TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P15725
P14806
No.3 Bearing Cap
P14805
P14786
3159
7
8
4
2
610 EM−98
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
10. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.3 journal position of
the cylinder block with the oil grooves facing outward.
11. PLACE CRANKSHAFT ON CYLINDER BLOCK
12. PLACE MAIN BEARING CAPS AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the 2 thrust washers on the No.3 bearing cap with
the grooves facing outward.
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
13. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any of the main bearing cap bolts is broken or deformed,
replace 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 10 bolts of the main bear-
ing caps, in several passes, in the sequence shown.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.

Downloaded from www.Manualslib.com manuals search engine Z15490
Front
Painted Mark90°
P14776
Z14823
Front
Mark
(Carity)
Front
P14778
Front
Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−99
1996 TOYOTA T100 (RM449U)
(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 above.
(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−84).
14. 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.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
15. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
16. INSTALL CONNECTING ROD CAP NUTS
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil on the threads and under
the nuts of the connecting rod cap.

Downloaded from www.Manualslib.com manuals search engine P04615
Nut
90°
Painted Mark
EM−100
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(b) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque:45 N·m (460 kgf·cm, 33 ft·lbf)
If any one of the connecting rod cap nuts does not meet the
torque specification, replace the connecting rod bolt and cap
nut as a set.
(c) Mark the front of the connecting rod cap nut and bolt with
paint.
(d) Retighten the connecting rod cap nuts 90° as shown.
(e) Check that the painted mark on the nut is at a 90° angle
in relation to the mark on the bolt.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance (See page
EM−84).

Downloaded from www.Manualslib.com manuals search engine P14810
Seal Packing
Z11442
P12478
Adhesive
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−101
1996 TOYOTA T100 (RM449U)
17. 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 retainer as shown in the illustra-
tion.
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.
HINT:
Avoid applying an excessive amount to the surface.
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 retainer with the 6 bolts.
Torque: 13.5 N·m (135 kgf·cm, 9.7 ft·lbf)
18. INSTALL LH ENGINE MOUNTING BRACKET
Install the bracket with the 5 bolts.
Torque:
Bolt A: 51 N·m (520 kgf·cm, 34 ft·lbf)
Bolt B: 20 N·m (200 kgf·cm, 14 ft·lbf)
19. INSTALL RH ENGINE MOUNTING BRACKET
Install the bracket with the 4 bolts.
Torque: 51 N·m (520 kgf·cm, 34 ft·lbf)
20. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent

Downloaded from www.Manualslib.com manuals search engine P15971
Oil Pressure Switch
SST
P14816
Knock
SensorSST
EM−102
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(b) Using SST, install the oil pressure switch.
SST 09816−30010
21. INSTALL ENGINE COOLANT DRAIN PLUG
(a) Apply adhesive to 2 or 3 threads of the engine coolant
drain plug.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the engine coolant drain plug.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
22. INSTALL OIL FILTER BRACKET UNION
(a) Install a new O−ring.
(b) Using 14 mm hexagon wrench, install the oil filter bracket
union.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
23. INSTALL OIL FILTER AND BRACKET
(a) Install a new O−ring and oil filter bracket with the 2 bolts
and nut.
Torque: 28 N·m (290 kgf·cm, 21 ft·lbf)
(b) Install the oil filter (See page LU−3).
24. INSTALL WATER BYPASS PIPE
Install the bolt and water bypass pipe.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
25. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816−30010
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
26. INSTALL FUEL FILTER
Install the 2 bolts and fuel filter.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
27. INSTALL TIMING CHAINS, GEARS AND SPROCKETS
(See page EM−20)
28. INSTALL CYLINDER HEAD (See page EM−50)
29. REMOVE ENGINE STAND

Downloaded from www.Manualslib.com manuals search engine Z11443
A
A B
Z11127
(6)(7)
(8) (9)
(10)
(1) (2)
(3)(4) (5)
Z15493
Up ward 90°
Painted Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
30. INSTALL REAR END PLATE
Install the rear end plate with the 3 bolts.
Torque:
Bolt A: 18 N·m (185 kgf·cm, 13 ft·lbf)
Bolt B: 20 N·m (200 kgf·cm, 14 ft·lbf)
31. M/T:
INSTALL FLYWHEEL
(a) Install and uniformly tighten 10 new bolts to the flywheel,
in several passes, in the sequence shown.
Torque: 26.5 N·m (270 kgf·cm, 19 ft·lbf)
(b) Mark the top of the flywheel bolt with paint.
(c) Retighten the flywheel bolts by 90° in the numerical order
shown above.
(d) Check that the painted mark is now at a 90° angle to the
top.
32. A/T:
INSTALL DRIVE PLATE
Install the front spacer, drive plate and rear spacer with the 10
bolts.
Torque: 74 N·m (750 kgf·cm, 56 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine EM07P−02
Z14985
: Specified torque 

39 (400, 29)
62 (630, 46)19 (195, 14)
N·m (kgf·cm, ft·lbf)

EM−104
− ENGINE MECHANICAL (3RZ−FE)EXHAUST SYSTEM
819 Author: Date:
1996 TOYOTA T100 (RM449U)
EXHAUST SYSTEM
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine EM – ENGINE MECHANICAL (5VZ-FE)

CO/HC EM-1
COMPRESSION EM-2
VALVE CLEARANCE EM-4
IGNITION TIMING EM-9
IDLE SPEED EM-10
TIMING BELT EM-11
CYLINDER HEAD EM-25
ENGINE UNIT (2WD) EM-62
ENGINE UNIT (4WD) EM-73
CYLINDER BLOCK EM-82
EXHAUST SYSTEM EM-108

Downloaded from www.Manualslib.com manuals search engine EM06B−03
P15056
− ENGINE MECHANICAL (5VZ−FE)CO/HC
EM−1
820 Author: Date:
1996 TOYOTA T100 (RM449U)
CO/HC
INSPECTION
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing checked correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180
SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When doing the 2 mode (2,500 rpm and idle) test, follow the
measurement order prescribed by the applicable local regula-
tions

Downloaded from www.Manualslib.com manuals search engine EM06C−05
P21054
EM−2
− ENGINE MECHANICAL (5VZ−FE)COMPRESSION
821 Author: Date:
1996 TOYOTA T100 (RM449U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−1)
3. REMOVE SPARK PLUGS
4. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,200 kPa (12.2 kgf/cm
2, 174 psi) or more
Minimum pressure:
1,000 kPa (10.2 kgf/cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 15 psi) or less
(e) If the cylinder compression in 1 or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
5. REINSTALL SPARK PLUGS