2001 TOYOTA AVALON intake manifold

A07505
(p)
(q)
(r)(o)
(n)
(m)
(n)
A09695
Throttle Body
Bracket
Engine
Hanger
A09699
8 mm Hexagon Wrench
A05074(b) (c)
EM-32
- ENGINE MECHANICALCYLINDER HEAD
1016 Author
: Date
:
2001 AVALON (RM808U)
(m) Disconnect the brake booster vacuum hose from the
throttle body.
(n) Disconnect the 2 water bypass hoses from the throttle
body.
(o) Disconnect the air assist hose from the throttle body.
(p) Disconnect the purge hose from the pipe on the emission
control valve set.
(q) Disconnect the 2 vacuum hoses from the vacuum tank for
the ACIS.
(r) Disconnect the engine wire clamp from the emission con-
trol valve set.
(s) Remove the 2 bolts and No.1 engine hanger.
(t) Remove the 2 bolts and throttle body bracket.
(u) Using an 8 mm hexagon wrench, remove the 2 bolts, 2
nuts, the air intake chamber assembly and gasket.
9. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the 6 injector connectors.
(b) Disconnect the fuel inlet hose from the fuel filter.
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.
(See page SF-1)
(c) Disconnect the heater hose from the intake manifold.

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.

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.

S04497
A07300
- ENGINE MECHANICALENGINE UNIT
EM-79
1063 Author
: Date
:
2001 AVALON (RM808U)
15. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel. Install the
grommet.
(b) Connect the 5 engine ECM connectors.
(c) Install the glove compartment.
16. CONNECT CONNECTORS, CABLE, CLAMPS AND
HOSES
(a) Connect the noise filter connector on the LH fender
apron.
(b) Connect the generator connector and wire.
(c) Connect the starter connector and wire.
(d) Connect the 2 ground strap connectors to the RH fender
apron
(e) Connect the strap connector to the LH fender apron with
the bolt.
(f) Connect the ground cable to the battery body bracket.
(g) Connect the engine wire protector clamp to the battery
body bracket.
(h) Connect the engine wire clamp to the bracket on the RH
fender apron.
(i) Connect the brake booster vacuum hose to the throttle
body.
(j) Connect the engine coolant reservoir hose to the water
outlet.
(k) Connect the heater hose to the intake manifold.
(l) Connect the heater hose to the water inlet housing.
(m) Connect the fuel inlet hose to the fuel filter.
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.
(See page SF-1)
(n) Connect the EVAP hose assembly to the pipe on the
emission control valve set.
(o) Connect the 2 vacuum hoses to the vacuum tank for the
ACIS.
17. INSTALL FRONT EXHAUST PIPE
(a) Temporarily install 3 new gaskets and the front exhaust
pipe with the 2 bolts, 2 compression springs and 4 nuts.
(b) Tighten the 4 nuts holding the exhaust manifolds to the
front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Tighten the 2 bolts and 2 compression springs holding the
front exhaust pipe to the center exhaust pipe.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)

EM0ZL-02
A10518
5 mm
Hexagon
Wrench
A07300
EM-72
- ENGINE MECHANICALENGINE UNIT
1056 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE HOOD
3. REMOVE ENGINE FENDER APRON SEALS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
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. DISCONNECT ACCELERATOR CABLE
8. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR
CLEANER CASE
9. REMOVE CRUISE CONTROL ACTUATOR
10. REMOVE RADIATOR (See page CO-17)
11. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts holding the support stay to the sup-
port bracket.
(b) Remove the 2 bolts and 2 compression springs holding
the front exhaust pipe to the center exhaust pipe.
(c) Remove the 4 nuts holding the front exhaust pipe to the
exhaust manifolds.
(d) Remove the front exhaust pipe and 3 gaskets.
12. DISCONNECT CONNECTORS, CABLE, CLAMPS AND
HOSES
(a) Remove the bolt and disconnect the ground strap from
the LH fender apron.
(b) Disconnect the 2 ground strap connectors from the RH
fender apron.
(c) Disconnect the ground cable from the A/T.
(d) Disconnect the engine wire protector clamp from the bat-
tery body bracket.
(e) Disconnect the engine wire clamp from the bracket on the
RH fender apron.
(f) Disconnect the brake booster vacuum hose from the
throttle body.
(g) Disconnect the engine coolant reservoir hose from the
water outlet.
(h) Disconnect the heater hose from the intake manifold.
(i) Disconnect the heater hose from the water inlet housing.

- 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

- INTRODUCTIONTERMS
IN-41
41 Author
: Date
:
2001 AVALON (RM808U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module-
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel-Shutoff-
ISCIdle Speed Control-
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE-ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

- 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.)