TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine EM07D−02
Z11449
Protrusion
47.0 mm
Mark
P14649
Sealant
P14662
Protrusion
P14651
SST
EM−48
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Mark the standard position away from the edge, onto the
spark plug tube.
Standard protrusion: 47.0 mm (1.850 in.)
(b) Apply adhesive to the spark plug tube hole of the cylinder
head.
Sealant:
Part No.08833−00070, Adhesive 1324, THREE BOND
1324 or equivalent
(c) Using a press, press in a new spark plug tube until there
is 47.0 mm (1.850 in.) protruding from the camshaft bear-
ing cap installation surface of the cylinder head.
NOTICE:
Avoid pressing a new spark plug tube in too far by measur-
ing the amount of protrusion while pressing.
2. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09236−00101 (09236−15010)
HINT:
Different oil seals are used for the intake and exhaust.
Code mark (Intake side only): ”H”

Downloaded from www.Manualslib.com manuals search engine P14652
(4)
(3)
(2)
(1)
P14702
SST
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−49
1996 TOYOTA T100 (RM449U)
(b) Install these parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to ensure a proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

Downloaded from www.Manualslib.com manuals search engine P14680
Z10935
EM1OL−01
Z15489
90°
90°
Front
Painted Mark
P14709
EM−50
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Apply seal packing to the 2 locations as shown.
Seal packing:
Part No. 08826−00080 or equivalent
NOTICE:
Do not apply too much seal packing.
(b) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(c) Place the cylinder head in position on the cylinder head
gasket.
2. INSTALL CYLINDER HEAD BOLTS
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install and uniformly tighten the 10 cylinder head bolts
and plate washers in several passes, in the sequence
shown.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts by 90° in the numerical
order shown.
(e) Retighten the cylinder head bolts by an additional 90°.
(f) Check that the painted mark is now facing rearward.
(g) Install and torque the 2 mounting bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P14911
Z11078
(1) (2) (3)
P14906
P14910
Service Bolt
SST
Turn
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−51
1996 TOYOTA T100 (RM449U)
3. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install these parts:
(1) Camshaft gear spring
(2) Camshaft sub−gear
(3) Wave washer
HINT:
Align the pins on the gears with the spring ends.
(c) Using snap ring pliers, install the snap ring.
(d) Using SST, align the holes of the camshaft main gear and
sub−gear by turning sub−gear clockwise, and install a
service bolt.
SST 09960−10010 (09962−01000, 09963−00500)
4. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, these
steps should be carried out.

Downloaded from www.Manualslib.com manuals search engine P14672
Straight Pin
P14711
P15749
7
3
1
5
98
4
2
6
10
P14699
Straight Pin
Aligh (Dot Mark)
P14701
EM−52
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(a) Install intake camshaft.
(1) Apply MP grease to the thrust portion of the intake
camshaft.
(2) Place the intake camshaft with knock pin facing up-
ward of camshaft angle on the cylinder head.
(3) Install the bearing caps in their proper locations.
(4) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(5) Install and uniformly tighten the 10 bearing cap
bolts in the sequence shown.
Torque: 15.5 N·m (160 kgf·cm, 12 ft·lbf)
(b) Install exhaust camshaft.
(1) Apply MP grease to the thrust portion of the exhaust
camshaft.
(2) Engage the exhaust camshaft gear to the intake
camshaft gear by matching the timing marks (1 and
2 dots) on each gear.
NOTICE:
There are also timing marks (for TDC) on each gear as
shown in the illustration. Do not use these marks.
(3) Roll down the exhaust camshaft onto the bearing
journals while engaging gears with each other.
(4) Install the bearing caps in their proper locations.

Downloaded from www.Manualslib.com manuals search engine P15748
7
3
1
5
98
4
2
6
10
Z11084
P14695
A01399
Dot Mark
P14698
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−53
1996 TOYOTA T100 (RM449U)
(5) Apply light coat of engine oil on the threads and un-
der the heads of the bearing cap bolts.
(6) Install and uniformly tighten the 10 bearing cap
bolts in several passes in the sequence shown.
(7) Remove a service bolt.
(8) Check that the intake and exhaust camshafts turn
smoothly.
5. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise, and align its groove
with the timing mark ”0” of the timing chain cover.
(b) Turn the camshafts so that the timing marks with one and
2 dots will be in straight line on the cylinder head surface
as shown in the illustration.
6. INSTALL CAMSHAFT TIMING GEAR
HINT:
Check that the matchmarks on the camshaft timing gear and
timing chain are aligned.
(a) Place the gear over the straight pin of the intake cam-
shaft.

Downloaded from www.Manualslib.com manuals search engine P14632
P14685
Front Mark
P04668
Hook
Pin
P14683
Push EM−54
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(b) Hold the intake camshaft with a wrench, install and torque
the bolt.
Torque: 73.5 N·m (750 kgf·cm, 54 ft·lbf)
(c) Hold the exhaust camshaft with a wrench, install the bolt
and distributor gear.
Torque: 46 N·m (465 kgf·cm, 34 ft·lbf)
7. INSTALL CHAIN TENSIONER
(a) Place a new gasket so that the front mark is toward the
front side.
(b) Release the ratchet pawl, fully push in the plunger and ap-
ply the hook to the pin so that the plunger cannot spring
out.
(c) Turn the crankshaft pulley clockwise to provide some
slack for the chain on the tensioner side.
NOTICE:
Do not turn the pulley counterclockwise.
(d) Push the tensioner by hand until it touches the head
installation surface, then install the 2 nuts.
(e) Tighten the 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(f) Check that the hook of the tensioner is not released.
NOTICE:
If the plunger springs out during installation of the chain
tensioner, repeat the operation in step (b) before installing
the tensioner.

Downloaded from www.Manualslib.com manuals search engine A01402
A01597
P14695
A01399
Dot Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−55
1996 TOYOTA T100 (RM449U)
8. SET CHAIN TENSIONER
Turn the crankshaft to the left so that the hook of the chain ten-
sioner is released from the pin of the plunger, causing the plung-
er to spring out and the slipper to be pushed into the chain.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver or your finger so that the
hook is released and the plunger springs out.
9. CHECK VALVE TIMING
(a) Turn the crankshaft pulley, and align its groove with the
timing mark ”0” of the timing chain cover.
NOTICE:
Always turn the crankshaft clockwise.
(b) Check that the timing marks (1 and 2 dots) of the camshaft
drive and driven gears are in straight line on the cylinder
head surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks as above.
10. CHECK AND ADJUST VALVE CLEARANCE (See page
EM−5)
Turn the camshaft and position the cam lobe upward and check
and adjust the valve clearance.
Valve clearance (Cold):
Intake
0.15 − 0.25 mm (0.006 − 0.010 in.)
Exhaust
0.25 − 0.35 mm (0.010 − 0.014 in.)
11. INSTALL SPARK PLUGS
Using a 16 mm plug wrench, install the spark plug.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P03789
P14695
P14687
P14686
EM−56
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
12. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head installation sur-
face of the semi−circular plugs.
Seal packing:
Part No. 08826−00080 or equivalent
(c) Install the semi−circular plug to the cylinder head.
13. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise, and align its groove
with the timing mark ”0” of the timing chain cover.
(b) Check that the timing marks with 1 and 2 dots are in
straight line on the cylinder head surface as shown in the
illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
mark as above.
14. INSTALL CYLINDER HEAD COVER
(a) Install the gasket to the cylinder head cover.
(b) Install the cylinder head cover with the 10 bolts.
Install the No.2 engine hanger and ground strap with the
bolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)
15. INSTALL NO.1 ENGINE HANGER
Install the No.1 engine hanger with the bolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)
16. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and exhaust manifold with the 6 nuts.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Install the heat insulator with the 2 bolts and 2 nuts.
Torque: 5.5 N·m (55 kgf·cm, 48 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P15073
P22272
P24691
A02538
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−57
1996 TOYOTA T100 (RM449U)
17. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with the 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 2 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect a new gasket and the front exhaust pipe assem-
bly to the TWC with the 2 bolts and retainer.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(e) Install camshaft position sensor.
18. INSTALL INTAKE MANIFOLD
Install a new gasket and intake manifold with the 3 bolts and 2
nuts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
19. INSTALL INJECTORS AND DELIVERY PIPE (See page
MF−21)
HINT:
When using a new cylinder head, spacers must be installed.
Apply a light coat of gasoline to a new O−ring a nd install it to
a new spacer.
20. INSTALL FUEL TUBE
Install the fuel inlet tube and 4 new gaskets with 2 union bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
21. INSTALL AIR INTAKE CHAMBER
(a) Install a new gasket and the air intake chamber with the
3 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(b) Connect the vacuum hose to the gas filter.
(c) Connect the brake booster vacuum hose to the intake
camber.