1996 TOYOTA T100 check engine

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Z11084
P14695
A01399
Dot Mark
P14698
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−53
1996 TOYOTA T100 (RM449U)
(5) Apply light coat of engine oil on the threads and un-
der the heads of the bearing cap bolts.
(6) Install and uniformly tighten the 10 bearing cap
bolts in several passes in the sequence shown.
(7) Remove a service bolt.
(8) Check that the intake and exhaust camshafts turn
smoothly.
5. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise, and align its groove
with the timing mark ”0” of the timing chain cover.
(b) Turn the camshafts so that the timing marks with one and
2 dots will be in straight line on the cylinder head surface
as shown in the illustration.
6. INSTALL CAMSHAFT TIMING GEAR
HINT:
Check that the matchmarks on the camshaft timing gear and
timing chain are aligned.
(a) Place the gear over the straight pin of the intake cam-
shaft.

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P14685
Front Mark
P04668
Hook
Pin
P14683
Push EM−54
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(b) Hold the intake camshaft with a wrench, install and torque
the bolt.
Torque: 73.5 N·m (750 kgf·cm, 54 ft·lbf)
(c) Hold the exhaust camshaft with a wrench, install the bolt
and distributor gear.
Torque: 46 N·m (465 kgf·cm, 34 ft·lbf)
7. INSTALL CHAIN TENSIONER
(a) Place a new gasket so that the front mark is toward the
front side.
(b) Release the ratchet pawl, fully push in the plunger and ap-
ply the hook to the pin so that the plunger cannot spring
out.
(c) Turn the crankshaft pulley clockwise to provide some
slack for the chain on the tensioner side.
NOTICE:
Do not turn the pulley counterclockwise.
(d) Push the tensioner by hand until it touches the head
installation surface, then install the 2 nuts.
(e) Tighten the 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(f) Check that the hook of the tensioner is not released.
NOTICE:
If the plunger springs out during installation of the chain
tensioner, repeat the operation in step (b) before installing
the tensioner.

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A01597
P14695
A01399
Dot Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−55
1996 TOYOTA T100 (RM449U)
8. SET CHAIN TENSIONER
Turn the crankshaft to the left so that the hook of the chain ten-
sioner is released from the pin of the plunger, causing the plung-
er to spring out and the slipper to be pushed into the chain.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver or your finger so that the
hook is released and the plunger springs out.
9. CHECK VALVE TIMING
(a) Turn the crankshaft pulley, and align its groove with the
timing mark ”0” of the timing chain cover.
NOTICE:
Always turn the crankshaft clockwise.
(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.
10. CHECK AND ADJUST VALVE CLEARANCE (See page
EM−5)
Turn the camshaft and position the cam lobe upward and check
and adjust the valve clearance.
Valve clearance (Cold):
Intake
0.15 − 0.25 mm (0.006 − 0.010 in.)
Exhaust
0.25 − 0.35 mm (0.010 − 0.014 in.)
11. INSTALL SPARK PLUGS
Using a 16 mm plug wrench, install the spark plug.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

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P14695
P14687
P14686
EM−56
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
12. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head installation sur-
face of the semi−circular plugs.
Seal packing:
Part No. 08826−00080 or equivalent
(c) Install the semi−circular plug to the cylinder head.
13. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise, and align its groove
with the timing mark ”0” of the timing chain cover.
(b) Check that the timing marks with 1 and 2 dots 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
mark as above.
14. INSTALL CYLINDER HEAD COVER
(a) Install the gasket to the cylinder head cover.
(b) Install the cylinder head cover with the 10 bolts.
Install the No.2 engine hanger and ground strap with the
bolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)
15. INSTALL NO.1 ENGINE HANGER
Install the No.1 engine hanger with the bolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)
16. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and exhaust manifold with the 6 nuts.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Install the heat insulator with the 2 bolts and 2 nuts.
Torque: 5.5 N·m (55 kgf·cm, 48 in.·lbf)

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EM−60
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
37. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP
(a) Connect the air cleaner hose clamp.
(b) Install the air cleaner cap, MAF meter and resonator with
the 4 clips.
(c) Connect the MAF meter connector, IAT sensor connector
and wire clamp.
38. FILL WITH ENGINE COOLANT
39. START ENGINE AND CHECK FOR LEAKS
40. CHECK IGNITION TIMING (See page EM−11)
41. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
42. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM−74
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
1996 TOYOTA T100 (RM449U)
23. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with 3 bolts.
(b) Install the air cleaner element.
24. INSTALL MAF METER, RESONATOR AND AIR
CLEANER CAP
(a) Connect the air cleaner hose clamp.
(b) Install the air cleaner cap, MAF meter and resonator with
the 4 clips.
(c) Connect the MAF meter connector, IAT sensor connector
and wire clamp.
25. INSTALL RADIATOR (See page CO−20)
26. INSTALL RADIATOR RESERVOIR TANK
27. FILL WITH ENGINE OIL
28. FILL WITH ENGINE COOLANT
29. FILL TRANSMISSION OIL
30. INSTALL BATTERY
31. START ENGINE AND CHECK FOR LEAKS
32. CHECK IGNITION TIMING (See page EM−11)
33. INSTALL ENGINE UNDER COVER
Install the engine under cover with the 4 bolts.
34. INSTALL HOOD
35. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, and smooth opera-
tion.
36. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS

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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.)

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Z11077
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P14787
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−79
1996 TOYOTA T100 (RM449U)
20. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
2.440 − 2.490 mm (0.0961 − 0.0980 in.)
21. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts
in several passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the main bearing
caps, lower bearings and (No.3 main bearing cap only)
lower thrust washers.
HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and upper thrust washers together
with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.