engine TOYOTA AVALON 2001 Service Repair Manual
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Page 1324 of 1897
A05275
- ENGINE MECHANICALCYLINDER HEAD
EM-41
1025 Author: Date:
2001 AVALON (RM808U)
4. REMOVE OIL CONTROL VALVE FILTER
Remove the plug, gasket and valve filter.
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INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYL-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high pressure compressed
air.
2. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
3. CLEAN COMBUSTION CHAMBERS
Using a wire brush, remove all the carbon from the combustion
chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
4. CLEAN CYLINDER HEADS
Using a soft brush and solvent, thoroughly clean the cylinder
head.
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1027 Author: Date:
2001 AVALON (RM808U)
5. CLEAN VALVE GUIDE BUSHINGS
Using a valve guide bushing brush and solvent, clean all the
guide bushings.
6. INSPECT FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder block and the manifolds for
warpage.
Maximum warpage: 0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake
ports, exhaust ports and cylinder block contact surface for
cracks.
If cracked, replace the cylinder head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.
Page 1327 of 1897
P12754
Z00052
Z00054
44.5°
EM0181
Margin Thickness EM-44
- ENGINE MECHANICALCYLINDER HEAD
1028 Author: Date:
2001 AVALON (RM808U)
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
5.510 - 5.530 mm (0.2169 - 0.2177 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake5.470 - 5.485 mm (0.2154 - 0.2159 in.)
Exhaust5.465 - 5.480 mm (0.2152 - 0.2157 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing guide bushing inside diameter measure-
ment.
Standard oil clearance:
Intake0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Exhaust0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing.
10. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.
Page 1328 of 1897
EM2534
Overall Length
EM0255
A05228
P12729
Width
Z03988
45°
1.0 - 1.4 mm30°
- ENGINE MECHANICALCYLINDER HEAD
EM-45
1029 Author: Date:
2001 AVALON (RM808U)
(d) Check the valve overall length.
Standard overall length:
Intake95.45 mm (3.5779 in.)
Exhaust95.40 mm (3.7559 in.)
Minimum overall length:
Intake94.95 mm (3.7382 in.)
Exhaust94.90 mm (3.7362 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
11. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with the following width:
1.0 - 1.4 mm (0.039 - 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.
Page 1329 of 1897
Z03989
45°
1.0 - 1.4 mm75°
P12705
EM0988
Deviation
EM0801
EM0281
EM-46
- ENGINE MECHANICALCYLINDER HEAD
1030 Author: Date:
2001 AVALON (RM808U)
(2) If the seating is too low on the valve face, use 75°
and 45° cutters to correct the seat.
(d) Hand-lap the valve and valve seat with an abrasive com-
pound.
(e) After hand-lapping, clean the valve and valve seat.
12. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
(b) Using vernier calipers, measure the free length of the
valve spring.
Free length: 45.50 mm (1.7913 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186 - 206 N (19.0 - 21.0 kgf, 41.9 - 46.3 lbf)
at 33.8 mm (1.331 in.)
If the installed tension is not as specified, replace the valve
spring.
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1031 Author: Date:
2001 AVALON (RM808U)
13. INSPECT CAMSHAFT FOR RUNOUT
(a) Place the camshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
14. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake42.932 - 43.032 mm (1.6902 - 1.6942 in.)
Exhaust42.764 - 42.864 mm (1.6836 - 1.6876 in.)
Minimum cam lobe height:
Intake42.78 mm (1.6842 in.)
Exhaust42.61 mm (1.6776 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
15. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 - 26.975 mm (1.0613 - 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
16. INSPECT CAMSHAFT BEARINGS
Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
Page 1331 of 1897
A05239
Plastigage
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- ENGINE MECHANICALCYLINDER HEAD
1032 Author: Date:
2001 AVALON (RM808U)
17. 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-
nal.
(d) Install the bearing caps. (See page EM-59)
Torque: 16 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:
Intake0.035 - 0.072 mm (0.0014 - 0.0028 in.)
Exhaust0.025 - 0.062 mm (0.0010 - 0.0024 in.)
Maximum oil clearance:
Intake0.10 mm (0.0039 in.)
Exhaust0.09 mm (0.0035 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.
(h) Remove the camshafts.
18. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts. (See page EM-59)
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.040 - 0.090 mm (0.0016 - 0.0035 in.)
Maximum thrust clearance: 0.12 mm (0.0047 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
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2001 AVALON (RM808U)
(c) Remove the camshafts.
19. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshafts without installing the exhaust cam
sub-gear (See page EM-59).
(b) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 - 0.200 mm (0.0008 - 0.0079 in.)
Maximum backlash: 0.30 mm (0.0188 in.)
If the backlash is greater then maximum, replace the cam-
shafts.
(c) Remove the camshafts.
20. INSPECT CAMSHAFT TIMING GEAR (VVT-i)
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
(b) Check that VVT-i will not turn.
(c) Cover the port except the port on the advance angle side
(nearest to the convex portion) shown in the illustration
with the vinyl tape.
(d) Using the air gun, apply about 100 kPa (1 kgf/cm
3, 14 psi)
of air pressure to the port on the advance side shown in
the illustration.
NOTICE:
When the oil is splashed, wipe it off with a shop lug and the
likes.
HINT:
Perform this in order to release the lock pin for the maximum
delay angle locking.
Standard: Must turn
HINT:
Depending on the air pressure, VVT-i will turn to the advance
angle side without applying force by hand. Also, under the
condition that the pressure can be hardly applied because of
the air leakage from the port, there may be the case that the lock
pin could be hardly released.
Page 1333 of 1897
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Free Distance
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1034 Author: Date:
2001 AVALON (RM808U)
(e) Under the condition of (d), turn VVT-i to the advance
angle side (the white arrow marked direction in the il-
lustration) with your hand.
(f) Except the position where the lock pin meets at the maxi-
mum delay angle, let VVT-i turn back and forth and check
the movable range and that there is no disturbance.
Standard: Movable smoothly in the range about 30°
(g) Turn VVT-i with your hand and lock it at the maximum
delay angle position.
21. INSPECT CAMSHAFT GEAR SPRING
Using vernier calipers, measure the free distance between the
spring ends.
Free distance: 18.2 - 18.8 mm (0.712 - 0.740 in.)
If the free distance is not as specified, replace the gear spring.
22. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.000 - 31.018 mm (1.2205 - 1.2212 in.)
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 - 30.976 mm (1.2191 - 1.2195 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.024 - 0.050 mm (0.0009 - 0.0020 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
23. INSPECT AIR INTAKE CHAMBER
Using a precision straight edge and feeler gauge, measure the
surface contacting the intake manifold for warpage.
Maximum warpage: 0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the chamber.