check engine TOYOTA AVALON 2001 Service Repair Manual

EM0ZO-02
P12499
Z09222
P12498
- ENGINE MECHANICALCYLINDER BLOCK
EM-93
1077 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material from the
top surface of the cylinder block.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, thoroughly clean the cylinder
block.
NOTICE:
If the cylinder is washed at high temperatures, the cylinder
liner sticks out beyond the cylinder block, so always wash
the cylinder block at a temperature of 45°C (113°F) or less.
3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head gasket for warpage.
Maximum warpage: 0.07 mm (0.0028 in.)
If warpage is greater than maximum, replace the cylinder block.
4. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.

P12583
105 mm
EM7639
P12506
Z04012
EM-96
- ENGINE MECHANICALCYLINDER BLOCK
1080 Author
: Date
:
2001 AVALON (RM808U)
11. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 105 mm (4.13 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the end gap.
Standard end gap:
No.10.25 - 0.35 mm (0.0098 - 0.0138 in.)
No.20.35 - 0.45 mm (0.0138 - 0.0177 in.) for G2 mark
0.55 - 0.65 mm (0.0217 - 0.0256 in.) for 2T mark
Oil (Side rail)0.15 - 0.40 mm (0.0059 - 0.0157 in.)
Maximum end gap:
No.10.95 mm (0.0374 in.)
No.21.05 mm (0.0413 in.) for G2 mark
1.25 mm (0.0492 in.) for 2T mark
Oil (Side rail)1.00 mm (0.0394 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, replace the cylinder block.
12. INSPECT PISTON PIN FIT
At 60°C (140°F), you should be able to push the piston pin into
the piston pin hole with your thumb.
13. INSPECT CONNECTING ROD ALIGNMENT
Using a rod aligner and feeler gauge, check the connecting rod
alignment.

Check for out-of-alignment.
Maximum out-of-alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.

Z04011
EM6525
EM0227
EM6347
P12406
- ENGINE MECHANICALCYLINDER BLOCK
EM-97
1081 Author
: Date
:
2001 AVALON (RM808U)

Check for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
14. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 - 22.014 mm (0.8663 - 0.8667 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 - 22.006 mm (0.8660 - 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 - 0.011 mm (0.0002 - 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
15. INSPECT CONNECTING ROD BOLTS
Using vernier calipers, measure the tension portion diameter of
the bolt.
Standard diameter: 7.2 - 7.3 mm (0.284 - 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than minimum, replace the bolt.
16. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT
(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout, as
shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.

P12493
EM-98
- ENGINE MECHANICALCYLINDER BLOCK
1082 Author
: Date
:
2001 AVALON (RM808U)
17. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
60.988 - 61.000 mm (2.4011 - 2.4016 in.)
Crank pin diameter:
52.992 - 53.000 mm (2.0862 - 2.0866 in.)
If the diameter is not as specified, check the oil clearance.
(See page EM-83)
If necessary, replace the crankshaft.
(b) Check each main journal and crank pin for taper and out-
of-round as shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than maximum, replace
the crankshaft.

A10530
A09696
Less than 6 mm
A10529
P12753
10 11
12 13
14
151
162
3
45
6
7
89
P25741
Painted Mark
Front90°
90° EM-104
- ENGINE MECHANICALCYLINDER BLOCK
1088 Author
: Date
:
2001 AVALON (RM808U)
(b) Temporarily place the 4 main bearing caps level and let
them in their proper locations.
(c) Apply a light coat of engine oil on the threads and under
the main bearing cap bolts for the 12 pointed head.
(d) Temporarily install the 8 main bearing cap bolts to the in-
side positions.
(e) Insert the main bearing cap with your hand until the clear-
ance between the main bearing cap and the cylinder
block will become less than 6 mm (0.23 in.) by making the
2 internal main bearing cap bolts as a guide.
(f) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure a proper fit.
8. INSTALL 12 POINTED HEAD MAIN BEARING CAP
BOLTS
HINT:

The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any of the main bearing cap bolts is broken or deformed,
replace it.
(a) Apply a light coat of engine oil on the threads and under
the main bearing cap bolts.
(b) Install and uniformly tighten the 16 main bearing cap bolts
in several passes and in the sequence shown.
Torque: 22 N´m (225 kgf´cm, 16 ft´lbf)
If any of the main bearing cap bolts does not meet the torque
specification, replace the main bearing cap bolt.
(c) Mark the front of the main bearing cap bolts with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.

P12586
1
2
34
567
8
A10528
Front Mark
(Cavity)
Front Mark
(Cavity)RH Piston
LH Piston
P12699
P12801
Front
Protrusion
- ENGINE MECHANICALCYLINDER BLOCK
EM-105
1089 Author
: Date
:
2001 AVALON (RM808U)
9. INSTALL HEXAGON HEAD MAIN BEARING CAP
BOLTS
(a) Install a new seal washer to the main bearing cap bolt.
(b) Install and uniformly tighten the 8 main bearing cap bolts
in several passes and in the sequence shown.
Torque: 27 N´m (275 kgf´cm, 20 ft´lbf)
10. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM-83)
11. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
HINT:
The shape of the piston varies for the RH and LH banks. The
RH piston is marked with ºRº, the LH piston with ºLº.
12. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Align the pin dowels of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod.
(c) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
13. INSTALL CONNECTING ROD CAP BOLTS
HINT:

The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any of the connecting rod cap bolts is broken or de-
formed, replace it.

P12697
P25743
Painted Mark
Front90°
90°
P12911
Seal Width
2 - 3 mm A
BA
B EM-106
- ENGINE MECHANICALCYLINDER BLOCK
1090 Author
: Date
:
2001 AVALON (RM808U)
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque: 24.5 N´m (250 kgf´cm, 18 ft´lbf)
If any of the connecting rod cap bolts does not meet the torque
specification, replace the connecting rod cap bolts.
(c) Mark the front of the connecting cap bolts with paint.
(d) Retighten the cap bolts by 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
14. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM-83)
15. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.

Using a razor blade and gasket scraper, remove all
the oil packing (FIPG) material from the gasket sur-
faces and sealing grooves.

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 oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 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 oil seal retainer with the 6 bolts. Uniformly tight-
en the bolt in several passes and in the sequence shown.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
16. INSTALL CYLINDER BLOCK SIDE COVER
Install a new gasket and the cylinder block side cover with the
3 bolts and 2 nuts.
Torque: 9 N´m (90 kgf´cm, 78 in.´lbf)

EM0ZP-02
EM6363
SST
EM6364
Oil
Hole
EM6535
P00326
P12589
- ENGINE MECHANICALCYLINDER BLOCK
EM-99
1083 Author
: Date
:
2001 AVALON (RM808U)
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHING
(a) Using SST and a press, press out the bushing.
SST 09222-30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222-30010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page EM-93) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
2. REPLACE CRANKSHAFT FRONT OIL SEAL
(See page LU-13)
3. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal which
are as follows:
(a) If the rear oil seal retainer is removed from the cylinder
block.
(1) Using a screwdriver and hammer, tap out the oil
seal.

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.