lock TOYOTA T100 1996 Factory Owner's Manual

Downloaded from www.Manualslib.com manuals search engine PP3MA−01
− PREPARATIONCOOLING (3RZ−FE)
PP−25
74 Author: Date:
1996 TOYOTA T100 (RM449U)
COOLING (3RZ−FE)
SST (Special Service Tools)
09230−00010Radiator Service Tool Set
(09231−00010)Lock Plate Bender
(09231−00020)Lock Plate Bender
(09231−00030)Plug Handle
(09231−00040)No.1 Plug
(09231−00050)No.2 Plug
09230−01010Radiator Service Tool Set
(09231−01010)Overhaul Handle
(09231−01020)Punch Assembly
(09231−01030)Claw
(09231−00060)No.3 Plug

Downloaded from www.Manualslib.com manuals search engine PP0GQ−01
PP−50
− PREPARATIONSTARTING (3RZ−FE)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Dial indicatorCommutator
Magnetic fingerSteel ball
PressMagnetic switch terminal kit
Pull scaleBrush spring
SandpaperCommutator
Torque wrench
V−blockCommutator
Vernier calipersCommutator, Brush

Downloaded from www.Manualslib.com manuals search engine PP026−02
− PREPARATIONSTARTING (5VZ−FE)
PP−53
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Dial indicatorCommutator
Magnetic fingerSteel ball
PressMagnetic switch terminal kit
Pull scaleBrush spring
SandpaperCommutator
Torque wrench
V−blockCommutator
Vernier calipersCommutator, Brush

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 SS093−02
− SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
SS−7
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Throttle body x Air intake chamber2020014
Spark plug x Cylinder head1920014
Cylinder head x Cylinder block 1st
2nd
3rd39
Turn 90°
Turn 90°
40029
Cylinder head x Timing chain cover2121015
Camshaft bearing cap x Cylinder head15.516012
Camshaft timing gear x Camshaft73.575054
Distributor gear x Camshaft4646534
Chain tensioner x Cylinder head2121015
Engine hanger x Cylinder head4242030
Exhaust manifold x Cylinder head4950036
Heat insulator x Exhaust manifold5.55548 in.·lbf
Front exhaust pipe x Exhaust manifold6263046
No.1 support bracket x Transmission3940029
No.1 support bracket clamp bolt1919514
Front exhaust pipe x TWC3940029
Intake manifold x Cylinder head2930022
Delivery pipe x Intake manifold2121015
Fuel inlet tube x Fuel filter2930022
Fuel inlet tube x Delivery pipe2930022
EGR valve x Air intake chamber, EGR pipe1919514
EGR vacuum modulator x Air intake chamber8.58574 in.·lbf
EGR pipe x Exhaust manifold2020015
EGR pipe x Cylinder head1818514
Cylinder head rear cover x Cylinder head13.513510
Water outlet x Cylinder head2020014
PS pump bracket x Cylinder head2020014
PS pump bracket x PS pump5859043
PS pump x PS pump pulley4344032
PS pump idler pulley x Cylinder head2020014
Balance shaft drive gear x Balance shaft2525018
No.2 chain tensioner, No.3 vibration damper x Cylinder block1818513
No.2 vibration damper x Cylinder block2727020
No.1 vibration damper x Cylinder block1818513
No.1 timing chain tensioner slipper x Cylinder block2727020
Timing chain cover x Cylinder block Bolt A
Bolt B
Bolt C
Nut D20
24.5
44
20200
250
440
20014
18
32
14
Timing chain cover mounting bolt1818513
No.1 water bypass pipe mounting nut2020014
Crankshaft pulley x Crankshaft2602,650193
No.2 and No.3 crankshaft pulley x Crankshaft pulley2525018

Downloaded from www.Manualslib.com manuals search engine SS−8
− SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
1996 TOYOTA T100 (RM449U) Oil strainer x Cylinder block
1818513
Oil pan x Cylinder block12.51309
Crankshaft position sensor x Timing chain cover8.58574 in.·lbf
Generator bracket x Cylinder block74.576055
Generator bracket x Timing chain cover1818513
Generator adjusting bar x Timing chain cover63.565047
A/C compressor bracket x Cylinder block4444032
A/C compressor x A/C compressor bracket2525018
Water pump pulley x Water pump2121016
Connecting rod cap x Connecting rod 1st
2nd45
Turn 90°46033
Main bearing cap x Cylinder block 1st
2nd39
Turn 90°40029
No.1 balance shaft x Timing gear3636526
No.2 balance shaft x Timing sprocket3636526
Balance shaft x Cylinder block1818513.4
Rear oil seal retainer x Cylinder block13.51359.7
RH, LH engine mounting bracket x Cylinder block4545034
Oil dipstick guide x LH engine mounting bracket2020014
Oil filter bracket union, Engine coolant drain plug x Cylinder block2525018
Oil filter bracket x Cylinder block2829021
Water bypass pipe x Cylinder block2020014
Knock sensor x Cylinder block3738027
Fuel filter x Cylinder block2020014
Rear end plate x Cylinder block1818513
Rear end plate x Water bypass pipe2020014
Flywheel x Crankshaft 1st
2nd26.5
Turn 90°27019
Front crossmember x Engine rear mounting bracket2526019
Front exhaust pipe clamp x Exhaust manifold6263046
Exhaust support bracket x Transmission3940029
Front exhaust pipe clamp1919514
Front exhaust pipe x TWC3940029
Engine rear mounting bracket x Engine rear mounting insulator1818313
Engine front mounting insulator x Frame3838728
Clutch release cylinder bracket x Transmission3940029
Clutch release cylinder x Transmission131309
Stabilizer bar bracket mounting bolt3030622
Stabilizer bar x Lower suspension arm131309
Intake air connector x Cylinder head1818513
Radiator x Body1818513

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 SS00P−11
SS−12
− SERVICE SPECIFICATIONSENGINE MECHANICAL (5VZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
No.1 idler pulley x Oil pump3535026
No.2 idler pulley x No.2 idler pulley bracket4040030
No.1 timing belt cover x Oil pump99080 in.·lbf
Crankshaft pulley x Crankshaft2502,500184
Camshaft timing pulley x Camshaft11 01,10081
Timing belt tensioner x Oil pump2727020
No.2 timing belt cover x No.3 timing belt cover99080 in.·lbf
Oil dipstick guide x Generator bracket88071 in.·lbf
Fluid coupling x Fan bracket5.45448 in.·lbf
Camshaft bearing cap x Cylinder head1616012
Rear plate x Cylinder head88071 in.·lbf
Cylinder head x Cylinder block 12 pointed head 1st
2nd
3rd
Recessed head34
Turn 90°
Turn 90°
18350
Turn 90°
Turn 90°
18525
Turn 90°
Turn 90°
13
Cylinder head cover x Cylinder head66053 in.·lbf
Exhaust manifold x Cylinder head4040030
Exhaust manifold heat insulator x Exhaust manifold88071 in.·lbf
Exhaust crossover pipe x Exhaust manifold4545033
Generator bracket x LH cylinder head18.518514
PS pump bracket x RH cylinder head4444032
Intake manifold x Cylinder head1818013
Intake manifold stay x Intake manifold18.518513
Intake manifold stay x No. 2 idler pulley bracket18.518513
No.3 timing belt cover x Cylinder head99080 in.·lbf
Camshaft position sensor x RH cylinder head88071 in.·lbf
Intake air connector x Intake manifold18.518513
Air intake chamber x Intake air connector18.518513
Air intake chamber stay x LH cylinder head, Air intake chamber4040030
EGR pipe x LH exhaust manifold18.518513
EGR pipe x EGR valve18.518513
EGR pipe x Cylinder head88071 in.·lbf
Engine hanger No.2 x RH cylinder head4040030
Frame crossmember x Engine rear mounting bracket5859043
Engine rear mounting bracket x Engine rear mounting insulator1818513
Engine front mounting insulator x Frame3838728
Connecting rod cap x Connecting rod 1st
2nd25
Turn 90°250
Turn 90°18
Turn 90°
Main bearing cap x Cylinder block 1st
2nd61
Turn 90°625
Turn 90°45
Turn 90°
Rear oil seal retainer x Cylinder block88071 in.·lbf
Oil cooler union x Cylinder block3030022
Oil hole cover plate x Cylinder block6060044
Engine coolant drain cock x Cylinder block3940029

Downloaded from www.Manualslib.com manuals search engine − SERVICE SPECIFICATIONSENGINE MECHANICAL (5VZ−FE)
SS−13
1996 TOYOTA T100 (RM449U) Engine mounting bracket x Cylinder block
4444032
Oil filter union x Cylinder block2525018
Oil pressure switch x Cylinder block1515011
Generator adjusting bar x Cylinder block4242031
Knock sensor x Cylinder block3940029
No.2 idler pulley bracket x Cylinder block3838028
Water bypass pipe x Cylinder block8.58575 in.·lbf
Rear end plate x Cylinder block7.57566 in.·lbf
Drive plate x Crankshaft8385063
Flywheel x Crankshaft8585063
Clutch release cylinder x Transmission121209
Stabilizer bar bracket mounting bolt3030622
Stabilizer bar x Lower suspension arm131309
Front exhaust pipe x Exhaust crossover pipe6263046
Front exhaust pipe x Center exhaust pipe4849035
Front exhaust pipe support bracket x Front exhaust pipe4445033
Front exhaust pipe support bracket x Transmission4445033
Center exhaust pipe x Tailpipe4849035
Center exhaust pipe support bracket x Body2930021