TOYOTA AVALON 2001 Service Repair Manual
Manufacturer: TOYOTA, Model Year: 2001, Model line: AVALON, Model: TOYOTA AVALON 2001Pages: 1897, PDF Size: 26.61 MB
Page 1351 of 1897
A07428
P20049Gasket
A05077
Clamp
Clamp
Clamp
A10531
- ENGINE MECHANICALCYLINDER HEAD
EM-33
1017 Author: Date:
2001 AVALON (RM808U)
(d) Remove the 9 bolts, 2 nuts, 2 plate washers, the intake
manifold, delivery pipes and injectors assembly.
NOTICE:
Be careful not to drop the injectors when removing
the delivery pipes.
Pay attention to put any hung load on the injector to
and from the side direction.
10. REMOVE WATER OUTLET
(a) Disconnect the ECT sender gauge connector.
(b) Disconnect the ECT sensor connector.
(c) Disconnect the ground strap connector.
(d) Disconnect the upper radiator hose.
(e) Disconnect the engine coolant reservoir hose.
(f) Remove the 2 bolts, 2 nuts and 2 plate washers.
(g) Disconnect the water bypass hose, and remove the water
outlet.
(h) Remove the 2 gaskets.
11. REMOVE IGNITION COILS
12. REMOVE SPARK PLUGS
13. REMOVE TIMING BELT (See page EM-15)
14. REMOVE CAMSHAFT TIMING PULLEYS
(See page EM-15)
15. REMOVE NO.2 IDLER PULLEY (See page EM-15)
16. REMOVE NO.3 TIMING BELT COVER
(a) Disconnect the 3 engine wire clamps from the timing belt
cover.
(b) Remove the 6 bolts and timing belt cover.
17. REMOVE CAMSHAFT POSITION SENSORS
18. REMOVE CAMSHAFT TIMING OIL CONTROL VALVES
19. DISCONNECT ENGINE WIRE PROTECTOR FROM
REAR SIDE
Remove the nut, and disconnect the engine wire protector from
the RH cylinder head.
Page 1352 of 1897
A10519
A05205
A07596
Rear
Plate
Inlet Pipe
A05189
A06661
Manifold
Stay
EM-34
- ENGINE MECHANICALCYLINDER HEAD
1018 Author: Date:
2001 AVALON (RM808U)
20. DISCONNECT ENGINE WIRE AND PROTECTOR
FROM RH SIDE
Remove the 5 nuts, and disconnect the engine wire and protec-
tor from the RH cylinder head cover.
21. DISCONNECT ENGINE WIRE PROTECTOR FROM LH
SIDE
Remove the 2 bolts, and disconnect the engine wire protector
from the LH cylinder head cover.
22. DISCONNECT CYLINDER HEAD REAR PLATE FROM
LH CYLINDER HEAD
Remove the 2 bolts, and disconnect the rear plate.
23. DISCONNECT WATER INLET PIPE FROM LH CYL-
INDER HEAD AND WATER INLET
(a) Remove the bolt, and disconnect the inlet pipe from the
water inlet.
(b) Remove the O-ring from the inlet pipe.
24. REMOVE PS PUMP BRACKET
Remove the 3 bolts and pump bracket.
25. REMOVE RH EXHAUST MANIFOLD
(a) Disconnect the A/F sensor connector.
(b) Remove the bolt, nut and exhaust manifold stay.
(c) Remove the 6 nuts, exhaust manifold and gasket.
Page 1353 of 1897
A07281
Manifold
Stay
A07283
O-Ring
A05193
A05280Align Intake
- ENGINE MECHANICALCYLINDER HEAD
EM-35
1019 Author: Date:
2001 AVALON (RM808U)
26. REMOVE LH EXHAUST MANIFOLD
(a) Disconnect the A/F sensor connector.
(b) Remove the bolt, nut and exhaust manifold stay.
(c) Remove the 6 nuts, exhaust manifold and gasket.
27. REMOVE OIL DIPSTICK AND GUIDE
(a) Remove the bolt holding the dipstick guide to the LH cylin-
der head.
(b) Pull out the dipstick guide together with the dipstick from
the No.1 oil pan.
(c) Remove the O-ring from the dipstick guide.
28. REMOVE CYLINDER HEAD COVERS
Remove the 9 bolts, cylinder head cover and gasket. Remove
the 2 cylinder head covers.
29. REMOVE CAMSHAFTS OF RH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept leveled while it is being installed. If
the camshaft is not kept leveled, the portion of the cylinder
head receiving the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid this, the
following steps should be carried out.
(a) Remove the intake camshaft.
(1) Align the timing marks (2 dot marks) of the camshaft
drive and driven gears by turning the camshaft with
a wrench.
Page 1354 of 1897
A05195
IntakeMain Gear
Sub-Gear
Service Bolt
A05207
Intake
7
8
5
6
3
41 2
9
10
A05197
7
85
6
3
41
2
9
10 Exhaust EM-36
- ENGINE MECHANICALCYLINDER HEAD
1020 Author: Date:
2001 AVALON (RM808U)
(2) Secure the exhaust camshaft sub-gear to the main
gear with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 - 20 mm (0.63 - 0.79 in.)
HINT:
When removing the camshaft, mark certain that the torsional
spring force of the sub-gear has been eliminated by the above
operation.
(3) Uniformly loosen and remove the 10 bearing cap
bolts in several passes and in the sequence shown.
(4) Remove the 5 bearing caps and intake camshaft.
(b) Remove the exhaust camshaft.
(1) Uniformly loosen and remove the 10 bearing cap
bolts in several passes and in the sequence shown.
(2) Remove the 5 bearing caps, oil seal and exhaust
camshaft.
30. REMOVE CAMSHAFTS OF LH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept leveled while it is being installed. If
the camshaft is not kept leveled, the portion of the cylinder
head receiving the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid this, the
following steps should be carried out.
Page 1355 of 1897
A05284Align Intake
A05198
Intake
Main GearSub-GearService Bolt
A05199
Intake
7
85
6
3
4
1
2
9
10
A05200
7
8
5
6
3
4
1
2
9
10 Exhaust
- ENGINE MECHANICALCYLINDER HEAD
EM-37
1021 Author: Date:
2001 AVALON (RM808U)
(a) Remove the intake camshaft.
(1) Align the timing marks (1 dot mark) of the camshaft
drive and driven gears by turning the camshaft with
a wrench.
(2) Secure the exhaust camshaft sub-gear to the main
gear with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 - 20 mm (0.63 - 0.79 in.)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub-gear has been eliminated by the above
operation.
(b) Uniformly loosen and remove the 10 bearing cap bolts in
several passes and in the sequence shown.
(c) Remove the 5 bearing caps and intake camshaft.
(d) Remove the exhaust camshaft.
(1) Uniformly loosen and remove the 10 bearing cap
bolts in several passes and in the sequence shown.
(2) Remove the 5 bearing caps, oil seal and exhaust
camshaft.
HINT:
Arrange the camshafts in the correct order.
Arrange the bearing caps in the correct order.
Page 1356 of 1897
P12596
P12797
SST
P12590
A05222
FrontRecessed Heat Bolt
8 mm Hexagon Wrench
EM-38
- ENGINE MECHANICALCYLINDER HEAD
1022 Author: Date:
2001 AVALON (RM808U)
31. DISASSEMBLE EXHAUST CAMSHAFTS
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using SST, turn the sub-gear counterclockwise, and re-
move the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, camshaft sub-gear, and cam-
shaft gear spring.
HINT:
Arrange the camshaft sub-gears and gear springs (RH and LH
side).
32. REMOVE CYLINDER HEADS
(a) Using an 8 mm hexagon wrench, remove the cylinder
head (recessed head) bolt on each cylinder head, then re-
peat for the other side, as shown.
Page 1357 of 1897
A05219
7
8
5
6
3
41
2
7
8
5
6
3
41
212 Pointed Head Bolt
Front
P12424
- ENGINE MECHANICALCYLINDER HEAD
EM-39
1023 Author: Date:
2001 AVALON (RM808U)
(b) Uniformly loosen and remove the 8 cylinder head (12
pointed head) bolts on each cylinder head in several
passes and in the sequence shown, then repeat for the
other side, as shown. Remove the 16 cylinder head bolts
and plate washers.
NOTICE:
Head warpage or cracking could result from removing
bolts in an incorrect order.
(c) Lift the cylinder head from the dowels on the cylinder
block and place the 2 cylinder heads on wooden blocks
on a bench.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
head and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
Page 1358 of 1897
EM0ZH-02
A05234
80 - 100°C
P12803
SST
P12956
Bushing sizeBushing bore diameter
mm (in.)
10.295 - 10.313
(0.4053 - 0.4060)Both intake and exhaust
Use STD
10.345 - 10.363
(0.4073 - 0.4080)Use O/S 0.05
P11510
34.5 mm
(1.358 in.) Intake Exhaust
40.5 mm
(1.594 in.) EM-52
- ENGINE MECHANICALCYLINDER HEAD
1036 Author: Date:
2001 AVALON (RM808U)
REPLACEMENT
1. REPLACE VALVE GUIDE BUSHINGS
(a) Gradually heat the cylinder head to 80 - 100°C (176 -
212°F).
(b) Using SST and a hammer, tap out the guide bushing.
SST 09201-01055, 09950-70010 (09951-07100)
(c) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
(d) Select a new guide bushing (STD or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
10.313 mm (0.4060 in.), machine the bushing bore to the fol-
lowing dimension:
10.345 - 10.363 mm (0.4073 - 0.4080 in.)
If the bushing bore diameter of the cylinder head is greater than
10.363 mm (0.4080 in.), replace the cylinder head.
HINT:
Different bushings are used for the intake and exhaust.
(e) Gradually heat the cylinder head to 80 - 100°C (176 -
212°F).
Page 1359 of 1897
P12802
SST
Z09124
A05739
A05740
- ENGINE MECHANICALCYLINDER HEAD
EM-53
1037 Author: Date:
2001 AVALON (RM808U)
(f) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)
Protrusion height:
Intake11.1 - 11.3 mm (0.437 - 0.453 in.)
Exhaust8.9 - 9.3 mm - (0.350 - 0.366 in.)
(g) Using a sharp 5.5 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See page
EM-42) between the guide bushing and valve stem.
2. REPLACE CAMSHAFT TIMING GEAR (VVT-i)
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i)
beside changing VVT-i or the camshaft.
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using a 46 mm socket wrench, remove the lock nut by
turning it clockwise.
NOTICE:
Remove it under the condition that the lock pin is op-
erated and lock at the maximum delay angle position.
The lock nut have LH threads.
Never use any tool other than the socket wrench,
otherwise that may result in deforming the cam angle
rotor portion.
(c) Remove the camshaft VVT-i.
HINT:
In case of having difficulty to remove VVT-i, apply a slight hit-
ting using a plastic-faced hammer and then remove it.
NOTICE:
Never remove the 3 bolts on the gear.
Page 1360 of 1897
A05706
Align
A05738
A05245
A05243
EM-54
- ENGINE MECHANICALCYLINDER HEAD
1038 Author: Date:
2001 AVALON (RM808U)
(d) Align the knock pin and knock pin groove and install VVT-
i on the camshaft.
NOTICE:
Install it under the condition that the lock pin is operated
and lock at the maximum delay angle position.
(e) Apply the engine oil on the nut, the placing surface of
VVT-i and the screw portion.
HINT:
Be sure to apply the oil, otherwise the prescribed torque cannot
be obtained.
(f) Using a 46 mm socket wrench, install and torque a new
lock nut by turning it counterclockwise.
Torque: 150 N´m (1,530 kgf´cm, 110 ft´lbf)
NOTICE:
Must change the nuts to the new ones when to change
VVT-i.
The lock nut have LH threads.
Never use any tool other than the socket wrench,
otherwise that may result in deforming the cam angle
rotor portion.
3. REPLACE SPARK PLUG TUBE GASKETS
(a) Bend up the tab on the ventilation baffle plate which pre-
vents the gasket from the slipping out.
(b) Using a screwdriver and hammer, tap out the gasket.
(c) Using needle-nose pliers, pry out the gasket.