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141XS01

OVERHAUL
1. REMOVE VALVE LIFTER HINT: Arrange the valve lifters in the correct order.
SST

2. (a) (b)

(c)

REMOVE INTAKE VALVE Place the cylinder head on wooden blocks. Using SST, compress the spring, then remove the 2 retainer locks. SST 0920270020 (0920200010) Remove the retainer, spring and valve from the cylinder head.

Wooden Block

A98132

HINT: Arrange the removed parts in the correct order. 3. (a) (b) REMOVE EXHAUST VALVE Place the cylinder head on wooden blocks. Using SST, compress the spring, then remove the 2 retainer locks. SST 0920270020 (0920200010) Remove the retainer, spring and valve from the cylinder head.

SST

(c)

Wooden Block

A98133

HINT: Arrange the removed parts in the correct order. 4. (a) REMOVE VALVE STEM OIL O SEAL OR RING Using needlenose pliers, remove the 16 oil seals.

A13356

5.

REMOVE VALVE SPRING SEAT

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6. (a)

REMOVE STUD BOLT Using torx socket wrenches E5 and E7, remove the 11 stud bolts.
Upper side:

Front side:

Intake side:

Exhaust side:

A98131

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7. (a)

CHECK CYLINDER HEAD FOR WARPAGE Using a precision straight edge and a feeler gauge, measure the surface that is in contact with the cylinder block and the manifolds for warpage. Maximum warpage: 0.08 mm (0.0032 in.) If the warpage is greater than maximum, replace the cylinder head.
Cylinder block side:

Intake manifold side:

Exhaust manifold side:

A98134

8. (a)

A13365

CHECK CYLINDER HEAD 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. 9. 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. NOTICE: Do not turn the valve.

(c)

Width

A62786

Check the valve face and seat in accordance with the following procedure. (1) If blue appears 360_ around the face, the valve is concentric. If not, replace the valve. (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 a width of between 1.0 to 1.4 mm (0.039 to 0.055 in.).
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ENGINE MECHANICAL CYLINDER HEAD ASSY (2AZFE)

10. REPAIR VALVE SEATS NOTICE: Releasing the seat cutter pressure gradually helps to make the valve seat faces smoother. (a)
45_ 30_

If the seating is too high on the valve face, use 30_ and 45_ cutters to correct the seat.

1.0 to 1.4 mm (0.039 to 0.055 in.)

A94213

75_ 45_

(b) (c) (d)

If the seating is too low on the valve face, use 75_ and 45_ cutters to correct the seat. Lap the valve and valve seat by hand with an abrasive compound. Recheck the valve seating position.

1.0 to 1.4 mm (0.039 to 0.055 in.)

A94214

11. (a) (b)

A36626

CHECK CAMSHAFT THRUST CLEARANCE Install the 2 camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 to 0.095 mm (0.0016 to 0.0037 in.) for intake 0.080 to 0.135 mm (0.0032 to 0.0053 in.) for exhaust Maximum thrust clearance: 0.110mm (0.0043 in.) for intake 0.150 mm (0.0059 in.) for exhaust S If the thrust clearance is greater than maximum, replace the cylinder head. S If damages are found on the camshaft thrust surfaces, replace the camshaft.

Plastigage

A36627

CHECK CAMSHAFT OIL CLEARANCE Clean the 10 bearing caps and camshaft journals. Place the 2 camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal. (d) Install the 10 bearing caps (see page 1435). NOTICE: Do not turn the camshaft. (e) Remove the 10 bearing caps (see page 1435).

12. (a) (b) (c)

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(f)

Measure the Plastigage at its widest point. Standard oil clearance:

Item Intake No. 1 journal Exhaust No. 1 journal Other journal Specification 0.007 to 0.038 mm (0.0003 to 0.0015 in.) 0.040 to 0.079 mm (0.0016 to 0.0031 in.) 0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum oil clearance:

Item
A36628

Specification 0.07 mm (0.0028 in.) 0.10 mm (0.0039 in.)

Intake No. 1 journal Other journal

NOTICE: Completely remove the Plastigage after the measurement. If the oil clearance is greater than maximum, replace the cylinder head or the camshaft. If the oil clearance on the No.1 journal is greater than maximum, choose a new bearing and install it. HINT: Cylinder head journal bore diameter:
Mark 1 Mark 2 Mark 3 40.000 to 40.008 mm (1.5748 to 1.5751 in.) 40.009 to 40.017 mm (1.5752 to 1.5755 in.) 40.018 to 40.025 mm (1.5755 to 1.5758 in.)

Standard bearing center wall thickness:

Number Mark
A98135

Mark 1 Mark 2 Mark 3

2.000 to 2.004 mm (0.0787 to 0.0789 in.) 2.005 to 2.008 mm (0.0789 to 0.0791 in.) 2.009 to 2.012 mm (0.0791 to 0.0792 in.)

Camshaft journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.)

13. (a)

INSPECT VALVE LIFTER Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) If the diameter is not as specified, replace the valve lifter.

P16860

14. (a)

CHECK VALVE LIFTER OIL CLEARANCE Using a caliper gauge, measure the valve lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) If the diameter is not as specified, replace the cylinder head.

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(b)

Subtract the valve lifter diameter measurement from the valve lifter bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.079 mm (0.0031 in.) S If the oil clearance is greater than maximum, replace the valve lifter. S If necessary, replace the cylinder head.

15. (a)

INSPECT INNER COMPRESSION SPRING Using vernier calipers, measure the free length of the valve spring. Free length: 45.7 mm (1.799 in.) If the length is not as specified, replace the compression spring.

EM0801

Deviation

Using a steel square, measure the deviation of the inner compression spring. Maximum deviation: 1.6 mm (0.063 in.) Maximum angle (Reference): 2_ If the deviation is greater than maximum, replace the compression spring.

(b)

A62784

16. (a)
Overall Length

INSPECT INTAKE VALVE 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.) If the overall length is less than minimum, replace the valve.

EM2534

(b)

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.) If the diameter is not as specified, replace the valve.

A32770

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(c)

Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than minimum, replace the valve.
Margin Thickness
A62785

17. (a)
Overall Length

INSPECT EXHAUST VALVE 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.) If the overall length is less than minimum, replace the valve.

EM2534

(b)

Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2158 in.) If the diameter is not as specified, replace the valve.

A32770

(c)

Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than minimum, replace the valve.
Margin Thickness

A62785

18. (a)

INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the valve guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) If the inside diameter is not as specified, replace the valve guide bush.
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(b)

Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance:
Item Intake Exhaust Specification 0.025 to 0.060 mm (0.0010 to 0.0024 in.) 0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Maximum oil clearance:

Item Intake Exhaust Specification 0.08 mm (0.0032 in.) 0.10 mm (0.0039 in.)

If the oil clearance is greater than maximum, replace the valve and valve guide bush.

19. (a)
SST

REMOVE INTAKE VALVE GUIDE BUSH Using SST, tap out the guide bush. SST 0920110000 (0920101050), 0995070010 (0995107100)

A98136

SST

20. (a)

21. (a)

A98137

(b)

REMOVE EXHAUST VALVE GUIDE BUSH Using SST , tap out the guide bush. SST 0920110000 (0920101050), 0995070010 (0995107100) INSTALL INTAKE VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4058 in.) Install the STD bush if the diameter is within the specified diameter. Standard diameter: 10.333 to 10.344 mm (0.4068 to 0.4072 in.)

(c)

SST

Using SST, tap in a new guide bush to the specified protrusion height. SST 0920110000 (0920101050), 0995070010 (0995107100) Protrusion height: 9.6 to 10 mm (0.3780 to 0.3937 in.)

A98138

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(d)

22. (a)

(b)

Using a sharp 5.5 mm reamer, ream the valve guide bush to the standard specified clearance between the valve guide bush and valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) INSTALL EXHAUST VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4058 in.) Install the STD bush if the diameter is within the specified diameter. Standard diameter: 10.333 to 10.344 mm (0.4068 to 0.4072 in.)

(c)
SST

(d)
A98139

Using SST, tap in a new guide bush to the specified protrusion height. SST 0920110000 (0920101050), 0995070010 (0995107100) Protrusion height: 9.6 to 10.0 mm (0.3780 to 0.3937 in.) Using a sharp 5.5 mm reamer, ream the valve guide bush to the standard specified clearance between the valve guide bush and valve stem. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Upper Side:

23. (a)

INSTALL RING W/HEAD PIN Using a plasticfaced hammer, tap in new 4 ring pins to the specified protrusion height. Protrusion height: 3.0 mm (0.12 in.)

11 (0.43)

3.0 (0.12)

8 (0.32) (mm (in.))

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ENGINE MECHANICAL CYLINDER HEAD ASSY (2AZFE)

24. (a)

INSTALL STUD BOLT Using torx socket wrenches E5 and E7, install the 11 stud bolts. Torque: 5.0 Nm (51 kgfcm, 44 in.lbf) for bolt A 5.0 Nm (51 kgfcm, 44 in.lbf) for bolt B 9.5 Nm (97 kgfcm, 84 in.lbf) for bolt C 9.5 Nm (97 kgfcm, 84 in.lbf) for bolt D

Front side: A A

Upper side:

B B

Intake side: C C

Exhaust side: D D

46.5 (1.83) 33.3 (1.31) 12 (0.47)

49.5 (1.95) 37.5 (1.48) 24 (0.94) 18 (0.71)

12 (0.47) 9 (0.35) A(M6) B(M6) 12 (0.47) C(M8) 13 (0.51) D(M8)

13 (0.51)

(mm(in.))
A98141

25.

INSTALL VALVE SPRING SEAT

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ENGINE MECHANICAL CYLINDER HEAD ASSY (2AZFE)

Intake: Gray

Exhaust:

Black

A98142

26. INSTALL VALVE STEM OIL O SEAL OR RING (a) Apply a light coat of engine oil to a new oil seals. NOTICE: Pay close attention when installing the intake and exhaust oil seals. Mixing up the two seals can cause installation problems. HINT: The intake valve stem oil seal is gray and exhaust valve stem oil seal is black. (b) Using SST, push in the 16 oil seals by hand. SST 0920141020

SST

A98143

SST

27. (a) (b) (c)

INSTALL INTAKE VALVE Place the cylinder head on wooden blocks. Install the valve, spring and retainer onto the cylinder head. Using SST, compress the spring, and place the 2 retainer locks around the valve stem. SST 0920270020 (0920200010)

Wooden Block

A98132

Vinyl Tape

(d)

Using a plasticfaced hammer and discarded valve (its tip is wrapped with tape), lightly tap the installed valve to fit into place. NOTICE: Be careful not to damage the valve stem tip.

Valve Stem

A98144

SST

28. (a) (b) (c)

INSTALL EXHAUST VALVE Place the cylinder head on wooden blocks. Install the valve, spring and retainer onto the cylinder head. Using SST, compress the spring, and place the 2 retainer locks around the valve stem. SST 0920270020 (0920200010)

Wooden Block
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ENGINE MECHANICAL CYLINDER HEAD ASSY (2AZFE)

Vinyl Tape

(d)

Using a plasticfaced hammer and discarded valve (its tip is wrapped with tape), lightly tap the installed valve to fit into place. NOTICE: Be careful not to damage the valve stem tip.

Valve Stem

A98144

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 in their original places.

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