clock TOYOTA T100 1996 Factory Service Manual

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− INTRODUCTIONFOR ALL OF VEHICLES
IN−9
9 Author: Date:
1996 TOYOTA T100 (RM449U)
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG
(a) The TOYOTA T100 is equipped with an SRS (Supple-
mental Restraint System), such as the driver airbag.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the battery (See page DI−365).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative (−) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back−up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (−) terminal cable from the battery, the SRS
may deploy.)
When the negative (−) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back−up power supply from out-
side the vehicle.
(3) Even in cases of a minor collision where the SRS
does not deploy, the steering wheel pad should be
inspected (See page RS−9).

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− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
EM−5
720 Author: Date:
1996 TOYOTA T100 (RM449U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR (See page EM−65)
3. REMOVE NO.1 AND NO.2 PCV HOSES
4. DISCONNECT HIGH−TENSION CORDS FROM SPARK
PLUGS
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
5. REMOVE THROTTLE BODY (See page MF−28)
6. DISCONNECT ENGINE WIRE
(a) Disconnect these connectors:
w/ A/C:
A/C compressor connector
Oil pressure sensor connector
ECT sensor connector
(b) Disconnect the 5 engine wire clamps and engine wire.
7. REMOVE CYLINDER HEAD COVER
Remove the 10 bolts, cylinder head cover and gasket.
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise and align its groove
with the ”0” mark on the timing chain cover.

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− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
24. REMOVE CYLINDER HEAD COVER
Remove the 10 bolts, cylinder head cover and gasket.
25. REMOVE SPARK PLUGS
26. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise and align its groove
with the ”0” mark on the timing chain cover.
(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.
27. REMOVE CHAIN TENSIONER
Remove the 2 nuts, chain tensioner and gasket.
28. REMOVE CAMSHAFT TIMING GEAR
(a) Remove the 2 semi−circular plugs.
(b) Place the matchmarks on the camshaft timing gear and
No.1 timing chain.

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Service Bolt
SST
Turn
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− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−35
1996 TOYOTA T100 (RM449U)
(b) Using SST, turn the sub−gear clockwise, and remove a
service bolt.
SST 09960−10010 (09962−01000, 09963−00500)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove these parts:
(1) Wave washer
(2) Camshaft sub−gear
(3) Camshaft gear spring
31. REMOVE CYLINDER HEAD
(a) Remove the 2 bolts in front of the head before the other
head bolts are removed.

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(1) (2) (3)
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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.

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− 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.

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Front Mark
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Hook
Pin
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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.

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− 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)

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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)

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− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−21
1996 TOYOTA T100 (RM449U)
(b) RH Camshaft Position:
Turn the camshaft, align the knock pin hole of the cam-
shaft with the timing mark of the No.3 timing belt cover.
(c) LH Camshaft Pulley Position:
Turn the camshaft timing pulley, align the timing marks of
the camshaft timing pulley and No.3 timing belt cover.
9. INSTALL TIMING BELT TO LH CAMSHAFT TIMING
PULLEY
(a) HINT (When re−using timing belt):
Check that the installation mark on the timing belt
matches the end of the No.1 timing belt cover.
If the installation mark do not align, shift the meshing of the tim-
ing belt and crankshaft timing pulley until they align.
(b) Remove any oil or water on the LH camshaft timing pulley,
and keep it clean.
(c) Using SST, slightly turn the LH camshaft timing pulley
clockwise. Align the installation mark on the timing belt
with the timing mark of the camshaft timing pulley, and
hang the timing belt on the LH camshaft timing pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(d) Using SST, align the timing marks of the LH camshaft
pulley and No.3 timing belt cover.
SST 09960−10010 (09962−01000, 09963−01000)
(e) Check that the timing belt has tension between the crank-
shaft timing and LH camshaft timing pulleys.