TOYOTA AVENSIS 2003 Service Repair Manual

141CE±01
A78459
A76713
A64023
A65078
14±6
±
ENGINE MECHANICALVALVE CLEARANCE(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1ZZ±FE/3ZZ±FE)
ADJUSTMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER(See page 14±27)
2.REMOVE ENGINE ROOM COVER SIDE(See page 14±27) 3. REMOVE CYLINDER HEAD COVER NO.2
(a) Remove the 2 nuts and 2 clips and detach cylinder headcover No.2.
4. DISCONNECT IGNITION COIL ASSY
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the 2 nuts which are used to secure the engine wire.
(d) Remove the 4 bolts and the 4 ignition coils.
5. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head cover.
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A64058
A64856
A62185
MarkMark
Mark Timing Chain
Cover Surface
Timing
Notch
A01131
±
ENGINE MECHANICAL VALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±7
AVENSIS REPAIR MANUAL (RM1018E)
6. DISCONNECT VENTILATION HOSE NO.2
(a) Disconnect the ventilation hose from the cylinder head
cover.
7. REMOVE CYLINDER HEAD COVER SUB±ASSY
(a) Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp brackets and cylinder head cover.
8. REMOVE ENGINE UNDER COVER SUB±ASSY NO.1
9. REMOVE ENGINE UNDER COVER RH
10. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align the timing notch with timing mark º0º of the timing chain cover.
(b) Check that the point marks of the camshaft timing sprock- et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
11. INSPECT VALVE CLEARANCE
(a) Check the valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and the 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.)
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A01132
A60622
A01045
A64005
14±8
±
ENGINE MECHANICAL VALVE 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.
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A11858

A76698
Paint Mark
Match Mark
A62178
Push
A62187
Hold
Tighten
±
ENGINE MECHANICAL VALVE 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.
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A62188
24 5 3 1
A32124
A6218924 31
A32125
A32556
14±10
±
ENGINE MECHANICAL VALVE 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.
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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 MECHANICAL VALVE 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.
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A79322
New lifter thickness mm (in.)
Lifter
No.
Thickness Lifter
No.
Thickness Lifter
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
28 30
32
34
36
38
40
42
44
46
48
50
52
54
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 MECHANICAL VALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
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A79323
New lifter thickness mm (in.)
Lifter
No.
Thickness Lifter
No.
Thickness Lifter
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
28 30
32
34
36
38
40
42
44
46
48
50
52
54
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 MECHANICAL VALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
14±13
AVENSIS REPAIR MANUAL (RM1018E)
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A62195
Painted Link
Timing Mark
A62196
4123
A62197
Painted Link
Timing Mark
A32124
A621983124
5
6 7
14±14
±
ENGINE MECHANICAL VALVE 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)
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A62187
Hold
Tighten
A62185
Mark Mark
Mark Timing Chain
Cover Surface
Timing
Notch
A62177
Raise
Push
Hook
Pin
A62178
Push
±
ENGINE MECHANICAL VALVE 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 asshown 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.
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