Page 3497 of 5135

A775031.0 to1.4mm75
45
A36626
A36627
A32645
14±42
± ENGINE MECHANICALCYLINDER HEAD ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(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) Recheck the valve seating position.
11. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts.
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
Intake 0.040 to 0.095 mm (0.0016 to 0.0037 in.)
Exhaust 0.080 to 0.135 m (0.0032 to 0.0053 in.)
Maximum thrust clearance:
Intake 0.11 mm (0.0043 in.)
Exhaust 0.15 mm (0.0059 in.)
(c) If the thrust clearance is greater than maximum, replace
the cylinder head. If the thrust surface is damaged, re-
place the camshaft.
12. 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.
Torque:
No. 1 30 Nm (301 kgfcm, 22 ftlbf)
No. 2 30 Nm (301 kgfcm, 22 ftlbf)
No. 3 9 Nm (92 kgfcm, 80 in.lbf)
NOTICE:
Do not turn the camshaft.
Page 3498 of 5135

A36628
A77460
Number Mark
Number Mark
EM0801
± ENGINE MECHANICALCYLINDER HEAD ASSY
14±43
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(e) Remove the bearing cap, and measure the Plastigage at
its widest point.
Standard oil clearance:
Intake No. 1 journal bearing mark 1
0.007 to 0.038 mm (0.0028 to 0.00150 in.)
Intake No. 1 journal bearing mark 2
0.008 to 0.038 mm (0.0031 to 0.00150 in.)
Intake No. 1 journal bearing mark 3
0.008 to 0.038 mm (0.0031 to 0.00150 in.)
Other journals
0.025 to 0.062 mm (0.00098 to 0.00244 in.)
Exhaust No. 1 journal
0.015 to 0.054 mm (0.0006 to 0.0021 in.)
Other journals
0.025 to 0.062 mm (0.00098 to 0.00244 in.)
Maximum oil clearance:
Intake No. 1 journal 0.07 mm (0.0028 in.)
Other journals 0.10 mm (0.0039 in.)
NOTICE:
Completely remove the Plastigage after the inspection.
(f) If the oil clearance is greater than maximum, replace the
camshaft. If necessary, replace the cylinder head.
(g) If the oil clearance on No. 1 journal is greater than maxi-
mum, replace the bearing.
HINT:
Cylinder head journal bore diameter:
Mark º1º40.000 to 40.008 mm (1.57480 to 1.57511 in.)
Mark º2º40.009 to 40.017 mm (1.57515 to 1.57547 in.)
Mark º3º40.018 to 40.025 mm (0.57551 to 1.57578 in.)
Standard bearing center wall thickness:
Mark º1º2.000 to 2.004 mm (0.07874 to 0.07890 in.)
Mark º2º2.005 to 2.008 mm (0.07894 to 0.07905 in.)
Mark º3º2.009 to 2.012 mm (0.07909 to 0.07921 in.)
Camshaft journal diameter:
35.971 to 35.985 mm (1.41648 to 1.41673 in.)
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.)
Page 3499 of 5135

A77461
Deviation
EM2534
A32770
A77462
Margin
Thickness
EM2534
14±44
± ENGINE MECHANICALCYLINDER HEAD ASSY
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(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 (4.0043 in.)
Minimum overall length: 101.21 mm (3.9846 in.)
(b) Check the diameter of the valve stem.
(1) Using a micrometer, measure the diameter of the
valve stem.
Valve stem diameter:
5.470 to 5.485 mm (0.2154 to 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 to 1.45 mm (0.041 to 0.057 in.)
Minimum margin thickness: 0.75 mm (0.030 in.)
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 (3.9823 in.)
Minimum overall length: 100.70 mm (3.9646 in.)
Page 3500 of 5135

Z00052
A77462
Margin
Thickness
A13367
A13367
A13100
± ENGINE MECHANICALCYLINDER HEAD ASSY
14±45
1AZ±FSE ENGINE REPAIR MANUAL (RM1019E)
(b) Check the diameter of the valve stem.
(1) Using a micrometer, measure the diameter of the
valve stem.
Valve stem diameter:
5.465 to 5.480 mm (0.2152 to 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 to 1.6 mm (0.047 to 0.063 in.)
Minimum margin thickness: 0.9 mm (0.035 in.)
16. INSPECT INTAKE VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing diameter.
Bushing inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the
guide bushing.
Standard oil clearance:
0.025 to 0.060 mm (0.00098 to 0.00236 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
17. INSPECT EXHAUST VALVE GUIDE BUSH
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing diameter.
Bushing inside diameter:
5.510 to 5.530 mm (0.2169 to 0.2177 in.)
(b) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
0.030 to 0.065 mm (0.0012 to 0.0026 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
18. REMOVE INTAKE VALVE GUIDE BUSH
(a) Gradually heat the cylinder head to 80 to 100C (176 to
212F).
Page 3501 of 5135

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 100C (176 to
212F).
(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.)
Page 3502 of 5135

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.)
Page 3503 of 5135
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.)
Page 3504 of 5135
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 Nm (51 kgfcm, 44 in.lbf)
Bolt B 5.0 Nm (51 kgfcm, 44 in.lbf)
Bolt C 9.5 Nm (97 kgfcm, 84 in.lbf)
Bolt D 9.5 Nm (97 kgfcm, 84 in.lbf)
27. INSTALL VALVE SPRING SEAT