1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine Z10936
Cylinder Head Side
Air Intake Chamber Side
P14622
P04666
Free
P04667
Lock EM−46
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
24. INSPECT INTAKE MANIFOLD
Using a precision straight edge and thickness gauge, measure
the surface contacting the cylinder head and air intake chamber
for warpage.
Maximum warpage: 0.20 mm (0.0078 in.)
If warpage is greater than maximum, replace the manifold.
25. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and thickness gauge, measure
the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 in.)
If warpage is greater than maximum, replace the manifold.
26. INSPECT CHAIN TENSIONER
(a) Check that the plunger moves smoothly when the ratchet
pawl is raised with your finger.
(b) Released the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushed with your finger.

Downloaded from www.Manualslib.com manuals search engine P14681
P22287
SST
0.5 − 2.5 mm
(0.020 − 0.098 in.)
A02827
Elongated
Thread
Measuring
Point
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−47
1996 TOYOTA T100 (RM449U)
27. IF NECESSARY, REPLACE SPARK PLUG TUBE GAS-
KETS
(a) Using a screwdriver, pry out the tube gasket.
(b) Using SST and a hammer, tap in a new tube gasket as
shown in the illustration.
SST 09950−60010 (09951−00260, 09951−00490),
09950−70010 (09951−07150)
(c) Apply a light coat of MP grease to the gasket lip.
28. INSPECT CYLINDER HEAD BOLTS
Using vernier calipers, measure the minimum diameter of the
elongate d thread at the measuring point.
Standard diameter:
10.76 − 10.97 mm (0.4236 − 0.4319 in.)
Minimum diameter:
10.40 mm (0.4094 in.)
If the diameter is less than minimum, replace the bolt.

Downloaded from www.Manualslib.com manuals search engine EM07D−02
Z11449
Protrusion
47.0 mm
Mark
P14649
Sealant
P14662
Protrusion
P14651
SST
EM−48
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Mark the standard position away from the edge, onto the
spark plug tube.
Standard protrusion: 47.0 mm (1.850 in.)
(b) Apply adhesive to the spark plug tube hole of the cylinder
head.
Sealant:
Part No.08833−00070, Adhesive 1324, THREE BOND
1324 or equivalent
(c) Using a press, press in a new spark plug tube until there
is 47.0 mm (1.850 in.) protruding from the camshaft bear-
ing cap installation surface of the cylinder head.
NOTICE:
Avoid pressing a new spark plug tube in too far by measur-
ing the amount of protrusion while pressing.
2. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09236−00101 (09236−15010)
HINT:
Different oil seals are used for the intake and exhaust.
Code mark (Intake side only): ”H”

Downloaded from www.Manualslib.com manuals search engine P14652
(4)
(3)
(2)
(1)
P14702
SST
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−49
1996 TOYOTA T100 (RM449U)
(b) Install these parts:
(1) Valve
(2) Spring seat
(3) Valve spring
(4) Spring retainer
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202−70020
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to ensure a proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

Downloaded from www.Manualslib.com manuals search engine P14680
Z10935
EM1OL−01
Z15489
90°
90°
Front
Painted Mark
P14709
EM−50
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Apply seal packing to the 2 locations as shown.
Seal packing:
Part No. 08826−00080 or equivalent
NOTICE:
Do not apply too much seal packing.
(b) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(c) Place the cylinder head in position on the cylinder head
gasket.
2. INSTALL CYLINDER HEAD BOLTS
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install and uniformly tighten the 10 cylinder head bolts
and plate washers in several passes, in the sequence
shown.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts by 90° in the numerical
order shown.
(e) Retighten the cylinder head bolts by an additional 90°.
(f) Check that the painted mark is now facing rearward.
(g) Install and torque the 2 mounting bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P14911
Z11078
(1) (2) (3)
P14906
P14910
Service Bolt
SST
Turn
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−51
1996 TOYOTA T100 (RM449U)
3. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install these parts:
(1) Camshaft gear spring
(2) Camshaft sub−gear
(3) Wave washer
HINT:
Align the pins on the gears with the spring ends.
(c) Using snap ring pliers, install the snap ring.
(d) Using SST, align the holes of the camshaft main gear and
sub−gear by turning sub−gear clockwise, and install a
service bolt.
SST 09960−10010 (09962−01000, 09963−00500)
4. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. 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, these
steps should be carried out.

Downloaded from www.Manualslib.com manuals search engine P14672
Straight Pin
P14711
P15749
7
3
1
5
98
4
2
6
10
P14699
Straight Pin
Aligh (Dot Mark)
P14701
EM−52
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(a) Install intake camshaft.
(1) Apply MP grease to the thrust portion of the intake
camshaft.
(2) Place the intake camshaft with knock pin facing up-
ward of camshaft angle on the cylinder head.
(3) Install the bearing caps in their proper locations.
(4) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(5) Install and uniformly tighten the 10 bearing cap
bolts in the sequence shown.
Torque: 15.5 N·m (160 kgf·cm, 12 ft·lbf)
(b) Install exhaust camshaft.
(1) Apply MP grease to the thrust portion of the exhaust
camshaft.
(2) Engage the exhaust camshaft gear to the intake
camshaft gear by matching the timing marks (1 and
2 dots) on each gear.
NOTICE:
There are also timing marks (for TDC) on each gear as
shown in the illustration. Do not use these marks.
(3) Roll down the exhaust camshaft onto the bearing
journals while engaging gears with each other.
(4) Install the bearing caps in their proper locations.

Downloaded from www.Manualslib.com manuals search engine P15748
7
3
1
5
98
4
2
6
10
Z11084
P14695
A01399
Dot Mark
P14698
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−53
1996 TOYOTA T100 (RM449U)
(5) Apply light coat of engine oil on the threads and un-
der the heads of the bearing cap bolts.
(6) Install and uniformly tighten the 10 bearing cap
bolts in several passes in the sequence shown.
(7) Remove a service bolt.
(8) Check that the intake and exhaust camshafts turn
smoothly.
5. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley clockwise, and align its groove
with the timing mark ”0” of the timing chain cover.
(b) Turn the camshafts so that the timing marks with one and
2 dots will be in straight line on the cylinder head surface
as shown in the illustration.
6. INSTALL CAMSHAFT TIMING GEAR
HINT:
Check that the matchmarks on the camshaft timing gear and
timing chain are aligned.
(a) Place the gear over the straight pin of the intake cam-
shaft.