2001 TOYOTA AVALON throttle cable

DI08L-15
DI-560
- DIAGNOSTICSCRUISE CONTROL SYSTEM
716 Author
: Date
:
2001 AVALON (RM808U)
PROBLEM SYMPTOMS TABLE
SymptomSuspect AreaSuspect AreaSee page
SET not occourring or CANCEL occurring.
(DTC is Normal)
1. Vehicle Speed Sensor
2. Control Switch Circuit (Cruise control switch)
3. Stop Light Switch Circuit
4. Park/Neutral Position Switch Circuit
5. Actuator Motor Circuit
6. Cruise Control Cable
7. Cruise Control ECUDI-568
DI-572
DI-578
DI-584
DI-561
DI-596
IN-30
SET not occurring or CANCEL occurring.
(DTC dose not output)1. ECU Power Source Circuit
2. Cruise Control ECUDI-587
IN-30
Actual vehicle speed deviates above or below the set speed.
1. Cruise Control Cable
2. Vehicle Speed Signal Abnormal
3. Electronically Controlled Transmission
Communication Circuit
4. Actuator Motor Circuit
5. Idle Signal Circuit (Main throttle position sensor)
6. Cruise Control ECUDI-596
DI-568
DI-581
DI-581
DI-561
DI-575
IN-30
Gear shifting frequent between 3rd O/D when driving on uphill
road. (Hurting)1. Electronically Controlled Transmission
Communication Circuit
2. Cruise Control ECUDI-581
DI-581
IN-30
Cruise control not cancelled, even when brake pedal is de-
pressed.
1. Cruise Control Cable
2. Stop Light Switch Circuit
3. Actuator Motor Circuit
4. Cruise Control ECUDI-596
DI-578
DI-561
IN-30
Cruise control not cancelled, even when transmission is shifted to
ºNº postion.
1. Cruise Control Cable
2. Park/Neutral Position Switch Circuit
3. Actuator Motor Circuit
4. Cruise Control ECUDI-596
DI-584
DI-561
IN-30
Control switch does not operate.
(SET/COAST, ACC/RES, CANCEL not possible)
1. Cruise Control Cable
2. Control Switch Circuit
3. Actuator Motor Circuit
4. Cruise Control ECUDI-596
DI-572
DI-561
IN-30
SET possible at 40 km/h (25 mph) or less, or CANCEL does not
operate at 40 km/h (25 mph) or less.
1. Cruise Control Cable
2. Vehicle Speed Signal Abnormal
3. Actuator Motor Circuit
4. Cruise Control ECUDI-596
DI-568
DI-561
IN-30
Poor response is in ACCEL and RESUME modes.
1. Cruise Control Cable
2. Electronically Controlled Transmission
Communication Circuit
3. Actuator Motor Circuit
4. Cruise Control ECUDI-596
DI-581
DI-581
DI-561
IN-30
O/D does not resume, even though the road is not uphill.
1. Electronically Controlled Transmission
Communication Circuit
2. Cruise Control ECUDI-581
DI-581
IN-30
DTC memory is erased.1. Cruise Control ECUIN-30
DTC is not output, or is output when should not be.1. Diagnosis Circuit
2. Cruise Control ECUDI-594
IN-30
Cruise MAIN indicator light remains ON or falls to light up.1. Cruise MAIN Indicator Light Switch CircuitDI-592

DI-42
- DIAGNOSTICSENGINE
198 Author
: Date
:
2001 AVALON (RM808U)
DTC P0121 Throttle/Pedal Position Sensor/Switch ºAº
Circuit Range/Performance Problem
CIRCUIT DESCRIPTION
Refer to DTC P0120 on page DI-38.
DTC No.DTC Detecting ConditionTrouble Area
P0121
After vehicle speed has been exceeded 30 km/h (19 mph)
even once, output value of throttle position sensor is out of
applicable range while vehicle speed between 30 km/h (19
mph) and 0 km/h (0 mph)

Throttle position sensor
INSPECTION PROCEDURE
HINT:
Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool. Because freeze frame records
the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining
whether the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was lean
or rich, etc. at the time of the malfunction.
1 Are there any other codes (besides DTC P0121) being output?
YES Go to relevant DTC chart (See page DI-14).
NO
Replace throttle position sensor.
DI07L-09

EM-2
- ENGINE MECHANICALCO/HC
986 Author
: Date
:
2001 AVALON (RM808U)
If the CO/HC concentration does not comply with regulations,
troubleshoot in the order given below.
See the table below for possible causes, and then inspect and
correct the applicable causes if necessary.
COHCProblemsCauses
NormalHighRough idle3. Faulty ignitions:

Incorrect timing

Fouled, shorted or improperly gapped plugs
4. Incorrect valve clearance
5. Leaky intake and exhaust valves
6. Leaky cylinders
LowHighRough idle
(Fluctuating HC reading)1. Vacuum leaks:

PCV hoses

Intake manifold

Air intake chamber

Throttle Body

IAC valve

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI systems:

Faulty pressure regulator

Defective ECT sensor

Faulty ECM

Faulty injectors

Faulty throttle position sensor

Faulty MAF meter

Water Bypass Hose
A10522
PS Pressure Tube
Throttle Body Bracket
Engine WireThrottle Position
Sensor Connector
Vacuum Hose Brake Booster
39 (400,29)
IAC Valve
Connector
Accelerator Cable
Purge Hose
Hose Vacuum

Gasket
VSV Connector for No.2 ACIS
Engine Coolant
Reservoir Hose
43 (440,32)
ECT Sender
Gauge Connector
ECT Sensor
Connector
Grand Strap
Connector
15 (150,11)
Water Outlet
15 (150,11)
Water Bypass
Hose
Upper Radiator
HoseFuel Inlet Hose
Injector Connector Intake Manifold
Assembly

Retainer
Heater Hose

GasketIgnition Coil
Connector

Non-reusable part: Specified torque
N´m (kgf´cm, ft´lbf)
19.5 (200, 14)
No.1 Engine
Hanger
VSV Connector for
EVAP
Ground Cable
PCV Hose Ground Cable
Air Intake Chamber
Assembly

Gasket
Spark PlugIgnition Coil
Ground Strap
DLC1
Gasket
Fuel Hose Clamp
VSV Connector
for No.1 ACIS
Throttle Cable
- ENGINE MECHANICALCYLINDER HEAD
EM-27
1011 Author
: Date
:
2001 AVALON (RM808U)

A07428
86
5 43 2
1
910
7
117
A09699
8 mm Hexagon Wrench
A09695
Throttle Body
Bracket
Engine
Hanger
EM-68
- ENGINE MECHANICALCYLINDER HEAD
1052 Author
: Date
:
2001 AVALON (RM808U)
26. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Install the intake manifold, delivery pipe and injectors as-
sembly with the 9 bolts, 2 plate washers and 2 nuts. Uni-
formly tighten the bolts and nuts in several passes and in
the sequence shown.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
(b) Connect the fuel inlet hose to the fuel filter.
CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precaution.
(See page SF-1)
(c) Connect the heater hose to the intake manifold.
27. RETIGHTEN WATER OUTLET MOUNTING BOLTS
AND NUTS
Tighten the 2 bolts and 2 nuts.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
28. INSTALL AIR INTAKE CHAMBER ASSEMBLY
(a) Using an 8 mm hexagon wrench, install a new gasket and
the air intake chamber assembly with the 2 bolts and 2
nuts. Uniformly tighten the bolts and nuts in several
passes.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(b) Install the No.1 engine hanger with the 2 bolts.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(c) Install the throttle body bracket with the 2 bolts.
Torque: 19.5 N´m (200 kgf´cm, 14 ft´lbf)
(d) Connect the PCV hose to the PCV valve on the RH cylin-
der head.
(e) Connect the ground strap and cable to the intake air con-
trol valve for the ACIS.
(f) Connect the ground cable and strap with the nut.
Torque: 14.5 N´m (145 kgf´cm, 10 ft´lbf)
(g) Connect the ground cable to the air intake chamber.
(h) Connect the brake booster vacuum hose to the throttle
body.
(i) Connect the 2 water bypass hoses to the throttle body.
(j) Connect the air assist hose to the throttle body.
(k) Connect the purge hose to the emission control valve set.
(l) Connect the 2 vacuum hoses to the vacuum tank for
ACIS.
(m) Connect the engine wire clamp to the emission control
valve set.

- 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

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.

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)