1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine Z10578
4, 5 or 6
P14783
EM−78
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with 1 having the same
number as marked on the bearing cap. There are 3 sizes of
standard bearings, marked ”4”, ”5”, ”6” accordingly.
Reference:
Connecting rod big end inside diameter:
STD Mark ”4”56.000 − 56.006 mm (2.2047 − 2.2050 in.)
STD Mark ”5”56.006 − 56.012 mm (2.2050 − 2.2052 in.)
STD Mark ”6”56.012 − 56.018 mm (2.2052 − 2.2054 in.)
U/S 0.2556.000 − 56.018 mm (2.2047 − 2.2054 in.)
Crankshaft crank pin diameter:
STD52.987 − 53.000 mm (2.0861 − 2.0866 in.)
U/S 0.2552.745 − 52.755 mm (2.0766 − 2.0770 in.)
Standard sized bearing center wall thickness:
STD Mark ”4”1.482 − 1.485 mm (0.0583 − 0.0585 in.)
STD Mark ”5”1.485 − 1.488 mm (0.0585 − 0.0586 in.)
STD Mark ”6”1.488 − 1.491 mm (0.0586 − 0.0587 in.)
U/S 0.251.601 − 1.607 mm (0.0630 − 0.0633 in.)
(k) Completely remove the Plastigage.
19. R E M O V E P I S TO N A N D C O N N E C T I N G R O D A S-
SEMBLIES
(a) Using a ridge reamer, remove the all carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in cor-
rect order.

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Z11077
6
10
82
1
5
9
7
3 4
P14787
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−79
1996 TOYOTA T100 (RM449U)
20. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
2.440 − 2.490 mm (0.0961 − 0.0980 in.)
21. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts
in several passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the main bearing
caps, lower bearings and (No.3 main bearing cap only)
lower thrust washers.
HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and upper thrust washers together
with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.

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Plastigage
P14793
P14794
No.5
No.4
No.3
No.2
No.1Mark 1, 2 or 3
EM−80
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps (See page EM−95).
Torque:
1st 39 N·m (400 kgf·cm, 29 ft·lbf)
2nd Turn 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps (See procedure (a) and
(b) above).
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD
No.3
0.030 − 0.055 mm (0.0012 − 0.0022 in.)
Others
0.024 − 0.049 mm (0.0009 − 0.0019 in.)
U/S 0.25
No.3
0.030 − 0.070 mm (0.0012 − 0.0028 in.)
Others
0.025 − 0.065 mm (0.0010 − 0.0026 in.)
Maximum clearance:
0.10 mm (0.0039 in.)
HINT:
If the oil clearance is greater than maximum, replace the
bearings. If necessary, grind or replace the crankshaft.
If using a standard bearing, replace with 1 having the
same number as marked on the block. There are 3 sizes
of standard bearings, marked ”1”, ”2” and ”3” accordingly.
Reference:
Cylinder block main journal bore diameter:
STD Mark ”1”64.004 − 64.010 mm (2.5198 − 2.5201 in.)
STD Mark ”2”64.011 − 64.016 mm (2.5201 − 2.5203 in.)
STD Mark ”3”64.017 − 64.022 mm (2.5203 − 2.5205 in.)
U/S 0.2564.000 − 64.024 mm (2.5197 − 2.5206 in.)

Downloaded from www.Manualslib.com manuals search engine P14796
P14745
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−81
1996 TOYOTA T100 (RM449U)
Crankshaft Journal diameter:
STD NO.359.981 − 59.994 mm (2.2615 − 2.3620 in.)
STD Others59.987 − 60.000 mm (2.3617 − 2.3622 in.)
U/S 0.25 No.359.740 − 59.750 mm (2.3520 − 2.3524 in.)
U/S 0.25 Others59.745 − 59.755 mm (2.3522 − 2.3526 in.)
Bearing center wall thickness:
STD Mark ”1”1.987 − 1.990 mm (0.0782 − 0.0783 in.)
STD Mark ”2”1.991 − 1.993 mm (0.0784 − 0.0785 in.)
STD Mark ”3”1.994 − 1.996 mm (0.0785 − 0.0786 in.)
U/S 0.252.106 − 2.112 mm (0.0829 − 0.0831 in.)
(k) Completely remove the Plastigage.
22. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust wash-
ers from the cylinder block.
HINT:
Arrange the main bearings and thrust washers in correct order.
23. REMOVE CYLINDER BLOCK ORIFICE
24. CHECK THRUST CLEARANCES OF NO.1 AND NO.2
BALANCE SHAFTS OF ENGINE BALANCER
Using a dial indicator, measure the thrust clearance while mov-
ing the balance shaft back and forth.
Standard thrust clearance:
0.07 − 0.13 mm (0.0027 − 0.0051 in.)
Maximum thrust clearance:
0.2 mm (0.0079 in.)
If the thrust clearance is greater than maximum, replace the bal-
ance shaft thrust washer.
If necessary, replace the balance shaft.

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P14748
No.1
Balance Shaft
No.2
Balance Shaft
P14753
Z11075
P14818
EM−82
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
25. REMOVE NO.1 AND NO.2 BALANCE SHAFTS
(a) Remove the 1 bolt from the No.1 balance shaft.
(b) Remove the 2 bolts from the No.2 balance shaft.
(c) Remove the balance shafts.
NOTICE:
When removing the balance shaft make sure you support
the balance shaft with both hands and avoid scratching the
balance shaft bearing on the cylinder block side.
HINT:
No.1 balance shaft (RH):
Has indentations.
No.2 balance shaft (LH):
Has no indentations.
26. DISASSEMBLE NO.1 BALANCE SHAFT
(a) Mount the hexagon wrench head portion of the balance
shaft in a vise.
NOTICE:
Be careful not to damage the balance shaft.
(b) Remove these parts from balance shaft assembly:
(1) No.1 balance shaft
(2) No.1 balance shaft thrust plate
(3) Balance shaft thrust spacer.
(4) Balance shaft timing gear.
(5) Key
27. DISASSEMBLE NO.2 BALANCE SHAFT
(a) Mount the hexagon wrench head portion of the balance
shaft in a vise.
NOTICE:
Be careful not to damage the balance shaft.

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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 P14798
EM07M−03
Z10814
Z10815
EM−84
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove gasket material.
Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Clean cylinder block.
Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and thickness gauge, measure
the surfaces contacting the cylinder head gasket for warpage.
Maximum warpage:
0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 4 cylinders. If nec-
essary, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter at
positions A, B and C in the thrust and axial directions.
Standard diameter:
STD
94.990 − 95.003 mm (3.7398 − 3.7403 in.)
Maximum diameter:
STD
95.06 mm (3.7425 in.)
If the diameter is greater than maximum, rebore all the 4 cylin-
ders. If necessary, replace the cylinder block.

Downloaded from www.Manualslib.com manuals search engine P14783
P14802
Elongated
Thread
Measuring
Point
P14767
P14822
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−85
1996 TOYOTA T100 (RM449U)
5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
6. INSPECT MAIN BEARING CAP BOLTS
Using vernier calipers, measure the thread outside diameter of
the bolt.
Standard outside diameter:
10.76 − 10.97 mm (0.4236 − 0.4319 in.)
Minimum outside diameter:
10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
7. INSPECT CYLINDER BLOCK ORIFICE
Check the orifice for clogging.
If necessary, replace the orifice.
8. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.