Page 811 of 2062

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
Page 812 of 2062

Downloaded from www.Manualslib.com manuals search engine Z15492
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.
Page 815 of 2062
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.
Page 822 of 2062

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.
Page 830 of 2062

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
Page 845 of 2062

Downloaded from www.Manualslib.com manuals search engine EM06I−06
A01568
No!
OIL
P20043
P12604
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−17
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT TIMING BELT
NOTICE:
Do not bend, twist or turn the timing belt inside out.Do not
allow the timing belt to come into contact with oil, water or
steam. Do not utilize timing belt tension when installing or
removing the mount bolt of the camshaft timing pulley.
If there are any defects, as shown in the illustrations, check
these points:
(a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft is locked.
(c) If there is noticeable wear or cracks on the belt face,
check to see if there are nicks on the side of the idler
pulley lock and water pump.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check timing
cover for damage and check gasket has been installed
correctly and for foreign material on the pulley teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS
(a) Visually check the seal portion of the idler pulley for oil
leakage.
If leakage is found, replace the idler pulley.
(b) Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.
Page 846 of 2062
Downloaded from www.Manualslib.com manuals search engine P18782
P18764
P18770
Protrusion EM−18
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
1996 TOYOTA T100 (RM449U)
3. INSPECT TIMING BELT TENSIONER
(a) Visually check the seal portion of the tensioner for oil leak-
age.
HINT:
If there is only the faintest trace of oil on the seal on the push
rod side, the tensioner is all right.
If leakage is found, replace the tensioner.
(b) Hold the tensioner with both hands and push the push rod
strongly as shown to check that it doesn’t move.
If the push rod moves, replace the tensioner.
NOTICE:
Never hold the tensioner push rod facing downward.
(c) Measure the protrusion of the push rod from the housing
end.
Protrusion:
10.0 − 10.8 mm (0.394 − 0.425 in.)
If the protrusion is not as specified, replace the tensioner.
Page 847 of 2062

Downloaded from www.Manualslib.com manuals search engine P20822
Inward
Sensor
EM06J−03
P20821
P20499
P20823
Front
− ENGINE MECHANICAL (5VZ−FE)TIMING BELT
EM−19
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the timing
pulley and slide on the timing pulley.
(b) Slide on the timing pulley, facing the flange side inward.
2. INSTALL NO. 1 IDLER PULLEY AND NO.2 IDLER
PULLEY
(a) Using a 10 mm hexagon wrench, install the No.1 idler
pulley with the plate washer and bolt.
Torque: 35 N·m (350 kgf·cm, 26 ft·lbf)
(b) Check that the pulley bracket moves smoothly.
(c) Install the No.2 idler pulley with the bolt.
Torque: 40 N·m (400 kgf·cm, 30 ft·lbf)
(d) Check that the pulley moves smoothly.
3. TEMPORARILY INSTALL TIMING BELT
NOTICE:
The engine should be cold.
(a) Use the crankshaft pulley bolt to turn the crankshaft and
align the timing marks on the crankshaft timing pulley and
on the oil pump body.
(b) Remove any oil or water on the crankshaft timing pulley,
idler pulley and water pump pulley, and keep them clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(c) Align the installation mark on the timing belt with the
drilled mark of the crankshaft timing pulley.
(d) Install the timing belt on the crankshaft timing pulley, No.1
idler and water pump pulleys.
4. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.