TOYOTA AVALON 2001 Service Repair Manual

A05415
EM0ZN-02
S04921
A05252
P18761
- ENGINE MECHANICALCYLINDER BLOCK
EM-83
1067 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE DRIVE PLATE
Remove the 8 bolts, rear plate, drive plate and front spacer.
2. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
3. REMOVE TIMING BELT AND PULLEYS
(See page EM-15)
4. REMOVE CYLINDER HEAD (See page EM-31)
5. DISCONNECT CRANKSHAFT POSITION SENSOR
CONNECTOR
6. DISCONNECT OIL PRESSURE SWITCH CONNECTOR
7. DISCONNECT OIL LEVEL SENSOR CONNECTOR
8. REMOVE ENGINE WIRE
(a) Disconnect the 2 wire clamps from the wire brackets.
(b) Remove the 2 bolts and nut, and disconnect the engine
wire.
9. REMOVE GENERATOR, ADJUSTING BAR AND
BRACKET ASSEMBLY
Remove the 3 nuts, the generator, adjusting bar and bracket as-
sembly.
10. REMOVE OIL PRESSURE SWITCH
(See page LU-1)
11. REMOVE A/C COMPRESSOR HOUSING BRACKET
Remove the 2 bolts and compressor housing bracket.
12. REMOVE NO.2 IDLER PULLEY BRACKET
Remove the 2 bolts and idler pulley bracket.

P12389
SST
A05253
P18763
WaterSeal
Plate
Oil Filter
Union
12 mm
Hexagon
Wrench
Coolant
Drain
Union
A02010
P12508
EM-84
- ENGINE MECHANICALCYLINDER BLOCK
1068 Author
: Date
:
2001 AVALON (RM808U)
13. REMOVE KNOCK SENSORS
(a) Disconnect the 2 knock sensor connectors.
(b) Using SST, remove the 2 knock sensors.
SST 09816-30010
14. REMOVE WATER INLET HOUSING
(a) Remove the engine wire band.
(b) Disconnect the engine wire clamp from the bracket.
(c) Remove the 8 bolts, 2 nuts and water inlet housing.
15. REMOVE WATER PUMP (See page CO-6)
16. REMOVE NO.2 OIL PAN (See page LU-9)
17. REMOVE OIL STRAINER (See page LU-3)
18. REMOVE NO.1 OIL PAN (See page LU-3)
19. REMOVE OIL PUMP (See page LU-9)
20. REMOVE OIL FILTER (See page LU-3)
21. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.
22. REMOVE WATER SEAL PLATE
Remove the 2 nuts and seal plate.
23. REMOVE ENGINE COOLANT DRAIN UNION
24. REMOVE CYLINDER BLOCK SIDE COVER
Remove the 3 bolts, 2 nuts, cylinder block side cover and gas-
ket.
25. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.

P12695
A09694
P12707
P12696
- ENGINE MECHANICALCYLINDER BLOCK
EM-85
1069 Author
: Date
:
2001 AVALON (RM808U)
26. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.15 - 0.30 mm (0.0059 - 0.0118 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly(s). If necessary, replace the crank-
shaft.
Connecting rod thickness:
20.80 - 20.85 mm (0.8189 - 0.8209 in.)
27. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap are
aligned to ensure correct reassembly.
(b) Remove the 2 connecting rod cap bolts.
(c) Using the 2 removed connecting rod cap bolts, remove
the connecting rod cap and lower bearing by wiggling the
connecting rod cap right and left.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Clean the crank pin and bearing.
(e) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.

P12728
Plastigage
P12697
P12698
A10523
Number Mark
Number
Mark
EM-86
- ENGINE MECHANICALCYLINDER BLOCK
1070 Author
: Date
:
2001 AVALON (RM808U)
(f) Lay a strip of Plastigage across the crank pin.
(g) Install the connecting rod cap with the 2 bolts (See page
EM-101).
Torque:
1st: 24.5 N´m (250 kgf´cm, 18 ft´lbf)
2nd: Turn extra 90°
NOTICE:
Do not turn the crankshaft.
(h) Remove the 2 bolts, connecting rod cap and lower bear-
ing (See steps (b) and (c)).
(i) Measure the Plastigage at its widest point.
Standard oil clearance:
0.038 - 0.064 mm (0.0015 - 0.0025 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If replacing a bearing, replace it with one having the same num-
ber as marked on the connecting rod. There are 4 sizes of stan-
dard bearings, marked º1º, º2º, º3º and º4º accordingly.
Reference:
Standard bearing center wall thickness:
Markmm (in.)
º1º1.484 - 1.487 (0.0584 - 0.0585)
º2º1.487 - 1.490 (0.0585 - 0.0587)
º3º1.490 - 1.493 (0.0587 - 0.0588)
º4º1.493 - 1.496 (0.0588 - 0.0589)
(j) Completely remove the Plastigage.

A05258
P12799
P12585
P12752
1011 12
1416
15
1 23 4
5
6
7 8
913
P12603
- ENGINE MECHANICALCYLINDER BLOCK
EM-87
1071 Author
: Date
:
2001 AVALON (RM808U)
28. REMOVE PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.
29. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.04 - 0.24 mm (0.0016 - 0.0095 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
1.930 - 1.980 mm (0.0760 - 0.0780 in.)
30. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the 8 main bearing cap
bolts and seal washers in the several passes and in the
sequence shown.
(b) Uniformly loosen and remove the 16 main bearing cap
bolts in several passes and in the sequence shown.
(c) Using a screwdriver, pry out main bearing caps. Remove
the 4 main bearing caps, lower bearings and (No.2 main
bearing cap only) 2 lower thrust washers.

S06200
Joint Surface
P12495
P12980
Plastigage
P12954
P12993
EM-88
- ENGINE MECHANICALCYLINDER BLOCK
1072 Author
: Date
:
2001 AVALON (RM808U)
NOTICE:
Pull up the main bearing cap little by little to the right and
the left by turns and pay attention not to damage the joint
surface of the cylinder block and the main bearing cap.
HINT:

Keep the lower bearing and main bearing cap together.

Arrange the main bearing caps and lower thrust washers
in correct order.
(d) Lift out the crankshaft.
HINT:
Keep the upper bearings together with the cylinder block.
(e) Clean each main journal and bearing.
(f) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(g) Place the crankshaft on the cylinder block.
(h) Lay a strip of Plastigage across each journal.
(i) Install the 4 main bearing caps. (See page EM-101)
Torque:
12 pointed head bolts:
1st: 22 N´m (225 kgf´cm, 16 ft´lbf)
2nd: Turn extra 90°
Hexagon head bolts:
27 N´m (275 kgf´cm, 20 ft´lbf)
NOTICE:
Do not turn the crankshaft.
(j) Remove the main bearing caps. (See steps (a) to (c) )
(k) Measure the Plastigage at its widest point.
Standard oil clearance:
No.1 and No.4 journals0.014 - 0.034 mm (0.0006 - 0.0013 in.)
No.2 and No.3 journals0.026 - 0.046 mm (0.0010 - 0.0018 in.)
Maximum clearance:
No.1 and No.4 journals0.05 mm (0.0020 in.)
No.2 and No.3 journals0.06 mm (0.0024 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, replace the crankshaft.

P12734
Number MarkNo.3
Number
MarkNo.4 No.2
No.1
No.3
No.4 No.2
No.1
Number Mark
EXAMPLE: Cylinder block º06º (A)
+ Crankshaft º08º (B)
= Total number 14 (Use bearing º5º) No.1 and No.4 journal bearings
Cylinder block (A)
Crankshaft (B)+
Total number º º: Number mark
0 - 5 12 - 176 - 11 18 - 23 24 - 28
º3º º4º º5º º6º º7º Use bearing
EXAMPLE: Cylinder block º06º, Crankshaft º08º
= Use bearing º5º No.1 and No.4 journal standard bearings selection chart
Crankshaft
number markCylinder block number mark
00
01
02
03
04
05
06
07
08
09
10
11
1200 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
4
5 3
3
3
3
3
3
4
4
4
4
43
3
3
3
3
4
4
4
4
4
4
5
53
3
3
3
4
4
4
4
4
4
5
5
53
3
3
4
4
4
4
4
4
5
5
5
53
3
4
4
4
4
4
4
5
5
5
5
53
4
4
4
4
4
4
5
5
5
5
5
54
4
4
4
4
4
5
5
5
5
5
5
64
4
4
4
4
5
5
5
5
5
5
6
64
4
4
4
5
5
5
5
5
5
6
6
64
4
4
5
5
5
5
5
5
6
6
6
64
4
5
5
5
5
5
5
6
6
6
6
64
5
5
5
5
5
5
6
6
6
6
6
65
5
5
5
5
5
6
6
6
6
6
6
75
5
5
5
5
6
6
6
6
6
6
7
75
5
5
5
6
6
6
6
6
6
7
7
75
5
5
6
6
6
6
6
6
7
7
7
75
5
6
6
6
6
6
6
7
7
7
7
7
- ENGINE MECHANICALCYLINDER BLOCK
EM-89
1073 Author
: Date
:
2001 AVALON (RM808U)
HINT:
If using a bearing, replace it with one having the same number.
If the number of the bearing cannot be determined, select the
correct bearing by adding together the numbers imprinted on
the cylinder block and crankshaft, then refer to the table below
for the appropriate bearing number. The No.1 and No.4 journal
bearings have 5 standard bearing sizes, marked º3º, º4º, º5º, º6º
and º7º accordingly. The No.2 and No.3 journal bearings have
5 standard bearing sizes, marked º1º, º2º, º3º, º4º and º5º ac-
cordingly.

EXAMPLE: Cylinder block º06º (A)
+ Crankshaft º08º (B)
= Total number 14 (Use bearing º3º) No.2 and No.3 journal bearings
Cylinder block (A)
Crankshaft (B)+
Total number º º: Number mark
0 - 5 12 - 176 - 11 18 - 23 24 - 28
º1º º2º º3º º4º º5º Use bearing
EXAMPLE: Cylinder block º06º, Crankshaft º08º
= Use bearing º3º No.2 and No.3 journal standard bearings selection chart
Crankshaft
number markCylinder block number mark
00
01
02
03
04
05
06
07
08
09
10
11
1200 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
2
3 1
1
1
1
1
1
2
2
2
2
21
1
1
1
1
2
2
2
2
2
2
3
31
1
1
1
2
2
2
2
2
2
3
3
31
1
1
2
2
2
2
2
2
3
3
3
31
1
2
2
2
2
2
2
3
3
3
3
31
2
2
2
2
2
2
3
3
3
3
3
32
2
2
2
2
2
3
3
3
3
3
3
42
2
2
2
2
3
3
3
3
3
3
4
42
2
2
2
3
3
3
3
3
3
4
4
42
2
2
3
3
3
3
3
3
4
4
4
42
2
3
3
3
3
3
3
4
4
4
4
42
3
3
3
3
3
3
4
4
4
4
4
43
3
3
3
3
3
4
4
4
4
4
4
53
3
3
3
3
4
4
4
4
4
4
5
53
3
3
3
4
4
4
4
4
4
5
5
53
3
3
4
4
4
4
4
4
5
5
5
53
3
4
4
4
4
4
4
5
5
5
5
5 EM-90
- ENGINE MECHANICALCYLINDER BLOCK
1074 Author
: Date
:
2001 AVALON (RM808U)

- ENGINE MECHANICALCYLINDER BLOCK
EM-91
1075 Author
: Date
:
2001 AVALON (RM808U)
Reference
ItemMarkmm (in.)
Cylinder block main journal bore diameter (A)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º
º13º
º14º
º15º
º16º66.000 (2.5984)
66.001 (2.5985)
66.002 (2.5985)
66.003 (2.5985)
66.004 (2.5986)
66.005 (2.5986)
66.006 (2.5987)
66.007 (2.5987)
66.008 (2.5987)
66.009 (2.5988)
66.010 (2.5988)
66.011 (2.5989)
66.012 (2.5989)
66.013 (2.5989)
66.014 (2.5990)
66.015 (2.5990)
66.016 (2.5990)
Crankshaft main journal diameter (B)º00º
º01º
º02º
º03º
º04º
º05º
º06º
º07º
º08º
º09º
º10º
º11º
º12º61.000 (2.4016)
60.999 (2.4015)
60.998 (2.4015)
60.997 (2.4015)
60.996 (2.4014)
60.995 (2.4014)
60.994 (2.4013)
60.993 (2.4012)
60.992 (2.4012)
60.991 (2.4012)
60.990 (2.4012)
60.989 (2.4011)
60.988 (2.4011)
Standard bearing center wall thicknessº1º
º2º
º3º
º4º
º5º
º6º
º7º2.486 - 2.489 (0.0979 - 0.0980)
2.489 - 2.492 (0.0980 - 0.0981)
2.492 - 2.495 (0.0981 - 0.0982)
2.495 - 2.498 (0.0982 - 0.0983)
2.498 - 2.501 (0.0983 - 0.0985)
2.501 - 2.504 (0.0985 - 0.0986)
2.504 - 2.507 (0.0986 - 0.0987)
(l) Completely remove the Plastigage.
31. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the 4 upper main bearings and 2 upper thrust
washers from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
the correct order.

P12404
P12405A09698
P12403
P12416
60°C
P12415
EM-92
- ENGINE MECHANICALCYLINDER BLOCK
1076 Author
: Date
:
2001 AVALON (RM808U)
32. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
33. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the piston rings in the correct order only.
34. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to approx. 60°C (140°F).
(c) Using a plastic-faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.