TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P15073
P15137
P15099
P23949
EM−68
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
25. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the 2 heated oxygen sensor connectors.
(b) Remove the 2 bolts, and retainer holding the front ex-
haust pipe to the TWC.
(c) Loosen the clamp bolt and disconnect the clamp from the
support bracket.
(d) Remove the 2 bolts and support bracket.
(e) Remove the 3 nuts, front exhaust pipe and 3 gaskets.
26. M/T:
REMOVE CLUTCH RELEASE CYLINDER
(a) Remove the 2 bolts, and disconnect clutch release cylin-
der.
(b) Remove the bolt and disconnect the clutch line.
27. A/T:
REMOVE CROSS SHAFT
28. DISCONNECT STARTER WIRE
(a) Remove the nut and disconnect the starter wire.
(b) Disconnect the starter connector.
(c) Remove the bolt and disconnect ground strap.
29. PLACE JACK UNDER TRANSMISSION
30. REMOVE ENGINE REAR MOUNTING BRACKET
M/T:
Remove the 8 bolts holding the mounting bracket to the
mounting insulator and cross member.
A/T:
Remove the 7 bolts holding the mounting bracket to the
mounting insulator and cross member.
31. REMOVE ENGINE WITH TRANSMISSION
(a) Install a rear engine hanger in the correct direction.
Part No:
HANGER, ENGINE, NO.2 12282−75020
BOLT 91512−61020
Torque: 42 N·m (420 kgf·cm,30 ft·lbf)

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P15092
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−69
1996 TOYOTA T100 (RM449U)
(b) Attach the engine hoist chain to the 2 engine hangers.
(c) Remove the 4 bolts and nuts holding the engine front
mounting insulators to the frame.
(d) Lift the engine with transmission out of the vehicle slowly
and carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(e) Place the engine and transmission assembly onto the
stand.
32. SEPARATE ENGINE AND TRANSMISSION

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EM1OM−01
P15092
P15099
P15092
P15137
EM−70
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL TRANSMISSION TO ENGINE
2. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
IN VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the en-
gine compartment.
(c) Keep the engine level, and align the RH and LH mount-
ings and body mountings.
(d) Attach the RH and LH mounting insulators to the body
mountings, and temporarily install the 4 bolts and nuts.
(e) Jack up and put the transmission onto the frame.
(f) Remove the hoist chain.
(g) Remove the bolt and rear engine hanger.
3. INSTALL ENGINE REAR MOUNTING BRACKET
(a) Raise the transmission slightly by raising the engine with
a jack and a wooden block under the transmission.
(b) Install the engine rear mounting bracket to the frame.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(c) Lower the transmission and rest it on the extension hous-
ing.
(d) Install the mounting bracket to the mounting insulator.
Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)
4. TIGHTEN RH AND LH ENGINE MOUNTING
INSULATOR BOLTS AND NUTS
Tighten the 4 bolts and nuts holding the mounting insulators to
the body mountings.
Torque: 38 N·m (380 kgf·cm, 28 ft·lbf)
5. CONNECT STARTER WIRE
(a) Connect the ground strap with the bolt.
(b) Connect the starter connector.
(c) Connect the starter wire with the nut.
6. M/T:
INSTALL CLUTCH RELEASE CYLINDER
(a) Connect the clutch line with the bolt.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Install the clutch release cylinder with the 2 bolts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
7. A/T:
INSTALL CROSS SHAFT

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P15072
R05270
P15078
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−71
1996 TOYOTA T100 (RM449U)
8. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with new 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) Connect the 2 heated oxygen sensor connectors.
9. CONNECT SPEEDOMETER CABLE
10. INSTALL PROPELLER SHAFT (See page PR−9)
11. INSTALL STABILIZER BAR
(a) Place the stabilizer bar in position and install both stabiliz-
er bar bushings and brackets to the frame.
(b) Torque the stabilizer bar mounting bolts.
Torque: 30 N·m (306 kgf·cm, 22 ft·lbf)
(c) Connect the stabilizer bar on both sides to the lower arms
with brackets, cushions and new nuts as shown.
(d) Torque the nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
12. M/T:
INSTALL SHIFT LEVER ASSEMBLY
(a) Install baffle and shift lever assembly with the 6 bolts.
(b) Install the shift lever boot with the 4 screws.
(c) Install the shift lever knob.

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P15094
P15086
EM−72
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
13. CONNECT WIRES AND CONNECTORS
(a) Push in the engine wire through the cowl panel.
(b) Connect the 4 engine wire clamps
(c) Connect these wires and connectors:
Ground strap to cowl top panel
Igniter connector
(d) Connect 2 connectors to cowl wire.
(e) Connect 4 connectors to the ECM.
(f) Install the ECM with the 3 bolts.
14. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
(a) Install the cowl side trim with the clip.
(b) Install the front door scuff plate with the 4 screws.
15. CONNECT GENERATOR WIRE
(a) Connect the generator connector.
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
16. CONNECT PS PUMP
(a) Connect the PS pump to the bracket with the 2 bolts.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(b) Using SST, install the PS pump pulley with the nut.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
17. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose

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P14935
P24651
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−73
1996 TOYOTA T100 (RM449U)
Brake booster vacuum hose
EVAP hose
2 PS hoses
18. CONNECT HEATER HOSES
19. 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)
(c) Connect the A/C compressor connector.
20. INSTALL INTAKE AIR CONNECTOR
(a) Install the intake air connector with the 2 bolts and hose
clamp.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Connect the 2 air hoses.
21. M/T:
CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
22. A/T:
CONNECT ACCELERATOR AND THROTTLE CABLES
TO THROTTLE BODY

Downloaded from www.Manualslib.com manuals search engine EM−74
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
23. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with 3 bolts.
(b) Install the air cleaner element.
24. INSTALL MAF METER, RESONATOR AND AIR
CLEANER CAP
(a) Connect the air cleaner hose clamp.
(b) Install the air cleaner cap, MAF meter and resonator with
the 4 clips.
(c) Connect the MAF meter connector, IAT sensor connector
and wire clamp.
25. INSTALL RADIATOR (See page CO−20)
26. INSTALL RADIATOR RESERVOIR TANK
27. FILL WITH ENGINE OIL
28. FILL WITH ENGINE COOLANT
29. FILL TRANSMISSION OIL
30. INSTALL BATTERY
31. START ENGINE AND CHECK FOR LEAKS
32. CHECK IGNITION TIMING (See page EM−11)
33. INSTALL ENGINE UNDER COVER
Install the engine under cover with the 4 bolts.
34. INSTALL HOOD
35. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, and smooth opera-
tion.
36. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS

Downloaded from www.Manualslib.com manuals search engine EM07K−03
P21632
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−75
790 Author: Date:
1996 TOYOTA T100 (RM449U)
CYLINDER BLOCK
COMPONENTS

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P14816
Knock
SensorSST
P15971
SST
Oil Pressure Switch
P14771
EM−76
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. M/T:
REMOVE FLYWHEEL
Remove the 10 bolts and flywheel.
2. A/T:
REMOVE DRIVE PLATE
Remove the 10 bolts, front spacer, drive plate and rear spacer.
3. REMOVE REAR END PLATE
Remove the 3 bolts and rear end plate.
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE CYLINDER HEAD (See page EM−28)
6. REMOVE TIMING CHAINS, GEARS AND SPROCKET
(See page EM−14)
7. REMOVE FUEL FILTER
Remove the 2 bolts and fuel filter.
8. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816−30010
9. REMOVE WATER BYPASS PIPE
Remove the bolt and water bypass pipe.
10. REMOVE OIL FILTER AND BRACKET
(a) Remove the oil filter (See page LU−3).
(b) Remove the 2 bolts, nut, oil filter bracket and O−ring.
11. REMOVE OIL FILTER BRACKET UNION
Using 14 mm hexagon wrench, remove the union and O−ring.
12. REMOVE ENGINE COOLANT DRAIN PLUG
13. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816−30010
14. REMOVE RH ENGINE MOUNTING BRACKET
Remove the 4 bolts and bracket.
15. REMOVE LH ENGINE MOUNTING BRACKET
Remove the 5 bolts and bracket.
16. REMOVE REAR OIL SEAL RETAINER
Remove the 6 bolts and retainer.

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P14773
P14776
P14777
Plastigage
P14781
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−77
1996 TOYOTA T100 (RM449U)
17. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.160 − 0.312 mm (0.0063 − 0.0123 in.)
Maximum thrust clearance:
0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
18. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Using a punch or numbering stamp, place the matchmark
on the connecting rod cap to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−95).
Torque:
1st 45 N·m (460 kgf·cm, 33 ft·lbf)
2nd Turn 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD
0.030 − 0.055 mm (0.0012 − 0.0022 in.)
U/S 0.25
0.031 − 0.071 mm (0.0012 − 0.0026 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)