Page 509 of 1897
R00954
Stop Light Switch
Push Rod
Pedal HeightBR0KI-04
R00935
Pedal Freeplay BR-6
- BRAKEBRAKE PEDAL
1405 Author: Date:
2001 AVALON (RM808U)
BRAKE PEDAL
ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
153.3 - 163.3 mm (6.035 - 6.429 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the lower No. 1 instrument panel and lower LH
instrument panel insert (See page BO-87).
(b) Disconnect the connector from the stop light switch.
(c) Loosen the stop light switch lock nut and remove the stop
light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
(f) Tighten the push rod lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(g) Install the stop light switch.
(h) Connect the connector to the stop light switch.
(i) Push the brake pedal in 5 - 15 mm (0.20 - 0.59 in.), turn
the stop light switch to lock the nut in the position where
the stop light goes off.
(j) After installation, push the brake pedal in 5 - 15 mm (0.20
- 0.59 in.), check that stop light lights up.
(k) After adjusting the pedal height, check the pedal freeplay.
(l) Install the lower LH instrument panel insert and lower No.
1 instrument panel (See page BO-87).
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the beginning of the resis-
tance is felt, then measure the distance.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
Stop light switch clearance:
0.5 - 2.4 mm (0.020 - 0.094 in.)
HINT:
The freeplay to the 1st resistance is due to the play between the
clevis and pin. This is magnified up to 1 - 6 mm (0.04 - 0.24 in.)
at the pedal.
Page 510 of 1897
R00934
Pedal Reserve Distance
- BRAKEBRAKE PEDAL
BR-7
1406 Author: Date:
2001 AVALON (RM808U)
4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake.
With the engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 75 mm (3.0 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.
Page 549 of 1897
CH03U-03
Z11577
Except Maintenance-Free Battery
Z11556
Maintenance-Free Battery
Voltmeter
- CHARGINGCHARGING SYSTEM
CH-1
1274 Author: Date:
2001 AVALON (RM808U)
CHARGING SYSTEM
ON-VEHICLE INSPECTION
CAUTION:
Check that the battery cables are connected to the
correct terminals.
Disconnect the battery cables when the battery is giv-
en a quick charge.
Do not perform tests with a high voltage insulation re-
sistance tester.
Never disconnect the battery while the engine is run-
ning.
1. CHECK BATTERY ELECTROLYTE LEVEL
Check the electrolyte quantity of each cell.
Maintenance-Free Battery:
If under the lower level, replace the battery (or add distilled wa-
ter if possible). Check the charging system.
Except Maintenance-Free Battery:
If under the lower level, add distilled water.
2. Except Maintenance-Free Battery:
CHECK BATTERY SPECIFIC GRAVITY
Check the specific gravity of each cell.
Standard specific gravity: 1.25 - 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.
3. Maintenance-Free Battery:
CHECK BATTERY VOLTAGE
(a) After having driven the vehicle and in the case that 20
minutes have not passed after having stopped the en-
gine, turn the ignition switch ON and turn on the electrical
system (headlight, blower motor, rear defogger etc.) for
60 seconds to remove the surface charge.
(b) Turn the ignition switch OFF and turn off the electrical sys-
tems.
(c) Measure the battery voltage between the negative (-)
and positive (+) terminals of the battery.
Standard voltage: 12.5 - 12.9 V at 20°C (68°F)
If the voltage is less than specification, charge the battery.
Page 550 of 1897
Z18811
Blue White Red
OK Charging
NecessaryInsufficient
Water Maintenance-Free Battery
Type A
GREE NEYEDARK EYECLEAR EYE or
CHARGED DISCHARGEDADD WATER
Type B
LIGHT YELLOW
P13121
Z00038
DENSO Borroughs
P13120
CORRECT
WRONG CH-2
- CHARGINGCHARGING SYSTEM
1275 Author: Date:
2001 AVALON (RM808U)
HINT:
Check the indicator as shown in illustration.
4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
(b) Check the fusible link and fuses for continuity.
5. INSPECT DRIVE BELT
(a) Visually check the 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 belt are considered acceptable. If the
belt has chunks missing from the ribs, it should be replaced.
(b) Using a belt tension gauge, measure the drive belt ten-
sion.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt175 ± 5 lbf
Used belt115 ± 20 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.
Page 551 of 1897
P19934
Z03473
Ammeter
Voltmeter
BatteryDisconnect Wire
from Terminal B
Generator
- CHARGINGCHARGING SYSTEM
CH-3
1276 Author: Date:
2001 AVALON (RM808U)
After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.
6. VISUALLY CHECK GENERATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
7. CHECK DISCHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch ºONº. Check that the discharge
warning light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the dis-
charge light circuit.
8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per the manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:
Disconnect the wire from terminal B of the genera-
tor, and connect it to the negative (-) probe of the
ammeter.
Connect the positive (+) probe of the ammeter to
terminal B of the generator.
Connect the positive (+) probe of the voltmeter to
terminal B of the generator.
Ground the negative (-) probe of the voltmeter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 13.2 -14.8 V
Page 552 of 1897
P20106
Terminal F CH-4
- CHARGINGCHARGING SYSTEM
1277 Author: Date:
2001 AVALON (RM808U)
If the voltmeter reading is more than standard voltage, replace
the voltage regulator.
If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator as follows:
With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.
If the voltmeter reading is more than standard volt-
age, replace the voltage regulator.
If the voltmeter reading is less than standard volt-
age, check the generator.
9. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
ºHIº.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, re-
pair the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.
Page 568 of 1897
CO02K-03
- COOLINGCOOLANT
CO-1
1194 Author: Date:
2001 AVALON (RM808U)
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ºLOWº and ºFULLº lines, when the engine is cold.
If low, check for leaks and add ''Toyota Long Life Coolantº or Equivalent up to the ºFULLº line.
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap from the water outlet.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or water outlet
filler hole, and the coolant should be free from oil.
If excessively dirty, clean the coolant passages and replace the coolant.
(c) Reinstall the radiator cap.
Page 569 of 1897
CO02L-03
B09030Drain PlugDrain Plug
CO-2
- COOLINGCOOLANT
1195 Author: Date:
2001 AVALON (RM808U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap from the water outlet.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the radiator drain plug and engine drain plugs,
and drain the coolant.
(c) Close the drain plugs.
Torque:
RH engine drain plug on cylinder block side cover:
7 N´m (70 kgf´cm, 61 in.´lbf)
LH engine drain plug on union:
13 N´m (130 kgf´cm, 9 ft´lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.
Use of improper coolants may damage engine cool-
ing system.
Use ºToyota Long life Coolantº or equivalent and
mix it with plan water according to the manufactur-
er's directions.
Using of coolant which includes more than 50 %
(freezing protection down to -35°C (-31°F) or 60 %
(freezing protection down to -50°C (-58°F)) of eth-
ylene-glycol is recommended but not more than 70
%.
NOTICE:
Do not use an alcohol type coolant or plain water
alone.
The coolant should be mixed with plain water (prefer-
ably demineralized water or distilled water).
Capacity: 9.0 liters (9.5 US qts, 7.9 lmp. qts)
(b) Install the radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) If necessary, refill coolant into the reservoir up to the
ºFULLº line.
3. CHECK ENGINE COOLANT FOR LEAKS
4. CHECK ENGINE COOLANT SPECIFIC GRAVITY COR-
RECTLY
