1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine P14653A03784
P14628A03785
P24689A03786
A02538
P24691A03787
EM−30
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
14. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Remove the bolt, 4 nuts, EGR pipe and 2 gaskets.
(b) Disconnect these hoses:
2 vacuum hoses from EGR VSV (with clamp)
Water bypass hose from water bypass pipe
(c) Remove the bolt, 2 nuts, EGR valve, vacuum modulator
and gasket.
15. REMOVE INTAKE CHAMBER STAY
Remove the 2 bolts and intake chamber stay.
16. REMOVE FUEL RETURN PIPE
(a) Disconnect these hoses:
Fuel return hose from fuel pressure regulator
Fuel return hose from fuel return pipe
(b) Remove the 2 bolts and fuel return pipe.
17. REMOVE AIR INTAKE CHAMBER
(a) Disconnect the vacuum hose from the gas filter.
(b) Disconnect the brake booster vacuum hose from intake
chamber.
(c) Remove the 3 bolts, 2 nuts, air intake chamber and gas-
ket.
18. REMOVE FUEL INLET TUBE
Remove the 2 union bolts, 4 gaskets and fuel inlet tube.

Downloaded from www.Manualslib.com manuals search engine P24692A03788
P22272
P15073A03789
P14686
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−31
1996 TOYOTA T100 (RM449U)
19. REMOVE DELIVERY PIPE AND INJECTORS
(a) Disconnect the vacuum hose from the fuel pressure regu-
lator.
(b) Remove the 2 bolts and delivery pipe together with the 4
injectors.
NOTICE:
Be careful not to drop the injectors when removing the de-
livery pipe.
(c) Remove the 4 insulators from the 4 spacers.
(d) Pull out the 4 injectors from the delivery pipe.
(e) Remove the O−ring and grommet from each injector.
20. REMOVE INTAKE MANIFOLD
Remove the 3 bolts, 2 nuts, intake manifold and gasket.
21. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts, and retainer holding the front ex-
haust pipe from the TWC.
(b) Loosen the clamp bolt and disconnect the clamp from the
support bracket.
(c) Remove the 2 bolts and support bracket.
(d) Remove the 3 nuts, front exhaust pipe and 3 gaskets.
22. REMOVE EXHAUST MANIFOLD
(a) Remove the 2 bolts, 2 nuts and heat insulator.
(b) Remove the 6 nuts, exhaust manifold and gasket.
23. REMOVE NO.1 ENGINE HANGER
(a) Remove the bolt and No.1 engine hanger.
(b) Remove the bolt and ground strap.

Downloaded from www.Manualslib.com manuals search engine P14687
P14695
A01399
Dot Mark
P14636
P15751A03790
EM−32
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
24. REMOVE CYLINDER HEAD COVER
Remove the 10 bolts, cylinder head cover and gasket.
25. REMOVE SPARK PLUGS
26. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise and align its groove
with the ”0” mark on the timing chain cover.
(b) Check that the timing marks (1 and 2 dots) of the camshaft
drive and driven gears are in straight line on the cylinder
head surface as shown in the illustration. If not, turn the
crankshaft 1 revolution (360°) and align the marks as
above.
27. REMOVE CHAIN TENSIONER
Remove the 2 nuts, chain tensioner and gasket.
28. REMOVE CAMSHAFT TIMING GEAR
(a) Remove the 2 semi−circular plugs.
(b) Place the matchmarks on the camshaft timing gear and
No.1 timing chain.

Downloaded from www.Manualslib.com manuals search engine P14632
P14645
Main Gear
Sub Gear
Service
Bolt
Z11081
4
8
10
6
2
15973
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−33
1996 TOYOTA T100 (RM449U)
(c) Hold the exhaust camshaft with a wrench, remove the bolt
and distributor gear.
(d) Hold the intake camshaft with a wrench and remove the
bolt.
(e) Remove the camshaft timing gear and chain from the in-
take camshaft and leave on the slipper and damper.
29. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Remove exhaust camshaft.
(1) Bring a service bolt hole of the driven sub−gear up-
ward by turning the hexagon wrench head portion
of the exhaust camshaft with a wrench.
(2) Secure the exhaust camshaft sub−gear to the main
gear with a service bolt.
Recommended service bolt:
Thread diameter 6 mm (0.24 in.)
Thread pitch 1.0 mm (0.039 in.)
Bolt length 16 − 20 mm (0.63 − 0.79 in.)

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Z11082
1
25
69
107
83
4
P14675
P14911
EM−34
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub−gear has been eliminated by the above
operation.
(b) Uniformly loosen and remove the 10 bearing cap bolts in
several passes, in the sequence shown.
(c) Remove the 5 bearing caps and camshaft.
HINT:
If the camshaft is not being lifted out straight and level, reinstall
the No.3 bearing cap with the 2 bolts. Then alternately loosen
and remove the bearing cap bolts with the camshaft gear pulled
up.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(d) Remove intake camshaft.
(1) Uniformly loosen and remove 10 bearing cap bolts
in several passes, in the sequence shown.
(2) Remove the 5 bearing caps and camshaft.
HINT:
If the camshaft is not being lifted out straight and level, reinstall
the No.3 bearing cap with the 2 bolts. Then alternately loosen
and remove the 2 bearing cap bolts with the camshaft gear
pulled up.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
30. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.

Downloaded from www.Manualslib.com manuals search engine P14910
Service Bolt
SST
Turn
P14906
Z11080A03791
P14709
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−35
1996 TOYOTA T100 (RM449U)
(b) Using SST, turn the sub−gear clockwise, and remove a
service bolt.
SST 09960−10010 (09962−01000, 09963−00500)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove these parts:
(1) Wave washer
(2) Camshaft sub−gear
(3) Camshaft gear spring
31. REMOVE CYLINDER HEAD
(a) Remove the 2 bolts in front of the head before the other
head bolts are removed.

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P14721
EM−36
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(b) Uniformly loosen and remove the 10 cylinder head bolts,
in several passes, in the sequence shown.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
(c) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
head and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.

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P14702
SST
P14713
P14712
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−37
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in correct order.
2. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202−70020
(b) Remove the spring retainer, valve spring and valve.
(c) Using needle−nose pliers, remove the oil seal.
(d) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in correct order.