2003 TOYOTA AVENSIS specification

A01082
EXAMPLE: (Intake)
Measure valve clearance = 0.44 mm (0.0173 in.)
0.44 mm (0.0173 in.) ± 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in\
.)
(Measured ± Specification = Excess clearance)
Used shim measurement = 5.30 mm (0.2087 in.)
0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.)\

(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 5.50 mm (0.2165 in.) = Shim No. º50º
A77295
±
ENGINE MECHANICALVALVE CLEARANCE(1AZ±FE)
14±107
AVENSIS REPAIR MANUAL (RM1018E)
9.ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to turn the crankshaft without the chain ten-
sioner.
(a)Set the No. 1 cylinder to TDC/compression.
(See page 14±171)
(b)Remove the chain tensioner. (See page 14±171)
(c)Remove the camshafts. (See page 14±171)
(d) Tie the timing chain with a string.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(e) Remove the valve lifters.
(f) Using a micrometer, measure the thickness of the re-
moved lifter.
(g) Calculate the thickness of a new lifter so that the valve
clearance comes within the specified valve.
AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance
Valve clearance:
Intake: A = B + (C ± 0.24 mm (0.0094 in.))
Exhaust: A = B + (C ± 0.35 mm (0.0138 in.))
HINT:

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

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.).

Identification number inside the valve lifter shows the val-
ue of the 2 decimal places. (The illustration shows 5.380
mm (0.2118 in.))

Refer to the New Lifter Thickness table on the next 2
pages.
http://vnx.su

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.)
http://vnx.su

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.
http://vnx.su

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.
http://vnx.su

A62185
MarkMark
Mark Timing Chain
Cover Surface
Groove
A01131
A01132
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1ZZ±FE/3ZZ±FE)
14±21
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
64. INSPECT VALVE CLEARANCE
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley, and align its groove with
timing mark º0º of the timing chain cover.
(2) Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line
on the timing chain cover surface as shown in the
illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
(b) Check only the valves indicated. (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 adjusting shim.
Valve clearance (Cold):
Intake 0.15 ± 0.25 mm (0.006 ± 0.010 in.)
Exhaust 0.25 ± 0.35 mm (0.010 ± 0.014 in.)
(c) Turn the crankshaft 1 revolution (360
) and set No. 4 cyl-
inder to TDC/compression.
(d) Check only the valves indicated. (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 adjusting shim.
Valve clearance (Cold):
Intake 0.15 ± 0.25 mm (0.006 ± 0.010 in.)
Exhaust 0.25 ± 0.35 mm (0.010 ± 0.014 in.)
http://vnx.su

01±10
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E) Abbreviations Meaning
PKBParking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take±Off
P/WPower Window
R & PRack And Pinion
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RRSRigid Rear Suspension
RHRight±Hand
RHDRight±Hand Drive
RLYRelay
ROMRead Only Memory
RRRear
RRSRear±Wheel Drive
RWDRear±Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold±Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer±Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension
TFTToyota Free±Tronic
TISTotal Information System For Vehicle Development
T/MTransmission
TMCTOYOTA Motor Corporation
TMMKTOYOTA Motor Manufacturing Kentucky, Inc.
TRCTraction Control System
TURBOTurbocharge
TWCThree±Way Catalyst
U/DUnderdrive
U/SUndersize
http://vnx.su

Illustration:what to do and where Task heading: what to do
Detailed text:how to do task
Set part No. Component part No.
A59974
01±2
±
INTRODUCTION HOW TO USE THIS MANUAL (1ZZ±FE/3ZZ±FE)
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
(d) Tightening torque, oil applying position, and non±reusable parts are described \
as important points in the procedure.
NOTICE:
There are cases where such information can only be indicated by an illustrati\
on. In that case, all the
information such as torque, oil, etc. are described in the illustration.
(e) Installing procedure of operation items is performed in the reverse order of the removing, and only the important points are described.
(f) Only items with points are described in the procedure, and the operational portion \
and content are placed using an illustration. In the explanations, details of the operational \
method, standard value and
notice are placed.
(g) There may be a case where the illustrations of similar models are used. In th\
at case the details may be different from the actual vehicle.
(h) The procedures are presented in a step±by±step format: (1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The detailed text tells how to perform the task and gives other information\
such as specificationsand warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
heading can be read at a glance when necessary, and the text below provides detailed information. Impor-
tant specifications and warnings always stand out in bold type.
5. SERVICE SPECIFICATIONS
(a) Specifications are presented in bold type throughout the manual. You never have to leave the proce- dure to look up your specifications. The specifications are also found in th\
e Service Specifications sec-
tion for a quick reference.
6. TERMS DEFINITION
CAUTIONIndicate the possibility of injury to you or other people.
NOTICEIndicate the possibility of damage to the components being repaired.
HINTProvide additional information to help you perform the repair efficiently.
http://vnx.su

L1L2
D02612
L2
L1
D01201
L2
L1
D01202
±
INTRODUCTION REPAIR INSTRUCTION (1NZ±FE/2NZ±FE)
01±5
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
NOTICE:
Do the torque checking with the lower limit value of the torque toleranc\
e.
(4) Depending on the seal lock agent to apply, there may be a case where it is necessary to leave
it for a specified time until it hardens.
(b) Gaskets: When necessary, use a sealer on gaskets to prevent leaks.
(c) Bolts, Nuts and Screws:
Carefully observe all specifications for bolt tightening torques. Always\
use a torque wrench.
(d) Torque When Using Extension Tool with Torque Wrench:(1) In case of tightening by extending the entire lengthof the torque wrench combined with SST or tool, if
you tighten until the reading of the torque wrench
reached the specified torque value, the actual
torque becomes excessive.
(2) In this text, only the specified torque is described.
In case of using SST or extension tool, find the read-
ing of the torque wrench by the formula.
(3) Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench N
m kgf
cm ft
lbf 
TTorque N
m kgf
cm ft
lbf 
L1Length of SST or tool (cm)
L2Length of torque wrench (cm)
10. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) Place for Removing and Installing Fuel System Parts:
(1) Place with good air ventilation and without anything flammable such as welder, grinder, drill, elec-
tric motor or stove in the surroundings.
(2) Never work in a place like a pit or nearby pit as there is a possibility that\
vaporized fuel fills those places.
(b) Removing and Installing of Fuel System Parts:
(1) Prepare a fire extinguisher before starting the operation.
(2) For prevention of the static electricity, install a ground on the fuel changer, vehicle and fuel tank,and do not spray much water so as to prevent slipping.
http://vnx.su