engine bearings TOYOTA T100 1996 Factory User Guide

Downloaded from www.Manualslib.com manuals search engine P14746
P14744
P14804
P14808
No.2, 4 Bearing Cap
2 or 4
P14809
No.1, 5 Bearing Cap
1 or 5
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−97
1996 TOYOTA T100 (RM449U)
8. INSTALL BALANCE SHAFTS
(a) Install balance shafts.
NOTICE:
When installing the balance shaft make sure you support
the balance shaft with both hands and avoid scratching the
balance shaft bearing on the cylinder block side.
(b) Install the No.1 balance shaft with the bolt.
(c) Install the No.2 balance shaft with the 2 bolts.
Torque: 18 N·m (185 kgf·cm, 13.4 ft·lbf)
9. INSTALL MAIN BEARINGS
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.

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 P20865
P20864
EM5345
EM−86
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−101).
Torque:
1st 25 N·m (250 kgf·cm, 18 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).

Downloaded from www.Manualslib.com manuals search engine P20863
P01284
Mark
1, 2 or 3
Mark
1, 2 or 3
P00884
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−87
1996 TOYOTA T100 (RM449U)
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD
0.024 − 0.053 mm (0.0009 − 0.0021 in.)
U/S 0.25
0.023 − 0.069 mm (0.0009 − 0.0027 in.)
Maximum oil clearance:
0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number marked on the connecting rod cap. There are 3 sizes
of standard bearings, marked ”1”, ”2” and ”3” accordingly.
Reference:
Standard bearing center wall thickness
Mark ”1”1.484 − 1.488 mm (0.0584 − 0.0586 in.)
Mark ”2”1.488 − 1.492 mm (0.0586 − 0.0587 in.)
Mark ”3”1.492 − 1.496 mm (0.0587 − 0.0589 in.)
(k) Completely remove the Plastigage.
25. R E M O V E P I S TO N A N D C O N N E C T I N G R O D A S-
SEMBLIES
(a) Using a ridge reamer, remove the all carbon from the top
of the cylinder.
(b) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(c) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in cor-
rect order.

Downloaded from www.Manualslib.com manuals search engine P20860
EM5365
P21453
EM4968
Plastigauge
EM4969
EM−88
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
26. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
2.440 − 2.490 mm (0.0961 − 0.0980 in.)
27. REMOVE MAIN BEARING CAP AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts,
in several passes, in the sequence shown.
(b) Using a screwdriver, pry up the main bearing cap, and re-
move the main bearing cap, lower main bearings and low-
er thrust washers (No.2 journal position of main bearing
cap only).
HINT:
Keep the lower main bearings and lower thrust washers togeth-
er with the main bearing cap.
(c) Lift out the crankshaft.
HINT:
Keep the upper main bearings and upper thrust washers to-
gether with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing cap with the 8 bolts (See page
EM−101).
Torque:
1st 61 N·m (625 kgf·cm, 45 ft·lbf)
2nd Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 8 bolts and main bearing cap (See procedure
(a) and (b) above).
(j) Measure the Plastigage at its widest point.

Downloaded from www.Manualslib.com manuals search engine Z04969
Mark
1, 2 or 3
Mark
1, 2, 3, 4 or 5 No. 1
No. 2
No. 3
No. 4
Mark 0, 1 or 2Mark F
No. 1
No. 2
No. 3
No. 4
No. 4
Crank Pin
No. 3 Crank Pin
5 Cylinder block
Crankshaft
Use bearingNumber marked
1
1
111
000 2
2
2
222 3
333
44
EXAMPLE: Cylinder block ”2” + Crankshaft ”1”
= Total number 3 (Use bearing ”3”)
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−89
1996 TOYOTA T100 (RM449U)
Standard clearance:
No.1
STD0.020 − 0.038 mm (0.0008 − 0.0015 in.)
U/S 0.250.019 − 0.059 mm (0.0007 − 0.0023 in.)
Others
STD0.024 − 0.042 mm (0.0009 − 0.0017 in.)
U/S 0.250.023 − 0.063 mm (0.0009 − 0.0025 in.)
Maximum clearance:
0.08 mm (0.0031 in.)
HINT:
If replacing the cylinder block subassembly, the bearing stan-
dard clearance will be:
No.1
0.010 − 0.049 mm (0.0004 − 0.0020 in.)
Others
0.014 − 0.053 mm (0.0006 − 0.0021 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then selecting the
bearing with the same number as the total. There are 5 sizes
of standard bearings, marked ”1”, ”2”, ”3”, ”4” and ”5” according-
ly.
Reference:
Standard sized bearing center wall thickness:
No.1
Mark ”1”1.991 − 1.994 mm (0.0784 − 0.0785 in.)
Mark ”2”1.994 − 1.997 mm (0.0785 − 0.0786 in.)
Mark ”3”1.997 − 2.000 mm (0.0786 − 0.0787 in.)
Mark ”4”2.000 − 2.003 mm (0.0787 − 0.0789 in.)
Mark ”5”2.003 − 2.006 mm (0.0789 − 0.0790 in.)

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 P21451
P01030
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−91
1996 TOYOTA T100 (RM449U)
31. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to about 60°C (140°F).
(c) Using a plastic−faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

Downloaded from www.Manualslib.com manuals search engine − ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
EM−99
1996 TOYOTA T100 (RM449U)
19. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
(a) Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure step 18).
(b) Install new main journal and/or crank pin undersized
bearings.

Downloaded from www.Manualslib.com manuals search engine P00592
P10205
No. 1
Others
22 mm20 mm
P10214
P10215
EM5354
EM−102
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
HINT:
Main bearings come in widths of 20 mm (0.79 in.) and 22
mm (0.87 in.). Install the 22 mm (0.87 in.) bearings in the
No.1 cylinder block journal position with the main bearing
caps. Install the 20 mm (0.79 in.) bearings in the other
positions.
Upper bearings have an oil holes lower bearings do not.
(a) Align the bearing claw with the claw groove of the main
bearing cap or cylinder block.
(b) Install the bearings in the cylinder block and main bearing
cap.
5. INSTALL UPPER THRUST WASHERS
Install the thrust washers under the No.2 journal position of the
cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. PLACE MAIN BEARING CAP AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the thrust washers on the No.2 journal position of
the bearing cap with the grooves facing outward.