2001 TOYOTA AVALON Service Repair Manual

Z03989
45°
1.0 - 1.4 mm75°
P12705
EM0988
Deviation
EM0801
EM0281
EM-46
- ENGINE MECHANICALCYLINDER HEAD
1030 Author
: Date
:
2001 AVALON (RM808U)
(2) If the seating is too low on the valve face, use 75°
and 45° cutters to correct the seat.
(d) Hand-lap the valve and valve seat with an abrasive com-
pound.
(e) After hand-lapping, clean the valve and valve seat.
12. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
(b) Using vernier calipers, measure the free length of the
valve spring.
Free length: 45.50 mm (1.7913 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
186 - 206 N (19.0 - 21.0 kgf, 41.9 - 46.3 lbf)
at 33.8 mm (1.331 in.)
If the installed tension is not as specified, replace the valve
spring.

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.

A05239
Plastigage
A05237
A05240
A05238
EM-48
- ENGINE MECHANICALCYLINDER HEAD
1032 Author
: Date
:
2001 AVALON (RM808U)
17. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nal.
(d) Install the bearing caps. (See page EM-59)
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
Intake0.035 - 0.072 mm (0.0014 - 0.0028 in.)
Exhaust0.025 - 0.062 mm (0.0010 - 0.0024 in.)
Maximum oil clearance:
Intake0.10 mm (0.0039 in.)
Exhaust0.09 mm (0.0035 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the Plastigage.
(h) Remove the camshafts.
18. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshafts. (See page EM-59)
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.040 - 0.090 mm (0.0016 - 0.0035 in.)
Maximum thrust clearance: 0.12 mm (0.0047 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.

A05241
A05739
A05705
- ENGINE MECHANICALCYLINDER HEAD
EM-49
1033 Author
: Date
:
2001 AVALON (RM808U)
(c) Remove the camshafts.
19. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshafts without installing the exhaust cam
sub-gear (See page EM-59).
(b) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 - 0.200 mm (0.0008 - 0.0079 in.)
Maximum backlash: 0.30 mm (0.0188 in.)
If the backlash is greater then maximum, replace the cam-
shafts.
(c) Remove the camshafts.
20. INSPECT CAMSHAFT TIMING GEAR (VVT-i)
(a) Mount the hexagon wrench head portion of the camshaft
in a vise.
(b) Check that VVT-i will not turn.
(c) Cover the port except the port on the advance angle side
(nearest to the convex portion) shown in the illustration
with the vinyl tape.
(d) Using the air gun, apply about 100 kPa (1 kgf/cm
3, 14 psi)
of air pressure to the port on the advance side shown in
the illustration.
NOTICE:
When the oil is splashed, wipe it off with a shop lug and the
likes.
HINT:
Perform this in order to release the lock pin for the maximum
delay angle locking.
Standard: Must turn
HINT:
Depending on the air pressure, VVT-i will turn to the advance
angle side without applying force by hand. Also, under the
condition that the pressure can be hardly applied because of
the air leakage from the port, there may be the case that the lock
pin could be hardly released.

EM3322
Free Distance
P12685
EM6368
P12400
EM-50
- ENGINE MECHANICALCYLINDER HEAD
1034 Author
: Date
:
2001 AVALON (RM808U)
(e) Under the condition of (d), turn VVT-i to the advance
angle side (the white arrow marked direction in the il-
lustration) with your hand.
(f) Except the position where the lock pin meets at the maxi-
mum delay angle, let VVT-i turn back and forth and check
the movable range and that there is no disturbance.
Standard: Movable smoothly in the range about 30°
(g) Turn VVT-i with your hand and lock it at the maximum
delay angle position.
21. INSPECT CAMSHAFT GEAR SPRING
Using vernier calipers, measure the free distance between the
spring ends.
Free distance: 18.2 - 18.8 mm (0.712 - 0.740 in.)
If the free distance is not as specified, replace the gear spring.
22. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
31.000 - 31.018 mm (1.2205 - 1.2212 in.)
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter:
30.966 - 30.976 mm (1.2191 - 1.2195 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.024 - 0.050 mm (0.0009 - 0.0020 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
23. INSPECT AIR INTAKE CHAMBER
Using a precision straight edge and feeler gauge, measure the
surface contacting the intake manifold for warpage.
Maximum warpage: 0.10 mm (0.0039 in.)
If warpage is greater than maximum, replace the chamber.

Z09167
Cylinder Head Side
Air Intake Chamber Side
A07443
RH Side
LH Side
P12496
- ENGINE MECHANICALCYLINDER HEAD
EM-51
1035 Author
: Date
:
2001 AVALON (RM808U)
24. INSPECT INTAKE MANIFOLD
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head and air intake chamber for
warpage.
Maximum warpage:
Air intake chamber side0.15 mm (0.0059 in.)
Cylinder head side0.08 mm (0.0031 in.)
If warpage is greater than maximum, replace the manifold.
25. INSPECT EXHAUST MANIFOLDS
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0196 in.)
If warpage is greater than maximum, replace the manifold.
26. INSPECT 12 POINTED HEAD CYLINDER HEAD
BOLTS
Using vernier calipers, measure the tension portion diameter of
the bolt.
Standard outside diameter:
8.95 - 9.05 mm (0.3524 - 0.3563 in.)
Minimum outside diameter: 8.75 mm (0.3445 in.)
If the diameter is less than minimum, replace the bolt.

EM0ZJ-02
A10520
A05218
12 Pointed Head Bolt
Front
7246
5318
7246
5318
A05223
Painted Mark
Front90°
- ENGINE MECHANICALCYLINDER HEAD
EM-59
1043 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place 2 new cylinder head gaskets in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(b) Place the 2 cylinder heads in position on the cylinder head
gaskets.
2. INSTALL 12 POINTED HEAD CYLINDER HEAD BOLTS
HINT:

The cylinder head bolts are tightened in 2 progressive
steps (steps (c) and (e)).

If any bolt is broken or deformed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install the plate washer to the cylinder head bolt.
(c) Install and uniformly tighten the cylinder head bolts on
each cylinder head in several passes and in the sequence
shown, then repeat for the other side, as shown.
Torque: 54 N´m (550 kgf´cm, 40 ft´lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(d) Mark the front of the cylinder head bolt head with paint.
(e) Retighten the cylinder head bolts by 90° in the numerical
order shown.
(f) Check that the painted mark is now at a 90° angle to the
front.

A05221
Recessed Head Bolt
Front8 mm Hexagon Wrench
P12595
Z09320
(3)
(2)
(1)
P12590
EM-60
- ENGINE MECHANICALCYLINDER HEAD
1044 Author
: Date
:
2001 AVALON (RM808U)
3. INSTALL RECESSED HEAD CYLINDER HEAD BOLTS
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Using an 8 mm hexagon wrench, install the cylinder head
bolt on each cylinder head, then repeat for the other side,
as shown.
Torque: 18.5 N´m (185 kgf´cm, 13 ft´lbf)
4. ASSEMBLE EXHAUST CAMSHAFTS
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring (1) and camshaft sub-
gear (2).
HINT:
Attach the pins on the gears to the gear spring ends.
(c) Install the wave washer (3).
(d) Using snap ring pliers, install the snap ring.