TOYOTA AVENSIS 2005 Service Repair Manual

A77463
SST
A13100
A77464
SST
A77465
SST 14±46
± ENGINE MECHANICALCYLINDER HEAD ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±10000 (09201±01050), 09950±70010
(09951±07100)
19. REMOVE EXHAUST VALVE GUIDE BUSH
(a) Gradually heat the cylinder head to 80 to 100
C (176 to
212
F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±10000 (09201±01050), 09950±70010
(09951±07100)
20. INSTALL INTAKE VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.)
(b) Install the STD bushing if the diameter is within specified
diameter.
HINT:
STD10.333 to 10.344 mm (0.4068 to 0.4072 in.)
(c) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
Protrusion height: 9.6 to 10.0 mm (0.3779 to 0.3937
in.)
SST 09201±10000 (09201±01050), 09950±70010
(09951±07100), 23801
(d) Using a sharp 5.5 mm reamer, ream the guide bushing to
obtain the standard specified clearance between the
guide bushing and valve stem.
Standard oil clearance:
0.025 to 0.060 mm (0.00098 to 0.00236 in.)
21. INSTALL EXHAUST VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

A77466
SST
P16860
A13374
± ENGINE MECHANICALCYLINDER HEAD ASSY
14±47
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(b) Install the STD bushing if the diameter is within specified
diameter.
HINT:
STD10.333 to 10.344 mm (0.4068 to 0.4072 in.)
(c) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
Protrusion height: 9.6 to 10.0 mm (0.3779 to 0.3937
in.)
(d) Using a sharp 5.5 mm reamer, ream the guide bushing to
obtain the standard specified clearance between the
guide bushing and valve stem.
SST 09201±10000 (09201±01050), 09950±70010
(09951±07100), 23801
Standard oil clearance:
0.030 to 0.065 mm (0.00118 to 0.00256 in.)
22. INSPECT VALVE LIFTER
(a) Check the lifter diameter.
(1) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 to 30.976 mm (1.2191 to 1.2195 in.)
(b) Check the valve lifter oil clearance.
(1) Using a caliper gauge, measure the lifter bore diam-
eter of the cylinder head.
Lifter bore diameter:
31.009 to 31.025 mm (1.2208 to 1.2215 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.033 to 0.059 mm (0.0013 to 0.0023 in.)
Maximum oil clearance: 0.08 mm (0.0032 in.)

A77256
Upper Side
5.5
[mm]
A77257
Upper Side
[mm]
A77258
Exhaust Manifold Side
Seal Packing1.5 ± 2.5
(0.059 ± 0.098)
{mm (in.)} 14±48
± ENGINE MECHANICALCYLINDER HEAD ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
23. INSTALL RING W/HEAD PIN
(a) Using a plastic±faced hammer, tap in a new ring pin to the
specified protrusion height.
Protrusion height: 5.5 mm (0.217 in.)
24. INSTALL RING PIN
(a) Using a plastic±faced hammer, tap in a new ring pin to the
specified protrusion height.
Protrusion height: 6.5 mm (0.256 in.)
25. INSTALL TIGHT PLUG
(a) Apply seal packing to the cylinder head as shown in the
illustration.
(b) Using SST, tap in plug to the specified protrusion height.
SST 09950±60010 (09951±00180), 09950±70010
(09951±07100)
Protrusion height: 1.5 to 2.5 mm (0.059 to 0.098 in.)

A77259
FrontUpper
Intake Manifold Side
Exhaust Manifold Side
[mm]
± ENGINE MECHANICALCYLINDER HEAD ASSY
14±49
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
26. INSTALL STUD BOLT
Torque:
Bolt A 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Bolt B 5.0 N
m (51 kgf
cm, 44 in.
lbf)
Bolt C 9.5 N
m (97 kgf
cm, 84 in.
lbf)
Bolt D 9.5 N
m (97 kgf
cm, 84 in.
lbf)
27. INSTALL VALVE SPRING SEAT

A77467
Intake Side Exhaust Side
Gray
Black
A77468
SST
A77455
SST
Wooden Blocks
A77469
Vinyl Tape
Valve Stem
A77456
SST
Wooden Blocks 14±50
± ENGINE MECHANICALCYLINDER HEAD ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
28. INSTALL VALVE STEM OIL O SEAL OR RING
(a) Apply a light coat of engine oil on new valve stem seals.
NOTICE:
Pay much attention assembling the oil seal for intake and
exhaust. Installing the wrong one may cause improper
installation.
HINT:
The intake valve oil seal is gray and the exhaust valve oil seal
is black.
(b) Using SST, push in the oil seal.
SST 09201±41020
29. INSTALL INTAKE VALVE
(a) Install the parts below to the cylinder head.
1Intake valve
2Spring
3Retainer
(b) Using SST and wooden blocks, compress and install 2
valve spring retainer locks.
SST 09202±70020 (09202±00010)
(c) Wrap the tip of a discarded valve with vinyl tape, place the
discarded valve tip on the installed valve. Using a plastic±
faced hammer, lightly tap the discarded valve head to en-
sure proper fitting of the installed valve.
NOTICE:
Be careful not to damage the valve stem tip.
30. INSTALL EXHAUST VALVE
(a) Install the parts below to the cylinder head.
1Exhaust valve
2Spring
3Retainer
(b) Using SST and wooden blocks, compress and install 2
valve spring retainer locks.
SST 09202±70020 (09202±00010)

A77469
Vinyl Tape
Valve Stem
± ENGINE MECHANICALCYLINDER HEAD ASSY
14±51
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(c) Wrap the tip of a discarded valve with vinyl tape, place the
discarded valve tip on the installed valve. Using a plastic±
faced hammer, lightly tap the discarded valve head to en-
sure proper fitting of the installed valve.
NOTICE:
Be careful not to damage the valve stem tip.
31. INSTALL VALVE LIFTER
(a) Apply a light coat of engine oil on the valve lifter.
NOTICE:
Install the valve lifters to the original locations.

190OK±01
A80108
B09748
B09749
B09750
± STARTING & CHARGINGGENERATOR ASSY
19±9
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
OVERHAUL
1. REMOVE GENERATOR REAR END COVER
(a) Remove the 2 terminal covers by turning them counter-
clockwise.
(b) Remove the screw and 2 nuts, and then detach the gener-
ator rear end cover.
2. REMOVE REGULATOR SUB±ASSY GENERATOR
W/BRUSH
(a) Remove the 3 screws and the regulator sub±assy gener-
ator w/ brush.
3. REMOVE STATOR SUB±ASSY GENERATOR
W/RECTIFIRE
(a) Remove the 4 bolts.

B10446
B10014
B10015
B10452ContinuityOhmmeter
B10453
Ohmmeter
No Continuity 19±10
± STARTING & CHARGINGGENERATOR ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(b) Using a screwdriver, pry out the stator sub±assy genera-
tor w/rectifire.
4. REMOVE BEARING SET GENERATOR
5. REMOVE PULLEY SET GENERATOR
(a) Clamp the swivel arm in a vise.
NOTICE:
Be careful not to damage the fan.
(b) Using an impact wrench or internal serration on rotor shaft
end together with a torque wrench,remove the nut and
spring washer, then detach the pulley.
6. REMOVE GENERATOR ROTOR ASSY
(a) Using a press, press out the generator rotor assy and
spacer ring.
7. INSPECT GENERATOR ROTOR ASSY
(a) Inspect the generator rotor assy for open circuit.
(1) Using an ohmmeter, check that there is continuity
between the slip rings.
Standard resistance: 2.27 to 2.53
at 20
C (68
F)
If there is no continuity, replace the generator rotor assy.
(b) Inspect the generator rotor assy for ground.
(1) Using an ohmmeter, check that there is no continu-
ity between the slip ring and the generator rotor
assy.
If there is continuity, replace the generator rotor assy.

B00896
B09842
Rectifier Terminal Positive (+) Terminal
No ContinuityOhmmeter
B09843
Negative (±) Terminal
No ContinuityOhmmeter Rectifier Terminal
B09844ContinuityOhmmeter Rectifier Terminal
± STARTING & CHARGINGGENERATOR ASSY
19±11
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(c) Inspect the slip rings.
(1) Check that the slip rings are not rough or scored.
If rough or scored, replace the generator rotor assy.
(2) Using vernier calipers, measure the slip ring diame-
ter.
Standard diameter: 15.3 to 15.5 mm (0.602 to 0.610 in.)
Minimum diameter: 14.3 mm (0.561 in.)
If the diameter is less than minimum, replace the generator ro-
tor assy.
8. INSPECT STATOR SUB±ASSY GENERATOR
W/RECTIFIRE
(a) Inspect the positive (+) rectifier.
(1) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
(2) Reverse the polarity of the tester probes and repeat
step (1).
(3) Check that one shows continuity and the other
shows no continuity.
If result is not as specified, replace the stator sub±assy genera-
tor w/ rectifire.
(b) Inspect the negative (±) rectifier.
(1) Using an ohmmeter, connect one tester probe to
each negative (±) terminal and the other to each
rectifier terminal.
(2) Reverse the polarity of the tester probes and repeat
step (1).
(3) Check that one shows continuity and the other
shows no continuity.
If result is not as specified replace the stator sub±assy genera-
tor w/ rectifire.
(c) Inspect the stator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the rectifier terminals.
If there is no continuity, replace the stator sub±assy generator
w/ rectifire.

B09845
Length
B10019
SST
B10014
B09847
B09750
19±12
± STARTING & CHARGINGGENERATOR ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
9. INSPECT BRUSH
(a) Using vernier calipers, measure the brush length.
Standard exposed length:
11.0 to 13.6 mm (0.433 to 0.535 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the expose length is less than minimum, replace the voltage
regulator and the brush assembly.
10. INSTALL GENERATOR ROTOR ASSY
(a) Using SST and a press, press in the generator rotor assy.
SST 09285±76010
NOTICE:
Avoid misalignment during pressing
11. INSTALL PULLEY SET GENERATOR
(a) Clamp the rotor in a soft jaw vise.
(b) Install the pulley with the spring washer and nut.
Torque: 65 N
m (663 kgf
cm, 48 ft
lbf)
12. INSTALL BEARING SET GENERATOR
(a) Insert the fitting ring into in the position shown in the il-
lustration.
(b) Align the key of the fitting ring with the keyway of the stator
sub±assy generator w/ rectifire.
(c) Install the bearing.
13. INSTALL STATOR SUB±ASSY GENERATOR
W/RECTIFIRE
(a) Align the key of the drive end frame with the keyway of the
stator sub±assy generator w/ rectifire.
(b) Install the stator sub±assy generator w/ rectifire with the
4 bolts.
Torque: 3.5 N
m (36 kgf
cm, 31 in.
lbf)