1996 TOYOTA T100 engine bearings

Downloaded from www.Manualslib.com manuals search engine MA0099
OK if coolOK if hot
Add if coolAdd if hot
MA−12
− MAINTENANCECHASSIS
47 Author: Date:
1996 TOYOTA T100 (RM449U)
(f) Check that the fluid level is in the ”HOT” range at the nor-
mal operating temperature (70 − 80°C or 158 − 176°F)
and add as necessary.
NOTICE:
Do not overfill.
10. REPACK FRONT WHEEL BEARINGS AND THRUST
BUSH
(a) Change the front wheel bearing grease.
(2WD: See page SA−19)
(4WD: See page SA−25)
(b) Repack the drive shaft thrust bush grease (See page
SA−41).
11. 4WD:
LUBRICATE PROPELLER SHAFT
Lubricate propeller shaft, referring to the lubrication chart. Be-
fore pumping in grease, wipe off any mud and dust on the
grease fitting.
Grease grade:
Propeller shaft (Except Double−cardan joint)
Lithium base chassis grease NLGI No.2
Double−cardan joint
Molybdenum disulphide lithium base chassis grease
NLGI No.2

Downloaded from www.Manualslib.com manuals search engine P03976
P03977
EM3322
Free Distance
P14668
Plastigage
P14665
EM−44
− ENGINE MECHANICAL (3RZ−FE)CYLINDER HEAD
1996 TOYOTA T100 (RM449U)
15. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake
45.31 − 45.41 mm (1.7839 − 1.7878 in.)
Exhaust
45.06 − 45.16 mm (1.7740 − 1.7779 in.)
If the cam lobe height is less than standard allowable, replace
the camshaft.
16. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
17. INSPECT CAMSHAFT BEARING
Check the bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
18. INSPECT CAMSHAFT GEAR SPRING
Using a vernier caliper, measure the free distance between the
spring ends.
Free distance:
22.5 − 22.9 mm (0.886 − 0.902 in.)
If the free distance is not as specified, replace the gear spring.
19. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps (See page EM−50).
Torque: 15.5 N·m (160 kgf·cm, 12 ft·lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
Maximum oil clearance:
0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the Plastigage.

Downloaded from www.Manualslib.com manuals search engine P14772
P14773
P14776
P14777
Plastigage
P14781
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−77
1996 TOYOTA T100 (RM449U)
17. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.160 − 0.312 mm (0.0063 − 0.0123 in.)
Maximum thrust clearance:
0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
18. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Using a punch or numbering stamp, place the matchmark
on the connecting rod cap to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.
(c) Using a plastic−faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap with the 2 nuts (See page
EM−95).
Torque:
1st 45 N·m (460 kgf·cm, 33 ft·lbf)
2nd Turn 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD
0.030 − 0.055 mm (0.0012 − 0.0022 in.)
U/S 0.25
0.031 − 0.071 mm (0.0012 − 0.0026 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)

Downloaded from www.Manualslib.com manuals search engine Z10578
4, 5 or 6
P14783
EM−78
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with 1 having the same
number as marked on the bearing cap. There are 3 sizes of
standard bearings, marked ”4”, ”5”, ”6” accordingly.
Reference:
Connecting rod big end inside diameter:
STD Mark ”4”56.000 − 56.006 mm (2.2047 − 2.2050 in.)
STD Mark ”5”56.006 − 56.012 mm (2.2050 − 2.2052 in.)
STD Mark ”6”56.012 − 56.018 mm (2.2052 − 2.2054 in.)
U/S 0.2556.000 − 56.018 mm (2.2047 − 2.2054 in.)
Crankshaft crank pin diameter:
STD52.987 − 53.000 mm (2.0861 − 2.0866 in.)
U/S 0.2552.745 − 52.755 mm (2.0766 − 2.0770 in.)
Standard sized bearing center wall thickness:
STD Mark ”4”1.482 − 1.485 mm (0.0583 − 0.0585 in.)
STD Mark ”5”1.485 − 1.488 mm (0.0585 − 0.0586 in.)
STD Mark ”6”1.488 − 1.491 mm (0.0586 − 0.0587 in.)
U/S 0.251.601 − 1.607 mm (0.0630 − 0.0633 in.)
(k) Completely remove the Plastigage.
19. R E M O V E P I S TO N A N D C O N N E C T I N G R O D A S-
SEMBLIES
(a) Using a ridge reamer, remove the all carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in cor-
rect order.

Downloaded from www.Manualslib.com manuals search engine P14785
Z11077
6
10
82
1
5
9
7
3 4
P14787
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−79
1996 TOYOTA T100 (RM449U)
20. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance:
0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
2.440 − 2.490 mm (0.0961 − 0.0980 in.)
21. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts
in several passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the main bearing
caps, lower bearings and (No.3 main bearing cap only)
lower thrust washers.
HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and upper thrust washers together
with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.

Downloaded from www.Manualslib.com manuals search engine P14790
Plastigage
P14793
P14794
No.5
No.4
No.3
No.2
No.1Mark 1, 2 or 3
EM−80
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
1996 TOYOTA T100 (RM449U)
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps (See page EM−95).
Torque:
1st 39 N·m (400 kgf·cm, 29 ft·lbf)
2nd Turn 90°
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps (See procedure (a) and
(b) above).
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD
No.3
0.030 − 0.055 mm (0.0012 − 0.0022 in.)
Others
0.024 − 0.049 mm (0.0009 − 0.0019 in.)
U/S 0.25
No.3
0.030 − 0.070 mm (0.0012 − 0.0028 in.)
Others
0.025 − 0.065 mm (0.0010 − 0.0026 in.)
Maximum clearance:
0.10 mm (0.0039 in.)
HINT:
If the oil clearance is greater than maximum, replace the
bearings. If necessary, grind or replace the crankshaft.
If using a standard bearing, replace with 1 having the
same number as marked on the block. There are 3 sizes
of standard bearings, marked ”1”, ”2” and ”3” accordingly.
Reference:
Cylinder block main journal bore diameter:
STD Mark ”1”64.004 − 64.010 mm (2.5198 − 2.5201 in.)
STD Mark ”2”64.011 − 64.016 mm (2.5201 − 2.5203 in.)
STD Mark ”3”64.017 − 64.022 mm (2.5203 − 2.5205 in.)
U/S 0.2564.000 − 64.024 mm (2.5197 − 2.5206 in.)

Downloaded from www.Manualslib.com manuals search engine P14796
P14745
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−81
1996 TOYOTA T100 (RM449U)
Crankshaft Journal diameter:
STD NO.359.981 − 59.994 mm (2.2615 − 2.3620 in.)
STD Others59.987 − 60.000 mm (2.3617 − 2.3622 in.)
U/S 0.25 No.359.740 − 59.750 mm (2.3520 − 2.3524 in.)
U/S 0.25 Others59.745 − 59.755 mm (2.3522 − 2.3526 in.)
Bearing center wall thickness:
STD Mark ”1”1.987 − 1.990 mm (0.0782 − 0.0783 in.)
STD Mark ”2”1.991 − 1.993 mm (0.0784 − 0.0785 in.)
STD Mark ”3”1.994 − 1.996 mm (0.0785 − 0.0786 in.)
U/S 0.252.106 − 2.112 mm (0.0829 − 0.0831 in.)
(k) Completely remove the Plastigage.
22. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust wash-
ers from the cylinder block.
HINT:
Arrange the main bearings and thrust washers in correct order.
23. REMOVE CYLINDER BLOCK ORIFICE
24. CHECK THRUST CLEARANCES OF NO.1 AND NO.2
BALANCE SHAFTS OF ENGINE BALANCER
Using a dial indicator, measure the thrust clearance while mov-
ing the balance shaft back and forth.
Standard thrust clearance:
0.07 − 0.13 mm (0.0027 − 0.0051 in.)
Maximum thrust clearance:
0.2 mm (0.0079 in.)
If the thrust clearance is greater than maximum, replace the bal-
ance shaft thrust washer.
If necessary, replace the balance shaft.

Downloaded from www.Manualslib.com manuals search engine Z11076
P14762
P14760
P14764
P03870
− ENGINE MECHANICAL (3RZ−FE)CYLINDER BLOCK
EM−83
1996 TOYOTA T100 (RM449U)
(b) Remove these parts from balance shaft assembly:
(1) No.2 balance shaft
(2) No.2 balance shaft thrust prate
(3) Balance shaft timing sprocket
28. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
29. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the rings in correct order only.
30. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 − 90°C ( 176 − 194
°F).
(c) Using plastic−faced hammer and brass bar, lightly tap out
the piston pin and remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.