length TOYOTA AVALON 2001 Service Repair Manual

Q05402
Q05643
OR0038
D01023
A
C
CB
C
DD
D01058
- AUTOMATIC TRANSAXLEVALVE BODY ASSEMBLY
AX-9
1299 Author
: Date
:
2001 AVALON (RM808U)
(c) Install the shift solenoid valve SLN with the bolt.
Torque: 6.6 N´m (67 kgf´cm, 58 in.´lbf)
(d) Coat 2 new O-rings with ATF and install them to the shift
solenoid valve No.1 and No.2.
(e) Install the shift solenoid valve No.1 and No.2 with the 3
bolts.
Torque: 6.6 N´m (67 kgf´cm, 58 in.´lbf)
16. PLACE NEW 2ND BRAKE APPLY GASKET
17. INSTALL VALVE BODY TO TRANSAXLE CASE
(a) While holding the cam down with your hand, slip the cable
end into the slot.
NOTICE:
Be careful not to entangle the solenoid wire.
(b) Install the valve body with the 9 bolts.
Torque: 11 N´m (110 kgf´cm, 8 ft´lbf)
HINT:
Temporarily install the 9 bolts first, then torque them.
Bolt length:
Bolt A: 30 mm (1.181 in.)
Bolt B: 43 mm (1.693 in.)
Bolt C: 48 mm (1.890 in.)
Bolt D: 52 mm (2.047 in.)
18. INSTALL B
3 APPLY PIPE
Using a plastic hammer, install the pipe into the position indi-
cated in the illustration.
NOTICE:
Be careful not to bend or damage the pipe.

D01059
A
B
D01021
B
B
A
Z19257
30
(1.18)
BAmm (in.)
Q05728
Connector AX-10
- AUTOMATIC TRANSAXLEVALVE BODY ASSEMBLY
1300 Author
: Date
:
2001 AVALON (RM808U)
19. INSTALL CONNECTOR CLAMP AND PIPE RETAINER
Install the connector clamp and pipe retainer with the 2 bolts.
Torque: 6.6 N´m (67 kgf´cm, 58 in.´lbf)
Bolt length:
Bolt A: 48 mm (1.890 in.)
Bolt B: 39 mm (1.535 in.)
20. INSTALL MANUAL VALVE BODY
(a) Aligning the valve body with the pin on the manual shaft
lever.
(b) Lower the manual valve body into place.
(c) Temporarily the 5 bolts first. Then, tighten them with a
torque wrench.
Torque: 11 N´m (110 kgf´cm, 8 ft´lbf)
Bolt length:
Bolt A: 22 mm (0.866 in.)
Bolt B: 37 mm (1.457 in.)
21. INSTALL DETENT SPRING AND OIL PIPE
(a) Place the detent springs on the manual valve body and
temporarily install the 2 bolts first. Then, tighten them with
a torque wrench.
Torque: 11 N´m (110 kgf´cm, 8 ft´lbf)
Bolt length:
Bolt A: 14 mm (0.551 in.)
Bolt B: 37 mm (1.457 in.)
(b) Check that the manual valve lever is touching the center
of the detent spring tip roller.
(c) Using a plastic hammer, install the pipe into the position.
NOTICE:
Be careful not to bend or damage the pipe.
(d) Install the bolt.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
22. CONNECT 3 SOLENOID CONNECTORS
23. INSTALL OIL PIPE
Using a plastic hammer, install the pipes into the positions.
NOTICE:
Be careful not to bend or damage the pipes.

Z19256
BA
B A
AT3741
AT3785
- AUTOMATIC TRANSAXLEVALVE BODY ASSEMBLY
AX-1 1
1301 Author
: Date
:
2001 AVALON (RM808U)
24. INSTALL OIL STRAINER AND APPLY PIPE BRACKET
Install the oil strainer and apply pipe bracket with the 6 bolts.
Torque:
Bolt A: 10 N´m (100 kgf´cm, 7 ft´lbf)
Bolt B: 11 N´m (110 kgf´cm, 8 ft´lbf)
Bolt length:
Bolt A: 22 mm (0.866 in.)
Bolt B: 53 mm (2.087 in.)
25. INSTALL MAGNET IN PLACE
Install the 3 magnets in the indentations of the oil pan, as shown
in the illustration.
NOTICE:
Make sure that the magnet does not interfere with the oil
pipes.
26. INSTALL OIL PAN AND GASKET
(a) Install the oil pan and a new gasket.
(b) Install the 17 bolts.
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
27. INSTALL DRAIN PLUG
Install a new gasket and drain plug.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
28. FILL ATF AND CHECK FLUID LEVEL
(See page DI-160)

BO2QJ-01
BO0632
BO0633
15°
45° BO-126
- BODYSEAT BELT
1911 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts,
nuts or sill-bar) if it has been used in a severe impact. The
entire assembly should be replaced even if damage is not
obvious.
1. RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and slam on the brakes.
Check that the belt locks and cannot be extended at this
time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. Driver 's seat belt (ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out over 45 degrees
of tilt.
If a problem is found, replace the assembly.
3. Except driver's seat belt (ALR/ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Pull out the whole belt and measure the length of the
whole belt.
Then retract the belt slightly and pull it out again
(d) Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.

N10070
Full Belt Length Minus
200 mm (7.87 in.)
BO0633
15°
45°
- BODYSEAT BELT
BO-127
1912 Author
: Date
:
2001 AVALON (RM808U)
(e) Retract the whole belt, then pull out the belt until 200 mm
(7.87 in.) of belt remains retracted.
(f) Tilt the retractor slowly.
(g) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.

BR152-01
F05420
SST Master
Cylinder
F05422
SST
F05421
SST
BR-24
- BRAKEBRAKE BOOSTER ASSEMBLY
1423 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Set the SST on the master cylinder, and lower the pin until
its tip slightly touches the piston.
SST 09737-0001 1
(b) Turn the SST upside down, and set it on the booster.
SST 09737-0001 1
(c) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(d) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737-00020
3. w/ VSC:
INSTALL PRECHARGE PUMP ASSEMBLY (See page
BR-58)
4. INSTALL MASTER CYLINDER (See page BR-20)
5. CONNECT VACUUM HOSE TO BRAKE BOOSTER
6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-4)
7. CHECK FOR LEAKS
8. CHECK AND ADJUST BRAKE PEDAL (See page
BR-6)
9. INSTALL NO. 2 HEATER TO REGISTER DUCT, LOWER
LH INSTRUMENT PANEL INSERT AND LOWER NO. 1
INSTRUMENT PANEL (See page BO-87)
10. DO OPERATIONAL CHECK (See page BR-21)

BR0KV-05
BR-20
- BRAKEBRAKE MASTER CYLINDER
1419 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-15).
HINT:

Before installation, adjust length of brake booster push rod (See page BR-24).

After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4), and
check for leaks.

Check and adjust brake pedal (See page BR-6).

P13535
Length
P00480
OhmmeterPositive (+)
Terminal
Rectifire
Terminal
P00481
OhmmeterNegative (-)
Terminal CH-10
- CHARGINGGENERATOR
1283 Author
: Date
:
2001 AVALON (RM808U)
3. INSPECT BRUSHES
Using a vernier caliper, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brushes
and brush holder assembly.
4. INSPECT RECTIFIERS (RECTIFIRE HOLDER)
(a) Check the positive (+) rectifire.
(1) Using an ohmmeter, connect one tester probe to the
positive (+) terminal and the other to each rectifier
terminal.
(2) Reverse the polarity of the tester probes and repeat
step (a).
(3) Check that one shows continuity and the other
shows no continuity.
If continuity is not as specified, replace the rectifier holder.
(b) Check the negative (-) rectifire.
(1) Using an ohmmeter, connect one tester probe to
each negative (-) terminal and the other to each
rectifier terminal.
(2) Reverse the polarity of the tester probes and repeat
step (a).
(3) Check that one shows continuity and the other
shows no continuity.
If continuity is not as specified, replace the rectifier holder.
5. INSPECT BEARING
Check that bearing is not rough or worn.
If necessary, replace the bearing (See page CH-1 1).

A02397
OCV Signal Waveform
1 m sec./Division5 V/
Division
GND
(A) (A) (A)
DI-128
- DIAGNOSTICSENGINE
284 Author
: Date
:
2001 AVALON (RM808U)
TOYOTA hand-held tester:
1 Check valve timing (See page EM-15).
NG Repair valve timing.
OK
2 Check operation of OCV.
PREPARATION:
(a) Start the engine and warmed it up.
(b) Connect the TOYOTA hand-held tester and select the VVT from the ACTIVE TEST menu.
CHECK:
Check the engine speed when operate the OCV by the TOYOTA hand-held tester.
OK:
OCV is OFF: Normal engine speed
OCV is ON: Rough idle or engine stall
OK VVT system is OK.*
*: DTCs P1349 and P1354 are also output after the foreign ob-
ject is caught in some part of the system in the engine oil and
the system returns to normal in a short time. As ECM controls
so that foreign objects are ejected, there is no problem about
VVT. There is also no problem since the oil filter should get the
foreign object in the engine oil.
NG
3 Check voltage between terminals OCV+ and OCV- of ECM connector.
Reference: INSPECTION USING OSCILLOSCOPE
Turn the ignition switch ON, and check the waveform between
terminals OCV+ and OCV- of the ECM connector.
HINT:

The correct waveform is as shown.

The waveform frequency (A) is lengthened as the engine
speed becomes higher.
NG Check and replace ECM (See page IN-30).

A06076
OCV Connector(a)
(b)
A02397
OCV Signal Waveform
1 msec./Division5 V/
Division
GND
(A) (A) (A)
- DIAGNOSTICSENGINE
DI-131
287 Author
: Date
:
2001 AVALON (RM808U)
2 Check operation of OCV.
PREPARATION:
Start the engine.
CHECK:
(a) Check the engine speed when disconnecting the OCV
connector.
(b) Check the engine speed when applying battery positive
voltage between the terminals of the OCV.
RESULT:
ResultCheck (a)Check (b)
1Normal engine speedRough idle or engine stall
2Except 1
2 Go to step 4.
1
3 Check voltage between terminals OCV+ and OCV- of ECM connector.
Reference: INSPECTION USING OSCILLOSCOPE
Turn the ignition switch ON, check the waveform between termi-
nals OCV+ and OCV- of the ECM connector.
HINT:

The correct waveform is as shown.

The waveform frequency (A) is lengthened as the engine
speed becomes higher.
OK VVT system is OK.*
*: DTCs P1349 and P1354 are also output after the foreign ob-
ject is caught in some part of the system in the engine oil and
the system returns to normal in a short time. As ECM controls
so that foreign objects are ejected, there is no problem about
VVT. There is also no problem since the oil filter should get the
foreign object in the engine oil.
NG