check engine light TOYOTA T100 1996 Factory Manual Online

Downloaded from www.Manualslib.com manuals search engine A01399
Dot Mark
P15017A03714
P15018A03715
P15045A03716
P15044
SST (A)
SST (B)
EM−6
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
721 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) Check that the timing marks (one and two 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.
9. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
Using a thickness gauge, measure the clearance
between the valve lifter and camshaft.
Record the out−of−specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
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.)
(b) Turn the crankshaft pulley 1 revolution (360°) and align
its groove with timing mark ”0” of the timing chain cover.
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
10. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the crankshaft to position the cam lobe of the
camshaft on the adjusting valve upward.
Position the notch of the valve lifter toward the spark
plug side.
Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter
flange. Remove SST (A).
SST 09248−55040 (09248−05410, 09248−05420)
HINT:
 Apply SST (B) at slight angle on the side marked with ”9”,
at the position shown in the illustration.
 When SST (B) is inserted too deeply, it will get pinched
by the shim. To prevent it from being stuck, insert it shal-
lowly from the outside of the cylinder head, at a slight
angle.

Downloaded from www.Manualslib.com manuals search engine EM06T−02
FI7231
TOYOTA Hand−Held Tester
DLC3
P16016A03719
P15946
− ENGINE MECHANICAL (3RZ−FE)IGNITION TIMING
EM−11
726 Author: Date:
1996 TOYOTA T100 (RM449U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND−HELD TESTER OR OBDII
SCAN TOOL
(a) Connect the TOYOTA hand−held tester or OBDII scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand−held tester or OBDII
scan tool operators manual for further details.
3. CHECK IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
(b) Using a timing light, connect the tester to No.1 high−
tension cord.
(c) Check ignition timing.
Ignition timing:
3 − 7° BTDC @ idle
(Air Conditioner OFF)
If the ignition timing is not as specified, check that following
conditions are normal:
Throttle valve fully closed
Continuity between terminals IDL and E2 of the
throttle position sensor
Valve timing
(d) Remove the SST from the DLC1.
SST 09843−18020
4. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBDII SCAN TOOL, AND TIMING LIGHT

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 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 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 P14772
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.)

Downloaded from www.Manualslib.com manuals search engine Z11076
P14762
P14760
P14764
P03870
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−83
1996 TOYOTA T100 (RM449U)
(b) Remove these parts from balance shaft assembly:
(1) No.2 balance shaft
(2) No.2 balance shaft thrust prate
(3) Balance shaft timing sprocket
28. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
29. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the rings in correct order only.
30. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 − 90°C ( 176 − 194
°F).
(c) Using plastic−faced hammer and brass bar, lightly tap out
the piston pin and remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.

Downloaded from www.Manualslib.com manuals search engine Z15490
Front
Painted Mark90°
P14776
Z14823
Front
Mark
(Carity)
Front
P14778
Front
Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−99
1996 TOYOTA T100 (RM449U)
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown above.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance (See page
EM−84).
14. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
15. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
16. INSTALL CONNECTING ROD CAP NUTS
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil on the threads and under
the nuts of the connecting rod cap.

Downloaded from www.Manualslib.com manuals search engine P01268
RH EX
6 4
5
LH EX LH IN RH IN
1
P21221
Upward
Cam Lobe
Notch
P21225
Front of No.1 and Rear of No.6 Cylinders
Others
SST (A) SST (B)SST (B)SST (A)
P21222
SST (B)
Magnetic Finger
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
EM−5
824 Author: Date:
1996 TOYOTA T100 (RM449U)
(c) Turn the crankshaft a further 2/3 of a revolution (240°),
and check only the valves indicated in the illustration.
Measure the valve clearance (See procedure step (a)).
6. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the camshaft so that the cam lobe for the valve
to be adjusted faces up.
Turn the valve lifter with a screwdriver so that the
notches are perpendicular to the camshaft.
Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248−55040 (09248−05410, 09248−05420)
HINT:
Apply SST (B) at a slight angle on the side marked with
”9” or ”7”, at the position shown in the illustration.
When SST (B) is inserted too deeply, it will get pinched by
the shim. To prevent it from being stuck, insert it gently
from the intake side, at a slight angle.
Using a small screwdriver and magnetic finger, re-
move the adjusting shim.