fuel TOYOTA AVALON 2001 Service Repair Manual
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Page 1280 of 1897
EC04L-03
B07254
Vent LineCharcoal Canister
Fuel Tank
EVAP Line
Air Drain Hose
Filler Pipe
Air Inlet Line
Purge Line
Cut Off Valve
Fill Check Valve
VSV for EVAPVacuum Surge TankEVAP Service Port
Vapor Pressure Sensor
Fuel Tank Cap
VSV for Pressure Switching Valve PCV Valve
VSV for Canister Closed Valve (CCV)
EC-2
- EMISSION CONTROLPARTS LAYOUT AND SCHEMATIC DRAWING
1096 Author: Date:
2001 AVALON (RM808U)
PARTS LAYOUT AND SCHEMATIC DRAWING
LOCATION
Page 1288 of 1897
EM0CC-03
P19471Compression Gauge
- ENGINE MECHANICALCOMPRESSION
EM-3
987 Author: Date:
2001 AVALON (RM808U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE IGNITION COILS (See page IG-5)
3. REMOVE SPARK PLUGS
Using a 16 mm plug wrench, remove the 6 spark plugs.
4. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine speed of
250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,500 kPa (15.3 kgf/cm
2, 218 psi)
Minimum pressure:
1,000 kPa (10.2 kgf/cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 15 psi) or less
(e) If the cylinder compression in 1 or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
5. REINSTALL SPARK PLUGS
6. INSTALL IGNITION COILS (See page IG-5)
Page 1319 of 1897
Water Bypass Hose
A10522
PS Pressure Tube
Throttle Body Bracket
Engine WireThrottle Position
Sensor Connector
Vacuum Hose Brake Booster
39 (400,29)
IAC Valve
Connector
Accelerator Cable
Purge Hose
Hose Vacuum
Gasket
VSV Connector for No.2 ACIS
Engine Coolant
Reservoir Hose
43 (440,32)
ECT Sender
Gauge Connector
ECT Sensor
Connector
Grand Strap
Connector
15 (150,11)
Water Outlet
15 (150,11)
Water Bypass
Hose
Upper Radiator
HoseFuel Inlet Hose
Injector Connector Intake Manifold
Assembly
Retainer
Heater Hose
GasketIgnition Coil
Connector
Non-reusable part: Specified torque
N´m (kgf´cm, ft´lbf)
19.5 (200, 14)
No.1 Engine
Hanger
VSV Connector for
EVAP
Ground Cable
PCV Hose Ground Cable
Air Intake Chamber
Assembly
Gasket
Spark PlugIgnition Coil
Ground Strap
DLC1
Gasket
Fuel Hose Clamp
VSV Connector
for No.1 ACIS
Throttle Cable
- ENGINE MECHANICALCYLINDER HEAD
EM-27
1011 Author: Date:
2001 AVALON (RM808U)
Page 1344 of 1897
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.
Page 1350 of 1897
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.
Page 1367 of 1897
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)
Page 1370 of 1897
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.
Page 1413 of 1897
- INTRODUCTIONFOR ALL OF VEHICLES
IN-17
17 Author: Date:
2001 AVALON (RM808U)
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle's electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
4. FOR USING OBD II SCAN TOOL OR TOYOTA HAND-HELD TESTER
CAUTION:
Observe the following items for safety reasons:
Before using the OBD II scan tool or TOYOTA hand-held tester, the OBD II scan tool's instruc-
tion book or TOYOTA hand-held tester's operator manual should be read thoroughly.
Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand-
held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel
and shift lever.)
Two persons are required when test driving with the OBD II scan tool or TOYOTA hand-held
tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or
TOYOTA hand-held tester.
Page 1423 of 1897
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN-27
27 Author: Date:
2001 AVALON (RM808U)
5. PROBLEM SYMPTOMS TABLE
The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to
troubleshoot the problem when a ºNormalº code is displayed in the diagnostic trouble code check but the
problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts
should be checked.
HINT:
When the problem is not detected by the diagnostic system even though the problem symptom is present,
it is considered that the problem is occurring outside the detection range of the diagnostic system, or that
the problem is occurring in a system other than the diagnostic system.
Symptom
Suspect AreaSee page
Engine does not crank (Does not start)
No initial combustion (Does not start)
No complete combustion (Does not start)1. Starter and starter relay
1. ECM power source circuit
2. Fuel pump control circuit
3. Engine control module (ECM)
1. Starter signal circuit
2. Fuel pump control circuit1. Fuel pump control circuitDI-147
DI-151
IN-29
PROBLEM SYMPTOMS TABLE
1. Compression
2. Fuel pump control circuit 1. A/C signal circuit
2. Fuel pump control circuit 1. A/C signal circuit (Compressor circuit)
2. ECM power source circuit 1. Starter signal circuit
2. Fuel pump control circuit1. Starter signal circuit
2. Fuel pump control circuit
3. Compression
idling) High engine idle speed (Poor idling) Hot engine Cold engine (Difficult to start)Engine cranks normally (Difficult to start)
AC-88 DI-144
DI-151
EM-3 DI-151
Problem Symptom Page
Indicates the page where the flow chart for each circuit
is located.
Circuit Inspection, Inspection Order
Indicates the circuit which needs to be checked for each problem
symptom. Check in the order indicated by the numbers.
Circuit or Part Name
Indicates the circuit or part which needs to be checked.
ST-2
ST-17
DI-144
DI-151
DI-144
DI-151
Page 1440 of 1897
IN04Q-08
- INTRODUCTIONTERMS
IN-35
35 Author: Date:
2001 AVALON (RM808U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti-Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir-Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi-Level
B/SBore-Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve