dimensions TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine P14803
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 EM5349
Z00149
EM−98
− ENGINE MECHANICAL (5VZ−FE)CYLINDER BLOCK
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 oil clearance
0.134 − 0.154 mm (0.0053 − 0.0060 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
(3) C.Bore and hone cylinder to calculated dimensions
Maximum honing:
0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
17. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V−blocks.
(b) Using a dial indicator, measure the circle runout at the
No.2 and No.3 journals.
Maximum circle runout:
0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
18. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
STD63.985 − 64.000 mm (2.5191 − 2.5197 in.)
U/S 0.2563.745 − 63.755 mm (2.5096 − 2.5100 in.)
Crank pin diameter:
STD54.987 − 55.000 mm (2.1648 − 2.1654 in.)
U/S 0.2554.745 − 54.755 mm (2.1553 − 2.1557 in.)
If the diameter is not as specified, check the oil clearance (See
page EM−84).
(b) Check each main journal and crank pin for taper and out−
of−round as shown.
Maximum taper and out−of−round:
0.02 mm (0.0008 in.)
If the taper or out−of−round is greater than maximum, grind or
replace the crankshaft.

Downloaded from www.Manualslib.com manuals search engine P25593
(1)
(2)
(3)
(4) (5) (6) (7)
Long
Short
Lead Terminal
P25597
40 mm
37 mm
20 mm Wooden Block
Contact
Plate
(kgf/cm2)
=
100 kgf
Ram diameter (cm)
2
2
2Ram diameter (in.) (psi)
=
x 3.14 (Ï€) x 3.14 (Ï€)
2
(kPa) = (kgf/cm
2) x 98.1
(kPa) = (psi) x 6.9221 lbf
P25596
SST
ST−12
− STARTING (3RZ−FE)STARTER
1996 TOYOTA T100 (RM449U)
(b) Terminal C:
Install these new parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O−ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulator (inside) in the
correct direction.
(c) Temporarily tighten the terminal nuts.
5. TIGHTEN TERMINAL NUT
(a) Put a wooden block on the contact plate and press it down
with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:
Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:
If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(b) Using SST, tighten the nuts to the specified torque.
SST 09810−38140
Torque: 17 N·m (173 kgf·cm, 12 ft·lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.

Downloaded from www.Manualslib.com manuals search engine P25641
Long
Short
Indentation
Protrusion
P25598
Long
Short
Lead Terminal
P25602
40 mm
37 mm
20 mm Wooden Block
Contact
Plate
− STARTING (5VZ−FE)STARTER
ST−11
1996 TOYOTA T100 (RM449U)
4. REINSTALL TERMINAL KIT PARTS
(a) Terminal 30:
Install these new parts:
(1) Insulation paper
(2) Terminal insulator (inside)
NOTICE:
Be careful to install the terminal insulator in the correct
direction.
(3) Contact plate
(4) Terminal bolt
(5) O−ring
(6) Packing and terminal insulator (outside)
Install the packing to the terminal insulator, and
install them.
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(7) Wave washer
(8) Terminal nut
(b) Terminal C:
Install these new parts:
(1) Terminal insulator (inside)
(2) Contact plate
(3) Terminal bolt
(4) O−ring
(5) Terminal insulator (outside)
(6) Wave washer
(7) Terminal nut
NOTICE:
Be careful to install the terminal insulator (inside) in the
correct direction.
(c) Temporarily tighten the terminal nuts.
5. TIGHTEN TERMINAL NUT
(a) Put a wooden block on the contact plate and press it down
with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)

Downloaded from www.Manualslib.com manuals search engine AB0158
Battery
SST
R05752
SST
H00401Weighty
y
x
RS−16
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 TOYOTA T100 (RM449U)
(d) Check functioning of SST.
SST 09082−00700
(e) Install the SST
CAUTION:
Place the disc wheel on the level ground.
(1) Connect the SST connector to the steering wheel
pad connector.
SST 09082−00700
NOTICE:
To avoid damaging the SST connector and wire harness,
do not lock the secondary lock of the twin lock. Also, se-
cure some slack for the SST wire harness inside the disc
wheel.
(2) Move the SST to at least 10 m (33 ft) away from
steering wheel pad tied down on the disc wheel.
(f) Cover steering wheel pad with cardboard box or tires.
Covering method using cardboard box:
Cover the steering wheel pad with the cardboard
box and weight the cardboard box down in 4 places
with at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
x=460 mm (18.11 in.)
When dimension of the cardboard box exceeds the di-
ameter of the disc wheel with the tire which the steer-
ing wheel pad is tied to−
x=460 mm (18.11 in.) + width of tire
y= 650 mm (25.59 in.)
NOTICE:
If a cardboard box smaller than the specified size is used,
the cardboard box will be broken by the shock from the air-
bag deployment.

Downloaded from www.Manualslib.com manuals search engine R04211
Inner Diam.
Tires
(3 or More)Width
H00400
10 m (33 ft) or more
AB0166
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−17
1996 TOYOTA T100 (RM449U)
Covering method using tires:
Place at least 3 tires without disc wheel on top of the
disc wheel with the tire to which the steering wheel
pad is tied.
Tire size: Must exceed the following dimensions−
Width: 185 mm (7.87 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.
NOTICE:
The tires may be marked by the airbag deployment, so use
the redundant tires.
(g) Deploy the airbag.
(1) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the battery negative
(−) terminal.
(2) Check that no one is within 10 m (33 ft) area around
the disc wheel which the steering wheel pad is tied
to.
(3) Press the SST activation switch and deploy the air-
bag.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
(h) Dispose of the steering wheel pad (with airbag)
CAUTION:
The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.
Use gloves and safety glasses when handling a steer-
ing wheel pad with deployed airbag.
Always wash your hands with water after completing
the operation.