height TOYOTA AVALON 2001 Service Repair Manual

R00954
Stop Light Switch
Push Rod
Pedal HeightBR0KI-04
R00935
Pedal Freeplay BR-6
- BRAKEBRAKE PEDAL
1405 Author
: Date
:
2001 AVALON (RM808U)
BRAKE PEDAL
ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
153.3 - 163.3 mm (6.035 - 6.429 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the lower No. 1 instrument panel and lower LH
instrument panel insert (See page BO-87).
(b) Disconnect the connector from the stop light switch.
(c) Loosen the stop light switch lock nut and remove the stop
light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
(f) Tighten the push rod lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(g) Install the stop light switch.
(h) Connect the connector to the stop light switch.
(i) Push the brake pedal in 5 - 15 mm (0.20 - 0.59 in.), turn
the stop light switch to lock the nut in the position where
the stop light goes off.
(j) After installation, push the brake pedal in 5 - 15 mm (0.20
- 0.59 in.), check that stop light lights up.
(k) After adjusting the pedal height, check the pedal freeplay.
(l) Install the lower LH instrument panel insert and lower No.
1 instrument panel (See page BO-87).
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the beginning of the resis-
tance is felt, then measure the distance.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
Stop light switch clearance:
0.5 - 2.4 mm (0.020 - 0.094 in.)
HINT:
The freeplay to the 1st resistance is due to the play between the
clevis and pin. This is magnified up to 1 - 6 mm (0.04 - 0.24 in.)
at the pedal.

B09041
B09046
H
- COOLINGRADIATOR
CO-21
1214 Author
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2001 AVALON (RM808U)

The points shown in the rib sides and oil cooler near here
cannot be staked with SST. Use pliers or similar object
and be careful not to damage the core plates.
(b) Check the lock plate height (H) after completing the caulk-
ing.
Plate height (H): 7.4 - 7.8 mm (0.2959 - 0.3119 in.)
If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
6. INSTALL CUSHION

A05704
EM2011
EM2538
A05236
- ENGINE MECHANICALCYLINDER HEAD
EM-47
1031 Author
: Date
:
2001 AVALON (RM808U)
13. INSPECT CAMSHAFT FOR RUNOUT
(a) Place the camshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
14. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake42.932 - 43.032 mm (1.6902 - 1.6942 in.)
Exhaust42.764 - 42.864 mm (1.6836 - 1.6876 in.)
Minimum cam lobe height:
Intake42.78 mm (1.6842 in.)
Exhaust42.61 mm (1.6776 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
15. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 - 26.975 mm (1.0613 - 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
16. INSPECT CAMSHAFT BEARINGS
Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.

P12802
SST
Z09124
A05739
A05740
- ENGINE MECHANICALCYLINDER HEAD
EM-53
1037 Author
: Date
:
2001 AVALON (RM808U)
(f) Using SST and a hammer, tap in a new guide bushing to
the specified protrusion height.
SST 09201-01055, 09950-70010 (09951-07100)
Protrusion height:
Intake11.1 - 11.3 mm (0.437 - 0.453 in.)
Exhaust8.9 - 9.3 mm - (0.350 - 0.366 in.)
(g) Using a sharp 5.5 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See page
EM-42) between the guide bushing and valve stem.
2. REPLACE CAMSHAFT TIMING GEAR (VVT-i)
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i)
beside changing VVT-i or the camshaft.
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using a 46 mm socket wrench, remove the lock nut by
turning it clockwise.
NOTICE:

Remove it under the condition that the lock pin is op-
erated and lock at the maximum delay angle position.

The lock nut have LH threads.

Never use any tool other than the socket wrench,
otherwise that may result in deforming the cam angle
rotor portion.
(c) Remove the camshaft VVT-i.
HINT:
In case of having difficulty to remove VVT-i, apply a slight hit-
ting using a plastic-faced hammer and then remove it.
NOTICE:
Never remove the 3 bolts on the gear.

IN04Q-08
- INTRODUCTIONTERMS
IN-35
35 Author
: Date
:
2001 AVALON (RM808U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti-Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir-Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi-Level
B/SBore-Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve

- INTRODUCTIONTERMS
IN-37
37 Author
: Date
:
2001 AVALON (RM808U) H-FUSE
High Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HSGHousing
HTHard Top
HWSHeated Windshield System
IACIdle Air Control
ICIntegrated circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
J/BJunction Block
J/CJunction Connector
KDKick-Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft-Hand
LHDLeft-Hand Drive
L/H/WLength, Height, Width
LLCLong-Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPXMultiplex Communication System
M/TManual Transmission
MTMount
MTGMounting
NNeutral
NANatural Aspiration
No.Number
O/DOverdrive

MA01O-02
B08915
- MAINTENANCECHASSIS
MA-7
49 Author
: Date
:
2001 AVALON (RM808U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel free-play (See page SR-8).
(b) Check the steering linkage for looseness or damage.
Check that:

Tie rod ends do not have excessive play.

Dust seals and boots are not damaged.

Boot clamps are not loose.
2. INSPECT SRS AIRBAG (See pages RS-15, RS-30)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.
4. INSPECT DRIVE SHAFT BOOTS
Check the drive shaft boots for clamp looseness, leakage or
damage.
5. INSPECT BALL JOINTS AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.

Jack up the front of the vehicle and place wooden
blocks with a height of 180 - 200 mm (7.09 - 7.87
in.) under the front tires.

Lower the jack until there is about half a load on the
front coil spring. Place stands under the vehicle for
safety.

Check that the front wheels are pointing straight
ahead, and block them with chocks.

Using a lever, pry up the end of the lower arm, and
check the amount of play.
Maximum ball joint vertical play: 0 mm (0 in.)
If there is play, replace the ball joint.
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE FLUID
Visually check the transaxle for fluid leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE FLUID (See page DI-160)

SS0FS-03
SS-30
- SERVICE SPECIFICATIONSBRAKE
146 Author
: Date
:
2001 AVALON (RM808U)
BRAKE
SERVICE DATA
Brake pedal height (from asphalt sheet)153.3 - 163.3 mm (6.035 - 6.429 in.)
Brake pedal freeplay1 - 6 mm (0.04 - 0.24 in.)
Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf)More than 75 mm (3.0 in.)
Brake booster push rod to piston clearance (w/ SST)0 mm (0 in.)
Front brake pad thickness STD
Minimum11.0 mm (0.433 in.)
1.0 mm (0.039 in.)
Front brake disc thickness STD
Minimum28.0 mm (1.102 in.)
26.0 mm (1.024 in.)
Front brake disc runout Maximum0.05 mm (0.0020 in.)
Rear brake pad thickness STD
Minimum10.0 mm (0.394 in.)
1.0 mm (0.039 in.)
Rear brake disc thickness STD
Minimum12.0 mm (0.472 in.)
10.5 mm (0.413 in.)
Rear brake disc runout Maximum0.15 mm (0.0059 in.)
Rear brake disc inside diameter STD
Maximum170 mm (6.69 in.)
171 mm (6.73 in.)
Parking brake shoe lining thickness STD
Minimum2.0 mm (0.079 in.)
1.0 mm (0.039 in.)
Parking brake pedal travel at 294 N (30 kgf, 66 lbf)3 - 6 clicks
Parking brake clearance between rear shoe and leverLess than 0.35 mm (0.0138 in.)
Parking brake adjusting shim thickness
0.3 mm (0.012 in.)
0.6 mm (0.024 in.)
0.9 mm (0.035 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.)

SS04W-07
- SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS-27
143 Author
: Date
:
2001 AVALON (RM808U)
SUSPENSION AND AXLE
SERVICE DATA
Cold tire inflation
pressureP205/65R15 92H Front, rear
P205/60R16 91H Front, rear210 kPa (2.1 kgf/cm2, 31 psi)
220 kPa (2.2 kgf/cm2, 32 psi)
Vehicle heightFront*1
Rear*2213 mm (8.39 in.)
266 mm (10.47 in.)
Camber
Right-left error-0°37' ± 45' (-0.62° ± 0.75°)
45' (0.75°) or less
Front Wheel
Caster
Right-left error2°10' ± 45' (2.17° ± 0.75°)
45' (0.75°) or less
Front Wheel
alignmentSteering axis inclination
Right-left error13°04' ± 45' (13.07° ± 0.75°)
45' (0.75°) or less
Toe-in (total)
Rack end length difference0° ± 12' (0° ± 0.2°, 0 ± 2 mm, 0 ± 0.08 in.)
1.5 mm (0.059 in.) or less
Wheel angle Inside wheel
Outside wheel: Reference35°45' ± 1° (35.75° ± 1°)
31°23' (31.38°)
Rear wheel
Camber
Right-left error-0°43' ± 45' (-0.72° ± 0.75°)
45' (0.75°) or less
Rear wheel
alignmentToe-in (total)
No. 2 lower suspension arm length difference0°24' ± 12' (0.4° ± 0.2°, 4 ± 2 mm, 0.16 ± 0.08 in.)
1 mm (0.04 in.) or less
FtlAxle bearing backlash Maximum0.05 mm (0.0020 in.)Front axleAxle hub deviationMaximum0.05 mm (0.0020 in.)
Front drive shaftDrive shaft standard length LH
RH586.0 ± 2.0 mm (23.071 ± 0.079 in.)
881.6 ± 2.0 mm (34.709 ± 0.079 in.)
Ft iLower ball joint turning torque1.0 - 3.4 N´m (10 - 35 kgf´cm, 8.7 - 30 in.´lbf)Front suspensionStabilizer bar link ball joint turning torque0.05 - 1.0 N´m (0.5 - 10 kgf´cm, 0.4 - 8.7 in.´lbf)
RlAxle bearing backlash Maximum0.05 mm (0.0020 in.)Rear axleAxle hub deviationMaximum0.07 mm (0.0028 in.)
RiNo. 2 lower suspension arm length512.3 mm (20.169 in.)Rear suspensionStabilizer bar link ball joint turning torque0.05 - 1.0 N´m (0.5 - 10 kgf´cm, 0.4 - 8.7 in.´lbf)
*1: Front measuring point
Measure the distance from the ground to the center of the front side lower suspension arm mounting bolt.
*2: Rear measuring point
Measure the distance from the ground to the center of the front side strut rod mounting bolt.