2001 TOYOTA AVALON check engine

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.

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.

A05210
Exhaust
8
7
6
5
4
32
1
9
10
A05211
Intake
Align
A05214
Intake
A05213
Intake6
5
4
3
2
1
910
7
8
A05198
IntakeService Bolt
EM-64
- ENGINE MECHANICALCYLINDER HEAD
1048 Author
: Date
:
2001 AVALON (RM808U)
(8) Apply a light coat of engine oil on the threads and
under the heads of the bearing cap bolts.
(9) Install and uniformly tighten the 10 bearing cap
bolts in several passes and in the sequence shown.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(b) Install the intake camshaft.
(1) Apply new engine oil to the thrust portion and jour-
nal of the camshaft.
(2) Align the timing marks (1 dot mark) of the camshaft
drive and driven gears.
(3) Place the intake camshaft on the cylinder head.
(4) Install the 5 bearing caps in their proper locations.
(5) Apply a light coat of engine oil on the threads and
under the heads of bearing cap bolts.
(6) Install and uniformly tighten the 10 bearing cap
bolts in several passes and in the sequence shown.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(7) Remove the service bolt.
7. CHECK AND ADJUST VALVE CLEARANCE
(See page EM-4)
Turn the camshaft and position the cam lobe upward, and
check and adjust the valve clearance.

A06661
Manifold
Stay
A07283
New O-Ring
A07281
Manifold
Stay
A05188Inlet PipeRear
Plate
EM-66
- ENGINE MECHANICALCYLINDER HEAD
1050 Author
: Date
:
2001 AVALON (RM808U)
11. INSTALL RH EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(b) Install the exhaust manifold stay with the bolt and nut. Al-
ternately tighten the bolt and nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(c) Connect the A/F sensor connector.
12. INSTALL OIL DIPSTICK AND GUIDE
(a) Install a new O-ring to the dipstick guide.
(b) Apply soapy water to the O-ring.
(c) Push in the dipstick guide end into the guide hole of the
No.1 oil pan.
(d) Install the dipstick guide with the bolt.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
(e) Install the dipstick.
13. INSTALL LH EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(b) Install the exhaust manifold stay with the bolt and nut. Al-
ternately tighten the bolt and nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(c) Connect the A/F sensor connector.
14. INSTALL WATER INLET PIPE
(a) Install a new O-ring to the water inlet pipe.
(b) Apply soapy water to the O-ring.
(c) Connect the water inlet pipe to the water inlet.
(d) Install the bolt holding the water inlet pipe to the cylinder
head.
Torque: 19.5 N´m (200 kgf´cm, 14 ft´lbf)
15. INSTALL CYLINDER HEAD REAR PLATE
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
16. INSTALL ENGINE WIRE PROTECTOR
17. INSTALL CAMSHAFT TIMING OIL CONTROL VALVES
18. INSTALL CAMSHAFT POSITION SENSORS
19. INSTALL NO.3 TIMING BELT COVER
(a) Check that the timing belt cover gaskets have no cracks
or peeling, etc.
If the gaskets have cracks or peeling etc., replace them using
these steps:

Using a screwdriver and gasket scraper, remove all
the old gasket material.

- 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

A05246
EM-58
- ENGINE MECHANICALCYLINDER HEAD
1042 Author
: Date
:
2001 AVALON (RM808U)
(d) Using a plastic-faced hammer and the valve stem (not in
use) tip wound with vinyl tape, lightly tap the valve stem
tip to assure proper fit.
NOTICE:
Be careful not do damage the valve stem tip.
6. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.

EM0M5-03
A07436
A07507
Ohmmeter
Continuity
A07508
Ohmmeter
No Continuity
A07509
Air
H G
E
A07566
Air
HE F
Battery
EM-76
- ENGINE MECHANICALENGINE UNIT
1060 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
1. INSPECT FRONT ENGINE MOUNTING INSULATOR
(a) Using a MITYVAC (Hand-Held Vacuum Pump), apply
vacuum of 80 kPa (600 mmHg, 25 in.Hg) and allow it to
stand for 1 minute.
(b) Check that there is no change in the needle movement.
(c) Check that there is no fluid leakage caused by a break of
a lower diaphragm.
If the operation is not as specified, replace the insulator.
2. INSPECT VSV FOR ACTIVE CONTROL ENGINE
MOUNT
(a) Inspect the VSV for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the terminals.
Resistance: 19 - 21 W at 20°C (68°F)
If there is no continuity, replace the VSV.
(b) Inspect the VSV for ground.
Using an ohmmeter, check that there is no continuity be-
tween each terminal and the body.
If there is continuity, replace the VSV.
(c) Inspect the VSV operation.
(1) Check that air flows from port G to port E and port
H.
(2) Apply battery positive voltage across the terminals.
(3) Check that air flows from port F to port E and port
H.
If operation is not as specified, replace the VSV.
3. INSPECT VACUUM TANK (See page SF-58)