check engine TOYOTA AVALON 2001 Service Repair Manual

DI01Q-10
THEFT DETERRENT SYSTEM Check Sheet
Inspector 's name:
Customer 's Name
Date of VehicleRegistration No.
Registration Year
Frame No.
Odometer Reading / /km
Mile
Weather Conditions
When Problem
Occurred Frequency Problem OccursWeather
Outdoor temperature
/ /

Constant
Sometimes ( Times per day, month)

Once only Brought in

Theft deterrent system cannot be set.

Indicator light does not flash when the theft deterrent system is set.
(It stays on or does not light at all.)

Theft deterrent system
does not operate.
When unlocked using the
door lock knob.

When the engine hood is
opened.

System cannot be
canceled once set.
When door is unlocked using key or wireless door lock control system.

When the key is inserted in the ignition key cylinder and turned to ACC or ON
position.
(However, only when the system has never operated)

When the luggage compartment door is opened with the key.

System cannot be
canceled during warning
operation.
When door is unlocked using key or wireless door lock control system.

When the key is inserted in the ignition key cylinder and turned to ACC or ON
position.

Warning operation starts when the system is set and the door or luggage compartment door is opened with
the key.

Others.
Date Problem First Occurred

Fine
Cloudy
Rainy
Snowy

Various/Others

Hot
Warm
Cool

Cold (Approx. 5F ( 5C))
Problem Symptom
Malfunction

Horns only

Theft deterrent horn only

Headlights only

Taillights only

Starter cut only

Door lock operation only
DI-518
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
674 Author
: Date
:
2001 AVALON (RM808U)
CUSTOMER PROBLEM ANALYSIS CHECK

DI4DL-03
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-519
675 Author
: Date
:
2001 AVALON (RM808U)
PRE-CHECK
1. THEFT DETERRENT SYSTEM
When the system is set to the theft deterrent mode and any of
the following conditions are met, the system sounds the horns
and flashes the headlights and the taillights for approx. 1 min-
ute.
At the same time the system locks all doors (If all door are not
locked at once, the system repeats door locking operation ev-
ery 6.38 seconds during the one minute alarm time).
There are 2 modes in this system, which are active mode and
passive mode.
All initial setting are performed in active mode. It can be
switched to passive mode by specified operation. (See step 4.
CHANGING METHOD OF PASSIVE MODE)
Condition:
Any of the doors (Including the engine hood and luggage
compartment door) is unlocked or opened without the
key. *1
The battery terminal is disconnected and reconnected.
The system receives panic signal from remote keyless
entry. *2
*1: Only active arming mode.
*2: When the ignition key is not inserted in the key cylinder.
There are 4 conditions in this system which are disarming
condition, disarming preparation condition, arming condition
and alarming condition.
(a) Disarming condition:
(1) When a user is near the vehicle.
(2) When the alarming function does not operate.
(3) When theft deterrent function is not performed.
(b) Disarming preparation condition:
(1) Time from a user locks a door to be leaves the ve-
hicle.
(2) Time until transferring to disarming condition.
(3) Theft deterrent function is not performed.
(c) Arming condition:
(1) When a user leaves the vehicle completely.
(2) When theft deterrent function is possible.

EC0B4-03
B01082
Gasket
B06544
Vacuum
Gauge
A10838
TOYOTA Hand-Held Tester
DLC3
B06722
Battery EC-6
- EMISSION CONTROLEVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
1100 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
1. VISUALLY INSPECT LINES AND CONNECTORS
Visually check for loose connections, sharp bends or damage.
2. VISUALLY INSPECT FUEL TANK FILLER PIPE
Visually check for deformation, cracks or fuel leakage.
3. INSPECT FUEL TANK CAP
Visually check if the cap and/or gasket are deformed or dam-
aged.
If necessary, repair or replace the cap.
4. INSPECT EVAP SYSTEM LINE
(a) Warm up the engine and stop the engine.
Allow the engine to warm up to normal operating tempera-
ture.
(b) Install a vacuum gauge (EVAP control system test equip-
ment vacuum gauge) to the EVAP service port on the
purge line.
(c) TOYOTA Hand-Held Tester:
Forced driving of the VSV for the EVAP.
(1) Connect a TOYOTA hand-held tester to the DLC3.
(2) Start the engine.
(3) Push the TOYOTA hand-held tester main switch
ON.
(4) Use the ACTIVE TEST mode on the TOYOTA
hand-held tester to operate the VSV for the EVAP.
(d) If you have no TOYOTA Hand-Held Tester:
Forced driving of the VSV for the EVAP.
(1) Disconnect the VSV connector for the EVAP.
(2) Connect the positive (+) and negative (-) leads from
the battery to the VSV terminals for the EVAP.
(3) Start the engine.

B06545
B08626
Hose Clipper
Air Drain Hose
B06546
Pressure
Gauge
Pressure
- EMISSION CONTROLEVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC-7
1101 Author
: Date
:
2001 AVALON (RM808U)
(e) Check the vacuum at idle.
Vacuum:
Maintain at 0.368 - 19.713 in.Hg (5 - 268 in.Aq) for over
5 seconds
HINT:
If the vacuum does not change, you can conclude that the hose
connecting the VSV to the service port has come loose or is
blocked, or the VSV is malfunctioning.
(f) TOYOTA Hand-Held Tester:
Conclude forced driving of the VSV for the EVAP.
(1) Stop the engine.
(2) Disconnect the TOYOTA hand-held tester from the
DLC3.
(g) If you have no TOYOTA Hand-Held Tester:
Conclude forced driving of the VSV for the EVAP.
(1) Stop the engine.
(2) Disconnect the positive (+) and negative (-) leads
from the battery from the VSV terminals for the
EVAP.
(3) Connect the VSV connector for the EVAP.
(h) Disconnect the vacuum gauge from the EVAP service
port on the purge line.
(i) Connect a pressure gauge to the EVAP service port on
the purge line.
(j) Check the pressure.
(1) Close off the air drain hose at the marked position
of the canister with a hose clipper or similar instru-
ment.
(2) Add the pressure (13.5 - 15.5 in.Aq) from the EVAP
service port.
Pressure:
2 minutes after the pressure is added, the gauge
should be over 7.7 - 8.8 in.Aq.
HINT:
If you can't add pressure, you can conclude that the hose con-
necting the VSV
canister
fuel tank has slipped off or the
VSV is open.

EM0CB-03
A10537
CO/HC Meter
- ENGINE MECHANICALCO/HC
EM-1
985 Author
: Date
:
2001 AVALON (RM808U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
(f) SFI system wiring connectors fully plugged
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Tachometer and CO/HC meter calibrated by hand
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When doing the 2 mode (2,500 rpm and idle) test, follow the
measurement order prescribed by the applicable local regula-
tions.

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)

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.

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.

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.