maintenance TOYOTA AVALON 2001 Service Repair Manual

CH03U-03
Z11577
Except Maintenance-Free Battery
Z11556
Maintenance-Free Battery
Voltmeter
- CHARGINGCHARGING SYSTEM
CH-1
1274 Author
: Date
:
2001 AVALON (RM808U)
CHARGING SYSTEM
ON-VEHICLE INSPECTION
CAUTION:

Check that the battery cables are connected to the
correct terminals.

Disconnect the battery cables when the battery is giv-
en a quick charge.

Do not perform tests with a high voltage insulation re-
sistance tester.

Never disconnect the battery while the engine is run-
ning.
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Maintenance-Free Battery:
If under the lower level, replace the battery (or add distilled wa-
ter if possible). Check the charging system.
Except Maintenance-Free Battery:
If under the lower level, add distilled water.
2. Except Maintenance-Free Battery:
CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity: 1.25 - 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.
3. Maintenance-Free Battery:
CHECK BATTERY VOLTAGE
(a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, turn the ignition switch ON and turn on the electrical
system (headlight, blower motor, rear defogger etc.) for
60 seconds to remove the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
tems.
(c) Measure the battery voltage between the negative (-)
and positive (+) terminals of the battery.
Standard voltage: 12.5 - 12.9 V at 20°C (68°F)
If the voltage is less than specification, charge the battery.

Z18811
Blue White Red
OK Charging
NecessaryInsufficient
Water Maintenance-Free Battery
Type A
GREE NEYEDARK EYECLEAR EYE or
CHARGED DISCHARGEDADD WATER
Type B
LIGHT YELLOW
P13121
Z00038
DENSO Borroughs
P13120
CORRECT
WRONG CH-2
- CHARGINGCHARGING SYSTEM
1275 Author
: Date
:
2001 AVALON (RM808U)
HINT:
Check the indicator as shown in illustration.
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
(b) Check the fusible link and fuses for continuity.
5. INSPECT DRIVE BELT
(a) Visually check the 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 belt are considered acceptable. If the
belt has chunks missing from the ribs, it should be replaced.
(b) Using a belt tension gauge, measure the drive belt ten-
sion.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt175 ± 5 lbf
Used belt115 ± 20 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.

MA0676B00995
MA01P-02
B08916
B09029
MA-8
- MAINTENANCEBODY
50 Author
: Date
:
2001 AVALON (RM808U)
BODY
INSPECTION
1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
Tighten the following parts:

Front seat mount bolts
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)

Front suspension member-to-body mounting bolts
Torque: 181 N´m (1,850 kgf´cm, 134 ft´lbf)

Rear suspension member-to-body mounting nuts
Torque: 51 N´m (520 kgf´cm, 38 ft´lbf)
2. FINAL INSPECTION
(a) Check the operation of the body parts:

Hood:
Auxiliary catch operates properly
Hood locks securely when closed

Front and rear doors:
Door lock operates properly
Doors close properly

Luggage compartment door:
Door lock operates properly

Seats:
Seat adjusts easily and locks securely in any posi-
tion
Front seat back locks securely in any position
Folding-down rear seat backs lock securely
(b) Road test:

Check the engine and chassis for abnormal noises.

Check that the vehicle dose not wander or pull to
one side.

Check that the brakes work properly and do not
drag.

Do setting of the parking brake shoes and drum.
(c) Be sure to deliver a clean car and especially check:

Steering wheel

Shift lever knob

All switch knobs

Door handles

Seats

B00632
MA01N-01
MA-6
- MAINTENANCEBRAKE
48 Author
: Date
:
2001 AVALON (RM808U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Check in a well lighted area. Check the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before checking the front brake.
(a) Check all brake lines and hoses for:

Damage

Wear

Deformation

Cracks

Corrosion

Leaks

Bends

Twists
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS
(See page BR-26)
3. INSPECT REAR BRAKE PADS AND DISCS
(See page BR-35)
4. INSPECT PARKING BRAKE LININGS AND DRUMS
(See page BR-45)

MA01O-02
B08915
- MAINTENANCECHASSIS
MA-7
49 Author
: Date
:
2001 AVALON (RM808U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel free-play (See page SR-8).
(b) Check the steering linkage for looseness or damage.
Check that:

Tie rod ends do not have excessive play.

Dust seals and boots are not damaged.

Boot clamps are not loose.
2. INSPECT SRS AIRBAG (See pages RS-15, RS-30)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.
4. INSPECT DRIVE SHAFT BOOTS
Check the drive shaft boots for clamp looseness, leakage or
damage.
5. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.

Jack up the front of the vehicle and place wooden
blocks with a height of 180 - 200 mm (7.09 - 7.87
in.) under the front tires.

Lower the jack until there is about half a load on the
front coil spring. Place stands under the vehicle for
safety.

Check that the front wheels are pointing straight
ahead, and block them with chocks.

Using a lever, pry up the end of the lower arm, and
check the amount of play.
Maximum ball joint vertical play: 0 mm (0 in.)
If there is play, replace the ball joint.
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE FLUID
Visually check the transaxle for fluid leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE FLUID (See page DI-160)

MA01M-02
P00495
Inside Outside
- MAINTENANCEENGINE
MA-5
47 Author
: Date
:
2001 AVALON (RM808U)
ENGINE
INSPECTION
HINT:
Inspect these items when the engine is cold.
1. REPLACE TIMING BELT (See page EM-15)
2. INSPECT DRIVE BELTS
(See pages CH-1, SR-3 and AC-17)
3. REPLACE SPARK PLUGS (See page IG-1)
4. INSPECT AIR FILTER
(a) Visually check that the air filter is not excessively dirty or
oily.
(b) Clean the air filter with compressed air.
First blow from the inside thoroughly, then blow off the
outside of the air filter.
5. REPLACE AIR FILTER
Replace the air filter with a new one.
6. REPLACE ENGINE OIL AND OIL FILTER
(See page LU-3)
7. REPLACE ENGINE COOLANT (See page CO-2)
8. REPLACE GASKET IN FUEL TANK CAP
(See page EC-6)
9. INSPECT FUEL LINES AND CONNECTIONS
(See page EC-6)
10. INSPECT EXHAUST PIPES AND MOUNTINGS
(See page EC-14)
11. ADJUST VALVE CLEARANCE (See page EM-4)

MA002-16
MA-2
- MAINTENANCEINSIDE VEHICLE
44 Author
: Date
:
2001 AVALON (RM808U)
INSIDE VEHICLE
GENERAL MAINTENANCE
These are maintenance and inspection items which are considered to be the owner's responsibility.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.

Failure to do even one item an cause the engine to run poorly and increase exhaust emissions.
2. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD GLASS
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater or air conditioner at defroster
mode.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and are mounted securely.
10. STEERING WHEEL
Check that it has the specified free-play. Be alert for changes in steering condition, such as hard steering,
excessive free-play or strange noises.
11. SEATS
(a) Check that the seat adjusters operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the head restraints move up and down smoothly and that the locks hold securely in any
latch position.
(d) For fold-down seat backs, check that the latches lock securely.
12. SEAT BELTS
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.

- MAINTENANCEINSIDE VEHICLE
MA-3
45 Author
: Date
:
2001 AVALON (RM808U)
13. ACCELERATOR PEDAL
Check the pedal for smooth operation and uneven pedal effort or catching.
14. BRAKE PEDAL (See page BR-6)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper reserve distance and free-play.
(c) Check the brake booster function.
15. BRAKES
At a safe place, check that the brakes do not pull to one side when applied.
16. PARKING BRAKE (See page BR-9)
(a) Check that the parking brake pedal has the proper travel.
(b) On a safe incline, check that the vehicle is held securely with only the parking brake applied.
17. AUTOMATIC TRANSMISSION ºPARKº MECHANISM
(a) Check the lock release mechanism of the selector lever for proper and smooth operation.
(b) On a safe incline, check that the vehicle is held securely with the selector lever in ºPº position and all
brakes released.

MA002-16
MA-2
- MAINTENANCEINSIDE VEHICLE
44 Author
: Date
:
2001 AVALON (RM808U)
INSIDE VEHICLE
GENERAL MAINTENANCE
These are maintenance and inspection items which are considered to be the owner's responsibility.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.

Failure to do even one item an cause the engine to run poorly and increase exhaust emissions.
2. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD GLASS
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater or air conditioner at defroster
mode.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and are mounted securely.
10. STEERING WHEEL
Check that it has the specified free-play. Be alert for changes in steering condition, such as hard steering,
excessive free-play or strange noises.
11. SEATS
(a) Check that the seat adjusters operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the head restraints move up and down smoothly and that the locks hold securely in any
latch position.
(d) For fold-down seat backs, check that the latches lock securely.
12. SEAT BELTS
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.

- MAINTENANCEINSIDE VEHICLE
MA-3
45 Author
: Date
:
2001 AVALON (RM808U)
13. ACCELERATOR PEDAL
Check the pedal for smooth operation and uneven pedal effort or catching.
14. BRAKE PEDAL (See page BR-6)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper reserve distance and free-play.
(c) Check the brake booster function.
15. BRAKES
At a safe place, check that the brakes do not pull to one side when applied.
16. PARKING BRAKE (See page BR-9)
(a) Check that the parking brake pedal has the proper travel.
(b) On a safe incline, check that the vehicle is held securely with only the parking brake applied.
17. AUTOMATIC TRANSMISSION ºPARKº MECHANISM
(a) Check the lock release mechanism of the selector lever for proper and smooth operation.
(b) On a safe incline, check that the vehicle is held securely with the selector lever in ºPº position and all
brakes released.