check engine light TOYOTA AVALON 2001 Service Owner's Guide

DI-6
- DIAGNOSTICSENGINE
162 Author
: Date
:
2001 AVALON (RM808U)

TOYOTA hand-held tester only:
When the diagnosis system is switched from the nor-
mal mode to the check mode, it erases all DTC and
freezed frame data recorded in the normal mode. So
before switching modes, always check the DTC and
freezed frame data, and note them down.
(1) Prepare the OBD II scan tool (complying with SAE
J 1978) or TOYOTA hand-held tester.
(2) Connect the OBD II scan tool or TOYOTA hand-
held tester to the DLC3 at the lower center of the
instrument panel.
(3) Turn the ignition switch ON and push the OBD II
scan tool or TOYOTA hand-held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand-held
tester to check the DTC and freezed frame data and
note them down (For operating instructions, see the
OBD II scan tool's instruction book.).
If there is no DTC in the normal mode, check the 1st
trip DTC using Continuous Test Results function
(Mode 7 for SAE J1979) on the OBD II scan tool or
TOYOTA hand-held tester.
(5) See page DI-14 to confirm the details of the DTC.
NOTICE:

When simulating symptoms with an OBD II scan tool
(excluding TOYOTA hand-held tester) to check the
DTC, use the normal mode. For code on the DTC chart
subject to º2 trip detection logicº, perform the follow-
ing either action.

Turn the ignition switch OFF after the symptom is
simulated the 1st time. Then repeat the simulation
process again. When the problem has been simulated
twice, the MIL lights up and the DTCs are recorded in
the ECM.

Check the 1st trip DTC using Mode 7 (Continuous Test
Results) for SAE J1979.
(c) Clear the DTC.
The DTCs and freezed frame data will be erased by either
action.

Operating the OBD II scan tool (complying
with SAE J1978) or TOYOTA hand-held tes-
ter to erase the codes. (See the OBD II scan
tool's instruction book for operating instruc-
tions.)

Disconnecting the battery terminals or EFI
fuse.

A00209
DLC1
TE1
E1
SST
DLC1
P12915
P12952
A02330
DI-10
- DIAGNOSTICSENGINE
166 Author
: Date
:
2001 AVALON (RM808U)
OK
6 Check ignition timing.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Switch off all the accessories.
(c) Switch off the A/C.
(d) Shift the transmission into the N position.
(e) Keep the engine speed at idle.
(f) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843-18020
(g) Using a timing light, connect the tester to check wire.
CHECK:
Check the ignition timing.
OK:
Ignition timing: 10° BTDC at idle
NG Proceed to page IG-1, and continue to trouble-
shoot.
OK
Proceed to problem symptoms table on page
DI-22.
7 Check fuel pressure.
PREPARATION:
(a) Be sure that enough fuel is in the tank.
(b) Connect the TOYOTA hand-held tester to the DLC3.
(c) Turn the ignition switch ON and push TOYOTA hand-held
tester main switch ON.
(d) Use the ACTIVE TEST mode to operate the fuel pump.
(e) If you have no TOYOTA hand-held tester, connect the
positive (+) and negative (-) leads from the battery to the
fuel pump connector (See page SF-6).
CHECK:
Check that the pulsation damper screw rises up when the fuel
pump operates.
NG Proceed to page SF-6, and continue to trouble-
shoot.

DI1AK-12
ENGINE IMMOBLISER Check SheetInspector 's
Name:
Customer 's Name
Date Vehicle
Brought InRegistration YearRegistration No.
Frame No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs/ /
ContinuousIntermittent ( times a day)
DTC Check1st Time
2nd TimeNormal Code
Malfunction Code (Code )
Normal CodeMalfunction Code (Code )
Symptomskm
miles
Engine does not start.
Check ItemMalfunction
Indicator LampNormal
Remains ON Does not Light Up
Immobiliser is not set.
(Engine starts with key codes other than the registered key code.)
DI-598
- DIAGNOSTICSENGINE IMMOBILISER SYSTEM
754 Author
: Date
:
2001 AVALON (RM808U)
CUSTOMER PROBLEM ANALYSIS CHECK

DI6LA-01
F07887DLC3Hand-held
Tester
N09214
DLC3
- DIAGNOSTICSENGINE IMMOBILISER SYSTEM
DI-599
755 Author
: Date
:
2001 AVALON (RM808U)
PRE-CHECK
1. DIAGNOSIS SYSTEM
(a) Description
ECM controls the function of immobiliser on this vehicle.
Data of the immobiliser or DTC can be read form DLC3 of
the vehicle. When a trouble occurs on immobiliser, check
engine warning light does not light up but DTC inspection
is performed.
Therefore when there seems to be a trouble on immobilis-
er, use hand-held tester or SST to check and trouble-
shoot it.
(b) Check the DLC3.
The vehicle's ECM uses ISO 14230 for communication.
The terminal arrangement of DLC3 complies with SAE
J1962 and matches the ISO 14230 format.
Terminal No.Connection / Voltage or ResistanceCondition
7Bus
Line / Pulse generationDuring transmission
4Chassis Ground e Body Ground / 1 W or lessAlways
16Battery Positive e Body Ground / 9 ~ 14 VAlways
HINT:
If your display shows ºUNABLE TO CONNECT TO VEHICLEº
when you have connected the cable of the hand-held tester to
DLC3, turned the ignition switch ON and operated the hand-
held tester, there is a problem on the vehicle side or tool side.

If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.

If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tool's instruction 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.

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.

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.

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)

EM2534
Overall Length
EM0255
A05228
P12729
Width
Z03988
45°
1.0 - 1.4 mm30°
- ENGINE MECHANICALCYLINDER HEAD
EM-45
1029 Author
: Date
:
2001 AVALON (RM808U)
(d) Check the valve overall length.
Standard overall length:
Intake95.45 mm (3.5779 in.)
Exhaust95.40 mm (3.7559 in.)
Minimum overall length:
Intake94.95 mm (3.7382 in.)
Exhaust94.90 mm (3.7362 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
11. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:

If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.

If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.

Check that the seat contact is in the middle of the
valve face with the following width:
1.0 - 1.4 mm (0.039 - 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.