1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine P14687
P14695
A01399
Dot Mark
P14636
P15751A03790
EM−32
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
24. REMOVE CYLINDER HEAD COVER
Remove the 10 bolts, cylinder head cover and gasket.
25. REMOVE SPARK PLUGS
26. 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.
(b) Check that the timing marks (1 and 2 dots) of the camshaft
drive and driven gears are in straight line on the cylinder
head surface as shown in the illustration. If not, turn the
crankshaft 1 revolution (360°) and align the marks as
above.
27. REMOVE CHAIN TENSIONER
Remove the 2 nuts, chain tensioner and gasket.
28. REMOVE CAMSHAFT TIMING GEAR
(a) Remove the 2 semi−circular plugs.
(b) Place the matchmarks on the camshaft timing gear and
No.1 timing chain.

Downloaded from www.Manualslib.com manuals search engine P14663
Z10933
P14696
EM0580
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−39
1996 TOYOTA T100 (RM449U)
5. CLEAN CYLINDER HEAD
Using a soft brush and solvent, thoroughly clean the cylinder
head.
6. INSPECT FOR FLATNESS
Using a precision straight edge and thickness gauge, measure
the surfaces contacting the cylinder block and the manifolds for
warpage.
Maximum warpage:
Cylinder block side
0.05 mm (0.0020 in.)
Manifold side
0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chambers, intake
ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

Downloaded from www.Manualslib.com manuals search engine Both intake and exhaust
11.050 − 11.077
(0.4350 − 0.4361) (0.4331 − 0.4341) 11.000 − 11.027mm (in.) Bushing bore diameter
Bushing size
Use STD
Use O/S 0.05
Z11079A03794
Z10934A03795
Z00054
44.5°
EM0181
Margin Thickness
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−41
1996 TOYOTA T100 (RM449U)
(d) Select a new guide bushing (STD size or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
11.027 mm (0.4341 in.), machine the bushing bore to these di-
mension:
11.050 − 11.077 mm (0.4350 − 0.4361 in.)
If the bushing bore diameter of the cylinder head is greater than
11.077 mm (0.4361 in.), replace the cylinder head.
(e) Gradually heat the cylinder head to 80 − 100°C (176 −
212°F).
(f) Using SST and a hammer, tap in a new guide bushing to
where there 8.2 − 8.6 mm (0.323 − 0.339 in.) protruding
from the cylinder head.
SST 09201−10000 (09201−01060),
09550−10012 (09252−10010)
(g) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See step 9
above) between the guide bushing and valve stem.
11. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle:
44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
1.0 mm (0.039 in.)
Minimum margin thickness:
0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.

Downloaded from www.Manualslib.com manuals search engine P03849
Overall Length
EM0255
A03806
P04415
Width
Z11441
45°30°
1.0 − 1.4 mm EM−42
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(d) Check the valve overall length.
Standard overall length:
Intake
103.45 mm (4.0728 in.)
Exhaust
103.60 mm (4.0787 in.)
Minimum overall length:
Intake
102.95 mm (4.0531 in.)
Exhaust
103.10 mm (4.0590 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
12. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for these:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with these width:
1.0 − 1.4 mm (0.039 − 0.055 in.)
If not, correct the valve seats as follows:
Intake:
If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.

Downloaded from www.Manualslib.com manuals search engine P03976
P03977
EM3322
Free Distance
P14668
Plastigage
P14665
EM−44
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
15. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
45.31 − 45.41 mm (1.7839 − 1.7878 in.)
Exhaust
45.06 − 45.16 mm (1.7740 − 1.7779 in.)
If the cam lobe height is less than standard allowable, replace
the camshaft.
16. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
17. INSPECT CAMSHAFT BEARING
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
18. INSPECT CAMSHAFT GEAR SPRING
Using a vernier caliper, measure the free distance between the
spring ends.
Free distance:
22.5 − 22.9 mm (0.886 − 0.902 in.)
If the free distance is not as specified, replace the gear spring.
19. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps (See page EM−50).
Torque: 15.5 N·m (160 kgf·cm, 12 ft·lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
Maximum oil clearance:
0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the Plastigage.

Downloaded from www.Manualslib.com manuals search engine Z10936
Cylinder Head Side
Air Intake Chamber Side
P14622
P04666
Free
P04667
Lock EM−46
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
24. INSPECT INTAKE MANIFOLD
Using a precision straight edge and thickness gauge, measure
the surface contacting the cylinder head and air intake chamber
for warpage.
Maximum warpage: 0.20 mm (0.0078 in.)
If warpage is greater than maximum, replace the manifold.
25. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and thickness gauge, measure
the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 in.)
If warpage is greater than maximum, replace the manifold.
26. INSPECT CHAIN TENSIONER
(a) Check that the plunger moves smoothly when the ratchet
pawl is raised with your finger.
(b) Released the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushed with your finger.

Downloaded from www.Manualslib.com manuals search engine P14652
(4)
(3)
(2)
(1)
P14702
SST
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−49
1996 TOYOTA T100 (RM449U)
(b) Install these parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to ensure a proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

Downloaded from www.Manualslib.com manuals search engine P14680
Z10935
EM1OL−01
Z15489
90°
90°
Front
Painted Mark
P14709
EM−50
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Apply seal packing to the 2 locations as shown.
Seal packing:
Part No. 08826−00080 or equivalent
NOTICE:
Do not apply too much seal packing.
(b) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(c) Place the cylinder head in position on the cylinder head
gasket.
2. INSTALL CYLINDER HEAD BOLTS
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install and uniformly tighten the 10 cylinder head bolts
and plate washers in several passes, in the sequence
shown.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts by 90° in the numerical
order shown.
(e) Retighten the cylinder head bolts by an additional 90°.
(f) Check that the painted mark is now facing rearward.
(g) Install and torque the 2 mounting bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)