TOYOTA AVALON 2001 Service Repair Manual

B01238
(1)(2)(3) (4) (5) (6) (7)
Long
Short
InsideLead Terminal
B01239
Wooden Block
Contact Plate
20 mm
40 mm
37 mm
(kgf/cm2) =100 kgf
Ram diameter (cm)
2x 3.14 (p)2
Ram diameter (in.)
2x 3.14 (p)2(psi) =221 lbf
(kPa) = x 98.1
x 6.9 (kgf/cm2)
(kPa) = (psi)
- STARTINGSTARTER
ST-15
1268 Author
: Date
:
2001 AVALON (RM808U)
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(6) Temporarily install a new wave washer.
(7) Temporarily install a new terminal nut.
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washers in the correct direction.
(e) Temporarily install new terminal kit parts.
(1) Temporarily install a new terminal insulator (inside).
(2) Temporarily install a new contact plate.
(3) Temporarily install a new terminal bolt.
(4) Temporarily install a new O-ring.
(5) Temporarily install a new terminal insulator (out-
side).
(6) Temporarily install a new wave washer.
(7) Temporarily install a new terminal nut.
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washers in the correct direction.
(f) Tighten terminal nuts.
(1) Put a wooden block on the contact plate and press
it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:

Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:

B01240
SST
B01241
ST-16
- STARTINGSTARTER
1269 Author
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2001 AVALON (RM808U)

If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(2) Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N´m (173 kgf´cm, 12 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
(g) Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(h) Install the plunger, new gasket, end cover and 3 bolts.
Torque: 2.5 N´m (25 kgf´cm, 22 in.´lbf)

ST04T-02
B01242
Terminal C
Battery
Terminal 50
B01243
Terminal C
BatteryDisconnect
B01244Battery
Disconnect
B01245
Battery
Terminal 50
Terminal 30
Ammeter
ST-18
- STARTINGSTARTER
1271 Author
: Date
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2001 AVALON (RM808U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL-IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD-IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (-) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
(a) Disconnect the negative (-) lead from the switch body.
(b) Check that the clutch pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
shows the specified current.
Specified current: 90 A or less at 11.5 V

B07464
Starter
Relay
ST04V-02
P07170
Ohmmeter
Ohmmeter No
ContinuityContinuity
31
5
2
P07171
Ohmmeter
Continuity
31
5
2
Battery
ST-20
- STARTINGSTARTER RELAY
1273 Author
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2001 AVALON (RM808U)
STARTER RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE STARTER RELAY (Marking: ST)
3. INSPECT STARTER 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.
4. REINSTALL STARTER RELAY
5. REINSTALL RELAY BOX COVER

ST04M-01
- STARTINGSTARTING SYSTEM
ST-1
1254 Author
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2001 AVALON (RM808U)
STARTING SYSTEM
ON-VEHICLE INSPECTION
NOTICE:
Before changing the starter, check the following items again:

Connector connection

Accessory installation, e.g.: theft deterrent system

P06717
SR0ED-03
Z00038
DENSO Borroughs
P06723
CORRECT WRONG WRONG
- STEERINGDRIVE BELT
SR-3
1466 Author
: Date
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2001 AVALON (RM808U)
DRIVE BELT
INSPECTION
INSPECT DRIVE BELT
(a) Visually check the drive belt for excessive wear, frayed
cords, etc.
If any defect has been found, replace the drive belt.
HINT:
Cracks on the rib side of a drive belt are considered acceptable.
If the missing chunks from the ribs are found on the drive belt,
it should be replaced.
(b) Using a belt tension gauge, measure the belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt: 120 - 185 lbf
Used belt: 95 - 135 lbf
If the belt tension is not as specified, adjust it.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing a belt, check that it fits properly in the
ribbed grooves.

Check with your hand to confirm that the belt has not
slipped out of the groove on the bottom of the pulley.

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.

SR0EE-03
R11741
Normal Abnormal SR-4
- STEERINGPOWER STEERING FLUID
1467 Author
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2001 AVALON (RM808U)
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL (See page SR-5)
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the steering wheel slowly from
lock to lock several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the steering wheel to left or
right full lock position and keep it there for 2-3 seconds,
then turn the steering wheel to the opposite full lock posi-
tion and keep it there for 2-3 seconds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL (See page SR-5)

R11740
HOT
COLD
SR0EF-04
R11741
Normal Abnormal
R11786Engine Idling
Engine Stopped 5 mm (0.20 in.)
or less
- STEERINGPOWER STEERING FLUID
SR-5
1468 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir. If the fluid is cold, check that it is within the COLD
LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem (See page SR-4).
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system (See page
SR-4).
(i) Check the fluid level.

R14662
Attachment
IN
OUT Pressure Feed Tube SST
Z15498
Oil
Reservoir
PS Vane
Pump PS Gear
SST Closed SR-6
- STEERINGPOWER STEERING FLUID
1469 Author
: Date
:
2001 AVALON (RM808U)
2. CHECK STEERING FLUID PRESSURE
(a) Disconnect the pressure feed tube (See page SR-27).
(b) Connect SST to pressure feed tubes, as shown in the il-
lustration below.
SST 09640- 10010 (09641- 01010, 09641- 01030,
09641-01060)
NOTICE:
Check that the valve of the SST is in the open position.
(c) Bleed the power steering system (See page SR-4).
(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 °C (176 °F)
(f) With the engine idling, close the valve of the SST and ob-
serve the reading on the SST.
Minimum fluid pressure:
7,845 kPa (80 kgf/cm
2, 1,138 psi)
NOTICE:

Do not keep the valve closed for more than 10 se-
conds.

Do not let the fluid temperature become too high.

Z15499
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open
Z15500
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open Lock Position
- STEERINGPOWER STEERING FLUID
SR-7
1470 Author
: Date
:
2001 AVALON (RM808U)
(g) With the engine idling, open the valve fully.
(h) Measure the fluid pressure at engine speeds of 1,000 rpm
and 3,000 rpm.
Difference fluid pressure:
490 kPa (5 kgf/cm
2, 71 psi) or less
NOTICE:
Do not turn the steering wheel.
(i) With the engine idling and valve fully opened, turn the
steering wheel to full lock.
Minimum fluid pressure:
7,845 kPa (80 kgf/cm
2, 1,138 psi)
NOTICE:

Do not maintain lock position for more than 10 se-
conds.

Do not let the fluid temperature become too high.
(j) Disconnect the SST.
SST 09640- 10010 (09641- 01010, 09641- 01030,
09641-01060)
(k) Connect the pressure feed tube (See page SR-35).
(l) Bleed the power steering system (See page SR-4).