Page 728 of 2062
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.
Page 733 of 2062
Downloaded from www.Manualslib.com manuals search engine P24401A03718
EM−10
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
725 Author: Date:
1996 TOYOTA T100 (RM449U)
11. REINSTALL CYLINDER HEAD COVER
(a) Install the gasket to the cylinder head cover.
(b) Install the cylinder head cover with the 10 bolts.
12. RECONNECT ENGINE WIRE
(a) Connect the 5 engine wire clamps.
(b) Connect these connectors:
ECT sensor connector
Oil pressure sensor connector
w/ A/C:
A/C compressor connector
13. REINSTALL THROTTLE BODY (See page MF−30)
14. REINSTALL HIGH−TENSION CORDS TO SPARK
PLUGS
15. REINSTALL NO.1 AND NO.2 PCV HOSES
16. REINSTALL AIR INTAKE CONNECTOR (See page
EM−70)
17. REFILL WITH ENGINE COOLANT
18. CHECK IGNITION TIMING
Page 734 of 2062
Downloaded from www.Manualslib.com manuals search engine EM06T−02
FI7231
TOYOTA Hand−Held Tester
DLC3
P16016A03719
P15946
− ENGINE MECHANICAL (3RZ−FE)IGNITION TIMING
EM−11
726 Author: Date:
1996 TOYOTA T100 (RM449U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND−HELD TESTER OR OBDII
SCAN TOOL
(a) Connect the TOYOTA hand−held tester or OBDII scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand−held tester or OBDII
scan tool operators manual for further details.
3. CHECK IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843−18020
(b) Using a timing light, connect the tester to No.1 high−
tension cord.
(c) Check ignition timing.
Ignition timing:
3 − 7° BTDC @ idle
(Air Conditioner OFF)
If the ignition timing is not as specified, check that following
conditions are normal:
Throttle valve fully closed
Continuity between terminals IDL and E2 of the
throttle position sensor
Valve timing
(d) Remove the SST from the DLC1.
SST 09843−18020
4. DISCONNECT TOYOTA HAND−HELD TESTER OR
OBDII SCAN TOOL, AND TIMING LIGHT
Page 737 of 2062
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.
Page 747 of 2062
Downloaded from www.Manualslib.com manuals search engine P14989A03765
P14953
Z11309BA
A EM−24
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
10. INSTALL OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the oil pan.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pan 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 or 3 − 4 mm (0.012 − 0.016 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 oil pan with the 16 bolts and 2 nuts.
Torque: 12.5 N·m (130 kgf·cm, 9 ft·lbf)
11. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install a new O−ring.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf)
12. I N S TA L L G E N E R ATO R , A D J U S T I N G B A R A N D
BRACKET
(a) Install the bracket with the 3 bolts.
Torque:
Bolt A: 74.5 N·m (760 kgf·cm, 55 ft·lbf)
Bolt B: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Install the adjusting bar with the bolt.
Torque: 63.5 N·m (650 kgf·cm, 47 ft·lbf)
Page 751 of 2062
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
Page 752 of 2062
Downloaded from www.Manualslib.com manuals search engine P15813A03782
P14635A03783
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−29
1996 TOYOTA T100 (RM449U)
8. REMOVE DISTRIBUTOR
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(a) Disconnect the distributor connector.
(b) Remove the hold−down bolts and distributor.
(c) Remove the O−ring.
9. REMOVE WATER OUTLET
(a) Disconnect the radiator inlet hose.
(b) Disconnect the ECT sender gauge connector.
(c) Remove the 2 bolts, water outlet and gasket.
10. REMOVE THROTTLE BODY (See page MF−28)
11. DISCONNECT ENGINE WIRE
(a) Disconnect these connectors:
w/ A/C:
A/C compressor connector
Oil pressure sensor connector
ECT sensor connector
EGR gas temperature sensor connector
EGR VSV connector
(b) Remove the 2 bolts and disconnect engine wire from the
intake chamber.
(c) Disconnect the 5 engine wire clamps and engine wire.
(d) Disconnect these connectors:
Knock sensor connector
Crankshaft position sensor connector
Fuel pressure control VSV connector
(e) Disconnect the DLC1 from the bracket.
(f) Disconnect the 2 engine wire clamps.
(g) Remove the bolt and disconnect the engine wire.
12. DISCONNECT INJECTOR CONNECTORS
13. REMOVE CYLINDER HEAD REAR COVER
(a) Disconnect the heater water bypass hose.
(b) Remove the 3 bolts and the rear cover and gasket.
Page 780 of 2062
Downloaded from www.Manualslib.com manuals search engine P15073
P22272
P24691
A02538
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−57
1996 TOYOTA T100 (RM449U)
17. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with the 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) Install camshaft position sensor.
18. INSTALL INTAKE MANIFOLD
Install a new gasket and intake manifold with the 3 bolts and 2
nuts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
19. INSTALL INJECTORS AND DELIVERY PIPE (See page
MF−21)
HINT:
When using a new cylinder head, spacers must be installed.
Apply a light coat of gasoline to a new O−ring a nd install it to
a new spacer.
20. INSTALL FUEL TUBE
Install the fuel inlet tube and 4 new gaskets with 2 union bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
21. INSTALL AIR INTAKE CHAMBER
(a) Install a new gasket and the air intake chamber with the
3 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(b) Connect the vacuum hose to the gas filter.
(c) Connect the brake booster vacuum hose to the intake
camber.
