Page 2241 of 5135
A79424
N´m (kgf´cm, ft´lbf)
: Specified torque
Non±reusable part
8.8 (90, 65 in.lbf)
8.8 (90, 6.5 in.lbf)
8.4 (86, 74 in.lbf)
21 (209, 15)
8.8 (90, 78 in.lbf)
34 (347, 25)
18 (184, 13)21 (210, 15)
21 (210, 15)
42 (428, 31)
37 (377, 27)
59 (600, 43)
21 (214, 15)
45 (454, 33)
O±ring
O±ring
Gasket
O±ring
O±ring
Vacuum Pump Oil Pipe
Union Bolt
Oil Cooler AssyFuel Filter To Injection Pump
Fuel Pipe
Rear End Plate
Crankshaft Position
Sensor
Thermostat
Water Inlet
Oil Level Gage Guide Oil Filter Bracket Sub±assy
Injection or Supply Pump Assy Compressor Mounting
Bracket No. 1Generator Bracket No. 1 V±ribbed Belt
Tensioner
AssyGenerator Assy
Oil Cooler Pipe
Gasket
Turbo Oil Outlet Pipe No. 2
31 (320, 23)
Gasket
33 (331, 24)
8.8 (90, 78 in.lbf)
47 (475, 34)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1CD±FTV)
14±285
AVENSIS REPAIR MANUAL (RM1018E)
Page 2242 of 5135

141C2±01
A78277
A79143
SST
14±270
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
VALVE CLEARANCE(1CD±FTV)
ADJUSTMENT
NOTICE:
Before removing the injection pipes, clean them up with a soft brush and compr\
essed air.
After removing the injection pipe, cover the supply pump, the common rail and the injector
mounting area of the cylinder head cover with vinyl tape to prevent dust from being introduce\
d.
After removing the cylinder head cover, protect the injector inlet with a vinyl or a plastic bag
to prevent foreign objects from being introduced.
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1.REMOVE RADIATOR SUPPORT OPENING COVER
2.REMOVE FRONT WHEEL RH
3.REMOVE ENGINE UNDER COVER RH
4.DRAIN ENGINE COOLANT (See page 16±44)
5.REMOVE ENGINE COVER NO.1
(a)Remove the 5 nuts and the engine cover.
6.REMOVE AIR TUBE NO.1
(a)Disconnect the vacuum hoses and the connectors.
(b)Loosen the hose clamps.
(c)Remove the 3 bolts and nut, and then detach the air tubeNo. 1.
7.REMOVE TIMING BELT NO.2 COVER (See page 14±307) 8. REMOVE INJECTION PIPE SUB±ASSY NO.1
(a) Remove the 2 nuts and 2 upper infection pipe clampsfrom the intake manifold.
(b) Using SST, remove the injection pipe from the common rail side.
SST 09023±12700
(c) Using SST, remove the injection pipe from the injector
side.
SST 09023±12700
(d) After removing the fuel pipe, to prevent dust or foreign ob- jects from being introduced, cover the common rail with
vinyl tape and protect the injector inlet with a vinyl or a
plastic bag.
Page 2243 of 5135

A09687
UpwardCam Lobe
Clearance
A80107
A81553
Upward
Notch
Cam Lobe
Intake
Manifold
Side
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
14±271
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE INJECTION PIPE SUB±ASSY NO.2
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
10.REMOVE INJECTION PIPE SUB±ASSY NO.3
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
11.REMOVE INJECTION PIPE SUB±ASSY NO.4
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
12.REMOVE CYLINDER HEAD COVER SUB±ASSY (See page 11±60)
13.REMOVE NOZZLE LEAKAGE PIPE ASSY (See page 11±60)
14.REMOVE INJECTOR ASSY (See page 11±60)
HINT:
Since each injector assembly has characteristic fuel injecting behavior, store them in correct order so that
they can be returned to the original locations when re±assembling.
15. INSPECT VALVE CLEARANCE
(a) Turn the crankshaft so that the cam lobe located over theinspecting valve faces upward.
(b) Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
(c) Measure the clearance at 16 places.
(d) Record the out±of specification valve clearance mea- surements. They will be used later to determine the re-
quired replacement adjusting shim.
Valve clearance (Cold):
Intake0.20 to 0.30 mm (0.008 to 0.012 in.)
Exhaust0.35 to 0.45 mm (0.014 to 0.018 in.)
16. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.(1) Turn the crankshaft so that the cam lobe located
over the adjusting valve faces upward.
(2) Position the notch of the valve lifter toward the in- take manifold side.
Page 2244 of 5135

SST (A)
SST (B)
A09616
A09615
Magnetic
Finger
A54826
EXAMPLE (Intake):
Measured valve clearance = 0.45 mm (0.0177 in.)
0.45 mm (0.0177 in.) ± 0.25 mm (0.0098 in.) = 0.20 mm (0.0078 in.)
(Measured ± Specification = Excess clearance)
Used shim measurement = 2.80 mm (0.1102 in.)
0.20 mm (0.0078 in.) + 2.80 mm (0.1102 in.) = 3.00 mm (0.1181 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 3.00 mm (0.1181 in.)
Select No. 21 Shim
14±272
± ENGINE MECHANICALVALVE CLEARANCE (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(3) Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter. Re-
move SST (A).
SST 09248±55050 (09248±05510, 09248±05520)
HINT:
Apply SST (B) which marked º11º.
(4) Remove the adjusting shim with a small screwdriver
and a magnetic finger.
(b) Determine the replacement adjusting shim size using the
following formula or the matrix attached to the end of this
section.
(1) Using a micrometer, measure the thickness of the
removed shim.
(2) Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
HINT:
T ........... Thickness of removed adjusting shim
A ........... Measured valve clearance
N ........... Thickness of new adjusting shim
Intake: N = T + (A ± 0.25 mm (0.010 in.))
Exhaust: N = T + (A ± 0.40 mm (0.016 in.))
(3) Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 17 sizes in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
Page 2245 of 5135

SST (A)
SST (B)
A09686
A79147
Fulcrum
Length
30 cm
SST
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
14±273
AVENSIS REPAIR MANUAL (RM1018E)
(c)Install a new adjusting shim.
(1)Place a new adjusting shim on the valve lifter.
(2)Using SST (A), press down the valve lifter and re-move SST (B).
SST09248±55050 (09248±05510, 09248±05520)
(d)Recheck the valve clearance. SST09248±55050 (09248±05510, 09248±05520)
17.INSTALL INJECTOR ASSY (See page 11±60)
18.INSTALL NOZZLE LEAKAGE PIPE ASSY (See page 11±60) SST 09992±00242
19.INSTALL CYLINDER HEAD COVER SUB±ASSY (See page 11±60) 20. INSTALL INJECTION PIPE SUB±ASSY NO.1 (See page 11±60)
NOTICE:
When assembling the pipes, perform the operation with the
engine cold under room temperature.
(a) Remove the vinyl or the plastic bag from the injector and vinyl tape from the common rail.
(b) Temporarily install the injection pipe.
(c) Using SST, tighten the nut of the injection pipe to the com- mon rail side.
SST 09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
Page 2246 of 5135

14±274
±
ENGINE MECHANICAL VALVE CLEARANCE(1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(d)Using SST, tighten the nut of the injection pipe to the injec- tor side.
SST09023±12700
Torque:
42 Nm (428 kgf cm, 31 ft lbf) for a used pipe using SST
46 N m (469 kgf cm, 34 ft lbf) for a used pipe not using
SST
31 N m (316 kgf cm, 23 ft lbf) for a new pipe using SST
34 N m (347 kgf cm, 25 ft lbf) for a new pipe not using
SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm
(11.81 in.)
Check if the used pipe has deflection or is installed prop-
erly after injection pipe is reassembled. If there is deflec-
tion or if it can not be installed properly, replace the used
pipe with a new pipe.
(e)Install the 2 upper injection pipe clamps with the 2 nuts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf)
21.INSTALL INJECTION PIPE SUB±ASSY NO.2
SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
22.INSTALL INJECTION PIPE SUB±ASSY NO.3 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
23.INSTALL INJECTION PIPE SUB±ASSY NO.4 SST09023±12700
HINT:
Perform the same procedures as injection pipe No. 1.
24.INSTALL TIMING BELT NO.2 COVER (See page 11±60)
25. INSTALL AIR TUBE NO.1 Torque: 25 N m (255 kgf cm, 18 ft lbf)
26. INSTALL ENGINE COVER NO.1 Torque: 8.0 N m (82 kgf cm, 71 in. lbf)
27. INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf)
28.ADD ENGINE COOLANT (See page 16±44)
29.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
30.CHECK FOR FUEL LEAKS (See page 11±60)
Page 2247 of 5135
A57526
Adjusting Shim Selection Chart (Intake)
New shim thickness
Intake valve clearance (Cold):
0.20 ± 0.30 mm (0.008 ± 0.012 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No.21
shim.mm (in.)
Shim
No.Thickness
01Shim
No.Thickness
03
05
07
09
11
13
1519
21
23
25
27 2.500 (0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
29
31
33 2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950 (0.1161)
3.000 (0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299)
Installed shim thickness
mm (in.)
Measured clearance
mm (in.)
17
± ENGINE MECHANICALVALVE CLEARANCE (1CD±FTV)
14±275
AVENSIS REPAIR MANUAL (RM1018E)
Page 2248 of 5135
A57527
Adjusting Shim Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.35 ± 0.45 mm (0.014 ± 0.018 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.590 mm (0.0232 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No.21
shim.
Installed shim thickness
mm (in.)
Measured clearance
mm (in.)
New shim thickness mm (in.)
Shim
No.Thickness
01Shim
No.Thickness
03
05
07
09
11
13
1519
21
23
25
27 2.500 (0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
29
31
33 2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950 (0.1161)
3.000 (0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299)
17
14±276
± ENGINE MECHANICALVALVE CLEARANCE (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)