1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine P14796
P14745
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−81
1996 TOYOTA T100 (RM449U)
Crankshaft Journal diameter:
STD NO.359.981 − 59.994 mm (2.2615 − 2.3620 in.)
STD Others59.987 − 60.000 mm (2.3617 − 2.3622 in.)
U/S 0.25 No.359.740 − 59.750 mm (2.3520 − 2.3524 in.)
U/S 0.25 Others59.745 − 59.755 mm (2.3522 − 2.3526 in.)
Bearing center wall thickness:
STD Mark ”1”1.987 − 1.990 mm (0.0782 − 0.0783 in.)
STD Mark ”2”1.991 − 1.993 mm (0.0784 − 0.0785 in.)
STD Mark ”3”1.994 − 1.996 mm (0.0785 − 0.0786 in.)
U/S 0.252.106 − 2.112 mm (0.0829 − 0.0831 in.)
(k) Completely remove the Plastigage.
22. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust wash-
ers from the cylinder block.
HINT:
Arrange the main bearings and thrust washers in correct order.
23. REMOVE CYLINDER BLOCK ORIFICE
24. CHECK THRUST CLEARANCES OF NO.1 AND NO.2
BALANCE SHAFTS OF ENGINE BALANCER
Using a dial indicator, measure the thrust clearance while mov-
ing the balance shaft back and forth.
Standard thrust clearance:
0.07 − 0.13 mm (0.0027 − 0.0051 in.)
Maximum thrust clearance:
0.2 mm (0.0079 in.)
If the thrust clearance is greater than maximum, replace the bal-
ance shaft thrust washer.
If necessary, replace the balance shaft.

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P14762
P14760
P14764
P03870
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−83
1996 TOYOTA T100 (RM449U)
(b) Remove these parts from balance shaft assembly:
(1) No.2 balance shaft
(2) No.2 balance shaft thrust prate
(3) Balance shaft timing sprocket
28. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
29. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the rings in correct order only.
30. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 − 90°C ( 176 − 194
°F).
(c) Using plastic−faced hammer and brass bar, lightly tap out
the piston pin and remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.

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EM07M−03
Z10814
Z10815
EM−84
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove gasket material.
Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Clean cylinder block.
Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and thickness gauge, measure
the surfaces contacting the cylinder head gasket for warpage.
Maximum warpage:
0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 4 cylinders. If nec-
essary, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore diameter at
positions A, B and C in the thrust and axial directions.
Standard diameter:
STD
94.990 − 95.003 mm (3.7398 − 3.7403 in.)
Maximum diameter:
STD
95.06 mm (3.7425 in.)
If the diameter is greater than maximum, rebore all the 4 cylin-
ders. If necessary, replace the cylinder block.

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P14802
Elongated
Thread
Measuring
Point
P14767
P14822
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−85
1996 TOYOTA T100 (RM449U)
5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
6. INSPECT MAIN BEARING CAP BOLTS
Using vernier calipers, measure the thread outside diameter of
the bolt.
Standard outside diameter:
10.76 − 10.97 mm (0.4236 − 0.4319 in.)
Minimum outside diameter:
10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.
7. INSPECT CYLINDER BLOCK ORIFICE
Check the orifice for clogging.
If necessary, replace the orifice.
8. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.

Downloaded from www.Manualslib.com manuals search engine P04002
125 mm
EM7639
P15014
P03829
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−87
1996 TOYOTA T100 (RM449U)
11. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 125 mm (4.92 in.) from the top of the
cylinder block.
(c) Using a thickness gauge, measure the end gap.
Standard end gap:
No.1
0.300 − 0.400 mm (0.0118 − 0.0157 in.)
No.2
Code mark ”T”
0.400 − 0.500 mm (0.0157 − 0.0196 in.)
Code mark ”N”
0.400 − 0.500 mm (0.0157 − 0.0196 in.)
If the end gap is not as specified, replace the piston ring. If the
end gap is not as specified, even with a new piston ring, rebore
all the 4 cylinders or replace the cylinder block.
12. INSPECT PISTON PIN FIT
At 80 − 90°C (176 − 194°F), you should be able to push the pis-
ton pin into the piston pin hole with your thumb.
13. INSPECT CONNECTING ROD ALIGNMENT
Using a connecting rod aligner and thickness gauge, check the
connecting rod alignment.
Check for out−of−alignment.
Maximum out−of−alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out−of−alignment is greater than maximum, replace the con-
necting rod assembly.

Downloaded from www.Manualslib.com manuals search engine P03828
P03868
EM0227
EM7426
SST
EM−88
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
Check for twist
Maximum twist:
0.15 mm (0.0059 in. ) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
14. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
24.008 − 24.017 mm (0.9452 − 0.9455 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
24.000 − 24.009 mm (0.9449 − 0.9452 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 − 0.011 mm (0.0002 − 0.0004 in.)
Maximum oil clearance:
0.015 mm (0.0006 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set.
15. IF NECESSARY, REPLACE CONNECTING ROD
BUSHING
(a) Using SST and a press, press out the bushing.
SST 09207−76010

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SST
Oil
Hole
P03827
P03867
P15015
EM8714
23 mm
(0.91 in.)
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−89
1996 TOYOTA T100 (RM449U)
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09207−76010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (see step 14 above) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
16. INSPECT CONNECTING ROD BOLTS
(a) Install the cap nut to the connecting rod bolt. Check that
the cap nut can be turned easily by hand to the end of the
thread.
(b) If the cap nut cannot be turned easily, measure the mini-
mum outside diameter of the connecting rod bolt with ver-
nier calipers.
Standard outside diameter:
7.80 − 7.90 mm (0.3071 − 0.3110 in.)
Minimum outside diameter:
7.60 mm (0.2992 in.)
HINT:
If the location of minimum diameter cannot be judged by
visual inspect ion, measure the outer diameter at the loca-
tion shown in the illustration.
If the outside diameter is less than limit, replace the con-
necting rod bolt and nut as a set.

Downloaded from www.Manualslib.com manuals search engine EM−92
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
If the diameter is not as specified, check the oil clearance (See
disassembly in cylinder block) If necessary, grind or replace the
crankshaft.
(b) Check each main journal and crank pin for taper and out−
of−round as shown.
Maximum taper and out−of−round:
0.005 mm (0.0002 in.)
If the taper and out−of−round is greater than maximum, replace
the crankshaft.
21. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure in step 20).
Install new main journal and/or crankshaft pin undersized
bearings.