engine TOYOTA AVALON 2001 Service Repair Manual

Z09167
Cylinder Head Side
Air Intake Chamber Side
A07443
RH Side
LH Side
P12496
- ENGINE MECHANICALCYLINDER HEAD
EM-51
1035 Author
: Date
:
2001 AVALON (RM808U)
24. INSPECT INTAKE MANIFOLD
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head and air intake chamber for
warpage.
Maximum warpage:
Air intake chamber side0.15 mm (0.0059 in.)
Cylinder head side0.08 mm (0.0031 in.)
If warpage is greater than maximum, replace the manifold.
25. INSPECT EXHAUST MANIFOLDS
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0196 in.)
If warpage is greater than maximum, replace the manifold.
26. INSPECT 12 POINTED HEAD CYLINDER HEAD
BOLTS
Using vernier calipers, measure the tension portion diameter of
the bolt.
Standard outside diameter:
8.95 - 9.05 mm (0.3524 - 0.3563 in.)
Minimum outside diameter: 8.75 mm (0.3445 in.)
If the diameter is less than minimum, replace the bolt.

EM0ZJ-02
A10520
A05218
12 Pointed Head Bolt
Front
7246
5318
7246
5318
A05223
Painted Mark
Front90°
- ENGINE MECHANICALCYLINDER HEAD
EM-59
1043 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place 2 new cylinder head gaskets in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(b) Place the 2 cylinder heads in position on the cylinder head
gaskets.
2. INSTALL 12 POINTED HEAD CYLINDER HEAD BOLTS
HINT:

The cylinder head bolts are tightened in 2 progressive
steps (steps (c) and (e)).

If any bolt is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install the plate washer to the cylinder head bolt.
(c) Install and uniformly tighten the cylinder head bolts on
each cylinder head in several passes and in the sequence
shown, then repeat for the other side, as shown.
Torque: 54 N´m (550 kgf´cm, 40 ft´lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(d) Mark the front of the cylinder head bolt head with paint.
(e) Retighten the cylinder head bolts by 90° in the numerical
order shown.
(f) Check that the painted mark is now at a 90° angle to the
front.

A05221
Recessed Head Bolt
Front8 mm Hexagon Wrench
P12595
Z09320
(3)
(2)
(1)
P12590
EM-60
- ENGINE MECHANICALCYLINDER HEAD
1044 Author
: Date
:
2001 AVALON (RM808U)
3. INSTALL RECESSED HEAD CYLINDER HEAD BOLTS
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Using an 8 mm hexagon wrench, install the cylinder head
bolt on each cylinder head, then repeat for the other side,
as shown.
Torque: 18.5 N´m (185 kgf´cm, 13 ft´lbf)
4. ASSEMBLE EXHAUST CAMSHAFTS
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring (1) and camshaft sub-
gear (2).
HINT:
Attach the pins on the gears to the gear spring ends.
(c) Install the wave washer (3).
(d) Using snap ring pliers, install the snap ring.

P12974
SST
Main Gear
Sub-Gear
A05201
90°Exhaust
P12804
Exhaust
Front
A02008
Exhaust
Seal
Packing
- ENGINE MECHANICALCYLINDER HEAD
EM-61
1045 Author
: Date
:
2001 AVALON (RM808U)
(e) Using SST, align the holes of the camshaft main gear and
sub-gear by turning camshaft sub-gear counterclock-
wise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(f) Align the gear teeth of the main gear and sub-gear, and
tighten the service bolt.
5. INSTALL CAMSHAFTS OF RH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept leveled while it is being installed. If
the camshaft is not kept leveled, the portion of the cylinder
head receiving the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid this, the
following steps should be carried out.
(a) Install the exhaust camshaft.
(1) Apply new engine oil to the thrust portion and jour-
nal of the camshaft.
(2) Place the exhaust camshaft at 90° angle of timing
mark (2 dot marks) on the cylinder head.
(3) Apply MP grease to a new oil seal lip.
(4) Install the oil seal to the camshaft.
(5) Remove any old packing (FIPG) material.
(6) Apply seal packing to the No.1 bearing cap as
shown.
Seal packing: Part No. 08826-00080 or equivalent

A05283
Exhaust
A05202
Exhaust
7
A05203
Intake
Align
A05204
Intake
A05196
Intake
8
7
6
5
4
32
1
9
10
EM-62
- ENGINE MECHANICALCYLINDER HEAD
1046 Author
: Date
:
2001 AVALON (RM808U)
(b) Install the 5 bearing caps in their proper locations.
(c) Apply a light coat of engine oil on the threads and under
the heads of the bearing cap bolts.
(d) Install and uniformly tighten the 10 bearing cap bolts in
several passes and in the sequence shown.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(e) Install the Intake camshaft.
(1) Apply new engine oil to the thrust portion and jour-
nal of the camshaft.
(2) Align the timing marks (2 dot marks) of the camshaft
drive and driven gears.
(3) Place the intake camshaft on the cylinder head.
(4) Install the 5 bearing caps in their proper locations.
(5) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(6) Install and uniformly tighten the 10 bearing cap
bolts in several passes and in the sequence shown.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)

A05195
Intake
Service Bolt
A05208
Exhaust
90°
P12805
Exhaust
Front
A02008
Exhaust
Seal
Packing
A05209
Exhaust
- ENGINE MECHANICALCYLINDER HEAD
EM-63
1047 Author
: Date
:
2001 AVALON (RM808U)
(7) Remove the service bolt.
6. INSTALL CAMSHAFTS OF LH CYLINDER HEAD
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept leveled while it is being installed. If
the camshaft is not kept leveled, the portion of the cylinder
head receiving the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid this, the
following steps should be carried out.
(a) Install the exhaust camshaft.
(1) Apply new engine oil to the thrust portion and jour-
nal of the camshaft.
(2) Place the exhaust camshaft at 90° angle of timing
mark (1 dot mark) on the cylinder head.
(3) Apply MP grease to a new oil seal lip.
(4) Install the oil seal to the camshaft.
(5) Remove any old packing (FIPG) material.
(6) Apply seal packing to the No.1 bearing cap as
shown.
Seal packing: Part No. 08826-00080 or equivalent
(7) Install the 5 bearing caps in their proper locations.

A05210
Exhaust
8
7
6
5
4
32
1
9
10
A05211
Intake
Align
A05214
Intake
A05213
Intake6
5
4
3
2
1
910
7
8
A05198
IntakeService Bolt
EM-64
- ENGINE MECHANICALCYLINDER HEAD
1048 Author
: Date
:
2001 AVALON (RM808U)
(8) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(9) Install and uniformly tighten the 10 bearing cap
bolts in several passes and in the sequence shown.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(b) Install the intake camshaft.
(1) Apply new engine oil to the thrust portion and jour-
nal of the camshaft.
(2) Align the timing marks (1 dot mark) of the camshaft
drive and driven gears.
(3) Place the intake camshaft on the cylinder head.
(4) Install the 5 bearing caps in their proper locations.
(5) Apply a light coat of engine oil on the threads and
under the heads of bearing cap bolts.
(6) Install and uniformly tighten the 10 bearing cap
bolts in several passes and in the sequence shown.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(7) Remove the service bolt.
7. CHECK AND ADJUST VALVE CLEARANCE
(See page EM-4)
Turn the camshaft and position the cam lobe upward, and
check and adjust the valve clearance.

A05215
Seal Packing
A05217
FrontSemi-Circular Plug
A05216
: Seal Packing
Front
RH Side
LH Side
- ENGINE MECHANICALCYLINDER HEAD
EM-65
1049 Author
: Date
:
2001 AVALON (RM808U)
8. INSTALL SEMI-CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi-circular plug grooves.
Seal packing: Part No. 08826-00080 or equivalent
(c) Install the 2 semi-circular plugs to the cylinder heads.
9. INSTALL CYLINDER HEAD COVERS
(a) Apply seal packing to the cylinder heads as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the 9 bolts. Uniformly
tighten the bolts in several passes. Install the 2 cylinder
head covers.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
10. INSTALL PS PUMP BRACKET
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)

A06661
Manifold
Stay
A07283
New O-Ring
A07281
Manifold
Stay
A05188Inlet PipeRear
Plate
EM-66
- ENGINE MECHANICALCYLINDER HEAD
1050 Author
: Date
:
2001 AVALON (RM808U)
11. INSTALL RH EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(b) Install the exhaust manifold stay with the bolt and nut. Al-
ternately tighten the bolt and nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(c) Connect the A/F sensor connector.
12. INSTALL OIL DIPSTICK AND GUIDE
(a) Install a new O-ring to the dipstick guide.
(b) Apply soapy water to the O-ring.
(c) Push in the dipstick guide end into the guide hole of the
No.1 oil pan.
(d) Install the dipstick guide with the bolt.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
(e) Install the dipstick.
13. INSTALL LH EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(b) Install the exhaust manifold stay with the bolt and nut. Al-
ternately tighten the bolt and nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(c) Connect the A/F sensor connector.
14. INSTALL WATER INLET PIPE
(a) Install a new O-ring to the water inlet pipe.
(b) Apply soapy water to the O-ring.
(c) Connect the water inlet pipe to the water inlet.
(d) Install the bolt holding the water inlet pipe to the cylinder
head.
Torque: 19.5 N´m (200 kgf´cm, 14 ft´lbf)
15. INSTALL CYLINDER HEAD REAR PLATE
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
16. INSTALL ENGINE WIRE PROTECTOR
17. INSTALL CAMSHAFT TIMING OIL CONTROL VALVES
18. INSTALL CAMSHAFT POSITION SENSORS
19. INSTALL NO.3 TIMING BELT COVER
(a) Check that the timing belt cover gaskets have no cracks
or peeling, etc.
If the gaskets have cracks or peeling etc., replace them using
these steps:

Using a screwdriver and gasket scraper, remove all
the old gasket material.

A05194
L = 133 mm (5.24 in.)
L = 180 mm (7.09 in.)L = 72 mm (2.83 in.)
L = 335 mm (13.19 in.)L = 180 mm
(7.09 in.)
L = Length Join
LineJoin
Line
Z14262New Gasket
- ENGINE MECHANICALCYLINDER HEAD
EM-67
1051 Author
: Date
:
2001 AVALON (RM808U)

Thoroughly clean all components to remove all the
loose material.

Remove the backing paper from a new gasket and
install the gasket evenly to the part of the timing belt
cover shaded black in the illustration.
NOTICE:
When joining 2 gaskets, do not leave a gap between them.
Cut off any excess gasket.

After installing the gasket, press down on it so that
the adhesive firmly sticks to the timing belt cover.
(b) Install the timing belt cover with the 6 bolts.
Torque: 8.5 N´m (85 kgf´cm, 74 in.´lbf)
(c) Install the 3 engine wire clamps to the timing belt cover.
20. INSTALL NO.2 IDLER PULLEY (See page EM-21)
21. INSTALL CAMSHAFT TIMING PULLEYS
(See page EM-21)
22. INSTALL TIMING BELT (See page EM-21)
23. INSTALL SPARK PLUGS
24. INSTALL IGNITION COILS
25. INSTALL WATER OUTLET
(a) Install 2 new gaskets.
(b) Connect the water outlet to the bypass hose.
(c) Install the water outlet with the 2 bolts, 2 nuts and 2 plate
washers. Alternately tighten the bolts and nuts.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
NOTICE:
Do not scratch the seal surface of the water outlet with the
stud bolt.
(d) Connect the ECT sender gauge connector.
(e) Connect the ECT sensor connector.
(f) Connect the ground strap connector.
(g) Connect the upper radiator hose.
(h) Connect the engine coolant reservoir hose.