)
17.6 − 23.5 N (1.80 − 2.40 kgf, 4.0 − 5.3 lbf)
11.8 N (1.20 kgf, 2.6 lbf)
30 mm (1.180 in.)
29 mm (1.140 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)
Starter
(1.8 kW type)Rated voltage and output power
No−load characteristicsCurrent
rpm
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runoutMaximum
Magnetic switch
Contact plate for wearMaximum12 V 1.8 kW
100 A or less at 11.5 V
2,500 rpm or more
15.0 mm (0.591 in.)
9.0 mm (0.354 in.)
21.5 − 27.5 N (2.20 − 2.80 kgf, 4.9 − 6.2 lbf)
12.7 N (1.30 kgf, 2.7 lbf)
35 mm (1.380 in.)
34 mm (1.340 in.)
0.7 mm (0.028 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)