1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine P15046A03717
EM0494
P15043
SST (A)
SST (B)
− ENGINE MECHANICAL (3RZ−FE)VALVE CLEARANCE
EM−7
722 Author: Date:
1996 TOYOTA T100 (RM449U)
Remove the adjusting shim with a small screwdriver and
magnetic finger.
(b) Determine the replacement adjusting shim size by follow-
ing the Formula or Charts:
Using a micrometer, measure the thickness of the
removed shim.
Calculate the thickness of a new shim so that the
valve clearance comes within the specified value.
T ....... Thickness of removed shim
A ....... Measured valve clearance
N ....... Thickness of new shim
Intake:
N=T + (A − 0.20 mm (0.008 in.))
Exhaust:
N=T + (A − 0.30 mm (0.012 in.))
Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 17 sized in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
Place a new adjusting shim on the valve lifter.
Using SST (A), press down the valve lifter and re-
move SST (B).
SST 09248−55040 (09248−05410, 09248−05420)
(d) Recheck the valve clearance.

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

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

Downloaded from www.Manualslib.com manuals search engine EM1OJ−01
EM−12
− ENGINE MECHANICAL (3RZ−FE)IDLE SPEED
727 Author: Date:
1996 TOYOTA T100 (RM449U)
IDLE SPEED
INSPECTION
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses for EGR system, etc. should be properly connected.
(f) MFI system wiring connectors fully plugged
(g) Ignition timing set correctly
(h) Transmission in neutral position
2. CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (See page EM−11)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed: 650 − 750 rpm
If the idle speed is not as specified, check the IAC valve.
4. DISCONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL

Downloaded from www.Manualslib.com manuals search engine P14927A03753
P14933A03754
P14928
Free
P14929
Lock
P14934
Air
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−19
1996 TOYOTA T100 (RM449U)
2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRA-
TION DAMPERS
Measure the chain tensioner slipper and vibration damper
wears.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the slipper and/or
dampers.
3. INSPECT NO.2 CHAIN TENSIONER
(a) Inspect the chain tensioner
Check that the plunger moves smoothly when the
ratchet pawl is raised with your finger.
Release the ratchet pawl and check that the plung-
er is locked in place by the ratchet pawl and does
not move when pushed with your finger.
(b) Inspect the oil jet (No.2 chain tensioner).
Check the oil jet for damage or clogging.
If necessary, replace the oil jet (No.2 chain tensioner).

Downloaded from www.Manualslib.com manuals search engine P14962
EM073−03
P15101
Aligin
Aligin
Aligin
P15100
P15080A03755
EM−20
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
INSTALLATION
NOTICE:
Check that No.1 cylinder is at TDC and that the weights of
the No.1 and No.2 balance shafts are at the bottom side.
1. INSTALL NO.4 VIBRATION DAMPER
Install the No.4 damper with the 2 bolts.
2. INSTALL NO.2 TIMING CHAIN
(a) Install the No.2 timing chain by matching its mark links
with the timing marks on the No.2 crankshaft timing
sprocket and balance shaft timing sprocket.
(b) Fit the other mark link of No.2 timing chain onto the
sprocket behind the large timing mark of the balance shaft
drive gear.
(c) Insert the balance shaft drive gear shaft through the bal-
ance shaft drive gear so that it fits into the thrust plate
hole.
Then align the small timing mark of the balance shaft drive
gear with the timing mark of the balance shaft timing gear.
(d) Install the bolt to the balance shaft drive gear and tighten
it.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(e) Check that each timing mark is matched with the corre-
sponding mark link.
3. INSTALL NO.2, NO.3 VIBRATION DAMPERS AND
NO.2 CHAIN TENSIONER
NOTICE:
Assemble the chain tensioner with the pin installed, then
remove the pin after assembly.
When doing this, avoid pushing the No.2 vibration damper
against the chain.
(a) Install the No.2 chain tensioner with the nut.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P14974A03756
P14932A03757
P15081Pin
P14923
P14919
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−21
1996 TOYOTA T100 (RM449U)
(b) Install No.3 damper with the 2 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(c) Install No.2 damper with the bolt.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)
(d) Remove a pin from the No.2 chain tensioner and free the
plunger.
4. INSTALL NO.1 TIMING CHAIN TENSIONER
SLIPPER AND NO.1 VIBRATION DAMPER
(a) Install the No.1 damper with the bolt and nut.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Install the slipper with the bolt.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)
(c) Check that the slipper moves smoothly.
5. INSTALL CRANKSHAFT TIMING GEAR

Downloaded from www.Manualslib.com manuals search engine P14907A03766
P14935
P14842
Adjusting Bolt
Lock Bolt
Pivot Bolt
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−25
1996 TOYOTA T100 (RM449U)
(c) Install the generator with the pivot bolt and lock bolt.
13. 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)
14. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN
WITH FLUID COUPLING AND DRIVE BELT
(a) Place the fan with fluid coupling, water pump pulley and
fan shroud in position.
(b) Temporarily install the water pump pulley mounting nuts.
(c) Install the No.1 fan shroud with the 4 bolts.
(d) Install the No.2 fan shroud with the 2 clips.
(e) Install the drive belts with the adjusting bolt and pivot bolt.
(f) Stretch the belt tight and tighten the 4 water pump pulley
mounting nuts.
Torque: 21 N·m (210 kgf·cm, 16 ft·lbf)
(g) Adjust the drive belts.
15. w/ A/C:
INSTALL A/C COMPRESSOR DRIVE BELT
Install and adjust the drive belt (See page CH−2).
16. INSTALL ENGINE UNDER COVER
Install the engine under cover with the bolts.
17. INSTALL CYLINDER HEAD (See page EM−50)
18. START ENGINE AND CHECK FOR LEAKS