engine TOYOTA AVALON 2001 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2001, Model line: AVALON, Model: TOYOTA AVALON 2001Pages: 1897, PDF Size: 26.61 MB
Page 1273 of 1897
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.
Page 1274 of 1897
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 VSVcanisterfuel tank has slipped off or the
VSV is open.
Page 1286 of 1897
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.
Page 1287 of 1897
EM-2
- ENGINE MECHANICALCO/HC
986 Author: Date:
2001 AVALON (RM808U)
If the CO/HC concentration does not comply with regulations,
troubleshoot in the order given below.
See the table below for possible causes, and then inspect and
correct the applicable causes if necessary.
COHCProblemsCauses
NormalHighRough idle3. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
4. Incorrect valve clearance
5. Leaky intake and exhaust valves
6. Leaky cylinders
LowHighRough idle
(Fluctuating HC reading)1. Vacuum leaks:
PCV hoses
Intake manifold
Air intake chamber
Throttle Body
IAC valve
Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI systems:
Faulty pressure regulator
Defective ECT sensor
Faulty ECM
Faulty injectors
Faulty throttle position sensor
Faulty MAF meter
Page 1288 of 1897
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)
Page 1289 of 1897
EM04B-04
A10521
Knock Sensor Connector
Engine Wire Band
Engine WireKnock Sensor
Water Inlet Housing
(With Water Inlet)
No.2 Idler Pulley Bracket
Water Seal Plate
Engine Coolant
Drain Union
Oil Filter Union
Oil Filter Gasket
Cylinder Block
Side Cover
Gasket
Water Pump
Crankshaft
Front Oil Seal
Crankshaft
Position Sensor
Connector Oil Pressure
Switch
Oil Pressure Switch
Connector
A/C Compressor
Housing Bracket
No.1 Oil Pan
x 17 Oil Pump
Gasket
Gasket
Engine WireGenerator
Drain Plugx 10No.2 Oil Pan Oil Strainer
Non-reusable part
N´m (kgf´cm, ft´lbf): Specified torque
Precoated part
8 (80, 69 in.´lbf)
8 (80, 69 in.´lbf)
10 mm Head 8 (80, 69 in.´lbf)
12 mm Head 19.5 (200, 14)
10 mm Head 8 (80, 69 in.´lbf)
12 mm Head 19.5 (200, 14)
45 (460, 33)
8 (80, 69 in.´lbf)
9 (90, 78 in.´lbf)
x 8
8 (80, 69 in.´lbf)
28 (290, 21)
18 (180, 13)
25 (250, 18)
39 (400, 29)
No.2 ECT Switch
Connector
O-Ring
x 9
19.5 (200, 14)
- ENGINE MECHANICALCYLINDER BLOCK
EM-81
1065 Author: Date:
2001 AVALON (RM808U)
CYLINDER BLOCK
COMPONENTS
Page 1290 of 1897
A09697
No.1 Piston Ring
Oil Ring (Expander)
PistonPiston Pin No.2 Piston Ring
Oil Ring (Side Rail)
Snap Ring
Connecting Rod Bushing Snap Ring
Connecting Rod
Connecting Rod Bearing
Connecting Rod Cap
1st 24.5 (250, 18)
2nd Turn 90° See Page EM-101
Seal Washer
Rear Oil Seal
Retainer
Cylinder Block
Upper Main Bearing
Lower Main Bearing
Main Bearing Cap Upper Crankshaft
Thrust Washer
Crankshaft
Lower Crankshaft
Thrust Washer
8 (80, 69 in.´lbf)x 6
1st 22 (225, 16)
2nd Turn 90° See Page EM-101
Seal Washer
27 (275, 20)
N´m (kgf´cm, ft´lbf): Specified torque
Non-reusable part
Crankshaft
Rear Oil Seal EM-82
- ENGINE MECHANICALCYLINDER BLOCK
1066 Author: Date:
2001 AVALON (RM808U)
Page 1291 of 1897
A05415
EM0ZN-02
S04921
A05252
P18761
- ENGINE MECHANICALCYLINDER BLOCK
EM-83
1067 Author: Date:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE DRIVE PLATE
Remove the 8 bolts, rear plate, drive plate and front spacer.
2. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
3. REMOVE TIMING BELT AND PULLEYS
(See page EM-15)
4. REMOVE CYLINDER HEAD (See page EM-31)
5. DISCONNECT CRANKSHAFT POSITION SENSOR
CONNECTOR
6. DISCONNECT OIL PRESSURE SWITCH CONNECTOR
7. DISCONNECT OIL LEVEL SENSOR CONNECTOR
8. REMOVE ENGINE WIRE
(a) Disconnect the 2 wire clamps from the wire brackets.
(b) Remove the 2 bolts and nut, and disconnect the engine
wire.
9. REMOVE GENERATOR, ADJUSTING BAR AND
BRACKET ASSEMBLY
Remove the 3 nuts, the generator, adjusting bar and bracket as-
sembly.
10. REMOVE OIL PRESSURE SWITCH
(See page LU-1)
11. REMOVE A/C COMPRESSOR HOUSING BRACKET
Remove the 2 bolts and compressor housing bracket.
12. REMOVE NO.2 IDLER PULLEY BRACKET
Remove the 2 bolts and idler pulley bracket.
Page 1292 of 1897
P12389
SST
A05253
P18763
WaterSeal
Plate
Oil Filter
Union
12 mm
Hexagon
Wrench
Coolant
Drain
Union
A02010
P12508
EM-84
- ENGINE MECHANICALCYLINDER BLOCK
1068 Author: Date:
2001 AVALON (RM808U)
13. REMOVE KNOCK SENSORS
(a) Disconnect the 2 knock sensor connectors.
(b) Using SST, remove the 2 knock sensors.
SST 09816-30010
14. REMOVE WATER INLET HOUSING
(a) Remove the engine wire band.
(b) Disconnect the engine wire clamp from the bracket.
(c) Remove the 8 bolts, 2 nuts and water inlet housing.
15. REMOVE WATER PUMP (See page CO-6)
16. REMOVE NO.2 OIL PAN (See page LU-9)
17. REMOVE OIL STRAINER (See page LU-3)
18. REMOVE NO.1 OIL PAN (See page LU-3)
19. REMOVE OIL PUMP (See page LU-9)
20. REMOVE OIL FILTER (See page LU-3)
21. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.
22. REMOVE WATER SEAL PLATE
Remove the 2 nuts and seal plate.
23. REMOVE ENGINE COOLANT DRAIN UNION
24. REMOVE CYLINDER BLOCK SIDE COVER
Remove the 3 bolts, 2 nuts, cylinder block side cover and gas-
ket.
25. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 6 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
Page 1293 of 1897
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.