1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine P14930
SST
P14975A03758
P14977A03759
P14917A03760
A03761
EM−22
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
HINT:
If necessary, install the gear with SST.
SST 09636−20010
6. INSTALL NO.1 TIMING CHAIN AND CAMSHAFT TIM-
ING GEAR
(a) Align the timing mark between the mark link of the No.1
timing chain, and install the No.1 timing chain to the timing
gear.
(b) Align the timing mark of the crankshaft timing gear with
the mark link of the No.1 timing chain and install the No.1
timing chain.
(c) Tie the No.1 timing chain with a cord as shown in the il-
lustration and make sure it doesn’t come loose.
7. INSTALL TIMING CHAIN COVER
(a) Install 3 new gaskets to the cylinder block and No.1 water
bypass pipe.
(b) Install the timing chain cover with the 9 bolts and 2 nuts.
Torque:
Bolt A: 20 N·m (200 kgf·cm, 14 ft·lbf)
Bolt B: 24.5 N·m (250 kgf·cm, 18 ft·lbf)
Bolt C: 44 N·m (440 kgf·cm, 32 ft·lbf)
Nut D: 20 N·m (200 kgf·cm, 14 ft·lbf)
(c) Remove the cord from the chain.

Downloaded from www.Manualslib.com manuals search engine P14986A03762
P15097A03763
P14954A03764
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−23
1996 TOYOTA T100 (RM449U)
(d) Install the 2 timing chain cover mounting bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(e) Install the 2 No.1 water bypass pipe mounting nuts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
8. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST, install and torque the pulley bolt.
SST 09213−54015, 09330−00021
Torque: 260 N·m (2,650 kgf·cm, 193 ft·lbf)
(c) w/ A/C:
Install the No.3 and No.2 crankshaft pulleies with the 4
bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
9. INSTALL OIL STRAINER
Install a new gasket and oil strainer with the 2 bolts and 2 nuts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P14989A03765
P14953
Z11309BA
A EM−24
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
1996 TOYOTA T100 (RM449U)
10. INSTALL OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surface of the oil pan.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non−residue solvent, clean both sealing
surfaces.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pan as shown in the illustra-
tion.
Seal packing:
Part No. 08826−00080 or equivalent
Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.)opening or 3 − 4 mm (0.012 − 0.016 in.)
opening.
HINT:
Avoid applying an excessive amount to the surface.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil pan with the 16 bolts and 2 nuts.
Torque: 12.5 N·m (130 kgf·cm, 9 ft·lbf)
11. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install a new O−ring.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf)
12. I N S TA L L G E N E R ATO R , A D J U S T I N G B A R A N D
BRACKET
(a) Install the bracket with the 3 bolts.
Torque:
Bolt A: 74.5 N·m (760 kgf·cm, 55 ft·lbf)
Bolt B: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Install the adjusting bar with the bolt.
Torque: 63.5 N·m (650 kgf·cm, 47 ft·lbf)

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P14935
P14842
Adjusting Bolt
Lock Bolt
Pivot Bolt
− ENGINE MECHANICAL (3RZ−FE)TIMING CHAIN
EM−25
1996 TOYOTA T100 (RM449U)
(c) Install the generator with the pivot bolt and lock bolt.
13. w/ A/C:
INSTALL A/C COMPRESSOR AND BRACKET
(a) Install the A/C compressor bracket with the 4 bolts.
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
(b) Install the A/C compressor with the 4 bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
14. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN
WITH FLUID COUPLING AND DRIVE BELT
(a) Place the fan with fluid coupling, water pump pulley and
fan shroud in position.
(b) Temporarily install the water pump pulley mounting nuts.
(c) Install the No.1 fan shroud with the 4 bolts.
(d) Install the No.2 fan shroud with the 2 clips.
(e) Install the drive belts with the adjusting bolt and pivot bolt.
(f) Stretch the belt tight and tighten the 4 water pump pulley
mounting nuts.
Torque: 21 N·m (210 kgf·cm, 16 ft·lbf)
(g) Adjust the drive belts.
15. w/ A/C:
INSTALL A/C COMPRESSOR DRIVE BELT
Install and adjust the drive belt (See page CH−2).
16. INSTALL ENGINE UNDER COVER
Install the engine under cover with the bolts.
17. INSTALL CYLINDER HEAD (See page EM−50)
18. START ENGINE AND CHECK FOR LEAKS

Downloaded from www.Manualslib.com manuals search engine EM075−02
21 (210, 15)
29 (300, 22)
29 (300, 22)
29 (300, 22)
49 (500, 36)
: Specified torqueN·m (kgf·cm, ft·lbf)
29 (300, 22)
EM−26
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
741 Author: Date:
1996 TOYOTA T100 (RM449U)
CYLINDER HEAD
COMPONENTS

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See page EM−50
46 (465, 34)
21 (210,15)
1st 39 (400, 29)
2nd Turn 90°
3rd Turn 90°
N·m (kgf·cm, ft·lbf):Specified torque
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−27
742 Author: Date:
1996 TOYOTA T100 (RM449U)

Downloaded from www.Manualslib.com manuals search engine EM1OK−01
P14841
Adjust Bolt
Lock Bolt
P15755SST
EM−28
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP, MAF METER AND RES-
ONATOR
(a) Disconnect the MAF meter connector, IAT sensor con-
nector and wire clamp.
(b) Loosen the air cleaner hose clamp.
(c) Loosen the 4 clips, and remove the air cleaner cap, MAF
meter and resonator.
3. M/T:
DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
4. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the 2 air hoses and VS hose.
(b) Remove the 2 bolts, hose clamp and intake air connector.
5. REMOVE PS PUMP DRIVE BELT AND IDLER PULLEY
(a) Loosen the lock bolt and adjusting bolt and remove the
drive belt.
(b) Remove the 3 bolts and idler pulley.
6. REMOVE PS PUMP AND BRACKET
(a) Using SST, remove the nut and PS pump pulley.
SST 09960−10010 (09962−01000, 09963−01000)
(b) Disconnect the 2 air hoses from air intake chamber.
(c) Remove the 2 bolts, and disconnect the PS pump.
(d) Remove the 4 bolts and PS pump bracket.
7. REMOVE NO.1 AND NO.2 PCV HOSES

Downloaded from www.Manualslib.com manuals search engine P15813A03782
P14635A03783
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−29
1996 TOYOTA T100 (RM449U)
8. REMOVE DISTRIBUTOR
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(a) Disconnect the distributor connector.
(b) Remove the hold−down bolts and distributor.
(c) Remove the O−ring.
9. REMOVE WATER OUTLET
(a) Disconnect the radiator inlet hose.
(b) Disconnect the ECT sender gauge connector.
(c) Remove the 2 bolts, water outlet and gasket.
10. REMOVE THROTTLE BODY (See page MF−28)
11. DISCONNECT ENGINE WIRE
(a) Disconnect these connectors:
w/ A/C:
A/C compressor connector
Oil pressure sensor connector
ECT sensor connector
EGR gas temperature sensor connector
EGR VSV connector
(b) Remove the 2 bolts and disconnect engine wire from the
intake chamber.
(c) Disconnect the 5 engine wire clamps and engine wire.
(d) Disconnect these connectors:
Knock sensor connector
Crankshaft position sensor connector
Fuel pressure control VSV connector
(e) Disconnect the DLC1 from the bracket.
(f) Disconnect the 2 engine wire clamps.
(g) Remove the bolt and disconnect the engine wire.
12. DISCONNECT INJECTOR CONNECTORS
13. REMOVE CYLINDER HEAD REAR COVER
(a) Disconnect the heater water bypass hose.
(b) Remove the 3 bolts and the rear cover and gasket.