Page 3729 of 5135

1.0±1.4mm
45
30
A53031
1.0±1.4mm
75
45
A53032
A36626
A36627
14±32
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
10. REPAIR VALVE SEATS
NOTICE:
Take off a cutter gradually to make smooth 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 75and 45
cutters to correct the seat.
(c) Hand±lap the valve and valve sat with an abrasive com-
pound.
(d) Check 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 ± 0.095 mm (0.0016 ± 0.0037 in.)
Exhaust 0.080 ± 0.135 mm (0.0032 ± 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.
Page 3730 of 5135

A32645
A36628
A57492Number MarkNumber Mark
± ENGINE MECHANICALCYLINDER HEAD ASSY (1AZ±FE)
14±33
1AZ±FE ENGINE REPAIR MANUAL (RM865E)
(d) Install the bearing caps.
Torque:
29.5 Nm (300 kgfcm, 22 ftlbf) for No. 1
29.5 Nm (300 kgfcm, 22 ftlbf) for No. 2
9 Nm (90 kgfcm, 80 in.lbf) for No. 3
NOTICE:
Do not turn the camshaft.
(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 ± 0.038 mm (0.0028 ± 0.00150 in.)
Exhaust No. 1 journal
0.040 ± 0.079 mm (0.0016 ± 0.003 in.)
Other journals
0.025 ± 0.062 mm (0.00098 ± 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, choose and replace the bearing.
Cylinder head journal bore diameter
Mark º1º40.000 ± 40.008 mm (1.57480 ± 1.57511 in.)
Mark º2º40.009 ± 40.017 mm (1.57515 ± 1.57547 in.)
Mark º3º40.018 ± 40.025 mm (1.57551 ± 1.57578 in.)
Standard bearing center wall thickness
Mark º1º2.000 ± 2.004 mm (0.07874 ± 0.07890 in.)
Mark º2º2.005 ± 2.008 mm (0.07894 ± 0.07905 in.)
Mark º3º2.009 ± 2.012 mm (0.07909 ± 0.07921 in.)
Camshaft journal diameter
35.971 ± 35.985 mm (1.41648 ± 1.41673 in.)
Page 3731 of 5135

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.)
Page 3732 of 5135

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.)
Page 3733 of 5135
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 ± 100C (176 ±
212F).
(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 ± 100C (176 ±
212F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201±01055, 09950±70010 (09951±07100)
Page 3734 of 5135

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.)
Page 3735 of 5135
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.)
Page 3736 of 5135
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 Nm (51 kgfcm, 44 in.lbf)
Bolt B 5 Nm (51 kgfcm, 44 in.lbf)
Bolt C 10 Nm (97 kgfcm, 84 in.lbf)
Bolt D 10 Nm (97 kgfcm, 84 in.lbf)
25. INSTALL VALVE SPRING SEAT