Page 1977 of 5135

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.
Page 1978 of 5135

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)
Page 1979 of 5135

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)
Page 1980 of 5135
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 Nm (133 kgfcm, 10 ftlbf)
(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 Nm (133 kgfcm, 10 ftlbf)
(r) Install the bearing cap No. 1.
Torque: 23 Nm (235 kgfcm, 17 ftlbf)
Page 1981 of 5135
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 Nm (551 kgfcm, 40 ftlbf)
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 Nm (92 kgfcm, 80 inlbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fixit.
Page 1982 of 5135
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 Nm (296 kgfcm, 21 ftlbf) for Nut
69 Nm (704 kgfcm, 51 ftlbf) 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 Nm (530 kgfcm, 38 ftlbf)
Page 1983 of 5135
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 Nm (112 kgfcm, 8 ftlbf) for A
9.0 Nm (92 kgfcm, 80 inlbf) for B
19. INSTALL IGNITION COIL ASSY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
Page 1984 of 5135
A76713
A78459
14±18
± ENGINE MECHANICALVALVE CLEARANCE (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the engine wire with the 2 nuts.
Torque: 9.0 Nm (92 kgfcm, 80 in.lbf)
20. INSTALL CYLINDER HEAD COVER NO.2
(a) Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 Nm (71 kgfcm, 62 in.lbf)
21. CHECK FOR ENGINE OIL LEAKS