Page 1321 of 1897
A06660
Engine Wire
Engine Wire
RH Exhaust Manifold
49 (500, 36)
x 6Cylinder Head Rear Plate
PS Pump Bracket
43 (440, 32)
Gasket
No.3 Timing Belt Cover
CollarWater Inlet
Pipe
x 6
O-Ring Oil Dipstick Guide
N´m (kgf´cm, ft´lbf) : Specified torque
Non-reusable part Gasket
Engine Wire
Engine Wire
49 (500, 36)
Bushing
Camshaft Position
Sensor
LH Exhaust
Manifold Stay
x 6
Gasket
O-Ring
O-Ring
LH Exhaust Manifold
O-Ring
Camshaft
Timing Oil
Control Valve
Camshaft Position
SensorRH Exhaust
Manifold Stay
O-Ring
O-Ring
- ENGINE MECHANICALCYLINDER HEAD
EM-29
1013 Author: Date:
2001 AVALON (RM808U)
Page 1342 of 1897
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.
Page 1343 of 1897
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.
Page 1345 of 1897
- ENGINE MECHANICALCYLINDER HEAD
EM-69
1053 Author: Date:
2001 AVALON (RM808U)
(n) Install the PS pressure tube with the 2 nuts.
(o) Connect the throttle position sensor connector.
(p) Connect the IAC valve connector.
(q) Connect the No.1 VSV connector for the ACIS.
(r) Connect the No.2 VSV connector for the ACIS.
(s) Connect the VSV connecter for the EVAP.
(t) Connect the DLC1 to the bracket on the intake air control
valve.
(u) Connect the throttle cable.
(v) Connect the accelerator cable.
29. INSTALL AIR CLEANER CAP HOSE WITH RESONA-
TOR
30. INSTALL 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.
31. INSTALL FRONT EXHAUST PIPE (See page EM-77)
32. INSTALL PS PUMP (See page SR-35)
33. INSTALL GENERATOR DRIVE BELT
(See page CH-16)
34. FILL WITH ENGINE COOLANT
35. START ENGINE AND CHECK FOR LEAKS
36. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smoothly operation.
37. RECHECK ENGINE COOLANT LEVEL
Page 1349 of 1897
EM0ZE-02
A10518
5 mm
Hexagon
Wrench
A06658
(j)
(k) (l)
- ENGINE MECHANICALCYLINDER HEAD
EM-31
1015 Author: Date:
2001 AVALON (RM808U)
REMOVAL
NOTICE:
Do not remove or install the camshaft timing gear (VVT-i)
beside changing VVT-i or the camshaft.
1. DRAIN ENGINE COOLANT
2. REMOVE RH FENDER APRON SEAL
3. REMOVE GENERATOR DRIVE BELT
(See page CH-6)
4. REMOVE PS PUMP (See page SR-27)
5. REMOVE FRONT EXHAUST PIPE (See page EM-72)
6. 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.
7. REMOVE AIR CLEANER HOSE WITH RESONATOR
8. REMOVE AIR INTAKE CHAMBER ASSEMBLY
(a) Disconnect the accelerator cable.
(b) Disconnect the throttle cable.
(c) Disconnect the throttle position sensor connector.
(d) Disconnect the IAC valve connector.
(e) Disconnect the No.1 VSV connector for the ACIS.
(f) Disconnect the No.2 VSV connector for the ACIS.
(g) Disconnect the VSV connector for the EVAP.
(h) Disconnect the DLC1 from the bracket on the intake air
control valve.
(i) Remove the 2 nuts, and disconnect the PS pressure tube
from the No.1 engine hanger.
(j) Disconnect the PCV hose from the PCV valve on the RH
cylinder head.
(k) Disconnect the ground strap and cable from the intake air
control valve for the ACIS.
(l) Disconnect the ground cable from the air intake chamber.
Page 1351 of 1897
A07428
P20049Gasket
A05077
Clamp
Clamp
Clamp
A10531
- ENGINE MECHANICALCYLINDER HEAD
EM-33
1017 Author: Date:
2001 AVALON (RM808U)
(d) Remove the 9 bolts, 2 nuts, 2 plate washers, the intake
manifold, delivery pipes and injectors assembly.
NOTICE:
Be careful not to drop the injectors when removing
the delivery pipes.
Pay attention to put any hung load on the injector to
and from the side direction.
10. REMOVE WATER OUTLET
(a) Disconnect the ECT sender gauge connector.
(b) Disconnect the ECT sensor connector.
(c) Disconnect the ground strap connector.
(d) Disconnect the upper radiator hose.
(e) Disconnect the engine coolant reservoir hose.
(f) Remove the 2 bolts, 2 nuts and 2 plate washers.
(g) Disconnect the water bypass hose, and remove the water
outlet.
(h) Remove the 2 gaskets.
11. REMOVE IGNITION COILS
12. REMOVE SPARK PLUGS
13. REMOVE TIMING BELT (See page EM-15)
14. REMOVE CAMSHAFT TIMING PULLEYS
(See page EM-15)
15. REMOVE NO.2 IDLER PULLEY (See page EM-15)
16. REMOVE NO.3 TIMING BELT COVER
(a) Disconnect the 3 engine wire clamps from the timing belt
cover.
(b) Remove the 6 bolts and timing belt cover.
17. REMOVE CAMSHAFT POSITION SENSORS
18. REMOVE CAMSHAFT TIMING OIL CONTROL VALVES
19. DISCONNECT ENGINE WIRE PROTECTOR FROM
REAR SIDE
Remove the nut, and disconnect the engine wire protector from
the RH cylinder head.
Page 1352 of 1897
A10519
A05205
A07596
Rear
Plate
Inlet Pipe
A05189
A06661
Manifold
Stay
EM-34
- ENGINE MECHANICALCYLINDER HEAD
1018 Author: Date:
2001 AVALON (RM808U)
20. DISCONNECT ENGINE WIRE AND PROTECTOR
FROM RH SIDE
Remove the 5 nuts, and disconnect the engine wire and protec-
tor from the RH cylinder head cover.
21. DISCONNECT ENGINE WIRE PROTECTOR FROM LH
SIDE
Remove the 2 bolts, and disconnect the engine wire protector
from the LH cylinder head cover.
22. DISCONNECT CYLINDER HEAD REAR PLATE FROM
LH CYLINDER HEAD
Remove the 2 bolts, and disconnect the rear plate.
23. DISCONNECT WATER INLET PIPE FROM LH CYL-
INDER HEAD AND WATER INLET
(a) Remove the bolt, and disconnect the inlet pipe from the
water inlet.
(b) Remove the O-ring from the inlet pipe.
24. REMOVE PS PUMP BRACKET
Remove the 3 bolts and pump bracket.
25. REMOVE RH EXHAUST MANIFOLD
(a) Disconnect the A/F sensor connector.
(b) Remove the bolt, nut and exhaust manifold stay.
(c) Remove the 6 nuts, exhaust manifold and gasket.
Page 1353 of 1897
A07281
Manifold
Stay
A07283
O-Ring
A05193
A05280Align Intake
- ENGINE MECHANICALCYLINDER HEAD
EM-35
1019 Author: Date:
2001 AVALON (RM808U)
26. REMOVE LH EXHAUST MANIFOLD
(a) Disconnect the A/F sensor connector.
(b) Remove the bolt, nut and exhaust manifold stay.
(c) Remove the 6 nuts, exhaust manifold and gasket.
27. REMOVE OIL DIPSTICK AND GUIDE
(a) Remove the bolt holding the dipstick guide to the LH cylin-
der head.
(b) Pull out the dipstick guide together with the dipstick from
the No.1 oil pan.
(c) Remove the O-ring from the dipstick guide.
28. REMOVE CYLINDER HEAD COVERS
Remove the 9 bolts, cylinder head cover and gasket. Remove
the 2 cylinder head covers.
29. REMOVE 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) Remove the intake camshaft.
(1) Align the timing marks (2 dot marks) of the camshaft
drive and driven gears by turning the camshaft with
a wrench.
