TOYOTA AVALON 2001 Service Repair Manual

IG0DM-02
A10518
5 mm
Hexagon
Wrench
B06515
- IGNITIONIGNITION COIL
IG-5
1248 Author
: Date
:
2001 AVALON (RM808U)
REPLACEMENT
1. 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.
2. REMOVE IGNITION COILS
(a) Disconnect the 6 ignition coil connectors.
(b) Remove the bolt, and pull out the ignition coil. Remove
the 6 ignition coils.
3. REINSTALL NEW IGNITION COILS
(a) Connect a new ignition coil to the spark plug, and attach
the ignition coil to the cylinder head cover, and install the
bolt. Install the 6 ignition coils.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
(b) Connect the 6 ignition coil connectors.
4. REINSTALL V-BANK COVER
(a) Using 5 mm hexagon wrench, install the V-bank cover
with the 3 cap nuts.
(b) Press down the V-bank cover fastener.

B09783
Engine Room J/B
Ignition
Relay
SF0DX-04
S04970
Continuity
No ContinuityOhmmeter
2
35 Ohmmeter
1
S04969ContinuityOhmmeter 2
35 1
Battery IG-10
- IGNITIONIGNITION RELAY (No.2)
1253 Author
: Date
:
2001 AVALON (RM808U)
IGNITION RELAY (No.2)
INSPECTION
1. REMOVE IGNITION RELAY (Marking: IG2)
2. INSPECT IGNITION RELAY
(a) Inspect the relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 1 and 2.
If there is no continuity, replace the relay.
(2) Check that there is no continuity between terminals
3 and 5.
If there is continuity, replace the relay.
(b) Inspect the relay operation.
(1) Apply battery positive voltage across terminals 1
and 2.
(2) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
If there is no continuity, replace the relay.
3. REINSTALL IGNITION RELAY

IG0DL-02
SPARK TEST
CHECK CONNECTIONS OF IGNITION COIL (WITH
CHECK POWER SUPPLY TO IGNITION COILS (WITH
1. Turn ignition switch to ON.
2. Check that there is battery positive voltage at ignition
CHECK RESISTANCE OF SENSORS
Resistance: Cold Hot
Camshaft position sensor
Crankshaft position sensor835 - 1,400 W
1,630 - 2,740 W1,060 - 1,645 W
2,065 - 3,225 W
CHECK IGT SIGNAL FROM ECM (See page DI-1 17)
TRY ANOTHER IGNITION COIL (WITH IGNITER) IGNITER) CONNECTORS
coil positive (+) terminal.
(See steps 4 and 5)NO
OK
NO
OK
OK
BAD
OK
BAD
BAD
BAD
Connect securely.
Replace ignition coil (with igniter).
Check wiring between ignition switch to
Replace camshaft position sensor.
Check wiring between ECM and ignition ignition coils (with igniters).
coils (with igniters), and then try another CHANGE IT TO NORMAL IGNITION COIL (WITH IGNITER)
AND PERFORM SPARK TEST AGAIN
Replace crankshaft position sensor.
ECM. OK IGNITER)
- IGNITIONIGNITION SYSTEM
IG-1
1244 Author
: Date
:
2001 AVALON (RM808U)
IGNITION SYSTEM
ON-VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in these sentences express the tempera-
ture of the coils themselves. ºColdº is from -10°C (14°F) to
50°C (122°F) and ºHotº is from 50°C (122°F) to 100°C
(212°F).
1. INSPECT SPARK TEST
Check that the spark occurs.
(1) Remove the ignition coils (with igniters) (See page
IG-5).
(2) Remove the spark plugs.
(3) Install the spark plug to the ignition coil, and connect
the ignition coil connector.
(4) Ground the spark plug.
(5) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors dur-
ing this test, crank the engine for no more than 5 - 10 se-
conds at time.
If the spark does not occur, do the test as follows:

IG0147
Megger
Ground
B02629
P13225
16 mm Plug
Wrench
B02630
1.1 mm IG-2
- IGNITIONIGNITION SYSTEM
1245 Author
: Date
:
2001 AVALON (RM808U)
2. INSPECT SPARK PLUGS
NOTICE:

Never use a wire brush for cleaning.

Never attempt to adjust the electrode gap on a used
spark plug.

Spark plugs should be replaced every 193,000 km
(120,000 miles).
(a) Remove the 6 ignition coils (with igniters) (See page
IG-5).
(b) Inspect the electrode.

Using a megger (insulation resistance meter), mea-
sure the insulation resistance.
Standard correct insulation resistance:
10 MW or more
If the resistance is less than specified, proceed to step (d).
HINT:
If a megger is not available, these simple method of inspection
provides fairly accurate results.

Simple Method:

Quickly race the engine to 4,000 rpm 5 times.

Remove the spark plug (See step (c)).

Visually check the spark plug.
If the electrode is dry ... OK
If the electrode is wet ... Proceed to step (d)

Reinstall the spark plug (See step (g)).
(c) Using a 16 mm plug wrench, remove the 6 spark plugs.
(d) Visually check the spark plug for thread damage and insu-
lator damage.
If abnormal, replace the spark plug.
Recommended spark plug:
DENSO madeSK20R11
NGK madeIFR6A11
(e) Inspect the electrode gaps.
Maximum electrode gap for used spark plug:
1.3 mm (0.051 in.)
If the gap is greater than maximum, replace the spark plug.
Correct electrode gap for new spark plug:
1.1 mm (0.043 in.)
NOTICE:
If adjusting the gap of a new spark plug, bend only the base
of the ground electrode. Do not touch the tip. Never attempt
to adjust the gap on the used plug.

IG0152
B06521
Ohmmeter
P14244
Ohmmeter
- IGNITIONIGNITION SYSTEM
IG-3
1246 Author
: Date
:
2001 AVALON (RM808U)
(f) Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry and then
clean with a spark plug cleaner.
Air pressure: Below 588 kPa (6 kgf/cm
2, 85 psi)
Duration: 20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
(g) Using a 16 mm plug wrench, install the 6 spark plugs.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
(h) Reinstall the 6 ignition coil (See page IG-5).
3. INSPECT IGNITION COILS (WITH IGNITERS)
(See step 1.)
4. INSPECT CAMSHAFT POSITION SENSORS
(a) Remove the V-bank cover.
(b) Remove the air cleaner hose w/ resonator.
(c) Disconnect the sensor connectors.
(d) Using an ohmmeter, measure the resistance between ter-
minals.
Resistance:
Cold835 - 1,400 W
Hot1,060 - 1,645 W
If the resistance is not as specified, replace the sensor.
(e) Reconnect the sensor connectors.
(f) Reinstall the air cleaner hose w/ resonator.
(g) Reinstall the V-bank cover.
5. INSPECT CRANKSHAFT POSITION SENSOR
(a) Remove the sensor (See page IG-9).
(b) Using an ohmmeter, measure the resistance between the
terminals.
Resistance:
Cold1,630 - 2,740 W
Hot2,065 - 3,225 W
If the resistance is not as specified, replace the sensor.
(c) Reinstall the sensor (See page IG-9).

IN0ED-02
BO4111
Negative Cable
IN-10
- INTRODUCTIONFOR ALL OF VEHICLES
10 Author
: Date
:
2001 AVALON (RM808U)
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The AVALON is equipped with an SRS (Supplemental
Restraint System), such as the driver airbag, front pas-
senger airbag assembly, side airbag assembly and seat
belt pretensioner.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the battery (See page DI-349).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (-) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back-up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (-) terminal cable from the battery, the SRS
may deploy.)
When the negative (-) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back-up power supply from anoth-
er battery.

F03856
Marks
- INTRODUCTIONFOR ALL OF VEHICLES
IN-1 1
11 Author
: Date
:
2001 AVALON (RM808U)
(3) Even in cases of a minor collision where the SRS
does not deploy, the steering wheel pad, front pas-
senger airbag assembly, side airbag assembly and
seat belt pretensioner should be inspected (See
page RS- 15, RS- 30, RS- 44, RS- 57 and
BO-130).
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the airbag sensor if shocks
are likely to be applied to the sensor during repairs.
(6) Never disassemble and repair the airbag sensor as-
sembly, steering wheel pad, front passenger airbag
assembly, side airbag assembly or seat belt preten-
sioner.
(7) If the airbag sensor assembly, steering wheel pad,
front passenger airbag assembly, side airbag as-
sembly or seat belt pretensioner has been dropped,
or if there are cracks, dents or other defects in the
case, bracket or connector, replace them with new
ones.
(8) Do not directly expose the airbag sensor assembly,
steering wheel pad, front passenger airbag assem-
bly, side airbag assembly or seat belt pretensioner
to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kW/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work on the supplemental restraint system is
completed, check the SRS warning light (See page
DI-349).
(c) SPIRAL CABLE (in Combination Switch)
The steering wheel must be fitted correctly to the steering
column with the spiral cable at the neutral position, other-
wise cable disconnection and other troubles may result.
Refer to SR-22 of this manual concerning correct steer-
ing wheel installation.

B09710
Example:Correct
Wrong
Z13950
Example: IN-12
- INTRODUCTIONFOR ALL OF VEHICLES
12 Author
: Date
:
2001 AVALON (RM808U)
(d) STEERING WHEEL PAD (with Airbag)
(1) When removing the steering wheel pad or handling
a new steering wheel pad, it should be placed with
the pad top surface facing up.
Storing the pad with its metallic surface facing up-
ward may lead to a serious accident if the airbag de-
ploys for some reason. In addition do not store a
steering wheel pad on top of another one.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be applied to the steering wheel
pad and the pad should not be cleaned with deter-
gents of any kind.
(4) Store the steering wheel pad where the ambient
temperature remains below 93°C (200°F), without
high humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) under the
steering column near the combination switch con-
nector before starting work.
(6) When disposing of a vehicle or the steering wheel
pad alone, the airbag should be deployed using an
SST before disposal (See page RS-17).
Carry out the operation in a safe place away from
electrical noise.

B02921
Example:
Correct
Wrong
Z13951
Example:
- INTRODUCTIONFOR ALL OF VEHICLES
IN-13
13 Author
: Date
:
2001 AVALON (RM808U)
(e) FRONT PASSENGER AIRBAG ASSEMBLY
(1) Always store a removed or new front passenger air-
bag assembly with the airbag deployment direction
facing up.
Storing the airbag assembly with the airbag deploy-
ment direction facing down could cause a serious
accident if the airbag inflates.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be applied to the front passen-
ger airbag assembly and the airbag door should not
be cleaned with detergents of any kind.
(4) Store the airbag assembly where the ambient tem-
perature remains below 93°C (200°F), without high
humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) installed on
the assembly before starting work.
(6) When disposing of a vehicle or the airbag assembly
alone, the airbag should be deployed using an SST
before disposal (See page RS-32).
Perform the operation in a safe place away from
electrical noise.

B02922
Example:
Correct
Wrong
N21642
Example:
IN-14
- INTRODUCTIONFOR ALL OF VEHICLES
14 Author
: Date
:
2001 AVALON (RM808U)
(f) SIDE AIRBAG ASSEMBLY
(1) Always store a removed or new side airbag assem-
bly with the airbag deployment direction facing up.
Storing the airbag assembly with the airbag deploy-
ment direction facing down could cause a serious
accident if the airbag deploys.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be applied to the side airbag as-
sembly and the surface should not be cleaned with
detergents of any kind.
(4) Store the airbag assembly where the ambient tem-
perature remains below 93°C (200°F), without high
humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) under the
seat before starting work.
(6) When disposing of a vehicle or the side airbag as-
sembly alone, the airbag should be deployed using
an SST before disposal (See page RS-45).
Perform the operation in a safe place away from
electrical noise.