TOYOTA AVALON 2001 Service Repair Manual

A05215
Seal Packing
A05217
FrontSemi-Circular Plug
A05216
: Seal Packing
Front
RH Side
LH Side
- ENGINE MECHANICALCYLINDER HEAD
EM-65
1049 Author
: Date
:
2001 AVALON (RM808U)
8. INSTALL SEMI-CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi-circular plug grooves.
Seal packing: Part No. 08826-00080 or equivalent
(c) Install the 2 semi-circular plugs to the cylinder heads.
9. INSTALL CYLINDER HEAD COVERS
(a) Apply seal packing to the cylinder heads as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the 9 bolts. Uniformly
tighten the bolts in several passes. Install the 2 cylinder
head covers.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
10. INSTALL PS PUMP BRACKET
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)

A06661
Manifold
Stay
A07283
New O-Ring
A07281
Manifold
Stay
A05188Inlet PipeRear
Plate
EM-66
- ENGINE MECHANICALCYLINDER HEAD
1050 Author
: Date
:
2001 AVALON (RM808U)
11. INSTALL RH EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(b) Install the exhaust manifold stay with the bolt and nut. Al-
ternately tighten the bolt and nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(c) Connect the A/F sensor connector.
12. INSTALL OIL DIPSTICK AND GUIDE
(a) Install a new O-ring to the dipstick guide.
(b) Apply soapy water to the O-ring.
(c) Push in the dipstick guide end into the guide hole of the
No.1 oil pan.
(d) Install the dipstick guide with the bolt.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
(e) Install the dipstick.
13. INSTALL LH EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(b) Install the exhaust manifold stay with the bolt and nut. Al-
ternately tighten the bolt and nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(c) Connect the A/F sensor connector.
14. INSTALL WATER INLET PIPE
(a) Install a new O-ring to the water inlet pipe.
(b) Apply soapy water to the O-ring.
(c) Connect the water inlet pipe to the water inlet.
(d) Install the bolt holding the water inlet pipe to the cylinder
head.
Torque: 19.5 N´m (200 kgf´cm, 14 ft´lbf)
15. INSTALL CYLINDER HEAD REAR PLATE
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
16. INSTALL ENGINE WIRE PROTECTOR
17. INSTALL CAMSHAFT TIMING OIL CONTROL VALVES
18. INSTALL CAMSHAFT POSITION SENSORS
19. INSTALL NO.3 TIMING BELT COVER
(a) Check that the timing belt cover gaskets have no cracks
or peeling, etc.
If the gaskets have cracks or peeling etc., replace them using
these steps:

Using a screwdriver and gasket scraper, remove all
the old gasket material.

A05194
L = 133 mm (5.24 in.)
L = 180 mm (7.09 in.)L = 72 mm (2.83 in.)
L = 335 mm (13.19 in.)L = 180 mm
(7.09 in.)
L = Length Join
LineJoin
Line
Z14262New Gasket
- ENGINE MECHANICALCYLINDER HEAD
EM-67
1051 Author
: Date
:
2001 AVALON (RM808U)

Thoroughly clean all components to remove all the
loose material.

Remove the backing paper from a new gasket and
install the gasket evenly to the part of the timing belt
cover shaded black in the illustration.
NOTICE:
When joining 2 gaskets, do not leave a gap between them.
Cut off any excess gasket.

After installing the gasket, press down on it so that
the adhesive firmly sticks to the timing belt cover.
(b) Install the timing belt cover with the 6 bolts.
Torque: 8.5 N´m (85 kgf´cm, 74 in.´lbf)
(c) Install the 3 engine wire clamps to the timing belt cover.
20. INSTALL NO.2 IDLER PULLEY (See page EM-21)
21. INSTALL CAMSHAFT TIMING PULLEYS
(See page EM-21)
22. INSTALL TIMING BELT (See page EM-21)
23. INSTALL SPARK PLUGS
24. INSTALL IGNITION COILS
25. INSTALL WATER OUTLET
(a) Install 2 new gaskets.
(b) Connect the water outlet to the bypass hose.
(c) Install the water outlet with the 2 bolts, 2 nuts and 2 plate
washers. Alternately tighten the bolts and nuts.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
NOTICE:
Do not scratch the seal surface of the water outlet with the
stud bolt.
(d) Connect the ECT sender gauge connector.
(e) Connect the ECT sensor connector.
(f) Connect the ground strap connector.
(g) Connect the upper radiator hose.
(h) Connect the engine coolant reservoir hose.

A07428
86
5 43 2
1
910
7
117
A09699
8 mm Hexagon Wrench
A09695
Throttle Body
Bracket
Engine
Hanger
EM-68
- ENGINE MECHANICALCYLINDER HEAD
1052 Author
: Date
:
2001 AVALON (RM808U)
26. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Install the intake manifold, delivery pipe and injectors as-
sembly with the 9 bolts, 2 plate washers and 2 nuts. Uni-
formly tighten the bolts and nuts in several passes and in
the sequence shown.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
(b) Connect the fuel inlet hose to the fuel filter.
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precaution.
(See page SF-1)
(c) Connect the heater hose to the intake manifold.
27. RETIGHTEN WATER OUTLET MOUNTING BOLTS
AND NUTS
Tighten the 2 bolts and 2 nuts.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
28. INSTALL AIR INTAKE CHAMBER ASSEMBLY
(a) Using an 8 mm hexagon wrench, install a new gasket and
the air intake chamber assembly with the 2 bolts and 2
nuts. Uniformly tighten the bolts and nuts in several
passes.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(b) Install the No.1 engine hanger with the 2 bolts.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(c) Install the throttle body bracket with the 2 bolts.
Torque: 19.5 N´m (200 kgf´cm, 14 ft´lbf)
(d) Connect the PCV hose to the PCV valve on the RH cylin-
der head.
(e) Connect the ground strap and cable to the intake air con-
trol valve for the ACIS.
(f) Connect the ground cable and strap with the nut.
Torque: 14.5 N´m (145 kgf´cm, 10 ft´lbf)
(g) Connect the ground cable to the air intake chamber.
(h) Connect the brake booster vacuum hose to the throttle
body.
(i) Connect the 2 water bypass hoses to the throttle body.
(j) Connect the air assist hose to the throttle body.
(k) Connect the purge hose to the emission control valve set.
(l) Connect the 2 vacuum hoses to the vacuum tank for
ACIS.
(m) Connect the engine wire clamp to the emission control
valve set.

- ENGINE MECHANICALCYLINDER HEAD
EM-69
1053 Author
: Date
:
2001 AVALON (RM808U)
(n) Install the PS pressure tube with the 2 nuts.
(o) Connect the throttle position sensor connector.
(p) Connect the IAC valve connector.
(q) Connect the No.1 VSV connector for the ACIS.
(r) Connect the No.2 VSV connector for the ACIS.
(s) Connect the VSV connecter for the EVAP.
(t) Connect the DLC1 to the bracket on the intake air control
valve.
(u) Connect the throttle cable.
(v) Connect the accelerator cable.
29. INSTALL AIR CLEANER CAP HOSE WITH RESONA-
TOR
30. INSTALL V-BANK COVER
(a) Using a 5 mm hexagon wrench, install the V-bank cover
with the 3 cap nuts.
(b) Press down the V-bank cover fastener.
31. INSTALL FRONT EXHAUST PIPE (See page EM-77)
32. INSTALL PS PUMP (See page SR-35)
33. INSTALL GENERATOR DRIVE BELT
(See page CH-16)
34. FILL WITH ENGINE COOLANT
35. START ENGINE AND CHECK FOR LEAKS
36. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smoothly operation.
37. RECHECK ENGINE COOLANT LEVEL

EM0ZI-02
P1151110 - 15 mm (0.39 - 0.59 in.)Adhesive
P12572
Protrusion
P12869
Flush
A05418
EM-56
- ENGINE MECHANICALCYLINDER HEAD
1040 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Apply adhesive to the end of the spark plug tube.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent
(b) Using a press, press in a new spark plug tube until there
is 42.4 - 43.4 mm (1.669 - 1.709 in.) protruding from the
camshaft bearing cap installation surface of the cylinder
head.
NOTICE:
Avoid pressing a new spark plug tube in too far by measur-
ing the amount of the protrusion while pressing.
2. INSTALL PCV PIPES
HINT:
When using a new cylinder head, PCV pipe must be installed.
Using a wooden block and hammer, tap in a new PCV pipe until
its top side is flush with the cylinder head edge.
NOTICE:
Be careful not to damage the cylinder head edge.
3. INSTALL OIL CONTROL VALVE FILTER
(a) Assemble the valve filter and plug.
(b) Install the plug with new gasket.
Torque: 45 N´m (460 kgf´cm, 33 ft´lbf)

A05276
P12719
SST
Z19062
Intake ExhaustMark
ºNOKº or
ºFN , INº
Light Brown SurfaceGray Surface
P12668
(4)
(3)
(2)
(1)
A05224
SST
- ENGINE MECHANICALCYLINDER HEAD
EM-57
1041 Author
: Date
:
2001 AVALON (RM808U)
4. INSTALL CYLINDER HEAD REAR COVER
Install the rear cover and gasket with the 6 bolts.
Torque: 10 N´m (100 kgf´cm, 7.3 ft´lbf)
5. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201-41020
HINT:
The intake valve oil seal is light brown and the exhaust valve oil
seal is gray.
NOTICE:
Pay much attention when assembling the oil seal for intake
and exhaust. Assembling the wrong one may cause a fail-
ure.
(b) Install the valve (1), spring seat (2), valve spring (3) and
spring retainer (4).
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202-70020 (09202-00010)

A05246
EM-58
- ENGINE MECHANICALCYLINDER HEAD
1042 Author
: Date
:
2001 AVALON (RM808U)
(d) Using a plastic-faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to assure proper fit.
NOTICE:
Be careful not do damage the valve stem tip.
6. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

EM0ZE-02
A10518
5 mm
Hexagon
Wrench
A06658
(j)
(k) (l)
- ENGINE MECHANICALCYLINDER HEAD
EM-31
1015 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i)
beside changing VVT-i or the camshaft.
1. DRAIN ENGINE COOLANT
2. REMOVE RH FENDER APRON SEAL
3. REMOVE GENERATOR DRIVE BELT
(See page CH-6)
4. REMOVE PS PUMP (See page SR-27)
5. REMOVE FRONT EXHAUST PIPE (See page EM-72)
6. REMOVE V-BANK COVER
(a) Using a 5 mm hexagon wrench, remove the 3 cap nuts.
(b) Loosen the V-bank cover fastener counterclockwise.
(c) Remove the V-bank cover.
7. REMOVE AIR CLEANER HOSE WITH RESONATOR
8. REMOVE AIR INTAKE CHAMBER ASSEMBLY
(a) Disconnect the accelerator cable.
(b) Disconnect the throttle cable.
(c) Disconnect the throttle position sensor connector.
(d) Disconnect the IAC valve connector.
(e) Disconnect the No.1 VSV connector for the ACIS.
(f) Disconnect the No.2 VSV connector for the ACIS.
(g) Disconnect the VSV connector for the EVAP.
(h) Disconnect the DLC1 from the bracket on the intake air
control valve.
(i) Remove the 2 nuts, and disconnect the PS pressure tube
from the No.1 engine hanger.
(j) Disconnect the PCV hose from the PCV valve on the RH
cylinder head.
(k) Disconnect the ground strap and cable from the intake air
control valve for the ACIS.
(l) Disconnect the ground cable from the air intake chamber.

A07505
(p)
(q)
(r)(o)
(n)
(m)
(n)
A09695
Throttle Body
Bracket
Engine
Hanger
A09699
8 mm Hexagon Wrench
A05074(b) (c)
EM-32
- ENGINE MECHANICALCYLINDER HEAD
1016 Author
: Date
:
2001 AVALON (RM808U)
(m) Disconnect the brake booster vacuum hose from the
throttle body.
(n) Disconnect the 2 water bypass hoses from the throttle
body.
(o) Disconnect the air assist hose from the throttle body.
(p) Disconnect the purge hose from the pipe on the emission
control valve set.
(q) Disconnect the 2 vacuum hoses from the vacuum tank for
the ACIS.
(r) Disconnect the engine wire clamp from the emission con-
trol valve set.
(s) Remove the 2 bolts and No.1 engine hanger.
(t) Remove the 2 bolts and throttle body bracket.
(u) Using an 8 mm hexagon wrench, remove the 2 bolts, 2
nuts, the air intake chamber assembly and gasket.
9. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the 6 injector connectors.
(b) Disconnect the fuel inlet hose from the fuel filter.
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.
(See page SF-1)
(c) Disconnect the heater hose from the intake manifold.