TOYOTA T100 1996 Factory Service Manual

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Adjusting Shim Selection Chart (Intake)
New shim thickness mm (in.)
HINT: New shims have the thickness in
millimeters imprinted on the face. Intake valve clearance (Cold):
0.15 − 0.25 mm (0.006 − 0.010 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is
installed and measured clearance is 0.440 mm
(0.0173 in.). Replace the 2.800 mm (0.1102 in.)
shim with a No. 12 shim.
Shim
No.Shim
No. Thickness Thickness
EM−8
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
723 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine V00832
Shim
No.Shim
No. Thickness Thickness
Adjusting Shim Selection Chart (Exhaust)
New shim thickness mm (in.)
HINT: New shims have the thickness in
millimeters imprinted on the face. Exhaust valve clearance (Cold):
0.25 − 0.35 mm (0.010 − 0.014 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is
installed and measured clearance is 0.440 mm
(0.0173 in.). Replace the 2.800 mm (0.1102 in.)
shim with a No. 10 shim.
Installed shim thickness
Measured clearancemm (in.)
mm (in.)
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
EM−9
724 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine P24401A03718
EM−10
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
725 Author: Date:
1996 TOYOTA T100 (RM449U)
11. REINSTALL CYLINDER HEAD COVER
(a) Install the gasket to the cylinder head cover.
(b) Install the cylinder head cover with the 10 bolts.
12. RECONNECT ENGINE WIRE
(a) Connect the 5 engine wire clamps.
(b) Connect these connectors:
ECT sensor connector
Oil pressure sensor connector
w/ A/C:
A/C compressor connector
13. REINSTALL THROTTLE BODY (See page MF−30)
14. REINSTALL HIGH−TENSION CORDS TO SPARK
PLUGS
15. REINSTALL NO.1 AND NO.2 PCV HOSES
16. REINSTALL AIR INTAKE CONNECTOR (See page
EM−70)
17. REFILL WITH ENGINE COOLANT
18. CHECK IGNITION TIMING

Downloaded from www.Manualslib.com manuals search engine EM06T−02
FI7231
TOYOTA Hand−Held Tester
DLC3
P16016A03719
P15946
− ENGINE MECHANICAL (3RZ−FE)IGNITION TIMING
EM−11
726 Author: Date:
1996 TOYOTA T100 (RM449U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND−HELD TESTER OR OBDII
SCAN TOOL
(a) Connect the TOYOTA hand−held tester or OBDII scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand−held tester or OBDII
scan tool operators manual for further details.
3. CHECK IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
(b) Using a timing light, connect the tester to No.1 high−
tension cord.
(c) Check ignition timing.
Ignition timing:
3 − 7° BTDC @ idle
(Air Conditioner OFF)
If the ignition timing is not as specified, check that following
conditions are normal:
Throttle valve fully closed
Continuity between terminals IDL and E2 of the
throttle position sensor
Valve timing
(d) Remove the SST from the DLC1.
SST 09843−18020
4. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBDII SCAN TOOL, AND TIMING LIGHT

Downloaded from www.Manualslib.com manuals search engine EM1OJ−01
EM−12
− ENGINE MECHANICAL (3RZ−FE)IDLE SPEED
727 Author: Date:
1996 TOYOTA T100 (RM449U)
IDLE SPEED
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 system, etc. should be properly connected.
(f) MFI system wiring connectors fully plugged
(g) Ignition timing set correctly
(h) Transmission in neutral position
2. CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (See page EM−11)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed: 650 − 750 rpm
If the idle speed is not as specified, check the IAC valve.
4. DISCONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL

Downloaded from www.Manualslib.com manuals search engine EM06X−02
P21630
A03720
25 (250, 20)
29 (300, 22)
27 (270, 20)
200 (2,650, 191)
18 (185, 13)
27 (270, 20)
N·m (kgf·cm, ft·lbf): Specified torque
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−13
728 Author: Date:
1996 TOYOTA T100 (RM449U)
TIMING CHAIN
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine EM06Z−03
P14842
Adjusting Bolt
Lock Bolt
Pivot Bolt
P14935
P14907A03721
P14953
EM−14
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE OIL
2. DRAIN ENGINE COOLANT
3. REMOVE CYLINDER HEAD
(See page EM−28)
4. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
5. w/ A/C:
REMOVE A/C COMPRESSOR DRIVE BELT
Loosen the idler pulley nut and adjusting bolt, and remove the
drive belt.
6. REMOVE DRIVE BELT, FAN WITH FLUID
COUPLING, WATER PUMP PULLEY AND FAN
SHROUD
(a) Stretch the belt and loosen the water pump pulley mount-
ing nuts.
(b) Loosen the lock, pivot and adjusting bolts of the genera-
tor, and remove the drive belts.
(c) Remove the 4 water pump pulley mounting nuts.
(d) Pull out the fan with fluid coupling and water pump pulley.
(e) Remove the No.2 fan shroud.
(f) Remove the 4 bolts and No.1 fan shroud.
7. w/ A/C:
DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Remove the 4 mounting bolts, and disconnect the com-
pressor from the bracket.
HINT:
Put a side the compressor, and suspend it.
(b) Remove the 4 bolts and A/C compressor bracket.
8. REMOVE GENERATOR, ADJUSTING BAR AND
BRACKET
(a) Remove the lock, pivot bolts and the generator.
(b) Remove the bolt and adjusting bar.
(c) Remove the 3 bolts and bracket.
9. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts and crankshaft position sensor.
(b) Remove the O−ring from the crankshaft position sensor.

Downloaded from www.Manualslib.com manuals search engine P15008A03722
SST
P14954A03723
P15097A03724
P18141
Crankshaft Puller Bolt
SST
P14986A03725
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−15
1996 TOYOTA T100 (RM449U)
10. REMOVE OIL PAN
(a) Remove the 16 mounting bolts and 2 nuts.
(b) Insert the blade of SST between the cylinder block and oil
pan, cut off applied sealer and remove the oil pan.
SST 09032−00100
NOTICE:
Be careful not to damage the oil pan flanges of the oil pan
and cylinder block.
11. REMOVE OIL STRAINER
Remove the 2 bolts, 2 nuts, oil strainer and gasket.
12. REMOVE CRANKSHAFT PULLEY
(a) w/ A/C:
Remove the 4 bolts, No.2 and No.3 crankshaft pulleies.
(b) Using SST, remove the pulley bolt.
SST 09213−54015, 09330−00021
(c) Remove the crankshaft pulley.
HINT:
If necessary, remove the pulley with SST and crankshaft pulley
bolt.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05010, 09954−05020)
13. REMOVE TIMING CHAIN COVER
(a) Remove the 2 water by pass pipe mounting nuts.
(b) Remove the 2 timing chain cover mounting bolts.

Downloaded from www.Manualslib.com manuals search engine P14973A03726
P18142
SST
Crankshaft Pulley Bolt
P14923
P15081Pin
P14932A03727
EM−16
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
(c) Remove the 9 mounting bolts and 2 mounting nuts.
(d) Using a plastic−faced hammer, loosen the chain cover
and remove the timing chain cover and 3 gaskets.
14. REMOVE NO.1 TIMING CHAIN AND CAMSHAFT
TIMING GEAR
15. REMOVE CRANKSHAFT TIMING GEAR
HINT:
If necessary, remove the gear with SST and crankshaft pulley
bolt.
SST 09950−40010 (09951−04010, 09952−04010,
09953−04010, 09954−04010, 09955−04060)
16. REMOVE NO.1 TIMING CHAIN TENSIONER
SLIPPER AND NO.1 VIBRATION DAMPER
(a) Remove the bolt and slipper.
(b) Remove the bolt, nut and No.1 damper.
17. REMOVE NO.2, NO.3 VIBRATION DAMPERS AND
NO.2 CHAIN TENSIONER
(a) Install a pin to the No.2 chain tensioner and lock the
plunger.
(b) Remove the bolt and No.2 damper.

Downloaded from www.Manualslib.com manuals search engine P14974A03728
P15080A03729
P14920A03730
P14962
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−17
1996 TOYOTA T100 (RM449U)
(c) Remove the 2 bolts and No.3 damper.
(d) Remove the nut and No.2 chain tensioner.
18. REMOVE NO.2 TIMING CHAIN
(a) Remove the bolt from the balance shaft drive gear.
(b) Remove the balance shaft drive gear with shaft.
(c) Remove the No.2 timing chain with the No.2 crankshaft
timing sprocket.
19. REMOVE NO.4 VIBRATION DAMPER
Remove the 2 bolts and No.4 damper.