2001 TOYOTA AVALON Service Repair Manual

B01165
P10595
SST
P10596
Upward
DownwardSST
P10593
P10594
- STARTINGSTARTER
ST-13
1266 Author
: Date
:
2001 AVALON (RM808U)
(9) Remove the starter housing and clutch assembly
from the brass bar.
(10) Using a plastic-faced hammer, tap the clutch shaft
and install the stop collar onto the snap ring.
2. REPLACE FRONT BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using SST and a press, press in a new bearing.
NOTICE:
Be careful of the bearing installation direction.
SST 09820-00030
3. REPLACE REAR BEARING
(a) Using SST, remove the bearing.
SST 09286-4601 1
(b) Using a press, press in a new bearing.

B01234
B01235
B01236
SST
B06430
(1)
(2)(4)
(5)
(6)
Inside
Identation
ProtrusionLong
Short
(3)
(7)
ST-14
- STARTINGSTARTER
1267 Author
: Date
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2001 AVALON (RM808U)
4. REPLACE MAGNETIC SWITCH TERMINAL KIT
PARTS
(a) Remove the 3 bolts, end cover, gasket and plunger.
(b) Using vernier calipers, measure the contact plate for
depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the
contact plate.
(c) Remove the terminal kit parts
(1) Using SST, loosen the terminal nuts.
SST 09810-38140
(2) Terminal C:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), O- ring, terminal bolt, contact
plate and terminal insulator (inside).
(3) Terminal 30:
Remove the terminal nut, wave washer, terminal in-
sulator (outside), packing, O-ring, terminal bolt,
contact plate, terminal insulator (inside).
(d) Install new terminal 30 kit parts.
(1) Temporarily install a new terminal insulator (inside).
(2) Temporarily install a new contact plate.
(3) Temporarily install a new terminal bolt.
(4) Temporarily install a new O-ring.
(5) Temporarily install a new packing and a new termi-
nal insulator (outside).
Install a new packing to a new terminal insulator,
and install them.

B01238
(1)(2)(3) (4) (5) (6) (7)
Long
Short
InsideLead Terminal
B01239
Wooden Block
Contact Plate
20 mm
40 mm
37 mm
(kgf/cm2) =100 kgf
Ram diameter (cm)
2x 3.14 (p)2
Ram diameter (in.)
2x 3.14 (p)2(psi) =221 lbf
(kPa) = x 98.1
x 6.9 (kgf/cm2)
(kPa) = (psi)
- STARTINGSTARTER
ST-15
1268 Author
: Date
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2001 AVALON (RM808U)
HINT:
Match the protrusion of the insulator with the indentation of the
housing.
(6) Temporarily install a new wave washer.
(7) Temporarily install a new terminal nut.
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washers in the correct direction.
(e) Temporarily install new terminal kit parts.
(1) Temporarily install a new terminal insulator (inside).
(2) Temporarily install a new contact plate.
(3) Temporarily install a new terminal bolt.
(4) Temporarily install a new O-ring.
(5) Temporarily install a new terminal insulator (out-
side).
(6) Temporarily install a new wave washer.
(7) Temporarily install a new terminal nut.
NOTICE:
Be careful to install the terminal insulators (inside) and
wave washers in the correct direction.
(f) Tighten terminal nuts.
(1) Put a wooden block on the contact plate and press
it down with a hand press.
Dimensions of wooden block:
20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:

Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when
981 N (100 kgf, 221 lbf) of force is applied.
Gauge pressure:

B01240
SST
B01241
ST-16
- STARTINGSTARTER
1269 Author
: Date
:
2001 AVALON (RM808U)

If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(2) Using SST, tighten the nuts to the specified torque.
SST 09810-38140
Torque: 17 N´m (173 kgf´cm, 12 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
(g) Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(h) Install the plunger, new gasket, end cover and 3 bolts.
Torque: 2.5 N´m (25 kgf´cm, 22 in.´lbf)

ST04T-02
B01242
Terminal C
Battery
Terminal 50
B01243
Terminal C
BatteryDisconnect
B01244Battery
Disconnect
B01245
Battery
Terminal 50
Terminal 30
Ammeter
ST-18
- STARTINGSTARTER
1271 Author
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2001 AVALON (RM808U)
TEST
NOTICE:
These tests must be done within 3 to 5 seconds to avoid
burning out the coil.
1. DO PULL-IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD-IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (-) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
(a) Disconnect the negative (-) lead from the switch body.
(b) Check that the clutch pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter
shows the specified current.
Specified current: 90 A or less at 11.5 V

B07464
Starter
Relay
ST04V-02
P07170
Ohmmeter
Ohmmeter No
ContinuityContinuity
31
5
2
P07171
Ohmmeter
Continuity
31
5
2
Battery
ST-20
- STARTINGSTARTER RELAY
1273 Author
: Date
:
2001 AVALON (RM808U)
STARTER RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE STARTER RELAY (Marking: ST)
3. INSPECT STARTER RELAY
(a) Inspect the relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 1 and 2.
If there is no continuity, replace the relay.
(2) Check that there is no continuity between terminals
3 and 5.
If there is continuity, replace the relay.
(b) Inspect the relay operation.
(1) Apply battery positive voltage across terminals 1
and 2.
(2) Using an ohmmeter, check that there is continuity
between terminals 3 and 5.
If there is no continuity, replace the relay.
4. REINSTALL STARTER RELAY
5. REINSTALL RELAY BOX COVER

ST04M-01
- STARTINGSTARTING SYSTEM
ST-1
1254 Author
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2001 AVALON (RM808U)
STARTING SYSTEM
ON-VEHICLE INSPECTION
NOTICE:
Before changing the starter, check the following items again:

Connector connection

Accessory installation, e.g.: theft deterrent system

P06717
SR0ED-03
Z00038
DENSO Borroughs
P06723
CORRECT WRONG WRONG
- STEERINGDRIVE BELT
SR-3
1466 Author
: Date
:
2001 AVALON (RM808U)
DRIVE BELT
INSPECTION
INSPECT DRIVE BELT
(a) Visually check the drive belt for excessive wear, frayed
cords, etc.
If any defect has been found, replace the drive belt.
HINT:
Cracks on the rib side of a drive belt are considered acceptable.
If the missing chunks from the ribs are found on the drive belt,
it should be replaced.
(b) Using a belt tension gauge, measure the belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt: 120 - 185 lbf
Used belt: 95 - 135 lbf
If the belt tension is not as specified, adjust it.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing a belt, check that it fits properly in the
ribbed grooves.

Check with your hand to confirm that the belt has not
slipped out of the groove on the bottom of the pulley.

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.