1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine P14980
SST
P14983Cut Position
P14966
SST
EM−94
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the oil seal retainer edge.
SST 09223 − 15030, 09608 − 30012 (09608 − 04020)
(3) Apply MP grease to the seal lip.
(b) If rear oil seal retainer is installed to cylinder block.
(1) Using knife, cut off the oil seal lip.
(2) Using a screwdriver pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223 − 15030, 09608 − 30012 (09608 − 04020)

Downloaded from www.Manualslib.com manuals search engine EM1ON−01
P04409
P15721
Front Mark
Front Mark
P14764
Z10816
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−95
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets, O−rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Install a new snap ring on one side of the piston pin hole.
(b) Gradually heat the piston to at 80 − 90°C (176 − 194°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.
(e) Install a new snap ring on the other side of the piston pin
hole.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark:
”1T” or ”1N” for No.1
”2T” or ”2N” for No.2

Downloaded from www.Manualslib.com manuals search engine P15016
No.1 Compression
Ring Upper Side
Rail
Front Mark
(Carirty)
No.2 Compression Ring ExpanderLower Side
Rail
P14796
P14748
No.1
Balanceshaft
No.2
Balanceshaft
Z11075
Z11076
EM−96
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting rod cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL CYLINDER BLOCK ORIFICE
5. INSTALL NO.1 AND NO.2 BALANCE SHAFTS
(a) No.1 balance shaft (RH):
Has indentations.
(b) No.2 balance shaft (LH):
Has no indentations.
6. ASSEMBLY 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) Install these parts to the balance shaft:
(1) No.1 balance shaft
(2) No.1 balance shaft thrust plate
(3) Balance shaft thrust spacer
(4) Balance shaft timing gear
(5) Key
(c) Install and torque the bolt.
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)
7. ASSEMBLY 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.
(b) Install these parts to the balance shaft:
(1) No.2 balance shaft
(2) No.2 balance shaft thrust plate
(3) Balance shaft timing sprocket
(c) Install and torque the bolt.
Torque: 36 N·m (365 kgf·cm, 26 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P14746
P14744
P14804
P14808
No.2, 4 Bearing Cap
2 or 4
P14809
No.1, 5 Bearing Cap
1 or 5
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−97
1996 TOYOTA T100 (RM449U)
8. INSTALL BALANCE SHAFTS
(a) Install balance shafts.
NOTICE:
When installing 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.
(b) Install the No.1 balance shaft with the bolt.
(c) Install the No.2 balance shaft with the 2 bolts.
Torque: 18 N·m (185 kgf·cm, 13.4 ft·lbf)
9. INSTALL MAIN BEARINGS
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.

Downloaded from www.Manualslib.com manuals search engine P15725
P14806
No.3 Bearing Cap
P14805
P14786
3159
7
8
4
2
610 EM−98
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
10. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.3 journal position of
the cylinder block with the oil grooves facing outward.
11. PLACE CRANKSHAFT ON CYLINDER BLOCK
12. PLACE MAIN BEARING CAPS AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the 2 thrust washers on the No.3 bearing cap with
the grooves facing outward.
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
13. INSTALL MAIN BEARING CAP BOLTS
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any of the main bearing cap bolts is broken or deformed,
replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(b) Install and uniformly tighten the 10 bolts of the main bear-
ing caps, in several passes, in the sequence shown.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.

Downloaded from www.Manualslib.com manuals search engine Z15490
Front
Painted Mark90°
P14776
Z14823
Front
Mark
(Carity)
Front
P14778
Front
Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−99
1996 TOYOTA T100 (RM449U)
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown above.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance (See page
EM−84).
14. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
15. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
16. INSTALL CONNECTING ROD CAP NUTS
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil on the threads and under
the nuts of the connecting rod cap.

Downloaded from www.Manualslib.com manuals search engine P04615
Nut
90°
Painted Mark
EM−100
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(b) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque:45 N·m (460 kgf·cm, 33 ft·lbf)
If any one of the connecting rod cap nuts does not meet the
torque specification, replace the connecting rod bolt and cap
nut as a set.
(c) Mark the front of the connecting rod cap nut and bolt with
paint.
(d) Retighten the connecting rod cap nuts 90° as shown.
(e) Check that the painted mark on the nut is at a 90° angle
in relation to the mark on the bolt.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance (See page
EM−84).

Downloaded from www.Manualslib.com manuals search engine P14810
Seal Packing
Z11442
P12478
Adhesive
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−101
1996 TOYOTA T100 (RM449U)
17. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the retainer
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the retainer as shown in the illustra-
tion.
Seal packing:
Part No. 08826−00080 or equivalent
Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the retainer with the 6 bolts.
Torque: 13.5 N·m (135 kgf·cm, 9.7 ft·lbf)
18. INSTALL LH ENGINE MOUNTING BRACKET
Install the bracket with the 5 bolts.
Torque:
Bolt A: 51 N·m (520 kgf·cm, 34 ft·lbf)
Bolt B: 20 N·m (200 kgf·cm, 14 ft·lbf)
19. INSTALL RH ENGINE MOUNTING BRACKET
Install the bracket with the 4 bolts.
Torque: 51 N·m (520 kgf·cm, 34 ft·lbf)
20. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent