TOYOTA AVENSIS 2002 Repair Manual

A01132
A60622
A01045
A64005
14±8
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Turn the crankshaft 1 revolution (360
) and set No. 4 cyl-
inder to TDC/compression.
(c) Check the valves indicated in the illustration.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record the out±of specification valve clearance
measurements. They will be used later to determine
the required replacement valve lifter.
Valve clearance (Cold):
Intake 0.15 to 0.25 mm (0.0059 to 0.0098 in.)
Exhaust 0.25 to 0.35 mm (0.0098 to 0.0138 in.)
12. REMOVE FAN AND GENERATOR V BELT
(a) Turn the V±ribbed belt tensioner clockwise slowly and
loosen it. Then, remove the fan and generator V belt and
put back the V±ribbed belt tensioner carefully.
13. REMOVE ENGINE MOUNTING INSULATOR
SUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine.
Remove the 4 bolts and 2 nuts and detach the engine
mounting insulator RH.

A11858

A76698
Paint Mark
Match Mark
A62178
Push
A62187
Hold
Tighten
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±9
AVENSIS REPAIR MANUAL (RM1018E)
14. REMOVE V±RIBBED BELT TENSIONER ASSY
(a) Remove the bolt and nut, then remove the V±ribbed belt
tensioner.
HINT:
Jack up and down to remove the bolt.
15. ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to revolve the crankshaft without the chain ten-
sioner.
(a) Set the No. 1 cylinder to the TDC/compression.
(b) Place match marks on the 2 camshaft sprockets and paint
marks on the timing chain.
(c) Remove the 2 nuts and the chain tensioner.
(d) Hold the camshaft with a wrench, loosen the camshaft
timing gear set bolt.
NOTICE:
Be careful not to damage the valve lifter.

A62188
24 5 3 1
A32124
A6218924 31
A32125
A32556
14±10
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(e) Using several steps, loosen the camshaft bearing cap
bolts on the No. 2 camshaft in the sequence shown in the
illustration and remove the bearing caps.
(f) Remove the camshaft timing gear as shown in the illustra-
tion.
(g) Using several steps, loosen the camshaft bearing cap
bolts on the camshaft in the sequence shown in the il-
lustration and remove the bearing caps.
(h) Remove the camshaft while holding the timing chain.
(i) Tie the timing chain with a string as shown in the illustra-
tion.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.

A01082
Example (Intake):
Measure intake valve clearance = 0.40 mm (0.0158 in.)
0.40 mm (0.0158 in.) ± 0.20 mm (0.0079 in.) = 0.20 mm (0.0079 in.)
(Measured ± Specification = Excess clearance)
Used lifter measurement = 5.250 mm (0.2067 in.)
0.20 mm (0.0079 in.) + 5.250 mm (0.2067 in.) = 5.450 mm (0.2146 in.)
(Excess clearance + Used lifter = Ideal new lifter)
Closest new lifter = 5.460 mm (0.2150 in.)
Select No. 46 lifter
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±11
AVENSIS REPAIR MANUAL (RM1018E)
(j) Remove the valve lifters.
(k) Using a micrometer, measure the thickness of the re-
moved lifter.
(l) Calculate the thickness of a new lifter so that the valve
clearance comes within the specified value.
AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance
Valve clearance:
Intake A = B + (C ± 0.20 mm (0.0079 in.))
Exhaust A = B + (C ± 0.30 mm (0.0118 in.))
HINT:

Select a new lifter with a thickness as close as possible
to the calculated values.

Lifter 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.).

Refer to new lifter thickness table on the next 2 pages.

A79322
New lifter thickness mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
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)
1ZZ±FE, 3ZZ±FE: Valve Lifter Selection Chart (Intake)
Intake valve clearance (Cold):
0.15 ± 0.25 mm (0.006 ± 0.010 in.)
EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and
the measured clearance is 0.400 mm (0.0157 in.).
Replace the 5.250 mm (0.2067 in.) lifter with a new No. 46 lifter.
14±12
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)

A79323
New lifter thickness mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
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)
1ZZ±FE, 3ZZ±FE: Valve Lifter Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.25 ± 0.35 mm (0.010 ± 0.014 in.)
EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and
the measured clearance is 0.440 mm (0.0173 in.).
Replace the 5.340 mm (0.2102 in.) lifter with a new No. 48 lifter.
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±13
AVENSIS REPAIR MANUAL (RM1018E)

A62195
Painted Link
Timing Mark
A62196
4123
A62197
Painted Link
Timing Mark
A32124
A621983124 5 67 14±14
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(m) Install the timing chain on the camshaft timing gear with
the painted links aligned with the timing marks on the
camshaft timing sprocket as shown in the illustration.
(n) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(o) Put the camshaft No.2 on the cylinder head with the
painted links of the chain aligned with the timing mark on
the camshaft timing sprocket.
(p) Tighten the camshaft timing gear set bolt temporarily.
(q) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(r) Install the bearing cap No. 1.
Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)

A62187
Hold
Tighten
A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Timing
Notch
A62177
Raise
Push
Hook
Pin
A62178
Push
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±15
AVENSIS REPAIR MANUAL (RM1018E)
(s) Hold the camshaft with a wrench, tighten the camshaft
timing gear set bolt.
Torque: 54 N
m (551 kgf
cm, 40 ft
lbf)
NOTICE:
Be careful not damage the valve lifter.
(t) Check the match marks on the 2 camshaft sprockets are
aligned with each other and aligned with the painted links
of the timing chain as shown in the illustration. Also, check
the timing notch is aligned with the timing mark º0º of the
chain cover.
(u) Install chain tensioner.
(1) Check that the O±ring is clean, and set the hook as
shown in the illustration.
(2) Apply engine oil to the chain tensioner and install it
with the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fixit.

A62180
Disconnect
Hook
Pin Turn
A62181
Plunger
Turn
Push
A11858
A64005
14±16
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(3) Turn the crankshaft counterclockwise, and take the
hook off the knock pin to release the plunger.
(4) Turn the crankshaft clockwise, and check that the
plunger is extended.
HINT:
If the plunger does not be extended, press the slipper into the
chain tensioner using a screwdriver so that the hook is took off
from the knock pin and let the plunger can be extended.
16. INSTALL V±RIBBED BELT TENSIONER ASSY
(a) Install the V±ribbed belt tensioner with the nut and bolt.
Torque:
29 N
m (296 kgf
cm, 21 ft
lbf) for Nut
69 N
m (704 kgf
cm, 51 ft
lbf) for Bolt
17. INSTALL ENGINE MOUNTING INSULATOR
SUB±ASSY RH
(a) Install the engine mounting insulator with the 4 bolts and
2 nuts.
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)

A62182
Seal Packing
A65687
A
AAA
A
A A A
ABB
A64023
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±17
AVENSIS REPAIR MANUAL (RM1018E)
18. INSTALL CYLINDER HEAD COVER SUB±ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the 2 locations as shown in the il-
lustration.
Seal packing: Part No. 08826±00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 3 minutes after
applying seal packing.

Do not expose the seal to engine oil 2 hours after
installing.
(c) Install the cylinder head cover and cable bracket with the
9 bolts, 2 seal washers and 2 nuts. Tighten the bolts and
nuts uniformly in the several steps.
Torque:
11 N
m (112 kgf
cm, 8 ft
lbf) for A
9.0 N
m (92 kgf
cm, 80 in
lbf) for B
19. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)