installation - Toyota Repair

installation - Toyota Repair
EM–19
ENGINE MECHANICAL (5VZ–FE)
–
TIMING BELT
EM06J–03
INSTALLATION
1.
(a)
(b)
INSTALL CRANKSHAFT TIMING PULLEY
Align the pulley set key with the key groove of the timing
pulley and slide on the timing pulley.
Slide on the timing pulley, facing the flange side inward.
Inward
Sensor
P20822
2.
(a)
(b)
(c)
(d)
P20821
INSTALL NO. 1 IDLER PULLEY AND NO.2 IDLER
PULLEY
Using a 10 mm hexagon wrench, install the No.1 idler
pulley with the plate washer and bolt.
Torque: 35 N·m (350 kgf·cm, 26 ft·lbf)
Check that the pulley bracket moves smoothly.
Install the No.2 idler pulley with the bolt.
Torque: 40 N·m (400 kgf·cm, 30 ft·lbf)
Check that the pulley moves smoothly.
3.
TEMPORARILY INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Use the crankshaft pulley bolt to turn the crankshaft and
align the timing marks on the crankshaft timing pulley and
on the oil pump body.
(b) Remove any oil or water on the crankshaft timing pulley,
idler pulley and water pump pulley, and keep them clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(c) Align the installation mark on the timing belt with the
drilled mark of the crankshaft timing pulley.
(d) Install the timing belt on the crankshaft timing pulley, No.1
idler and water pump pulleys.
P20499
4.
INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
Front
P20823
1996 TOYOTA T100 (RM449U)
EM–20
ENGINE MECHANICAL (5VZ–FE)
–
TIMING BELT
5.
Length = 425 mm
(16.73 in.)
P20918
length = 145 mm
(5.71 in.)
INSTALL NO.1 TIMING BELT COVER AND STARTER
WIRE BRACKET
(a) Check that the timing belt cover gaskets have cracks or
peeling, etc.
If the gasket does have cracks or peeling, etc., replace it using
following steps.peeling, etc., replace them 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 back in the illustration.
(b) Install the timing belt cover with the 4 bolts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
(c) Install the starter wire bracket with the 2 bolts.
P21686
6.
(a)
SST
(b)
SST
INSTALL CRANKSHAFT PULLEY
Align the pulley set key with the key groove of the pulley,
and slide the pulley.
Using SST, install and torque the bolt.
SST 09213–54015 (90119–08216),
09330–00021
Torque: 250 N·m (2,500 kgf·cm, 184 ft·lbf)
P20516
7.
(a)
(b)
(c)
(d)
INSTALL LH CAMSHAFT TIMING PULLEY
Slide the timing pulley, facing the flange side outward.
Align the knock pin hole of the camshaft with the knock pin
groove of the timing pulley as shown.
Install the knock pin.
Using SST, install and torque the bolt.
SST 09960–10010 (09962–01000, 09963–01000)
Torque: 110 N·m (1,100 kgf·cm, 81 ft·lbf)
P20828
8.
(a)
P20827
1996 TOYOTA T100 (RM449U)
SET NO.1 CYLINDER TO TDC/COMPRESSION
Crankshaft Position:
Turn the crankshaft pulley, and align its groove with the
”O” timing mark of the No.1 timing belt cover.
EM–21
ENGINE MECHANICAL (5VZ–FE)
(b)
(c)
–
TIMING BELT
RH Camshaft Position:
Turn the camshaft, align the knock pin hole of the camshaft with the timing mark of the No.3 timing belt cover.
LH Camshaft Pulley Position:
Turn the camshaft timing pulley, align the timing marks of
the camshaft timing pulley and No.3 timing belt cover.
P20820
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 timing belt and crankshaft timing pulley until they align.
P20826
(b)
(c)
Remove any oil or water on the LH camshaft timing pulley,
and keep it clean.
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)
P20834
(d)
(e)
P20836
1996 TOYOTA T100 (RM449U)
Using SST, align the timing marks of the LH camshaft
pulley and No.3 timing belt cover.
SST 09960–10010 (09962–01000, 09963–01000)
Check that the timing belt has tension between the crankshaft timing and LH camshaft timing pulleys.
EM–22
ENGINE MECHANICAL (5VZ–FE)
10.
(a)
(b)
(c)
(d)
(e)
–
TIMING BELT
INSTALL RH CAMSHAFT TIMING PULLEY AND TIMING BELT
Remove any oil or water on the RH camshaft timing and
No.2 idler pulleys, and keep them clean.
Align the installation mark on the timing belt with the timing mark of the RH camshaft timing pulley as shown.
Hang the timing belt on the RH camshaft timing pulley.
Align the timing marks of the RH camshaft timing pulley
and No.3 timing belt cover.
Slide the RH camshaft timing pulley on the camshaft.
P20839
(f)
(g)
Using SST, align the knock pin hole of the camshaft with
the knock pin groove marked R of the pulley and install the
knock pin.
SST 09960–10010 (09962–01000, 09963–01000)
Using SST, install and torque the bolt.
SST 09960–10010 (09962–01000, 09963–01000)
Torque: 110 N·m (1,100 kgf·cm, 81 ft·lbf)
P20832
11.
(a)
(c)
SET TIMING BELT TENSIONER
Using a press, slowly press in the push rod using 100 –
1,000 kg (220 – 2,205 lb, 981 – 9,807 N) of pressure.
Align the holes of the push rod and housing, pass a 1.5
mm hexagon wrench through the holes to keep the setting position of the push rod.
Release the press.
(d)
Install the dust boot to the tensioner.
(b)
P08325
P10221
1996 TOYOTA T100 (RM449U)
EM–23
ENGINE MECHANICAL (5VZ–FE)
12.
(a)
(b)
–
TIMING BELT
INSTALL TIMING BELT TENSIONER
Install the tensioner with the 2 bolts.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)
Remove the 1.5 mm hexagon wrench from the tensioner.
P20817
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.
P20819
14.
(a)
(b)
INSTALL FAN BRACKET
Install the fan bracket with the bolt and nut.
Install the PS pump adjusting strut with the nut.
P20830
15.
(a)
Length = 955 mm (37.60 in.)
Length = 270 mm (10.63 in.)
1996 TOYOTA T100 (RM449U)
P20837
INSTALL NO.2 TIMING BELT COVER
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 timing belt cover.
(d) Connect the camshaft position sensor connector to the
No.2 timing belt cover.
EM–24
ENGINE MECHANICAL (5VZ–FE)
16.
–
TIMING BELT
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 PULLEYS
Torque:5.4 N·m (54 kgf·cm, 48 in.·lbf)
20. INSTALL NO.2 FAN SHROUD
21. INSTALL AND ADJUST DRIVE BELT FOR GENERATOR (See page CH–1)
22. w/ A/C:
INSTALL AND ADJUST DRIVE BELT FOR A/C COMPRESSOR
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
1996 TOYOTA T100 (RM449U)
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