compression ratio TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine PP0G8−01
PP−6
− PREPARATIONENGINE MECHANICAL (3RZ−FE)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Engine tune−up tester
Heater
Magnetic finger
Micrometer
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring testerValve spring
Steel squareValve spring
Thermometer
Torque wrench
V−block
Valve seat cutter
Vernier calipers

Downloaded from www.Manualslib.com manuals search engine PP018−03
PP−12
− PREPARATIONENGINE MECHANICAL (5VZ−FE)
1996 TOYOTA T100 (RM449U)
EQUIPMENT
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Timing lightIgnition timing
OBDII scan toolEngine speed
Heater
Magnetic finger
Micrometer
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring testerValve spring
Steel squareValve spring
Thermometer
Torque wrench
Valve seat cutter
Vernier calipers

Downloaded from www.Manualslib.com manuals search engine DI0TB−03
− DIAGNOSTICSENGINE (3RZ−FE)
DI−21
1996 TOYOTA T100 (RM449U)
PROBLEM SYMPTOMS TABLE
SymptomSuspect AreaSee page
Engine does not crank (Does not start)1. Starter and starter relayST−15
No initial combustion (Does not start)1. ECM power source circuit
2. Fuel pump control circuitDI−11 5
DI−11 8
No complete combustion (Does not start)1. Fuel pump control circuitDI−11 8
Engine cranks normally (Difficult to start)
1. Starter signal circuit
2. Fuel pump control circuit
3. CompressionDI−11 0
DI−11 8
EM−3
Cold engine (Difficult to start)1. Starter signal circuit
2. Fuel pump control circuitDI−11 0
DI−11 8
Hot engine (Difficult to start)1. Starter signal circuit
2. Fuel pump control circuitDI−11 0
DI−11 8
High engine idle speed (Poor idling)1. A/C signal circuit (Compressor circuit)
2. ECM power source circuitAC−79
DI−11 5
Low engine idle speed (Poor idling)1. A/C signal circuit (Compressor circuit)
2. Fuel pump control circuitAC−79
DI−11 8
Rough idling (Poor idling)1. Compression
2. Fuel pump control circuitEM−3
DI−11 8
Hunting (Poor idling)1. ECM power source circuit
2. Fuel pump control circuitDI−11 5
DI−11 8
Hesitation/Poor acceleration (Poor driveability)1. Fuel pump control circuit
2. A/T faultyDI−11 8
DI−282
Surging (Poor driveability)1. Fuel pump control circuitDI−11 8
Soon after starting (Engine stall)1. Fuel pump control circuitDI−11 8
During A/C operation (Engine stall)1. A/C signal circuit (Compressor circuit)
2. Engine control module (ECM)AC−79
IN−26

Downloaded from www.Manualslib.com manuals search engine DI−58
− DIAGNOSTICSENGINE (3RZ−FE)
1996 TOYOTA T100 (RM449U)
DTC P0300 Random/Multiple Cylinder Misfire Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
CIRCUIT DESCRIPTION
Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in
the crankshaft rotation for each cylinder.
The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. And
when the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the
MIL lights up.
If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks
when misfiring occurs.
DTC No.DTC Detecting ConditionTrouble Area
P0300Misfiring of random cylinders is detected during any
particular 200 or 1,000 revolutionsIgnition system
Injector
Fuel line pressure
EGR
Compression pressure
Valve clearance not to specification
Valve timing
Mass air flow meter
Engine coolant temp. sensor
P0301
P0302
P0303
P0304For any particular 200 revolutions for engine, misfiring is
detected which can cause catalyst overheating
(This causes MIL to blink)
For any particular 1,000 revolutions for engine, misfiring is
detected which causes a deterioration in emissions
(2 trip detection logic)
HINT:
When the 2 more codes for a misfiring cylinder are recorded repeatedly but no random misfire code is re-
corded, it indicates that the misfires were detected and recorded at different times.
DI0TP−03

Downloaded from www.Manualslib.com manuals search engine DI0UF−01
DI−148
− DIAGNOSTICSENGINE (5VZ−FE)
1996 TOYOTA T100 (RM449U)
PROBLEM SYMPTOMS TABLE
SymptomSuspect AreaSee page
Engine does not crank (Does not start)1. Starter and starter relayST−6
ST−14
No initial combustion (Does not start)
1. ECM power source circuit
2. Fuel pump control circuit
3. Engine control module (ECM)DI−251
DI−255
IN−26
No complete combustion (Does not start)1. Fuel pump control circuitDI−255
Engine cranks normally (Difficult to start)
1. Starter signal circuit
2. Fuel pump control circuit
3. CompressionDI−248
DI−255
EM−2
Cold engine (Difficult to start)1. Starter signal circuit
2. Fuel pump control circuitDI−248
DI−255
Hot engine (Difficult to start)1. Starter signal circuit
2. Fuel pump control circuitDI−248
DI−255
High engine idle speed (Poor idling)1. A/C signal circuit (Compressor circuit)
2. ECM power source circuitAC−79
DI−251
Low engine idle speed (Poor idling)1. A/C signal circuit (Compressor circuit)
2. Fuel pump control circuitAC−79
DI−255
Rough idling (Poor idling)1. Compression
2. Fuel pump control circuitEM−2
DI−255
Hunting (Poor idling)1. ECM power source circuit
2. Fuel pump control circuitDI−251
DI−255
Hesitation/Poor acceleration (Poor driveability)1. Fuel pump control circuit
2. A/T faultyDI−255
DI−282
Surging (Poor driveability)1. Fuel pump control circuitDI−255
Soon after starting (Engine stall)1. Fuel pump control circuitDI−255
During A/C operation (Engine stall)1. A/C signal circuit (Compressor circuit)
2. Engine control module (ECM)AC−79
IN−26

Downloaded from www.Manualslib.com manuals search engine − DIAGNOSTICSENGINE (5VZ−FE)
DI−183
1996 TOYOTA T100 (RM449U)
DTC P0300 Random/Multiple Cylinder Misfire Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
DTC P0305 Cylinder 5 Misfire Detected
DTC P0306 Cylinder 6 Misfire Detected
CIRCUIT DESCRIPTION
Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in
the crankshaft rotation for each cylinder.
The ECM counts the number of times the engine speed change rate indicates that misfire has occur-
red.When the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated,
the MIL lights up.
If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks
when misfiring occurs.
DTC No.DTC Detecting ConditionTrouble Area
P0300Misfiring of random cylinders is detected during any
particular 200 or 1,000 revolutionsIgnition system
Injector
Fuel line pressure
EGR*
Compression pressure
Valve clearance not to specification
Valve timing
Mass air flow meter
Engine coolant temp. sensor
P0301
P0302
P0303
P0304
P0305
P0306For any particular 200 revolutions for engine, misfiring is
detected which can cause catalyst overheating
(This causes MIL to blink)
For any particular 1,000 revolutions of engine, misfiring is de-
tected which causes a deterioration in emission
(2 trip detection logic)
*: Only for 2WD models with a load capacity of 0.5 ton and regular cab.
HINT:
When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no Random Misfire
code is
recorded, it indicates that the misfires were detected and recorded at different times.
DI0UT−01

Downloaded from www.Manualslib.com manuals search engine P14687
P14695
A01399
Dot Mark
P14636
P15751A03790
EM−32
− 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.

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 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 EM06D−03
P21120
P21152
Dot Mark
P01269
RH EX
12
36
LH EX LH IN RH IN
P01270
RH EX
34
5
LH EX LH IN RH IN
2 EM−4
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
823 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 INTAKE AIR CONNECTOR
(See page EM−65)
3. REMOVE CYLINDER HEAD COVERS
(See page EM−30)
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark ”0” of the No.1 timing belt cover.
(b) Check that the timing marks (1 dot) of the camshaft drive
and driven gears are in straight line on the cylinder heads
surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated in the illustration.
Using a thickness gauge, measure the clearance
between the valve lifter and camshaft.
Record out of specification valve clearance mea-
surements. They will be used later to determine the
required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.13 − 0.23 mm (0.006 − 0.009 in.)
Exhaust 0.27 − 0.37 mm (0.011 − 0.014 in.)
(b) Turn the crankshaft 2/3 of a revolution (240°), and check
only the valves indicated in the illustration. Measure the
valve clearance. (See procedure step (a))