TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P03828
P03868
EM0227
EM7426
SST
EM−88
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
Check for twist
Maximum twist:
0.15 mm (0.0059 in. ) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
14. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
24.008 − 24.017 mm (0.9452 − 0.9455 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
24.000 − 24.009 mm (0.9449 − 0.9452 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 − 0.011 mm (0.0002 − 0.0004 in.)
Maximum oil clearance:
0.015 mm (0.0006 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set.
15. IF NECESSARY, REPLACE CONNECTING ROD
BUSHING
(a) Using SST and a press, press out the bushing.
SST 09207−76010

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SST
Oil
Hole
P03827
P03867
P15015
EM8714
23 mm
(0.91 in.)
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−89
1996 TOYOTA T100 (RM449U)
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09207−76010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (see step 14 above) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
16. INSPECT CONNECTING ROD BOLTS
(a) Install the cap nut to the connecting rod bolt. Check that
the cap nut can be turned easily by hand to the end of the
thread.
(b) If the cap nut cannot be turned easily, measure the mini-
mum outside diameter of the connecting rod bolt with ver-
nier calipers.
Standard outside diameter:
7.80 − 7.90 mm (0.3071 − 0.3110 in.)
Minimum outside diameter:
7.60 mm (0.2992 in.)
HINT:
If the location of minimum diameter cannot be judged by
visual inspect ion, measure the outer diameter at the loca-
tion shown in the illustration.
If the outside diameter is less than limit, replace the con-
necting rod bolt and nut as a set.

Downloaded from www.Manualslib.com manuals search engine P14747
P14749
P14765
EM−90
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
17. INSPECT RH AND LH BALANCE SHAFTS
(a) Using a cylinder gauge, measure the inside diameter of
the balance shaft bearing.
Bearing inside diameter (from front side):
No.1 38.025 − 38.045 mm (1.4970 − 1.4978 in.)
No.2 37.525 − 37.545 mm (1.4774 − 1.4781 in.)
(b) Using a micrometer, measure the diameter of the balance
shaft main journals.
Main journal diameter (from front side):
No.1 37.969 − 37.985 mm (1.4948 − 1.4955 in.)
No.2 37.449 − 37.465 mm (1.4744 − 1.4750 in.)
(c) Subtract the balance shaft main journal diameter mea-
surement from the balance shaft bearing inside diameter
measurement.
Standard oil clearance:
No.1 0.040 − 0.076 mm (0.0016 − 0.0031 in.)
No.2 0.060 − 0.096 mm (0.0024 − 0.0038 in.)
Maximum oil clearance:
No.1 0.15 mm (0.0059 in.)
No.2 0.15 mm (0.0059 in.)
If the clearance is greater than maximum, replace the cylinder
block and balance shaft.
18. CYLINDER BORING
HINT:
Bore all the 4 cylinders for the oversized piston outside di-
ameter.
Replace all the piston rings with ones to match the over-
sized pistons.
(a) Select oversized pistons
Oversized piston diameter:
O/S 0.50
95.433 − 95.443 mm (3.7572 − 3.7576 in.)
(b) Calculate amount to bore cylinders
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 37.5 mm
(1.47 in.) from the piston head.

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P14813
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−91
1996 TOYOTA T100 (RM449U)
(2) Calculate the amount of each cylinder is to be re-
bored as follows:
Size to be rebored = P + C − H
P = Piston diameter
C = Piston clearance
0.047 − 0.070 mm (0.0019 − 0.0028 in.)
H = Allowance for honing
0.020 mm (0.0008 in.) or less
(c) Bore and hone cylinder to calculated dimensions
Maximum honing:
0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
19. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout:
0.03 mm (0.0012 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
20. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
STD size
No.3
59.981 − 59.994 mm (2.2615 − 2.3620 in.)
Others
59.987 − 60.000 mm (2.3617 − 2.3622 in.)
U/S 0.25
No.3
59.740 − 59.750 mm (2.3520 − 2.3524 in.)
Others
59.745 − 59.755 mm (2.3522 − 2.3526 in.)
Crank pin diameter:
STD
52.987 − 53.000 mm (2.0861 − 2.0866 in.)
U/S 0.25
52.745 − 52.755 mm (2.0766 − 2.0770 in.)

Downloaded from www.Manualslib.com manuals search engine EM−92
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
If the diameter is not as specified, check the oil clearance (See
disassembly in cylinder block) If necessary, grind or replace the
crankshaft.
(b) Check each main journal and crank pin for taper and out−
of−round as shown.
Maximum taper and out−of−round:
0.005 mm (0.0002 in.)
If the taper and out−of−round is greater than maximum, replace
the crankshaft.
21. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure in step 20).
Install new main journal and/or crankshaft pin undersized
bearings.

Downloaded from www.Manualslib.com manuals search engine EM07N−02
P14862
P14864
SST
P14861
P14863
SST
P14984
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−93
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods (A and B) to replace the oil seal which are
as follows:
(a) If oil pump is removed from cylinder block.
(1) Using a screwdriver and a hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump case edge.
SST 09223 − 50010
(3) Apply MP grease to the oil seal lip.
(b) If oil pump is installed to the cylinder block.
(1) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(2) Apply MP grease to a new oil seal lip.
(3) Using SST and a hammer, tap, in the oil seal until
its surface is flush with the oil pump case edge.
SST 09223 − 50010
2. REPLACE CRANKSHAFT REAR OIL SEL
(a) If rear oil seal retainer is removed from cylinder block.
(1) Using a screwdriver and a hammer, tap out the oil
seal.

Downloaded from www.Manualslib.com manuals search engine P14980
SST
P14983Cut Position
P14966
SST
EM−94
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil seal retainer edge.
SST 09223 − 15030, 09608 − 30012 (09608 − 04020)
(3) Apply MP grease to the seal lip.
(b) If rear oil seal retainer is installed to cylinder block.
(1) Using knife, cut off the oil seal lip.
(2) Using a screwdriver pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223 − 15030, 09608 − 30012 (09608 − 04020)

Downloaded from www.Manualslib.com manuals search engine EM1ON−01
P04409
P15721
Front Mark
Front Mark
P14764
Z10816
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−95
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, O−rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Install a new snap ring on one side of the piston pin hole.
(b) Gradually heat the piston to at 80 − 90°C (176 − 194°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.
(e) Install a new snap ring on the other side of the piston pin
hole.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark:
”1T” or ”1N” for No.1
”2T” or ”2N” for No.2

Downloaded from www.Manualslib.com manuals search engine P15016
No.1 Compression
Ring Upper Side
Rail
Front Mark
(Carirty)
No.2 Compression Ring ExpanderLower Side
Rail
P14796
P14748
No.1
Balanceshaft
No.2
Balanceshaft
Z11075
Z11076
EM−96
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting rod cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL CYLINDER BLOCK ORIFICE
5. INSTALL NO.1 AND NO.2 BALANCE SHAFTS
(a) No.1 balance shaft (RH):
Has indentations.
(b) No.2 balance shaft (LH):
Has no indentations.
6. ASSEMBLY NO.1 BALANCE SHAFT
(a) Mount the hexagon wrench head portion of the balance
shaft in a vise.
NOTICE:
Be careful not to damage the balance shaft.
(b) Install these parts to the balance shaft:
(1) No.1 balance shaft
(2) No.1 balance shaft thrust plate
(3) Balance shaft thrust spacer
(4) Balance shaft timing gear
(5) Key
(c) Install and torque the bolt.
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
7. ASSEMBLY NO.2 BALANCE SHAFT
(a) Mount the hexagon wrench head portion of the balance
shaft in a vise.
NOTICE:
Be careful not to damage the balance shaft.
(b) Install these parts to the balance shaft:
(1) No.2 balance shaft
(2) No.2 balance shaft thrust plate
(3) Balance shaft timing sprocket
(c) Install and torque the bolt.
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)

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P14744
P14804
P14808
No.2, 4 Bearing Cap
2 or 4
P14809
No.1, 5 Bearing Cap
1 or 5
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−97
1996 TOYOTA T100 (RM449U)
8. INSTALL BALANCE SHAFTS
(a) Install balance shafts.
NOTICE:
When installing the balance shaft make sure you support
the balance shaft with both hands and avoid scratching the
balance shaft bearing on the cylinder block side.
(b) Install the No.1 balance shaft with the bolt.
(c) Install the No.2 balance shaft with the 2 bolts.
Torque: 18 N·m (185 kgf·cm, 13.4 ft·lbf)
9. INSTALL MAIN BEARINGS
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.