TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P14674
EM07C−03
P14673
P14693
P14692
P14660
EM−38
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS ANDCYLINDER
BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high−compressed air.
2. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
3. CLEAN COMBUSTION CHAMBERS
Using a wire brush, remove all the carbon from the combustion
chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
4. CLEAN VALVE GUIDE BUSHINGS
Using a valve guide bushing brush and solvent, clean all the
guide bushings.

Downloaded from www.Manualslib.com manuals search engine P14663
Z10933
P14696
EM0580
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−39
1996 TOYOTA T100 (RM449U)
5. CLEAN CYLINDER HEAD
Using a soft brush and solvent, thoroughly clean the cylinder
head.
6. INSPECT FOR FLATNESS
Using a precision straight edge and thickness gauge, measure
the surfaces contacting the cylinder block and the manifolds for
warpage.
Maximum warpage:
Cylinder block side
0.05 mm (0.0020 in.)
Manifold side
0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chambers, intake
ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

Downloaded from www.Manualslib.com manuals search engine P14659
P03864A03793
P14670
SST
P14667
EM−40
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
6.010 − 6.030 mm (0.2366 − 0.2374 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake
5.970 − 5.985 mm (0.2350 − 0.2356 in.)
Exhaust
5.965 − 5.980 mm (0.2348 − 0.2354 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake
0.025 − 0.060 mm (0.0010 − 0.0024 in.)
Exhaust
0.030 − 0.065 mm (0.0012 − 0.0026 in.)
Maximum oil clearance:
Intake
0.08 mm (0.0031 in.)
Exhaust
0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing.
10. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS
(a) Gradually heat the cylinder head to 80 − 100°C (176 −
212°F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201−10000 (09201−01060),
09550−10012 (09252−10010)
(c) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.

Downloaded from www.Manualslib.com manuals search engine Both intake and exhaust
11.050 − 11.077
(0.4350 − 0.4361) (0.4331 − 0.4341) 11.000 − 11.027mm (in.) Bushing bore diameter
Bushing size
Use STD
Use O/S 0.05
Z11079A03794
Z10934A03795
Z00054
44.5°
EM0181
Margin Thickness
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−41
1996 TOYOTA T100 (RM449U)
(d) Select a new guide bushing (STD size or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
11.027 mm (0.4341 in.), machine the bushing bore to these di-
mension:
11.050 − 11.077 mm (0.4350 − 0.4361 in.)
If the bushing bore diameter of the cylinder head is greater than
11.077 mm (0.4361 in.), replace the cylinder head.
(e) Gradually heat the cylinder head to 80 − 100°C (176 −
212°F).
(f) Using SST and a hammer, tap in a new guide bushing to
where there 8.2 − 8.6 mm (0.323 − 0.339 in.) protruding
from the cylinder head.
SST 09201−10000 (09201−01060),
09550−10012 (09252−10010)
(g) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See step 9
above) between the guide bushing and valve stem.
11. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle:
44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
1.0 mm (0.039 in.)
Minimum margin thickness:
0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.

Downloaded from www.Manualslib.com manuals search engine P03849
Overall Length
EM0255
A03806
P04415
Width
Z11441
45°30°
1.0 − 1.4 mm EM−42
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(d) Check the valve overall length.
Standard overall length:
Intake
103.45 mm (4.0728 in.)
Exhaust
103.60 mm (4.0787 in.)
Minimum overall length:
Intake
102.95 mm (4.0531 in.)
Exhaust
103.10 mm (4.0590 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
12. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for these:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with these width:
1.0 − 1.4 mm (0.039 − 0.055 in.)
If not, correct the valve seats as follows:
Intake:
If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.

Downloaded from www.Manualslib.com manuals search engine Z11379
45° 60°
1.0 − 1.4 mm
P14703
EM0988
Deviation
EM0281
P14704
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−43
1996 TOYOTA T100 (RM449U)
If the seating is too low on the valve face, use 60°
and 45° cutters to correct the seat.
(d) Hand−lap the valve and valve seat with an abrasive com-
pound.
(e) After hand−lapping, clean the valve and valve seat.
13. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation:
2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
(b) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
177 − 204 N (18.0 − 20.8 kgf, 45.9 − 39.7 lbf)
at 35.7 mm (1.406 in.)
If the installed tension is not as specified, replace the valve
spring.
14. INSPECT CAMSHAFT FOR RUNOUT
(a) Place the camshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.

Downloaded from www.Manualslib.com manuals search engine P03976
P03977
EM3322
Free Distance
P14668
Plastigage
P14665
EM−44
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
15. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
45.31 − 45.41 mm (1.7839 − 1.7878 in.)
Exhaust
45.06 − 45.16 mm (1.7740 − 1.7779 in.)
If the cam lobe height is less than standard allowable, replace
the camshaft.
16. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
17. INSPECT CAMSHAFT BEARING
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 a vernier caliper, measure the free distance between the
spring ends.
Free distance:
22.5 − 22.9 mm (0.886 − 0.902 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−50).
Torque: 15.5 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:
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
Maximum oil clearance:
0.08 mm (0.0031 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.

Downloaded from www.Manualslib.com manuals search engine P14708
P14706
P14650
EM2196
P14624
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−45
1996 TOYOTA T100 (RM449U)
20. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshaft (See page EM−50).
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.040 − 0.095 mm (0.0016 − 0.0037 in.)
Maximum thrust clearance:
0.12 mm (0.0047 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
21. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshafts without installing the exhaust cam
sub−gear (See page EM−50).
(b) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
Maximum backlash:
0.30 mm (0.0188 in.)
If the backlash is greater than maximum, replace the cam-
shafts.
22. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.000 − 31.016 mm (1.2205 − 1.2211 in.)
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 − 30.976 mm (1.1578 − 1.2195 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.024 − 0.055 mm (0.0009 − 0.0022 in.)
Maximum oil clearance:
0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
23. INSPECT AIR INTAKE CHAMBER
Using a precision straight edge and thickness gauge, measure
the surface contacting the intake manifold for warpage.
Maximum warpage: 0.20 mm (0.0078 in.)
If warpage is greater than maximum, replace the air intake
chamber.

Downloaded from www.Manualslib.com manuals search engine Z10936
Cylinder Head Side
Air Intake Chamber Side
P14622
P04666
Free
P04667
Lock EM−46
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
24. INSPECT INTAKE MANIFOLD
Using a precision straight edge and thickness gauge, measure
the surface contacting the cylinder head and air intake chamber
for warpage.
Maximum warpage: 0.20 mm (0.0078 in.)
If warpage is greater than maximum, replace the manifold.
25. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and thickness gauge, measure
the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 in.)
If warpage is greater than maximum, replace the manifold.
26. INSPECT CHAIN TENSIONER
(a) Check that the plunger moves smoothly when the ratchet
pawl is raised with your finger.
(b) Released the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushed with your finger.

Downloaded from www.Manualslib.com manuals search engine P14681
P22287
SST
0.5 − 2.5 mm
(0.020 − 0.098 in.)
A02827
Elongated
Thread
Measuring
Point
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−47
1996 TOYOTA T100 (RM449U)
27. IF NECESSARY, REPLACE SPARK PLUG TUBE GAS-
KETS
(a) Using a screwdriver, pry out the tube gasket.
(b) Using SST and a hammer, tap in a new tube gasket as
shown in the illustration.
SST 09950−60010 (09951−00260, 09951−00490),
09950−70010 (09951−07150)
(c) Apply a light coat of MP grease to the gasket lip.
28. INSPECT CYLINDER HEAD BOLTS
Using vernier calipers, measure the minimum diameter of the
elongate d thread at the measuring point.
Standard diameter:
10.76 − 10.97 mm (0.4236 − 0.4319 in.)
Minimum diameter:
10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.