2002 TOYOTA AVENSIS Repair Manual

141CE±01
A78459
A76713
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14±6
±
ENGINE MECHANICAL VALVE 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.

A64058
A64856
A62185
Mark
Mark
Mark
Timing Chain
Cover Surface
Timing
Notch
A01131
± ENGINE MECHANICALVALVE 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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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
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A32124
A6218924 31
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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)