TOYOTA T100 1996 Factory Service Manual

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EM070−02
EM−18
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT TIMING CHAINS, TIMING GEARS AND TIM-
ING SPROCKETS
(a) Measure the length of 16 links with the chain fully
stretched.
Maximum chain elongation:
No.1 Timing chain
147.5 mm (5.807 in.)
No.2 Timing chain
123.6 mm (4.866 in.)
If the elongation is greater than maximum, replace the chain.
HINT:
Make the same measurements pulling at 3 or more places se-
lected at random.
(b) Wrap the chain around the timing gear and timing sprock-
et.
(c) Using vernier calipers, measure the timing gear and tim-
ing sprocket diameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.
Minimum gear diameter:
Camshaft
113.8 mm (4.480 in.)
Crankshaft
59.4 mm (2.339 in.)
Balance shaft
75.9 mm (2.988 in.)
Minimum sprocket diameter:
No.2 crankshaft
96.7 mm (3.807 in.)
If the diameter is less than minimum, replace the chain, gears
and sprocket.

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− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−19
1996 TOYOTA T100 (RM449U)
2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRA-
TION DAMPERS
Measure the chain tensioner slipper and vibration damper
wears.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the slipper and/or
dampers.
3. INSPECT NO.2 CHAIN TENSIONER
(a) Inspect the chain tensioner
Check that the plunger moves smoothly when the
ratchet pawl is raised with your finger.
Release the ratchet pawl and check that the plung-
er is locked in place by the ratchet pawl and does
not move when pushed with your finger.
(b) Inspect the oil jet (No.2 chain tensioner).
Check the oil jet for damage or clogging.
If necessary, replace the oil jet (No.2 chain tensioner).

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− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
INSTALLATION
NOTICE:
Check that No.1 cylinder is at TDC and that the weights of
the No.1 and No.2 balance shafts are at the bottom side.
1. INSTALL NO.4 VIBRATION DAMPER
Install the No.4 damper with the 2 bolts.
2. INSTALL NO.2 TIMING CHAIN
(a) Install the No.2 timing chain by matching its mark links
with the timing marks on the No.2 crankshaft timing
sprocket and balance shaft timing sprocket.
(b) Fit the other mark link of No.2 timing chain onto the
sprocket behind the large timing mark of the balance shaft
drive gear.
(c) Insert the balance shaft drive gear shaft through the bal-
ance shaft drive gear so that it fits into the thrust plate
hole.
Then align the small timing mark of the balance shaft drive
gear with the timing mark of the balance shaft timing gear.
(d) Install the bolt to the balance shaft drive gear and tighten
it.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(e) Check that each timing mark is matched with the corre-
sponding mark link.
3. INSTALL NO.2, NO.3 VIBRATION DAMPERS AND
NO.2 CHAIN TENSIONER
NOTICE:
Assemble the chain tensioner with the pin installed, then
remove the pin after assembly.
When doing this, avoid pushing the No.2 vibration damper
against the chain.
(a) Install the No.2 chain tensioner with the nut.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

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− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−21
1996 TOYOTA T100 (RM449U)
(b) Install No.3 damper with the 2 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(c) Install No.2 damper with the bolt.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)
(d) Remove a pin from the No.2 chain tensioner and free the
plunger.
4. INSTALL NO.1 TIMING CHAIN TENSIONER
SLIPPER AND NO.1 VIBRATION DAMPER
(a) Install the No.1 damper with the bolt and nut.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Install the slipper with the bolt.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)
(c) Check that the slipper moves smoothly.
5. INSTALL CRANKSHAFT TIMING GEAR

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− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
HINT:
If necessary, install the gear with SST.
SST 09636−20010
6. INSTALL NO.1 TIMING CHAIN AND CAMSHAFT TIM-
ING GEAR
(a) Align the timing mark between the mark link of the No.1
timing chain, and install the No.1 timing chain to the timing
gear.
(b) Align the timing mark of the crankshaft timing gear with
the mark link of the No.1 timing chain and install the No.1
timing chain.
(c) Tie the No.1 timing chain with a cord as shown in the il-
lustration and make sure it doesn’t come loose.
7. INSTALL TIMING CHAIN COVER
(a) Install 3 new gaskets to the cylinder block and No.1 water
bypass pipe.
(b) Install the timing chain cover with the 9 bolts and 2 nuts.
Torque:
Bolt A: 20 N·m (200 kgf·cm, 14 ft·lbf)
Bolt B: 24.5 N·m (250 kgf·cm, 18 ft·lbf)
Bolt C: 44 N·m (440 kgf·cm, 32 ft·lbf)
Nut D: 20 N·m (200 kgf·cm, 14 ft·lbf)
(c) Remove the cord from the chain.

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− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−23
1996 TOYOTA T100 (RM449U)
(d) Install the 2 timing chain cover mounting bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(e) Install the 2 No.1 water bypass pipe mounting nuts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
8. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST, install and torque the pulley bolt.
SST 09213−54015, 09330−00021
Torque: 260 N·m (2,650 kgf·cm, 193 ft·lbf)
(c) w/ A/C:
Install the No.3 and No.2 crankshaft pulleies with the 4
bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
9. INSTALL OIL STRAINER
Install a new gasket and oil strainer with the 2 bolts and 2 nuts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

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A EM−24
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
10. INSTALL OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the oil pan.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pan 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 or 3 − 4 mm (0.012 − 0.016 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 oil pan with the 16 bolts and 2 nuts.
Torque: 12.5 N·m (130 kgf·cm, 9 ft·lbf)
11. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install a new O−ring.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf)
12. I N S TA L L G E N E R ATO R , A D J U S T I N G B A R A N D
BRACKET
(a) Install the bracket with the 3 bolts.
Torque:
Bolt A: 74.5 N·m (760 kgf·cm, 55 ft·lbf)
Bolt B: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Install the adjusting bar with the bolt.
Torque: 63.5 N·m (650 kgf·cm, 47 ft·lbf)

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Adjusting Bolt
Lock Bolt
Pivot Bolt
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−25
1996 TOYOTA T100 (RM449U)
(c) Install the generator with the pivot bolt and lock bolt.
13. w/ A/C:
INSTALL A/C COMPRESSOR AND BRACKET
(a) Install the A/C compressor bracket with the 4 bolts.
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
(b) Install the A/C compressor with the 4 bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
14. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN
WITH FLUID COUPLING AND DRIVE BELT
(a) Place the fan with fluid coupling, water pump pulley and
fan shroud in position.
(b) Temporarily install the water pump pulley mounting nuts.
(c) Install the No.1 fan shroud with the 4 bolts.
(d) Install the No.2 fan shroud with the 2 clips.
(e) Install the drive belts with the adjusting bolt and pivot bolt.
(f) Stretch the belt tight and tighten the 4 water pump pulley
mounting nuts.
Torque: 21 N·m (210 kgf·cm, 16 ft·lbf)
(g) Adjust the drive belts.
15. w/ A/C:
INSTALL A/C COMPRESSOR DRIVE BELT
Install and adjust the drive belt (See page CH−2).
16. INSTALL ENGINE UNDER COVER
Install the engine under cover with the bolts.
17. INSTALL CYLINDER HEAD (See page EM−50)
18. START ENGINE AND CHECK FOR LEAKS

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21 (210, 15)
29 (300, 22)
29 (300, 22)
29 (300, 22)
49 (500, 36)
: Specified torqueN·m (kgf·cm, ft·lbf)
29 (300, 22)
EM−26
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
741 Author: Date:
1996 TOYOTA T100 (RM449U)
CYLINDER HEAD
COMPONENTS

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See page EM−50
46 (465, 34)
21 (210,15)
1st 39 (400, 29)
2nd Turn 90°
3rd Turn 90°
N·m (kgf·cm, ft·lbf):Specified torque
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−27
742 Author: Date:
1996 TOYOTA T100 (RM449U)