Toyota Avalon (XX50): Cylinder Head

*1

VALVE SPRING RETAINER LOCK

*2

VALVE SPRING RETAINER

*3

INNER COMPRESSION SPRING

*4

INTAKE VALVE STEM OIL SEAL

*5

VALVE SPRING SEAT

*6

INTAKE VALVE GUIDE BUSH

*7

SPARK PLUG TUBE

*8

INTAKE MANIFOLD TO CYLINDER HEAD STUD BOLT

*9

RING PIN

*10

STRAIGHT PIN

*11

NO. 2 STRAIGHT SCREW PLUG

*12

CYLINDER HEAD SCREW PLUG GASKET

*13

NO. 1 STRAIGHT SCREW PLUG

*14

WATER HOLE GASKET

*15

CYLINDER HEAD LH

*16

INTAKE VALVE

*17

EXHAUST VALVE

*18

EXHAUST VALVE STEM OIL SEAL

*19

EXHAUST VALVE GUIDE BUSH

*20

NO. 3 STRAIGHT SCREW PLUG

*21

STUD BOLT

-

-

N*m (kgf*cm, ft.*lbf): Specified torque

●

Non-reusable part

Adhesive 1324

★

Precoated part

Battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane departure alert system (w/ Steering Control)

Pre-collision system

Intelligent Clearance Sonar System*1

Lighting System (for Gasoline Model with Cornering Light)

Memorize steering angle neutral point

Parking Assist Monitor System

Panoramic View Monitor System

Replacement of ECM

Vehicle Identification Number (VIN) registration

MIL comes on

ECU communication ID registration (Immobiliser system)

Engine start function

• Replacement of throttle body with motor assembly
• Cleaning the deposits from the throttle body with motor assembly
• Replacement of cylinder head sub-assembly
• Replacement of camshaft (for intake or exhaust camshaft)
• Replacement of camshaft timing gear assembly
• Replacement of camshaft timing exhaust gear assembly
• Replacement of fuel injector assembly (for port injection)
• Replacement of fuel injector assembly (for direct injection)
• Replacement of fuel pump assembly (for high pressure side)
• Replacement of engine coolant temperature sensor
• Replacement of spark plug
• Replacement of ignition coil assembly
• Air leaks from intake system
• Gas leak from exhaust system is repaired
• Replacement of knock control sensor

Inspection after repair

• Poor idle, etc.
• Engine start function, etc.

Replacement of automatic transaxle assembly

• Perform reset memory
• Input transaxle compensation code into ECM
• Perform road test to allow ECM to learn

• Large shift shock
• Deterioration of fuel efficiency

for Initialization

for Registration

Replacement of ECM

(If transaxle compensation code read from ECM)

• Perform reset memory*2
• Transfer transaxle compensation code
• Perform road test to allow ECM to learn

Replacement of ECM

(If transaxle compensation code not read from ECM)

• Perform reset memory*2
• Reset transaxle compensation code
• Perform road test to allow ECM to learn

Replacement of automatic transaxle fluid

ATF thermal degradation estimate reset

The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

Replacement of ECM

Code registration (Smart Key System (for Start Function))

• Wireless Door Lock Control System
• Smart Key System (for Entry Function)
• Smart Key System (for Start Function)
• Steering lock function

Suspension, tires, etc.

• Measure ultrasonic sensor detection angle
• Ultrasonic sensor detection angle registration

• Intelligent Clearance Sonar System
• Intuitive Parking Assist System

Rear television camera assembly optical axis adjustment (Back camera position setting)

Parking Assist Monitor System

for Initialization

for Calibration

• Parking assist ECU initialization
• Adjust steering angle
• Television camera assembly optical axis adjustment (Back camera position setting)

Panoramic View Monitor System

for Initialization

for Calibration

Perform headlight ECU sub-assembly LH initialization

Lighting system (for Gasoline Model with Cornering Light)

Front wheel alignment adjustment

Perform system variant learning and acceleration sensor zero point calibration.

• VSC is disabled or malfunctions
• DTCs are output
• Slip indicator light illuminates
• ABS warning light illuminates

(a) Using SST and wooden blocks, compress the inner compression spring and remove the 6 valve spring retainer locks from the valve spring retainer.

SST: 09202-70020

09202-01010

09202-01020

SST: 09202-00021

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(a) Using SST and wooden blocks, compress the inner compression spring and remove the 6 valve spring retainer locks from the valve spring retainer.

SST: 09202-70020

09202-01010

09202-01020

SST: 09202-00021

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(a) Using needle-nose pliers, remove the 6 intake valve stem oil seals from the intake valve guide bush.

(a) Using compressed air and a Magnet Hand, remove the 12 valve spring seats by blowing air onto them from the cylinder head LH.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(a) Using a 10 mm hexagon socket wrench, remove the 2 No. 1 straight screw plugs and 2 water hole gaskets from the cylinder head LH.

(a) Using a 14 mm hexagon wrench, remove the No. 2 straight screw plug and cylinder head screw plug gasket from the cylinder head LH.

(a) Using a 10 mm hexagon socket wrench, remove the 4 No. 3 straight screw plugs and 4 cylinder head screw plug gaskets from the cylinder head LH.

*a

Bottom Side

*b

Intake Manifold Side

*c

Exhaust Manifold Side

-

-

Bottom Side

0.05 mm (0.00197 in.)

Intake Manifold Side

0.08 mm (0.00315 in.)

Exhaust Manifold Side

0.08 mm (0.00315 in.)

Bottom Side

0.10 mm (0.00394 in.)

Intake Manifold Side

0.10 mm (0.00394 in.)

Exhaust Manifold Side

0.10 mm (0.00394 in.)

(a) Using a dye penetrant, check the intake ports, exhaust ports and bottom surface of the cylinder head LH for cracks.

HINT:

If cracks are found, replace the cylinder head LH.

(a) Using a micrometer, measure the diameter of the valve stem.

Standard Valve Stem Diameter:

5.470 to 5.485 mm (0.215 to 0.216 in.)

HINT:

If the valve stem diameter is not as specified, check the intake valve guide bush oil clearance.

(b) Using a vernier caliper, measure the valve head margin thickness.

Standard Margin Thickness:

1.0 mm (0.0394 in.)

Minimum Margin Thickness:

0.5 mm (0.0197 in.)

HINT:

If the margin thickness is less than the minimum, replace the intake valve.

(c) Using a vernier caliper, measure the overall length of the intake valve.

Standard Overall Length:

105.85 mm (4.17 in.)

Minimum Overall Length:

105.35 mm (4.15 in.)

HINT:

If the overall length is less than the minimum, replace the intake valve.

(a) Using a micrometer, measure the diameter of the valve stem.

Standard Valve Stem Diameter:

5.465 to 5.480 mm (0.215 to 0.216 in.)

HINT:

If the valve stem diameter is not as specified, check the exhaust valve guide bush oil clearance.

(b) Using a vernier caliper, measure the valve head margin thickness.

Standard Margin Thickness:

1.0 mm (0.0394 in.)

Minimum Margin Thickness:

0.5 mm (0.0197 in.)

HINT:

If the margin thickness is less than the minimum, replace the exhaust valve.

(c) Using a vernier caliper, measure the overall length of the exhaust valve.

Standard Overall Length:

110.40 mm (4.35 in.)

Minimum Overall Length:

109.90 mm (4.33 in.)

HINT:

If the overall length is less than the minimum, replace the exhaust valve.

(c) Check the valve face and intake valve seat by using the following procedure:

(1) If Prussian blue appears 360° around the entire intake valve face, the valve face is concentric.

HINT:

If the valve face is not concentric, replace the intake valve.

(2) If Prussian blue appears 360° around the entire intake valve seat, the intake valve seat and valve face are concentric.

HINT:

If the valve face is not concentric, resurface the intake valve seat.

(3) Measure the width of the contact area of the intake valve seat and valve face.

Standard Width:

1.1 to 1.5 mm (0.0433 to 0.0591 in.)

(c) Check the valve face and exhaust valve seat by using the following procedure:

(1) If Prussian blue appears 360° around the entire exhaust valve face, the valve face is concentric.

HINT:

If the valve face is not concentric, replace the exhaust valve.

(2) If Prussian blue appears 360° around the entire exhaust valve seat, the exhaust valve seat and valve face are concentric.

HINT:

If the valve face is not concentric, resurface the exhaust valve seat.

(3) Measure the width of the contact area of the exhaust valve seat and valve face.

Standard Width:

1.1 to 1.5 mm (0.0433 to 0.0591 in.)

(a) Using a vernier caliper, measure the free length of the inner compression spring.

Standard Free Length:

54.53 mm (2.15 in.)

Minimum Free Length:

52.43 mm (2.06 in.)

HINT:

If the free length is not as specified, replace the inner compression spring.

(b) Using a steel square, measure the deviation of the inner compression spring.

Maximum Deviation (Reference):

1.4 mm (0.0551 in.)

HINT:

If the deviation is more than the maximum, replace the inner compression spring.

(a) Using a caliper gauge, measure the inside diameter of the valve guide bush.

Standard Valve Guide Bush Inside Diameter:

5.510 to 5.530 mm (0.217 to 0.218 in.)

Intake

0.025 to 0.060 mm (0.000984 to 0.00236 in.)

Exhaust

0.030 to 0.065 mm (0.00118 to 0.00256 in.)

Intake

0.12 mm (0.00472 in.)

Exhaust

0.12 mm (0.00472 in.)

(a) Apply adhesive to a new spark plug tube as shown in the illustration.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Standard Application Width:

1.0 to 3.0 mm (0.0394 to 0.118 in.)

NOTICE:

Install the spark plug tube within 3 minutes of applying adhesive.

(b) Using a hammer and wooden block, tap in the 3 spark plug tubes to the specified protrusion height.

Standard Protrusion Height:

73 mm (2.87 in.)

NOTICE:

• Do not tap in the spark plug tube more than specified.
• Do not start the engine for at least 1 hour after installation.
• Be careful not to deform the spark plug tubes.
• Be careful not to let adhesive drip into the cylinder head LH.

(a) Using a 10 mm hexagon socket wrench, install 4 new cylinder head screw plug gaskets and the 4 No. 3 straight screw plugs to the cylinder head LH.

Torque:

65 N·m {663 kgf·cm, 48 ft·lbf}

NOTICE:

• Do not apply adhesive to the No. 3 straight screw plug.
• The cylinder head screw plug gasket for the No. 3 straight screw plug is not the same as the water hole gasket for the No. 1 straight screw plug.

(a) Using a 14 mm hexagon wrench, install a new cylinder head screw plug gasket and the No. 2 straight screw plug to the cylinder head LH.

Torque:

80 N·m {816 kgf·cm, 59 ft·lbf}

(b) Using a 10 mm hexagon socket wrench, install 2 new water hole gaskets and the 2 No. 1 straight screw plugs to the cylinder head LH.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

(a) Apply a light coat of engine oil to a new intake valve stem oil seal.

NOTICE:

Make sure to install each valve stem oil seal to the correct side. Installing an intake valve stem oil seal to the exhaust side or installing an exhaust valve stem oil seal to the intake side can cause installation problems later.

HINT:

The intake valve stem oil seals are gray and the exhaust valve stem oil seals are black.

(b) Using SST, push in the 6 intake valve stem oil seals to the intake valve guide bush.

SST: 09201-41020

NOTICE:

• Failure to use SST will cause the intake valve stem oil seal to be damaged or improperly seated.
• Do not push in the intake valve stem oil seal at an angle.

(a) Sufficiently apply engine oil to the tip area of the exhaust valve shown in the illustration.

*1

Valve Spring Retainer

*2

Inner Compression Spring

*3

Cylinder Head LH

Top Side

(c) Using SST and wooden blocks, compress the inner compression spring and install the 6 valve spring retainer locks to the valve spring retainer.

SST: 09202-70020

09202-01010

09202-01020

SST: 09202-00021

NOTICE:

Install the same parts in the same combination to their original locations.

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:

• Be careful not to damage the valve stem tip.
• Be careful not to damage the valve spring retainer.

(a) Sufficiently apply engine oil to the tip area of the intake valve shown in the illustration.

*1

Valve Spring Retainer

*2

Inner Compression Spring

*3

Cylinder Head LH

Top Side

(c) Using SST and wooden blocks, compress the inner compression spring and install the 6 valve spring retainer locks to the valve spring retainer.

SST: 09202-70020

09202-01010

09202-01020

SST: 09202-00021

NOTICE:

Install the same parts in the same combination to their original locations.

(d) Using a plastic hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:

• Be careful not to damage the valve stem tip.
• Be careful not to damage the valve spring retainer.

(a) Using a 45° cutter, resurface the intake valve seat so that the intake valve seat width is more than the standard.

(b) Using 30° and 60° cutters, correct the intake valve seat so that the intake valve contacts the entire circumference of the intake valve seat. The contact should be in the center of the intake valve seat, and the intake valve seat width should be as specified around the entire circumference of the intake valve seat.

Standard Width:

1.1 to 1.5 mm (0.0433 to 0.0591 in.)

(a) Using a 45° cutter, resurface the exhaust valve seat so that the exhaust valve seat width is more than the standard.

(b) Using 30° and 75° cutters, correct the exhaust valve seat so that the exhaust valve contacts the entire circumference of the exhaust valve seat. The contact should be in the center of the exhaust valve seat, and the exhaust valve seat width should be as specified around the entire circumference of the exhaust valve seat.

Standard Width:

1.1 to 1.5 mm (0.0433 to 0.0591 in.)

(c) Using SST and a hammer, tap out the intake valve guide bush.

SST: 09201-10000

09201-01050

SST: 09950-70010

09951-07100

(d) Using a caliper gauge, measure the intake valve guide bush bore diameter of the cylinder head LH.

Standard Intake Valve Guide Bush Bore Diameter:

10.285 to 10.306 mm (0.405 to 0.406 in.)

New Guide Bush Selection Chart:

HINT:

• If the intake valve guide bush bore diameter is more than 10.306 mm (0.406 in.), machine the intake valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 intake valve guide bush.
• If the intake valve guide bush bore diameter of the cylinder head LH is more than 10.356 mm (0.40772 in.), replace the cylinder head LH.

(g) Using SST and a hammer, tap in a new intake valve guide bush to the specified protrusion height.

SST: 09201-10000

09201-01050

SST: 09950-70010

09951-07100

Standard Protrusion Height:

9.30 to 9.70 mm (0.366 to 0.382 in.)

(h) Using a sharp 5.5 mm reamer, ream the intake valve guide bush to obtain the specified oil clearance.

Standard Oil Clearance:

0.025 to 0.060 mm (0.000984 to 0.00236 in.)

(c) Using SST and a hammer, tap out the exhaust valve guide bush.

SST: 09201-10000

09201-01050

SST: 09950-70010

09951-07100

(d) Using a caliper gauge, measure the exhaust valve guide bush bore diameter of the cylinder head LH.

Standard Exhaust Valve Guide Bush Bore Diameter:

10.285 to 10.306 mm (0.405 to 0.406 in.)

New Guide Bush Selection Chart:

HINT:

• If the exhaust valve guide bush bore diameter is more than 10.306 mm (0.406 in.), machine the exhaust valve guide bush bore to a dimension of 10.335 to 10.356 mm (0.407 to 0.408 in.) to install an O/S 0.05 exhaust valve guide bush.
• If the exhaust valve guide bush bore diameter of the cylinder head LH is more than 10.356 mm (0.40772 in.), replace the cylinder head LH.

(g) Using SST and a hammer, tap in a new exhaust valve guide bush to the specified protrusion height.

SST: 09201-10000

09201-01050

SST: 09950-70010

09951-07100

Standard Protrusion Height:

9.30 to 9.70 mm (0.366 to 0.382 in.)

(h) Using a sharp 5.5 mm reamer, ream the exhaust valve guide bush to obtain the specified oil clearance.

Standard Oil Clearance:

0.030 to 0.065 mm (0.00118 to 0.00256 in.)

*A

for Bank 1

*B

for Bank 2

*a

Protrusion Height

-

-

*A

for Bank 2

-

-

*a

Intake Side

*b

Exhaust Side

*c

Rear Side

*d

20 mm (0.787 in.)

*e

13 mm (0.512 in.)

*f

35 mm (1.38 in.)

*g

16 mm (0.630 in.)

*h

9 mm (0.354 in.)

*i

27 mm (1.06 in.)

*j

26 mm (1.02 in.)

*k

16.7 mm (0.657 in.)

*l

51.7 mm (2.04 in.)

*A

for Bank 1

-

-

*a

Intake Side

*b

Exhaust Side

*c

Rear Side

*d

20 mm (0.787 in.)

*e

13 mm (0.512 in.)

*f

35 mm (1.38 in.)

*g

16 mm (0.630 in.)

*h

9 mm (0.354 in.)

*i

27 mm (1.06 in.)

*j

26 mm (1.02 in.)

*k

16.7 mm (0.657 in.)

*l

51.7 mm (2.04 in.)

*A

for Bank 1

*B

for Bank 2

*a

34 mm (1.34 in.)

*b

Protrusion Height