TOYOTA AVALON 2001 Service Repair Manual

A06660
Engine Wire
Engine Wire
RH Exhaust Manifold
49 (500, 36)
x 6Cylinder Head Rear Plate
PS Pump Bracket
43 (440, 32)
Gasket
No.3 Timing Belt Cover
CollarWater Inlet
Pipe
x 6

O-Ring Oil Dipstick Guide
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable part
Gasket
Engine Wire
Engine Wire
49 (500, 36)
Bushing
Camshaft Position
Sensor
LH Exhaust
Manifold Stay
x 6

Gasket

O-Ring

O-Ring
LH Exhaust Manifold

O-Ring
Camshaft
Timing Oil
Control Valve
Camshaft Position
SensorRH Exhaust
Manifold Stay

O-Ring

O-Ring
- ENGINE MECHANICALCYLINDER HEAD
EM-29
1013 Author
: Date
:
2001 AVALON (RM808U)

A05703
Adjusting Shim
Valve Lifter
Keeper
Spring Retainer
Valve Spring
Spring Seat

Oil Seal
Valve
Valve Guide BushingLH Cylinder Head Cover
LH Intake
Camshaft
Snap Ring Camshaft Sub-Gear
LH Exhaust
Camshaft RH Cylinder Head Cover
Gasket
RH Intake
Camshaft Camshaft Sub-Gear
Camshaft Gear Spring
RH Exhaust
CamshaftWave Washer
Semi-Circular PlugSemi-Circular
Plug
LH Cylinder Head
Camshaft
Bearing Cap

Camshaft Oil Seal RH Cylinder Head

RH Cylinder
Head Gasket

LH Cylinder Head Gasket18 (185, 13)x 8
16 (160, 12)
See Page EM-59
1st 54 (550, 40)
2nd Turn 90°
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable part

Spark Plug
Tube Gasket
Wave WasherGasketSnap RingCamshaft Gear Spring
Oil Control Valve Filter

Gasket
Camshaft Timing
Gear (VVT-i)

Gasket

Gasket
Oil Control
Valve FilterCylinder Head
Rear CoverCylinder Head
Rear Cover
Gasket
150 (1,530, 110)
NOTICE:
Intake Camshaft
Do not remove or install the camshaft timing
gear (VVT-i) beside changing VVT-i or the
camshaft.


EM-30
- ENGINE MECHANICALCYLINDER HEAD
1014 Author
: Date
:
2001 AVALON (RM808U)

EM0ZF-02
P12683
A05224
SST
P12686
P12720
Magnetic Finger
A05276
EM-40
- ENGINE MECHANICALCYLINDER HEAD
1024 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in the correct order.
2. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202-70020 (09202-00010)
(b) Remove the spring retainer, valve spring and valve.
(c) Using needle-nose pliers, remove the oil seal.
(d) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in the correct order.
3. REMOVE CYLINDER HEAD REAR COVER
Remove the 6 bolts, rear cover and gasket.

A05275
- ENGINE MECHANICALCYLINDER HEAD
EM-41
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:
2001 AVALON (RM808U)
4. REMOVE OIL CONTROL VALVE FILTER
Remove the plug, gasket and valve filter.

A05225
EM0ZG-02
A05226
A05230
A05233
A05232
EM-42
- ENGINE MECHANICALCYLINDER HEAD
1026 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYL-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high pressure compressed
air.
2. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
3. CLEAN COMBUSTION CHAMBERS
Using a wire brush, remove all the carbon from the combustion
chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
4. CLEAN CYLINDER HEADS
Using a soft brush and solvent, thoroughly clean the cylinder
head.

P12755
A05231
A05227
EM0580
- ENGINE MECHANICALCYLINDER HEAD
EM-43
1027 Author
: Date
:
2001 AVALON (RM808U)
5. CLEAN VALVE GUIDE BUSHINGS
Using a valve guide bushing brush and solvent, clean all the
guide bushings.
6. INSPECT FOR FLATNESS
Using a precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder block and the manifolds for
warpage.
Maximum warpage: 0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS
Using a dye penetrant, check the combustion chamber, intake
ports, exhaust ports and cylinder block contact surface for
cracks.
If cracked, replace the cylinder head.
8. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

P12754
Z00052
Z00054
44.5°
EM0181
Margin Thickness EM-44
- ENGINE MECHANICALCYLINDER HEAD
1028 Author
: Date
:
2001 AVALON (RM808U)
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
5.510 - 5.530 mm (0.2169 - 0.2177 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake5.470 - 5.485 mm (0.2154 - 0.2159 in.)
Exhaust5.465 - 5.480 mm (0.2152 - 0.2157 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing guide bushing inside diameter measure-
ment.
Standard oil clearance:
Intake0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Exhaust0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing.
10. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness: 1.0 mm (0.039 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.

EM2534
Overall Length
EM0255
A05228
P12729
Width
Z03988
45°
1.0 - 1.4 mm30°
- ENGINE MECHANICALCYLINDER HEAD
EM-45
1029 Author
: Date
:
2001 AVALON (RM808U)
(d) Check the valve overall length.
Standard overall length:
Intake95.45 mm (3.5779 in.)
Exhaust95.40 mm (3.7559 in.)
Minimum overall length:
Intake94.95 mm (3.7382 in.)
Exhaust94.90 mm (3.7362 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
11. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:

If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.

If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.

Check that the seat contact is in the middle of the
valve face with the following width:
1.0 - 1.4 mm (0.039 - 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.

Z03989
45°
1.0 - 1.4 mm75°
P12705
EM0988
Deviation
EM0801
EM0281
EM-46
- ENGINE MECHANICALCYLINDER HEAD
1030 Author
: Date
:
2001 AVALON (RM808U)
(2) If the seating is too low on the valve face, use 75°
and 45° cutters to correct the seat.
(d) Hand-lap the valve and valve seat with an abrasive com-
pound.
(e) After hand-lapping, clean the valve and valve seat.
12. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
(b) Using vernier calipers, measure the free length of the
valve spring.
Free length: 45.50 mm (1.7913 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186 - 206 N (19.0 - 21.0 kgf, 41.9 - 46.3 lbf)
at 33.8 mm (1.331 in.)
If the installed tension is not as specified, replace the valve
spring.

A05704
EM2011
EM2538
A05236
- ENGINE MECHANICALCYLINDER HEAD
EM-47
1031 Author
: Date
:
2001 AVALON (RM808U)
13. INSPECT CAMSHAFT FOR RUNOUT
(a) Place the camshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
14. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake42.932 - 43.032 mm (1.6902 - 1.6942 in.)
Exhaust42.764 - 42.864 mm (1.6836 - 1.6876 in.)
Minimum cam lobe height:
Intake42.78 mm (1.6842 in.)
Exhaust42.61 mm (1.6776 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
15. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 - 26.975 mm (1.0613 - 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
16. INSPECT CAMSHAFT BEARINGS
Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.