TOYOTA AVENSIS 2005 Service Repair Manual

140KN±01
A62780
SST
A62781
SST
14±28
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
OVERHAUL
1. REMOVE W/HEAD TAPER SCREW PLUG NO.2
(a) Using a socket hexagon wench 10, remove the taper screw plug and gasket.
2. REMOVE VALVE LIFTER
(a) Remove the 16 valve lifters from the cylinder head.
3. REMOVE INNER COMPRESSION SPRING
(a) Using SST, compress the valve spring and remove the 2
keepers, the retainer, and the spring seat.
SST 09202±70020 (09202±00010)
4. REMOVE INTAKE VALVE
(a) Remove the 8 intake valves from the cylinder head.
5. REMOVE EXHAUST VALVE
(a) Remove the 8 exhaust valves from the cylinder head.
6. REMOVE VALVE STEM OIL O SEAL OR RING
(a) Remove the 16 valve stem oil seals from the valve guide bush.
7. REMOVE VALVE SPRING SEAT
(a) Remove the 16 valve spring seats from the cylinder head.
8. REMOVE VALVE GUIDE BUSH
(a) Heat the cylinder head to 80 ± 100
C (176 ± 212
F).
(b) Using SST, tap out the valve guide bush.
SST 09201±10000, 09201±01055, 09950±70010
(09951±07100)
9. REMOVE STUD BOLT
(a) Remove the 11 stud bolts from the cylinder head.

A01075
A01071
A62782
A62783
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±29
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
10. INSPECT CYLINDER HEAD FOR FLATNESS
(a) Using a precision straight edge and a feeler gauge, mea-
sure the surface contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side0.05 mm (0.0020 in.)
Intake manifold side0.10 mm (0.0040 in.)
Exhaust manifold side0.10 mm (0.0040 in.)
11. INSPECT CYLINDER HEAD FOR CRACKS
(a) Using a dye penetrate, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
12. INSPECT VALVE GUIDE BUSHING OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
valve guide bush.
Busing 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:
Intake 5.470 ± 5.485 mm (0.2154 ± 0.2159 in.)
Exhaust 5.465 ± 5.480 mm (0.2152 ± 0.2158 in.)

A01445
EM0801
A62784
Deviation 14±30
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake 0.025 ± 0.060 mm (0.0010 ± 0.0024 in.)
Exhaust 0.030 ± 0.065 mm (0.0012 ± 0.0026 in.)
Maximum oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.01 mm (0.0039 in.)
13. INSPECT VALVE GUIDE BUSH
(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) If the bushing bore diameter of the cylinder head is great-
er than 10.306 mm (0.4057 in.), machine the bushing
bore to the dimension of 10.335 ± 10.356 mm (0.4068 ±
0.4077 in.) to install a over size bushing.
HINT:
bushing bore diameter
mm (in.)
Bushing size
10.285 ± 10.306
(0.4049 ± 0.4057)Use STD
10.335 ± 10.356
(0.4068 ± 0.4077)Use O/S 0.05
14. INSPECT INNER COMPRESSION SPRING
(a) Using a vernier caliper, measure the free length of the
valve spring.
Free length: 43.40 mm (1.7087 in.)
(b) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.078 in.)
Maximum angle (reference): 2

EM2534
A62785
Margin
Thickness
EM2534
A62785
Margin
Thickness
A62786
Width
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±31
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
15. INSPECT INTAKE VALVE
(a) Using a vernier calipers, check the valve overall length.
Standard overall length: 88.65 mm (3.4902 in.)
Minimum overall length: 88.35 mm (3.4784 in.)
(b) Using a vernier calipers, check the valve head margin
thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
16. INSPECT EXHAUST VALVE
(a) Using a vernier calipers, check the valve overall length.
Standard overall length: 88.69 mm (3.4917 in.)
Minimum overall length: 88.39 mm (3.4799 in.)
(b) Using a vernier calipers, check the valve head margin
thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.7 mm (0.028 in.)
17. INSPECT VALVE SEATS
(a) Apply a light coat of prussian blue (or white lead) to the
valve face.
(b) Lightly press the valve against the seat.
(c) Check the valve face and seat according to the following
procedure.
(1) If blue appears 360around the face, the valve is
concentric. If not, replace the valve.

A62787
1.0 ± 1.4 mm30
45

A62788
1.0 ± 1.4 mm60

45

P16860
A01080
14±32
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(2) If blue appears 360
around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the width between 1.0 ± 1.4 mm
(0.039 ± 0.055 in.).
18. REPAIR VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth valve seats.
(a) If the seating is too high on the valve face, use 30
and
45
cutters to correct the seat.
(b) If the seating is too low on the valve face, use 75
and 45

cutters to correct the seat.
(c) Hand±lap the valve and valve seat with an abrasive com-
pound.
(d) Check the valve seating position.
19. INSPECT VALVE LIFTER
(a) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 ± 30.976 mm (1.2191 ±1.2195 in.)
20. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.000 ± 31.025 mm (1.2205 ± 1.2215 in.)
(b) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.024 ± 0.059 mm (0.0009 ± 0.0023 in.)
Maximum oil clearance: 0.1 mm (0.0039 in.)

A01455
A62789
Plastigage
A01454
A01453
±
ENGINE MECHANICAL CYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±33
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
21. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the 2 camshafts.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.040 ± 0.095 mm (0.0016 ± 0.0037 in.)
Maximum thrust clearance: 0.110 mm (0.0043 in.)
(c) If the thrust clearance is greater than maximum, replace the cylinder head. If damages are found on the camshaft
thrust surfaces, the camshaft also has to be replaced.
22. INSPECT CAMSHAFT 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 14±4). Torque:
No. 1 23 N
m (235 kgf
cm, 17 ft
lbf)
No. 3 13 N
m (132 kgf
cm, 10 ft
lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the plastigage at its widest point.
Standard oil clearance:
0.035 ± 0.072 mm (0.0014 ± 0.0028 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
NOTICE:
Completely remove the Plastigage after the measuring.
If the oil clearance is greater than maximum, replace the cylin-
der head.

A62790
AB
F
D C
E
24.5
ABD
E C
F 168934.5
953.516.5
1238.522.5
1248.5
5 38.5 21.5
12
[mm]C Front side:
Exhaust side: Intake side:Upper side: 14±34
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
23. INSTALL STUD BOLT AND RING PIN
(a) Install the 11 stud bolts to cylinder head,
Torque:
Stud bolt A, D and E 9.5 N
m (97, 84 in.
lbf)
Stud bolt B and C 5.0 N
m (51, 44 in.
lbf)
(b) Using a plastic hammer, install the new 2 ring pins to the cylinder head.
Standard protrusion: 5 mm (0.020 in.)

A62791
14 mm
25 mm
9 mm A
B
C
A62792
Adhesive
A62793
B
A
C
A62794
SST
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±35
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
24. INSTALL UNION
(a) Mark the standard position away from the edge, onto the
water hose union as shown in the illustration.
(b) Apply adhesive to the water hose union hole of the cylin-
der head.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent.
(c) Using a press, press in a new water hose union until the
standard marks come to the level of the cylinder head sur-
face.
Standard protrusion:
A 29 mm (1.14 in.)
B 66.5 mm (2.62 in.)
C 24 mm (0.95 in.)
NOTICE:

Install the water hose union within 3 minutes after ap-
plying adhesive.

Do not put into coolant within an hour after installing.
25. INSTALL VALVE GUIDE BUSH
(a) Gradually heat the cylinder head to 80 ± 100C (176 ±
212F).
(b) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
SST 09201±10000, 09201±01055, 09950±70010
(09951±07100)
Protrusion height: 8.7 ± 9.1 mm (0.342 ± 0.358 in.)

A62795
Exhaust IntakeMark
ºNOKº
Black Surface
Gray Surface
A62796
SST
A01065
A62780
SST
A07307
14±36
± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
26. INSTALL VALVE STEM OIL O SEAL OR RING
(a) Apply a light coat of engine oil on the valve stem oil seals.
NOTICE:
Be very careful to assemble the oil seal for intake and ex-
haust. Assembling the wrong one may cause a failure.
HINT:
The intake valve stem oil seal is gray and the exhaust valve
stem oil seal is black.
(b) Using SST, push in a new valve stem oil seal.
SST 09201±41020
27. INSTALL INNER COMPRESSION SPRING
(a) Install the valve, spring seat, valve spring, and spring re-
tainer.
(b) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202±70020 (09202±00010)
(c) Using a plastic 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.

± ENGINE MECHANICALCYLINDER HEAD ASSY (1ZZ±FE/3ZZ±FE)
14±37
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
28. INSTALL W/HEAD TAPER SCREW PLUG NO.2
(a) Using a socket hexagon wrench 10, install the taper screw plug with a new gasket.
Torque: 44 N
m (449 kgf
cm, 33 ft
lbf)