1996 TOYOTA T100 check engine

Downloaded from www.Manualslib.com manuals search engine Z15490
Front
Painted Mark90°
P14776
Z14823
Front
Mark
(Carity)
Front
P14778
Front
Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−99
1996 TOYOTA T100 (RM449U)
(c) Mark the front of the main bearing cap bolt with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown above.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
(g) Check the crankshaft thrust clearance (See page
EM−84).
14. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
15. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
16. INSTALL CONNECTING ROD CAP NUTS
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil on the threads and under
the nuts of the connecting rod cap.

Downloaded from www.Manualslib.com manuals search engine P04615
Nut
90°
Painted Mark
EM−100
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(b) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque:45 N·m (460 kgf·cm, 33 ft·lbf)
If any one of the connecting rod cap nuts does not meet the
torque specification, replace the connecting rod bolt and cap
nut as a set.
(c) Mark the front of the connecting rod cap nut and bolt with
paint.
(d) Retighten the connecting rod cap nuts 90° as shown.
(e) Check that the painted mark on the nut is at a 90° angle
in relation to the mark on the bolt.
(f) Check that the crankshaft turns smoothly.
(g) Check the connecting rod thrust clearance (See page
EM−84).

Downloaded from www.Manualslib.com manuals search engine Z11443
A
A B
Z11127
(6)(7)
(8) (9)
(10)
(1) (2)
(3)(4) (5)
Z15493
Up ward 90°
Painted Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−103
1996 TOYOTA T100 (RM449U)
30. INSTALL REAR END PLATE
Install the rear end plate with the 3 bolts.
Torque:
Bolt A: 18 N·m (185 kgf·cm, 13 ft·lbf)
Bolt B: 20 N·m (200 kgf·cm, 14 ft·lbf)
31. M/T:
INSTALL FLYWHEEL
(a) Install and uniformly tighten 10 new bolts to the flywheel,
in several passes, in the sequence shown.
Torque: 26.5 N·m (270 kgf·cm, 19 ft·lbf)
(b) Mark the top of the flywheel bolt with paint.
(c) Retighten the flywheel bolts by 90° in the numerical order
shown above.
(d) Check that the painted mark is now at a 90° angle to the
top.
32. A/T:
INSTALL DRIVE PLATE
Install the front spacer, drive plate and rear spacer with the 10
bolts.
Torque: 74 N·m (750 kgf·cm, 56 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine EM06B−03
P15056
− ENGINE MECHANICAL (5VZ−FE)CO/HC
EM−1
820 Author: Date:
1996 TOYOTA T100 (RM449U)
CO/HC
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 systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged
(g) Ignition timing checked correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180
SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When doing the 2 mode (2,500 rpm and idle) test, follow the
measurement order prescribed by the applicable local regula-
tions

Downloaded from www.Manualslib.com manuals search engine EM06C−05
P21054
EM−2
− ENGINE MECHANICAL (5VZ−FE)COMPRESSION
821 Author: Date:
1996 TOYOTA T100 (RM449U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE HIGH−TENSION CORDS WITH IGNITION
COILS (See page IG−1)
3. REMOVE SPARK PLUGS
4. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,200 kPa (12.2 kgf/cm
2, 174 psi) or more
Minimum pressure:
1,000 kPa (10.2 kgf/cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 15 psi) or less
(e) If the cylinder compression in 1 or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
5. REINSTALL SPARK PLUGS

Downloaded from www.Manualslib.com manuals search engine EM06D−03
P21120
P21152
Dot Mark
P01269
RH EX
12
36
LH EX LH IN RH IN
P01270
RH EX
34
5
LH EX LH IN RH IN
2 EM−4
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
823 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 INTAKE AIR CONNECTOR
(See page EM−65)
3. REMOVE CYLINDER HEAD COVERS
(See page EM−30)
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark ”0” of the No.1 timing belt cover.
(b) Check that the timing marks (1 dot) of the camshaft drive
and driven gears are in straight line on the cylinder heads
surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated in the illustration.
Using a thickness gauge, measure the clearance
between the valve lifter and camshaft.
Record out of specification valve clearance mea-
surements. They will be used later to determine the
required replacement adjusting shim.
Valve clearance (Cold):
Intake 0.13 − 0.23 mm (0.006 − 0.009 in.)
Exhaust 0.27 − 0.37 mm (0.011 − 0.014 in.)
(b) Turn the crankshaft 2/3 of a revolution (240°), and check
only the valves indicated in the illustration. Measure the
valve clearance. (See procedure step (a))

Downloaded from www.Manualslib.com manuals search engine P01268
RH EX
6 4
5
LH EX LH IN RH IN
1
P21221
Upward
Cam Lobe
Notch
P21225
Front of No.1 and Rear of No.6 Cylinders
Others
SST (A) SST (B)SST (B)SST (A)
P21222
SST (B)
Magnetic Finger
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
EM−5
824 Author: Date:
1996 TOYOTA T100 (RM449U)
(c) Turn the crankshaft a further 2/3 of a revolution (240°),
and check only the valves indicated in the illustration.
Measure the valve clearance (See procedure step (a)).
6. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
Turn the camshaft so that the cam lobe for the valve
to be adjusted faces up.
Turn the valve lifter with a screwdriver so that the
notches are perpendicular to the camshaft.
Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248−55040 (09248−05410, 09248−05420)
HINT:
Apply SST (B) at a slight angle on the side marked with
”9” or ”7”, at the position shown in the illustration.
When SST (B) is inserted too deeply, it will get pinched by
the shim. To prevent it from being stuck, insert it gently
from the intake side, at a slight angle.
Using a small screwdriver and magnetic finger, re-
move the adjusting shim.

Downloaded from www.Manualslib.com manuals search engine EM0494
P21223
SST (B)
SST (A)
EM−6
− ENGINE MECHANICAL (5VZ−FE)VALVE CLEARANCE
825 Author: Date:
1996 TOYOTA T100 (RM449U)
(b) Determine the replacement adjusting shim size according
to these Formula or Charts:
Using a micrometer, measure the thickness of the
removed shim.
Calculate the thickness of a new shim so the valve
clearance comes within the specified value.
T .......... Thickness of used shim
A .......... Measured valve clearance
N .......... Thickness of new shim
Intake
N = T + (A − 0.18 mm (0.007 in.))
Exhaust
N = T + (A − 0.32 mm (0.013 in.))
Select a new shim with a thickness as close as pos-
sible to the calculated values.
HINT:
Shims are available in 17 sizes in increments of 0.050 mm
(0.0020 in.), from 2.500 mm (0.0984 in.) to 3.300 mm (0.1299
in.).
(c) Install a new adjusting shim.
Place a new adjusting shim on the valve lifter, with
imprinted numbers facing down.
Press down the valve lifter with SST (A), and re-
move SST (B).
SST 09248−55040 (09248−05410, 09248−05420)
(d) Recheck the valve clearance.
7. REINSTALL CYLINDER HEAD COVERS (See page
EM−51)
8. REINSTALL INTAKE AIR CONNECTOR
(See page EM−69)
9. REFILL WITH ENGINE COOLANT
10. START ENGINE AND CHECK FOR LEAKS