1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine A03810
P14765
P14821
EM−86
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
9. INSPECT PISTON OIL CLEARANCE
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 37.5 mm (1.47 in.)
from the piston head.
Piston diameter:
STD
94.933 − 94.943 mm (3.7375 − 3.7379 in.)
O/S 0.50
95.433 − 95.443 mm (3.7572 − 3.7576 in.)
(b) Measure the cylinder bore diameter in the thrust direc-
tions (See step 4.).
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.047 − 0.070 mm (0.0019 − 0.0028 in.)
If the oil clearance is greater than maximum, replace all the 4
pistons and rebore all the 4 cylinders. If necessary, replace the
cylinder block.
HINT:
Use new cylinder block: Use a piston with the same number
mark as the cylinder bore diameter marked on the cylinder
block.
10. INSPECT PISTON RING GROOVE CLEARANCE
Using a thickness gauge, measure the clearance between new
piston ring and the wall of the piston ring groove.
Ring groove clearance:
No.1
0.020 − 0.070 mm (0.0008 − 0.0028 in.)
No.2
0.030 − 0.070 mm (0.0012 − 0.0028 in.)
If the clearance is not as specified, replace the piston.

Downloaded from www.Manualslib.com manuals search engine P04002
125 mm
EM7639
P15014
P03829
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−87
1996 TOYOTA T100 (RM449U)
11. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 125 mm (4.92 in.) from the top of the
cylinder block.
(c) Using a thickness gauge, measure the end gap.
Standard end gap:
No.1
0.300 − 0.400 mm (0.0118 − 0.0157 in.)
No.2
Code mark ”T”
0.400 − 0.500 mm (0.0157 − 0.0196 in.)
Code mark ”N”
0.400 − 0.500 mm (0.0157 − 0.0196 in.)
If the end gap is not as specified, replace the piston ring. If the
end gap is not as specified, even with a new piston ring, rebore
all the 4 cylinders or replace the cylinder block.
12. INSPECT PISTON PIN FIT
At 80 − 90°C (176 − 194°F), you should be able to push the pis-
ton pin into the piston pin hole with your thumb.
13. INSPECT CONNECTING ROD ALIGNMENT
Using a connecting rod aligner and thickness gauge, check the
connecting rod alignment.
Check for out−of−alignment.
Maximum out−of−alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out−of−alignment is greater than maximum, replace the con-
necting rod assembly.

Downloaded from www.Manualslib.com manuals search engine P03828
P03868
EM0227
EM7426
SST
EM−88
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
Check for twist
Maximum twist:
0.15 mm (0.0059 in. ) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
14. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
24.008 − 24.017 mm (0.9452 − 0.9455 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
24.000 − 24.009 mm (0.9449 − 0.9452 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 − 0.011 mm (0.0002 − 0.0004 in.)
Maximum oil clearance:
0.015 mm (0.0006 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set.
15. IF NECESSARY, REPLACE CONNECTING ROD
BUSHING
(a) Using SST and a press, press out the bushing.
SST 09207−76010

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SST
Oil
Hole
P03827
P03867
P15015
EM8714
23 mm
(0.91 in.)
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−89
1996 TOYOTA T100 (RM449U)
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09207−76010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (see step 14 above) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
16. INSPECT CONNECTING ROD BOLTS
(a) Install the cap nut to the connecting rod bolt. Check that
the cap nut can be turned easily by hand to the end of the
thread.
(b) If the cap nut cannot be turned easily, measure the mini-
mum outside diameter of the connecting rod bolt with ver-
nier calipers.
Standard outside diameter:
7.80 − 7.90 mm (0.3071 − 0.3110 in.)
Minimum outside diameter:
7.60 mm (0.2992 in.)
HINT:
If the location of minimum diameter cannot be judged by
visual inspect ion, measure the outer diameter at the loca-
tion shown in the illustration.
If the outside diameter is less than limit, replace the con-
necting rod bolt and nut as a set.

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P14749
P14765
EM−90
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
17. INSPECT RH AND LH BALANCE SHAFTS
(a) Using a cylinder gauge, measure the inside diameter of
the balance shaft bearing.
Bearing inside diameter (from front side):
No.1 38.025 − 38.045 mm (1.4970 − 1.4978 in.)
No.2 37.525 − 37.545 mm (1.4774 − 1.4781 in.)
(b) Using a micrometer, measure the diameter of the balance
shaft main journals.
Main journal diameter (from front side):
No.1 37.969 − 37.985 mm (1.4948 − 1.4955 in.)
No.2 37.449 − 37.465 mm (1.4744 − 1.4750 in.)
(c) Subtract the balance shaft main journal diameter mea-
surement from the balance shaft bearing inside diameter
measurement.
Standard oil clearance:
No.1 0.040 − 0.076 mm (0.0016 − 0.0031 in.)
No.2 0.060 − 0.096 mm (0.0024 − 0.0038 in.)
Maximum oil clearance:
No.1 0.15 mm (0.0059 in.)
No.2 0.15 mm (0.0059 in.)
If the clearance is greater than maximum, replace the cylinder
block and balance shaft.
18. CYLINDER BORING
HINT:
Bore all the 4 cylinders for the oversized piston outside di-
ameter.
Replace all the piston rings with ones to match the over-
sized pistons.
(a) Select oversized pistons
Oversized piston diameter:
O/S 0.50
95.433 − 95.443 mm (3.7572 − 3.7576 in.)
(b) Calculate amount to bore cylinders
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 37.5 mm
(1.47 in.) from the piston head.

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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 EM−92
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
If the diameter is not as specified, check the oil clearance (See
disassembly in cylinder block) If necessary, grind or replace the
crankshaft.
(b) Check each main journal and crank pin for taper and out−
of−round as shown.
Maximum taper and out−of−round:
0.005 mm (0.0002 in.)
If the taper and out−of−round is greater than maximum, replace
the crankshaft.
21. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure in step 20).
Install new main journal and/or crankshaft pin undersized
bearings.

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P14862
P14864
SST
P14861
P14863
SST
P14984
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−93
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods (A and B) to replace the oil seal which are
as follows:
(a) If oil pump is removed from cylinder block.
(1) Using a screwdriver and a hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil pump case edge.
SST 09223 − 50010
(3) Apply MP grease to the oil seal lip.
(b) If oil pump is installed to the cylinder block.
(1) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(2) Apply MP grease to a new oil seal lip.
(3) Using SST and a hammer, tap, in the oil seal until
its surface is flush with the oil pump case edge.
SST 09223 − 50010
2. REPLACE CRANKSHAFT REAR OIL SEL
(a) If rear oil seal retainer is removed from cylinder block.
(1) Using a screwdriver and a hammer, tap out the oil
seal.