1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine EM06Z−03
P14842
Adjusting Bolt
Lock Bolt
Pivot Bolt
P14935
P14907A03721
P14953
EM−14
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE OIL
2. DRAIN ENGINE COOLANT
3. REMOVE CYLINDER HEAD
(See page EM−28)
4. REMOVE ENGINE UNDER COVER
Remove the 4 bolts and engine under cover.
5. w/ A/C:
REMOVE A/C COMPRESSOR DRIVE BELT
Loosen the idler pulley nut and adjusting bolt, and remove the
drive belt.
6. REMOVE DRIVE BELT, FAN WITH FLUID
COUPLING, WATER PUMP PULLEY AND FAN
SHROUD
(a) Stretch the belt and loosen the water pump pulley mount-
ing nuts.
(b) Loosen the lock, pivot and adjusting bolts of the genera-
tor, and remove the drive belts.
(c) Remove the 4 water pump pulley mounting nuts.
(d) Pull out the fan with fluid coupling and water pump pulley.
(e) Remove the No.2 fan shroud.
(f) Remove the 4 bolts and No.1 fan shroud.
7. w/ A/C:
DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Remove the 4 mounting bolts, and disconnect the com-
pressor from the bracket.
HINT:
Put a side the compressor, and suspend it.
(b) Remove the 4 bolts and A/C compressor bracket.
8. REMOVE GENERATOR, ADJUSTING BAR AND
BRACKET
(a) Remove the lock, pivot bolts and the generator.
(b) Remove the bolt and adjusting bar.
(c) Remove the 3 bolts and bracket.
9. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts and crankshaft position sensor.
(b) Remove the O−ring from the crankshaft position sensor.

Downloaded from www.Manualslib.com manuals search engine P15008A03722
SST
P14954A03723
P15097A03724
P18141
Crankshaft Puller Bolt
SST
P14986A03725
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−15
1996 TOYOTA T100 (RM449U)
10. REMOVE OIL PAN
(a) Remove the 16 mounting bolts and 2 nuts.
(b) Insert the blade of SST between the cylinder block and oil
pan, cut off applied sealer and remove the oil pan.
SST 09032−00100
NOTICE:
Be careful not to damage the oil pan flanges of the oil pan
and cylinder block.
11. REMOVE OIL STRAINER
Remove the 2 bolts, 2 nuts, oil strainer and gasket.
12. REMOVE CRANKSHAFT PULLEY
(a) w/ A/C:
Remove the 4 bolts, No.2 and No.3 crankshaft pulleies.
(b) Using SST, remove the pulley bolt.
SST 09213−54015, 09330−00021
(c) Remove the crankshaft pulley.
HINT:
If necessary, remove the pulley with SST and crankshaft pulley
bolt.
SST 09950−50010 (09951−05010, 09952−05010,
09953−05010, 09954−05020)
13. REMOVE TIMING CHAIN COVER
(a) Remove the 2 water by pass pipe mounting nuts.
(b) Remove the 2 timing chain cover mounting bolts.

Downloaded from www.Manualslib.com manuals search engine P14973A03726
P18142
SST
Crankshaft Pulley Bolt
P14923
P15081Pin
P14932A03727
EM−16
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
(c) Remove the 9 mounting bolts and 2 mounting nuts.
(d) Using a plastic−faced hammer, loosen the chain cover
and remove the timing chain cover and 3 gaskets.
14. REMOVE NO.1 TIMING CHAIN AND CAMSHAFT
TIMING GEAR
15. REMOVE CRANKSHAFT TIMING GEAR
HINT:
If necessary, remove the gear with SST and crankshaft pulley
bolt.
SST 09950−40010 (09951−04010, 09952−04010,
09953−04010, 09954−04010, 09955−04060)
16. REMOVE NO.1 TIMING CHAIN TENSIONER
SLIPPER AND NO.1 VIBRATION DAMPER
(a) Remove the bolt and slipper.
(b) Remove the bolt, nut and No.1 damper.
17. REMOVE NO.2, NO.3 VIBRATION DAMPERS AND
NO.2 CHAIN TENSIONER
(a) Install a pin to the No.2 chain tensioner and lock the
plunger.
(b) Remove the bolt and No.2 damper.

Downloaded from www.Manualslib.com manuals search engine P14974A03728
P15080A03729
P14920A03730
P14962
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−17
1996 TOYOTA T100 (RM449U)
(c) Remove the 2 bolts and No.3 damper.
(d) Remove the nut and No.2 chain tensioner.
18. REMOVE NO.2 TIMING CHAIN
(a) Remove the bolt from the balance shaft drive gear.
(b) Remove the balance shaft drive gear with shaft.
(c) Remove the No.2 timing chain with the No.2 crankshaft
timing sprocket.
19. REMOVE NO.4 VIBRATION DAMPER
Remove the 2 bolts and No.4 damper.

Downloaded from www.Manualslib.com manuals search engine Z14864
16 Links
Z11085A03751
Z11088A03752
EM070−02
EM−18
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
INSPECTION
1. INSPECT TIMING CHAINS, TIMING GEARS AND TIM-
ING SPROCKETS
(a) Measure the length of 16 links with the chain fully
stretched.
Maximum chain elongation:
No.1 Timing chain
147.5 mm (5.807 in.)
No.2 Timing chain
123.6 mm (4.866 in.)
If the elongation is greater than maximum, replace the chain.
HINT:
Make the same measurements pulling at 3 or more places se-
lected at random.
(b) Wrap the chain around the timing gear and timing sprock-
et.
(c) Using vernier calipers, measure the timing gear and tim-
ing sprocket diameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.
Minimum gear diameter:
Camshaft
113.8 mm (4.480 in.)
Crankshaft
59.4 mm (2.339 in.)
Balance shaft
75.9 mm (2.988 in.)
Minimum sprocket diameter:
No.2 crankshaft
96.7 mm (3.807 in.)
If the diameter is less than minimum, replace the chain, gears
and sprocket.

Downloaded from www.Manualslib.com manuals search engine P14927A03753
P14933A03754
P14928
Free
P14929
Lock
P14934
Air
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−19
1996 TOYOTA T100 (RM449U)
2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRA-
TION DAMPERS
Measure the chain tensioner slipper and vibration damper
wears.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the slipper and/or
dampers.
3. INSPECT NO.2 CHAIN TENSIONER
(a) Inspect the chain tensioner
Check that the plunger moves smoothly when the
ratchet pawl is raised with your finger.
Release the ratchet pawl and check that the plung-
er is locked in place by the ratchet pawl and does
not move when pushed with your finger.
(b) Inspect the oil jet (No.2 chain tensioner).
Check the oil jet for damage or clogging.
If necessary, replace the oil jet (No.2 chain tensioner).

Downloaded from www.Manualslib.com manuals search engine P14962
EM073−03
P15101
Aligin
Aligin
Aligin
P15100
P15080A03755
EM−20
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
INSTALLATION
NOTICE:
Check that No.1 cylinder is at TDC and that the weights of
the No.1 and No.2 balance shafts are at the bottom side.
1. INSTALL NO.4 VIBRATION DAMPER
Install the No.4 damper with the 2 bolts.
2. INSTALL NO.2 TIMING CHAIN
(a) Install the No.2 timing chain by matching its mark links
with the timing marks on the No.2 crankshaft timing
sprocket and balance shaft timing sprocket.
(b) Fit the other mark link of No.2 timing chain onto the
sprocket behind the large timing mark of the balance shaft
drive gear.
(c) Insert the balance shaft drive gear shaft through the bal-
ance shaft drive gear so that it fits into the thrust plate
hole.
Then align the small timing mark of the balance shaft drive
gear with the timing mark of the balance shaft timing gear.
(d) Install the bolt to the balance shaft drive gear and tighten
it.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(e) Check that each timing mark is matched with the corre-
sponding mark link.
3. INSTALL NO.2, NO.3 VIBRATION DAMPERS AND
NO.2 CHAIN TENSIONER
NOTICE:
Assemble the chain tensioner with the pin installed, then
remove the pin after assembly.
When doing this, avoid pushing the No.2 vibration damper
against the chain.
(a) Install the No.2 chain tensioner with the nut.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P14974A03756
P14932A03757
P15081Pin
P14923
P14919
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−21
1996 TOYOTA T100 (RM449U)
(b) Install No.3 damper with the 2 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(c) Install No.2 damper with the bolt.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)
(d) Remove a pin from the No.2 chain tensioner and free the
plunger.
4. INSTALL NO.1 TIMING CHAIN TENSIONER
SLIPPER AND NO.1 VIBRATION DAMPER
(a) Install the No.1 damper with the bolt and nut.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Install the slipper with the bolt.
Torque: 27 N·m (270 kgf·cm, 20 ft·lbf)
(c) Check that the slipper moves smoothly.
5. INSTALL CRANKSHAFT TIMING GEAR