TOYOTA AVENSIS 2005 Service Repair Manual

EM0801
A57493
Deviation
EM2534
A32770
A57494
Margin
Thickness 14±34
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
13. INSPECT INNER COMPRESSION SPRING
(a) Check the free length.
(1) Using vernier calipers, measure the free length of
the valve spring.
Free length: 45.7 mm (1.799 in.)
(b) Check the deviation.
(1) Using a steel square, measure the deviation of the
valve spring.
Maximum deviation: 1.6 mm (0.063 in.)
Maximum angle (reference): 2

14. INSPECT INTAKE VALVE
(a) Check the valve overall length.
(1) Using vernier calipers, measure the valve overall
length.
Standard overall length: 101.71 mm (4.0043in.)
Minimum overall length: 101.21 mm (3.9846in.)
(b) Check the diameter of the valve stem.
(1) Using a micrometer, measure the diameter of the
valve stem.
Valve stem diameter:
5.470 ± 5.485 mm (0.2154 ± 0.2159 in.)
(c) Check the valve head margin thickness.
(1) Using vernier calipers, measure the valve head
margin thickness.
Standard margin thickness:
1.05 ± 1.45 mm (0.041 ± 0.057 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)

EM2534
Z00052
A57494
Margin
Thickness
A13367
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
14±35
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
15. INSPECT EXHAUST VALVE
(a) Check the valve overall length.
(1) Using vernier calipers, measure the valve overall
length.
Standard overall length: 101.15 mm (3.9823in.)
Minimum overall length: 100.70 mm (3.9646 in.)
(b) Check the diameter of the valve stem.
(1) Using a micrometer, measure the diameter of the
valve stem.
Valve stem diameter:
5.465 ± 5.480 mm (0.2152 ± 0.2157 in.)
(c) Check the valve head margin thickness.
(1) Using vernier calipers, measure the valve head
margin thickness.
Standard margin thickness:
1.2 ± 1.6 mm (0.047 ± 0.063 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
16. INSPECT INTAKE VALVE GUIDE BUSHING
(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) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)

A13367
A13837
SST
A36632
A13837
SST
A36633
14±36
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
17. INSPECT EXHAUST VALVE 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) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
0.030 ± 0.065 mm (0.0012 ± 0.0026 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
18. REMOVE INTAKE VALVE GUIDE BUSHING
(a) Gradually heat the cylinder head to 80 ± 100
C (176 ±
212
F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±01055, 09950±70010 (09951±07100)
19. REMOVE EXHAUST VALVE GUIDE BUSHINGS
(a) Gradually heat the cylinder head to 80 ± 100
C (176 ±
212
F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±01055, 09950±70010 (09951±07100)

SST
A36634
SST
A36635
P16860
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
14±37
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
20. INSTALL INTAKE VALVE GUIDE BUSHING
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.285 ± 10.306 mm (0.4049 ± 0.4057 in.)
(b) Install the STD bushing if the diameter is within specified
diameter.
STD10.333 ± 10.344 mm (0.4068 ± 0.4072 in.)
(c) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
Protrusion height: 9.6 ± 10.0 mm (0.3779 ± 0.3937 in.)
SST 09201±01055, 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 ± 0.060 mm (0.00098 ± 0.00236 in.)
21. INSTALL EXHAUST VALVE GUIDE BUSHINGS
(a) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
Diameter: 10.285 ± 10.306 mm (0.4049 ± 0.4057 in.)
(b) Install the STD bushing if the diameter is within specified
diameter.
STD10.333 ± 10.344 mm (0.4068 ± 0.4072 in.)
(c) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
Protrusion height: 9.6 ± 10.0 mm (0.3779 ± 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±01055, 09950±70010 (09951±07100),
23801
Standard oil clearance:
0.030 ± 0.065 mm (0.00118 ± 0.00256 in.)
22. INSPECT VALVE LIFTER
(a) Check the lifter diameter.
(1) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 ± 30.976 mm (1.2191 ± 1.2195 in.)

A13374

mm
5.5
11 11
A57495
Upper Side 14±38
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(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 ± 31.025 mm (1.2208 ± 1.2215 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.033 ± 0.059 mm (0.0013 ± 0.0023 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
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 (0.2165 in.)

14
912
31.546.518
13
(M6) (M8)49.5
37.5
12
(M6) (M8) A
B C
D
[mm]
A57496
FrontUpper
Intake SideExhaust Side
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
14±39
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
24. INSTALL STUD BOLT
Torque:
Bolt A 5 N
m (51 kgf
cm, 44 in.
lbf)
Bolt B 5 N
m (51 kgf
cm, 44 in.
lbf)
Bolt C 10 N
m (97 kgf
cm, 84 in.
lbf)
Bolt D 10 N
m (97 kgf
cm, 84 in.
lbf)
25. INSTALL VALVE SPRING SEAT

A57497
Intake Side Exhaust Side
Gray
Black
SST
A36639
SST
A57498Wooden Blocks
A57499
Vinyl Tape
Valve Stem 14±40
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
26. 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. Assembling the wrong one may cause a failure.
HINT:
The intake valve oil seal is gray and the exhaust valve oil seal
is black.
(b) Using SST, push in a the oil seal.
SST 09201±41020
27. 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) Using a plastic±faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.

SST
A57500Wooden Blocks
A57499
Vinyl Tape
Valve Stem
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
14±41
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
28. 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)
(c) Using a plastic±faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to ensure a proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
29. INSTALL VALVE LIFTER
(a) Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied.
NOTICE:
Install the valve lifters originally placed.

4103Z±01
C83559
C83560
Matchmarks
C83561
C83562
41±78
±
MANUAL TRANSMISSION/TRANSAXLE DIFFERENTIAL CASE ASSY (E355/E356)
E355,E356 M/T REPAIR MANUAL (RM867E)
DIFFERENTIAL CASE ASSY (E355/E356)
OVERHAUL
HINT:
COMPONENTS: See page 41±1 1. REMOVE SPEEDOMETER DRIVE (MTM) GEAR
(a) Remove the speedometer drive (MTM) gear from front dif-ferential case assy.
2. REMOVE FRONT DIFFERENTIAL RING GEAR
(a) Place machmarks on the from the front differential ring gear and from the front differential case.
(b) Remove the 16 bolts. using a plastic hammer, remove the front differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH
(a) Fixing the front differential pinion to the front differential
case side. Using a dial indicator, measure the front differ-
ential side gear backlash.
Standard backlash: 0.05 ± 0.2 mm (0.0020 ± 0.0079 in.)

SST
C83563
C83564
C83565
C83566
C68517
± MANUAL TRANSMISSION/TRANSAXLEDIFFERENTIAL CASE ASSY (E355/E356)
41±79
E355,E356 M/T REPAIR MANUAL (RM867E)
4. REMOVE FRONT DIFFERENTIAL PINION SHAFT
STRAIGHT PIN
(a) Using SST and a hammer, loosen the stacked part of the
front differential case.
SST 09930±00010
(b) Using a pin punch and a hammer, remove the front differ-
ential pinion shaft straight pin from the front differential
case.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFT
NO.1
(a) Remove the front differential pinion shaft No.1 to the front
differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR
(a) Remove the 2 front differential pinions, 2 front differential
pinion thrust washers, 2 front differential side gear and 2
front differential side gear thrust washer No.1 from the
front differential case.
HINT:
Revolving front differential pinion, remove the 2 pinion thrust
washers and side gear thrust washers.
7. INSPECT FRONT DIFFERENTIAL PINION THRUST
WASHER
(a) Using a micrometer, measure the thickness of the front
differential pinion thrust washer.
Minimum thickness: 0.94 mm (0.03701 in)
If the thickness exceed the minimum, replace the front differen-
tial pinion thrust washer.