drain bolt TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine SS−8
− SERVICE SPECIFICATIONSENGINE MECHANICAL (3RZ−FE)
1996 TOYOTA T100 (RM449U) Oil strainer x Cylinder block
1818513
Oil pan x Cylinder block12.51309
Crankshaft position sensor x Timing chain cover8.58574 in.·lbf
Generator bracket x Cylinder block74.576055
Generator bracket x Timing chain cover1818513
Generator adjusting bar x Timing chain cover63.565047
A/C compressor bracket x Cylinder block4444032
A/C compressor x A/C compressor bracket2525018
Water pump pulley x Water pump2121016
Connecting rod cap x Connecting rod 1st
2nd45
Turn 90°46033
Main bearing cap x Cylinder block 1st
2nd39
Turn 90°40029
No.1 balance shaft x Timing gear3636526
No.2 balance shaft x Timing sprocket3636526
Balance shaft x Cylinder block1818513.4
Rear oil seal retainer x Cylinder block13.51359.7
RH, LH engine mounting bracket x Cylinder block4545034
Oil dipstick guide x LH engine mounting bracket2020014
Oil filter bracket union, Engine coolant drain plug x Cylinder block2525018
Oil filter bracket x Cylinder block2829021
Water bypass pipe x Cylinder block2020014
Knock sensor x Cylinder block3738027
Fuel filter x Cylinder block2020014
Rear end plate x Cylinder block1818513
Rear end plate x Water bypass pipe2020014
Flywheel x Crankshaft 1st
2nd26.5
Turn 90°27019
Front crossmember x Engine rear mounting bracket2526019
Front exhaust pipe clamp x Exhaust manifold6263046
Exhaust support bracket x Transmission3940029
Front exhaust pipe clamp1919514
Front exhaust pipe x TWC3940029
Engine rear mounting bracket x Engine rear mounting insulator1818313
Engine front mounting insulator x Frame3838728
Clutch release cylinder bracket x Transmission3940029
Clutch release cylinder x Transmission131309
Stabilizer bar bracket mounting bolt3030622
Stabilizer bar x Lower suspension arm131309
Intake air connector x Cylinder head1818513
Radiator x Body1818513

Downloaded from www.Manualslib.com manuals search engine SS099−01
SS−22
− SERVICE SPECIFICATIONSCOOLING (3RZ−FE)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Cylinder block x Drain plug2425018
Fluid coupling x Fan5.55549 in.·lbf
Water pump x Cylinder block expect bolt A
for bolt A8.9
24.590
25078 in.·lbf
18
Water inlet x Water inlet housing2020015
Radiator support x Radiator tank M/T
A/T13
5.5130
569
49 in.·lbf
Radiator mounting bolt3131023

Downloaded from www.Manualslib.com manuals search engine SS07W−01
− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (R150, R150F)
SS−45
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transmission x Engine7273053
Stiffener plate x Engine (4WD)3738027
Stiffener plate x Transmission (4WD)3738027
Starter x Transmission3940029
Engine rear mounting x Transmission6566048
Rear end plate x Transmission (2WD)1818513
Clutch release cylinder x Transmission121209
Front exhaust pipe x TWC4849035
Front exhaust pipe support bracket4445033
Front exhaust pipe x Exhaust manifold6263046
Crossmember x Engine rear mounting (4WD)1818013
Engine rear mounting bracket x Engine rear mounting (2WD)1818013
Engine rear mounting bracket x Frame (2WD)5859043
Crossmember x Frame (4WD)9597070
Transmission x Transfer (4WD)3738027
Reverse shift arm bracket set bolt1818513
Rear bearing retainer x Intermediate plate1818513
Shift fork x Shift fork shaft2020014
Straight screw plug1919014
Front bearing retainer x Transmission case1717012
Transmission case x Transfer adaptor3738027
Transmission case x Extension housing3738027
Shift lever housing set bolt3839028
Clutch housing x Transmission case3637027
Oil receiver x Extension housing1111 58
Back−up light switch4445032
Restrict pin3738027
Control shift lever retainer x Transfer adaptor1818513
Control shift lever retainer x Extension housing1818513
Filler and drain plug3738027
Speedometer driven gear (2WD)1111 58

Downloaded from www.Manualslib.com manuals search engine SS060−03
SS−48
− SERVICE SPECIFICATIONSMANUAL TRANSMISSION (W59)
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Transmission x Engine7273053
Transmission x Starter3940029
Rear end plate x Clutch housing3738027
Shift fork set bolt2020014
Straight screw plug2525018
Reverse idler gear shaft stopper bolt2525018
Oil separator x Intermediate plate1818513
Front bearing retainer set bolt2525018
Extension housing x Intermediate plate3738027
Restrict pin4041030
Shift lever housing x Shift and select lever shaft3940029
Control shift lever retainer x Extension housing1818513
Drain and filler plugs3738027
Back−up light switch4041030
Clutch housing x Transmission case3738027
Rear bearing retainer x Intermediate plate1818513
Speedometer driven gear131309

Downloaded from www.Manualslib.com manuals search engine SS08A−03
− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
SS−51
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Valve body x Transmission case101007
Oil strainer x Valve body (A340E)5.45548 in.·lbf
Oil strainer case x Valve body (A340F)101007
Oil strainer x Valve body (A340F)6.97061 in.·lbf
Oil pan7.47565 in.·lbf
Drain plug2020515
Parking lock pawl bracket x Transmission case7.47565 in.·lbf
Extension housing x Transmission case (A340E)3637027
Extension housing x Rear mounting insulator2525018
Rear support member x Rear mounting insulator (A340F)1818013
Rear support member x Body (A340F)9597070
Rear mounting insulator x Rear mounting bracket (A340E)1818013
Rear mounting bracket x Frame (A340E)5859042
Propeller shaft x Rear differential (A340E)7475054
Front propeller shaft x Front differential (A340F)7475054
Front propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Rear differential (A340F)7475054
Center support bearing x Body3637027
Drive plate x Crankshaft8385061
Torque converter clutch x Drive plate4142030
Stiffener plate x Engine (A340F)3738027
Stiffener plate x Transmission3738027
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x TWC4849035
Rear support member x Dynamic damper6162044
Oil cooler pipe3435025
Transmission x Engine7173053
Rear end plate x Transmission3738027
Rear support member x Transfer under cover2930021
Cross shaft x Frame2829021
Cross shaft x Transmission131309
Cross shaft x No.1 gear shifting rod131309
Exhaust pipe clamp(3RZ−FE)1919514
Exhaust pipe support bracket x Transmission (3RZ−FE)7173053
Exhaust pipe support bracket x Transmission (5VZ−FE)4445033
Exhaust pipe support bracket x Exhaust pipe (5VZ−FE)4445033
Park/neutral position switch (Nut)3.94035 in.·lbf
Park/neutral position switch (Bolt)131309
No.2 vehicle speed sensor5.45548 in.·lbf
Speedometer driven gear sleeve x Locking plate1616012
ATF temperature sensor x Transmission1515011
Shift lever assembly x Steering column assembly2930022

Downloaded from www.Manualslib.com manuals search engine SS−68
− SERVICE SPECIFICATIONSSUSPENSION AND AXLE
1996 TOYOTA T100 (RM449U)Part tightened
N·mkgf·cmft·lbf
Front drive shaft x Side gear shaft8384561
Lower suspension arm x Frame1962,000145
Upper suspension arm shaft x Frame1781,810131
Hub nut1031,05076
ABS speed sensor x Steering knuckle8.08271 in.·lbf
ABS speed sensor wire harness5.05144 in.·lbf
Companion flange x Front differential assembly1081,10080
Drain plug4950036
Filler plug3940029
Crossmember x Frame1261,28093
Front mounting bolt1471,500108
Rear mounting bolt1671,700123
Actuator x Clutch case cover2121015
Screw plug x Clutch case cover2020014
A.D.D. indicator switch x Clutch case cover4041030
Carrier cover x Oil deflector7.47565 in.·lbf
Ring gear x Differential case9798571
Differential carrier x Bearing cap7880058
Clutch case x Tube7880058
Clutch case x Differential carrier78800500
Differential x Front propeller shaft7475054
Clutch case cover x Clutch case2121015
Differential carrier cover x Differential carrier4747534
Tube x Bearing retainer121209
Rear
Ring gear x Differential case1251,27092
Bearing cap x Differential carrier11 31,15083
Differential carrier x Axle housing7374054
Rear axle housing x Rear brake assembly6970051
Rear shock absorber x Spring seat2626019
Rear shock absorber x Frame2626019
U−bolt x Spring seat1321,35097
Shackle pin x Leaf spring9193067
Differential x Propeller shaft7678056
Hanger pin x Leaf spring9193067
Hanger pin lock bolt2626019
Leaf spring center bolt4445033
Hub nut1031,05076
Spring bumper seat set bolt2930022
ABS speed sensor x Rear axle housing8.08271 in.·lbf
Brake line1515511
Parking brake set bolt2526019
Drain plug4950036
Filler plug3940029

Downloaded from www.Manualslib.com manuals search engine EM06S−03
P24401A03713
P14695
− 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.

Downloaded from www.Manualslib.com manuals search engine EM06Z−03
P14842
Adjusting Bolt
Lock Bolt
Pivot Bolt
P14935
P14907A03721
P14953
EM−14
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE OIL
2. DRAIN ENGINE COOLANT
3. REMOVE CYLINDER HEAD
(See page EM−28)
4. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
5. w/ A/C:
REMOVE A/C COMPRESSOR DRIVE BELT
Loosen the idler pulley nut and adjusting bolt, and remove the
drive belt.
6. REMOVE DRIVE BELT, FAN WITH FLUID
COUPLING, WATER PUMP PULLEY AND FAN
SHROUD
(a) Stretch the belt and loosen the water pump pulley mount-
ing nuts.
(b) Loosen the lock, pivot and adjusting bolts of the genera-
tor, and remove the drive belts.
(c) Remove the 4 water pump pulley mounting nuts.
(d) Pull out the fan with fluid coupling and water pump pulley.
(e) Remove the No.2 fan shroud.
(f) Remove the 4 bolts and No.1 fan shroud.
7. w/ A/C:
DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Remove the 4 mounting bolts, and disconnect the com-
pressor from the bracket.
HINT:
Put a side the compressor, and suspend it.
(b) Remove the 4 bolts and A/C compressor bracket.
8. REMOVE GENERATOR, ADJUSTING BAR AND
BRACKET
(a) Remove the lock, pivot bolts and the generator.
(b) Remove the bolt and adjusting bar.
(c) Remove the 3 bolts and bracket.
9. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts and crankshaft position sensor.
(b) Remove the O−ring from the crankshaft position sensor.

Downloaded from www.Manualslib.com manuals search engine EM1OK−01
P14841
Adjust Bolt
Lock Bolt
P15755SST
EM−28
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
(a) Disconnect the MAF meter connector, IAT sensor con-
nector and wire clamp.
(b) Loosen the air cleaner hose clamp.
(c) Loosen the 4 clips, and remove the air cleaner cap, MAF
meter and resonator.
3. M/T:
DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
4. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the 2 air hoses and VS hose.
(b) Remove the 2 bolts, hose clamp and intake air connector.
5. REMOVE PS PUMP DRIVE BELT AND IDLER PULLEY
(a) Loosen the lock bolt and adjusting bolt and remove the
drive belt.
(b) Remove the 3 bolts and idler pulley.
6. REMOVE PS PUMP AND BRACKET
(a) Using SST, remove the nut and PS pump pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Disconnect the 2 air hoses from air intake chamber.
(c) Remove the 2 bolts, and disconnect the PS pump.
(d) Remove the 4 bolts and PS pump bracket.
7. REMOVE NO.1 AND NO.2 PCV HOSES

Downloaded from www.Manualslib.com manuals search engine EM07I−03
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−65
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. DRAIN TRANSMISSION OIL
6. REMOVE HOOD
7. REMOVE RADIATOR RESERVOIR TANK
8. REMOVE RADIATOR (See page CO−15)
9. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
(a) Disconnect the MAF meter connector, IAT sensor con-
nector and wire clamp.
(b) Loosen the air cleaner hose clamp.
(c) Loosen the 4 clips, and remove the air cleaner cap, MAF
meter and resonator.
10. REMOVE AIR CLEANER CASE
(a) Remove the air cleaner element.
(b) Remove the 3 bolts and air cleaner case.
11. M/T:
DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
12. A/T:
DISCONNECT ACCELERATOR AND THROTTLE
CABLES FROM THROTTLE BODY
13. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the 2 air hoses and vs hose.
(b) Remove the 2 bolts, hose clamp and intake air connector.