2001 TOYOTA AVALON width

A10524
Code Mark
Code Mark No.1
No.2
A10525
RH Piston
Lower Side Rail
No.2
CompressionFront Mark
Expander
Upper Side Rail
No.1
Compression
Lower Side Rail
Upper Side Rail LH Piston
No.2
Compression
Expander
No.1
CompressionFront Mark
P12402
Z09177
No.1 and No.4 No.2 and No.3
Upper
Lower
22.4 mm 19.0 mm EM-102
- ENGINE MECHANICALCYLINDER BLOCK
1086 Author
: Date
:
2001 AVALON (RM808U)
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code mark:
No.1T or G1
No.22T or G2
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the ring ends.
3. INSTALL CONNECTING ROD BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
HINT:

Main bearings come in widths of 19.0 mm (0.748 in.) and
22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bear-
ings in the No.1 and No.4 cylinder block journal positions
with the main bearing cap. Install the 19.0 mm (0.748 in.)
bearings in the No.2 and No.3 positions.

Upper bearings have an oil groove and oil holes; lower
bearings do not.

P12697
P25743
Painted Mark
Front90°
90°
P12911
Seal Width
2 - 3 mm A
BA
B EM-106
- ENGINE MECHANICALCYLINDER BLOCK
1090 Author
: Date
:
2001 AVALON (RM808U)
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque: 24.5 N´m (250 kgf´cm, 18 ft´lbf)
If any of the connecting rod cap bolts does not meet the torque
specification, replace the connecting rod cap bolts.
(c) Mark the front of the connecting cap bolts with paint.
(d) Retighten the cap bolts by 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
14. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM-83)
15. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.

Using a razor blade and gasket scraper, remove all
the oil packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil seal retainer with the 6 bolts. Uniformly tight-
en the bolt in several passes and in the sequence shown.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
16. INSTALL CYLINDER BLOCK SIDE COVER
Install a new gasket and the cylinder block side cover with the
3 bolts and 2 nuts.
Torque: 9 N´m (90 kgf´cm, 78 in.´lbf)

P12477
Seal Packing
Z09223
Seal Width
3 - 5 mmA
BA
B
- ENGINE MECHANICALCYLINDER BLOCK
EM-107
1091 Author
: Date
:
2001 AVALON (RM808U)
17. INSTALL ENGINE COOLANT DRAIN UNION
(a) Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826-00100 or equivalent
(b) Install the drain union.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
HINT:
After applying the specified torque, rotate the drain union clock-
wise until its drain port is facing downward.
18. INSTALL WATER SEAL PLATE
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the seal plate
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the seal plate as shown in the il-
lustration.
Seal packing: Part No. 08826-00100 or equivalent

Install a nozzle that has been cut to a 3 - 5 mm (0.12
- 0.20 in.) opening.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the seal plate with the 2 nuts.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
19. INSTALL OIL FILTER UNION
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
20. INSTALL OIL FILTER (See page LU-3)
21. INSTALL OIL PUMP (See page LU-15)
22. INSTALL NO.1 OIL PAN (See page LU-15)
23. INSTALL OIL STRAINER (See page LU-15)
24. INSTALL NO.2 OIL PAN (See page LU-15)
25. INSTALL WATER PUMP (See page CO-8)
26. INSTALL WATER INLET HOUSING
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water in-
let housing and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

P12909
Seal Width 3 - 5 mm
A05253410
2
5
7
93
1
6
8
P12389
SST EM-108
- ENGINE MECHANICALCYLINDER BLOCK
1092 Author
: Date
:
2001 AVALON (RM808U)

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the water inlet housing as shown in
the illustration.
Seal packing: Part No. 08826-00100 or equivalent

Install a nozzle that has been cut to a 3 - 5 mm (0.12
- 0.20 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the water inlet housing with the 8 bolts and 2 nuts.
Uniformly tighten the bolts and nuts in several passes and
in the sequence shown.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
(d) Connect the No.2 ECT switch connector.
(e) Connect the engine wire clamp to the water inlet.
(f) Install the engine wire band.
(g) Install the engine wire clamp.
27. INSTALL KNOCK SENSORS
(a) Using SST, install the 2 knock sensors.
SST 09816-30010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Connect the 2 knock sensor connectors.
28. INSTALL NO.2 IDLER PULLEY BRACKET
Torque: 28 N´m (290 kgf´cm, 21 ft´lbf)
29. INSTALL A/C COMPRESSOR HOUSING BRACKET
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)

EM2534
Overall Length
EM0255
A05228
P12729
Width
Z03988
45°
1.0 - 1.4 mm30°
- ENGINE MECHANICALCYLINDER HEAD
EM-45
1029 Author
: Date
:
2001 AVALON (RM808U)
(d) Check the valve overall length.
Standard overall length:
Intake95.45 mm (3.5779 in.)
Exhaust95.40 mm (3.7559 in.)
Minimum overall length:
Intake94.95 mm (3.7382 in.)
Exhaust94.90 mm (3.7362 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
11. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:

If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.

If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.

Check that the seat contact is in the middle of the
valve face with the following width:
1.0 - 1.4 mm (0.039 - 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.

- 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

LU0IC-01
B04145
AB
C
Seal Width
2 - 3 mm A
B
C
P18779
New O-Ring
- LUBRICATIONOIL PUMP
LU-15
1240 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
1. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pump
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing: Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Place a new O-ring on the cylinder block.

B04146
B04147
AB
Seal Width
3 - 4 mmAB Region ºYº Region ºXº LU-16
- LUBRICATIONOIL PUMP
1241 Author
: Date
:
2001 AVALON (RM808U)
(d) Engage the spline teeth of the oil pump drive gear with the
large teeth of the crankshaft, and slide the oil pump on the
crankshaft.
(e) Install the oil pump with the 9 bolts. Uniformly tighten the
bolts in several passes.
Torque:
10 mm head: 8 N´m (80 kgf´cm, 69 in.´lbf)
12 mm head: 19.5 N´m (200 kgf´cm, 14 ft´lbf)
2. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
3. INSTALL BAFFLE PLATE TO NO.1 OIL PAN
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
4. INSTALL NO.1 OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pan,
oil pump and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the oil pan as shown in the illustra-
tion.
Seal packing: Part No. 08826-00080 or equivalent
Region ºXº is at the outer side of the bolt hole.
Region ºYº is at the inner side of the bolt hole.

Install a nozzle that has been cut to a or 3 - 4 mm
(0.12 - 0.16 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 3 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil pan with the 17 bolts and 2 nuts. Uniformly
tighten the bolts and nuts in several passes.
Torque:
10 mm head: 8 N´m (80 kgf´cm, 69 in.´lbf)
12 mm head: 19.5 N´m (200 kgf´cm, 14 ft´lbf)
14 mm head: 37.2 N´m (380 kgf´cm, 27 ft´lbf)