2001 TOYOTA AVALON Service Repair Manual

Z04011
EM6525
EM0227
EM6347
P12406
- ENGINE MECHANICALCYLINDER BLOCK
EM-97
1081 Author
: Date
:
2001 AVALON (RM808U)

Check for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
14. INSPECT PISTON PIN OIL CLEARANCE
(a) Using a caliper gauge, measure the inside diameter of the
connecting rod bushing.
Bushing inside diameter:
22.005 - 22.014 mm (0.8663 - 0.8667 in.)
(b) Using a micrometer, measure the piston pin diameter.
Piston pin diameter:
21.997 - 22.006 mm (0.8660 - 0.8664 in.)
(c) Subtract the piston pin diameter measurement from the
bushing inside diameter measurement.
Standard oil clearance:
0.005 - 0.011 mm (0.0002 - 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
15. INSPECT CONNECTING ROD BOLTS
Using vernier calipers, measure the tension portion diameter of
the bolt.
Standard diameter: 7.2 - 7.3 mm (0.284 - 0.287 in.)
Minimum diameter: 7.0 mm (0.276 in.)
If the diameter is less than minimum, replace the bolt.
16. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT
(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout, as
shown in the illustration.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.

P12493
EM-98
- ENGINE MECHANICALCYLINDER BLOCK
1082 Author
: Date
:
2001 AVALON (RM808U)
17. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
60.988 - 61.000 mm (2.4011 - 2.4016 in.)
Crank pin diameter:
52.992 - 53.000 mm (2.0862 - 2.0866 in.)
If the diameter is not as specified, check the oil clearance.
(See page EM-83)
If necessary, replace the crankshaft.
(b) Check each main journal and crank pin for taper and out-
of-round as shown.
Maximum taper and out-of-round:
0.02 mm (0.0008 in.)
If the taper and out-of-round is greater than maximum, replace
the crankshaft.

EM0ZQ-02
A05260
P12417
60°C
A10527
Front Mark
(Cavity)
Front Mark
(Mold Mark) RH Piston
LH Piston
Front Mark
(Cavity)
Front Mark
(Mold Mark)
- ENGINE MECHANICALCYLINDER BLOCK
EM-101
1085 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets, O-rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Using a small screwdriver, install a new snap ring at one
end of the piston pin hole.
HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.
(b) Gradually heat the piston to about 60°C (140°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod,
and push in the piston pin with your thumb.
(e) Using a small screwdriver, install a new snap ring on the
other end of the piston pin hole.
HINT:
Be sure that end gap of the snap ring is not aligned with the pin
hole cutout portion of the piston.

A10524
Code Mark
Code Mark No.1
No.2
A10525
RH Piston
Lower Side Rail
No.2
CompressionFront Mark
Expander
Upper Side Rail
No.1
Compression
Lower Side Rail
Upper Side Rail LH Piston
No.2
Compression
Expander
No.1
CompressionFront Mark
P12402
Z09177
No.1 and No.4 No.2 and No.3
Upper
Lower
22.4 mm 19.0 mm EM-102
- ENGINE MECHANICALCYLINDER BLOCK
1086 Author
: Date
:
2001 AVALON (RM808U)
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark:
No.1T or G1
No.22T or G2
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.
3. INSTALL CONNECTING ROD BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
HINT:

Main bearings come in widths of 19.0 mm (0.748 in.) and
22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bear-
ings in the No.1 and No.4 cylinder block journal positions
with the main bearing cap. Install the 19.0 mm (0.748 in.)
bearings in the No.2 and No.3 positions.

Upper bearings have an oil groove and oil holes; lower
bearings do not.

P12599
A05263
Mark
1, 2, 3 or 4
P12600
P12495
A05264
- ENGINE MECHANICALCYLINDER BLOCK
EM-103
1087 Author
: Date
:
2001 AVALON (RM808U)
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 4 upper bearings.
NOTICE:
Install the bearing with the oil hole in the cylinder block.
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 4 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
5. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.2 journal position of
the cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. PLACE MAIN BEARING CAPS AND LOWER THRUST
WASHERS ON CYLINDER BLOCK
(a) Install the 2 thrust washers on the No.2 bearing cap with
the grooves facing outward.

A10530
A09696
Less than 6 mm
A10529
P12753
10 11
12 13
14
151
162
3
45
6
7
89
P25741
Painted Mark
Front90°
90° EM-104
- ENGINE MECHANICALCYLINDER BLOCK
1088 Author
: Date
:
2001 AVALON (RM808U)
(b) Temporarily place the 4 main bearing caps level and let
them in their proper locations.
(c) Apply a light coat of engine oil on the threads and under
the main bearing cap bolts for the 12 pointed head.
(d) Temporarily install the 8 main bearing cap bolts to the in-
side positions.
(e) Insert the main bearing cap with your hand until the clear-
ance between the main bearing cap and the cylinder
block will become less than 6 mm (0.23 in.) by making the
2 internal main bearing cap bolts as a guide.
(f) Using a plastic-faced hammer, lightly tap the bearing cap
to ensure a proper fit.
8. INSTALL 12 POINTED HEAD MAIN BEARING CAP
BOLTS
HINT:

The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any of the main bearing cap bolts is broken or deformed,
replace it.
(a) Apply a light coat of engine oil on the threads and under
the main bearing cap bolts.
(b) Install and uniformly tighten the 16 main bearing cap bolts
in several passes and in the sequence shown.
Torque: 22 N´m (225 kgf´cm, 16 ft´lbf)
If any of the main bearing cap bolts does not meet the torque
specification, replace the main bearing cap bolt.
(c) Mark the front of the main bearing cap bolts with paint.
(d) Retighten the main bearing cap bolts by 90° in the numer-
ical order shown.
(e) Check that the painted mark is now at a 90° angle to the
front.

P12586
1
2
34
567
8
A10528
Front Mark
(Cavity)
Front Mark
(Cavity)RH Piston
LH Piston
P12699
P12801
Front
Protrusion
- ENGINE MECHANICALCYLINDER BLOCK
EM-105
1089 Author
: Date
:
2001 AVALON (RM808U)
9. INSTALL HEXAGON HEAD MAIN BEARING CAP
BOLTS
(a) Install a new seal washer to the main bearing cap bolt.
(b) Install and uniformly tighten the 8 main bearing cap bolts
in several passes and in the sequence shown.
Torque: 27 N´m (275 kgf´cm, 20 ft´lbf)
10. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM-83)
11. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
HINT:
The shape of the piston varies for the RH and LH banks. The
RH piston is marked with ºRº, the LH piston with ºLº.
12. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Align the pin dowels of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod.
(c) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
13. INSTALL CONNECTING ROD CAP BOLTS
HINT:

The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any of the connecting rod cap bolts is broken or de-
formed, replace it.

P12697
P25743
Painted Mark
Front90°
90°
P12911
Seal Width
2 - 3 mm A
BA
B EM-106
- ENGINE MECHANICALCYLINDER BLOCK
1090 Author
: Date
:
2001 AVALON (RM808U)
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque: 24.5 N´m (250 kgf´cm, 18 ft´lbf)
If any of the connecting rod cap bolts does not meet the torque
specification, replace the connecting rod cap bolts.
(c) Mark the front of the connecting cap bolts with paint.
(d) Retighten the cap bolts by 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
14. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM-83)
15. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.

Using a razor blade and gasket scraper, remove all
the oil packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil seal retainer with the 6 bolts. Uniformly tight-
en the bolt in several passes and in the sequence shown.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
16. INSTALL CYLINDER BLOCK SIDE COVER
Install a new gasket and the cylinder block side cover with the
3 bolts and 2 nuts.
Torque: 9 N´m (90 kgf´cm, 78 in.´lbf)