Witam. W związku z niedawno poszukiwanymi informacjami na temat rozrządu w silniku 1,6 4A-FE samochodu Toyota Avensis, stałem się posiadaczem w/w wiadomości w formacie pdf. W artykułach zamieszczone są ilustrowane i opisane (niestety po angielsku) zagadnienia na temat budowy, ustawienia paska i wałków rozrządu, oraz czynności związane z regulacją luzu zaworów(niestety niekompletne). W opisie są pokazane wszystkie czynności, znaki na wałkach rozrządu i wszystko co po kolei należy ustawić, wykonać oraz sposób montażu i demontażu. Jak będę miał czas to wrzucę opis innych silników.
ENGINE MECHANICAL
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO/HC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . .
EM–1
EM–2
EM–4
EM–5
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . .
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .
EM–12
EM–13
EM–14
EM–28
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . .
EM–51
EM–1
ENGINE MECHANICAL
–
AIR FILTER
AIR FILTER
Out Side
EM0HP–04
INSPECTION
Inside
A14321
1AZ–FSE ENGINE (RM783E)
1.
REMOVE AIR FILTER
2.
INSPECT AIR FILTER
Visually check that the filter is not excessively dirty, oily or damaged.
3.
CLEAN AIR FILTER
Clean the filter element with compressed air. First blow from the
inside thoroughly. Then blow off the out side of the filter element.
4.
REINSTALL AIR FILTER
EM–2
ENGINE MECHANICAL
–
CO/HC
CO/HC
EM19V–04
INSPECTION
HINT:
This check is used only to determine whether or not the idle
CO/HC complies with specifications.
1.
INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
(f)
EFI system wiring connectors fully plugged
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i)
Tachometer and CO/HC meter calibrated by hand
2.
START ENGINE
3.
RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS
CO/HC Meter
A02622
1AZ–FSE ENGINE (RM783E)
4.
INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5.
CHECK CO/HC CONCENTRATION AT IDLE
Idle CO concentration: 0 – 0.5 %
Idle HC concentration: Applicable local regulation
If the CO/HC concentration does not conform to specifications,
perform troubleshooting in the order given below.
(1) Check the oxygen sensor operation (See page
FI–51).
(2) See the table next page for possible causes, and
then inspect and correct the applicable causes if
necessary.
EM–3
ENGINE MECHANICAL
CO
HC
–
CO/HC
Problems
Causes
Normal
High
Rough idle
2. Faulty ignitions:
S Incorrect timing
S Fouled, shorted or improperly gapped plugs
3. Incorrect valve clearance
4. Leaky intake and exhaust valves
5. Leaky cylinders
Low
High
Rough idle
(Fluctuating HC reading)
1. Vacuum leaks:
S PCV hoses
S Intake manifold
S Intake air control valve
S Throttle body
S Brake booster line
2. Lean mixture causing misfire
High
High
Rough idle
(Black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty EFI system:
S Faulty fuel pressure release valve
S Faulty fuel pressure sensor
S Faulty water temperature sensor
S Faulty engine ECU
S Faulty injectors
S Faulty accelerator pedal position sensor
S Faulty vacuum sensor
1AZ–FSE ENGINE (RM783E)
EM–4
ENGINE MECHANICAL
–
COMPRESSION
COMPRESSION
EM19W–03
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1.
WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2.
REMOVE IGNITION COILS (See page IG–5)
3.
REMOVE SPARK PLUGS
Compression Gauge
A14226
1AZ–FSE ENGINE (RM783E)
4.
(a)
(b)
(c)
INSPECT CYLINDER COMPRESSION PRESSURE
Insert a compression gauge into the spark plug hole.
Fully open the throttle.
While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as possible.
Compression pressure:
1,470 kPa (15.0 kgf/cm2, 213 psi)
Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm2, 15 psi) or less
(e) If the cylinder compression in one more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
S
If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
S
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage
through the gasket.
5.
REINSTALL SPARK PLUGS
6.
REINSTALL IGNITION COILS (See page IG–5)
EM–5
ENGINE MECHANICAL
–
VALVE CLEARANCE
VALVE CLEARANCE
EM1JT–01
ADJUSTMENT
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1.
REMOVE FUEL PUMP (HIGH PRESSURE)
(See page FI–13)
2.
REMOVE IGNITION COILS
3.
DISCONNECT NO. 1 PCV HOSE FROM PCV VALVE
4.
REMOVE VSV FOR INTAKE AIR CONTROL VALVE
Remove the bolt and VSV.
5.
REMOVE CYLINDER HEAD COVER
(See page EM–15)
6.
(a)
SET NO. 1 CYLINDER TO TDC/COMPRESSION
Turn the crankshaft pulley, and align its groove with the
timing mark 0 of the timing chain cover.
A13901
(b)
Timing
Marks
Timing Marks
Check that the timing marks of the camshaft timing
sprocket and VVT timing sprocket are aligned with the
timing marks of the No. 1 and No. 2 bearing caps as
shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks as above.
A13902
1 1
1 1
7.
(a)
2 2
3 3
1AZ–FSE ENGINE (RM783E)
A14188
INSPECT VALVE CLEARANCE
Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
EM–6
ENGINE MECHANICAL
–
VALVE CLEARANCE
(2)
Record the out–of–specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting valve lifter.
Valve clearance (Cold):
Intake
0.19 – 0.29 mm (0.007 – 0.011 in.)
Exhaust
0.30 – 0.40 mm (0.012 – 0.016 in.)
(b)
(c)
ADJUST VALVE CLEARANCE
Set the No. 1 cylinder to the TDC/compression (See step
2).
Place matchmarks on the timing chain, VVT timing
sprocket and camshaft timing sprocket.
Remove the 2 nuts, gasket and chain tensioner.
4 4
4 4
2 2
Check only the valves indicated as shown. Measure the
valve clearance (See step (a)).
8.
(a)
3 3
Turn the crankshaft 1 revolution (360°) and align the mark
as above (See step 2).
A14187
(b)
(c)
Matchmarks
A13690
(d)
Hold the hexagonal head portion of the camshaft with a
wrench, and loosen the camshaft timing sprocket set bolt.
NOTICE:
Be careful not to damage the cylinder head and valve lifter
with the wrench.
A14263
(e)
(f)
1
2
5
9
7
3
6
10
8
4
1AZ–FSE ENGINE (RM783E)
A14189
Uniformly loosen and remove the 10 camshaft bearing
cap bolts in several passes and in the sequence shown.
Remove the 5 camshaft bearing caps.
EM–7
ENGINE MECHANICAL
(g)
(h)
(i)
–
VALVE CLEARANCE
Raising the camshaft, remove the camshaft timing
sprocket set bolt.
Disconnect the camshaft timing sprocket with the timing
chain from the exhust camshaft.
Remove the camshaft timing sprocket from the timing
chain.
A14227
1
(j)
5
9
7
3
(k)
(l)
2
6
10
8
Uniformly loosen and remove the 10 camshaft bearing
cap bolts in several passes and in the sequence shown.
Remove the 5 camshaft bearing caps.
Remove the intake camshaft with the VVT timing sprocket.
4
A14190
(m) Tie the timing chain as shown in the illustration.
NOTICE:
S
Be careful not to drop anything inside the timing
chain cover.
S
Do not allow the chain to come into contact with water
or dust.
(n) Remove the valve lifter.
Valve Lifter
A13693
(o)
A01082
Determine the replacement valve lifter size according to
these Formula or Charts:
S
Using a micrometer, measure the thickness of the
removed valve lifter.
S
Calculate the thickness of a new valve lifter so the
valve clearance comes within the specified value.
T .......... Thickness of used valve lifter
A ......... Measured valve clearance
N ......... Thickness of new valve lifter
Intake
N = T + (A – 0.24 mm (0.009 in.))
Exhaust
N = T + (A – 0.35 mm (0.014 in.))
S
Select a new valve lifter with a thickness as close as
possible to the calculated values.
HINT:
S
1AZ–FSE ENGINE (RM783E)
Valve lifters are available in 35 sizes in increments of
0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to
5.740 mm (0.2260 in.).
EM–8
ENGINE MECHANICAL
S
–
VALVE CLEARANCE
(p)
Identification number inside the valve lifter shows the value of the two decimal places. (The illustration shows
5.380 mm (0.2118 in.).)
Apply a light coat engine oil to new valve lifters.
(q)
Reinstall the valve lifters.
A08425
Valve Lifter
A13693
(r)
A13696
7
3
1
5
9
4
2
6
10
A
8
A14190
1AZ–FSE ENGINE (RM783E)
Align the crankshaft pulley groove with the timing mark 0
of the timing chain cover.
(s) Hold the timing chain.
(t)
Align the matchmarks on the timing chain and VVT timing
sprocket, and place the intake camshaft on the cylinder
head.
(u) Apply a light coat engine oil on the threads and under the
camshaft bearing cap bolts.
(v) Install the 5 intake camshaft bearing caps in their proper
locations (See page EM–47).
(w) Uniformly tighten the 10 bearing cap bolts in several
passes and in the sequence shown.
Torque:
29.5 N·m (300 kgf·cm, 22 ft·lbf) for bolt A
9 N·m (90 kgf·cm, 80 in.·lbf) for others
(x) Align the matchmarks on the timing chain and camshaft
timing sprocket, and install them.
(y) Temporarily install the camshaft timing sprocket with timing chain to the exhaust camshaft with the bolt.
(z) Place the exhaust camshaft on the cylinder head.
(aa) Apply a light coat engine oil on the threads and under the
camshaft bearing cap bolts.
(ab) Install the 5 exhaust camshaft bearing caps in their proper
locations (See page EM–47).
EM–9
ENGINE MECHANICAL
7
3
1
5
2
6
10
VALVE CLEARANCE
(ac) Uniformly tighten the 10 bearing cap bolts in several
passes and in the sequence shown.
Torque:
29.5 N·m (300 kgf·cm, 22 ft·lbf) for bolt A
9 N·m (90 kgf·cm, 80 in.·lbf) for others
9
4
–
A
8
A14189
(ad) Hold the hexagon head portion of the exhaust camshaft
with a wrench, and tighten the bolt.
Torque: 54 N·m (550 kgf·cm, 40 ft·lbf)
A14263
Matchmarks
A13690
1AZ–FSE ENGINE (RM783E)
(ae) Check each sprocket aligns with the matchmarks as
shown in the illustration.
(af) Install the chain tensioner (See page EM–20).
(ag) Recheck the valve clearance (See step 7).
(ah) Check the valve timing (See page EM–20).
9.
REINSTALL CYLINDER HEAD COVER
(See page EM–20)
10. REINSTALL VSV FOR INTAKE AIR CONTROL VALVE
Install the VSV with the bolt.
11. RECONNECT NO. 1 PCV HOSE
12. REINSTALL IGNITION COILS
13. REINSTALL FUEL PUMP (HIGH PRESSURE)
(See page FI–14)
1AZ–FSE ENGINE (RM783E)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
34
36
38
40
42
44
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
10
12
14
16
18
20
5.460 (0.2150)
5.280 (0.2079)
52
5.520 (0.2173)
5.500 (0.2165)
50
5.260 (0.2071)
26
5.480 (0.2157)
48
5.240 (0.2063)
24
28
5.360 (0.2110)
46
5.220 (0.2055)
5.320 (0.2094)
32
5.080 (0.2000)
08
22
5.300 (0.2087)
30
5.060 (0.1992)
06
5.340 (0.2102)
Thickness
Thickness
74
72
70
68
66
64
62
60
58
56
54
Lifter
No.
5.740 (0.2260)
5.720 (0.2252)
5.700 (0.2244)
5.680 (0.2236)
5.660 (0.2228)
5.640 (0.2220)
5.620 (0.2213)
5.600 (0.2205)
5.580 (0.2197)
5.560 (0.2189)
5.540 (0.2181)
Thickness
mm (in.)
–
Lifter
No.
Lifter
No.
New Valve Lifter Thickness
ENGINE MECHANICAL
Intake valve clearance (Cold):
0.19 – 0.29 mm (0.007 – 0.011 in.)
EXAMPLE: The 5.250 mm (0.2067 in.) valve lifter is installed, and
the measured clearance is 0.400 mm (0.0157 in.).
Replace the 5.250 mm (0.2067 in.) valve lifter with a new No. 42 valve lifter.
Valve Lifter Selection Chart (Intake)
EM–10
VALVE CLEARANCE
A13314
1AZ–FSE ENGINE (RM783E)
68 5.680 (0.2236)
70 5.700 (0.2244)
72 5.720 (0.2252)
36 5.360 (0.2110)
38 5.380 (0.2118)
40 5.400 (0.2126)
42 5.420 (0.2134)
44 5.440 (0.2142)
46 5.460 (0.2150)
48 5.480 (0.2157)
50 5.500 (0.2165)
52 5.520 (0.2173)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
12
14
16
18
20
22
24
26
28
5.660 (0.2228)
74 5.740 (0.2260)
66
64 5.640 (0.2220)
62 5.620 (0.2213)
60 5.600 (0.2205)
58 5.580 (0.2197)
34 5.340 (0.2102)
Thickness
5.100 (0.2008)
08
10
5.060 (0.1992)
06
56 5.560 (0.2189)
No.
Lifter
32 5.320 (0.2094)
Thickness
5.080 (0.2000)
No.
Lifter
54 5.540 (0.2181)
Thickness
30 5.300 (0.2087)
No.
Lifter
New Valve Lifter Thickness mm (in.)
–
Exhaust valve clearance (Cold):
0.30 – 0.40 mm (0.012 – 0.016 in.)
EXAMPLE: The 5.340 mm (0.2102 in.) valve lifter is installed, and
the measured clearance is 0.440 mm (0.0173 in.).
Replace the 5.340 mm (0.2102 in.) valve lifter with a new No. 42 lifter.
Valve Lifter Selection Chart (Exhaust)
ENGINE MECHANICAL
VALVE CLEARANCE
EM–11
A13315
EM–12
ENGINE MECHANICAL
–
IGNITION TIMING
IGNITION TIMING
EM1K2–01
INSPECTION
1.
REMOVE NO. 1 ENGINE COVER
2.
WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
3.
CHECK IDLE SPEED (See page EM–13)
4.
CONNECT TIMING LIGHT
Connect the tester clip of a timing light to the black service wire
of the wire harness as shown in the illustration.
NOTICE:
After using the service wire, be sure to fix it with a vinyl
tape.
Black
A14315
5.
(a)
TC
INSPECT IGNITION TIMING
Using SST, connect terminals to TC and CG of the DLC3.
SST 09843–18040
HINT:
After engine rpm is kept at 900 – 1,500 rpm for 5 seconds, check
that it returns to idle speed.
SST
DLC3
CG
A14196
(b)
(c)
6.
A14197
1AZ–FSE ENGINE (RM783E)
Using a timing light, check the ignition timing.
Ignition timing: 8 – 12° BTDC @ idle
Remove the SST from the DLC3.
FURTHER CHECK IGNITION TIMING
Ignition timing: 5 – 23° BTDC @ idle
HINT:
The timing mark moves in a range between 5° and 23°.
7.
DISCONNECT TIMING LIGHT
8.
REINSTALL NO. 1 ENGINE COVER
EM–13
ENGINE MECHANICAL
–
IDLE SPEED
IDLE SPEED
EM1JS–01
INSPECTION
1.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
Hand–held
Tester
INITIAL CONDITIONS
Engine at normal operating temperature
Air cleaner installed
All pipes and hoses of air induction system connected
All vacuum lines properly connected
EFI system wiring connectors fully plugged
All operating accessories switched OFF
Ignition timing check correctly
Transmission in neutral position
Air conditioner switched OFF
2.
(a)
(b)
CONNECT HAND–HELD TESTER
Connect the hand–held tester to the DLC3.
Please refer to the hand–held tester operator’s for further
details.
DLC3
A14194
Tachometer
TAC
DLC3
SST
1AZ–FSE ENGINE (RM783E)
Battery
A14195
If you do not have hand–held tester, connect a tachometer tester probe to terminal TAC of the DLC3 with SST.
SST 09843–18030
3.
INSPECT IDLE SPEED
(a) Race the engine at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed (w/ Cooling fan OFF): 675 ± 50 rpm
If the idle speed is not as specified, check the throttle body and
air intake system.
4.
DISCONNECT HAND–HELD TESTER
EM–14
ENGINE MECHANICAL
–
TIMING CHAIN
TIMING CHAIN
EM1A0–04
COMPONENTS
25 (255, 18)
Fuel Pump
z Insulator
No. 1 PCV Hose
VSV for Intake Air Control Valve
Ignition Coil
Timing Tensioner
11 (110, 8)
z Gasket
21 (215, 15)
9 (90, 80 in.·lbf)
14 (145, 10)
Crankshaft
Position
Sensor
9 (90, 80 in.·lbf)
Drive Belt Tensioner
11 (110, 8)
x5
43 (440, 32)
59.5 (610, 44)
*1
*2
Cylinder Head Cover
*3
59.5 (610, 44)
x8
21 (220,15)
z O–Ring
9 (90, 80 in.·lbf)
Crankshaft Timing Chain Cover
Front Oil Seal
VVT Timing Sprocket
Crankshaft
Pulley
54 (550, 40)
Gasket
170 (1,735, 125)
Chain Tensioner
Timing Chain
Slipper
Camshaft
Timing Sprocket
54 (550, 40)
Timing Chain Guide
19 (195, 14)
Alternator
9 (90, 80 in.·lbf)
*1:
43 (440, 32)
*2:
9 (90, 80 in.·lbf)
*3:
9.5 (100, 7)
Crankshaft Timing
Sprocket
Chain Vibration
Damper
x4
9 (90, 80 in.·lbf)
Oil Pan
Crank Angle
Sensor Plate
Oil Pan
N·m (kgf·cm, ft·lbf) : Specified torque
z Non–reusable part
1AZ–FSE ENGINE (RM783E)
52 (530, 38)
9 (90, 80 in.·lbf)
x 12
21 (215, 15)
9 (90, 80 in.·lbf)
A14318
EM–15
ENGINE MECHANICAL
–
TIMING CHAIN
EM1JU–01
REMOVAL
45°
A14319
NOTICE:
Under the condition with the timing chain cover removed,
in case of rotating the camshafts, make the position of the
crankshaft rotated clockwise by about 45° from TDC/comĆ
pression of No. 1 cylinder.
1.
DRAIN ENGINE OIL
2.
REMOVE ALTERNATOR
Remove the 2 bolts and alternator.
3.
REMOVE FUEL PUMP (HIGH PRESSURE)
(See page FI–13)
4.
REMOVE IGNITION COILS
5.
DISCONNECT NO. 1 PCV HOSE FROM PCV VALVE
6.
REMOVE VSV FOR INTAKE AIR CONTROL VALVE
Remove the bolt and VSV.
7.
REMOVE CYLINDER HEAD COVER
Remove the 9 bolts, 2 nuts, cylinder head cover and gasket.
A14260
8.
(a)
SET NO. 1 CYLINDER TO TDC/COMPRESSION
Turn the crankshaft pulley, and align its groove with timing
mark 0 of the timing chain cover.
A13696
(b)
Timing
Marks
Timing Marks
A13902
1AZ–FSE ENGINE (RM783E)
Check that the timing marks of the camshaft timing
sprocket and VVT timing sprocket are aligned with the
timing marks of the No. 1 and No. 2 bearing caps as
shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks as above.
EM–16
ENGINE MECHANICAL
9.
(a)
(b)
–
TIMING CHAIN
REMOVE CRANKSHAFT PULLEY
Using SST, remove the pulley bolt.
SST 09213–54015, 09330–00021
Remove the crankshaft pulley.
SST
SST
A13697
SST
SST
HINT:
If necessary, remove the pulley with SST.
SST 09950–40011 (09957–04010), 09950–50012
(09951–05010, 09952–05010, 09953–05020,
09954–05020)
10. REMOVE CRANKSHAFT POSITION SENSOR
(See page IG–7)
11. REMOVE OIL PAN (See page LU–7)
A14223
12. REMOVE CHAIN TENSIONER
Remove the 2 nuts, chain tensioner and gasket.
Push
A14261
13. REMOVE DRIVE BELT TENSIONER
Remove the bolt, nut and drive belt tensioner.
A13759
A14221
14.
(a)
Trox Socket
Wrench
A14253
1AZ–FSE ENGINE (RM783E)
REMOVE TIMING CHAIN COVER
Using a trox socket wrench (E10), remove the stud bolt for
the drive belt tensioner.
EM–17
ENGINE MECHANICAL
–
TIMING CHAIN
(b)
(c)
Remove the 14 bolts and 2nuts.
Using a screwdriver, pry between the timing chain cover
and cylinder head or cylinder block.
(d) Remove the timing chain cover.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder head and cylinder block.
15. REMOVE CRANK ANGLE SENSOR PLATE
16. REMOVE CHAIN TENSIONER SLIPPER
Remove the bolt and slipper.
17. REMOVE CHAIN VIBRATION DAMPER
Remove the 2 bolts and damper.
Pry
A14271
18. REMOVE TIMING CHAIN GUIDE
Remove the bolt and chain guide.
19. REMOVE TIMING CHAIN
20. REMOVE CRANKSHAFT TIMING SPROCKET
A13769
21.
A14264
1AZ–FSE ENGINE (RM783E)
REMOVE CAMSHAFT TIMING SPROCKET AND VVT
TIMING SPROCKET
(a) Hold the hexagonal head wrench portion of the camshaft
with a wrench, and loosen the sprocket set bolts.
NOTICE:
Be careful not to damage the cylinder head and valve lifter
by a wrench.
(b) Remove the bolt and camshaft timing sprocket.
(c) Remove the bolt and VVT timing sprocket.
NOTICE:
Do not disassemble the VVT timing sprocket.
EM–18
ENGINE MECHANICAL
–
TIMING CHAIN
EM1A2–03
INSPECTION
1.
(a)
122.6 mm
16 Links
P04776
INSPECT TIMING CHAIN AND TIMING SPROCKETS
Using vernier calipers, measure the length of the 16 links
with the chain fully stretched.
Maximum chain elongation: 122.6 mm (4.827 in.)
If the elongation is greater than maximum, replace the chain.
HINT:
Make the same pulling measurements at 3 or more places selected at random.
(b)
(c)
Wrap the chain around the timing sprocket.
Using vernier calipers, measure the timing sprocket diameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for measuring.
Minimum sprocket diameter (w/ Chain):
Camshaft
97.3 mm (3.831 in.)
Crankshaft
EM2378
51.6 mm (2.031 in.)
If the diameter is less than minimum, replace the chain and
sprockets.
2.
INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER
Measure the chain tensioner slipper and vibration damper
wears.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the slipper and/or
damper.
Wear
A13770
3.
(a)
Raise
Move
Lock
A13765
1AZ–FSE ENGINE (RM783E)
INSPECT CHAIN TENSIONER
Check that the plunger moves smoothly when the ratchet
pawl is raised with your finger.
(b) Release the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushed with your finger.
4.
INSPECT OIL JET (See page LU–9)
5.
INSPECT DRIVE BELT TENSIONER
Check the oil leakage and crack.
If necessary, replace the drive belt tensioner.
EM–19
ENGINE MECHANICAL
–
TIMING CHAIN
EM1JV–01
REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a)
If the timing chain cover is removed from the cylinder
head and block.
(1) Using a screwdriver and a hammer, tap out the oil
seal.
A13766
(2)
Using SST and a hammer, tap in a new oil seal until
its surface is flush with the timing chain cover edge.
SST 09309–37010
(3) Apply MP grease to the oil seal lip.
SST
A13767
(b)
SST
If the timing chain cover is installed to the cylinder head
and block.
(1) Using SST, remove the oil seal.
SST 09308–10010, 09950–40011 (09957–04010)
SST
A14273
(2)
Using SST and a hammer, tap in a new oil seal until
its surface is flush with the timing chain cover edge.
SST 09309–37010
SST
A13737
1AZ–FSE ENGINE (RM783E)
EM–20
ENGINE MECHANICAL
–
TIMING CHAIN
EM1A4–02
INSTALLATION
1.
(a)
Timing Mark
A14279
INSTALL CAMSHAFT TIMING SPROCKET AND VVT
TIMING SPROCKET
Install the camshaft timing sprocket.
(1) Face the timing mark of the sprocket outward.
(2) Align the exhaust camshaft knock pin with the
knock pin groove on the camshaft timing sprocket
with the timing mark, and slide on the camshaft timing sprocket.
(3) Temporary install the camshaft timing sprocket set
bolt.
(4)
Hold the hexagon wrench head portion of the exhaust camshaft with a wrench, and tighten the bolt.
Torque: 54 N·m (550 kgf·cm, 40 ft·lbf)
A14265
(b)
Timing Mark
A14268
1AZ–FSE ENGINE (RM783E)
Install the VVT timing sprocket.
(1) Holding the VVT timing sprocket in the position
where the VVT timing sprocket knock pin groove is
slightly to right of the camshaft pin looking from the
front side, install the VVT timing sprocket to the intake camshaft, lightly pressing and turning it counterclockwise. Check that there is virtually no clearance between the VVT timing sprocket and
camshaft flange.
NOTICE:
Be careful not to turn the VVT timing sprocket clockwise
when installing it.
(2) Temporary install the VVT timing sprocket set bolt.
EM–21
ENGINE MECHANICAL
–
TIMING CHAIN
(3)
Hold the hexagon wrench head portion of the intake
camshaft with a wrench.
(4) Taking care of the VVT timing sprocket, tighten the
bolt.
Torque: 54 N·m (550 kgf·cm, 40 ft·lbf)
(5) After tighten the bolt, check that the VVT timing
sprocket turns clockwise and that it is locked when
the lock pin in hole at the locking point.
A14266
2.
(a)
Timing
Marks
(b)
Timing Marks
SET NO. 1 CYLINDER TO TDC/COMPRESSION
Turn the hexagonal wrench head portion of the intake
camshaft, and align the timing marks of the VVT timing
sprocket with the No. 1 bearing cap.
Turn the hexagonal wrench head portion of the exhaust
camshaft, and align the timing marks of the camshaft timing sprocket with the No. 2 bearing cap.
A13726
Set Key
(c)
Upward
Using the crankshaft pulley bolt, turn the crankshaft and
set the set key on the crankshaft upward.
A14198
3.
INSTALL CHAIN VIBRATION DAMPER
Install the damper with the 2 bolts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
4.
INSTALL CRANKSHAFT TIMING SPROCKET
Align the sprocket set key with the key groove of the sprocket,
and slide on the sprocket.
A13728
Orange or
Blue
Mark Link
Timing
Mark
A13730
1AZ–FSE ENGINE (RM783E)
5.
(a)
INSTALL TIMING CHAIN
Install the timing chain on the crankshaft timing sprocket
with the orange or blue mark link aligned with the timing
mark on the crankshaft timing sprocket.
EM–22
ENGINE MECHANICAL
(b)
Yellow or Golden Mark Link
Timing Mark
–
TIMING CHAIN
Install the timing chain on the camshaft timing sprocket
and VVT timing sprocket with the yellow or golden mark
links aligned with the timing marks on the camshaft timing
sprocket and VVT timing sprocket.
A13732
6.
INSTALL TIMING CHAIN GUIDE
Install the timing chain guide with the bolt.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
A13729
7.
(a)
Hold
(b)
INSTALL CHAIN TENSIONER SLIPPER
Install the slipper with the bolt.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
Check that the slipper is held on the cylinder block stopper.
A13733
A14199
1AZ–FSE ENGINE (RM783E)
8.
INSTALL CRANK ANGLE SENSOR PLATE
Install the plate with the F mark facing forward.
9.
INSTALL TIMING CHAIN COVER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
chain cover, cylinder head, cylinder block and crank case.
S
Using a razor blade and a gasket scraper, remove
all the old packing (FIPG) material from the gasket
surfaces and sealing grooves.
S
Thoroughly clean all components to remove all the
loose material.
S
Using a non–residue solvent, clean both sealing
surfaces.
EM–23
ENGINE MECHANICAL
(b)
FIPG
FIPG
–
TIMING CHAIN
Apply seal packing to the timing chain cover as shown in
the illustration.
Seal packing: Part No. 08826–00100 or equivalent
S
Install a nozzle that has been cut to a 3 – 4 mm (0.12
– 0.16 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
S
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed
and reapplied.
S
Immediately remove nozzle from the tube and reinstall cap.
Seal Width
3 – 4 mm
A13735
(c)
Seal Width
2 mm
Seal Packing
1AZ–FSE ENGINE (RM783E)
A13736
Apply seal packing to 2 locations as shown in the illustration.
Seal packing: Part No. 08826–00080 or equivalent
S
Install a nozzle that has been cut to a 2 mm (0.08
in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
S
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed
and reapplied.
S
Immediately remove nozzle from the tube and reinstall cap.
EM–24
ENGINE MECHANICAL
(d)
Nut
Nut
D
C
C
C
C
B
30 mm (1.18 in.) length for 12 mm head
Bolt C
40 mm (1.57 in.) length for 14 mm head
Bolt D
B
30 mm (1.18 in.) length for 10 mm head
Bolt B
B
B
Install the timing chain cover with the 14 bolts and 2 nuts.
Uniformly tighten the bolts and nuts in several passes.
Torque:
9 N·m (90 kgf·cm, 80 in.·lbf) for bolt A
21 N·m (210 kgf·cm, 15 ft.·lbf) for bolt B
43 N·m (440 kgf·cm, 32 ft·lbf) for bolt C
43 N·m (440 kgf·cm, 32 ft·lbf) for bolt D
9 N·m (90 kgf·cm, 80 in.·lbf) for nut
Bolt A
A
B
TIMING CHAIN
HINT:
Bolt length:
B
B
–
65 mm (2.56 in.) length for 14 mm head
B
A14278
(e)
Trox Socket
Wrench
Using a torx socket wrench (E10), install the stud bolt for
the drive belt tensioner.
Torque: 9.5 N·m (100 kgf·cm, 7 ft·lbf)
A14253
A13759
A14221
10. INSTALL DRIVE BELT TENSIONER
Install the drive belt tensioner with the bolt and nut.
Torque: 59.5 N·m (610 kgf·cm, 44 ft·lbf)
NOTICE:
As the drive belt tensioner should be torqued together with
the timing chain cover, so be sure install it within 15 minutes after the timing chain cover is installed.
11. INSTALL OIL PAN (See page LU–12)
12. INSTALL CRANKSHAFT POSITION SENSOR
13.
(a)
(b)
SST
SST
(c)
A13895
1AZ–FSE ENGINE (RM783E)
INSTALL CRANKSHAFT PULLEY
Clean the crankshaft pulley inside.
Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
Using SST, install the pulley bolt.
SST 09213–54015, 09330–00021
Torque: 170 N·m (1,735 kgf·cm, 125 ft·lbf)
EM–25
ENGINE MECHANICAL
–
TIMING CHAIN
14.
(a)
(b)
Place a new gasket on the timing chain cover with portion
A facing as shown in the illustration.
(c)
Push the chain tensioner into the timing chain cover, and
install the 2 nuts.
Torque: 9 N·m (90 kgf·cm, 80 in.·lbf)
15.
(a)
SET CHAIN TENSION
Turn the crankshaft counterclockwise, and disconnect
the plunger knock pin from the hook.
(b)
Raise
INSTALL CHAIN TENSIONER
Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring
out.
Turn the crankshaft clockwise, and check that the slipper
is pushed by the plunger.
Push
Hook
Pin
A13738
Portion A
A14262
Push
A14261
Hook
Disconnect
Turn
Pin
A14269
Plunger
Push
1AZ–FSE ENGINE (RM783E)
Turn
A14270
EM–26
ENGINE MECHANICAL
–
TIMING CHAIN
16.
(a)
CHECK VALVE TIMING
Turn the crankshaft pulley, and align its groove with timing
mark 0 of the timing chain cover.
NOTICE:
Always turn the crankshaft clockwise.
A13696
(b)
Timing
Marks
Timing Marks
Check that the timing marks of the camshaft timing
sprocket and VVT timing sprocket are aligned with the
timing marks of the No. 1 and No. 2 bearing caps as
shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the
marks as above.
A13902
17.
(a)
(b)
Seal Packing
A14213
A
A
B
B
C
A Nut
1AZ–FSE ENGINE (RM783E)
A
C
A
Nut
A14260
INSTALL CYLINDER HEAD COVER
Remove any old packing (FIPG) material.
Apply seal packing to 2 locations as shown in the illustration.
Seal packing: Part No. 08826–00080 or equivalent
(c) Install the gasket to the cylinder head cover.
If the gasket has damage, replace a new one.
HINT:
Part must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
(d) Install the cylinder head cover with the 9 bolts and 2 nuts.
Torque:
11 N·m (110 kgf·cm, 8 ft·lbf) for 10 mm head bolt A
21 N·m (215 kgf·cm, 15 ft·lbf) for 12 mm head bolt B
14 N·m (145 kgf·cm, 10 ft·lbf) for 10 mm head bolt C
11 N·m (110 kgf·cm, 8 ft·lbf) for nut
18. INSTALL VSV FOR INTAKE AIR CONTROL VALVE
Install the VSV with the bolt.
19. CONNECT NO. 1 PCV HOSE
20. INSTALL IGNITION COILS
21. INSTALL FUEL PUMP (HIGH PRESSURE)
(See page FI–14)
EM–27
ENGINE MECHANICAL
–
TIMING CHAIN
22. INSTALL ALTERNATOR
Install the alternator with the 2 bolts.
Torque:
52 N·m (530 kgf·cm, 38 ft·lbf) for bolt A
21 N·m (215 kgf·cm, 15 ft·lbf) for bolt B
23. FILL WITH ENGINE OIL (See page CO–1)
A
B
A13988
1AZ–FSE ENGINE (RM783E)
EM–28
ENGINE MECHANICAL
–
CYLINDER HEAD
CYLINDER HEAD
EM1K3–01
COMPONENTS
No. 1 PCV Hose
Washer
30 (305, 22)
Washer
21 (215, 15)
Fuel Hose
Intake Manifold and
Throttle Body Assembly
25 (255, 18)
Fuel Pulsation
Damper
Throttle Bracket
32.5 (330, 24)
Fuel Pump
(High Pressure)
30 (305, 22)
No. 1
Intake
Manifold
Insulator
z Gasket
z Insulator
Intake Air Control
Valve
9 (90, 80 in.·lbf)
z Gasket
19 (195, 14)
Delivery Pipe
w/ Injector
Ignition Coil
z Gasket
Spark Plug
z Gasket
12.5 (125, 9)
Nozzle Holder
Clamp
z Fuel Injector Seal
21 (215, 15)
12 (120, 9)
Upper Heat
Insulator
12 (120, 9)
Air Intake
Chamber Stay
No. 2 Intake
Manifold Insulator
Camshaft Timing
Oil Control Valve (OCV)
x5
z Gasket
Exhaust Manifold
37 (375, 27)
40 (410, 33)
9 (90, 80 in.·lbf)
z O–Ring
40 (410, 33)
Exhaust
Manifold Stay
Exhaust
Manifold Stay
52 (530, 38)
12 (120, 9)
21 (215, 15)
Alternator
N·m (kgf·cm, ft·lbf) : Specified torque
z Non–reusable part
1AZ–FSE ENGINE (RM783E)
No. 2 Lower
Heat Insulator
No. 1 Lower
Heat Insulator
A14320
EM–29
ENGINE MECHANICAL
–
CYLINDER HEAD
Cylinder Head Cover
9 (90, 80 in.·lbf)
21 (215, 15)
Chain Tensioner
z Gasket
14 (145, 10)
9 (90, 80 in.·lbf)
11 (110, 8)
Crankshaft
Position Sensor
11 (110, 8)
x5
Drive Belt Tensioner
43 (440, 32)
59.5 (610, 44)
*1
*2
*3
Gasket
59.5 (610, 44)
x8
9 (90, 80 in.·lbf)
21 (220, 15)
z O–Ring
Timing Chain Cover
Crankshaft Pulley
170 (1,735, 125)
VVT Timing
Sprocket
Camshaft
Timing Sprocket
54 (550, 40)
Chain Tensioner
Slipper
54 (550, 40)
Timing Chain
19 (195, 14)
Chain Vibration
Damper
9 (90, 80 in.·lbf)
Crank Angle
Sensor Plate
x 12
9 (90, 80 in.·lbf)
*1:
N·m (kgf·cm, ft·lbf) : Specified torque
z Non–reusable part
1AZ–FSE ENGINE (RM783E)
43 (440, 32)
*2:
9 (90, 80 in.·lbf)
*3:
Oil Pan
9.5 (100, 7)
x4
9 (90, 80 in.·lbf)
A14219
EM–30
ENGINE MECHANICAL
–
CYLINDER HEAD
Valve Lifter
9 (90, 80 in.·lbf)
Keeper
29.5 (300, 22)
No. 3 Camshaft
Bearing Cap
Spring Retainer
No. 1 Camshaft
Bearing Cap
Valve Spring
z Oil Seal
No. 2 Camshaft
Bearing Cap
Spring Seat
Upper
Camshaft
Bearing
Valve Guide Bushing
L Oil Pressure Switch
13 (130, 10)
Intake Camshaft
Lower
Camshaft
Bearing
Camshaft
Housing
Plug
See page EM–47
1st 79 (800, 58)
2nd Turn 90°
Camshaft Position
Sensor
9 (90, 80 in.·lbf)
z O–Ring
x 10
Exhaust Camshaft
Water Temperature
Sensor
13 (130, 10)
z Gasket
Cylinder Head
Valve
9 (90, 80 in.·lbf)
z Gasket
N·m (kgf·cm, ft·lbf) : Specified torque
z Non–reusable part
L Precoated part
1AZ–FSE ENGINE (RM783E)
A14211
EM–31
ENGINE MECHANICAL
–
CYLINDER HEAD
EM1JY–01
REMOVAL
1.
2.
3.
4.
5.
DRAIN ENGINE OIL
REMOVE ALTERNATOR (See page EM–15)
REMOVE FUEL PUMP (HIGH PRESSURE)
(See page FI–13)
REMOVE IGNITION COILS
REMOVE SPARK PLUGS
6.
(a)
(b)
(c)
REMOVE EXHAUST MANIFOLD
Remove the 2 bolts, 2 nuts and 2 exhaust manifold stays.
Remove the 3 bolts, nut and upper heat insulator.
Remove the 3 bolts and No. 1 lower heat insulator.
(d)
(e)
Remove the 5 nuts, exhaust manifold and gasket.
Remove the 4 bolts and No. 2 lower heat insulator.
7.
REMOVE INTAKE MANIFOLD AND THROTTLE BODY
ASSEMBLY AND INTAKE AIR CONTROL VALVE
Remove the No. 1 PCV hose.
Remove the 2 bolts, 2 nuts, 2 washers and throttle body
bracket.
Disconnect the 2 vacuum hoses from the intake manifold.
Disconnect the 2 water hoses from the throttle body.
Remove the 5 bolts, 2 nuts, the intake manifold and
throttle body assembly, No. 1 intake manifold insulator, intake air control valve and gasket.
Remove the gasket from the intake manifold and throttle
body assembly.
REMOVE INJECTORS (See page FI–21)
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
(OCV)
REMOVE CAMSHAFT TIMING CHAIN
(See page EM–15)
REMOVE CAMSHAFT TIMING SPROCKET AND VVT
TIMING SPROCKET (See page EM–15)
A14216
A14215
(a)
(b)
(c)
(d)
(e)
A14272
(f)
8.
9.
10.
11.
1AZ–FSE ENGINE (RM783E)
EM–32
ENGINE MECHANICAL
9 10
13 14
17 18
5
15
20 19
8
2
3
4
11
16
7
A14186
1
5
9
7
8
10
6
4
REMOVE CAMSHAFTS
Uniformly loosen and remove the 20 bearing cap bolts in
several passes and in the sequence shown.
(b) Remove the 10 bearing caps, intake camshaft and exhaust camshaft.
(c) Remove the camshaft bearings from the No. 1 camshaft
bearing cap and intake camshaft No. 1 journal part of the
cylinder head.
13. DISCONNECT WATER BYPASS PIPE FROM CYLINDER HEAD
Remove the bolt holding the water bypass pipe and cylinder
head.
14.
(a)
(b)
3
2
CYLINDER HEAD
12.
(a)
6
1
12
–
A13102
REMOVE CYLINDER HEAD
Remove the camshaft housing plug.
Using a 10 mm bi–hexagon wrench, uniformly loosen and
remove the 10 cylinder head bolts in several passes and
in the sequence shown.
NOTICE:
Head warpage or cracking could result from removing
bolts in an incorrect order.
(c) Remove the 10 plate washers.
(d)
Using a screwdriver, pry between the cylinder head and
cylinder block, and remove the cylinder head.
NOTICE:
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
A13104
1AZ–FSE ENGINE (RM783E)
EM–33
ENGINE MECHANICAL
–
CYLINDER HEAD
EM1JW–01
DISASSEMBLY
1.
REMOVE OIL PRESSURE SWITCH
2.
REMOVE WATER TEMPERATURE SENSOR
3.
REMOVE CAMSHAFT POSITION SENSOR
4.
REMOVE VALVE LIFTERS
HINT:
Arrange the valve lifters in the correct order.
A14185
(b)
REMOVE VALVES
Using SST, compress the valve spring and remove the 2
keepers.
SST 09202–70020 (09202–00010)
Remove the spring retainer, valve spring and valve.
(c)
Using needle–nose pliers, remove the oil seal.
(d)
SST
5.
(a)
Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
SST
A14193
A14202
HINT:
Arrange the valves, valve springs, spring seats and spring retainers in the correct order.
A14192
1AZ–FSE ENGINE (RM783E)
EM–34
ENGINE MECHANICAL
–
CYLINDER HEAD
EM1JZ–01
INSPECTION
1.
(a)
CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK
Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the carbon from the piston surface.
A14175
(b)
A14176
Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high pressure compressed
air.
2.
INSPECT CYLINDER BLOCK FOR FLATNESS
(See page EM–60)
3.
(a)
CLEAN CYLINDER HEAD
Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact surface.
A14178
(b)
Using a wire brush, remove all the carbon from the combustion chambers.
NOTICE:
Be careful not to scratch the cylinder block contact surface.
A14179
(c)
A14184
1AZ–FSE ENGINE (RM783E)
Using a soft brush and solvent, thoroughly clean the cylinder head.
EM–35
ENGINE MECHANICAL
–
CYLINDER HEAD
(d)
Using a valve guide bushing brush and solvent, clean all
the guide bushings.
4.
(a)
INSPECT CYLINDER HEAD
Inspect for flatness.
Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
A13880
Cylinder block side
0.05 mm (0.0020 in.)
Manifold side
Cylinder Block Side
0.08 mm (0.0031 in.)
If warpage is greater than maximum, replace the cylinder head.
Intake Manifold Side
Exhaust Manifold Side
A14201
(b)
Inspect for cracks.
Using a dye penetrate, check the combustion chamber,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
A14180
5.
(a)
(b)
EM0580
1AZ–FSE ENGINE (RM783E)
CLEAN VALVES
Using a gasket scraper, chip off any carbon from the valve
head.
Using a wire brush, thoroughly clean the valve.
EM–36
ENGINE MECHANICAL
–
CYLINDER HEAD
6.
(a)
INSPECT VALVE STEMS AND GUIDE BUSHINGS
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)
Using a micrometer, measure the diameter of valve stem.
Valve stem diameter:
A13879
Intake
Exhaust
(c)
5.470 – 5.485 mm (0.2154 – 0.2159 in.)
5.465 – 5.480 mm (0.2152 – 0.2157 in.)
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
Z00052
0.030 – 0.065 mm (0.0012 – 0.0026 in.)
Maximum oil clearance:
Intake
0.08 mm (0.0031 in.)
Exhaust
0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing (See page EM–43).
7.
(a)
INSPECT VALVES
Check the valve is ground to the correct valve face angle.
Valve face angle: 44.5°
(b) Check that the surface of the valve for wear.
If the valve face is worn, replace the valve.
44.5°
EM0180
(c)
Check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.028 in.)
If the margin thickness is less than minimum, replace the valve.
Margin Thickness
EM0181
1AZ–FSE ENGINE (RM783E)