1996 TOYOTA T100 engine

Downloaded from www.Manualslib.com manuals search engine P14632
P14685
Front Mark
P04668
Hook
Pin
P14683
Push EM−54
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
(b) Hold the intake camshaft with a wrench, install and torque
the bolt.
Torque: 73.5 N·m (750 kgf·cm, 54 ft·lbf)
(c) Hold the exhaust camshaft with a wrench, install the bolt
and distributor gear.
Torque: 46 N·m (465 kgf·cm, 34 ft·lbf)
7. INSTALL CHAIN TENSIONER
(a) Place a new gasket so that the front mark is toward the
front side.
(b) Release the ratchet pawl, fully push in the plunger and ap-
ply the hook to the pin so that the plunger cannot spring
out.
(c) Turn the crankshaft pulley clockwise to provide some
slack for the chain on the tensioner side.
NOTICE:
Do not turn the pulley counterclockwise.
(d) Push the tensioner by hand until it touches the head
installation surface, then install the 2 nuts.
(e) Tighten the 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(f) Check that the hook of the tensioner is not released.
NOTICE:
If the plunger springs out during installation of the chain
tensioner, repeat the operation in step (b) before installing
the tensioner.

Downloaded from www.Manualslib.com manuals search engine A01402
A01597
P14695
A01399
Dot Mark
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−55
1996 TOYOTA T100 (RM449U)
8. SET CHAIN TENSIONER
Turn the crankshaft to the left so that the hook of the chain ten-
sioner is released from the pin of the plunger, causing the plung-
er to spring out and the slipper to be pushed into the chain.
HINT:
If the plunger does not spring out, press the slipper into the
chain tensioner with a screwdriver or your finger so that the
hook is released and the plunger springs out.
9. CHECK VALVE TIMING
(a) Turn the crankshaft pulley, and align its groove with the
timing mark ”0” of the timing chain cover.
NOTICE:
Always turn the crankshaft clockwise.
(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.
10. CHECK AND ADJUST VALVE CLEARANCE (See page
EM−5)
Turn the camshaft and position the cam lobe upward and check
and adjust the valve clearance.
Valve clearance (Cold):
Intake
0.15 − 0.25 mm (0.006 − 0.010 in.)
Exhaust
0.25 − 0.35 mm (0.010 − 0.014 in.)
11. INSTALL SPARK PLUGS
Using a 16 mm plug wrench, install the spark plug.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)

Downloaded from www.Manualslib.com manuals search engine P03789
P14695
P14687
P14686
EM−56
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
12. INSTALL SEMI−CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head installation sur-
face of the semi−circular plugs.
Seal packing:
Part No. 08826−00080 or equivalent
(c) Install the semi−circular plug to the cylinder head.
13. 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) Check that the timing marks with 1 and 2 dots 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
mark as above.
14. INSTALL CYLINDER HEAD COVER
(a) Install the gasket to the cylinder head cover.
(b) Install the cylinder head cover with the 10 bolts.
Install the No.2 engine hanger and ground strap with the
bolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)
15. INSTALL NO.1 ENGINE HANGER
Install the No.1 engine hanger with the bolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)
16. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and exhaust manifold with the 6 nuts.
Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)
(b) Install the heat insulator with the 2 bolts and 2 nuts.
Torque: 5.5 N·m (55 kgf·cm, 48 in.·lbf)

Downloaded from www.Manualslib.com manuals search engine P15073
P22272
P24691
A02538
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−57
1996 TOYOTA T100 (RM449U)
17. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe assembly
with the 3 nuts.
Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the support bracket with the 2 bolts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect a new gasket and the front exhaust pipe assem-
bly to the TWC with the 2 bolts and retainer.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(e) Install camshaft position sensor.
18. INSTALL INTAKE MANIFOLD
Install a new gasket and intake manifold with the 3 bolts and 2
nuts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
19. INSTALL INJECTORS AND DELIVERY PIPE (See page
MF−21)
HINT:
When using a new cylinder head, spacers must be installed.
Apply a light coat of gasoline to a new O−ring a nd install it to
a new spacer.
20. INSTALL FUEL TUBE
Install the fuel inlet tube and 4 new gaskets with 2 union bolts.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
21. INSTALL AIR INTAKE CHAMBER
(a) Install a new gasket and the air intake chamber with the
3 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(b) Connect the vacuum hose to the gas filter.
(c) Connect the brake booster vacuum hose to the intake
camber.

Downloaded from www.Manualslib.com manuals search engine P24689
P14628
Z15935
P14635
EM−58
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
22. INSTALL FUEL RETURN PIPE
(a) Install the fuel return pipe with the 2 bolts.
(b) Connect these hoses:
Fuel return hose to fuel pressure regulator
Fuel return hose to fuel return pipe
23. INSTALL INTAKE CHAMBER STAY
Install the intake chamber stay with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
24. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket, EGR valve and vacuum modulator
with the bolt and 2 nuts.
Torque:
Bolt: 8.5 N·m (85 kgf·cm, 74 in.·lbf)
Nut: 19 N·m (195 kgf·cm, 14 ft·lbf)
(b) Connect these hoses:
2 vacuum hoses to EGR VSV (with clamp)
Water bypass hose to water bypass pipe
(c) Install 2 new gaskets and EGR pipe with the bolt and 4
nuts.
Torque:
Bolt: 18 N·m (185 kgf·cm, 14 ft·lbf)
Nut A: 19 N·m (195 kgf·cm, 14 ft·lbf)
Nut B: 20 N·m (200 kgf·cm, 15 ft·lbf)
25. INSTALL CYLINDER HEAD REAR COVER
(a) Install a new gasket and rear cover with the 3 bolts.
Torque: 13.5 N·m (135 kgf·cm, 10 ft·lbf)
(b) Connect the heater water bypass pipe.
26. CONNECT INJECTOR CONNECTORS
27. CONNECT ENGINE WIRE
(a) Connect the engine wire to the intake manifold with the
bolt.
(b) Connect the 2 engine wire clamps.
(c) Connect the DLC1 to the bracket.
(d) Connect these connectors:
Fuel pressure control VSV connector
Knock sensor connector
Crankshaft position sensor connector
(e) Connect the 5 engine wire clamps.
(f) Connect the engine wire to the intake chamber with the
2 bolts.
(g) Connect these connectors:
EGR VSV connector
EGR gas temperature sensor connector

Downloaded from www.Manualslib.com manuals search engine P15813
P15755SST
P14841
Adjusting Bolt
Look Bolt
P24651
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
EM−59
1996 TOYOTA T100 (RM449U)
ECT sensor connector
Oil pressure sensor connector
w/ A/C:
A/C compressor connector
28. INSTALL THROTTLE BODY (See page MF−30)
29. INSTALL WATER OUTLET
(a) Install a new gasket and water outlet with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Connect the ECT sender gauge connector.
(c) Connect the radiator inlet hose.
30. INSTALL IGNITION COIL.
31. INSTALL NO.1 AND NO.2 PCV HOSES
32. INSTALL PS PUMP AND BRACKET
(a) Install the PS pump bracket with the 4 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Connect the PS pump to the bracket with the 2 bolts.
Torque: 58 N·m (590 kgf·cm, 43 ft·lbf)
(c) Connect the 2 air hoses to the intake chamber.
(d) Using SST, install the PS pump pulley with the nut.
SST 09960−10010 (09962−01000, 09963−01000)
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
33. INSTALL PS PUMP DRIVE BELT AND IDLER
PULLEY
(a) Install the idler pulley with the 3 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Install and adjust drive belt (See page CH−2).
34. INSTALL AIR INTAKE CONNECTOR
(a) Install the air intake connector with the 2 bolts and hose
clamp.
(b) Connect the 2 air hoses.
35. M/T:
CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
36. A/T:
CONNECT THROTTLE AND ACCELERATOR CABLES
TO THROTTLE BODY

Downloaded from www.Manualslib.com manuals search engine P15087
EM−60
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
37. I N S TA L L M A F M E T E R , R E S O N ATO R A N D A I R
CLEANER CAP
(a) Connect the air cleaner hose clamp.
(b) Install the air cleaner cap, MAF meter and resonator with
the 4 clips.
(c) Connect the MAF meter connector, IAT sensor connector
and wire clamp.
38. FILL WITH ENGINE COOLANT
39. START ENGINE AND CHECK FOR LEAKS
40. CHECK IGNITION TIMING (See page EM−11)
41. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
42. RECHECK ENGINE COOLANT LEVEL

Downloaded from www.Manualslib.com manuals search engine EM07H−03
− ENGINE MECHANICAL (3RZ−FE)ENGINE UNIT
EM−61
776 Author: Date:
1996 TOYOTA T100 (RM449U)
ENGINE UNIT
COMPONENTS