check engine light TOYOTA AVALON 2001 Service Service Manual

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.

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.

A05246
EM-58
- ENGINE MECHANICALCYLINDER HEAD
1042 Author
: Date
:
2001 AVALON (RM808U)
(d) Using a plastic-faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to assure proper fit.
NOTICE:
Be careful not do damage the valve stem tip.
6. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

A10518
5 mm
Hexagon
Wrench
EM15O-01
A10838
TOYOTA
Hand-Held Tester
DLC3
A10536
Lead Wire
A07285
E1DLC1
TE1
DLC1SST
A05184
EM-10
- ENGINE MECHANICALIGNITION TIMING
994 Author
: Date
:
2001 AVALON (RM808U)
IGNITION TIMING
INSPECTION
1. REMOVE V-BANK COVER
(a) Using a 5 mm hexagon wrench, remove the 3 cap nuts.
(b) Loosen the V-bank cover fastener counterclockwise.
(c) Remove the V-bank cover.
2. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
3. CONNECT TOYOTA HAND-HELD TESTER OR OBDII
SCAN TOOL
(a) Connect the TOYOTA hand-held tester or OBDII scan
tool to the DLC3.
(b) Please refer to the TOYOTA hand-held tester or OBDII
scan tool operator's manual for further details.
4. CONNECT TIMING LIGHT TO ENGINE
Connect the clip of a timing light to the lead wire as shown.
5. CHECK IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 se-
conds.
(b) Check the idle speed.
Idle speed: 650 ± 50 rpm
6. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843-18020
(b) Using a timing light, check the ignition timing.
Ignition timing: 8 - 12° BTDC @ idle
(Transmission in neutral position)
(c) Remove the SST from the DLC1.
SST 09843-18020

- ENGINE MECHANICALIGNITION TIMING
EM-1 1
995 Author
: Date
:
2001 AVALON (RM808U)
7. FURTHER CHECK IGNITION TIMING
Ignition timing: 10 - 25° BTDC @ idle
(Transmission in neutral position)
HINT:
The timing mark moves in a range between 10° and 25°.
8. DISCONNECT TIMING LIGHT FROM ENGINE
9. DISCONNECT TOYOTA HAND- HELD TESTER OR
OBDII SCAN TOOL
10. REINSTALL V-BANK COVER
(a) Using a 5 mm hexagon wrench, install the V-bank cover
with the 3 cap nuts.
(b) Press down the V-bank cover fastener.

B09711
B09808
B09711
IN-18
- INTRODUCTIONFOR ALL OF VEHICLES
18 Author
: Date
:
2001 AVALON (RM808U)
5. FOR VEHICLES EQUIPPED WITH TRACTION CON-
TROL (TRAC) & VEHICLE SKID CONTROL (VSC) SYS-
TEM
NOTICE:

When replacing the steering angle sensor or ECU, or
when adjusting the front wheel alignment or steering
wheel center point in accordance with the removing
and installing or replacing the suspension, axle, or
steering parts, make sure to perform the steering
angle sensor zero point calibration (See page
DI-252).

Do not remove or install the VSC related parts unless
necessary. Otherwise, there is a possibility that the
setting of the VSC to be affected.

When working on the VSC related operation, make
sure to check that the preparations before and after
work are completed according to the following
instruction.

When using a drum tester such as a speedometer tes-
ter or chassis dynamometer, etc., or jacking up the
front wheels and driving the wheels, always push in
the TRAC & VSC cut (ºVSC OFFº) switch and turn the
TRAC & VSC system OFF.
(a) Press the VSC OFF switch.
(b) Check that the VSC OFF indicator light comes ON.
HINT:
The VSC OFF indicator light should be always OFF when the
engine is restarted.
(c) Begin measurements.
(d) Press the VSC OFF switch again to change the TRAC &
VSC system to operational condition and check that the
VSC OFF indicator light goes off.
HINT:

The SLIP indicator light blinks when the TRAC system is
operational.

The SLIP indicator light blinks and the VSC buzzer
sounds when the VSC system is operational.

V07268
VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
WIRE HARNESS
PARTS AND SENSOR1
Slightly shake the connector vertically and horizontally.
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough-
ly.
Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check that the mal-
function occurs.Shake Slightly
Swing Slightly
Vibrate Slightly
HINT:
Applying strong vibration to relays may result in open relays. IN-24
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
24 Author
: Date
:
2001 AVALON (RM808U)
3. SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customer's vehicle. No matter how much experience a
technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem
symptoms he will tend to overlook something important in the repair operation and make a wrong guess
somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the en-
gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the prob-
lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the
vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which
is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex-
ternal causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-
toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the problem symp-
toms at the same time. Refer to the problem symptoms table for each system to narrow down the possible
causes of the symptom.

B02389
B02390
HEAT METHOD: When the problem seems to occur when the suspect area is heated. 2
NOTICE:3 WATER SPRINKLING METHOD:
(1)
(2)
4 OTHER: When a malfunction seems to occur when electrical load is excessive.When the malfunction seems to occur on a rainy day or in a
high-humidity condition. Heat the component that is the likely cause of the malfunction
with a hair dryer or similar object. Check to see if the malfunction
occurs.
Sprinkle water onto the vehicle and check to see if the malfunc-
tion occurs.
Turn on all electrical loads including the heater blower, head
lights, rear window defogger, etc. and check to see if the mal-
function occurs.ON HINT:
If a vehicle is subject to water leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leak-
age problem, special caution must be taken.
Malfunc-
tion
Do not heat to more than 60 °C (140 °F). (Temperature
is limited not to damage the components.)
Do not apply heat directly to parts in the ECU. (1)
(2)
Never sprinkle water directly into the engine compart-
ment, but indirectly change the temperature and hu-
midity by applying water spray onto the radiator front
surface.
Never apply water directly onto the electronic compo-
nents. NOTICE:
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN-25
25 Author
: Date
:
2001 AVALON (RM808U)

LU01Q-03
B06524
B06486
SST
B06479
SST
Additional
3/4 Turn
- LUBRICATIONOIL AND FILTER
LU-3
1228 Author
: Date
:
2001 AVALON (RM808U)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful
contaminants which may cause skin cancer.

Exercise caution in order to minimize the length and
frequency of contact of your skin to used oil. Wear
protective clothing and gloves. Wash your skin thor-
oughly with soap and water, or use water-less hand
cleaner, to remove any used engine oil. Do not use
gasoline, thinners, or solvents.

In order to preserve the environment, used oil and
used oil filter must be disposed of only at designated
disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug, and drain the oil into a contain-
er.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228-07501
(b) Check and clean the oil filter installation surface.
(c) Apply clean engine oil to the gasket of a new oil filter.
(d) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(e) Using SST, tighten it an additional 3/4 turn.
SST 09228-07501

MA002-16
MA-2
- MAINTENANCEINSIDE VEHICLE
44 Author
: Date
:
2001 AVALON (RM808U)
INSIDE VEHICLE
GENERAL MAINTENANCE
These are maintenance and inspection items which are considered to be the owner's responsibility.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.

Failure to do even one item an cause the engine to run poorly and increase exhaust emissions.
2. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD GLASS
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater or air conditioner at defroster
mode.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and are mounted securely.
10. STEERING WHEEL
Check that it has the specified free-play. Be alert for changes in steering condition, such as hard steering,
excessive free-play or strange noises.
11. SEATS
(a) Check that the seat adjusters operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the head restraints move up and down smoothly and that the locks hold securely in any
latch position.
(d) For fold-down seat backs, check that the latches lock securely.
12. SEAT BELTS
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.