engine TOYOTA AVALON 2001 Service Repair Manual

P12909
Seal Width 3 - 5 mm
A05253410
2
5
7
93
1
6
8
P12389
SST EM-108
- ENGINE MECHANICALCYLINDER BLOCK
1092 Author
: Date
:
2001 AVALON (RM808U)

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the water inlet housing as shown in
the illustration.
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.
HINT:
Avoid applying an excessive amount to the surface.

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 water inlet housing with the 8 bolts and 2 nuts.
Uniformly tighten the bolts and nuts in several passes and
in the sequence shown.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
(d) Connect the No.2 ECT switch connector.
(e) Connect the engine wire clamp to the water inlet.
(f) Install the engine wire band.
(g) Install the engine wire clamp.
27. INSTALL KNOCK SENSORS
(a) Using SST, install the 2 knock sensors.
SST 09816-30010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Connect the 2 knock sensor connectors.
28. INSTALL NO.2 IDLER PULLEY BRACKET
Torque: 28 N´m (290 kgf´cm, 21 ft´lbf)
29. INSTALL A/C COMPRESSOR HOUSING BRACKET
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)

P00601
A05416
1
2 34 5
67
8
- ENGINE MECHANICALCYLINDER BLOCK
EM-109
1093 Author
: Date
:
2001 AVALON (RM808U)
30. INSTALL OIL PRESSURE SWITCH
(See page LU-1)
31. INSTALL GENERATOR, BRACKET AND ADJUSTING
BAR ASSEMBLY
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
32. INSTALL ENGINE WIRE
33. CONNECT OIL LEVEL SENSOR CONNECTOR
34. CONNECT OIL PRESSURE SWITCH CONNECTOR
35. CONNECT CRANKSHAFT POSITION SWITCH CON-
NECTOR
36. INSTALL CYLINDER HEAD (See page EM-59)
37. INSTALL TIMING PULLEYS AND BELT
(See page EM-21)
38. REMOVE ENGINE STAND
39. INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324
or equivalent
(b) Install the front spacer, drive plate and rear plate on the
crankshaft.
(c) Install and uniformly tighten the 8 bolts in several passes
and in the sequence shown.
Torque: 83 N´m (850 kgf´cm, 61 ft´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.

P12570
SST
P12808
Cut Position
P12810
SST EM-100
- ENGINE MECHANICALCYLINDER BLOCK
1084 Author
: Date
:
2001 AVALON (RM808U)
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223-15030, 09950-70010 (09951-07100)
(3) Apply MP grease to the oil seal lip.
(b) If the rear oil seal retainer is installed to the cylinder block.
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(3) Apply MP grease to a new oil seal lip.
(4) Using SST and a hammer, tap in the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

EM042-03
A10835
RH Fender Apron Seal
Generator
Drive Belt
No.2 RH Engine
Mounting Bracket
PS Pump
Drive Belt
PS Pump

Non-reusable part: Specified torque
64 (650, 47)
32 (320, 23)
43 (440, 32)
N´m (kgf´cm, ft´lbf)

Gasket
62 (630, 46)
43 (440, 32)

Gasket


62 (630, 46)
33 (330, 24)

Front Exhaust Pipe
Stay

Gasket
Compression Spring
V-Bank Cover
Air Cleaner Hose
w/ Resonator
Vacuum Hose
Engine Moving Control Rod V-Bank Cover Fastener
EM-26
- ENGINE MECHANICALCYLINDER HEAD
1010 Author
: Date
:
2001 AVALON (RM808U)
CYLINDER HEAD
COMPONENTS

Water Bypass Hose
A10522
PS Pressure Tube
Throttle Body Bracket
Engine WireThrottle Position
Sensor Connector
Vacuum Hose Brake Booster
39 (400,29)
IAC Valve
Connector
Accelerator Cable
Purge Hose
Hose Vacuum

Gasket
VSV Connector for No.2 ACIS
Engine Coolant
Reservoir Hose
43 (440,32)
ECT Sender
Gauge Connector
ECT Sensor
Connector
Grand Strap
Connector
15 (150,11)
Water Outlet
15 (150,11)
Water Bypass
Hose
Upper Radiator
HoseFuel Inlet Hose
Injector Connector Intake Manifold
Assembly

Retainer
Heater Hose

GasketIgnition Coil
Connector

Non-reusable part: Specified torque
N´m (kgf´cm, ft´lbf)
19.5 (200, 14)
No.1 Engine
Hanger
VSV Connector for
EVAP
Ground Cable
PCV Hose Ground Cable
Air Intake Chamber
Assembly

Gasket
Spark PlugIgnition Coil
Ground Strap
DLC1
Gasket
Fuel Hose Clamp
VSV Connector
for No.1 ACIS
Throttle Cable
- ENGINE MECHANICALCYLINDER HEAD
EM-27
1011 Author
: Date
:
2001 AVALON (RM808U)

A05070
Timing Belt
Gasket No.2 Timing Belt Cover
RH Engine Mounting Bracket
Crankshaft
Pulley No.1 Timing Belt Cover
Gasket
Engine Wire
Protector
No.2 Idler Pulley
RH Camshaft Timing Pulley
LH Camshaft
Timing Pulley
Timing Belt TensionerTiming Belt Guide
No.2 Generator
Bracket
Dust Boot
N´m (kgf´cm, ft´lbf) : Specified torque
* For use with SST
Non-reusable part
28 (290, 21)
215 (2,200, 159)
125 (1,300, 94)
*88 (900, 65)
27 (280, 20)
43 (440, 32)
125 (1,300, 94)
EM-28
- ENGINE MECHANICALCYLINDER HEAD
1012 Author
: Date
:
2001 AVALON (RM808U)

A06660
Engine Wire
Engine Wire
RH Exhaust Manifold
49 (500, 36)
x 6Cylinder Head Rear Plate
PS Pump Bracket
43 (440, 32)
Gasket
No.3 Timing Belt Cover
CollarWater Inlet
Pipe
x 6

O-Ring Oil Dipstick Guide
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable part
Gasket
Engine Wire
Engine Wire
49 (500, 36)
Bushing
Camshaft Position
Sensor
LH Exhaust
Manifold Stay
x 6

Gasket

O-Ring

O-Ring
LH Exhaust Manifold

O-Ring
Camshaft
Timing Oil
Control Valve
Camshaft Position
SensorRH Exhaust
Manifold Stay

O-Ring

O-Ring
- ENGINE MECHANICALCYLINDER HEAD
EM-29
1013 Author
: Date
:
2001 AVALON (RM808U)

A05703
Adjusting Shim
Valve Lifter
Keeper
Spring Retainer
Valve Spring
Spring Seat

Oil Seal
Valve
Valve Guide BushingLH Cylinder Head Cover
LH Intake
Camshaft
Snap Ring Camshaft Sub-Gear
LH Exhaust
Camshaft RH Cylinder Head Cover
Gasket
RH Intake
Camshaft Camshaft Sub-Gear
Camshaft Gear Spring
RH Exhaust
CamshaftWave Washer
Semi-Circular PlugSemi-Circular
Plug
LH Cylinder Head
Camshaft
Bearing Cap

Camshaft Oil Seal RH Cylinder Head

RH Cylinder
Head Gasket

LH Cylinder Head Gasket18 (185, 13)x 8
16 (160, 12)
See Page EM-59
1st 54 (550, 40)
2nd Turn 90°
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable part

Spark Plug
Tube Gasket
Wave WasherGasketSnap RingCamshaft Gear Spring
Oil Control Valve Filter

Gasket
Camshaft Timing
Gear (VVT-i)

Gasket

Gasket
Oil Control
Valve FilterCylinder Head
Rear CoverCylinder Head
Rear Cover
Gasket
150 (1,530, 110)
NOTICE:
Intake Camshaft
Do not remove or install the camshaft timing
gear (VVT-i) beside changing VVT-i or the
camshaft.


EM-30
- ENGINE MECHANICALCYLINDER HEAD
1014 Author
: Date
:
2001 AVALON (RM808U)

EM0ZF-02
P12683
A05224
SST
P12686
P12720
Magnetic Finger
A05276
EM-40
- ENGINE MECHANICALCYLINDER HEAD
1024 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in the correct order.
2. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202-70020 (09202-00010)
(b) Remove the spring retainer, valve spring and valve.
(c) Using needle-nose pliers, remove the oil seal.
(d) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in the correct order.
3. REMOVE CYLINDER HEAD REAR COVER
Remove the 6 bolts, rear cover and gasket.