TOYOTA AVALON 2001 Service Repair Manual

A05244
SST
- ENGINE MECHANICALCYLINDER HEAD
EM-55
1039 Author
: Date
:
2001 AVALON (RM808U)
(d) Using SST and a hammer, tap in a new gasket until its sur-
face is flush with the upper edge of the cylinder head cov-
er.
SST 09608-03071
(e) Apply a light coat of MP grease to the gasket lip.
(f) Return the ventilation plate tab to its original position.

EM0ZK-02
A10837
No.2 Cooling Fan Connector
Upper Radiator
Support
Radiator
Assembly RH Fender
Apron
Seal
Generator
Drive
Belt
A/C Compressor
Connector
Battery
Insulator
Battery
Battery
Tray Generator Drive
Belt Adjusting
Bar Bracket
LH Fender
Apron Seal

Gasket A/C Compressor
43 (440, 32)
25 (250, 18)

Non-reusable partStay
N´m (kgf´cm, ft´lbf) Front Exhaust Pipe: Specified torque
Gasket
62 (630, 46)
33 (330, 24)


62 (630, 46)
43 (430, 32)

Gasket
Actuator Cover No.3 Engine Room
Relay BlockHood
Hold-Down
Clamp
Washer
Hose for
Windshield
Air Filter
Air Cleaner Case
O-Ring
Drain Plug Lower Radiator
SupportAir Cleaner
Cap Assembly Radiator Upper Hose
Cruise Control
Actuator
Cruise Control
Actuator
ConnectorAccelerator Cable
PS Pump

PS Pump
Drive Belt
Compression Spring
V-Bank Cover
A/T Oil Cooler Hose
Radiator Lower
HoseEVAP Hose
Assembly
MAF Meter Connector
VSV for Active
Control Engine
Mount
No.1 ECT Switch Wire Connector
No.1 Cooling Fan Connector
Vacuum Hose
Air Hose
EM-70
- ENGINE MECHANICALENGINE UNIT
1054 Author
: Date
:
2001 AVALON (RM808U)
ENGINE UNIT
COMPONENTS

A10839
Non-reusable part
RH Drive Shaft
Tie Rod End
Engine Moving
Control Rod
No.2 RH Engine
Mounting Bracket
Engine and Transaxle
Assembly
LH Drive Shaft




Lower Suspension Arm
Front Engine
Mounting InsulatorRear Engine
Mounting
Insulator
Engine Mounting Absorber
: Specified torque
N´m (kgf´cm, ft´lbf)
64 (650, 47)
64 (650, 47)
64 (650, 47)
64 (650, 47)
32 (320, 23)
294 (3,000, 217)
49 (500, 36)
127 (1,300, 94)
48 (490, 35)
44 (450, 32) for Silver Color
66 (670, 49) for Green Color
66 (670, 48)
Transaxle
Control Cable
- ENGINE MECHANICALENGINE UNIT
EM-71
1055 Author
: Date
:
2001 AVALON (RM808U)

EM0M5-03
A07436
A07507
Ohmmeter
Continuity
A07508
Ohmmeter
No Continuity
A07509
Air
H G
E
A07566
Air
HE F
Battery
EM-76
- ENGINE MECHANICALENGINE UNIT
1060 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
1. INSPECT FRONT ENGINE MOUNTING INSULATOR
(a) Using a MITYVAC (Hand-Held Vacuum Pump), apply
vacuum of 80 kPa (600 mmHg, 25 in.Hg) and allow it to
stand for 1 minute.
(b) Check that there is no change in the needle movement.
(c) Check that there is no fluid leakage caused by a break of
a lower diaphragm.
If the operation is not as specified, replace the insulator.
2. INSPECT VSV FOR ACTIVE CONTROL ENGINE
MOUNT
(a) Inspect the VSV for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the terminals.
Resistance: 19 - 21 W at 20°C (68°F)
If there is no continuity, replace the VSV.
(b) Inspect the VSV for ground.
Using an ohmmeter, check that there is no continuity be-
tween each terminal and the body.
If there is continuity, replace the VSV.
(c) Inspect the VSV operation.
(1) Check that air flows from port G to port E and port
H.
(2) Apply battery positive voltage across the terminals.
(3) Check that air flows from port F to port E and port
H.
If operation is not as specified, replace the VSV.
3. INSPECT VACUUM TANK (See page SF-58)

EM0ZM-02
A07437
Lower
A07434
A07435
ABD
C
A07432
- ENGINE MECHANICALENGINE UNIT
EM-77
1061 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
1. ASSEMBLE ENGINE AND TRANSAXLE
2. INSTALL REAR ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
3. INSTALL FRONT ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
4. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN
VEHICLE
(a) Attach the engine sling device to the engine hangers.
(b) Lower the engine into the engine compartment.
Tilt the transaxle downward, lower the engine and clear
the LH mounting.
NOTICE:
Be careful not to hit the park/neutral position switch.
(c) Keep the engine level, and align RH and LH mountings
with the body bracket.
5. INSTALL NO.2 RH ENGINE MOUNTING BRACKET
AND ENGINE MOVING CONTROL ROD
(a) Temporarily install the No.2 RH engine mounting bracket
and engine moving control rod with the 3 bolts.
(b) Tighten the bolt (A).
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
(c) Tighten the other 3 bolts (B, C and D).
Torque:
64 N´m (650 kgf´cm, 47 ft´lbf) for bolts B and C
32 N´m (320 kgf´cm, 23 ft´lbf) for bolt D
6. CONNECT FRONT ENGINE MOUNTING INSULATOR
Connect the mounting insulator with the 3 bolts.
Torque:
44 N´m (450 kgf´cm, 32 ft´lbf) for silver color bolt
66 N´m (670 kgf´cm, 49 ft´lbf) for green color bolt

A07431
P18752
A07430
P18775
A10833
BracketA
B
A
A
C
A EM-78
- ENGINE MECHANICALENGINE UNIT
1062 Author
: Date
:
2001 AVALON (RM808U)
7. INSTALL ENGINE MOUNTING ABSORBER
Install the engine mounting absorber with the 4 bolts.
Torque: 48 N´m (490 kgf´cm, 35 ft´lbf)
8. CONNECT REAR ENGINE MOUNTING INSULATOR
(a) Connect the mounting insulator with the 4 nuts.
Torque: 66 N´m (670 kgf´cm, 48 ft´lbf)
(b) Install the 2 hole plugs.
9. CONNECT LH ENGINE MOUNTING INSULATOR
Connect the mounting insulator with the 4 bolts.
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
10. REMOVE ENGINE SLING DEVICE
11. CONNECT TRANSAXLE CONTROL CABLE TO
TRANSAXLE
12. INSTALL PS PUMP
(a) Install the PS pump with the 2 bolts.
Torque: 43 N´m (440 kgf´cm, 31 ft´lbf)
(b) Install the drive belt.
(c) Connect the PS pressure tube with the 2 nuts.
13. INSTALL A/C COMPRESSOR
(a) Install the A/C compressor and drive belt adjusting bar
bracket with the 5 bolts and nut.
Torque:
25 N´m (250 kgf´cm, 18 ft´lbf) for bolt A
18 N´m (185 kgf´cm, 13 ft´lbf) for bolt B
25 N´m (250 kgf´cm, 18 ft´lbf) for nut C
(b) Install the drive belt.
(c) Connect the A/C compressor connector.
14. INSTALL DRIVE SHAFTS (See page SA-24)

S04497
A07300
- ENGINE MECHANICALENGINE UNIT
EM-79
1063 Author
: Date
:
2001 AVALON (RM808U)
15. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel. Install the
grommet.
(b) Connect the 5 engine ECM connectors.
(c) Install the glove compartment.
16. CONNECT CONNECTORS, CABLE, CLAMPS AND
HOSES
(a) Connect the noise filter connector on the LH fender
apron.
(b) Connect the generator connector and wire.
(c) Connect the starter connector and wire.
(d) Connect the 2 ground strap connectors to the RH fender
apron
(e) Connect the strap connector to the LH fender apron with
the bolt.
(f) Connect the ground cable to the battery body bracket.
(g) Connect the engine wire protector clamp to the battery
body bracket.
(h) Connect the engine wire clamp to the bracket on the RH
fender apron.
(i) Connect the brake booster vacuum hose to the throttle
body.
(j) Connect the engine coolant reservoir hose to the water
outlet.
(k) Connect the heater hose to the intake manifold.
(l) Connect the heater hose to the water inlet housing.
(m) Connect the fuel inlet hose to the fuel filter.
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.
(See page SF-1)
(n) Connect the EVAP hose assembly to the pipe on the
emission control valve set.
(o) Connect the 2 vacuum hoses to the vacuum tank for the
ACIS.
17. INSTALL FRONT EXHAUST PIPE
(a) Temporarily install 3 new gaskets and the front exhaust
pipe with the 2 bolts, 2 compression springs and 4 nuts.
(b) Tighten the 4 nuts holding the exhaust manifolds to the
front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Tighten the 2 bolts and 2 compression springs holding the
front exhaust pipe to the center exhaust pipe.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)

EM-80
- ENGINE MECHANICALENGINE UNIT
1064 Author
: Date
:
2001 AVALON (RM808U)
(d) Install the support stay with the 2 bolts.
Torque: 33 N´m (330 kgf´cm, 24 ft´lbf)
18. INSTALL RADIATOR (See page CO-22)
19. INSTALL CRUISE CONTROL ACTUATOR
20. INSTALL AIR CLEANER CAP ASSEMBLY AND AIR
CLEANER CASE
21. CONNECT ACCELERATOR CABLE
22. 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.
23. INSTALL ENGINE FENDER APRON SEALS
24. INSTALL BATTERY TRAY AND BATTERY
25. INSTALL HOOD
26. FILL ENGINE WITH OIL
27. FILL WITH ENGINE COOLANT
28. START ENGINE AND CHECK FOR LEAKS
29. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
30. RECHECK ENGINE COOLANT AND OIL LEVELS

EM0ZL-02
A10518
5 mm
Hexagon
Wrench
A07300
EM-72
- ENGINE MECHANICALENGINE UNIT
1056 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE HOOD
3. REMOVE ENGINE FENDER APRON SEALS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
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. DISCONNECT ACCELERATOR CABLE
8. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR
CLEANER CASE
9. REMOVE CRUISE CONTROL ACTUATOR
10. REMOVE RADIATOR (See page CO-17)
11. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts holding the support stay to the sup-
port bracket.
(b) Remove the 2 bolts and 2 compression springs holding
the front exhaust pipe to the center exhaust pipe.
(c) Remove the 4 nuts holding the front exhaust pipe to the
exhaust manifolds.
(d) Remove the front exhaust pipe and 3 gaskets.
12. DISCONNECT CONNECTORS, CABLE, CLAMPS AND
HOSES
(a) Remove the bolt and disconnect the ground strap from
the LH fender apron.
(b) Disconnect the 2 ground strap connectors from the RH
fender apron.
(c) Disconnect the ground cable from the A/T.
(d) Disconnect the engine wire protector clamp from the bat-
tery body bracket.
(e) Disconnect the engine wire clamp from the bracket on the
RH fender apron.
(f) Disconnect the brake booster vacuum hose from the
throttle body.
(g) Disconnect the engine coolant reservoir hose from the
water outlet.
(h) Disconnect the heater hose from the intake manifold.
(i) Disconnect the heater hose from the water inlet housing.

S04497
A10833
Bracket
P18775
A07430
- ENGINE MECHANICALENGINE UNIT
EM-73
1057 Author
: Date
:
2001 AVALON (RM808U)
(j) Disconnect the fuel inlet hose from the fuel filter.
CAUTION:
Perform disconnecting operation of the fuel tube connec-
tor (quick type) after observing the precautions (See page
SF-1).
(k) Disconnect the EVAP hose assembly from the pipe on the
emission control valve set.
(l) Disconnect the 2 vacuum hoses from the vacuum tank for
the ACIS.
13. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the glove compartment.
(b) Disconnect the 5 ECM connectors.
(c) Disconnect the grommet from the cowl panel, and pull out
the engine wire.
14. REMOVE DRIVE SHAFTS (See page SA-16)
15. DISCONNECT A/C COMPRESSOR FROM ENGINE
(a) Disconnect the A/C compressor connector.
(b) Remove the drive belt.
(c) Remove the 5 bolts, nut and drive belt adjusting bar
bracket.
(d) Disconnect the A/C compressor from the engine.
16. DISCONNECT TRANSAXLE CONTROL CABLE FROM
TRANSAXLE
17. DISCONNECT PS PUMP FROM ENGINE
(a) Remove the 2 nuts, and disconnect the PS pressure tube
from the No.1 engine hanger.
(b) Loosen the 2 bolts, and remove the drive belt.
(c) Remove the 2 bolts, and disconnect the PS pump from
the engine.
18. DISCONNECT TRANSAXLE FROM LH ENGINE
MOUNTING INSULATOR
Remove the 4 bolts holding the transaxle to the mounting insu-
lator.