engine TOYOTA AVALON 2001 Service Repair Manual

PP0RN-03
- PREPARATIONSFI
PP-9
59 Author
: Date
:
2001 AVALON (RM808U)
RECOMMENDED TOOLS
09040-0001 1Hexagon Wrench Set .
09082-00040TOYOTA Electrical Tester.
09200-00010Engine Adjust Kit .
09258-00030Hose Plug Set .Plug for the vacuum hose, fuel
hose etc.

SS05W-07
SS-40
- SERVICE SPECIFICATIONSAIR CONDITIONING
156 Author
: Date
:
2001 AVALON (RM808U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Compressor x Discharge hose101007
Compressor x Suction hose101007
Condenser x Disaharge hose5.45548 in.´lbf
Condenser x Liquid tube5.45548 in.´lbf
Expansion valve x Evaporator5.45548in.´lbf
Compressor x Engine2525018
Compressor x Compressor bracket2525018
Drive belt adjusting bar bracket x Compressor2525018
Pivot bolt5656041
Adjusting lock bolt1818513
Pressure switch x Liquied tube101007
Pressure plate x Compressor13.21359

SS0BL-04
SS-24
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE
140 Author
: Date
:
2001 AVALON (RM808U)
AUTOMATIC TRANSAXLE
SERVICE DATA
Line pressure (wheel locked)Engine idling
D position
R position
at stall (Throttle valve fully opened)
D position
R position
401 - 461 kPa (4.1 - 4.7 kgf/cm2, 58 - 66 psi)
804 - 882 kPa (8.2 - 9.0 kgf/cm2, 117 - 128 psi)
1,138 - 1,236 kPa (11.6 - 12.6 kgf/cm
2, 165 - 179 psi)
1,716 - 1,854 kPa (17.5 - 18.9 kgf/cm2, 249 - 269 psi)
Engine stall revolution2,325 - 2,775 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF)
N position
700 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)Between boot and face and inner cable stopper
0 - 1 mm (0 - 0.04 in.)
Drive plate runoutMax.
Torque converter clutch runout Max.
Torque converter clutch installation distance0.3 mm (0.0118 in.)
0.20 mm (0.0079 in.)
More than 13.7 mm (0.539 in.)
Lock-up point(Throttle valve opening 5%)
3rd gear (O/D main switch OFF) Lock-up ON
Lock-up OFF
O/D gear Lock-up ON
Lock-up OFF
65 - 70 km/h (40 - 43 mph)
57 - 62 km/h (35 - 39 mph)
65 - 70 km/h (40 - 43 mph)
57 - 62 km/h (35 - 39 mph)
Shift schedule
D position
(Throttle valve fully opened) 1 "2
2 "3
3 "O/D
O/D "3
3 "2
2 "1
(Throttle valve fully closed) 3 "O/D
O/D "3
2 position
(Throttle valve fully opened) 1 "2
3 "2
2 "1
L position
(Throttle valve fully opened) 3 "2
2 "1
65 - 71 km/h (40 - 44 mph)
122 - 131 km/h (76 - 81 mph)
188 - 198 km/h (117 - 123 mph)
181 - 191 km/h (112 - 119 mph)
113 - 122 km/h (70 - 76 mph)
54 - 59 km/h (34 - 37 mph)
38 - 43 km/h (24 - 27 mph)
22 - 27 km/h (14 - 17 mph)
65 - 71 km/h (40 - 44 mph)
132 - 141 km/h (82 - 88 mph)
54 - 59 km/h (34 - 37 mph)
115 - 124 km/h (71 - 77 mph)
59 - 64 km/h (37 - 40 mph)

SS0BM-04
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE
SS-25
141 Author
: Date
:
2001 AVALON (RM808U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Front side engine mounting insulator x Front frame assembly8082059
Rear engine mounting insulator x Front frame assembly6667048
LH transaxle mounting insulator x Front frame assembly8082059
Engine mounting insulator x Front frame assembly4849035
Transaxle x Engine 17 mm bolt
14 mm bolt66
48670
49048
35
Torque converter clutch x Drive plate4142030
Valve body x Transaxle case1111 08
Oil strainer x Valve body Bolt A
(See page AX-35) Bolt B10
11100
11 07
8
Oil pan x Transaxle case7.88069 in.´lbf
Oil pan drain plug4950036
Park/Neutral position switch x Transaxle case Bolt
Nut5.4
6.955
7048 in.´lbf
61 in.´lbf
Connector clamp x Valve body6.66758 in.´lbf
Manual valve body x Transaxle case1111 08
Line pressure test plug x Transaxle case7.58069 in.´lbf
Detent spring x Manual valve body1111 08
Oil pipe bracket x Transaxle case101007
Steering gear housing x Front frame assembly1811,850134
Stabilizer bar bracket x Front frame assembly1919514
Stabilizer bar link x Stabilizer bar3940029
Lower suspension arm x Lower ball joint1271,30094
Tie rod end x Steering knuckle4950036
Drive shaft lock nut2943,000217
Direct clutch speed sensor x Transaxle case1111 08
Exhaust manifold bracket x Transaxle case2020015
Exhaust manifold plate2020015
Front frame assembly x Body 19 mm bolt
14 mm bolt
Nut181
32
361,850
330
370134
24
27
Front exhaust pipe x Exhaust center pipe4344032
Exhaust manifold x Front exhaust pipe6263046
Exhaust front pipe support stay x Exhaust front pipe support bracket3333024
Starter x Torque converter clutch housing3940029
Transaxle control shaft lever x Park/neutral position switch1515011
Throttle cable adjusting nut1515011
Drive plate x Crankshaft8385061
Shift control cable x Transaxle control shaft lever1515011
Throttle cable retaining plate set bolt5.45548 in.´lbf
Shift solenoid valve No. 1, No. 2, SL, SLN x Valve body6.66758 in.´lbf
Front wheel nut1031,05076
Exhaust front pipe support bracket x Body2121015
PS reservoir pipe x Front frame101007

SS-26
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE
142 Author
: Date
:
2001 AVALON (RM808U) Engine hood x Hood hinge
2626519
Engine hanger x Engine2020014
Cruise control actuator x Body131309
RH drive shaft x Rear side engine mounting insulator3233024
Hole cover x Torque converter clutch housing4142030
Floor shift assembly x Body121209

SS-36
- SERVICE SPECIFICATIONSBODY ELECTRICAL
152 Author
: Date
:
2001 AVALON (RM808U) ENGINE COOLANT TEMPERATURE SENDER GAUGE (Resistance)
Temperature °C (°F)Resistance (W)
A - BApprox. 250 W
C - DApprox. 250 W
LIGHT FAILURE RELAY (Wire Harness Side)
3 - Ground (Light control switch OFF)No voltage
3 - Ground (Light control switch TAIL or HEAD)Battery positive voltage
4 - Ground (Ignition switch LOCK or ACC)No voltage
4 - Ground (Ignition switch ON)Battery positive voltage
7 - Ground (Stop light switch OFF)No voltage
7 - Ground (Stop light switch ON)Battery positive voltage
8 - Ground (Ignition switch LOCK or ACC)No voltage
8 - Ground (Ignition switch ON)Battery positive voltage
SLIDING ROOF CONTROL RELAY AND SWITCH (Wire Harness Side)
8 - Ground (Ignition switch LOCK or ACC)* No voltage
8 - Ground (Ignition switch ON)Battery positive voltage
5 - Ground (Constant)Battery positive voltage
*: Exceptions: For 60 seconds after the ignition switch ON"OFF (ACC) or until driver or passenger door is
opened after the ignition switch ON"OFF (ACC).

SS0EM-01
- SERVICE SPECIFICATIONSCOOLING
SS-15
131 Author
: Date
:
2001 AVALON (RM808U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
RH engine drain plug x EGR cooler77061 in.´lbf
LH engine drain plug x Union on cylinder block131309
Water pump x Cylinder block66053 in.´lbf
Water inlet x Water inlet housing88069 in.´lbf
Water inlet pipe x LH cylinder head19.520014
Radiator support x Body12.81309
No.1 cooling fan shroud x Radiator5.05044 in.´lbf
No.1 cooling fan x Cooling fan motor6.26355 in.´lbf
No.2 cooling fan shroud x Radiator5.05044 in.´lbf

SS0EF-02
SS-6
- SERVICE SPECIFICATIONSENGINE MECHANICAL
122 Author
: Date
:
2001 AVALON (RM808U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,500 kPa (15.3 kgf/cm2, 218 psi)
1,000 kPa (10.2 kgf/cm2, 145 psi)
100 kPa (1.0 kgf/cm2, 15 psi) or less
Valve
clearanceat cold Intake
Exhaust
Adjusting shim for repair part Mark 2.500
Mark 2.550
Mark 2.600
Mark 2.650
Mark 2.700
Mark 2.750
Mark 2.800
Mark 2.850
Mark 2.900
Mark 2.950
Mark 3.000
Mark 3.050
Mark 3.100
Mark 3.150
Mark 3.200
Mark 3.250
Mark 3.3000.15 - 0.25 mm (0.006 - 0.010 in.)
0.25 - 0.35 mm (0.010 - 0.014 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Ignition timingw/ Terminals TE1 and E1 connected of DLC18 - 12° BTDC @ idle
Idle speed-650 ± 50 rpm
Timing belt
tensionerProtrusion from housing side10.0 - 10.8 mm (0.394 - 0.425 in.)
Cylinder headWarpage Maximum
Valve seat
Refacing angle
Contacting angle
Contacting width
Valve guide bushing bore diameter STD
O/S 0.05
12 pointed head cylinder head bolt diameter
at tension portion STD
Minimum0.10 mm (0.039 in.)
30°, 45°, 75°
45°
1.0 - 1.4 mm (0.039 - 0.055 in.)
10.295 - 10.313 mm (0.4053 - 0.4080 in.)
10.345 - 10.363 mm (0.4073 - 0.4080 in.)
8.95 - 9.05 mm (0.3524 - 0.3563 in.)
8.75 mm (0.3445 in.)
Valve guide
bushingInside diameter
Outside diameter for repair part STD
O/S 0.055.510 - 5.530 mm (0.2169 - 0.2177 in.)
10.333 - 10.344 mm (0.4068 - 0.4072 in.)
10.383 - 10.394 mm (0.4088 - 0.4092 in.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Maximum95.45 mm (3.5779 in.)
95.40 mm (3.7559 in.)
94.95 mm (3.7382 in.)
94.90 mm (3.7362 in.)
44.5°
5.470 - 5.485 mm (0.2154 - 0.2159 in.)
5.465 - 5.480 mm (0.2152 - 0.2157 in.)
0.025 - 0.060 mm (0.0010 - 0.0024 in.)
0.030 - 0.065 mm (0.0012 - 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
1.0 mm (0.039 in.)
0.5 mm (0.020 in.)

- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-7
123 Author
: Date
:
2001 AVALON (RM808U) Valve spring
Deviation Maximum
Free length
Installed tension at 33.8 mm (1.331 in.)2.0 mm (0.079 in.)
45.50 mm (1.7913 in.)
186 - 206 N (19.0 - 21.0 kgf, 41.9 - 46.3 lbf)
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum30.966 - 30.976 mm (1.2191 - 2.2195 in.)
31.000 - 31.016 mm (1.2205 - 1.2211 in.)
0.024 - 0.050 mm (0.0009 - 0.0020 in.)
0.07 mm (0.0028 in.)
CamshaftThrust clearance STD
Maximum
Journal oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Journal diameter
Circle runout Maximum
Cam lobe height STD Intake
Exhaust
Minimum Intake
Exhaust
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.040 - 0.090 mm (0.0016 - 0.0035 in.)
0.12 mm (0.0047 in.)
0.035 - 0.072 mm (0.0014 - 0.0028 in.)
0.025 - 0.062 mm (0.0010 - 0.0024 in.)
0.10 mm (0.0039 in.)
0.09 mm (0.0035 in.)
26.949 - 26.965 mm (1.0610 - 1.0616 in.)
0.06 mm (0.0024 in.)
42.11 - 42.21 mm (1.6579 - 1.6618 in.)
41.96 - 42.06 mm (1.6520 - 1.6559 in.)
41.96 mm (1.6520 in.)
41.81 mm (1.6461 in.)
0.020 - 0.200 mm (0.0008 - 0.0079 in.)
0.30 mm (0.0188 in.)
18.2 - 18.8 mm (0.712 - 0.740 in.)
Air intake
chamberWarpage Maximum0.10 mm (0.0039 in.)
Intake
manifoldWarpage
Air intake chamber side Maximum
Cylinder head side Maximum
0.15 mm (0.0059 in.)
0.08 mm (0.0031 in.)
Exhaust
manifoldWarpage Maximum0.50 mm (0.0196 in.)
Cylinder blockCylinder head surface warpage Maximum
Cylinder bore diameter
Maximum
12 pointed head main bearing cap bolt diameter
at tension portion STD
Minimum0.07 mm (0.0028 in.)
87.500 - 87.512 mm (3.4449 - 3.4453 in.)
87.52 mm (3.4457 in.)
7.500 - 7.600 mm (0.2953 - 0.2992 in.)
7.20 mm (0.2835 in.)
Piston and
piston ringPiston diameter
AISIN made
at 23.2 mm (0.913 in.) from the piston head
MAHLE made
at 41.2 mm (1.622 in.) from the piston head
Piston oil clearance
AISIN made STD
Maximum
MAHLE made STD
Maximum
Piston ring groove clearance No.1
No.2
Piston ring end gap STD No.1
No.2
Oil
Maximum No.1
No.2
Oil
87.406 - 87.416 mm (3.4412 - 3.4416 in.)
87.453 - 87.467 mm (3.4430 - 3.4436 in.)
0.084 - 0.106 mm (0.0033 - 0.0042)
0.13 mm (0.0051 in.)
0.033 - 0.059 mm (0.0013 - 0.0023)
0.08 mm (0.0031 in.)
0.020 - 0.070 mm (0.0008 - 0.0028 in.)
0.020 - 0.060 mm (0.0008 - 0.0024 in.)
0.25 - 0.35 mm (0.0098 - 0.0138 in.)
0.35 - 0.45 mm (0.0138 - 0.0177 in.)
0.15 - 0.40 mm (0.0059 - 0.0157 in.)
0.95 mm (0.0374 in.)
1.05 mm (0.0413 in.)
1.00 mm (0.0394 in.)

SS-8
- SERVICE SPECIFICATIONSENGINE MECHANICAL
124 Author
: Date
:
2001 AVALON (RM808U) Connecting
rod
Thrust clearance STD
Maximum
Connecting rod thickness
Connecting rod bearing center wall thickness
Reference Mark 1
Mark 2
Mark 3
Mark 4
Connecting rod oil clearance STD
Maximum
Rod bend Maximum per 100 mm (3.94 in.)
Rod twist Maximum per 100 mm (3.94 in.)
Bushing inside diameter
Piston pin diameter
Bushing oil clearance STD
Maximum
Connecting rod bolt diameter
at tension portion STD
Minimum0.15 - 0.30 mm (0.0059 - 0.0118 in.)
0.35 mm (0.0138 in.)
20.80 - 20.85 mm (0.8189 - 0.8209 in.)
1.484 - 1.487 mm (0.0584 - 0.0585 in.)
1.487 - 1.490 mm (0.0585 - 0.0587 in.)
1.490 - 1.493 mm (0.0587 - 0.0588 in.)
1.493 - 1.496 mm (0.0588 - 0.0589 in.)
0.038 - 0.064 mm (0.0015 - 0.0025 in.)
0.08 mm (0.0031 in.)
0.05 mm (0.0020 in.)
0.15 mm (0.0059 in.)
22.005 - 22.014 mm (0.8663 - 0.8667 in.)
21.997 - 22.006 mm (0.8660 - 0.8664 in.)
0.005 - 0.011 mm (0.0002 - 0.0004 in)
0.05 mm (0.0020 in.)
7.2 - 7.3 mm (0.284 - 0.287 in.)
7.0 mm (0.276 in.)
CrankshaftThrust clearance STD
Maximum
Thrust washer thickness
Main journal oil clearance STD No.1 and No.4
No.2 and No.3
Maximum No.1 and No.4
No.2 and No.3
Main journal diameter
Main bearing center wall thickness
Reference Mark 10.04 - 0.24 mm (0.0016 - 0.0095 in.)
0.30 mm (0.0118 in.)
1.930 - 1.980 mm (0.0760 - 0.0780 in.)
0.016 - 0.036 mm (0.0006 - 0.0014 in.)
0.028 - 0.048 mm (0.0011 - 0.0019 in.)
0.05 mm (0.0020 in.)
0.06 mm (0.0024 in.)
60.988 - 61.000 mm (2.4011 - 2.4016 in.)
2.485 - 2.488 mm (0.0978 - 0.0980 in.)
Reference Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
Mark 7
Crank pin diameter
Circle runout Maximum
Main journal taper and out-of-round Maximum
Crank pin taper and out-of-round Maximum
2.485 2.488 mm (0.0978 0.0980 in.)
2.488 - 2.491 mm (0.0980 - 0.0981 in.)
2.491 - 2.494 mm (0.0981 - 0.0982 in.)
2.494 - 2.497 mm (0.0982 - 0.0983 in.)
2.497 - 2.500 mm (0.0983 - 0.0984 in.)
2.500 - 2.503 mm (0.0984 - 0.0985 in.)
2.503 - 2.506 mm (0.0985 - 0.0987 in.)
52.992 - 53.000 mm (2.0863 - 2.0866 in.)
0.06 mm (0.0024 in.)
0.02 mm (0.0008 in.)
0.02 mm (0.0008 in.)