clock TOYOTA AVALON 2001 Service User Guide
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2001, Model line: AVALON, Model: TOYOTA AVALON 2001Pages: 1897, PDF Size: 26.61 MB
Page 559 of 1897
P01364
Pulley
CH040-02
P00427
P01763
29 mm
Socket
Wrench
P19942
A
AB
A
P10835
SST (B)Turn
SST (A)
- CHARGINGGENERATOR
CH-13
1286 Author: Date:
2001 AVALON (RM808U)
REASSEMBLY
1. INSTALL ROTOR TO DRIVE END FRAME
(a) Place the rectifier end frame on the pulley.
(b) Install the rotor to the rectifier end frame.
2. INSTALL RECTIFIER END FRAME
(a) Place the thrust washer on the rotor.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) NUT A:
Install the cord clip and 4 nuts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
(d) NUT B:
Install the cord clip and 4 nuts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(e) Install the wire clamp.
3. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820-63010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(c) Check that SST (A) is secured to the pulley shaft.
Page 591 of 1897
CO0SW-02
A10518
5 mm
Hexagon
Wrench
B08906
B06725
B04150
CO-10
- COOLINGTHERMOSTAT
1203 Author: Date:
2001 AVALON (RM808U)
REMOVAL
HINT:
Removal of the thermostat would have an adverse effect, caus-
ing a lowering of cooling efficiency. Do not remove the thermo-
stat, even if the engine tends to overheat.
1. DRAIN ENGINE COOLANT
2. REMOVE V-BANK COVER
(a) Using a 5 mm hexagon wrench, remove the 3 cap nuts.
(b) Loosen the V-bank cover fastener counterclockwise.
(c) Remove the V-bank cover.
3. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
4. REMOVE AIR CLEANER HOSE WITH RESONATOR
5. DISCONNECT HEATER HOSES
6. DISCONNECT NO.2 ECT SWITCH CONNECTOR
7. DISCONNECT ENGINE WIRE PROTECTOR FROM
WATER INLET AND RH CYLINDER HEAD
Remove the nut and disconnect the clamp, and disconnect the
engine wire protector from the water inlet and cylinder head.
8. DISCONNECT WATER INLET PIPE FROM WATER IN-
LET AND LH CYLINDER HEAD
(a) Remove the bolt, and disconnect the inlet pipe from the
water inlet.
(b) Remove the O-ring from the inlet pipe.
9. REMOVE WATER INLET AND THERMOSTAT
(a) Remove the 3 nuts, water inlet and thermostat.
(b) Remove the gasket from the thermostat.
Page 1281 of 1897
EC04T-03
B07459
N´m (kgf´cm, ft´lbf) : Specified torque
Non-reusable part Gasket
44 (450, 33)
Damper Gasket
43 (440, 32)
TWC
Compression Spring
Center Exhaust PipeCompression Spring
43 (440, 32)
Heated Oxygen Sensor
(Bank 1 Sensor 2)
Heated Oxygen Sensor (Bank 1 Sensor 2)
HINT:
Before installing the heated oxygen sensor,
twist the sensor wire counterclockwise
3 and 1/2 turns.
After installing the heated oxygen sensor,
check that the sensor wire is not twisted,
if it is twisted, remove the heated oxygen
sensor and reinstall it.
- EMISSION CONTROLTHREE-W AY CATALYTIC CONVERTER (TWC)
SYSTEMEC-15
1109 Author: Date:
2001 AVALON (RM808U)
COMPONENTS
Page 1313 of 1897
P12477
Seal Packing
Z09223
Seal Width
3 - 5 mmA
BA
B
- ENGINE MECHANICALCYLINDER BLOCK
EM-107
1091 Author: Date:
2001 AVALON (RM808U)
17. INSTALL ENGINE COOLANT DRAIN UNION
(a) Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826-00100 or equivalent
(b) Install the drain union.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
HINT:
After applying the specified torque, rotate the drain union clock-
wise until its drain port is facing downward.
18. INSTALL WATER SEAL PLATE
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the seal plate
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the seal plate as shown in the il-
lustration.
Seal packing: Part No. 08826-00100 or equivalent
Install a nozzle that has been cut to a 3 - 5 mm (0.12
- 0.20 in.) opening.
Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the seal plate with the 2 nuts.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
19. INSTALL OIL FILTER UNION
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
20. INSTALL OIL FILTER (See page LU-3)
21. INSTALL OIL PUMP (See page LU-15)
22. INSTALL NO.1 OIL PAN (See page LU-15)
23. INSTALL OIL STRAINER (See page LU-15)
24. INSTALL NO.2 OIL PAN (See page LU-15)
25. INSTALL WATER PUMP (See page CO-8)
26. INSTALL WATER INLET HOUSING
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water in-
let housing and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Page 1337 of 1897
P12974
SST
Main Gear
Sub-Gear
A05201
90°Exhaust
P12804
Exhaust
Front
A02008
Exhaust
Seal
Packing
- ENGINE MECHANICALCYLINDER HEAD
EM-61
1045 Author: Date:
2001 AVALON (RM808U)
(e) Using SST, align the holes of the camshaft main gear and
sub-gear by turning camshaft sub-gear counterclock-
wise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(f) Align the gear teeth of the main gear and sub-gear, and
tighten the service bolt.
5. INSTALL 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) Install the exhaust camshaft.
(1) Apply new engine oil to the thrust portion and jour-
nal of the camshaft.
(2) Place the exhaust camshaft at 90° angle of timing
mark (2 dot marks) on the cylinder head.
(3) Apply MP grease to a new oil seal lip.
(4) Install the oil seal to the camshaft.
(5) Remove any old packing (FIPG) material.
(6) Apply seal packing to the No.1 bearing cap as
shown.
Seal packing: Part No. 08826-00080 or equivalent
Page 1349 of 1897
EM0ZE-02
A10518
5 mm
Hexagon
Wrench
A06658
(j)
(k) (l)
- ENGINE MECHANICALCYLINDER HEAD
EM-31
1015 Author: Date:
2001 AVALON (RM808U)
REMOVAL
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i)
beside changing VVT-i or the camshaft.
1. DRAIN ENGINE COOLANT
2. REMOVE RH FENDER APRON SEAL
3. REMOVE GENERATOR DRIVE BELT
(See page CH-6)
4. REMOVE PS PUMP (See page SR-27)
5. REMOVE FRONT EXHAUST PIPE (See page EM-72)
6. REMOVE V-BANK COVER
(a) Using a 5 mm hexagon wrench, remove the 3 cap nuts.
(b) Loosen the V-bank cover fastener counterclockwise.
(c) Remove the V-bank cover.
7. REMOVE AIR CLEANER HOSE WITH RESONATOR
8. REMOVE AIR INTAKE CHAMBER ASSEMBLY
(a) Disconnect the accelerator cable.
(b) Disconnect the throttle cable.
(c) Disconnect the throttle position sensor connector.
(d) Disconnect the IAC valve connector.
(e) Disconnect the No.1 VSV connector for the ACIS.
(f) Disconnect the No.2 VSV connector for the ACIS.
(g) Disconnect the VSV connector for the EVAP.
(h) Disconnect the DLC1 from the bracket on the intake air
control valve.
(i) Remove the 2 nuts, and disconnect the PS pressure tube
from the No.1 engine hanger.
(j) Disconnect the PCV hose from the PCV valve on the RH
cylinder head.
(k) Disconnect the ground strap and cable from the intake air
control valve for the ACIS.
(l) Disconnect the ground cable from the air intake chamber.
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 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.
Page 1369 of 1897
EM0ZL-02
A10518
5 mm
Hexagon
Wrench
A07300
EM-72
- ENGINE MECHANICALENGINE UNIT
1056 Author: Date:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE HOOD
3. REMOVE ENGINE FENDER APRON SEALS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. REMOVE V-BANK COVER
(a) Using a 5 mm hexagon wrench, remove the 3 cap nuts.
(b) Loosen the V-bank cover fastener counterclockwise.
(c) Remove the V-bank cover.
7. DISCONNECT ACCELERATOR CABLE
8. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR
CLEANER CASE
9. REMOVE CRUISE CONTROL ACTUATOR
10. REMOVE RADIATOR (See page CO-17)
11. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts holding the support stay to the sup-
port bracket.
(b) Remove the 2 bolts and 2 compression springs holding
the front exhaust pipe to the center exhaust pipe.
(c) Remove the 4 nuts holding the front exhaust pipe to the
exhaust manifolds.
(d) Remove the front exhaust pipe and 3 gaskets.
12. DISCONNECT CONNECTORS, CABLE, CLAMPS AND
HOSES
(a) Remove the bolt and disconnect the ground strap from
the LH fender apron.
(b) Disconnect the 2 ground strap connectors from the RH
fender apron.
(c) Disconnect the ground cable from the A/T.
(d) Disconnect the engine wire protector clamp from the bat-
tery body bracket.
(e) Disconnect the engine wire clamp from the bracket on the
RH fender apron.
(f) Disconnect the brake booster vacuum hose from the
throttle body.
(g) Disconnect the engine coolant reservoir hose from the
water outlet.
(h) Disconnect the heater hose from the intake manifold.
(i) Disconnect the heater hose from the water inlet housing.