1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine P15082
EM1OM−01
P15092
P15099
P15092
P15137
EM−70
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL TRANSMISSION TO ENGINE
2. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
IN VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the en-
gine compartment.
(c) Keep the engine level, and align the RH and LH mount-
ings and body mountings.
(d) Attach the RH and LH mounting insulators to the body
mountings, and temporarily install the 4 bolts and nuts.
(e) Jack up and put the transmission onto the frame.
(f) Remove the hoist chain.
(g) Remove the bolt and rear engine hanger.
3. INSTALL ENGINE REAR MOUNTING BRACKET
(a) Raise the transmission slightly by raising the engine with
a jack and a wooden block under the transmission.
(b) Install the engine rear mounting bracket to the frame.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(c) Lower the transmission and rest it on the extension hous-
ing.
(d) Install the mounting bracket to the mounting insulator.
Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)
4. TIGHTEN RH AND LH ENGINE MOUNTING
INSULATOR BOLTS AND NUTS
Tighten the 4 bolts and nuts holding the mounting insulators to
the body mountings.
Torque: 38 N·m (380 kgf·cm, 28 ft·lbf)
5. CONNECT STARTER WIRE
(a) Connect the ground strap with the bolt.
(b) Connect the starter connector.
(c) Connect the starter wire with the nut.
6. M/T:
INSTALL CLUTCH RELEASE CYLINDER
(a) Connect the clutch line with the bolt.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Install the clutch release cylinder with the 2 bolts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
7. A/T:
INSTALL CROSS SHAFT

Downloaded from www.Manualslib.com manuals search engine P15073
P15072
R05270
P15078
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−71
1996 TOYOTA T100 (RM449U)
8. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with new 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 2 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect a new gasket and the front exhaust pipe assem-
bly to the TWC with the 2 bolts and retainer.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(e) Connect the 2 heated oxygen sensor connectors.
9. CONNECT SPEEDOMETER CABLE
10. INSTALL PROPELLER SHAFT (See page PR−9)
11. INSTALL STABILIZER BAR
(a) Place the stabilizer bar in position and install both stabiliz-
er bar bushings and brackets to the frame.
(b) Torque the stabilizer bar mounting bolts.
Torque: 30 N·m (306 kgf·cm, 22 ft·lbf)
(c) Connect the stabilizer bar on both sides to the lower arms
with brackets, cushions and new nuts as shown.
(d) Torque the nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
12. M/T:
INSTALL SHIFT LEVER ASSEMBLY
(a) Install baffle and shift lever assembly with the 6 bolts.
(b) Install the shift lever boot with the 4 screws.
(c) Install the shift lever knob.

Downloaded from www.Manualslib.com manuals search engine P15739
P15094
P15086
EM−72
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
13. CONNECT WIRES AND CONNECTORS
(a) Push in the engine wire through the cowl panel.
(b) Connect the 4 engine wire clamps
(c) Connect these wires and connectors:
Ground strap to cowl top panel
Igniter connector
(d) Connect 2 connectors to cowl wire.
(e) Connect 4 connectors to the ECM.
(f) Install the ECM with the 3 bolts.
14. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
(a) Install the cowl side trim with the clip.
(b) Install the front door scuff plate with the 4 screws.
15. CONNECT GENERATOR WIRE
(a) Connect the generator connector.
(b) Connect the generator wire with the nut.
(c) Connect the wire harness clip to the generator.
16. CONNECT PS PUMP
(a) Connect the PS pump to the bracket with the 2 bolts.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(b) Using SST, install the PS pump pulley with the nut.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
17. CONNECT HOSES
Connect these hoses:
Fuel return hose
Fuel inlet hose

Downloaded from www.Manualslib.com manuals search engine P15085
P14935
P24651
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−73
1996 TOYOTA T100 (RM449U)
Brake booster vacuum hose
EVAP hose
2 PS hoses
18. CONNECT HEATER HOSES
19. w/ A/C:
INSTALL A/C COMPRESSOR AND BRACKET
(a) Install the A/C compressor bracket with the 4 bolts.
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
(b) Install the A/C compressor with the 4 bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Connect the A/C compressor connector.
20. INSTALL INTAKE AIR CONNECTOR
(a) Install the intake air connector with the 2 bolts and hose
clamp.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Connect the 2 air hoses.
21. M/T:
CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
22. A/T:
CONNECT ACCELERATOR AND THROTTLE CABLES
TO THROTTLE BODY

Downloaded from www.Manualslib.com manuals search engine P14772
P14773
P14776
P14777
Plastigage
P14781
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−77
1996 TOYOTA T100 (RM449U)
17. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.160 − 0.312 mm (0.0063 − 0.0123 in.)
Maximum thrust clearance:
0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
18. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Using a punch or numbering stamp, place the matchmark
on the connecting rod cap to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−95).
Torque:
1st 45 N·m (460 kgf·cm, 33 ft·lbf)
2nd Turn 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD
0.030 − 0.055 mm (0.0012 − 0.0022 in.)
U/S 0.25
0.031 − 0.071 mm (0.0012 − 0.0026 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)

Downloaded from www.Manualslib.com manuals search engine P14790
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 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.