Toyota - Avalon - Workshop Manual - 2001 - 2001

BODY PANEL REPLACEMENT BODY DIMENSION DRAWINGS ENGINE COMPARTMENT (Three-Dimensional Distance) Vehicle Dimensions Left ↔ Right K-k C-K or c-k C-K or c-k 1,524 (60.00) 666 (26.22) 1,639 (64.53) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear.) mm (in.) Symbol Hole dia. Symbol 6 (0.24) nut G, g Front crossmember gusset standard hole 7 (0.28) Front spring support hole-inner 11 (0.43) H, h Radiator side defector installation hole 7 (0.28) Front fender installation nut-rear 6 (0.24) nut Name A, a Front fender installation nut-front B, b C, c Cowl ventilator louver installation hole E, e Front side member standard hole 13 (0.51) F, f Front side member working hole 15 (0.59) I, i Front crossmember standard hole J, j Hood hinge installation nut-rear K, k Front apron to cowl side member upper cut-out portion 12 (0.47) 8 (0.31) nut BP-81 D, d 7 (0.28) Name Hole dia. BODY PANEL REPLACEMENT BODY OPENING AREAS (Side View-Rear) (Three-Dimensional Distance) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear). Vehicle Dimensions Left ↔ Right N-n O-o P-p Q-q S-s T-t 1,415 (55.71) 1,498 (58.98) 1,242 (48.90) 1,494 (58.82) 1,373 (54.06) 1,491 (58.70) G-q or g-Q 1,831 (72.09) I-p or i-P 1,347 (53.03) I-r or i-R 1,572 (61.89) N-s or n-S 1,558 (61.34) N-t or n-T 1,679 (66.10) O-t or o-T 1,650 (64.96) P-q or p-Q 1,689 (66.50) S-t or s-T 1,550 (59.06) mm (in.) Symbol Name Hole dia. Symbol Name Rocker panel assembly mark I, i Roof side rail assembly mark R, r Roof side rail assembly mark Quarter panel assembly mark Quarter panel assembly mark Q, q N, n Center body pillar assembly mark S, s O, o Center body pillar assembly mark T, t P, p Roof side rail assembly mark Hole dia. Rocker panel assembly mark BP-83 G, g 1,339 (52.72) 1,541 (60.67) C-F or C-f 618 (24.33) C-F or c-f 1,160 (45.67) mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Roof panel / Quarter panel adjoining portion E, e Quarter panel standard hole 10 (0.39) B, b Upper back panel / Quarter panel adjoining portion F, f Rear floor finish plate installation hole 7 (0.28) C, c Quarter panel / Upper back panel adjoining portion G, g Rear spring support hole inner - rear 9.5 (0.374) D, d Luggage compartment opening trough / Quarter panel adjoining portion H, h Center body pillar assembly mark BODY PANEL REPLACEMENT E-e BP-84 HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear). C-c BODY OPENING AREAS (Rear View) (Three-Dimensional Distance) Vehicle Dimensions Left ↔ Right F-f G-g H-h I-i J-j K-k 1,326 (52.20) 1,491 (58.70) 1,491 (58.70) 1,491 (58.70) 1,242 (48.90) 1,402 (55.20) 1,498 (58.98) E-f or e-F 1,623 (63.90) Hole dia. Symbol E-h or e-H 1,654 (65.12) E-j or e-J 1,483 (58.39) F-j or f-J 1,880 (74.02) F-k or f-K 1,742 (68.58) H-i or h-I 1,691 (66.57) J-k or j-K 1,574 (61.97) mm (in.) Symbol Name Name A, a Roof panel / Front body pillar adjoining portion H, h Rocker panel assembly mark B, b Cowl panel / Front body pillar adjoining portion I, i Roof side rail assembly mark Hole dia. C, c Front door hinge installation nut-rear 8 (0.31) nut J, j Center body pillar assembly mark D, d Front door hinge installation nut-upper 8 (0.31) nut K, k Center body pillar assembly mark E, e Front body pillar assembly mark L, l Rear door hinge installation hole-front 15 (0.59) F, f Front body pillar assembly mark M, m Rear door hinge installation hole-front 15 (0.59) G, g Rocker panel assembly mark BODY PANEL REPLACEMENT E-e BP-82 Vehicle Dimensions Left ↔ Right BODY OPENING AREAS (Side View-Front) (Three-Dimensional Distance) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear). BODY PANEL REPLACEMENT Center-to-center straight-line distance Three-dimensional distance BP-79 GENERAL INFORMATION 1. BASIC DIMENSIONS (a) There are two typed of dimensions in the diagram. (1) (Three-dimensional distance)
Straight-line distance between the centers of two measuring points. F10115A (2) (Two-dimensional distance) Center-to-center Horizontal distance in forward / rearward Two-dimensional distance
Horizontal distance in forward/ rearward between the centers of two measuring points.
The height from an imaginary standard line. Vertical distance in lower surface Vertical distance in center Imaginary Standard Line F10116A Under Surface of The Rocker Panel A mm 1 B mm 2 (b) Incases in which only one dimension is given, left and right are symmetrical. (c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference. (d) The line that connects the places listed below is the imaginary standard line when measuring the height. (The dimensions are printed in the text.) SYMBOL Name 1 The place that was lowered A mm from the under surface of the rocker panel centered on the front jack up point. 2 The place that was lowered B mm from the under surface of the rocker panel centered between 1 and 3. 3 The place that was lowered C mm from the under surface of the rocker panel centered on the rear jack up point. C mm 3 Imaginary Standard Line F10026A BODY PANEL REPLACEMENT BP-80 Plate Looseness 2. MEASURING (a) Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used. Body Looseness (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers. Pointer Looseness Pointer Master Gauge Wrong F10117A HINT: 1. The height of the left and right points must be equal. Correct 2. Always calibrate the tracking gauge before measuring or after adjusting the pointer height. 3. Take care not to drop the tracking gauge or otherwise shock it. 4. Confirm that the pointers are securely in the holes. Pointer F10118A Front Spring Support Inner Hole Tape Measure Along Body Surface Front Suspension Member Rear Side Upper Installation Hole F10118A (c) When using a tape measure, avoid twists and bends in the tape. (d) when tracking a diagonal measurement from the front spring support inner hole to the suspension member upper rear installation hole, measure along the front spring support panel surface. (Two-Dimensional Distance) BODY PANEL REPLACEMENT SUSPENSION CROSSMEMBER (Three-Dimensional Distance) Imaginary Standard Line mm (in.) Symbol Name Hole dia. Symbol Front frame standard hole 13 (0.51) D, d Front frame standard hole 13 (0.51) B, b Front frame standard hole 13 (0.51) E, e Lower control link installation hole-lower 15 (0.59) C, c Front frame standard hole 13 (0.51) A, a Name Hole dia. BP-87 UNDER BODY (Three-Dimensional Distance) BODY PANEL REPLACEMENT mm (in.) Symbol Name A, a Front crossmember standard hole B, b Front frame installation nut C, c Front side member standard hole Name Hole dia. Hole dia. Symbol 10 (0.39) G, g Front floor under reinforcement standard hole 15 (0.59) 14 (0.55) nut H, h Strut bar installation hole-inner 12 (0.47) Rear floor side member standard hole 18 (0.71) 18 (0.71) I, i 14 (0.55) nut J, j Rear suspension member installation nut Front side member standard hole 18 (0.71) K, k Rear floor side member standard hole 18 (0.71) Front side member working hole 15 (0.59) L, l Rear floor side member standard hole 18 (0.71) Front frame installation nut E, e F, f 12 (0.47) nut BP-85 D, d 2 3 100 (3.94) 100 (3.94) 101 (3.98) BODY PANEL REPLACEMENT 1 Imaginary Standard Line mm (in.) Symbol Name A, a Front crossmember standard hole B, b Front frame installation nut C, c Hole dia. Symbol BP-86 2,720 (107.09) UNDER BODY (Cont’d) (Two-Dimensional Distance) Wheel base Name Hole dia. Front floor under reinforcement standard hole 15 (0.59) Strut bar installation hole-inner 12 (0.47) Rear floor side member standard hole 18 (0.71) 10 (0.39) H, h 14 (0.55) nut I, i Front side member standard hole 18 (0.71) J, j D, d Front spring support hole outer-front 11 (0.43) K, k Rear suspension member installation nut E, e Front frame installation nut 14 (0.55) nut L, l Rear spring support hole-outer F, f Front side member standard hole 18 (0.71) M, m Rear floor side member standard hole 18 (0.71) G, g Front side member working hole 15 (0.59) N, n Rear floor side member standard hole 18 (0.71) 12 (0.47) nut 9.5 (0.374) BODY PANEL REPLACEMENT BP-58 BODY LOWER BACK PANEL (ASSY) REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL Braze Braze F10187 BODY PANEL REPLACEMENT 2. BP-59 INSTALL BODY LOWER BACK PANEL HINT: Inspect the fitting of the luggage compartment door and rear combination light, etc., before welding, since this attacts the appearance of the finish. Braze Braze F10188 3. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 4. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 5. APPLYING UNDER COATING (See page PC-6 ) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-33 CENTER BODY PILLAR (CUT) REPLACEMENT 1. REMOVE CENTER BODY PILLAR (a) Cut and join the parts at the locations as shown below. (b) Shift the each cut and join location of the pillar section. (center body outer pillar, center body pillar upper reinforcement and center body inner pillar.) (c) Shift the each cut and join location of the rocker section. (center body outer pillar and center body pillar lower reinforcement.) Cut and Join Location (Cut Location for Supply Parts) Cut and Join Location Cut and Join Location (Cut Location for Supply Parts) 20 mm [Cut and Join Location] 50 mm 50 mm mm in. 20 50 0.79 1.97 F10167 BP-34 BODY PANEL REPLACEMENT Cut and Join Locations (Cut Location for Supply Parts) F10168 BODY PANEL REPLACEMENT BP-35 2. INSTALL CENTER BODY PILLAR HINT: Inspect the fitting of the front door and rear door, etc., before welding since this affects the appearance of the finish. (a) Before temporarily installing the new parts, weld the center body inner pillar, center body pillar lower reinforcement and center body pillar upper reinforcement. (b) After welding the center body inner pillar, center body pillar lower reinforcement and center body pillar upper reinforcement to the vehicle, install the center body outer pillar. (c) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. Center Body Pillar Upper Reinforcement Center Body Inner Pillar Center Body Pillar Lower Reinforcement Butt Weld Butt Weld F10169 BODY PANEL REPLACEMENT BP-36 Butt Weld Butt Weld Butt Weld Butt Weld F10170 3. MEASURING THE OPENING PORTION DIMENSIONS (See page BP-84 ) 4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 5. APPLYING UNDER COATING (See page PC-6 ) 6. CHARGING THE POLYURETHANE FOAM (See page PC-8 ) 7. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-18 COWL TOP SIDE PANEL (ASSY) REPLACEMENT 1. REMOVE COWL TOP SIDE PANEL Cut with disc sander, etc. Cut with disc sander, etc. F10154 BODY PANEL REPLACEMENT 2. BP-19 INSTALL COWL TOP SIDE PANEL mm 14 16 20
30 in. 0.55 0.63 0.79 1.18 F10155 3. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 4. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-5 FRONT CROSSMEMBER (ASSY) REPLACEMENT 1. REMOVE FRONT CROSSMEMBER F10144 BP-6 2. BODY PANEL REPLACEMENT INSTALL FRONT CROSSMEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the hood lock support. F10145 3. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81 ) 4. MEASURING THE UNDERBODY DIMENSIONS (See page BP-85 ) 5. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-15 FRONT FENDER APRON (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1 ) 2. REMOVE COWL TOP SIDE PANEL (See page BP-18 ) 3. REMOVE FRONT FENDER APRON RH LH F10152 BP-16 BODY PANEL REPLACEMENT 4. INSTALL FRONT FENDER APRON HINT: Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish. (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Make sure each measurement is correct, as this parts affects the front wheel alignment. RH LH F10153 BODY PANEL REPLACEMENT 5. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81 ) 6. INSTALL COWL TOP SIDE PANEL (See page BP-18 ) 7. INSTALL RADIATOR UPPER SUPPORT (See page BP-1 ) 8. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 9. APPLYING UNDER COATING (See page PC-6 ) BP-17 10. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-24 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1 ) 2. REMOVE FRONT CROSSMEMBER SIDE GUSSET (See page BP-3 ) 3. REMOVE FRONT CROSSMEMBER (See page BP-5 ) 4. REMOVE COWL TOP SIDE PANEL (See page BP-18 ) 5. REMOVE FRONT FENDER APRON (See page BP-15 ) 6. REMOVE FRONT SIDE MEMBER (a) Leave the floor side member No. 4 reinforcement to the vehicle, remove the front side member. Floor Side Member No. 4 Reinforcement F10158 BODY PANEL REPLACEMENT BP-25 F10159 BODY PANEL REPLACEMENT BP-26 7. INSTALL FRONT SIDE MEMBER (a) Remove the floor side member No. 4 reinforcement from the new parts of front side member. (b) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Make sure each measurement is correct, as this parts affects the front wheel alignment. Front Side Member No. 4 Reinforcement (Remove) Floor Side Member No. 4 Reinforcement F10160 BODY PANEL REPLACEMENT BP-27 F10161 8. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81 ) 9. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85 ) 10. INSTALL FRONT FENDER APRON (See page BP-15 ) 11. INSTALL COWL TOP SIDE PANEL (See page BP-18 ) 12. INSTALL FRONT CROSSMEMBER (See page BP-5 ) 13. INSTALL FRONT CROSSMEMBER SIDE GUSSET (See page BP-3 ) 14. INSTALL RADIATOR UPPER SUPPORT (See page BP-1 ) 15. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 16. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-2 ) 17. APPLYING UNDER COATING (See page PC-6 ) 18. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 19. INSTALL FRONT FLOOR SILENCER SHEET (See page PC-9 ) BP-12 BODY PANEL REPLACEMENT FRONT APRON TO COWL SIDE UPPER MEMBER (ASSY) REPLACEMENT 1. REMOVE COWL TOP SIDE PANEL (See page BP-18 ) 2. REMOVE RADIATOR UPPER SUPPORT (See page BP-1 ) 3. REMOVE FRONT FENDER FRONT APRON (See page BP-9 ) 4. REMOVE FRONT APRON TO COWL SIDE UPPER MEMBER (a) After removing the front apron to cowl side lower member, remove the front apron to cowl side upper member. Front Apron to Cowl Side Lower Member F10150 BODY PANEL REPLACEMENT 5. BP-13 INSTALL FRONT APRON TO COWL SIDE UPPER MEMBER HINT: Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish. (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10151 BP-14 BODY PANEL REPLACEMENT 6. INSTALL FRONT FENDER FRONT APRON (See page BP-9 ) 7. INSTALL RADIATOR UPPER SUPPORT (See page BP-1 ) 8. INSTALL COWL TOP SIDE PANEL (See page BP-18 ) 9. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 10. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-28 FRONT BODY PILLAR (CUT) REPLACEMENT 1. REMOVE COWL TOP SIDE PANEL (See page BP-18 ) 2. REMOVE FRONT BODY PILLAR (a) Cut and join the parts at the locations as shown below. HINT:
Shift the each cut and join locations of the outer pillar, pillar reinforcement and inner pillar.
Shift the each cut and join locations of the rocker outer panel and center body pillar lower reinforcement.
This part of the outer panel is reused, since the rocker panel section is cutoff at the rear the outer panel supply part cutting position. 140 mm [Cut and Join Location] Cut and Join Location Cut with disc sander, etc. 50 mm 50 mm [Cut and Join Location] 60 mm Rocker Outer Panel 100 mm mm in. 50 60 100 140 1.97 2.36 3.94 5.51 Reuse Cut and Join Location Center Body Pillar Lower Reinforcement F10162 BODY PANEL REPLACEMENT BP-29 F10163 BP-30 BODY PANEL REPLACEMENT 3. INSTALL FRONT BODY PILLAR HINT: Inspect the fitting of the front door, front fender and windshield glass, etc., before welding, since this affects the appearance of the finish. (a) Before temporarily installing the new parts, weld the front pillar lower reinforcement, center body pillar lower reinforcement and front body inner pillar with standard points. (b) After welding the front pillar lower reinforcement, center body pillar lower reinforcement and front body inner pillar to the vehicle, install the outer pillar. (c) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. Front Body Inner Pillar Butt Weld Center Body Pillar Lower Reinforcement Front Pillar Lower Reinforcement Butt Weld F10164 BODY PANEL REPLACEMENT Butt Weld BP-31 mm in. 25 0.98 Tack Weld (25 mm) Front Body Pillar Lower Gusset F10165 BODY PANEL REPLACEMENT BP-32 Butt Weld Front Body Piller Outer Bracket Butt Weld F10166 4. MEASURING OPENING PORTION DIMENSIONS (See page BP-84 ) 5. INSTALL COWL TOP SIDE PANEL (See page BP-18 ) 6. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 8. APPLYING UNDER COATING (See page PC-6 ) 9. CHARGING THE POLYURTHANE FOAM (See page PC-8 ) 10. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-3 FRONT CROSSMEMBER SIDE GUSSET (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1 ) 2. REMOVE FRONT CROSSMEMBER SIDE GUSSET F10142 BP-4 3. BODY PANEL REPLACEMENT INSTALL FRONT CROSSMEMBER SIDE GUSSET (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10143 4. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81 ) 5. INSTALL RADIATOR UPPER SUPPORT (See page BP-1 ) 6. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 7. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-37 FRONT DOOR OUTER PANEL (ASSY) REPLACEMENT 1. REMOVE FRONT DOOR OUTER PANEL (a) Before removing the outer panel, make the installation position with a tape. (b) After grinding off the hemming location, remove the outer panel. Braze Positioning Tape Braze Installation Position Hemming Location Disc Sander F10171 BODY PANEL REPLACEMENT BP-38 2. INSTALL FRONT DOOR OUTER PANEL (a) Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and back side of the new parts. HINT:
Apply just enough sealer for the reinforcement and side impact beam to touch the new panel. Apply sealer evenly around the flange area, about 10 mm (0.39 in.) from the edge, as shown.
For other sealing points, refer to section PC. (b) Bend the flange hem about 30° with a hammer and dolly, then fasten tightly with a hemming tool. HINT:
Perform hemming in three steps, being careful not to warp the panel.
If a hemming tool cannot be used, hem with a hammer and dolly. Positioning Tape Braze Body Sealer Braze about 10 mm Do not close the drain hole. Cloth Tape Body Sealer 30° Hemming Tool mm in. 10 0.39 F10172 BODY PANEL REPLACEMENT 3. APPLYING SEALER TO THE DOOR PARTS (See page PC-1 ) 4. APPLYING ANTI-RUST AGENT BP-39 (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-9 FRONT FENDER FRONT APRON (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1 ) 2. REMOVE FRONT FENDER FRONT APRON (a) Replace the fender apron plate at the same time. Fender Apron Plate LH: RH: F10148 BP-10 3. BODY PANEL REPLACEMENT INSTALL FRONT FENDER FRONT APRON (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. Fender Apron Plate RH LH RH LH F10149 BODY PANEL REPLACEMENT 4. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81 ) 5. INSTALL RADIATOR UPPER SUPPORT (See page BP-1 ) 6. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 7. APPLYING UNDERCOATING (See page PC-6 ) 8. APPLYING ANTI-RUST AGENT BP-11 (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-20 FRONT SIDE MEMBER (CUT-P) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1 ) 2. REMOVE FRONT CROSSMEMBER SIDE GUSSET (See page BP-3 ) 3. REMOVE FRONT CROSSMEMBER (See page BP-5 ) 4. REMOVE FRONT SIDE MEMBER (a) Cut and join the parts at the locations as shown below. [RH] [RH] 340 mm [RH] Cut and Join Location 20 mm mm in. 20 340 0.79 13.39 F10156A BODY PANEL REPLACEMENT BP-21 (b) LH only: After removing the battery carrier support, cut and join the front side member. HINT: Leave the reinforcement to the vehicle side. [LH only] Battery Carrier Support [LH] 20 mm [LH] 340 mm mm 20 340 in. 0.79 13.39 F10156B BODY PANEL REPLACEMENT BP-22 5. INSTALL FRONT SIDE MEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. [RH] [RH] Butt Weld Butt Weld [RH] [RH] Front Suspension Member Mounting Bracket Front Bumper Mounting Reinforcement F10157A BODY PANEL REPLACEMENT [LH only] BP-23 [LH] Butt Weld [LH] Butt Weld [LH] [LH] F Bracket Front Bumper Mounting Reinforcement F10157B 6. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81 ) 7. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85 ) 8. INSTALL FRONT CROSSMEMBER (See page BP-5 ) 9. INSTALL FRONT CROSSMEMBER SIDE GUSSET (See page BP-3 ) 10. INSTALL RADIATOR UPPER SUPPORT (See page BP-1 ) 11. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 12. APPLYING ANTI-RUST AGENT (See page PC-7 ) (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-60 BODY PANEL REPLACEMENT LUGGAGE COMPARTMENT OPENING TROUGH (ASSY) REPLACEMENT 1. REMOVE LUGGAGE COMPARTMENT OPENING TROUGH Braze F10189 BODY PANEL REPLACEMENT 2. BP-61 INSTALL LUGGAGE COMPARTMENT OPENING TROUGH HINT: Inspect the fitting of the luggage compartment door and rear combination light, etc., before welding, since this affects the appearance of the finish. Braze F10190 3. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 4. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 5. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-55 QUARTER WHEEL HOUSING OUTER PANEL (ASSY): Left Side REPLACEMENT 1. REMOVE QUARTER PANEL (See page BP-49 ) 2. REMOVE ROCKER OUTER EXTENSION (See page BP-47 ) 3. REMOVE QUARTER WHEEL HOUSING OUTER PANEL (a) Remove the roof side outer panel at the location shown in the below figure and remove the quarter wheel housing outer panel. Roof Side Outer Panel F10185 BP-56 BODY PANEL REPLACEMENT 4. INSTALL QUARTER WHEEL HOUSING OUTER PANEL HINT: Temporarily install the quarter panel and inspect the fitting before welding, since this affects the appearance of the finish. (a) Determine the position of the new parts by the assembly marks of the inner and outer panels. Assembly Mark Assembly Mark Assembly Mark F10186 BODY PANEL REPLACEMENT 5. INSTALL ROCKER OUTER EXTENSION (See page BP-47 ) 6. INSTALL QUARTER PANEL (See page BP-49 ) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 8. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 9. APPLYING UNDER COATING (See page PC-6 ) BP-57 10. CHARGING THE POLYURETHANE FOAM (See page PC-6 ) 11. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-49 QUARTER PANEL (CUT) REPLACEMENT 1. REMOVE QUARTER PANEL (a) Cut and join the parts at the locations as shown below. (b) Replace the fuel filler opening lid at the same time. [Cut and Join Location] 150 mm Cut and Join Location Cut and Join Location Fuel Filler Opening Lid 200 mm Cut and Join Location (Cut Location for Supply Parts) Braze [Cut and Join Location] mm in. 150 200 5.91 7.87 F10181 BODY PANEL REPLACEMENT BP-50 2. INSTALL QUARTER PANEL HINT: Inspect the fitting of the rear door, luggage compartment door and rear combination light, etc., before welding, since this affects the appearance of the finish. (a) Before temporarily installing the new parts, weld the quarter lock pillar reinforcement with standard points. (b) Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT:
Apply body sealer about 5 mm (0.20 in.) from the flange, avoiding any oozing.
Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16 in.) in diameter.
For other sealing points, refer to section PC. (c) Use water proof rivets for the fuel opening lid installation. Body Sealer about 5 mm Butt Weld Butt Weld Quarter Panel Retainer Quarter Lock Pillar Reinforcement Body Sealer mm in. 5 0.20 Butt Weld F10182A BODY PANEL REPLACEMENT BP-51 Braze Fuel Filler Opening Lid Waterproof Rivets F10182B 3. MEASURING THE OPENING PORTION DIMENSIONS (See page BP-84 ) 4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 5. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 6. CHARGING THE POLYURETHANE FOAM (See page PC-8 ) 7. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-52 BODY PANEL REPLACEMENT QUARTER WHEEL HOUSING OUTER PANEL (ASSY): Right Side REPLACEMENT 1. REMOVE QUARTER PANEL (See page BP-49 ) 2. REMOVE ROCKER OUTER EXTENSION (See page BP-47 ) 3. REMOVE QUARTER WHEEL HOUSING OUTER PANEL (a) Remove the roof side outer panel at the location shown in below figure and remove the quarter wheel housing outer panel. Roof Side Outer Panel F10183 BODY PANEL REPLACEMENT BP-53 4. INSTALL QUARTER WHEEL HOUSING OUTER PANEL HINT: Temporarily install the quarter panel and inspect the fitting before welding, since this affects the appearance of the finish. (a) Determine the position of the new parts by the assembly marks of the inner and outer panels. Assembly Mark Assembly Mark Assembly Mark F10184 BP-54 BODY PANEL REPLACEMENT 5. INSTALL ROCKER EXTENSION (See page BP-47 ) 6. INSTALL QUARTER PANEL (See page BP-49 ) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 8. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 9. APPLYING UNDER COATING (See page PC-6 ) 10. CHARGING THE POLYURETHANE FOAM (See page PC-8 ) 11. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-7 RADIATOR SUPPORT (ASSY) REPLACEMENT 1. REMOVE RADIATOR SUPPORT (a) After removing the front side member extension, remove the radiator support. Front Side Member Extension F10146 BP-8 2. BODY PANEL REPLACEMENT INSTALL RADIATOR SUPPORT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10147 3. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81 ) 4. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85 ) 5. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-1 RADIATOR UPPER SUPPORT (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT F10140 BP-2 2. BODY PANEL REPLACEMENT INSTALL RADIATOR UPPER SUPPORT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the hood lock support. F10141 3. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81 ) 4. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1 ) 5. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-40 REAR DOOR OUTER PANEL (ASSY) REPLACEMENT 1. REMOVE REAR DOOR OUTER PANEL (a) Before removing the outer panel, make the installation position with a tape. (b) After grinding off the hemming location, remove the outer panel. Positioning Tape Braze Braze Installation Position Hemming Location Disc Sander F10173 BODY PANEL REPLACEMENT 2. BP-41 INSTALL FRONT DOOR OUTER PANEL (a) Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and back side of the new parts. HINT:
Apply just enough sealer for the reinforcement and side impact beam to touch the new panel. Apply sealer evenly around the flange area, about 10 mm (0.39 in.) from the edge, as shown.
For other sealing points, refer to section PC. (b) Bend the flange hem about 30° with a hammer and dolly, then fasten tightly with a hemming tool. HINT:
Perform hemming in three steps, being careful not to warp the panel.
If a hemming tool cannot be used, hem with a hammer and dolly. Positioning Tape Braze Body Sealer Braze 10 mm Do not close the drain hole. Body Sealer Cloth Tape 30 ° Hemming Tool mm in. 10 0.39 F10174 BP-42 BODY PANEL REPLACEMENT 3. APPLYING SEALER TO THE DOOR PARTS (See page PC-1 ) 4. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-64 REAR FLOOR PAN (ASSY) REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58 ) 2. REMOVE REAR FLOOR NO. 3 CROSSMEMBER (See page BP-62 ) 3. REMOVE REAR FLOOR PAN (a) After removing the rear floor pan reinforcement, remove the rear floor pan. Rear Floor Pan Reinforcement [LH] [RH] F10193 BODY PANEL REPLACEMENT 4. BP-65 INSTALL REAR FLOOR PAN [LH] [RH] F10194 BP-66 BODY PANEL REPLACEMENT 5. INSTALL REAR FLOOR NO. 3 CROSSMEMBER (See page BP-62 ) 6. INSTALL BODY LOWER BACK PANEL (See page BP-58 ) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 8. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 9. APPLYING UNDER COATING (See page PC-6 ) 10. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 11. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9 ) 12. INSTALL REAR FLOOR SILENCER NO. 2 SHEET (See page PC-9 ) BODY PANEL REPLACEMENT BP-67 REAR FLOOR SIDE PANEL (ASSY): Right Side REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58 ) 2. REMOVE REAR FLOOR NO. 3 CROSSMEMBER (See page BP-62 ) 3. REMOVE REAR FLOOR PAN (See page BP-64 ) 4. REMOVE REAR FLOOR SIDE PANEL F10195 BP-68 3. BODY PANEL REPLACEMENT INSTALL REAR FLOOR SIDE PANEL F19196 4. INSTALL REAR FLOOR PAN (See page BP-64 ) 5. INSTALL REAR FLOOR NO. 3 CROSSMEMBER (See page BP-62 ) 6. INSTALL BODY LOWER BACK PANEL (See page BP-58 ) 7. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 8. APPLYING UNDER COATING (See page PC-6 ) 9. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 10. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9 ) 11. INSTALL REAR FLOOR SILENCER NO. 2 SHEET (See page PC-9 ) BODY PANEL REPLACEMENT BP-69 REAR FLOOR SIDE PANEL (ASSY): Left Side REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58 ) 2. REMOVE REAR FLOOR NO. 3 CROSSMEMBER (See page BP-62 ) 3. REMOVE REAR FLOOR PAN (See page BP-64 ) 4. REMOVE REAR FLOOR SIDE PANEL F10197 BP-70 3. BODY PANEL REPLACEMENT INSTALL REAR FLOOR SIDE PANEL F10198 4. INSTALL REAR FLOOR PAN (See page BP-64 ) 5. INSTALL REAR FLOOR NO. 3 CROSSMEMBER (See page BP-62 ) 6. INSTALL BODY LOWER BACK PANEL (See page BP-58 ) 7. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 8. APPLYING UNDER COATING (See page PC-6 ) 9. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 10. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9 ) 11. INSTALL REAR FLOOR SILENCER NO. 2 SHEET (See page PC-9 ) BODY PANEL REPLACEMENT BP-71 REAR FLOOR SIDE REAR MEMBER (ASSY) REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58 ) 2. REMOVE REAR FLOOR NO. 3 CROSSMEMBER (See page BP-62 ) 3. REMOVE REAR FLOOR SIDE REAR MEMBER F10199 BODY PANEL REPLACEMENT BP-72 4. INSTALL REAR FLOOR SIDE REAR MEMBER (a) When temporarily installing the new parts, determine the installation position by the assembly mark. Then, measure each part in accordance with the body dimension diagram. [LH only] Assembly Mark With CD Changer only: Rear Floor Pan No. 1 Reinforcement With Navigation System only: Rear Floor Pan No. 2 Reinforcement F10200 5. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85 ) 6. INSTALL REAR FLOOR NO. 3 CROSSMEMBER (See page BP-62 ) 7. INSTALL BODY LOWER BACK PANEL (See page BP-58 ) 8. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 9. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 10. APPLYING UNDER COATING (See page PC-6 ) 11. APPLYING AUTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 12. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9 ) BODY PANEL REPLACEMENT BP-73 REAR FLOOR NO. 2 CROSSMEMBER (ASSY) REPLACEMENT 1. REMOVE REAR FLOOR NO. 2 CROSSMEMBER F10201 BP-74 2. BODY PANEL REPLACEMENT INSTALL REAR FLOOR NO. 2 CROSSMEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10202 3. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85 ) 4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 5. APPLYING UNDER COATING (See page PC-6 ) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structoral weld spots. 7. INSTALL CENTER FLOOR SILENCER SHEET (See page PC-9 ) 8. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9 ) BP-62 BODY PANEL REPLACEMENT REAR FLOOR NO. 3 CROSSMEMBER (ASSY) REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58 ) 2. REMOVE REAR FLOOR NO. 3 CROSSMEMBER F10191 BODY PANEL REPLACEMENT 3. BP-63 INSTALL REAR FLOOR NO. 3 CROSSMEMBER F10192 4. INSTALL BODY LOWER BACK PANEL (See page BP-58 ) 5. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 6. APPLYING UNDER COATING (See page PC-6 ) 7. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-47 ROCKER OUTER EXTENSION (CUT) REPLACEMENT 1. REMOVE QUARTER PANEL (See page BP-49 ) 2. REMOVE ROCKER OUTER EXTENSION (a) Cut and join the parts at the location as shown below. 50 mm Cut and Join Location mm in. 50 1.97 F10179 BODY PANEL REPLACEMENT BP-48 3. INSTALL ROCKER OUTER EXTENSION HINT: Temporarily install the quarter panel and inspect the fitting before welding, since this affects the appearance of the finish. Butt Weld F10180 4. INSTALL QUARTER PANEL (See page BP-49 ) 5. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 6. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 7. APPLYING UNDER COATING (See page PC-6 ) 8. CHARGING THE POLYURETHANE FOAM (See page PC-8 ) 9. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-43 ROCKER OUTER PANEL (CUT) REPLACEMENT 1. REMOVE ROCKER OUTER PANEL (a) Cut and join the parts at the locations as shown below. HINT: Take care not to damage the internal reinforcement. (b) After removing the center body outer pillar, remove the center body pillar lower reinforcement. [Cut and Join Location] Cut and Join Location 40 mm Cut and Join Location (Cut Location for Supply Parts) Cut and Join Location (Cut Location for Supply Parts) [Cut and Join Location] mm in. 40 1.57 F10175 BODY PANEL REPLACEMENT BP-44 Cut and Join Location 50 mm Center Body Pillar Lower Reinforcement mm 50 in. 1.97 F10176 BODY PANEL REPLACEMENT BP-45 2. INSTALL ROCKER OUTER PANEL HINT: Inspect the fitting of the front door and rear door, etc., before welding, since this affects the appearance of the finish. (a) After installing the center body pillar lower reinforcement, install the center body outer pillar. (b) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. Butt Weld F10177 BODY PANEL REPLACEMENT BP-46 Butt Weld Butt Weld Butt Weld F10178 3. MEASURING THE OPENING PORTION DIMENSIONS (See page BP-84 ) 4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 5. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-77 ROOF PANEL (ASSY): w/ Moon Roof REPLACEMENT 1. REMOVE ROOF PANEL (If resusing the roof panel reinforcement) Hemming Location Disc Sander F10205 BODY PANEL REPLACEMENT BP-78 2. INSTALL ROOF PANEL (a) Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back window frame. HINT:
Apply just enough sealer for the new parts to make contact.
For other sealing points, refer to section PC. (b) Bend the flange hem with a wooden hammer and dolly. HINT: Perform hemming three steps, being careful not to warp the panel. Cloth Tape Wooden Hammer Body Sealer F10206 3. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 4. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 5. CHARGING THE POLYURETHANE FOAM (See page PC-8 ) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-75 ROOF PANEL (ASSY): w/o Moon Roof REPLACEMENT 1. REMOVE ROOF PANEL F10203 BP-76 2. BODY PANEL REPLACEMENT INSTALL ROOF PANEL (a) Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back window frame. HINT:
Apply just enough sealer for the new parts to make contact.
For other sealing points, refer to section PC. Body Sealer F10204 3. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1 ) 4. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1 ) 5. CHARGING THE POLYURETHANE FOAM (See page PC-8 ) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. INTRODUCTION SS-17 ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual. ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g. Exempli Gratia (for Example) Ex. Except FWD Front Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in. inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without FOREWORD This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA AVALON. Applicable models: MCX20 series This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fenders of the TOYOTA model is bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collisiondamaged body components of the TOYOTA AVALON refer to the repair manuals. If you require the above manuals, please contact your TOYOTA Dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice. TOYOTA MOTOR CORPORATION INTRODUCTION SS-1 GENERAL REPAIR INSTRUCTIONS 1. WORK PRECAUTIONS (a) VEHICLE PROTECTION Glass Cover (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fire-proof covers. Seat Cover F10001A (b) SAFETY (1) Never stand in direct line with the chain when using a pulley on the body or frame, and be sure to attach a safety cable. WRONG F10002A (2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening totally. (3) If it is necessary to use a frame in the area of the fuel tank, first remove the tank and plug the fuel line. WRONG F10003A (c) SAFETY WORK CLOTHES (1) In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands. F10004 Code Name A Dust-Prevention Mask B Face Protector C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves INTRODUCTION SS-2 2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS (1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following chart. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must given to the property of the plastic. Code Material name Heat* resistant temperature limit °C (°F) Resistance to alcohol or gasoline Notes AAS Acrylonitrile Acrylic Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease.) Avoid gasoline and organic or aromatic solvents. ABS Acrylonitrile Butadiene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. AES Acylonitrile Ethylene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ASA Acrylonitrile Styrene Acrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. CAB Cellulose Acetate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. EPDM Ethylene Propylene 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. FRP Fiber Reinforced Plastics 180 (356) Alcohol and gasoline are harmless. Avoid alkali. EVA Ethylene Acetate 70 (158) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic oraromatic solvents. PA Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless. Avoid battery acid. PBT Polybutylene Terephthalate 160 (320) Alcohol and gasoline are harmless. Most solvents are harmless. PC Polycarbonate 120 (248) Alcohol is harmless. Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali. *Temperatures higher than those listed here may result in material deformation during repair. INTRODUCTION Code Material name Heat* resistant temperature limit °C (°F) Resistance to alcohol or gasoline SS-3 Notes PE Polyethylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PET Polyethylene Terephthalate 75 (167) Alcohol and gasoline are harmless. Avoid dipping in water. PMMA Polymethyl Methacrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Polyoxymethylene (Polyacetal) 100 (212) Alcohol and gasoline are harmless. Most solvents are harmless. PP Polypropylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PPO Modified Polyphenylene Oxide 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for quick wiping to remove grease. Polystyrene 60 (140) Alcohol and gasoline are harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PUR Polyurethane 80 (176) Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PVC Polyvinylchloride (Vinyl) 80 (176) Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. SAN Styrene Acrylonitrile 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents etc. TPO Thermoplastic Olefine 80 (176) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. TPU Thermoplastic Polyurethane 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. TOYOTA Super Olefine Polymer 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. Unsaturated Polyester 110 (233) Alcohol and gasoline are harmless. Avoid alkali. POM PS TSOP UP *Temperatures higher than those listed here may result in material deformation during repair. INTRODUCTION SS-4 3. LOCATION OF PLASTIC BODY PARTS Parts Name Code Radiator Grille ABS Front Bumper Cover TSOP Headlight PC/PP/UP Fog Light PP/PC Front Bumper Hole Cover ABS Outside Moulding PVC Body Rocker Moulding Panel PP/TSOP Outer Rear View Mirror ABS Outside Handle PC Back Door Outside Garnish ABS License Plate Light PC Back Light ASA/PMMA Rear Combination Light PMMA/AAS Rear Bumper Cover TSOP HINT:
Resin material differs with model. / Made up of 2 or more kinds of materials. INTRODUCTION SS-14 HANDLING PRECAUTIONS ON RELATED COMPONENTS 1. BRAKE SYSTEM The brake system is one of the most important safety components. Always follow the directions and notes given in section BR of the repair manual for the relevant model year when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system. 2. DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate repair of the body must also be done to ensure correct alignment. HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model during alignment and section DI of this manual. Component to be aligned 3. Section of repair manual for relevant model Front Wheels Suspension and Axle (SA) section Rear Wheels Suspension and Axle (SA) section COMPONENTS ADJACENT TO THE BODY PANELS Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.
Before repairing the body panels, remove their components or apply protective covers over the components.
Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool tip or blade to prevent damaging the components and the body paint.
Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas. HINT: Apply touch-up paint to any damaged paint surfaces.
Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side. 4. ECU (ELECTRONIC CONTROL UNIT) Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs.
Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery. When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all equipped with memory function, it is not possible to make a record of the memory contents. So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory.
Do not expose the ECUs to ambient temperatures above 80°C (176°F). NOTICE: If it is possible the ambient temperature may reach 80°C (176°F) or more, remove the ECUs from the vehicle before starting work.
Be careful not to drop the ECUs and not to apply physical shocks to them. INTRODUCTION SS-5 HOW TO USE THIS MANUAL 1. BODY PANEL REPLACEMENT THIS MANUAL BP-34 BODY PANEL REPLACEMENT QUARTER PANEL (CUT) REPLACEMENT 1. REMOVE QUARTER PANEL (a) Cut and join the part at the location as shown below Cut and Join Location 200 mm (Cut and Join Location) Cut and Join Location (Cut Location for supply parts) Braze (Cut and Join Location) REPLACEMENT PARTS QUARTER PANEL (CUT) Replacement method (ASSY) . . . . Assembly replacement (CUT) . . . . . Major cutting (less than 1/2 of parts used) (CUT-H) . . Half cutting (about 1/2 parts used) (CUT-P) . . . Partial cutting (most of parts used) Replacement Parts REMOVAL DIAGRAM Describes in detail removal of the damaged parts involving repair by cutting. REMOVAL GUIDE Provides additional information to more efficiently help you perform the removal. F10113 INTRODUCTION SS-6 BODY PANEL REPLACEMENT BP-35 2. INSTALL QUARTER PANEL HINT: Inspect the fitting of the rear door , luggage compartment door and rear combination light, etc., before welding, since this affects the appearance of the finish, (a) Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT:
Apply body sealer about 5 mm (0.20 in) from the flange, avoiding any oozing.
Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16 in.) in diameter.
For other sealing points, refer to section PC. Butt Weld Body Sealer Braze Butt Weld Body Sealer about 5 mm 3. 4. 5. 6. 7. (a) MEASURING THE OPENING PORTION DIMENSIONS (See page BP-XX) APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-XX) APPLYING SEALER TO THE REAR, LUGGAGE COMPARTMENT (Seepage PC-XX) CHARGING THE POLYURETHANE FOAM (See page PC-XX) APPLYING ANTI-RUST AGENT After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. INSTALLATION GUIDE Provides additional information to more efficiently help you perform the installation. INSTALLATION DIAGRAM Describes in detail installation of the new parts involving repair by welding and / or cutting, but excluding painting SYMBOLS See page SS-7 . ILLUSTRATION OF WELD POINTS Weld method and panel position symbols. See page SS-8 . F10114A INTRODUCTION 2. SS-7 SYMBOLS The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required. SYMBOLS MEANING ILLUSTRATION SAW CUT OR ROUGH CUT REMOVE BRAZE WELD POINTS SPOT WELD OR MIG PLUG WELD (See Page SS-8 ) CONTINUOUS MIG WELD (BUTT WELD OR TACK WELD) BRAZE BODY SEALER F10005A INTRODUCTION SS-8 3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE: REMOVAL INSTALLATION Braze Braze Weld points Weld points Remove weld point and panel position SYMBOL MEANING ILLUSTRATION Remove Weld Points Weld method and panel position SYMBOL MEANING ILLUSTRATION Spot Weld (Outside) (Middle) Mig Plug Weld (Inside) Spot MIG Weld HINT: Panel position symbols are as seen from the working posture. F10005A INTRODUCTION SS-15 PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS 1. HEAT REPAIR FOR BODY STRUCTURE PANELS Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are being sought after. At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve the strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If a body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized. 2. STRUCTURE PANEL KINKS A sharp deformation angle on the panel that cannot be returned to its original shape by pulling or hammering is called a kink. Since structure parts were designed to exhibit a 100% performance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are repaired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the part where the kink has occurred. SS-16 INTRODUCTION 3. IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts in maintaining a survival space for passengers in a side collision. For impact beam, we use special high tensile strength steel. The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives. Since these parts were designed to exhibit a 100% performance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are repaired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the door assembly when impact beam or bracket is damaged. INTRODUCTION SS-9 PROPER AND EFFICIENT WORK PROCEDURES 1. REMOVAL (a) PRE-REMOV AL MEASURING (1) Before removal or cutting operations, take measurements in accordance with the dimension diagram. Always use a puller to straighten a damaged body or frame. F10007 (b) CUTTING AREA Cutting Okay Reinforcement (1) Always cut in a straight line and avoid reinforced area. Corners F10008A (c) PRECAUTIONS FOR DRILLING OR CUTTING (1) Check behind any area to be drilled or cut to insure that there are no hoses, wires, etc., that may be damaged. HINT: See ”Handling Precautions on Related Components” on page SS-14 . WRONG F10009A (d) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage. HINT: See ”Handling Precautions on Related Components” on page SS-14 . F10010 INTRODUCTION SS-10 2. PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding. HINT: Spot welding will not provide sufficient durability for panels over 3 mm (0.12 in.) thick. Less than 3mm F10011A (b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) (1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through primer. F10012 (c) MAKING HOLES FOR PLUG WELDING (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding. REFERENCE: mm (in.) Puncher Thickness of welded portion Size of plug hole 1.0 (0.04) under 5 (0.20) φ over 1.0 (0.04) - 1.5 (0.06) 6.4 (0.26) φ over 1.5 (0.06) over 8 (0.31) φ over F10013A (d) SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS (1) When welding, there is a danger that electrical components will be damaged by the electrical current flowing through the body. (2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body. F10014 (e) ROUGH CUTTING OF JOINTS Air Saw 20~30mm Overlap F10015A (1) For joint areas, rough cut the new parts, leaving 20 30 mm (0.79 - 1.18 in.) overlap. INTRODUCTION 3. SS-11 INSTALLATION (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing underbody or engine components to insure correct assembly. After installation, confirm proper fit. Body Measurement Diagrams F10016A (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs. (2) Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than specified. WRONG F10017A (c) POST-WELDING REFINISHING (1) Always check the welded spots to insure they are secure. (2) When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this would weaken the weld. OKAY WRONG F10018A (d) SPOT WELD LOCATIONS (1) Try to avoid welding over previous spots. Tip Cutter F10019A (e) SPOT WELDING PRECAUTIONS Old Spot Locations New Spot Locations (1) The shape of the welding tip point has an effect on the strength of the weld. (2) Always insure that the seams and welding tip are free of paint. F10020A INTRODUCTION SS-12 4. Sealer Gun ANTI-RUST TREATMENT (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hoods, etc. F10021A (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from damage by flying stones, always apply sufficient undercoat to the bottom surface of the under body and inside of the wheel housings. F10022 5. ANTI-RUST TREATMENT AFTER PAINTING PROCESS (a) ANTI-RUST AGENT (WAX) APPLICATION (2) To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc. F10023 INTRODUCTION 6. SS-13 ANTI-RUST TREATMENT BY PAINTING REFERENCE: Painting prevents corrosion and protect the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, valance panel, etc. HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat.
Apply the anti-chipping paint after the top coat.
Apply the anti-chipping paint before the second coat. Anti-Chipping Paint Top Coat Second Coat Top Coat Second Coat Under coat (ED Primer) Steel Metal Anti-Chipping Paint Under coat (ED Primer) Steel Metal Fl0024A VIEWS OF THIS TEXT Scope of the repair work explanation
This text explains the welding panel replacement instructions from the vehicle’s white body condition. We have abbreviated the explanations for the removal and reinstallation of the equipment parts up to the white body condition and for the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel. Section categories
Each section has been divided as shown below. Section Title Contents Examples INTRODUCTION Explanation of general body repair. Views of weld panel replacement instructions. Cautionary items. Views of weld panel replacement instructions. BODY PANEL REPLACEMENT Body aligning measurements and instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts. Front side member replacement. Quarter panel replacement. Dimension diagrams. PAINT
COATING Scope and type of anti-rust treatment, etc. together with weld panel replacement. Under coat. Body sealer. Abbreviation of contents in this text.
The following essential procedures have been abbreviated. When actually working, conduct this work properly. (1) Jack and lift operations. (2) Clean and wash removed parts, if necessary. (3) Visual inspection. PC-6 PAINT COATING BODY PANEL UNDERCOATING AREAS HINT: 1. First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover. 2. Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are accidently coated, wipe off the coating immediately. 3. Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the entire area. 4. Do not coat parts which become hot, such as the tailpipe, or moving parts, such as the propeller shaft. 5. Besides the locations described below, apply undercoating to all weld points under the body to insure corrosion prevention. 6. Be sure to seal the edge of the flange of the member and bracket with undercoating. 7. If undercoat is damaged by peeling, cracks, etc., be sure to repair as necessary. 8. Before the undercoat apply sealer allowing rust prevention to be attained. F10212 REFERENCE: Referring to the notes above, undercoating should be applied according to the specifications for your country. PAINT COATING PC-7 BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS HINT: 1. Whenever adjusting the doors and hoods, apply anti-rust agent (wax) around the hinges. 2. Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part. 3. Wipe off the anti-rust agent immediately with a rag soaked in a grease, wax and silicone remover, if accidently applied to other areas. Fuel Filler Opening Lid Hinge Hood Hinge Luggage Compartment Door Door Hood Rocker Panel Front Door Lower Hinge Front Door Upper Hinge & Rear Door Hinge F10213 PC-10 PAINT COATING BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS HINT: 1. Anti-chipping paint should be applied to some areas before the second coat and to others after the top coat. 2. If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in grease, wax and silicone remover. Soft-Chip Primer Urethane Primer PVC Chipping Primer Jack Position F10216 PAINT COATING PC-1 BODY PANEL SEALING AREAS HINT: 1. Prior to applying body sealer, clean the area with a rag soaked in a grease, wax and silicone remover. 2. If weld-through primer was used, first wipe off any excess and coat with anti-corrosion primer before applying body sealer. 3. Wipe off excess body sealer with a rag soaked in a grease, wax and silicone remover. 4. If body sealer is damaged by peeling, cracks, etc., be sure to repair as necessary. 1. ENGINE COMPARTMENT Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing F10207 PAINT COATING PC-2 2. INSIDE Flat Surfacing Flat Surfacing Flat Surfacing F10208 PAINT COATING 3. PC-3 REAR LUGGAGE COMPARTMENT Flat Surfacing Flat Surfacing Flat Surfacing F10209 PAINT COATING PC-4 4. DOOR PARTS Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing Fiat Surfacing Flat Surfacing Flat Surfacing Flat Surfacing F10210 PAINT COATING PC-5 Flat Surfacing Flat Surfacing F10211 PC-8 PAINT COATING FOAMED MATERIAL APPLICATION AREAS The sections shown in the figure below are filled with foamed material to provide noise insullation. After repairing these sections or their peripheries, refill with foamed materials. HINT: 1. Use the service holes located on the reverse side of the body panel to refill with foamed materials. 2. When handling foamed material, follow the directions of the material’s manufacturer. F10214 PAINT COATING PC-9 SILENCER SHEET INSTALLATION AREAS Thickness of Asphalt Sheet 3.7 mm (0.146 in.) 3.0 mm (0.118 in.) 1.5 mm (0.059 in.) F10215 BODY PANEL REPLACEMENT BODY DIMENSION DRAWINGS ENGINE COMPARTMENT BP-81 BODY PANEL REPLACEMENT BODY OPENING AREAS (Side View-Rear) BP-83 BP-84 BODY PANEL REPLACEMENT BODY OPENING AREAS (Rear View) BP-82 BODY PANEL REPLACEMENT BODY OPENING AREAS (Side View-Front) BODY PANEL REPLACEMENT BP-79 GENERAL INFORMATION 1. BASIC DIMENSIONS (a) There are two typed of dimensions in the diagram. (1) (Three-dimensional distance)
F10115A Straight-line distance between the centers of two measuring points. (2) (Two-dimensional distance)
Horizontal distance in forward/rearward between the centers of two measuring points.
The height from an imaginary standard line. (b) Incases in which only one dimension is given, left and right are symmetrical. (c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference. (d) The line that connects the places listed below is the imaginary standard line when measuring the height. (The dimensions are printed in the text.) SYMBOL Name 1 The place that was lowered A mm from the under surface of the rocker panel centered on the front jack up point. 2 The place that was lowered B mm from the under surface of the rocker panel centered between 1 and 3. 3 The place that was lowered C mm from the under surface of the rocker panel centered on the rear jack up point. F10116A F10026A BP-80 BODY PANEL REPLACEMENT 2. MEASURING (a) (b) Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used. Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers. F10117A F10118A F10119A HINT: 1. The height of the left and right points must be equal. 2. Always calibrate the tracking gauge before measuring or after adjusting the pointer height. 3. Take care not to drop the tracking gauge or otherwise shock it. 4. Confirm that the pointers are securely in the holes. (c) When using a tape measure, avoid twists and bends in the tape. (d) When tracking a diagonal measurement from the front spring support inner hole to the suspension member upper rear installation hole, measure along the front spring support panel surface. BODY PANEL REPLACEMENT SUSPENSION CROSSMEMBER BP-87 BODY PANEL REPLACEMENT UNDER BODY BP-85 BP-86 UNDER BODY (Cont’d) BODY PANEL REPLACEMENT BP-58 BODY PANEL REPLACEMENT BODY LOWER BACK PANEL (ASSY) REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL F10187 2. BODY PANEL REPLACEMENT INSTALL BODY LOWER BACK PANEL BP-59 HINT: Inspect the fitting of the luggage compartment door and rear combination light, etc., before welding, since this attacts the appearance of the finish. F10188 3. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 4. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 5. APPLYING UNDER COATING (See page PC-6) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-33 CENTER BODY PILLAR (CUT) REPLACEMENT 1. REMOVE CENTER BODY PILLAR (a) Cut and join the parts at the locations as shown below. (b) Shift the each cut and join location of the pillar section. (center body outer pillar, center body pillar upper reinforcement and center body inner pillar.) (c) Shift the each cut and join location of the rocker section. (center body outer pillar and center body pillar lower reinforcement.) F10167 BP-34 BODY PANEL REPLACEMENT F10168 BODY PANEL REPLACEMENT 2. BP-35 INSTALL CENTER BODY PILLAR HINT: Inspect the fitting of the front door and rear door, etc., before welding since this affects the appearance of the finish. (a) Before temporarily installing the new parts, weld the center body inner pillar, center body pillar lower reinforcement and center body pillar upper reinforcement. (b) After welding the center body inner pillar, center body pillar lower reinforcement and center body pillar upper reinforcement to the vehicle, install the center body outer pillar. (c) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10169 BP-36 BODY PANEL REPLACEMENT F10170 3. MEASURING THE OPENING PORTION DIMENSIONS (See page BP-84) 4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 5. APPLYING UNDER COATING (See page PC-6) 6. CHARGING THE POLYURETHANE FOAM (See page PC-8) 7. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-18 BODY PANEL REPLACEMENT COWL TOP SIDE PANEL (ASSY) REPLACEMENT 1. REMOVE COWL TOP SIDE PANEL F10154 BODY PANEL REPLACEMENT 2. BP-19 INSTALL COWL TOP SIDE PANEL Tack Weld (30 mm) Tack Weld (20 mm each) Tack Weld (16 mm) Tack Weld (14 mm) F10155 3. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 4. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-5 FRONT CROSSMEMBER (ASSY) REPLACEMENT 1. REMOVE FRONT CROSSMEMBER F10144 BP-6 BODY PANEL REPLACEMENT 2. INSTALL FRONT CROSSMEMBER (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the hood lock support. F10145 3. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81) 4. MEASURING THE UNDERBODY DIMENSIONS (See page BP-85) 5. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-15 FRONT FENDER APRON (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1) 2. REMOVE COWL TOP SIDE PANEL (See page BP-18) 3. REMOVE FRONT FENDER APRON F10152 BP-16 BODY PANEL REPLACEMENT 4. INSTALL FRONT FENDER APRON HINT: Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish. (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Make sure each measurement is correct, as this parts affects the front wheel alignment. F10153 5. BODY PANEL REPLACEMENT MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81) 6. INSTALL COWL TOP SIDE PANEL (See page BP-18) 7. INSTALL RADIATOR UPPER SUPPORT (See page BP-1) 8. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 9. APPLYING UNDER COATING (See page PC-6) 10. BP-17 APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-24 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1) 2. REMOVE FRONT CROSSMEMBER SIDE GUSSET (See page BP-3) 3. REMOVE FRONT CROSSMEMBER (See page BP-5) 4. REMOVE COWL TOP SIDE PANEL (See page BP-18) 5. REMOVE FRONT FENDER APRON (See page BP-15) 6. REMOVE FRONT SIDE MEMBER (a) Leave the floor side member No.4 reinforcement to the vehicle, remove the front side member. F10158 BODY PANEL REPLACEMENT BP-25 F10159 BP-26 BODY PANEL REPLACEMENT 7. INSTALL FRONT SIDE MEMBER (a) Remove the floor side member No.4 reinforcement from the new parts of front side member. (b) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: Make sure each measurement is correct, as this parts affects the front wheel alignment. F10160 BODY PANEL REPLACEMENT BP-27 F10161 8. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81) 9. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85) 10. INSTALL FRONT FENDER APRON (See page BP-15) 11. INSTALL COWL TOP SIDE PANEL (See page BP-18) 12. INSTALL FRONT CROSSMEMBER (See page BP-5) 13. INSTALL FRONT CROSSMEMBER SIDE GUSSET (See page BP-3) 14. INSTALL RADIATOR UPPER SUPPORT (See page BP-1) 15. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 16. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-2) 17. APPLYING UNDER COATING (See page PC-6) 18. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 19. INSTALL FRONT FLOOR SILENCER SHEET (See page PC-9) BP-12 BODY PANEL REPLACEMENT FRONT APRON TO COWL SIDE UPPER MEMBER (ASSY) REPLACEMENT 1. REMOVE COWL TOP SIDE PANEL (See page BP-18) 2. REMOVE RADIATOR UPPER SUPPORT (See page BP-1) 3. REMOVE FRONT FENDER FRONT APRON (See page BP-9) 4. REMOVE FRONT APRON TO COWL SIDE UPPER MEMBER (a) After removing the front apron to cowl side lower member, remove the front apron to cowl side upper member. F10150 5. BODY PANEL REPLACEMENT INSTALL FRONT APRON TO COWL SIDE UPPER MEMBER BP-13 HINT: Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish. (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10151 BP-14 BODY PANEL REPLACEMENT 6. INSTALL FRONT FENDER FRONT APRON (See page BP-9) 7. INSTALL RADIATOR UPPER SUPPORT (See page BP-1) 8. INSTALL COWL TOP SIDE PANEL (See page BP-18) 9. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 10. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-28 BODY PANEL REPLACEMENT FRONT BODY PILLAR (CUT) REPLACEMENT 1. REMOVE COWL TOP SIDE PANEL (See page BP-18) 2. REMOVE FRONT BODY PILLAR (a) Cut and join the parts at the locations as shown below. HINT:
Shift the each cut and join locations of the outer pillar, pillar reinforcement and inner pillar.
Shift the each cut and join locations of the rocker outer panel and center body pillar lower reinforcement.
This part of the outer panel is reused, since the rocker panel section is cut off at the rear the outer panel supply part cutting position. 140 mm 50 mm 50 mm 60 mm 100 mm Center Body Pillar Lower Reinforcement F10162 BODY PANEL REPLACEMENT BP-29 F10163 BP-30 3. INSTALL FRONT BODY PILLAR BODY PANEL REPLACEMENT HINT: Inspect the fitting of the front door, front fender and windshield glass, etc., before welding, since this affects the appearance of the finish. (a) Before temporarily installing the new parts, weld the front pillar lower reinforcement, center body pillar lower reinforcement and front body inner pillar with standard points. (b) After welding the front pillar lower reinforcement, center body pillar lower reinforcement and front body inner pillar to the vehicle, install the outer pillar. (c) Temporarily install the new parts and measure each part in accordance with the body demension diagram. F10164 BODY PANEL REPLACEMENT BP-31 F10165 BP-32 BODY PANEL REPLACEMENT F10166 4. MEASURING OPENING PORTION DIMENSIONS (See page BP-84) 5. INSTALL COWL TOP SIDE PANEL (See page BP-18) 6. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 8. APPLYING UNDER COATING (See page PC-6) 9. CHARGING THE POLYURTHANE FOAM (See page PC-8) 10. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-3 FRONT CROSSMEMBER SIDE GUSSET (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1) 2. REMOVE FRONT CROSSMEMBER SIDE GUSSET F10142 BP-4 BODY PANEL REPLACEMENT 3. INSTALL FRONT CROSSMEMBER SIDE GUSSET (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10143 4. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81) 5. INSTALL RADIATOR UPPER SUPPORT (See page BP-1) 6. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 7. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-37 FRONT DOOR OUTER PANEL (ASSY) REPLACEMENT 1. REMOVE FRONT DOOR OUTER PANEL (a) Before removing the outer panel, make the installation position with a tape. (b) After grinding off the hemming location, remove the outer panel. F10171 BP-38 BODY PANEL REPLACEMENT 2. INSTALL FRONT DOOR OUTER PANEL (a) Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and back side of the new parts. HINT:
Apply just enough sealer for the reinforcement and side impact beam to touch the new panel. Apply sealer evenly around the flange area, about 10 mm (0.39 in.) from the edge, as shown.
For other sealing points, refer to section PC. (b) Bend the flange hem about 30 with a hammer and dolly, then fasten tightly with a hemming tool. HINT:
Perform hemming in three steps, being careful not to warp the panel.
If a hemming tool cannot be used, hem with a hammer and dolly. F10172 3. BODY PANEL REPLACEMENT APPLYING SEALER TO THE DOOR PARTS (See page PC-1) 4. APPLYING ANTI-RUST AGENT BP-39 (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-9 FRONT FENDER FRONT APRON (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1) 2. REMOVE FRONT FENDER FRONT APRON (a) Replace the fender apron plate at the same time. F10148 BP-10 BODY PANEL REPLACEMENT 3. INSTALL FRONT FENDER FRONT APRON (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10149 4. BODY PANEL REPLACEMENT MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81) 5. INSTALL RADIATOR UPPER SUPPORT (See page BP-1) 6. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 7. APPLYING UNDERCOATING (See page PC-6) 8. APPLYING ANTI-RUST AGENT BP-11 (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-20 BODY PANEL REPLACEMENT FRONT SIDE MEMBER (CUT-P) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT (See page BP-1) 2. REMOVE FRONT CROSSMEMBER SIDE GUSSET (See page BP-3) 3. REMOVE FRONT CROSSMEMBER (See page BP-5) 4. REMOVE FRONT SIDE MEMBER (a) Cut and join the parts at the locations as shown below. 340 mm 20 mm F10156A BODY PANEL REPLACEMENT BP-21 (b) LH only: After removing the battery carrier support, cut and join the front side member. HINT: Leave the reinforcement to the vehicle side. 20 mm 340 mm F10156B BP-22 5. INSTALL FRONT SIDE MEMBER BODY PANEL REPLACEMENT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10157A BODY PANEL REPLACEMENT BP-23 F10157B 6. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81) 7. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85) 8. INSTALL FRONT CROSSMEMBER (See page BP-5) 9. INSTALL FRONT CROSSMEMBER SIDE GUSSET (See page BP-3) 10. INSTALL RADIATOR UPPER SUPPORT (See page BP-1) 11. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 12. APPLYING ANTI-RUST AGENT (See page PC-7) (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-60 BODY PANEL REPLACEMENT LUGGAGE COMPARTMENT OPENING TROUGH (ASSY) REPLACEMENT 1. REMOVE LUGGAGE COMPARTMENT OPENING TROUGH F10189 2. BODY PANEL REPLACEMENT INSTALL LUGGAGE COMPARTMENT OPENING TROUGH BP-61 HINT: Inspect the fitting of the luggage compartment door and rear combination light, etc., before welding, since this affects the appearance of the finish. F10190 3. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 4. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 5. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-55 QUARTER WHEEL HOUSING OUTER PANEL (ASSY): Left Side REPLACEMENT 1. REMOVE QUARTER PANEL (See page BP-49) 2. REMOVE ROCKER OUTER EXTENSION (See page BP-47) 3. REMOVE QUARTER WHEEL HOUSING OUTER PANEL (a) Remove the roof side outer panel at the location shown in the below figure and remove the quarter wheel housing outer panel. F10185 BP-56 BODY PANEL REPLACEMENT 4. INSTALL QUARTER WHEEL HOUSING OUTER PANEL HINT: Temporarily install the quarter panel and inspect the fitting before welding, since this affects the appearance of the finish. (a) Determine the position of the new parts by the assembly marks of the inner and outer panels. F10186 5. BODY PANEL REPLACEMENT INSTALL ROCKER OUTER EXTENSION (See page BP-47) 6. INSTALL QUARTER PANEL (See page BP-49) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 8. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 9. APPLYING UNDER COATING (See page PC-6) 10. CHARGING THE POLYURETHANE FOAM (See page PC-6) 11. APPLYING ANTI-RUST AGENT BP-57 (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-49 QUARTER PANEL (CUT) REPLACEMENT 1. REMOVE QUARTER PANEL (a) Cut and join the parts at the locations as shown below. (b) Replace the fuel filler opening lid at the same time. F10181 BP-50 2. INSTALL QUATER PANEL BODY PANEL REPLACEMENT HINT: Inspect the fitting of the rear door, luggage compartment door and rear combination light, etc., before welding, since this affects the appearance of the finish. (a) Before temporarily installing the new parts, weld the quarter lock pillar reinforcement with standard points. (b) Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT:
Apply body sealer about 5 mm (0.20 in.) from the flange, avoiding any oozing.
Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16 in.) in diameter.
For other sealing points, refer to section PC. (c) Use warter proof rivets for the fuel opening lid installation. F10182A BODY PANEL REPLACEMENT BP-51 F10182B 3. MEASURING THE OPENING PORTION DIMENSIONS (See page BP-84) 4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 5. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 6. CHARGING THE POLYURETHANE FOAM (See page PC-8) 7. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-52 BODY PANEL REPLACEMENT QUARTER WHEEL HOUSING OUTER PANEL (ASSY): Right Side REPLACEMENT 1. REMOVE QUARTER PANEL (See page BP-49) 2. REMOVE ROCKER OUTER EXTENSION (See page BP-47) 3. REMOVE QUARTER WHEEL HOUSING OUTER PANEL (a) Remove the roof side outer panel at the location shown in below figure and remove the quarter wheel housing outer panel. F10183 4. BODY PANEL REPLACEMENT INSTALL QUARTER WHEEL HOUSING OUTER PANEL BP-53 HINT: Temporarily install the quarter panel and inspect the fitting before welding, since this affects the appearance of the finish. (a) Determine the position of the new parts by the assembly marks of the inner and outer panels. F10184 BP-54 BODY PANEL REPLACEMENT 5. INSTALL ROCKER EXTENSION (See page BP-47) 6. INSTALL QUARTER PANEL (See page BP-49) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 8. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 9. APPLYING UNDER COATING (See page PC-6) 10. CHARGING THE POLYURETHANE FOAM (See page PC-8) 11. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-7 RADIATOR SUPPORT (ASSY) REPLACEMENT 1. REMOVE RADIATOR SUPPORT (a) After removing the front side member extension, remove the radiator support. F10146 BP-8 2. INSTALL RADIATOR SUPPORT BODY PANEL REPLACEMENT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10147 3. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81) 4. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85) 5. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-1 RADIATOR UPPER SUPPORT (ASSY) REPLACEMENT 1. REMOVE RADIATOR UPPER SUPPORT F10140 BP-2 BODY PANEL REPLACEMENT 2. INSTALL RADIATOR UPPER SUPPORT (a) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. HINT: First install the hood lock spport. 3. MEASURING THE ENGINE COMPARTMENT DIMENSIONS (See page BP-81) 4. APPLYING SEALER TO THE ENGINE COMPARTMENT (See page PC-1) 5. APPLYING ANTI-RUST AGENT F10141 (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-40 BODY PANEL REPLACEMENT REAR DOOR OUTER PANEL (ASSY) REPLACEMENT 1. REMOVE REAR DOOR OUTER PANEL (a) Before removing the outer panel, make the installation position with a tape. (b) After grinding off the hemming location, remove the outer panel. F10173 2. BODY PANEL REPLACEMENT INSTALL FRONT DOOR OUTER PANEL BP-41 (a) Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and back side of the new parts. HINT:
Apply just enough sealer for the reinforcement and side impact beam to touch the new panel. Apply sealer evenly around the flange area, about 10 mm (0.39 in.) from the edge, as shown.
For other sealing points, refer to section PC. (b) Bend the flange hem about 30 with a hammer and dolly, then fasten tightly with a hemming tool. HINT:
Perform hemming in three steps, being careful not to warp the panel.
If a hemming tool cannot be used, hem with a hammer and dolly. F10174 BP-42 BODY PANEL REPLACEMENT 3. APPLYING SEALER TO THE DOOR PARTS (See page PC-1) 4. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BP-64 BODY PANEL REPLACEMENT REAR FLOOR PAN (ASSY) REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58) 2. REMOVE REAR FLOOR NO.3 CROSSMEMBER (See page BP-62) 3. REMOVE REAR FLOOR PAN (a) After removing the rear floor pan reinforcement, remove the rear floor pan. F10193 BODY PANEL REPLACEMENT 4. BP-65 INSTALL REAR FLOOR PAN F10194 BP-66 BODY PANEL REPLACEMENT 5. INSTALL REAR FLOOR NO.3 CROSSMEMBER (See page BP-62) 6. INSTALL BODY LOWER BACK PANEL (See page BP-58) 7. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 8. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 9. APPLYING UNDER COATING (See page PC-6) 10. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 11. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9) 12. INSTALL REAR FLOOR SILENCER NO.2 SHEET (See page PC-9) BODY PANEL REPLACEMENT BP-67 REAR FLOOR SIDE PANEL (ASSY): Right Side REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58) 2. REMOVE REAR FLOOR NO.3 CROSSMEMBER (See page BP-62) 3. REMOVE REAR FLOOR PAN (See page BP-64) 4. REMOVE REAR FLOOR SIDE PANEL F10195 BP-68 BODY PANEL REPLACEMENT 3. INSTALL REAR FLOOR SIDE PANEL F10196 4. INSTALL REAR FLOOR PAN (See page BP-64) 5. INSTALL REAR FLOOR NO.3 CROSSMEMBER (See page BP-62) 6. INSTALL BODY LOWER BACK PANEL (See page BP-58) 7. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 8. APPLYING UNDER COATING (See page PC-6) 9. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 10. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9) 11. INSTALL REAR FLOOR SILENCER NO.2 SHEET (See page PC-9) BODY PANEL REPLACEMENT BP-69 REAR FLOOR SIDE PANEL (ASSY): Left Side REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58) 2. REMOVE REAR FLOOR NO.3 CROSSMEMBER (See page BP-62) 3. REMOVE REAR FLOOR PAN (See page BP-64) 4. REMOVE REAR FLOOR SIDE PANEL F10197 BP-70 BODY PANEL REPLACEMENT 3. INSTALL REAR FLOOR SIDE PANEL F10198 4. INSTALL REAR FLOOR PAN (See page BP-64) 5. INSTALL REAR FLOOR NO.3 CROSSMEMBER (See page BP-62) 6. INSTALL BODY LOWER BACK PANEL (See page BP-58) 7. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 8. APPLYING UNDER COATING (See page PC-6) 9. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 10. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9) 11. INSTALL REAR FLOOR SILENCER NO.2 SHEET (See page PC-9) BODY PANEL REPLACEMENT BP-71 REAR FLOOR SIDE REAR MEMBER (ASSY) REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58) 2. REMOVE REAR FLOOR NO.3 CROSSMEMBER (See page BP-62) 3. REMOVE REAR FLOOR SIDE REAR MEMBER F10199 BP-72 BODY PANEL REPLACEMENT 4. INSTALL REAR FLOOR SIDE REAR MEMBER (a) When temporarily installing the new parts, determine the installation position by the assembly mark. Then, measure each part in accordance with the body dimension diagram. F10200 5. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85) 6. INSTALL REAR FLOOR NO.3 CROSSMEMBER (See page BP-62) 7. INSTALL BODY LOWER BACK PANEL (See page BP-58) 8. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 9. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 10. APPLYING UNDER COATING (See page PC-6) 11. APPLYING AUTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. 12. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9) BODY PANEL REPLACEMENT BP-73 REAR FLOOR NO.2 CROSSMEMBER (ASSY) REPLACEMENT 1. REMOVE REAR FLOOR NO.2 CROSSMEMBER F10201 BP-74 BODY PANEL REPLACEMENT 2. INSTALL REAR FLOOR NO.2 CROSSMEMBER (a) Temprarily install the new parts and measure each part in accordance with the body dimension diagram. F10202 3. MEASURING THE UNDER BODY DIMENSIONS (See page BP-85) 4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 5. APPLYING UNDER COATING (See page PC-6) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structoral weld spots. 7. INSTALL CENTER FLOOR SILENCER SHEET (See page PC-9) 8. INSTALL REAR FLOOR SILENCER SHEET (See page PC-9) BP-62 BODY PANEL REPLACEMENT REAR FLOOR NO.3 CROSSMEMBER (ASSY) REPLACEMENT 1. REMOVE BODY LOWER BACK PANEL (See page BP-58) 2. REMOVE REAR FLOOR NO.3 CROSSMEMBER F10191 3. BODY PANEL REPLACEMENT INSTALL REAR FLOOR NO.3 CROSSMEMBER BP-63 F10192 4. INSTALL BODY LOWER BACK PANEL (See page BP-58) 5. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 6. APPLYING UNDER COATING (See page PC-6) 7. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-47 ROCKER OUTER EXTENSION (CUT) REPLACEMENT 1. REMOVE QUARTER PANEL (See page BP-49) 2. REMOVE ROCKER OUTER EXTENSION (a) Cut and join the parts at the location as shown below. F10179 BP-48 BODY PANEL REPLACEMENT 3. INSTALL ROCKER OUTER EXTENSION HINT: Temporarily install the quarter panel and inspect the fitting before welding, since this affects the appearance of the finish. F10180 4. INSTALL QUARTER PANEL (See page BP-49) 5. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 6. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 7. APPLYING UNDER COATING (See page PC-6) 8. CHARGING THE POLYURETHANE FOAM (See page PC-8) 9. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-43 ROCKER OUTER PANEL (CUT) REPLACEMENT 1. REMOVE ROCKER OUTER PANEL (a) Cut and join the parts at the locations as shown below. HINT: Take care not to damage the internal reinforcement. (b) After removing the center body outer pillar, remove the center body pillar lower reinforcement. 40 mm F10175 BP-44 BODY PANEL REPLACEMENT F10176 BODY PANEL REPLACEMENT 2. BP-45 INSTALL ROCKER OUTER PANEL HINT: Inspect the fitting of the front door and rear door, etc., before welding, since this affects the appearance of the finish. (a) After installing the center body pillar lower reinforcement, install the center body outer pillar. (b) Temporarily install the new parts and measure each part in accordance with the body dimension diagram. F10177 BP-46 BODY PANEL REPLACEMENT F10178 3. MEASURING THE OPENING PORTION DIMENSIONS (See page BP-84) 4. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 5. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-77 ROOF PANEL (ASSY): w/ Moon Roof REPLACEMENT 1. REMOVE ROOF PANEL F10205 BP-78 2. INSTALL ROOF PANEL BODY PANEL REPLACEMENT (a) Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back window frame. HINT:
Apply just enough sealer for the new parts to make contact.
For other sealing points, refer to section PC. (b) Bend the flange hem with a wooden hammer and dolly. HINT: Perform hemming three steps, being careful not to warp the panel. F10206 3. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 4. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 5. CHARGING THE POLYURETHANE FOAM (See page PC-8) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT BP-75 ROOF PANEL (ASSY): w/o Moon Roof REPLACEMENT 1. REMOVE ROOF PANEL F10203 BP-76 2. INSTALL ROOF PANEL BODY PANEL REPLACEMENT (a) Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel reinforcement and back window frame. HINT:
Apply just enough sealer for the new parts to make contact.
For other sealing points, refer to section PC. F10204 3. APPLYING SEALER TO THE INSIDE OF THE VEHICLE (See page PC-1) 4. APPLYING SEALER TO THE REAR LUGGAGE COMPARTMENT (See page PC-1) 5. CHARGING THE POLYURETHANE FOAM (See page PC-8) 6. APPLYING ANTI-RUST AGENT (a) After applying the top coat layer, apply the anti-rust agent to the inside of the necked section structural weld spots. INTRODUCTION SS-17 ABBREVIATIONS USED IN THIS MANUAL For convenience, the following abbreviations are used in this manual. ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g. Exempli Gratia (for Example) Ex. Except FWD Front Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in. inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without FOREWORD This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA AVALON. Applicable models: MCX20 series This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fenders of the TOYOTA model is bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collisiondamaged body components of the TOYOTA AVALON refer to the repair manuals. If you require the above manuals, please contact your TOYOTA Dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice. INTRODUCTION SS-1 GENERAL REPAIR INSTRUCTIONS 1. WORK PRECAUTIONS (a) VEHICLE PROTECTION (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fire-proof covers. F10001A (b) SAFETY (1) Never stand in direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable. F10002A (2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening totally. (3) If it is necessary to use a frame in the area of the fuel tank, first remove the tank and plug the fuel line. F10003A (c) F10004 SAFETY WORK CLOTHES (1) In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands. Code Name A Dust-Prevention Mask B Face Protector C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves SS-2 2. INTRODUCTION HANDLING PRECAUTIONS OF PLASTIC BODY PARTS (1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following chart. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must given to the property of the plastic. Code Material name Heat* resistant temperature limit C (F) Resistance to alcohol or gasoline Notes AAS Acrylonitrile Acrylic Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ABS Acrylonitrile Butadiene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. AES Acylonitrile Ethylene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ASA Acrylonitrile Styrene Acrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. CAB Cellulose Acetate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. EPDM Ethylene Propylene 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. FRP Fiber Reinforced Plastics 180 (356) Alcohol and gasoline are harmless. Avoid alkali. EVA Ethylene Acetate 70 (158) Alcohol is harmless if applid only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic oraromatic solvents. Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless. Avoid battery acid. PBT Polybutylene Terephthalate 160 (320) Alcohol and gasoline are harmless. Most solvents are harmless. PC Polycarbonate 120 (248) Alcohol is harmless. Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali. PA *Temperatures higher than those listed here may result in material deformation during repair. INTRODUCTION Code Material name Heat* resistant temperature limit C (F) Resistance to alcohol or gasoline SS-3 Notes PE Polyethylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PET Polyethylene Terephthalate 75 (167) Alcohol and gasoline are harmless. Avoid dipping in water. PMMA Polymethyl Methacrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Polyoxymethylene (Polyacetal) 100 (212) Alcohol and gasoline are harmless. Most solvents are harmless. PP Polypropylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PPO Modified Polyphenylene Oxide 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for quick wiping to remove grease. Polystyrene 60 (140) Alcohol and gasoline are harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PUR Polyurethane 80 (176) Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PVC Polyvinylchloride (Vinyl) 80 (176) Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. SAN Styrene Acrylonitrile 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents etc. TPO Thermoplastic Olefine 80 (176) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. TPU Thermoplastic Polyurethane 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. TOYOTA Super Olefine Polymer 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. Unsaturated Polyester 110 (233) Alcohol and gasoline are harmless. Avoid alkali. POM PS TSOP UP *Temperatures higher than those listed here may result in material deformation during repair. SS-4 3. INTRODUCTION LOCATION OF PLASTIC BODY PARTS Parts Name Code Radiator Grille ABS Front Bumper Cover TSOP Headlight PC/PP/UP Fog Light PP/PC Front Bumper Hole Cover ABS Outside Moulding PVC Body Rocker Moulding Panel PP/TSOP Outer Rear View Mirror ABS Outside Handle PC Back Door Outside Garnish ABS License Plate Light PC Back Light ASA/PMMA Rear Conbination Light PMMA/AAS Rear Bumper Cover TSOP HINT:
Resin material differs with model. / Made up of 2 or more kinds of materials. SS-14 INTRODUCTION HANDLING PRECAUTIONS ON RELATED COMPONENTS 1. BRAKE SYSTEM The brake system is one of the most important safety components. Always follow the directions and notes given in section BR of the repair manual for the relevant model year when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system. 2. DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate repair of the body must also be done to ensure correct alignment. HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model during alignment and section DI of this manual. 3. Component to be aligned Section of repair manual for relevant model Front Wheels Suspension and Axle (SA) section Rear Wheels Suspension and Axle (SA) section COMPONENTS ADJACENT TO THE BODY PANELS Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.
Before repairing the body panels, remove their components or apply protective covers over the components.
Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool tip or blade to prevent damaging the components and the body paint.
Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas. HINT: Apply touch-up paint to any damaged paint surfaces.
Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side. 4. ECU (ELECTRONIC CONTROL UNIT) Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs.
Before starting electric welding operations, disconnect the negative (-) terminal cable from the battery. When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all equipped with memory function, it is not possible to make a record of the memory contents. So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory.
Do not expose the ECUs to ambient temperatures above 80C (176F). NOTICE: If it is possible the ambient temperature may reach 80C (176F) or more, remove the ECUs from the vehicle before starting work.
Be careful not to drop the ECUs and not to apply physical shocks to them. INTRODUCTION SS-5 HOW TO USE THIS MANUAL 1. BODY PANEL REPLACEMENT THIS MANUAL F10113 SS-6 INTRODUCTION F10114A INTRODUCTION 2. SS-7 SYMBOLS The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required. F10005A SS-8 INTRODUCTION 3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE: F10005A INTRODUCTION SS-15 PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS 1. HEAT REPAIR FOR BODY STRUCTURE PANELS Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are being sought after. At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve the strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If a body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized. 2. STRUCTURE PANEL KINKS A sharp deformation angle on the panel that cannot be returned to its original shape by pulling or hammering is called a kink. Since structure parts were designed to exhibit a 100% performance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are repaired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the part where the kink has occurred. SS-16 INTRODUCTION 3. IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts in maintaining a survival space for passengers in a side collision. For impact beam, we use special high tensile strength steel. The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives. Since these parts were designed to exhibit a 100% performance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are repaired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the door assembly when impact beam or bracket is damaged. INTRODUCTION SS-9 PROPER AND EFFICIENT WORK PROCEDURES 1. REMOVAL (a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measurements in accordance with the dimension diagram. Always use a puller to straighten a damaged body or frame. F10007 (b) CUTTING AREA (1) Always cut in a straight line and avoid reinforced area. F10008A (c) PRECAUTIONS FOR DRILLING OR CUTTING (1) Check behind any area to be drilled or cut to insure that there are no hoses, wires, etc., that may be damaged. HINT: See “Handling Precautions on Related Components” on page SS-14. F10009A (d) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage. HINT: See “Handling Precautions on Related Components” on page SS-14. F10010 SS-10 INTRODUCTION 2. PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding. HINT: Spot welding will not provide sufficient durability for panels over 3 mm (0.12 in.) thick. F10011A (b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) (1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through primer. F10012 (c) MAKING HOLES FOR PLUG WELDING (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding. REFERENCE: mm (in.) Thickness of welded portion Size of plug hole 1.0 (0.04) under 5 (0.20) ø over 1.0 (0.04) - 1.5 (0.06) 6.4 (0.26) ø over 1.5 (0.06) over 8 (0.31) ø over F10013A (d) SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS (1) When welding, there is a danger that electrical components will be damaged by the electrical current flowing through the body. (2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body. F10014 (e) ROUGH CUTTING OF JOINTS (1) For joint areas, rough cut the new parts, leaving 20 - 30 mm (0.79 - 1.18 in.) overlap. F10015A INTRODUCTION 3. SS-11 INSTALLATION (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing underbody or engine components to insure correct assembly. After installation, confirm proper fit. F10016A (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs. (2) Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than specified. F10017A (c) POST-WELDING REFINISHING (1) Always check the welded spots to insure they are secure. (2) When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this would weaken the weld. F10018A (d) SPOT WELD LOCATIONS (1) Try to avoid welding over previous spots. F10019A (e) SPOT WELDING PRECAUTIONS (1) The shape of the welding tip point has an effect on the strength of the weld. (2) Always insure that the seams and welding tip are free of paint. F10020A SS-12 INTRODUCTION 4. ANTI-RUST TREATMENT (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hoods, etc. F10021A (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from damage by flying stones, always apply sufficient undercoat to the bottom surface of the under body and inside of the wheel housings. F10022 5. ANTI-RUST TREATMENT AFTER PAINTING PROCESS (a) ANTI-RUST AGENT (WAX) APPLICATION (2) To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc. F10023 INTRODUCTION 6. SS-13 ANTI-RUST TREATMENT BY PAINTING REFERANCE: Painting prevents corrosion and protect the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, valance panel, etc. HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat. F10024A VIEWS OF THIS TEXT Scope of the repair work explanation
This text explains the welding panel replacement instructions from the vehicle’s white body condition. We have abbreviated the explanations for the removal and reinstallation of the equipment parts up to the white body condition and for the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel. Section categories
Each section has been divided as shown below. Section Title Contents Examples INTRODUCTION Explanation of general body repair. Views of weld panel replacement instructions. Cautionary items. Views of weld panel replacement instructions. BODY PANEL REPLACEMENT Body aligning measurements and instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts. Front side member replacement. Quarter panel replacement. Dimension diagrams. PAINT
COATING Scope and type of anti-rust treatment, etc. together with weld panel replacement. Under coat. Body sealer. Abbreviation of contents in this text.
The following essential procedures have been abbreviated. When actually working, conduct this work properly. (1) Jack and lift operations. (2) Clean and wash removed parts, if necessary. (3) Visual inspection. PC-6 PAINT
COATING BODY PANEL UNDERCOATING AREAS HINT: 1. First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover. 2. Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are accidently coated, wipe off the coating immediately. 3. Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the entire area. 4. Do not coat parts which become hot, such as the tailpipe, or moving parts, such as the propeller shaft. 5. Besides the locations described below, apply undercoating to all weld points under the body to insure corrosion prevention. 6. Be sure to seal the edge of the flange of the member and bracket with undercoating. 7. If undercoat is damaged by peeling, cracks, etc., be sure to repair as necessary. 8. Before the undercoat apply sealer allowing rust prevention to be attaind. F10212 REFERENCE: Referring to the notes above, undercoating should be applied according to the specifications for your country. PAINT
COATING PC-7 BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS HINT: 1. Whenever adjusting the doors and hoods, apply anti-rust agent (wax) around the hinges. 2. Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part. 3. Wipe off the anti-rust agent immediately with a rag soaked in a grease, wax and silicone remover, if accidently applied to other areas. F10213 PC-10 PAINT
COATING BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS HINT: 1. Anti-chipping paint should be applide to some areas before the second coat and to others after the top coat. 2. If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in grease, wax and silicone remover. F10216 PAINT
COATING PC-1 BODY PANEL SEALING AREAS HINT: 1. Prior to applying body sealer, clean the area with a rag soaked in a grease, wax and silicone remover. 2. If weld-through primer was used, first wipe off any excess and coat with anti-corrosion primer before applying body sealer. 3. Wipe off excess body sealer with a rag soaked in a grease, wax and silicone remover. 4. If body sealer is damaged by peeling, cracks, etc., besure to repair as necessary. 1. ENGINE COMPARTMENT F10207 PC-2 2. PAINT
COATING INSIDE F10208 PAINT
COATING 3. PC-3 REAR LUGGAGE COMPARTMENT F10209 PC-4 4. PAINT
COATING DOOR PARTS F10210 PAINT
COATING PC-5 F10211 PC-8 PAINT
COATING FOAMED MATERIAL APPLICATION AREAS The sections shown in the figure below are filled with foamed material to provide noise insullation. After repairing these sections or their peripheries, refill with foamed materials. HINT: 1. Use the service holes located on the reverse side of the body panel to refill with foamed materials. 2. When handling foamed material, follow the directions of the material’s manufacturer. F10214 PAINT
COATING PC-9 SILENCER SHEET INSTALLATION AREAS F10215 ABBREVIATIONS D ABBREVIATIONS The following abbreviations are used in this manual. ABS = Anti-Lock Brake System A/C = Air Conditioning ACIS = Acoustic Control Induction System ACM = Active Control Engine Mount A/T = Automatic Transaxle BA = Brake Assist COMB. = Combination EC = Electrochromic ECU = Electronic Control Unit ESA = Electronic Spark Advance EVAP = Evaporative Emission FL = Fusible Link J/B = Junction Block LH = Left-Hand O/D = Overdrive R/B = Relay Block RH = Right-Hand SFI = Sequential Multiport Fuel Injection SRS = Supplemental Restraint System SW = Switch TEMP. = Temperature TRAC = Traction Control VSC = Vehicle Skid Control VSV = Vacuum Switching Valve VVT = Variable Valve Timing w/ = With w/o = Without ∗ The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being abbreviations. 2001 AVALON (EWD431U) 17 K CONNECTOR LIST A1 A2 A3 A4 A5 BLACK GRAY GRAY GRAY GRAY 1 2 1 1 2 2 2 3 1 1 4 7 9 3 4 3 5 6 8 10 11 2 A6 A7 A8 A9 GRAY BLACK GRAY GRAY 1 2 3 4 5 6 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 31 30 29 28 27 19 18 17 1 2 1 16 A10 A11 A12 A13 A14 DARK GRAY DARK GRAY YELLOW YELLOW BLACK 1 2 3 4 1 2 3 4 1 A15 2 1 A16 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 14 15 16 17 18 19 20 21 22 23 24 25 26 9 10 11 12 13 14 15 16 1 2 A17 A18 BLACK BLACK 12 1 2 3 2 3 4 A19 12 A20 28 27 26 25 24 23 22 55 54 53 52 51 50 49 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 48 47 46 45 44 43 42 41 40 39 38 37 36 35 6 5 4 3 2 1 34 33 32 31 30 29 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 A21 A22 A23 A24 A25 (Automatic A/C) 1 2 3 456 78 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 2001 AVALON (EWD431U) 298 1 2 3 4 5 2 K A25 A26 A27 A28 (Manual A/C) BLACK YELLOW YELLOW BLACK 1 2 3 4 5 6 7 8 1 2 B1 1 B2 A30 2 1 2 1 1 2 3 4 B3 GRAY 1 2 A29 B4 BLACK 2 1 2 1 2 1 2 3 4 5 6 3 4 12 13 14 15 16 17 18 19 20 21 22 23 24 25 B5 B6 1 B7 2 1 2 7 8 9 10 11 B8 B9 1 2 1 2 1 2 3 4 5 6 7 8 9 101112 13 14 15 16171819 2021222324 25 C1 C2 C3 C4 C5 BLACK BLACK BLACK BLACK YELLOW 1 2 1 2 1 2 1 2 3 4 A B 1 2 3 4 5 6 7 8 9 101112 1 2 3 C6 C7 YELLOW YELLOW A B A 4 5 6 7 8 9 1011121314151617 B 1 2 3 4 5 6 C8 C9 1 2 1 2 3 4 5 6 7 8 9 10 11 3 4 12 13 14 15 16 17 18 19 20 21 22 7 8 9 101112 1819 2021 22 23 2425 26 27 28 C10 C11 C12 C13 BLACK 1 2 3 4 5 6 7 8 9 1 2 3 456 78 1 2 3 4 5 6 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 1112131415 16 17 2001 AVALON (EWD431U) 299 K CONNECTOR LIST ∗ 1 : w/ Driving Position Memory ∗ 2 : w/o Driving Position Memory C14 C15 D1 BLACK BLACK 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 1 2 3 9 10 11 12 13 14 15 16 10 11 12 131415 16 17 18 5 6 4 19 7 8 9 12 13 14 D2 10 11 20 15 16 17 21 22 23 D3 DARK GRAY 17 16 18 D4 D5 ORANGE ORANGE 1 2 3 1 2 3 15 14 13 12 11 10 9 8 7 16 15 14 13 12 11 10 9 6 5 4 3 2 1 8 7 6 5 4 3 2 1 D6 D7 ORANGE BLACK 1 2 3 1 2 D8 1 2 3 4 5 D13 D14 1 1 D9 D10 GRAY GRAY 1 1 2 2 D11 D12 1 1 D15 D16 D17 BLACK BLACK BLACK 1 2 3 4 1 2 3 4 1 2 3 4 5 6 D18 D19 D19 BLACK (∗ 1) GRAY (∗ 2) 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 101112 13 1 2 3 4 5 6 7 8 9 101112 13 14 15 16171819 14 15 16171819 2021222324 25 2001 AVALON (EWD431U) 300 2021222324 25 K ∗ 1 : w/ Driving Position Memory ∗ 2 : w/o Driving Position Memory E1 E2 E3 GRAY DARK GRAY BLACK E4 E5 1 2 1 2 3 4 5 6 1 2 1 2 E6 3 4 5 6 7 8 9 1 2 3 4 5 6 7 10 11 12 13 14 15 16 17 18 19 20 21 8 9 10 11 12 13 14 15 16 22 23 24 25 26 17 18 19 20 21 E7 27 28 29 30 31 E8 22 23 24 F1 GRAY 1 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 13 14 15 20 21 22 16 17 16 17 7 8 9 1 2 3 4 5 23 24 25 26 27 28 2 6 7 18 19 20 21 22 F2 F3 F4 F5 GRAY GRAY GRAY BLACK F6 1 1 2 1 2 3 1 2 3 1 2 3 4 5 F7 F8 F9 1 1 F10 F11 F12 1 2 3 4 5 1 1 1 F13 F14 F14 (∗ 1) GRAY (∗ 2) 1 1 2 3 4 2 9 10 11 12 13 14 15 16 17 18 19 20 F15 2 5 6 7 G1 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 G2 BLACK G3 H1 BLACK BROWN 1 1 2 4 3 1 2 1 3 2 1 2 5 2001 AVALON (EWD431U) 301 K CONNECTOR LIST H2 H3 H4 H5 H6 H7 BLACK BROWN BROWN BLACK BLACK BLACK 1 1 2 1 2 1 1 1 2 2 3 4 5 6 7 8 9 10 H8 H9 H10 H11 I1 DARK GRAY 1 BLACK 2 3 1 1 2 3 4 5 6 7 8 9 4 4 10 11 12 13 14 15 16 17 18 1 2 3 5 2 1 2 3 6 7 8 I2 I3 I4 I5 BLACK BLACK BLACK BLACK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 I6 I7 I8 I9 I10 I11 BLACK BLACK GRAY GRAY GRAY GRAY 1 2 3 4 1 2 3 4 12 12 12 12 I12 I13 GRAY GRAY 12 12 I14 I15 I16 I17 BLACK 1 2 1 2 1 2 3 4 5 6 7 8 1 2 J1 J2 J3 J4 GRAY GRAY BLUE GRAY A A A B B A A A B B B B B A A A B B A A A B B B B B A B B C C A A B DD D C C A A A B B A A A B B B B B J5 A A B C C A A B B B B C C J6 A A B C C A A B B B B C C J7 J8 BLACK BLUE A A A A A A A A A A A A A A B B C C A A B DD D C C 2001 AVALON (EWD431U) 302 K J9 J10 A A A A A A A A J14 A A A A A L3 1 A A A J13 AA A AAAAA A B B C C A A B DD D C C A K1 K2 K3 L1 L2 DARK GRAY GRAY BLACK BLACK 1 2 1 2 1 2 1 L4 2 J12 DARK GRAY 1 A A B C C A A B B B B C C 1 A J11 L5 L6 1 2 3 4 5 6 7 8 9 101112 2 L7 L8 L9 BLACK GRAY GRAY 1 1 2 2 1 1 L10 L11 M1 M2 BLACK BLACK M3 1234 2 1 2 3 4 5 1 1 1 2 3 4 5 6 7 8 9 10 11 3 2 12 13 14 15 16 17 18 19 20 21 22 M4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 M5 M6 BLACK GRAY 1 2 3 4 5 6 7 8 9 10 11 1213141516171819 20 1 2 3 4 5 6 7 8 9 10 M7 M8 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 N2 N3 1 1 2 M9 N1 BLUE GRAY 1 2 3 1 2 3 4 5 6 7 8 9 10 O1 O2 O3 O3 BLACK GRAY (Floor Shift) BLUE (Columm Shift) 1 1 2 3 4 1 2 3 1 2 2001 AVALON (EWD431U) 303 K CONNECTOR LIST ∗ 1 : w/ Driving Position Memory ∗ 2 : w/o Driving Position Memory P1 P2 GRAY BLACK P3 P4 P5 P6 1 1 7 5 6 2 8 1 3 4 9 10 P7 P8 1234 2 1 1 2 P9 P10 P11 P12 1234 1 2 1 1 2 3 3 4 5 6 2 1 3 4 5 6 1 2 2 3 4 3 4 5 6 5 6 P13 P14 1 2 P15 1 2 P16 P17 P18 YELLOW YELLOW (∗ 1) GRAY 1 2 1 2 1 2 P18 3 4 5 6 7 8 9 10 1 2 P19 P20 P21 (∗ 2) BLACK 1 2 3 4 1 2 5 6 7 8 9 10 3 4 1 2 5 6 7 8 9 10 5 6 3 4 7 8 1 2 3 4 5 6 7 8 9 101112 13 9 10 14 15 16171819 P22 P23 BLUE GREEN P24 1 2 1 2 1 2 P29 P30 BLUE GREEN 1 2 3 1 2 3 P25 P26 ORANGE GREEN 1 2 1 2 P31 1 2 3 P27 1 2 P32 R1 ORANGE GRAY 1 2 3 R4 R3 2 R5 BLACK 1 2 1 2 3 4 5 6 7 8 9 10 11 1213141516171819 20 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 2001 AVALON (EWD431U) 304 P28 ORANGE 1 R2 2021222324 25 1 2 K ∗ 1 : w/ Driving Position Memory ∗ 4 : w/o Driving Position Memory and w/o Mirror Heater ∗ 3 : w/o Driving Position Memory and w/ Mirror Heater ∗ 5 : Taiwan R6 R7 R8 R9 R10 R11 R12 2 1 2 1 1 1 1 1 4 3 4 3 2 2 2 2 6 5 6 5 BLACK 1 2 3 R13 R13 R13 R13 (∗ 1) (∗ 3) (∗ 4) (∗ 5) 321 5 4 3 2 1 3 2 1 6 5 4 R14 R14 R14 R14 S1 (∗ 1) (∗ 3) (∗ 4) (∗ 5) BLACK 321 5 4 3 2 1 3 2 1 6 5 4 2 1 3 7 6 5 4 10 9 8 7 6 1 2 1 3 7 6 5 4 10 9 8 7 6 S2 S3 S3 S4 S5 S6 (Floor Shift) (Column Shift) BLUE YELLOW YELLOW 1 2 3 4 1 2 3 4 1 1 2 3 4 5 6 1 1 2 3 4 5 2 3 4 S7 S8 S9 S10 S11 YELLOW YELLOW BLACK BLACK BLACK 1 2 3 4 5 6 7 8 9 1011121314 1 2 S12 1 2 S13 S14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 T1 T2 T3 GRAY BLACK BLACK 1 1 2 1 2 1 2 3 4 1 2 3 1 2 2001 AVALON (EWD431U) 305 K CONNECTOR LIST T4 T5 T6 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 14 15 16 17 18 19 20 21 22 23 24 25 26 14 15 16 17 18 19 20 21 22 23 24 25 26 T7 T8 T9 U1 V1 BROWN 1 1 2 2 1 2 1 2 1 3 2 V2 V3 V4 V5 V6 BROWN BLUE BLACK BLUE BLACK 1 2 1 2 1 1 2 2 1 V7 V8 V9 GRAY BLACK BLACK 1 2 3 4 1 2 V10 V12 V11 BLACK 1 1 2 2 2 1 2 1 2 3 V13 V14 W1 W2 W3 W4 BLUE BLUE BLACK BLACK GRAY GRAY 1 1 2 3 1 2 1 12 3 456 7 8 1 W5 2 W6 2 W7 Y1 GRAY 1 1 2 BLACK 1 2 1 2 4 3 5 2001 AVALON (EWD431U) 306 6 MEMO 2001 AVALON (EWD431U) 307 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points : Location of Splice Points 2001 AVALON (EWD431U) 54 G Connector Joining Wire Harness and Wire Harness EA1 1 4 7 9 3 5 6 8 11 10 2 EB1 GRAY 3 5 8 11 2 6 10 1 4 7 9 1 2 3 4 EC1 DARK GRAY 2 1 4 3 Code Joining Wire Harness and Wire Harness (Connector Location) EA1 Cowl Wire and Engine Room No.2 Wire (Near the Engine Room R/B No.2) EB1 Engine Wire and Sensor Wire (LH Bank of the Cylinder Head) EC1 Engine Room Main Wire and Engine Room No.3 Wire (Near the Radiator Fan) 1 2 DARK GRAY 2 1 2001 AVALON (EWD431U) 55 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness [Column Shift] : Location of Ground Points 2001 AVALON (EWD431U) 56 G Connector Joining Wire Harness and Wire Harness Code IA1 IB1 IB2 IC1 ID1 ID2 IE1 Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 Wire and Instrument Panel Wire (Left Kick Panel) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Behind the Driver Side J/B) IF1 IF2 Engine g Room Main Wire and Cowl Wire ((Left Side of Instrument Panel)) IF3 IG1 Roof Wire and Cowl Wire (Front Left Pillar) 2001 AVALON (EWD431U) 57 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness [Column Shift] : Location of Splice Points 2001 AVALON (EWD431U) 58 G Connector Joining Wire Harness and Wire Harness Code IH1 II1 II2 IJ1 IK1 IK2 IL1 Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Cowl No.2 Wire (Behind the Center Cluster) Engine Wire and Cowl Wire (Behind the Glove Box) Engine Wire and Instrument Panel Wire (Right Kick Panel) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Cowl Wire and Instrument Panel Wire (Right Kick Panel) IM1 IM2 Floor No.2 Wire and Instrument Panel Wire ((Right g Kick Panel)) IM3 IN1 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) 2001 AVALON (EWD431U) 59 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness [Floor Shift] : Location of Ground Points 2001 AVALON (EWD431U) 60 G Connector Joining Wire Harness and Wire Harness Code IA1 IB1 IB2 IC1 ID1 ID2 IE1 Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 Wire and Instrument Panel Wire (Left Kick Panel) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Behind the Driver Side J/B) IF1 IF2 Engine g Room Main Wire and Cowl Wire ((Left Side of Instrument Panel)) IF3 IG1 Roof Wire and Cowl Wire (Front Left Pillar) 2001 AVALON (EWD431U) 61 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness [Floor Shift] : Location of Splice Points 2001 AVALON (EWD431U) 62 G Connector Joining Wire Harness and Wire Harness Code II1 II2 IJ1 IK1 IK2 IL1 Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Cowl Wire (Behind the Glove Box) Engine Wire and Instrument Panel Wire (Right Kick Panel) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Cowl Wire and Instrument Panel Wire (Right Kick Panel) IM1 IM2 Floor No.2 Wire and Instrument Panel Wire ((Right g Kick Panel)) IM3 IN1 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IO1 Floor No.3 Wire and Floor No.1 Wire (Under the Console Box) 2001 AVALON (EWD431U) 63 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points : Location of Splice Points 2001 AVALON (EWD431U) 64 G Connector Joining Wire Harness and Wire Harness BA1 1 2 3 4 5 6 7 8 9 10 11 12 BB1 2 1 7 6 5 4 3 12 11 10 9 8 1 2 3 4 5 6 7 8 9 10 11 12 Code Joining Wire Harness and Wire Harness (Connector Location) BA1 Rear Door No.2 Wire and Floor No.1 Wire (Under the Left Center Pillar) BB1 Rear Door No.1 Wire and Floor No.2 Wire (Under the Right Center Pillar) 2 1 7 6 5 4 3 12 11 10 9 8 2001 AVALON (EWD431U) 65 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness [Column Shift] : Location of Splice Points 2001 AVALON (EWD431U) 66 G Connector Joining Wire Harness and Wire Harness BC1 1 2 3 4 5 6 7 8 9 10 11 BD1 GRAY 4 3 2 1 11 10 9 8 7 6 5 1 2 3 4 5 6 7 8 9 10 11 Code Joining Wire Harness and Wire Harness (Connector Location) BC1 Floor No.1 Wire and Seat No.1 Wire (Under the Driver’s Seat) BD1 Floor No.2 Wire and Seat No.2 Wire (Under the Front Passenger’s Seat) GRAY 4 3 2 1 11 10 9 8 7 6 5 2001 AVALON (EWD431U) 67 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness [Floor Shift] : Location of Splice Points 2001 AVALON (EWD431U) 68 G Connector Joining Wire Harness and Wire Harness BC1 1 2 3 4 5 6 7 8 9 10 11 BD1 GRAY 4 3 2 1 11 10 9 8 7 6 5 1 2 3 4 5 6 7 8 9 10 11 Code Joining Wire Harness and Wire Harness (Connector Location) BC1 Floor No.1 Wire and Seat No.1 Wire (Under the Driver’s Seat) BD1 Floor No.2 Wire and Seat No.2 Wire (Under the Front Passenger’s Seat) GRAY 4 3 2 1 11 10 9 8 7 6 5 2001 AVALON (EWD431U) 69 G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment A A A A 1 2 3 4 A 5 A 6 A 7 A 8 A 9 A 10 A 11 A 12 A 13 A/C Ambient Temp. Sensor A/C Condenser Fan Motor A/C Magnetic Clutch and Lock Sensor A/C Triple Pressure SW (A/C Dual and Single Pressure SW) ABS & BA & TRAC & VSC Actuator ABS & BA & TRAC & VSC Actuator ABS Actuator and ECU ABS Speed Sensor Front LH ABS Speed Sensor Front RH Air Fuel Ratio Sensor (Bank 1 Sensor 1) Air Fuel Ratio Sensor (Bank 2 Sensor 1) Airbag Sensor Front LH Airbag Sensor Front RH B 1 Brake Fluid Level Warning SW C C C C 1 2 3 4 Camshaft Position Sensor LH Camshaft Position Sensor RH Crankshaft Position Sensor Cruise Control Actuator D 1 Data Link Connector 1 E 1 Electronically Controlled Transmission Solenoid E 2 Engine Coolant Temp. Sensor E 3 Engine Hood Courtesy SW F 1 F 2 F 3 F 4 F 5 F 6 F 7 F 8 F 9 F 10 Front Fog Light LH Front Fog Light RH Front Turn Signal Light and Parking Light LH Front Turn Signal Light and Parking Light RH Front Wiper Motor Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block G 1 Generator G 2 Generator H H H H H H 1 2 3 4 5 6 Headlight High LH Headlight High RH Headlight Low LH Headlight Low RH Horn LH Horn RH 2001 AVALON (EWD431U) 44 G Position of Parts in Engine Compartment I I I I I I I I I I I I I 1 2 3 4 5 6 7 8 9 10 11 12 13 Idle Air Control Valve Ignition Coil and Igniter No.1 Ignition Coil and Igniter No.2 Ignition Coil and Igniter No.3 Ignition Coil and Igniter No.4 Ignition Coil and Igniter No.5 Ignition Coil and Igniter No.6 Injector No.1 Injector No.2 Injector No.3 Injector No.4 Injector No.5 Injector No.6 K 1 Knock Sensor 1 K 2 Knock Sensor 2 M 1 Mass Air Flow Meter M 2 Masster Cylinder Pressure Sensor P 1 Park/Neutral Position SW, A/T Indicator Light SW and Back-Up Light SW P 2 Power Steering Oil Pressure SW R 1 Radiator Fan Motor S 1 Starter S 2 Starter T 1 Theft Deterrent Buzzer T 2 Theft Deterrent Horn T 3 Throttle Position Sensor V V V V V V V 1 2 3 4 5 6 7 VSV (ACIS No.1) VSV (ACIS No.2) VSV (ACM) VSV (Canister Closed Valve) VSV (EVAP) VVT Solenoid LH VVT Solenoid RH W W W W W W 1 2 3 4 5 6 Washer Level Warning SW Washer Motor Water Temp. Sender Water Temp. SW No.1 Water Temp. SW No.2 Wireless Door Lock Buzzer N 1 Noise Filter (Ignition) O 1 O/D Direct Clutch Speed Sensor O 2 Oil Pressure SW 2001 AVALON (EWD431U) 45 G ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel [Column Shift] A 14 A 15 A 16 A 17 A 18 A 19 A 20 A 21 A 22 A 23 A 24 A 25 A 26 A 27 A 28 A/C Blower Motor Linear Controller A/C Control Assembly A/C Control Assembly A/C Room Temp. Sensor A/C Solar Sensor A/C Thermistor ABS & BA & TRAC & VSC ECU Active Light Relay Air Inlet Control Servo Motor Air Mix Control Servo Motor (Driver Side) Air Mix Control Servo Motor (Front Passenger Side) Air Outlet Control Servo Motor Airbag Squib (Front Passenger Airbag Assembly) Airbag Squib (Steering Wheel Pad) Automatic Light Control Sensor B B B B Blower Motor Blower Resistor Body ECU Body ECU 2 3 4 5 C 5 C 6 C 7 C 8 C 9 C10 C 11 C12 C13 C14 C15 Center Airbag Sensor Assembly Center Airbag Sensor Assembly Center Airbag Sensor Assembly Cigarette Lighter Combination Meter Combination Meter Combination SW Combination SW Combination SW Combination SW Cruise Control ECU D D D D D 2 3 4 5 6 Data Link Connector 2 Data Link Connector 3 Diode (A/C) Diode (A/T Indicator Light 1) Diode (A/T Indicator Light 2) E E E E E 4 5 6 7 8 Engine Control Module Engine Control Module Engine Control Module Engine Control Module Engine Control Module 2001 AVALON (EWD431U) 46 G Position of Parts in Instrument Panel [Column Shift] G 3 Glove Box Light SW O 3 O/D Main SW H 7 H 8 H 9 H10 P P P P 3 4 6 8 Parking Brake SW Power Outlet Power Outlet Power Outlet Main SW R R R R R 2 3 4 5 6 Radio and Player Radio and Player Radio and Player Remote Control Mirror SW Rheostat Hazard SW Heated Oxygen Sensor (Bank 1 Sensor 2) Heater Control SW Heater Control SW I 14 Ignition Key Cylinder Light I 15 Ignition SW J J J J J J J J J 1 2 3 4 5 6 7 8 9 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector K 3 Key Interlock Solenoid L 1 Luggage Compartment Door Opener Main SW L 2 Luggage Compartment Door Opener SW M M M M M 3 4 5 6 7 Multi Display Multi Display Multi Display Multi Display Multi Display S 3 Shift Lock ECU S 4 Stop Light SW T T T T T T 4 5 6 7 8 9 Theft Deterrent ECU Translate ECU Transponder Key Amplifier Turn Signal Flasher Relay Tweeter LH Tweeter RH U 1 Unlock Warning SW V 8 VSC Off SW V 9 VSC Warning Buzzer Y 1 Yaw Rate Sensor 2001 AVALON (EWD431U) 47 G ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel [Floor Shift] A 14 A 15 A 16 A 17 A 18 A 19 A 20 A 21 A 22 A 23 A 24 A 25 A 26 A 27 A 28 A/C Blower Motor Linear Controller A/C Control Assembly A/C Control Assembly A/C Room Temp. Sensor A/C Solar Sensor A/C Thermistor ABS & BA & TRAC & VSC ECU Active Light Relay Air Inlet Control Servo Motor Air Mix Control Servo Motor (Driver Side) Air Mix Control Servo Motor (Front Passenger Side) Air Outlet Control Servo Motor Airbag Squib (Front Passenger Airbag Assembly) Airbag Squib (Steering Wheel Pad) Automatic Light Control Sensor B B B B Blower Motor Blower Resistor Body ECU Body ECU 2 3 4 5 C 5 C 6 C 7 C 8 C 9 C10 C 11 C12 C13 C14 C15 Center Airbag Sensor Assembly Center Airbag Sensor Assembly Center Airbag Sensor Assembly Cigarette Lighter Combination Meter Combination Meter Combination SW Combination SW Combination SW Combination SW Cruise Control ECU D D D D 2 3 4 5 Data Link Connector 2 Data Link Connector 3 Diode (A/C) Diode (A/T Indicator Light 1) E E E E E 4 5 6 7 8 Engine Control Module Engine Control Module Engine Control Module Engine Control Module Engine Control Module 2001 AVALON (EWD431U) 48 G Position of Parts in Instrument Panel [Floor Shift] G 3 Glove Box Light SW O 3 O/D Main SW H 7 H 8 H 9 H10 P P P P 3 5 7 8 Parking Brake SW Power Outlet Power Outlet Power Outlet Main SW R R R R R 2 3 4 5 6 Radio and Player Radio and Player Radio and Player Remote Control Mirror SW Rheostat Hazard SW Heated Oxygen Sensor (Bank 1 Sensor 2) Heater Control SW Heater Control SW I 14 Ignition Key Cylinder Light I 15 Ignition SW J J J J J J J J J 1 2 3 4 5 6 7 8 9 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector K 3 Key Interlock Solenoid L 1 Luggage Compartment Door Opener Main SW L 2 Luggage Compartment Door Opener SW M M M M M 3 4 5 6 7 Multi Display Multi Display Multi Display Multi Display Multi Display S 3 Shift Lock ECU S 4 Stop Light SW T T T T T T 4 5 6 7 8 9 Theft Deterrent ECU Translate ECU Transponder Key Amplifier Turn Signal Flasher Relay Tweeter LH Tweeter RH U 1 Unlock Warning SW V 8 VSC Off SW V 9 VSC Warning Buzzer Y 1 Yaw Rate Sensor 2001 AVALON (EWD431U) 49 G ELECTRICAL WIRING ROUTING Position of Parts in Body A 29 ABS Speed Sensor Rear LH A 30 ABS Speed Sensor Rear RH B B B B 6 7 8 9 D 7 D 8 D 9 D10 D 11 D12 D13 D14 D15 D16 D17 F 11 F 12 F 13 F 14 F 15 Back-Up Light LH Back-Up Light RH Buckle SW LH Buckle SW RH Field Magnetic Sensor Front Door Speaker LH Front Door Speaker RH Front Passenger Door ECU Fuel Pump and Sender H 11 High Mounted Stop Light Diode (Luggage Compartment Light) Door Control Receiver Door Courtesy Light Front LH Door Courtesy Light Front RH Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Door Courtesy SW Rear RH Door Lock Motor Rear LH Door Lock Motor Rear RH Door Lock Motor,Door Key Lock and Unlock SW and Door Unlock Detection SW Front LH D18 Door Lock Motor,Door Key Lock and Unlock SW and Door Unlock Detection SW Front RH D19 Driver Door ECU I 16 Inner Mirror I 17 Interior Light J 10 J 11 J 12 J 13 Junction Connector Junction Connector Junction Connector Junction Connector L L L L L L L License Plate Light LH License Plate Light RH Light Failure Sensor Luggage Compartment Door Key Unlock SW Luggage Compartment Door Unlock Motor Luggage Compartment Light Luggage Compartment Light SW 3 4 5 6 7 8 9 2001 AVALON (EWD431U) 50 G Position of Parts in Body M 8 Moon Roof Control ECU M 9 Moon Roof Control SW N 2 Noise Filter (Rear Window Defogger) N 3 Noise Filter (Stop Light and Luggage Compartment Light) P 9 P 10 P 11 P 12 P 13 P 14 P 15 P 16 P 17 Personal Light Power Window Control SW Rear LH Power Window Control SW Rear RH Power Window Motor Front LH Power Window Motor Front RH Power Window Motor Rear LH Power Window Motor Rear RH Pretensioner LH Pretensioner RH R 7 R 8 R 9 R10 R 11 R12 R13 R14 Rear Combination Light LH Rear Combination Light RH Rear Door Speaker LH Rear Door Speaker RH Rear Interior Light LH Rear Interior Light RH Remote Control Mirror LH Remote Control Mirror RH S 5 S 6 S 7 S 8 S 9 S 10 S 11 Side Airbag Sensor LH Side Airbag Sensor RH Side Airbag Squib LH Side Airbag Squib RH Stereo Component Amplifier Stereo Component Amplifier Seat Belt Warning Occupant Detection Sensor V 10 V 11 V 12 V 13 V 14 Vanity Light LH and Garage Door Opener Vanity Light RH Vapor Pressure Sensor Voltage Inverter VSV (Pressure Switching Valve) W 7 Woofer 2001 AVALON (EWD431U) 51 G ELECTRICAL WIRING ROUTING Position of Parts in Seat [Column Shift] B 8 Buckle SW LH B 9 Buckle SW RH J 14 Junction Connector P 18 P 19 P 20 P 21 P 22 P 23 P 24 P 25 P 26 Power Seat Control SW (Driver’s Seat) Power Seat Control SW (Front Passenger’s Seat) Power Seat ECU Power Seat ECU Power Seat Motor (Driver’s Seat Front Vertical Control) Power Seat Motor (Driver’s Seat Rear Vertical Control) Power Seat Motor (Driver’s Seat Reclining Control) Power Seat Motor (Driver’s Seat Slide Control) Power Seat Motor (Front Passenger’s Seat Rear Vertical Control) P 27 Power Seat Motor (Front Passenger’s Seat Reclining Control) P 28 Power Seat Motor (Front Passenger’s Seat Slide Control) P 29 Power Seat Position Sensor (Driver’s Seat Front Vertical Control) P 30 Power Seat Position Sensor (Driver’s Seat Rear Vertical Control) P 31 Power Seat Position Sensor (Driver’s Seat Reclining Control) P 32 Power Seat Position Sensor (Driver’s Seat Slide Control) S 11 S 12 S 13 S 14 Seat Belt Warning Occupant Detection Sensor Seat Heater (Driver’s Seat) Seat Heater (Front Passenger’s Seat) Seat Memory SW 2001 AVALON (EWD431U) 52 G Position of Parts in Seat [Floor Shift] B 8 Buckle SW LH B 9 Buckle SW RH J 14 Junction Connector L 10 Lumbar Support Control Motor (Driver’s Seat) L 11 Lumbar Support Control SW (Driver’s Seat) P 18 P 19 P 20 P 21 P 22 P 23 P 24 P 25 P 26 Power Seat Control SW (Driver’s Seat) Power Seat Control SW (Front Passenger’s Seat) Power Seat ECU Power Seat ECU Power Seat Motor (Driver’s Seat Front Vertical Control) Power Seat Motor (Driver’s Seat Rear Vertical Control) Power Seat Motor (Driver’s Seat Reclining Control) Power Seat Motor (Driver’s Seat Slide Control) Power Seat Motor (Front Passenger’s Seat Rear Vertical Control) P 27 Power Seat Motor (Front Passenger’s Seat Reclining Control) P 28 Power Seat Motor (Front Passenger’s Seat Slide Control) P 29 Power Seat Position Sensor (Driver’s Seat Front Vertical Control) P 30 Power Seat Position Sensor (Driver’s Seat Rear Vertical Control) P 31 Power Seat Position Sensor (Driver’s Seat Reclining Control) P 32 Power Seat Position Sensor (Driver’s Seat Slide Control) S 11 S 12 S 13 S 14 Seat Belt Warning Occupant Detection Sensor Seat Heater (Driver’s Seat) Seat Heater (Front Passenger’s Seat) Seat Memory SW 2001 AVALON (EWD431U) 53 E GLOSSARY OF TERMS AND SYMBOLS GROUND The point at which wiring attaches to the Body, thereby providing a return path for an electrical circuit; without a ground, current cannot flow. BATTERY Stores chemical energy and converts it into electrical energy. Provides DC current for the auto’s various electrical circuits. CAPACITOR (Condenser) A small holding unit for temporary storage of electrical voltage. CIGARETTE LIGHTER An electric resistance heating element. HEADLIGHTS Current flow causes a headlight 1. SINGLE filament to heat up and emit light. A FILAMENT headlight may have either a single (1) filament or a double (2) filament 2. DOUBLE FILAMENT CIRCUIT BREAKER Basically a reusable fuse, a circuit breaker will heat and open if too much current flows through it. Some units automatically reset when cool, others must be manually reset. HORN An electric device which sounds a loud audible signal. DIODE A semiconductor which allows current flow in only one direction. IGNITION COIL Converts low-voltage DC current into high-voltage ignition current for firing the spark plugs. DIODE, ZENER LIGHT Current flow through a filament causes the filament to heat up and emit light. A diode which allows current flow in one direction but blocks reverse flow only up to a specific voltage. Above that potential, it passes the excess voltage. This acts as a simple voltage regulator. PHOTODIODE The photodiode is a semiconductor which controls the current flow according to the amount of light. LED (LIGHT EMITTING DIODE) Upon current flow, these diodes emit light without producing the heat of a comparable light. DISTRIBUTOR, IIA Channels high-voltage current from the ignition coil to the individual spark plugs. METER, ANALOG Current flow activates a magnetic coil which causes a needle to move, thereby providing a relative display against a background calibration. FUSE METER, DIGITAL Current flow activates one or many LED’s, LCD’s, or fluorescent displays, which provide a relative or digital display. A thin metal strip which burns through when too much current flows through it, thereby stopping current flow and protecting a circuit from damage. FUEL FUSIBLE LINK (for Medium Current Fuse) (for High Current Fuse or Fusible Link) A heavy-gauge wire placed in high amperage circuits which burns through on overloads, thereby protecting the circuit. The numbers indicate the crosssection surface area of the wires. M 2001 AVALON (EWD431U) 18 MOTOR A power unit which converts electrical energy into mechanical energy, especially rotary motion. E RELAY Basically, an electrically operated 1. NORMALLY switch which may be normally CLOSED closed (1) or open (2). Current flow through a small coil creates a magnetic field which either opens or closes an attached switch. SPEAKER An electromechanical device which creates sound waves from current flow. 2. NORMALLY OPEN SWITCH, MANUAL 1. NORMALLY OPEN RELAY, DOUBLE THROW A relay which passes current through one set of contacts or the other. Opens and closes circuits, i it thereby th b stopping (1) or allowing (2) current flow. 2. NORMALLY CLOSED RESISTOR An electrical component with a fixed resistance, placed in a circuit to reduce voltage to a specific value. SWITCH, DOUBLE THROW A switch which continuously passes current through one set of contacts or the other. RESISTOR, TAPPED A resistor which supplies two or more different non adjustable resistance values. SWITCH, IGNITION A key operated switch with several positions which allows various circuits, particularly the primary ignition circuit, to become operational. RESISTOR, VARIABLE or RHEOSTAT A controllable resistor with a variable rate of resistance. Also called a potentiometer or rheostat. SENSOR (Thermistor) A resistor which varies its resistance with temperature. SWITCH, WIPER PARK Automatically returns wipers to the stop position when the wiper switch is turned off. SENSOR, SPEED Uses magnetic impulses to open and close a switch to create a signal for activation of other components. TRANSISTOR A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at ”base”. (Reed Switch Type) SHORT PIN Used to provide an unbroken connection within a junction block. SOLENOID An electromagnetic coil which forms a magnetic field when current flows, to move a plunger, etc. WIRES Wires are always drawn as (1) NOT straight lines on wiring CONNECTED diagrams. Crossed wires (1) without a black dot at the junction are j nott joined; j i d crossed wires (2) with a black dot or octagonal ( ) (2) SPLICED mark at the junction are spliced (joined) connections. 2001 AVALON (EWD431U) 19 I GROUND POINT ENGINE CONTROL MODULE BR (E1) BR IDLE AIR CONTROL VALVE A BR A A BR 10 II2 BR B B BR B BR W- B HEADLIGHT LOW RH 11 IJ1 W- B IGNITION COIL AND IGNITER NO. 2 W- B IGNITION COIL AND IGNITER NO. 3 W- B IGNITION COIL AND IGNITER NO. 4 W- B IGNITION COIL AND IGNITER NO. 5 W- B IGNITION COIL AND IGNITER NO. 6 W- B MULTI DISPLAY (GND1) W- B 7 4G LUGGAGE COMPARTMENT DOOR OPENER SW W- B 7 4H W- B 20 4H W- B 20 4A W- B 7 4A W- B 20 4B W- B BR (E02) (E05) W- B ENGINE CONTROL MODULE (E03) W- B BR I22 W- B E4 W- B (CG) BLOWER RESISTOR HEATER CONTROL SW FRONT TURN SIGNAL LIGHT AND PARKING LIGHT RH POWER OUTLET W- B A I13 W- B A A (MANUAL A/C) W- B A W- B A W- B ABS & BA & TRAC & VSC ECU BK/UP LP RELAY J9 JUNCTION CONNECTOR W- B I16 TURN SIGNAL FLASHER RELAY POWER OUTLET MAIN SW 21 3B 8 3B W- B A W- B 7 3A 20 3B W- B 20 3A W- B 7 3B W- B 7 3G W- B 20 3G W- B A W- B W- B W- B A IJ 21 3A A CRUISE CONTROL ECU (ECC) COMBINATION SW (ESS) COMBINATION SW (EP) COMBINATION METER RHEOSTAT W- B W- B I25 8 IC1 W- B W- B W- B W- B W- B 11 EA1 W- B R- L (*9) (- ) COMBINATION METER 2 DRL NO. 3 RELAY 2 DRL NO. 4 RELAY W- B FRONT FOG LIGHT RH (GND2) 6 W- B W- B A A FRONT WIPER MOTOR WIRELESS DOOR LOCK BUZZER W- B (COLUMN SHIFT) A/C BLOWER MOTOR LINEAR CONTROLLER W- B 8 3A 7 4B W- B (MANUAL A/C) CRUISE CONTROL ACTUATOR THEFT DETERRENT BUZZER W- B I15 (MANUAL A/C) W- B I14 W- B W- B W- B O/D MAIN SW W- B (E04) 9 II1 W- B J5 JUNCTION CONNECTOR THEFT DETERRENT ECU W- B I22 EC W- B GLOVE BOX LIGHT SW (EXCEPT CANADA) EA 2001 AVALON (EWD431U) 282 (E01) W- B EB DATA LINK CONNECTOR 3 (E0M) W- B I23 HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) (SG) W- B BR (ET) IGNITION COIL AND IGNITER NO. 1 HEADLIGHT LOW RH BR (CANADA) MULTI DISPLAY DATA LINK CONNECTOR 3 21 IK2 B BR J5 JUNCTION CONNECTOR J7 JUNCTION A CONNECTOR W- B DATA LINK CONNECTOR 1 A ABS ACTUATOR AND ECU W- B (GND1) (* 4) ABS SOL RELAY 10 2F W- B 3 (* 3) 8 2D W- B 5 2D W- B 3 1 EC1 FAN NO. 2 RELAY W- B WATER TEMP. SW NO. 1 W- B B 1 2F W- B A/C DUAL PRESSURE SW BRAKE FLUID LEVEL WARNING SW W- B B 6 2D W- B A/C SINGLE PRESSURE SW ENGINE HOOD COURTESY SW W- B B 7 2D W- B W- B B W- B B FRONT FOG LIGHT LH 10 2C ST RELAY HTR RELAY 5 J1 JUNCTION CONNECTOR A/F RELAY B 4 2D W- B * 1 : W/ DRIVING POSITION MEMORY * 2 : W/O DRIVING POSITION MEMORY * 3 : W/ TRACTION CONTROL * 4 : W/O TRACTION CONTROL * 9 : W/ DAYTIME RUNNING LIGHT * 10 : W/ MOON ROOF W- B ABS ACTUATOR AND ECU W- B EFI RELAY IG2 RELAY 4 2F W- B W- B ABS & BA & TRAC & VSC ACTUATOR RADIATOR FAN MOTOR W- B (GND2) W- B FRONT TURN SIGNAL LIGHT AND PARKING LIGHT LH HEADLIGHT LOW LH ED EE 20 IE1 W- B (* 4) W- B (* 4) NOISE FILTER 1 NOISE FILTER 2 8 1L IG1 RELAY CENTER AIRBAG SENSOR ASSEMBLY (E2) 9 1H W- B 3 1F W- B 4 1F W- B W- B W- B (* 10) 3 1B W- B W- B I13 17 IG1 (EL) W- B W- B W- B COMBINATION SW I9 B4 B4 W- B W- B CIGARETTE LIGHTER BL (* 3) (E) COMBINATION SW ACTIVE LIGHT RELAY (* 3) W- B PERSONAL LIGHT INNER MIRROR W- B MOON ROOF CONTROL SW W- B MOON ROOF CONTROL ECU W- B (E1) W- B W- B 5 IF1 W- B A/C CONTROL ASSEMBLY W- B W- B W- B W- B VANITY LIGHT LH VANITY LIGHT RH B UNLOCK WARNING SW KEY INTERLOCK SOLENOID B W- B 9 3D W- B 22 3C W- B W- B 22 3D W- B B W- B J4 JUNCTION CONNECTOR B W- B W- B B W- B B TRANSLATE ECU BODY ECU (GND1) ABS & BA & TRAC & VSC ECU IG 2001 AVALON (EWD431U) 283 I GROUND POINT W- B FUEL PUMP W- B(*8) W- B 4 IO1 W- B DOOR LOCK MOTOR REAR LH W- B 8 BA1 W- B A A POWER WINDOW CONTROL SW REAR LH W- B 12 BA1 W- B A A 21 4D TRANSPONDER KEY AMPLIFIER W- B 8 4D AIR OUTLET CONTROL SERVO MOTOR W- B 8 4C W- B 21 4F BODY ECU (*11) W- B B J14 JUNCTION CONNECTOR 8 4F B C W- B C W- B B W- B B C W- B 11 BC1 W- B 4 W- B B13 (* 2) W- B B12 W- B (* 2) (* 2) W- B PWR POINT RELAY W- B 7 I5 7 4D WASHER LEVEL WARNING SW W- B 20 4D A/C CONTROL ASSEMBLY W- B 7 4C HEATER CONTROL SW REMOTE CONTROL MIRROR SW (AUTOMATIC A/C) W- B (MANUAL A/C) W- B 20 4F W- B W- B 7 4F IF 2001 AVALON (EWD431U) 284 POWER SEAT CONTROL SW (DRIVER’ S SEAT) W- B POWER SEAT ECU W- B B6 20 4C W- B SHIFT LOCK ECU W- B(* 7) W- B II BUCKLE SW LH IA1 B13 BODY ECU SEAT HEATER (DRIVER’ S SEAT) (* 6) W- B VSC OFF SW W- B B LUMBAR SUPPORT CONTROL SW (DRIVER’ S SEAT) (*2) 8 4E 11 IB1 W- B(*5) W- B W- B DOOR CONTROL RECEIVER W- B POWER SEAT CONTROL SW (DRIVER’ S SEAT) (*5) I21 W- B W- B W- B 13 IN1 W- B DRIVER DOOR ECU W- B W- B(*1) W- B(*2) (* 1) W- B I3 W- B REMOTE CONTROL MIRROR LH W- B W- B C W- B FRONT PASSENGER DOOR ECU BK B12 (* 1) J6 JUNCTION CONNECTOR W- B W- B W- B REMOTE CONTROL MIRROR RH B1 A W- B POWER OUTLET W- B BUCKLE SW LH J11 JUNCTION CONNECTOR A W- B W- B(* 7) VOLTAGE INVERTER W- B REAR INTERIOR LIGHT LH POWER SEAT CONTROL SW (FRONT PASSENGER’ S SEAT) W- B(* 7) W- B SEAT HEATER (FRONT PASSENGER’ S SEAT) W- B B14 W- B(* 7) B15 * 1 : W/ DRIVING POSITION MEMORY * 2 : W/O DRIVING POSITION MEMORY * 5 : FLOOR SHIFT W/ DRIVING POSITION MEMORY * 6 : COLUMN SHIFT W/ DRIVING POSITION MEMORY * 7 : W/ POWER SEAT * 8 : W/O POWER SEAT * 11 : TAIWAN W- B W- B (* 8) (* 7) SEAT BELT WARNING OCCUPANT DETECTION SENSOR W- B(* 7) LUGGAGE COMPARTMENT DOOR KEY UNLOCK SW 11 BD1 B7 W- B(*8) (* 8) W- B (* 7) W- B W- B BUCKLE SW RH J12 JUNCTION CONNECTOR C W- B BACK- UP LIGHT LH W- B HIGH MOUNTED STOP LIGHT C W- B REAR COMBINATION LIGHT LH C W- B REAR COMBINATION LIGHT RH A W- B LICENSE PLATE LIGHT RH W- B W- B A J10 JUNCTION CONNECTOR C W- B LICENSE PLATE LIGHT LH B8 STEREO COMPONENT AMPLIFIER W- B A REAR INTERIOR LIGHT RH W- B A LIGHT FAILURE SENSOR W- B A A W- B B9 W- B W- B BACK- UP LIGHT RH BN POWER SEAT POSITION SENSOR (DRIVER’ S SEAT FRONT VERTICAL CONTROL) BR POWER SEAT POSITION SENSOR (DRIVER’ S SEAT REAR VERTICAL CONTROL) B12 8 BB1 W- B DOOR LOCK MOTOR REAR RH W- B 12 BB1 W- B POWER WINDOW CONTROL SW REAR RH BM BR B J14 JUNCTION CONNECTOR BR W- B B BR B BR POWER SEAT POSITION SENSOR (DRIVER’ S SEAT RECLINING CONTROL) B BR POWER SEAT POSITION SENSOR (DRIVER’ S SEAT SLIDE CONTROL) BR B POWER SEAT ECU BR 9 BC1 IA1 BR 9 A BR RADIO AND PLAYER A J3 JUNCTION CONNECTOR COMBINATION METER (ES) BR BR A IH 2001 AVALON (EWD431U) 285 I GROUND POINT : PARTS LOCATION Code J1 J3 J4 J5 See Page 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) Code J5 J6 J7 J9 See Page 49 (Floor Shift) Code 50 47 (Column Shift) J11 50 49 (Floor Shift) J12 50 47 (Column Shift) 49 (Floor Shift) J14 47 (Column Shift) 49 (Floor Shift) : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 2 24 Engine Room R/B No.2 (Engine Compartment Right) 3 24 Engine Room R/B No.3 (Near the Radiator Fan) 5 25 Engine Room R/B No.5 (Engine Compartment Left) 6 42 Driver Side R/B No.6 (Left Kick Panel) 7 42 Front Passenger Side R/B No.7 (Right Kick Panel) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1H 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1L 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 30 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 (Right ( g Kick Panel)) 1F 2C 2D 2F 3A 3B 3C 3D 3G 4A 4B 4C 4D 4E 4F 4G 4H 2001 AVALON (EWD431U) 286 See Page J10 52 (Column Shift) 53 (Floor Shift) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) EA1 54 Cowl Wire and Engine Room No.2 Wire (Near the Engine Room R/B No.2) EC1 54 Engine Room Main Wire and Engine Room No.3 Wire (Near the Radiator Fan) IA1 IB1 IC1 IE1 IF1 IG1 II1 II2 IJ1 IK2 IN1 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Behind the Driver Side J/B) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) Roof Wire and Cowl Wire (Front Left Pillar) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Engine Wire and Cowl Wire (Behind the Glove Box) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Engine Wire and Instrument Panel Wire (Right Kick Panel) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IO1 62 (Floor Shift) Floor No.3 Wire and Floor No.1 Wire (Under the Console Box) BA1 64 Rear Door No.2 Wire and Floor No.1 Wire (Under the Left Center Pillar) BB1 64 Rear Door No.1 Wire and Floor No.2 Wire (Under the Right Center Pillar) BC1 BD1 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) Floor No No.1 1 Wire and Seat No No.1 1 Wire (Under the Driver’s Seat) Floor No No.2 2 Wire and Seat No No.2 2 Wire (Under the Front Passenger’s Seat) 2001 AVALON (EWD431U) 287 I GROUND POINT : GROUND POINTS Code See Page Ground Points Location EA 54 Front Side of Right Fender EB 54 Surge Tank RH EC 54 Rear Side of Surge Tank 54 Front Side of Left Fender ED EE IF IG IH II IJ 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Left Kick Panel Cowl Side Panel LH Instrument Panel Brace RH Right Kick Panel Cowl Side Panel RH BK 64 Rear Quarter Inner LH BL 64 Roof Left BM 64 Back Panel Center BN 64 Rear Quarter Inner RH : SPLICE POINTS Code E4 I3 I5 I9 I13 I14 I15 I16 I21 I22 See Page 54 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Engine Wire Code I23 Front Door LH Wire I25 Instrument Panel Wire See Page 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Engine Wire Cowl Wire B1 64 Floor No.1 Wire 58 (Column Shift) B4 64 Roof Wire 62 (Floor Shift) B6 64 Floor No.1 Wire 58 (Column Shift) B7 62 (Floor Shift) B8 64 Floor No.2 Wire 58 (Column Shift) B9 62 (Floor Shift) Cowl Wire B12 58 (Column Shift) 62 (Floor Shift) B13 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) B14 Front Door RH Wire B15 Engine Wire 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) Seat No.1 No 1 Wire 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) 2001 AVALON (EWD431U) 288 Wire Harness with Splice Points Seat No.2 No 2 Wire MEMO 2001 AVALON (EWD431U) 289 HOW TO USE THIS MANUAL B This manual provides information on the electrical circuits installed on vehicles by dividing them into a circuit for each system. The actual wiring of each system circuit is shown from the point where the power source is received from the battery as far as each ground point. (All circuit diagrams are shown with the switches in the OFF position.) When troubleshooting any problem, first understand the operation of the circuit where the problem was detected (see System Circuit section), the power source supplying power to that circuit (see Power Source section), and the ground points (see Ground Point section). See the System Outline to understand the circuit operation. When the circuit operation is understood, begin troubleshooting of the problem circuit to isolate the cause. Use Relay Location and Electrical Wiring Routing sections to find each part, junction block and wiring harness connectors, wiring harness and wiring harness connectors, splice points, and ground points of each system circuit. Internal wiring for each junction block is also provided for better understanding of connection within a junction block. Wiring related to each system is indicated in each system circuit by arrows (from__, to__). When overall connections are required, see the Overall Electrical Wiring Diagram at the end of this manual. 2001 AVALON (EWD431U) 3 B HOW TO USE THIS MANUAL ∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. [A] STOP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 66) ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, [C] 15A STOP 7. 5A GAUGE 4 IB 2 1 ,,,, @@@@ €€€€ ÀÀÀÀ @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, 7 3C [G] 15 3C R-L W-R R (W/G) 3 IB L (S/D) [B] R-L 4 2 C7 REAR LIGHTS WARNING LIGHT [COMB. METER] S6 STOP LIGHT SW 14 [E] IE1 13 1 G-W [D] L (S/D) I5 [F] G-W Y-G G-W TO ABS ECU [H] 7 L4 LIGHT FAILURE SENSOR 8 DELAY CIRCUIT 2 G [K] (SHIELDED) R6 STOP LIGHT RH [REAR COMB. LIGHT LH] H17 HIGH MOUNTED STOP LIGHT [L] 1 W-B B18 W-B 1 BV1 W-B W-B 3 2 BO 50 [M] BL [N] 2001 AVALON (EWD431U) 4 W-B R7 STOP LIGHT RH [REAR COMB. LIGHT RH] 4 W-B 3 [J] B18 G-R G-R G-R 1 BV1 4 11 G-R [I] 1 4 B [I] [A] : System Title [B] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: Indicates Relay Block No.1 : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red G = Green LG = Light Green [C] : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. P Y GR = Gray [D] : Indicates related system. The first letter indicates the basic wire color and the second letter indicates the color of the stripe. [E] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. = Pink = Yellow O = Orange Example: L-Y L (Blue) Female Male ( ) Y (Yellow) [J] : Indicates a wiring Splice Point (Codes are ”E” for the Engine Room, ”I” for the Instrument Panel, and ”B” for the Body). The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. [F] : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. [G] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: ,,,, ,,,, 3C indicates ,,,, that it is inside ,,,, Junction Block ,,,, No.3 ,,,, ,,,, The Location of splice Point I 5 is indicated by the shaded section. [K] : Indicates a shielded cable. [L] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order from upper left to lower right Female Numbered in order from upper right to lower left Male [M] : Indicates a ground point. [H] : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. The first letter of the code for each ground point(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. [N] : Page No. 2001 AVALON (EWD431U) 5 B HOW TO USE THIS MANUAL [O] SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. [P] SERVICE HINTS S6 STOP LIGHT SW 2-1 : Closed with the brake pedal depressed L4 LIGHT FAILURE SENSOR 1, 2, 7-GROUND : Approx. 12 volts with the stop light SW on 4, 8-GROUND : Approx. 12 volts with the ignition SW at ON position 11-GROUND : Always continuity [Q] : PARTS LOCATION Code See Page See Page See Page L4 36 R7 37 H17 36 R6 37 S6 35 : RELAY BLOCKS Code 1 @@@ €€€ ÀÀÀ ,,, ,,, @@@ €€€ ÀÀÀ ,,, @@@ €€€ ÀÀÀ Code See Page 18 Relay Blocks (Relay Block Location) R/B No.1 (Instrument Panel Left) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR See Page Junction Block and Wire Harness (Connector Location) IB 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 3C 22 Instrument Panel Wire and J/B No.3 (Instrument Panel Left Side) [T] : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 42 Floor Wire and Instrument Panel Wire (Left Kick Panel) BV1 50 Luggage Room Wire and Floor Wire (Luggage Compartment Left) [U] : GROUND POINTS Code See Page Ground Points Location BL 50 Under the Left Quarter Pillar BO 50 Back Panel Center [V] : SPLICE POINTS Code I5 See Page 44 Wire Harness with Splice Points Cowl Wire Code B18 2001 AVALON (EWD431U) 6 Code 34 [R] [S] Code C7 See Page 50 Wire Harness with Splice Points Luggage Room Wire B [O] : Explains the system outline. [P] : Indicates values or explains the function for reference during troubleshooting. [Q] : Indicates the reference page showing the position on the vehicle of the parts in the system circuit. Example : Part ”L4” (Light Failure Sensor) is on page 36 of the manual. ∗ The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. Example : L 4 Á Á Parts is 4th in order Light Failure Sensor [R] : Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector ”1” is described on page 18 of this manual and is installed on the left side of the instrument panel. [S] : Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector ”3C” connects the Instrument Panel Wire and J/B No.3. It is described on page 22 of this manual, and is installed on the instrument panel left side. [T] : Indicates the reference page describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example : Connector ”IE1” connects the floor wire (female) and Instrument panel wire (male). It is described on page 42 of this manual, and is installed on the left side kick panel. [U] : Indicates the reference page showing the position of the ground points on the vehicle. Example : Ground point ”BO” is described on page 50 of this manual and is installed on the back panel center. [V] : Indicates the reference page showing the position of the splice points on the vehicle. Example : Splice point ”I5” is on the Cowl Wire Harness and is described on page 44 of this manual. 2001 AVALON (EWD431U) 7 B HOW TO USE THIS MANUAL The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points ( EA , IB and IC shown below) can also be checked this way. I GROUND POINT FAN MAIN RELAY 5 A/C FAN RELAY NO.2 5 A/C FAN RELAY NO.3 5 E3 O/D MAIN SW E3 CLOCK W-B W-B A A A A E5 E6 W-B FRONT SIDE MARKER LIGHT RH W-B FRONT SIDE MARKER LIGHT LH W-B BRAKE FLUID LEVEL WARNING SW W-B 2 IA1 W-B ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, I4 W-B W-B B4 COMBINATION METER W-B CRUISE CONTROL MIRROR SW 3 3F W-B REMOTE CONTROL MIRROR SW 13 3G W-B TURN SIGNAL FLASHER 5 W-B 3E I2 REAR WINDOW DEFOGGER SW 6 3E I2 LIGHT CONTROL SW [COMB. SW] WIPER AND WASHER SW [COMB. SW] W-B 15 ID1 W-B I5 W-B W-B 8 IB1 4 4 POWER WINDOW CONTROL RELAY B5 DOOR KEY LOCK SW LH B5 DOOR LOCK CONTROL SW FUEL CONTROL SW 3 IC3 I5 W-B WOOFER AMPLIFIER BR COMBINATION METER 4 BR BR 4 I3 BR I3 COMBINATION METER BR FUEL SENDER W-B 4 BR BR 5 BA1 W-B AUTO ANTENNA MOTOR B5 (4A-GZE) W-B HEATER RELAY POWER WINDOW MASTER SW I5 4 W-B BR B5 DOOR LOCK MOTOR LH W-B 4 RADIO AND PLAYER UNLOCK WARNING SW W-B I8 W-B W-B A/C AMPLIFIER DIMMER SW [COMB. SW] I2 W-B I5 BLOWER RESISTOR HORN SW [COMB. SW] 1 3D W-B W-B BLOWER SW W-B 10 EA2 I4 I6 I5 W-B B4 W-B HEATER SERVO MOTOR AMPLIFIER W-B EA ELECTRICAL IDLE−UP CUT RELAY (M/T) I6 PARKING BRAKE SW 7 W-B 3C E4 B4 HEATER CONTROL ASSEMBLY W-B 7 3B W-B DOOR LOCK MOTOR RH A E5 E4 W-B J1 JUNCTION CONNECTOR W-B W-B W-B E4 W-B DOOR KEY LOCK SW RH A E2 E4 W-B W-B E3 W-B DOOR LOCK CONTROL SW RH DOOR LOCK CONTROL RELAY CIGARETTE LIGHTER E3 W-B RETRACT MOTOR LH PARKING LIGHT LH W-B W-B RETRACT MOTOR RH FRONT TURN SIGNAL LIGHT LH W-B W-B RETRACT CONTROL RELAY PARKING LIGHT RH W-B W-B RADIATOR FAN MOTOR FRONT TURN SIGNAL LIGHT RH W-B W-B 5 W-B FAN MAIN RELAY IB ∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 2001 AVALON (EWD431U) 8 IC B The ”Current Flow Chart” section, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. J POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. 10A ECU-B Short Pin 2 2 7.5A DOME 15A EFI Battery 30A AM2 Fusible Link Block 2 10A HAZARD 6 2 20A RADIO NO.1 Starter S2 10A HORN 100A ALT 60A ABS 6 5 Engine Room R/B (See Page 20) Fuse 20A 10A System Page STOP ABS ABS and Traction Control Cruise Control Electronically Controlled Transmission and A/T Indicator Multiplex Communication System 194 187 180 166 210 DOME Cigarette Lighter and Clock Combination Meter Headlight Interior Light Key Reminder and Seat Belt Warning Light Auto Turn Off Theft Deterrent and Door Lock Control 214 230 112 122 POWER SOURCE 40A DOOR LOCK CB 1.25B FL MAIN W W W 2 2 7 EB1 W W B W B 1 7.5A DOME I2 50A MAIN E7 2 W-L W W W I2 1 1 R W I2 1 B W 1 W B 2 2 4 W-B 2 B 4 B B 2 3 2 4 1 2 1 W-B 2 2 3 1 3 2 B-W G 15A TAIL 1 20A DEFOG B-Y 1 G W-R 1 B 2 1 4 I8 IGNITION SW B-W STARTER RELAY E7 8 IG1 3 ACC 2 1 IG2 B 2 1 TAIL RELAY INJECTION RELAY B-O E7 2 W 15A HAZ-RADIO AM1 2 6 EB1 W-R W-R 2 AM2 E7 7.5A AM2 B G-W W BATTERY 3 EA2 1 EA1 W-B 1 1 E6 15A RAD CIG B-Y 1 ∗ P-L 1 The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 2001 AVALON (EWD431U) 9 B HOW TO USE THIS MANUAL K CONNECTOR LIST [A] I14 I15 DARK GRAY GRAY 1 1 2 I16 J1 J2 BLACK 2 A A 1 2 A A A A B B D D A A B CC CD D A 6 7 8 [B] J3 J4 K1 K2 L1 1 2 1 2 DARK GRAY A A A A A A A A A B B DD A A B CC CDD L2 L3 L4 M1 M2 1 2 3 4 5 6 7 8 9 101112 1 2 3 45 6 78 M3 1 2 1 1 2 3 4 2 M4 [D] N1 GRAY 1 2 3 [C] BLACK GRAY 1 1 1 7 5 6 2 3 4 8 9 10 N2 O1 O2 GRAY BLACK DARK GRAY 1 1 1 2 [A] : Indicates connector to be connected to a part. (The numeral indicates the pin No.) [B] : Junction Connector Indicates a connector which is connected to a short terminal. Junction Connector Junction connector in this manual include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to a wire harness from a different part.) Wire harness sharing the same short terminal grouping have the same color. Same Color Short Terminal [C] : Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. [D] : Connector Color Connectors not indicated are milky white in color. 2001 AVALON (EWD431U) 10 B L PART NUMBER OF CONNECTORS Code A1 Part Name A/C Ambient Temp. Sensor Part Name Part Number Part Number Code 90980-1 1070 D4 Diode (Door Courtesy Light) 90980-1 1608 90980-10962 A2 A/C Condenser Fan Motor 90980-1 1237 D5 Diode (Key Off Operation) A3 A/C Condenser Fan Relay 90980-10940 D6 Diode (Luggage Compartment Light) 90980-1 1608 D7 Door Lock Control Relay 90980-10848 ÁÁ ÁÁ A4 [A] A5 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) A/T Oil Temp. Sensor [B] ÁÁ ÁÁ 90980-10943 D8 Door Courtesy Light LH [C]1413 90980-1 D9 Door Courtesy Light RH 90980-1 1148 A6 ABS Actuator 90980-1 1151 D10 Door Courtesy SW LH A7 ABS Actuator 90980-1 1009 D11 Door Courtesy SW RH A8 ABS Speed Sensor Front LH 90980-10941 D12 Door Courtesy SW Front LH A9 ABS Speed Sensor Front RH 90980-1 1002 D13 Door Courtesy SW Front RH A10 Airbag Sensor Front LH D14 Door Courtesy SW Rear LH A11 Airbag Sensor Front RH A12 Auto Antenna Motor 90980-1 1097 90980-1 1856 D15 Door Courtesy SW Rear RH 90980-1 1194 D16 Door Key Lock and Unlock SW LH 90980-1 1194 D17 Door Key Lock and Unlock SW RH 90980-1 1156 90980-1 1170 [A] : Part Code [B] : Part Name [C] : Part Number Toyota Part Number are indicated. Not all of the above part numbers of the connector are established for the supply. In case of ordering a connector or terminal with wire, please confirm in advance if there is supply for it using “Parts Catalog News” (published by Parts Engineering Administration Dept.). 2001 AVALON (EWD431U) 11 FOREWORD This wiring diagram manual has been prepared to provide information on the electrical system of the 2001 AVALON. Applicable models: MCX20 Series For service specifications and repair procedures of the above models other than those listed in this manual, refer to the following manuals; Manual Name
2001 AVALON Repair Manual Volume 1 Volume 2
2001 AVALON New Car Features Pub. No. RM808U1 RM808U2 NCF191U All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. NOTICE When handling supplemental restraint system components (removal, installation or inspection, etc.), always follow the direction given in the repair manuals listed above to prevent accidents and supplemental restraint system malfunction. 2001 AVALON (EWD431U) 1 A INTRODUCTION This manual consists of the following 13 sections: No. Section Description INDEX Index of the contents of this manual. INTRODUCTION Brief explanation of each section. B HOW TO USE THIS MANUAL Instructions on how to use this manual. C TROUBLESHOOTING Describes the basic inspection procedures for electrical circuits. D ABBREVIATIONS Defines the abbreviations used in this manual. E GLOSSARY OF TERMS AND SYMBOLS Defines the symbols and functions of major parts. F RELAY LOCATIONS Shows position of the Electronic Control Unit, Relays, Relay Block, etc. This section is closely related to the system circuit. G ELECTRICAL WIRING ROUTING Describes position of Parts Connectors, Splice points, Ground points, etc. This section is closely related to the system circuit. INDEX Index of the system circuits. SYSTEM CIRCUITS Electrical circuits of each system are shown from the power supply through ground points. Wiring connections and their positions are shown and classified by code according to the connection method. (Refer to the section, ”How to use this manual”). The ”System Outline” and ”Service Hints” useful for troubleshooting are also contained in this section. I GROUND POINT Shows ground positions of all parts described in this manual. J POWER SOURCE (Current Flow Chart) Describes power distribution from the power supply to various electrical loads. K CONNECTOR LIST Describes the form of the connectors for the parts appeared in this book. This section is closely related to the system circuit. L PART NUMBER OF CONNECTORS Indicates the part number of the connectors used in this manual. M OVERALL ELECTRICAL WIRING DIAGRAM Provides circuit diagrams showing the circuit connections. A H 2001 AVALON (EWD431U) 2 1 AVALON ELECTRICAL WIRING DIAGRAM B- W B- W B- W W- B W- B B- W W- B B- W W- B B- W W- B B- W W- B B- W W- B I7 IGNITION COIL AND IGNITER NO. 6 I6 IGNITION COIL AND IGNITER NO. 5 I5 IGNITION COIL AND IGNITER NO. 4 I4 IGNITION COIL AND IGNITER NO. 3 I3 IGNITION COIL AND IGNITER NO. 2 I2 IGNITION COIL AND IGNITER NO. 1 N1 NOISE FILTER (Ignition) B- R LG B- Y L B- Y L- Y B- Y LG- B B- Y B- R B- Y GR B- Y W- B LG L L- Y LG- B B- R B- Y GR W- B W- B To Engine Control Module<3- 11> To Combination Meter <21- 5> From Engine Control Module<3- 6> J1 JUNCTION CONNECTOR B- R B- R B S1 A , S2 B BATTERY EC Rear side of surge tank Front side of left fender ED P1 PARK/NEUTRAL POSITION SW B- R W- B B- R F 6 A , F7 B FUSIBLE LINK BLOCK B W- B W- B B- R B- R B B B- W B- W 40A MAIN 10A AM2 N B- Y B- Y B- Y 3 3 3 3 3 3 2 6 3 2 B- W B- W B- O W- R 1 A 11 A B FL MAIN 3. 0W B- R 4 II2 4 2F 4 2D 2 2 2 2 2 2 IG2 RELAY ST RELAY 1 1 5 3 3 2B 6 2A 4 4 4 4 4 P B- W B- W 1 1 1 1 1 1 5 15A IG2 B- W W- R 2 4 5 8 2B 11 2C 7 2C 7 II1 W- B W- B 2 1J 4 IF1 1 1 2001 AVALON (EWD431U) 1 B 7 1C I15 IGNITION SW 4 3 2 1 B- W B- O B- W B- W IG2 6 ST2 8 7 AM2 10 2C 8 2A 2 2G S tarting and Ignition P ow er S ource STARTER M B 2001 AVALON (EWD431U) W- R B B- L W R- L Y Y W- B (*4) 17 IG1 B W- B (*4) B- L FL MAIN 3. 0W Roof left 4 8 GND RDEF 7 4F 7 4C W- B IF Left kick panel A15 REAR WINDOW DEFOGGER SW [A/C CONTROL ASSEMBLY] W- B (*3) W- B (*4) I16 INNER MIRROR W- B To Body ECU <8- 8> GENERATOR G1 A , G2 B BATTERY BL 4 1I 24 GND RDEF 18 3 1L 5 4G 5 4H 1 IB2 B 14 4H To Engine Control Module<3- 11> 1 IN1 Right kick panel B B B 13 IN1 11 IB1 II J6 JUNCTION CONNECTOR 1 C (*4 *5) 10 A (*3) 6 B (*4 *6) 2 C (*4 *5) 5 A (*3) 3 B (*4 *6) 1 C (*4 *5) 10 A (*3) 6 B (*4 *6) 2 C (*4 *5) 5 A (*3) 3 B (*4 *6) 11 1B 10A MIR HTR W- B IG 1 8 ID2 DEF RELAY W- B B J4 JUNCTION CONNECTOR 5 1E 2 2 1 W- B B REAR WINDOW DEFOGGER 40A DEF 1 5 3 1 : Manual A/C 2 : Automatic A/C 3 : w/ Driving Position Memory 4 : w/o Driving Position Memory 5 : Taiwan 6 : Except Taiwan 7 : w/ Daytime Running Light B , C W- B Cowl side panel LH W- B 1 2 13 IG1 1 NOISE FILTER 2 N2 NOISE FILTER (Rear Window Defogger) 2 NOISE FILTER 1 * * * * * * * 4 MIRROR HEATER RH [REMOTE CONTROL MIRROR RH] W- B 2 S A 3 A 1 IG L A 13 4C 4 4D R- B 1 B B 5A ECU- IG NO. 1 B , C FUSIBLE LINK BLOCK 10 1D 10A GAUGE NO. 1 2 1 R13 A , F 9 D , F10 E R- L W- B (*1) F 6 A , F 7 B , F8 C Y 16 II1 IG1 RELAY 3 R ear W indow D efogger and M irror H eater R14 A , 1 A R- L B 120A ALT 1 D M7 CHARGE WARNING LIGHT [MULTI DISPLAY] R- B 1 B B- O 11 3A 2 3A Y R- L (*7) 5 1D 2 1 1 1G R- B 6 IJ1 12 3 1B 4 3 4 1C 2 B B 1 C 5A ALT- S 11 13 1A 7 1C W- R W A utomatic G lare- R es istant E C M irror R- B (*1) B 1 2G 2 2G 10A AM2 11 2B B- O IG2 6 ST2 W- R IG1 4 ACC C harging R- B (*2) 1 2H 7 2C W- R B B 1 E 5 40A AM1 4 IF1 I15 IGNITION SW 7 AM2 2 AM1 W- R 1 W- L 5 W- R 2 7 IF1 W- L 1 P ow er S ource 2 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM MIRROR HEATER LH [REMOTE CONTROL MIRROR LH] W- B (*2) H9 REAR WINDOW DEFOGGER SW [HEATER CONTROL SW] B MEMO 2001 AVALON (EWD431U) W- L W- L IG1 RELAY B 40A AM1 2001 AVALON (EWD431U) W- B B- R F 6 A , F 7 B , F 8 C , F10 E W- B ED Front side of left fender B- W J11 JUNCTION CONNECTOR 2 2B B- W BK W- B B- O W- B Rear quarter inner LH A 2 5 M 4 1 ID2 B B 8 4F II W- B IG 13 2B 3 1 IF1 8 4D 5 GND +B 1 1 2 CODE ANT1 3 RXCK 2 4 TXCT ANT2 TRANSPONDER KEY COIL Right kick panel J6 JUNCTION CONNECTOR W- B BATTERY 12 2B 3 IG2 RELAY 8 II1 2 1 L- B FL MAIN 3. 0W 1 A EFI RELAY 13 2C 4 2F 2 5 6 2 6 6 P- G Cowl side panel LH B- L 7. 5A OBD- II 1 C 10 2B 3 5 3 1 B- W B- W B- W B- W B- W B- W B- W L- O B B- W B- R B- O B- W G- B P- G L- O L- Y T6 TRANSPONDER KEY AMPLIFIER 1 2G W 120A ALT B 1 B 1 7 1C B- R 1 E 1 12 1B 2 1J C/OPN RELAY 1 2H 5 11 2C 6 L- B 2 2G 15A IG2 2 2A 5 F15 FUEL PUMP G- B 1 1G 2 2F B- O W- B 3 1B B 5 L- O 25A A/F 6 2B B- W 4 7. 5A EFI NO. 2 B- W 1 2A B- W 1 15A EFI NO. 1 B- W 9 2B 6 IF1 B- O B- W 4 R- B R Q P O N M L K J I H G F E D C B A (Cont. next page) E ngine Immobiliser S y stem B- W 1 10A AM2 W- R 4 2B B- W B- O B- W 3 W- R 7 2C ST2 8 IG2 6 IG1 4 B- W 1 1I I15 IGNITION SW 7 AM2 2 AM1 3 B- O 2 4 1C W- R W- R 4 IF1 W- L ACC 2 B- R 5 10A GAUGE NO. 1 1 P ow er S ource B- O 2 7 IF1 R- B 10 1D 3 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM L- Y L- O W- B B- R B- W A/F RELAY B- R B- R FUSIBLE LINK BLOCK B 3 AVALON (Cont’ d) (Cont. next page) E ngine C ontrol A B C D E B- W B- W B- W B- W B- W B- W B- W B- W 4 A 3 A #30 2 A 1 A PS G 8 D HTS OXS NEO ENG+ ENG- TRC+ TRC- VG E2G THA 16 D 14 E 21 E 13 E 20 E 10 B 19 B 22 B L- B R- B R G- W BR GR V Y- B D 2 1 3 2 1 M1 MASS AIR FLOW METER 1 P2 POWER STEERING OIL PRESSURE SW 4 5 From Translate ECU<11- 1> W B- W B- W B- R D L 2 9 B To Multi Display <21- 8> I8 INJECTOR NO. 1 B- W B- W CF D L B- W 1 B- W B- W B- W B- W B- W B- W 2 I9 INJECTOR NO. 2 2 1 TC 9 D L J8 JUNCTION CONNECTOR 1 I10 INJECTOR NO. 3 2 I11 INJECTOR NO. 4 1 26 D 5 B R Y W 2 I12 INJECTOR NO. 5 I13 INJECTOR NO. 6 To ST Relay <1- 2> W- B 21 7 3G G- B G G B- R 1 5 D #10 6 B V 22 BR ENGINE CONTROL MODULE #20 10 IC1 C9 SECURITY INDICATOR LIGHT [COMB. METER] B- W B- O B- W A J5 JUNCTION CONNECTOR B- W J9 JUNCTION CONNECTOR A Cowl side panel RH IJ A Cowl side panel LH W- B W- B B- W B- R W- B R TBP V- W B- R Q #40 18 IK2 BR 7 E #50 BR 22 E #60 19 IK2 B 1 E STA B- W P 3 D ACI1 B 2 E B- O L- O P- G G- B W L- Y P- G C L- O L- Y J5 JUNCTION CONNECTOR C 4 IC1 3 E IMLD IGSW BATT 8 IK2 (*1) 18 D 19 D 28 D FC 7 3A O CCV (*1) ACM1 OX 3 LG ACIS 15 B HT 1 G 4 E TXCT RXCK CODE W N MREL 10 E E1 L 6 E B- Y M RSO 11 C F 12 II1 P- B SIL W- B L EVP1 17 E E4 A , E5 B , E6 C , E7 D , E8 E W 7 7 4B K +B 8 E E 4 +B LG 8 G W- R NSW B- Y W- B 20 4B 4 26 A D BR TE1 2 B- W E1 6 IF3 6 ID1 G SIL 7 R- B CG 4 M6 MALFUNCTION INDICATOR LAMP[MULTI DISPLAY] SG W D3 DATA LINK CONNECTOR 3 5 BAT 7 B C W- B B- W H8 HEATED OXYGEN SENSOR (Bank 1 Sensor 2) +B From FAN NO. 1 Relay <18- 4> G 18 II1 3 D1 DATA LINK CONNECTOR 1 W- B 1 12 LG- R 2 2 B- W 1 V14 VSV(Pressure Switching Valve) B- W P- B 1 W- L BR B 2001 AVALON (EWD431U) 16 16 E 16 IK2 B- W 13 4F 20 D B BR 3 ID1 V2 VSV(ACIS NO. 2) V4 VSV(Canister Closed Valve) 2 B- W B- W 2 V3 VSV(ACM) 2 BR G- B B- R B- W B- W 4 4D 3 1 R- Y 1 L- O R- B 2 17 II1 B- W B- W 1 B- W B- W BR 2 V1 VSV(ACIS NO. 1) 1 B- W B- W B- W 16 II2 B- W B- W B- W B- W A B- W B- W B- W B- W J L- O I1 IDLE AIR CONTROL VALVE I BR BR V5 VSV(EVAP) H 8 B L- O G * 1 : Shielded 7 6 B- W F 5 R- B IG H M M OVERALL ELECTRICAL WIRING DIAGRAM A BR (*1) EC A A W- B (*1) BR J7 JUNCTION CONNECTOR A A W- B EB Surge tank RH 2 1 L C C 2 1 22 A VV2+ C C 1 EB1 W 4 EB1 (*1) 2 EB1 W 2 1 3 EB1 (*1) 1 K1 KNOCK SENSOR 1 1 K2 KNOCK SENSOR 2 W E2 ENGINE COOLANT TEMP. SENSOR 2 W 1 G- Y L- R W 20 ID1 E2 14 II2 W 2 1 W VTA E2 T3 THROTTLE POSITION SENSOR L- R L- R W W L- R W 1 2 PTNK 3 P VC P VCC V12 VAPOR PRESSURE SENSOR LG 3 Y- G (*2) To Multi Display <23- 6> To A/C Control Assembly <22- 5> B (*2) To Multi Display <22- 5><21- 8> R- Y To Unlock Warning SW<8- 10> 2001 AVALON (EWD431U) W Y- R (*3) H 2 B 7 D 23 B VTA1 KSW B- W 4 ID1 NE- 24 B W Y- R (*2) TACH THWO G BR BR F W- B E B- W D BR B- W C B A BR A10 AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) 23 D 27 D 14 D 1 3 B B- R 2 B- W A/C 20 B 11 B 3 9 4 B- R AFR+ BR AFR- VC (*1) C2 CAMSHAFT POSITION SENSOR RH 10 A VV1+ KNKR W (*1) HAFR A11 AIR FUEL RATIO SENSOR (BANK 2 SENSOR 2) C1 CAMSHAFT POSITION SENSOR LH L J8 JUNCTION CONNECTOR HAFL 4 B 1 2 B- R A A E1 8 B 17 B 1 B E04 E03 E02 E01 NE+ 16 B 21 A 31 A 30 A SPD IGT6 IGT5 IGT4 IGT3 IGT2 IGT1 L L- R B- W C3 CRANKSHAFT POSITION SENSOR B- W 5 ID1 21 B B- W IGF AFL+ 12 B 3 4 B- W AFL- (*1) L (*1) (*1) 1 2 R- B TACH ACMG E05 V7 VVT SOLENOID RH 10 6 D 5 A R (*1) W- B 27 A 1 2 R- L KNKL V6 VVT SOLENOID LH W- B (*1) E2 R- W BR W- B 18 B 28 A G THW From ” TAIL” Fuse <6- 2> W- B 14 B B W- B (*1) E 4 A , E 5 B , E 6 C , E 7 D , E 8 E ENGINE CONTROL MODULE E ngine C ontrol From ” MIR HTR” Fuse<2- 4> W- B (*1) PTNK G- W From Stop Light SW<6- 3> W- B L STP B- Y BR L ELS2 GR ELS B- R 4 D 13 D 15 E 25 A 11 A 12 A 13 A 14 A 15 A 16 A 22 D 27 D LG- B OC2- L- Y 18 A 11 From Ignition Coil and Igniters <1- 3><1- 4> L OC2+ LG 29 A V- W 6 A From Multi Display <21- 6><21- 8> OC1- B OC1+ LG- R From Diode(A/C) <22- 3><23- 6> 17 E 1 D B EOM B BR B BR BR 15 II2 B B BR 21 IK2 12 BR 10 L2 BR A (*1) BR Rear side of surge tank A A * 1 : Shielded * 2 : Automatic A/C * 3 : Manual A/C (*1) W- B J5 JUNCTION CONNECTOR 3 AVALON (Cont’ d) A A BR (*1) MEMO 2001 AVALON (EWD431U) B W 2001 AVALON (EWD431U) B B- L 1 A W- B ED B- W Front side of left fender 25 D 24 D OD1 G- Y S2 E2 THW B 2 4 SLN- 1 SLN+ Y SL SLN+ E02 E1 E03 2 W- B EB A 1 B E04 L W- B J7 JUNCTION CONNECTOR BR G- W P EC 6 II2 Rear side of surge tank 9 E Y G- Y R- B G- O G- O ODMS ODLP 8 B 12 C E05 Y 7 II2 18 II2 W- R W- G W H G F E D C B A (Cont. next page) W- B Surge tank RH A A 21 A 31 A 17 B 30 A E01 R 8 C 14 C 13 C BR E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 3 S1 G- Y 6 SLN- 19 A 20 A SPD W- B S2 B B SL 7 A 15 C SI ENGINE CONTROL MODULE 1 C B VTA1 22 D 4 W- B BATTERY 16 E IDLO VC 2 B 23 B 18 B 14 B E4 A , E5 B , E6 C , E7 D , E8 E STP 15 E See Engine Control System<3- 9><3- 10> W- B FL MAIN 3. 0W 1 E +B NC2- GR F 6 A , F 7 B , F 8 C , F10 E 17 II1 8 E BATT NC2+ 23 A J8 JUNCTION CONNECTOR G- Y FUSIBLE LINK BLOCK B- R 8 II1 4 2B L- O 120A ALT B- W 6 IF1 10 2B MREL IGSW R 24 A G NSW B- O 2 E O1 O/D DIRECT CLUTCH SPEED SENSOR 1 B EFI RELAY 7. 5A EFI NO. 2 B- W 20 D 1 2 G- W 1 C 2 2F 3 2 12 1B 7 1C From Stop Light SW<6- 3> 4 2F 15A EFI NO. 1 5 1 B- O B- W V- W 2 2G IG2 6 ST2 8 W- R To Speedometer [Multi Display] <21- 6> 1 2G 7 2C W- R I15 IGNITION SW 7 AM2 W- L IG1 4 W- G 3 R- B 1 2H 10A AM2 4 IF1 2 AM1 ACC 3 2 E lectronically C ontrolled Transmission and A /T Indicator G- Y 1 E 5 40A AM1 1 P ow er S ource W- R 1 5 W- L 2 7 IF1 4 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM G- O G- O W- B BR P- L From Cruise Control ECU<14- 3> Y B- W B- R L- O L- O B- R 4 AVALON (Cont’ d) E lectronically C ontrolled T ransmiss ion and A /T Indicator A B * 3 : w/ Traction Control * 4 : w/o Traction Control 7 6 8 W- G W- R W- G C 5 W * 1 : Floor Shift * 2 : Column Shift R- L W 2 W- R P1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] 10 1C 1 1G 4 1C 2 II2 R Y 1 II2 4 II1 19 II2 1 II1 3 II2 1 To Body ECU <8- 22> 7 To Translate ECU(*3) <11- 2> To Diode(A/T Indicator Light 1)(*4)<13- 6> PL 8 To Diode(A/T Indicator Light 1)(*4)<13- 6> RL 9 G- W NL 10 R- B DL 3 Y- R 2L 4 G- Y LL 3 5A ECU- ACC IG1 RELAY 2 4 8 1D GR (*2) 13 1B 15 3C 1 1C 3 1B R- L 18 3H G- O 8 II2 2 3C 16 3F 6 4F 6 4D 18 3G Y- R Y- R G- W R- B R G- Y 3 4 A (*1) 1 B (*2) R- L (*1) W- B O/D OFF P R N D 2 L W- B A R- L (*2) 7 4B G- O A G- O IG Cowl side panel LH Cowl side panel RH J9 JUNCTION CONNECTOR W- B W- B H 2 7 4A A G 1 IJ D6 DIODE (A/T Indicator Light 2) 7 11 4C GR (*2) 15 20 3D R- L (*2) C9 COMBINATION METER 1 7 3A J5 JUNCTION CONNECTOR 2 4D W- B 2 20 3C 2 A (*1) 3 B (*2) O3 A , B 3 O/D MAIN SW 4 16 3A G- O 5 G- O 6 16 3G Y- G W- B Y 2 3F To Translate ECU<11- 2> 7 3G 21 18 3F 7 3C G- O 17 3G R- L 18 3B 15 3D R- L GR (*2) 18 3A Y- R 18 3D G- W G- W 18 3C 19 4C G- W 6 4C 15 IC1 R- B 16 3C R- B 16 3D Y- R (*4) 17 3B Y- R 17 3A G- Y Y 10A GAUGE NO. 2 R R G- Y G- Y F To Cruise Control ECU<14- 4> Y 2001 AVALON (EWD431U) E 10A ECU- IG NO. 2 R Y D R R- B 20 II1 R- L IG Cowl side panel LH M B W 2001 AVALON (EWD431U) R- L FUSIBLE LINK BLOCK F 6 A , F 7 B , F10 E B TAIL LIGHT CONTROL SW DIMMER SW 15A HEAD LH B- Y B- W ON OFF FLASH HIGH 13 8 HF HU HL H4 HEADLIGHT LOW RH R- Y Front side of right fender Front side of left fender Front side of right fender F2 FRONT FOG LIGHT RH W- B W- B W- B W- B W- B B- W B- Y FOG LIGHT SW ED EA W- B EA R- Y W- B Cowl side panel LH 11 FOG RELAY Front side of left fender B B 4 2F 4 2D J1 JUNCTION CONNECTOR 1 2 10 1H ED W- B IG 16 EL LFG BFG 1 2 4 1B 3 5 W- B LOW HEAD T 2 1C 1 2 15A FOG W- B BATTERY H2 HEADLIGHT HIGH RH H R- L OFF R- L 10 1 2 3 1H G- R 17 R- L 2 IF1 1 2 From ” HEAD LH LWR” Fuse<8- 3> 1 1G 4 F1 FRONT FOG LIGHT LH FL MAIN 3. 0W R- W 7 C9 HIGH BEAM INDICATOR LIGHT[COMB. METER] W- B 1 2 R- L C13 COMBINATION SW R- L 8 IC1 12 R- W 1 2 11 9 IC1 R- W R- B (*2) W F og Light G- R 1 A HEAD 3 A R- W R- W H1 HEADLIGHT HIGH LH 120A ALT HF R- W 2 A B4 A 3 IF1 15A HEAD RH BODY ECU 5 R- W (*2) 3 R- B 1 B 8 5 2 R- W HRLY B- R 1 1 * 1 : w/ Daytime Running Light * 2 : w/o Daytime Running Light R- W 2 2G R- B 4 1J 5 HEAD RELAY 3 5 2 R- B 1 E R- B R- W 1 40A MAIN 5 1 2 5 R- B 4 3 5 R R- B R- B(*2) W H eadlight (w /o D aytime R unning Lig ht) R- B (*1) 2 1 P ow e r S ourc e R- B (*1) 1 2E 5 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM R- Y H3 HEADLIGHT LOW LH 6 AVALON P ow er S ource T aillight and S top Light 1 * 1 : w/ Traction Control * 2 : w/o Traction Control 3 2 4 11 1D 1 1B G- W(*1) G- W(*2) 16 4D 16 4F To Engine Control Module<3- 11><4- 3> G- W 16 4C 2 A 3 G 2 B STOP TAIL 1 6 J12 JUNCTION CONNECTOR W- B C C W- B Rear quarter inner RH Back panel center C W- B BN W- B A 1 N3 NOISE FILTER (Stop Light) 2 C J10 JUNCTION CONNECTOR A W- B R- W 3 H11 HIGH MOUNTED STOP LIGHT W- B 1 R8 REAR COMBINATION LIGHT RH 6 G- R LG 5 SIDE MARKER R7 REAR COMBINATION LIGHT LH 3 STOP Cowl side panel RH W- B IJ TAIL 1 W- B W- B ED J9 JUNCTION CONNECTOR Front side of left fender 2 W- B W- B W- B A W- B IG 1 SIDE MARKER 2 2 G G- R LG G 1 L4 LICENSE PLATE LIGHT RH 2 L3 LICENSE PLATE LIGHT LH 1 G F4 FRONT PARKING LIGHT RH H 1 11 R- W G G G G G HEAD C13 16 LIGHT CONTROL SW[COMB. SW] Cowl side panel LH B B 5 1 W- B A 2 1B G- R F3 FRONT PARKING LIGHT LH OFF B BATTERY EL TAIL W FL MAIN 3. 0W A BODY ECU 14 T 2 A LG P 1 E W 1 A 9 B4 A TAIL 14 A F 6 A , F 8 C , F10 E FUSIBLE LINK BLOCK 120A ALT W- B B- L 1 C A R- W 1 2G 4 J12 JUNCTION CONNECTOR 4 1H TRLY L5 8 LIGHT FAILURE SENSOR G- R 9 3 1B 1 1G A J12 JUNCTION CONNECTOR 1 J13 JUNCTION CONNECTOR LG 4 To Engine Control Module<3- 11> 10A TAIL IG1 RELAY 1 2H 7 A G 3 A 3 5 B 2001 AVALON (EWD431U) 1 TAIL RELAY 17 IM2 5 IK1 G- W 40A AM1 15A STOP 10A GAUGE NO. 1 2 5 G 1 R- B 10 1D 13 4F Y- G To ABS & BA & TRAC & VSC ECU<11- 9> To ABS Actuator and ECU<13- 2> W- L 4 1C 4 4E 14 E Y- G G- W 3 3F 4 D R- B To Shift Lock ECU <12- 2> 12 3C 4 4D G- W 3 3C G- W 3 3D G- W R R- B W- R G- W To Cruise Control ECU<14- 4> 1 IK1 G- W 5 1B M6 D , M7 E W- L I15 IGNITION SW 5 4 1E S4 STOP LIGHT SW G 7 IF1 3 1D G- W REAR LIGHTS WARNING LIGHT [MULTI DISPLAY] 1 2 R R- B IG1 4 R- B ACC 2 AM1 BM M W W- B G G W- G W- G W- B W- G W- G W- G 120A ALT 2001 AVALON (EWD431U) See Taillight and Stop Light System<6- 2> FUSIBLE LINK BLOCK F 6 A , F10 E B W- B H7 HAZARD SW P8 POWER OUTLET MAIN SW R5 REMOTE CONTROL MIRROR SW RADIO AND PLAYER R2 A , R3 B , R4 C G IJ W- B IG Cowl side panel LH W- B 20 3G A15 A/C SW [A/C CONTROL ASSEMBLY] Cowl side panel RH A A 7 3A W- B 3 E ILL- 2 13 3F 4 3F 19 16 W- G A C8 CIGARETTE LIGHTER J5 JUNCTION CONNECTOR 4 3C 4 4A W- G 13 3C W- G (*5) 4 4B 23 15 9 1 3 3G R6 RHEOSTAT 1 * 5 : Floor Shift C9 COMBINATION METER ILLUMINATION [COMB. METER] J9 JUNCTION CONNECTOR W- G 13 4A 3 O3 O/D MAIN SW 7 4B 20 4H 4 1 3 3B 4 * 3 : Manual A/C * 4 : Automatic A/C T G BATTERY G 4 4G G 13 4B 2 G 7 4G 9 12 3B W- G (*3) 13 4G 4 2 12 3A W- G (*4) 13 4H 11 1 9 4F 12 3G H9 A/C SW [HEATER CONTROL SW] 4 4H 10 8 22 4F 3 3A G (*5) 12 A (*1) 5 C (*2) 1 22 4D 9 4C G G (*3) BACK LIGHT CIRCUIT M3 MULTI DISPLAY ILLUMINATION 3 [MULTI DISPLAY] B G (*4) 6 5 B G W- G FL MAIN 3. 0W G G 2 A (*1) 10 B (*2) B B 3 * 1 : 7 Speaker * 2 : 6 Speaker G 1 A 4 1A 5A PANEL TAIL RELAY B G 3 5 B G 2 1 J2 JUNCTION CONNECTOR 2 Illumination G 1 E W 1 1G 1 P ow e r S ourc e 7 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM G3 GLOVE BOX LIGHT SW MEMO 2001 AVALON (EWD431U) W- L 5 B 2001 AVALON (EWD431U) 30A DCC BATTERY B W B- L 15A DOOR NO. 2 B 40A MAIN EA : Front side of right fender(*11) EB : Surge tank RH(*12) 2 EA W- B R- B H3 HEADLIGHT LOW LH R- B W- B G- W H4 HEADLIGHT LOW RH G- W W- B 10A HORN Front side of left fender Front side of right fender R- W ED 2 8 IC1 12 11 9 IC1 R- W 2 1 W- B 1 W- B 11 EA1 W- B DRL NO. 4 RELAY W- B 9 IF1 2 1 10 EA1 C9 HIGH BEAM INDICATOR LIGHT [COMB. METER] 1 2 R- W 9 EA1 2 2 1 R- W FL MAIN 3. 0W R- B W- B 3 4 2 IF1 L 3 IF1 W- B 2 DRL NO. 3 RELAY 2 R- W R- W 1 A 5 2 2 1 2 H2 HEADLIGHT HIGH RH F 6 A , F 7 B , F 8 C , F10 E 5 2 3 5 2 W- R G L FUSIBLE LINK BLOCK B- R 2 15A HEAD LH LWR 4 2 5 EA1 G 2 HEAD RELAY 15A HEAD RH LWR 1 5 R 5 R- L 1 7. 5A DRL G G 120A ALT 5 4 2 5 2 EA1 R 3 1 1 2 2 1 2 10A HEAD LH UPR 2 3 4 2 2 2 2 10A HEAD RH UPR R 2 4 R 1 B 1 1 5 10 IF3 W- R 1 2 1 2E 3 5 R- L 3 W- B R- B DRL NO. 2 RELAY R- B B- R L- R W W- R R- G W- L *11 : Except Canada *12 : Canada R- B 1 E W- L R- B 1 C R- B 4 2E R- B 2 2G B- R 5 2C 2 5 R W- R 1 2G L- R 12 2C 8 IF1 R 1 2C 6 EA1 R R- B G 1 2H 40A AM1 W- R R- G 2 M u ltiplex C ommunication S ystem R 1 W- L 5 I15 IGNITION SW ST1 IG1 4 ACC 3 1 P ow er S ourc e I H G F E D C B A (Cont. next Page) R 2 7 IF1 2 AM1 8 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM H1 HEADLIGHT HIGH LH L To Fog Relay<5- 3> 8 AVALON (Cont’ d) (Cont. next Page) M ultiplex C ommun ication S y stem 5 A B C 7 6 8 W- L W- L R- G L- O W- R R- B W R- B D A B C D L- R E B- R F B4 A , B5 B R- B G R- B 7 IF3 BDR2 HEAD SIG BDR1 TRLY 3 7 2 1 9 8 ALTL L- O R- L SH BODY ECU 6 B 5A ECU- ACC B- R T4 THEFT DETERRENT ECU 24 ACC E P- B F L G LG LGU 1 14 Y- R L- R R- Y V W- G R- B 4 L- R 10 10 1C 5 1J 4 1J R- G 2 IG R- B +B2 20A RL P/W 5 P 1 10 1A 20A RR P/W 1 LG 25A FL P/W 3 1 1L 2 3 1 5 PWR RELAY 2 3C 7 3A 13 1B 3 1B 10 1E 1 1G Y- R L- R R- Y V W Y- R 4 2F 7 4E L- R W- G W- B W- B A W- B J5 JUNCTION CONNECTOR A W- B 20 4A W- G W- B 4 2D R- B R- B W- B W- B W- B J9 JUNCTION A CONNECTOR A A J10 JUNCTION CONNECTOR Rear quarter inner RH 2 IG1 RELAY W- B W- B 4 12 1L 9 1L 20A FR P/W 2 TAIL RELAY 3 11 3F 25A DOOR NO. 1 1 L 8 1A P- B 10 1D 10A ECU- IG NO. 2 B 2 1D 2 10A GAUGE NO. 1 Y- R J1 JUNCTION CONNECTOR B 8 1I 30A PWR SEAT 18 4H W- B 21 E3 ENGINE HOOD COURTESY SW 2 4 1C BN H I L- O 18 4B B 1 W- B W- B I T2 THEFT DETERRENT HORN H KSW W- B B 22 7 3G 1 12 MPX1 18 IF3 V 1 10 IC1 C9 SECURITY INDICATOR LIGHT [COMB. METER] G- W L6 LUGGAGE COMPARTMENT DOOR KEY UNLOCK SW 2 V- W G- W W 2001 AVALON (EWD431U) 1 IK2 6 +B1 R- B 12 E L- O 3 DSWH W- R 25 IND From Generator <2- 2> SH- Front side of left fender ED IJ Cowl side panel RH W- B W- B R- Y W- B EA V J K L M N Front side of right fender M 2001 AVALON (EWD431U) W- B Y- G Y- G (*1) From Translate ECU <11- 11> Y- G (*2) From Active Light Relay <13- 7> IG R- Y W- B Cowl side panel LH W6 WIRELESS DOOR LOCK BUZZER A 2 W- B IJ A 1 CLTS CLTE 7 B 1 1 CLTB 3 CLTE W- B DIMMER SW V R- B Cowl side panel RH J9 JUNCTION CONNECTOR 2 CLTB 20 B A28 AUTOMATIC LIGHT CONTROL SENSOR CLTS 4 8 B W- B V P3 PARKING BRAKE SW 7 4B BZ 20 A T1 THEFT DETERRENT BUZZER N G- O W- B W- B R- Y LIGHT CONTROL SW W- B W- B B W- B B B U1 UNLOCK WARNING SW R- Y W- B J4 JUNCTION CONNECTOR L2 LUGGAGE COMPARTMENT DOOR OPENER SW 7 4H 2 1 2 1 L 22 3D L1 LUGGAGE COMPARTMENT DOOR OPENER MAIN SW BUZZER 9 3D 1 2 4A 11 4B R- Y TKL 18 B P- L R- B B- R C13 COMBINATION SW 1 2 2 4B 11 4A B4 A , B5 B BODY ECU P- L BUZZER W- G 16 B- W TR+ 25 A M 2 4 IK1 L M R- B 5 3B 17 A KSW L- B P- L FLASH P DCTY 5 A 1 17 3E 17 3D 17 3C 17 4C From Moon Roof Control ECU <18- 3> R- L HIGH R- Y O LOW Y- G 5 3A 11 A GND2 R- Y 12 14 3A 15 A PKB LG 14 14 3B 4 A AUTO Y- B 13 14 A TAIL L PCTY 3 B 1 17 4E 17 4F 12 RCTY 16 B 14 4F 5 4F 1 2 IA1 R- W AUTO 8 3 A HEAD L HEAD 7 2 A HF 11 R- L TAIL OFF 13 A HU 10 O 8 EA1 P LG L P- B L- O 23 A MPX1 9 * 1 : w/ Traction Control * 2 : w/o Traction Control R- W 1 5 4E P LG L P- B L- O R- B R- B L- O W- L W- B W- G R- W L DRL 10 A R- B R- B L- O W- L M ultiplex C ommun ication S y stem I H G F E D C B A (Cont. next Page) K J D14 DOOR COURTESY SW REAR RH K J I H G F E D C B A 8 AVALON (Cont’ d) M OVERALL ELECTRICAL WIRING DIAGRAM D13 DOOR COURTESY SW REAR LH R- W D12 DOOR COURTESY SW FRONT RH O D11 DOOR COURTESY SW FRONT LH R- L L7 LUGGAGE COMPARTMENT DOOR UNLOCK MOTOR W- B From Engine Control Module<3- 9> 8 AVALON (Cont’ d) (Cont. next page) M ultiplex C ommun ication S y stem 13 A B C D 15 14 16 W- L W- L L- O L- O R- B R- B R- B R- B A B C D B 4 A , B 5 B BODY ECU TC LGC 18 A E F G 8 A RRD RRU 22 B 22 A LSW 10 B ACT- 5 B 15 B L- O L- O P- B P- B L L LG G- B L- B 6 3F 1 IM2 17 ID1 4 IM2 3 IM2 L- O 9 BA1 2 BA1 1 BA1 C C 10 BB1 10 BA1 L L 8 BB1 5 IA1 L- B 3 11 IM2 J3 JUNCTION CONNECTOR L 1 C L- B P15 POWER WINDOW MOTOR RH M W- B 2 4 L 8 BA1 1 C L 4 2 W- B M M L 1 2 W- B 12 BB1 W- B W- B P14 POWER WINDOW MOTOR LH U 5 3 W- B 2 D G M UP R 1 DOWN 2 W- B G R 12 BA1 E 3 6 D16 DOOR LOCK MOTOR REAR RH U 5 B L- R L- O D 1 D15 DOOR LOCK MOTOR REAR LH UP 2 W- B 1 R- W TC D1 DATA LINK CONNECTOR 1 K 11 3 L9 LUGGAGE COMPARTMENT LIGHT SW LG- R J W- G D2 DATA LINK CONNECTOR 2 TC E R- W 22 II2 DOWN 4 9 BB1 L- O B 6 P11 POWER WINDOW CONTROL SW REAR RH LG- R LG- R 4 1 G- B 4 L- R 3 BB1 R- B 3 4E 1 BB1 LG 12 4E P10 POWER WINDOW CONTROL SW REAR LH 6 4A G- Y Y- R P 13 3A 2 BB1 3 BA1 H 10 IN1 10 IM2 L- O G- B R- B L- W 12 4C G- Y 6 4H Y- R 4 3G L- O 6 3E LG- R F G L 18 ID1 L- Y 4 3A R LG- R 2001 AVALON (EWD431U) 19 3F 1 IA1 E L R- B P G- Y P Y- R I 6 A RLU L- O H RLD L- R L- R R- W W- G W- B W- B W- B W- B I J K L M N O W- B BM Back panel center M 2001 AVALON (EWD431U) L- O Y- G D10 DOOR COURTESY LIGHT FRONT RH R- L R B Y LOCK L- Y UNLOCK L- R 2 M 1 6 KL LSWD 4 24 D17 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH 5 22 3 9 KEYE 5 CTYB 1 2 6 CTYE W- L R- B R- B L- O W- L W- B R W- B P13 POWER WINDOW MOTOR FRONT RH W- B G- O W- B G- Y W- B Y- B W- G W- B W- B L- R W- G 5 BB1 L- R O LG- B L- R W- B 5 BA1 L- R 11 IN1 9 IB2 KUL 10 B R- W 3 IB2 L- R N G UNLOCK M 13 IN1 A D19 DRIVER DOOR ECU R L- R 7 13 IA1 A 12 IM2 A BDR 25 R- L R- W 8 A L- R R14 REMOTE CONTROL MIRROR RH 9 8 GND L L LG M 6 PVC 19 LOCK J 1 MH 14 W- B M 2 15 7 WLSW 20 K J I H G F E D C B A (Cont. next page) D9 DOOR COURTESY LIGHT FRONT LH K L- B M+ 7 L- R 1 3 17 MPX2 8 2 IB1 6 IB2 8 IB1 G LG L- R L- W MV 18 PMVR PM+R PMHR GND2 VSSR HSSR 16 L- R M 2 1 UP2 L- B D18 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH 9 DWN2 L- R L- R 1 2 5 CTYE ACTD 1 B L- W 6 4 6 CTYB A J2 JUNCTION CONNECTOR L- R M 3 KEYE 13 MPX2 11 L- R 2 4 LSWP CPUB 12 G ACT+ 2 B 19 L- W 1 KL MPX1 L 10 9 IN1 G- B BDR 7 IN1 W- G 20 8 IN1 G 6 IN1 L G 3 MPX4 21 B G- B P- B 2 BODY ECU B4 A , B5 B 18 W- L L- O KUL F14 FRONT PASSENGER DOOR ECU 17 P- B 5 L- B L P- B L- O R- B R- B L- O W- L M ultiplex C ommun ication S y stem L- O I H G F E D C B A 8 AVALON (Cont’ d) M OVERALL ELECTRICAL WIRING DIAGRAM 8 AVALON (Cont’ d) (Cont. next page) M ultiplex C ommun ication S y stem 21 A B C D * 3 : Taiwan 23 22 24 W- L W- L L- O L- O R- B R- B R- B R- B A B C D B 4 A , B 5 B BODY ECU P B MPX3 1 A 9 B DBEW 24 A PBEW 23 B 11 B AJAR 25 B CLTC 13 B W- L W- G G- W W- G W- L R- Y E W- L R- B 9 IB1 W- B (*3) R G- R 4 4D 10 E 2 E OPEN DOOR 13 4F PASSENGER SEAT BELT 4 4F DRIVER SEAT BELT 7 5 3D 8 4F 5 IB1 R- B R- B M6 D , M7 E 4 D 8 4E 3 E W- B W- B P- L MULTI DISPLAY R- B K W- B 5 3C W- G J B W- B I W- B H W- B G B 14 3E 21 4F R- B W- B LIMIT SW F P12 POWER WINDOW MOTOR FRONT LH W- B B 14 3D 2 D M J6 JUNCTION CONNECTOR R13 REMOTE CONTROL MIRROR LH B 8 5 3F SIG R- B 9 14 3F 21 GR 6 DVC 11 GR- L 1 MH 19 LG- B 2 M+ VSSR HSSR 18 LG- R 3 MV M E2 12 BR- W 11 IB1 16 Y- G BR- Y W- B 5 B 15 G- W DMVR DM+R DMHR 17 R- B GND 13 W 4 PULSE SENSOR M 3 Y 2 P G R 1 E 4 W- G LMT 2 W- G PLS 3 CPUB W- G UP2 1 23 MPX1 W- L DWN2 14 20 W- L W- G D19 DRIVER DOOR ECU P- L W- B W- B R- W R- W F G 1 IB1 R- Y 2001 AVALON (EWD431U) From A/T Indicator Light SW [Park/Neutral Position SW] <4- 7> E H I J K W- G W- B W- B W- B W- B W- B W- B II L M N Right kick panel M 2001 AVALON (EWD431U) W- B Left kick panel DOOR W- B W- B (*4) BL Roof left W- B 1 2 A W- B A A W- B BK A 1 2 7 ID1 W- B W- B See Horn System <9- 3> W- B W- B W- B Rear quarter inner LH J11 JUNCTION CONNECTOR W- B 1 2 R12 REAR INTERIOR LIGHT RH IF L8 LUGGAGE COMPARTMENT LIGHT P- L R- W 4 IA1 W- B W- B 1 W- B W- B G- R 2 2 P- L 1 1J * 3 : Taiwan W- B N P- L G- R W- B I14 IGNITION KEY CYLINDER LIGHT 17 IG1 11 IG1 1 DOOR G- R I17 INTERIOR LIGHT ON OFF 1 3 P- L P9 PERSONAL LIGHT ON OFF G- R G- R 8 IG1 P- L P- L M P- L 2 2 5 IG1 From Center Airbag Sensor Assembly <15- 2> HORN 10 V11 VANITY LIGHT RH W- B D7 DIODE(Luggage Compartment Light) 1 1 10 4C P- L 2 2 1 1 4C 10 4D P- L GSW 19 A V10 VANITY LIGHT LH W- B 2 P- L 1 4E 10 4E See Stop Light System <6- 3> P- L W- B L 5 +B G- R 1 E PRG 1 4D 3 1D B 4 A , B 5 B BODY ECU P- L W- B L- W 3 G- R 2 P- L 1 4E P- L RDA 1 4F P- L 11 STOP R11 REAR INTERIOR LIGHT LH R- W L- W 20 IK2 G- R 9 IK2 3 1C 5 ILL P- L P- L W- B 7 A PRG L P- L J 21 A RDA 28 W- B W- B P- L R- B W- G W- G R- B R- B L- O W- L J I H G F E D C B A (Cont. next page) P- L K 14 B GND1 27 L W- B P- L R- B W- G W- G R- B R- B L- O W- L 26 M ultiplex C ommun ication S y stem P- L I H G F E D C B A 25 8 AVALON (Cont’ d) M OVERALL ELECTRICAL WIRING DIAGRAM G- R N3 NOISE FILTER (Luggage Compartment Light) D8 DOOR CONTROL RECEIVER P- L 8 AVALON (Cont’ d) (Cont. next page) * * * * M ultiplex C ommun ication S y stem 29 A B C D 4 : w/ Moon Roof 5 : w/o Moon Roof 6 : w/o Power Seat 7 : w/ Driving Position Memory * 8 : w/o Driving Position Memory * 9 : Floor Shift w/ Driving Position Memory *10 : Column Shift w/ Driving Position Memory 31 30 32 W- L W- L L- O L- O R- B R- B R- B R- B A B C D B4 A , B5 B PBKL SEAT 17 B 4 B G H R- W F BODY ECU 16 A W- R G E DBKL W- G W- G W- G W- G R- B R- B P- L P- L 6 IM2 2 IM2 1 I SWE MMRY POWER SEAT ECU SW2 LFT+ LFT6 A 5 A R L- Y 1 M 2 P23 POWER SEAT MOTOR (Driver’ s Seat Rear Vertical Control) 2 20 B SW1 P25 POWER SEAT MOTOR (Driver’ s Seat Slide Control) M P20 A , P21 B 21 B L 1 Y 9 B G- W G- Y 2 4 L- B M 2 3 W- B 1 1 1 1 SLD- SLD+ 3 A 4 A P22 POWER SEAT MOTOR (Driver’ s Seat Front Vertical Control) M LDWN FRV- FRV+ 9 A 10 A MMRY 2 Y- G E P W- L 9 14 IA1 LUP E 7 B L- R Y- G 15 IA1 2 11 B L- W P 3 IA1 SLDF RCL- RCL+ 1 A 2 A P24 POWER SEAT MOTOR (Driver’ s Seat Reclining Control) 4 BC1 SLDR 8 22 B R- W 3 BC1 6 B R- B Y- G 10 BC1 8 B 7 R- Y MIRG 2 B 9 R- W FUP MIRB 1 B 6 B FDWN MIRE 18 B 11 BC1 W- B H S14 SEAT MEMORY SW B- R RCLF GND 7 A W- B (*5) I W- B (*6) W- B 23 B RCLR W- L J14 JUNCTION CONNECTOR 24 B P 1 C 10 B 10 B- Y M 12 B 5 R- B W- B(*7) 3 W- L 11 BD1 W- B (*7) 2 G- B W- B (*7) W- B (*6) C 2 1 W- B(*7) W- B (*7) W- B (*5) W- B(*8) W- B (*6) C W- B(*9) W- B (*7) W- B (*10) W- B (*5) W- B (*5) W- B (*9) W- B(*9) 3 G 2 4 W- B (*9) 2 B8 BUCKLE SW LH 2 L10 LUMBAR SUPPORT CONTROL MOTOR (Driver’ s Seat) R- W (*9) 2 1 S11 SEAT BELT WARNING OCCUPANT DETECTION SENSOR F G 1 R- L (*9) B9 BUCKLE SW RH R- W (*5) W- R (*5) G (*5) 1 L11 LUMBAR SUPPORT CONTROL SW (Driver’ s Seat) 6 BC1 R- W (*6) G (*6) 8 BD1 P18 POWER SEAT CONTROL SW(Driver’ s Seat) R- W (*5) R- W (*5) G (*5) 6 BD1 L- O(*9) 9 ID1 W- R (*6) 2001 AVALON (EWD431U) L- O(*9) E 8 7 MSW M+ W- B (*6) A J W- B J10 JUNCTION CONNECTOR A BN R5 REMOTE CONTROL MIRROR SW Rear quarter inner RH M F I R- B W- G 2001 AVALON (EWD431U) BR B B BR 2 1 JUNCTION CONNECTOR A R P32 POWER SEAT POSITION SENSOR (Driver’ s Seat Slide Control) R BR J14 JUNCTION CONNECTOR 2 L B 3 A A SSFV 4 B 3 BR P29 POWER SEAT POSITION SENSOR (Driver’ s Seat Front Vertical Control) R Instrument panel brace RH 9 IA1 2 1 A PVCC 5 B J14 POWER SEAT ECU L- B B 3 R SSRS 3 B P20 A , P21 B R B BR 1 SSRR 16 B L- R SGND 19 B MPX1 14 B 7. 5A DOME BR IH W- G G- W IG P- L 13 B 3 2 1 SSRL 17 B L- O(*9) R- B A R- B 7 ID2 1 BC1 +B 8 A L- O SYSB G- W 8 BC1 9 1B L- O 25 B G- W 10 ID1 7 1D 9 1J 7. 5A ECU- B 7 BC1 BR 8 ID1 R- B MPX2 9 A R- B 5 BC1 9 BC1 B4 A , B5 B BODY ECU 34 L- O J3 JUNCTION CONNECTOR A BR L- O(*9) P- L R- B W- G 33 L- O H G W- G R- B R- B L- O W- L M ultiplex C ommun ication S y stem W- L E D C B A 8 AVALON (Cont’ d) 35 36 * 7 : w/ Driving Position Memory * 9 : Floor Shift w/ Driving Position Memory M OVERALL ELECTRICAL WIRING DIAGRAM P30 POWER SEAT POSITION SENSOR (Driver’ s Seat Rear Vertical Control) L- W W- G R BR P31 POWER SEAT POSITION SENSOR (Driver’ s Seat Reclining Control) BR 9 AVALON P ow er S ourc e B ac k- U p Light 1 R- L IG1 4 4 1 : Floor Shift 2 : Column Shift 3 : w/ Moon Roof 4 : w/ Driving Position Memory 5 : w/o Driving Position Memory 2 2G 1 2C 9 1J W- L 7 3C 5A ECU- ACC 7 IF1 W- L 20 3D 7. 5A DOME 30A ECU- B NO. 1 10A HORN I15 IGNITION SW 20 3C 8 1D 7 1D R- L (*2) GR (*2) W- R 5 R- L 40A AM1 1 GR (*2) 3 2F 3 2C 2 3 6 11 1C G- W 8 3A R- B R- L (*2) D 21 3B 20 II1 B J4 JUNCTION CONNECTOR IG BN Rear quarter inner RH Cowl side panel LH IG W- B (*3) J10 JUNCTION CONNECTOR Cowl side panel LH B W- B IG 17 IG1 W- B A W- B W- B (*2) R- B(*2) W- B (*3) W- B W- B R- B(*1) Cowl side panel LH 1 W- B 1 2 B7 BACK- UP LIGHT RH 2 1 II1 BATTERY 1 J12 JUNCTION CONNECTOR R- B A V10 GARAGE DOOR OPENER [VANITY LIGHT LH] R- B B6 BACK- UP LIGHT LH J5 JUNCTION CONNECTOR R- B 8 A 2 R- B 2 P1 BACK- UP LIGHT SW [PARK/NEUTRAL POSITION SW] B FL MAIN 3. 0W W- B (*2) R- L W- B F 6 A , F 7 B , F 8 C , F10 E FUSIBLE LINK BLOCK D H6 HORN RH W- B 120A ALT 6 1 C12 HORN SW [COMB. SW] 1 H5 HORN LH 8 IK1 G- B B- L D6 DIODE(A/T Indicator Light 2) R- B (*1) 2 5 IG1 R- B(*2) P- L W- B (*2) 3 3 1B 1 E 1 1J 6 R- L (*1) 2 W G- B 11 4C R- L (*2) 1 1G 10 4C BK/UP LP RELAY 1 1 2G 2 5 2 4D GR (*2) 4 3 G- W IG1 RELAY B 1 2H 6 P- L 1 10A GAUGE NO. 2 3 B 2001 AVALON (EWD431U) 1 1C 1 5 HORN RELAY 1 4D 6 15 3D 4 1C 1 P- L R- B (*2) 15 3C 1 C 5 R- L(*1) R- L (*2) 2 1 A W- L B * * * * * W- G 10 1C 1 B G arage D oor O pener 3 2 ACC 3 2 AM1 H orn Roof left BL M W- L 5 B L- O L- O W- B L W 2001 AVALON (EWD431U) B- L F5 FRONT WIPER MOTOR M E L W- B B W- B EA 4 Front side of right fender 10 HR B , M+ 2 A (*1 *3) 2 B (*2 *3) 7 C (*4) REMOTE CONTROL MIRROR LH R13 A , M 3 C MV 6 C MH M 4 A 3 B 1 A 1 B 3 C B , M C M+ * * * * 1 : w/ Mirror Heater 2 : w/o Mirror Heater 3 : Except Taiwan 4 : Taiwan Y- G 9 4G 9 4H 7 M+ LEFT/ UP 8 E 7 4F 20 4F Left kick panel RIGHT/ DOWN R5 REMOTE CONTROL MIRROR SW 22 4H 2 A (*1 *3) 2 B (*2 *3) 7 C (*4) REMOTE CONTROL MIRROR RH R14 A , M MV 6 C MH 4 A 3 B 1 A 1 B 2 IN1 12 IN1 Y- G 3 IN1 C VR 5 IB2 2 MV DOWN B 2 IB2 3 VL UP 4 11 4F 4 IB2 Y- G LG 15 3C BR- W Cowl Side panel LH L- B B BR- W BR- Y W- B IG L- B +S L- Y +1 L- Y +2 2 9 RIGHT GR MH BR- Y Y- G BATTERY 1 L 17 HL LEFT 8 1D LG LG FL MAIN 3. 0W W- B 5 16 +B WF BR- W LG- B F 6 A , F 8 C , F10 E 3 7 +S EW BR- Y FUSIBLE LINK BLOCK L 8 +1 WIPER RELAY +2 B1 LG- B Y- G 1 A 2 M 1 2 E INT2 INT1 +S L 120A ALT L W2 WASHER MOTOR 11 WF L- W 1 E 3 1B HI WASHER +1 2 4D Y- G 1 C 25A WIP 5 1C 4 LOW INT OFF C14 WIPER AND WASHER SW[COMB. SW] 15 3D GR 4 W- B 1 2G IG1 RELAY 1 1G 2 3 +2 5A ECU- ACC 10 1C 3 R emote C ontrol M irror (w /o D riving P osition M emory) W- B IF OPERATION SW 1 2H 40A AM1 1 +B W- G 2 W iper and W asher GR 1 W- L 5 4 1C W- R 2 7 IF1 IG1 4 I15 IGNITION SW 2 AM1 ACC 3 1 P ow er S ource 10 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM SELECT SW W- B L MEMO 2001 AVALON (EWD431U) M OVERALL ELECTRICAL WIRING DIAGRAM 2001 AVALON (EWD431U) (Cont. next page) 11 AVALON V S C (w / T ra ction C on tro l) P o w e r S o urc e 1 4 3 2 W W- L W- R A B C A5 A , A6 B ABS & BA & TRAC & VSC ACTUATOR ACC W- L W W- L 2 AM1 IG1 4 W- R 5 2 3 3 GND 10 A SMC1 SFRR 9 A SFLH 11 A 8 A SRRH SRRR 4 A 5 A SRLH SRLR 1 A 3 A L- Y Y- B G- R GR 4 IE1 5 IE1 7 IE1 10 IE1 W- R G- O GR G- R 5 3 SFRR SFLH SFLR SRRH SRRR 4 L- Y 6 11 IE1 Y- B W- G 55 SFRH W- L L L GR- R R W- B 25A ABS NO. 2 25A ABS NO. 3 26 SMC1 R+ 2 53 25 SRLH SRLR SR 36 MT 27 MR 7 CSW 67 PMC 68 E2 69 BR- Y 8 IF3 R- L 1 P- L B- L V8 VSC OFF SW GR- L O R GR- R R GR- L 5A ABS NO. 4 4 6 3A VCM 44 W- L 19 3H 19 3A 6 IE1 49 9 IF3 2 IF3 W- B 5 3 3 IF3 BR- Y 21 4D R- L P- L GR- R R- B O 6 IE1 G- O W- R 3 IE1 A20 ABS & BA & TRAC & VSC ECU 17 IE1 2 1 C W- G 3 2 IE1 B- W 3 12 IE1 G- Y 3 5 120A ALT SFLR 7 A 21 IF3 GR- R 3 6 B- W 3 G- Y 2 W- B 4 2 ABS MTR RELAY 1 2H 1 2G SFRH 3 B 3 1 1 1 E BM 6 A L 1 3 B 8 2F 2 A W- L W W- L W 2001 AVALON (EWD431U) 9 2F 3 3 4 5 GR- R ABS SOL RELAY 40A AM1 60A ABS 1 BS GR- R I15 IGNITION SW 2 1 W W 5 7 IF1 2 1 8 4F 1 A W- B O GR- L F 6 A , F 8 C , F10 E B B FUSIBLE LINK BLOCK FL MAIN 3. 0W J6 JUNCTION CONNECTOR B M2 MASTER CYLINDER PRESSURE SENSOR R- B W- B EE W- B W- B BATTERY Front side of left fender II Right kick panel D E M 2001 AVALON (EWD431U) 11 AVALON (Cont’ d) (Cont. next page) V S C (w / T ra c tio n C o ntro l) 5 W A B C 8 7 6 W W- L W- R W- R LG- B ABS & BA & TRAC & VSC ACTUATOR Y- R 9 D 7 A 16 4A 15 4A E F G H 1 15 4H 71 VSCW 31 WT L- W 72 TC R- B L- O R- L V 86 TS 6 IL1 4 4D Y- R 42 D/G LG- R 2 R- W 13 4F BUZZER 15 4C D V9 VSC WARNING BUZZER 16 4H C R- B 15 4F 3 D L- O V 4 3G 4 D Y- R 15 4B P- B 46 BAT 7 E P- B 51 ML- R- L 24 ML+ 6 4H LG- R 22 19 4A LG- B SRC2 13 3A 10 D W 52 SRC1 19 4B 5 D 18 IL1 3 4A W- L 54 SMC2 V W- R R- B B- Y V- W 50 70 IND 88 SP1 BZ A20 ABS & TRAC & VSC ECU YD 77 GYAW 78 YAW 79 YIGA YGNA 34 80 GL1 RL+ 18 RL- 13 14 RR(Shielded) 12 2 1 17 18 IE1 2 BR Y1 YAW RATE SENSOR 6 GNDA 19 IE1 B- R IGA 20 IE1 (Shielded) (Shielded) Y 3 11 IK1 G V 4 12 IK1 (Shielded) LG BR 1 10 IK1 FR+ 16 B- W 21 ID1 (Shielded) FR- 8 (Shielded) L 22 ID1 FL+ 10 BR A Y G A BR BR- W G YD FLBR- W V 11 ID1 A LG A J4 JUNCTION CONNECTOR BR- W BR- W A BR BR A 15 ID1 1 2 E 11 (Shielded) BR- W 16 ID1 W L YAW2 14 ID1 R Y BR (Shielded) GYW2 13 ID1 G 12 ID1 W R 2 ID1 L Y BR 1 ID1 D RR+ BR B- R (Shielded) (Shielded) 2001 AVALON (EWD431U) C 12 4B R- L 1 IE1 6 4A LG- R 9 IE1 LG- R 8 IE1 LG- B 15 IE1 LG- R 14 IE1 LG- B J5 JUNCTION CONNECTOR 13 IE1 12 4A 14 R- L W W- L V W- R R- B B- Y V- W LG- B C ABS 4 CUP B R- B TC 22 II2 BRAKE II2 SLIP 11 VSC OFF 6 B 11 R- B VSC 1 B 16 TS 14 7 R- W ABS 4 B ML- M3 A , M6 D , M7 E 5 B ML+ LG- R 2 B SRC2 D2 DATA LINK CONNECTOR 2 TC LG- B SIL SRC1 R- L MULTI DISPLAY D3 DATA LINK CONNECTOR 3 TS SMC2 LG- R D1 DATA LINK CONNECTOR 1 A5 A , A6 B A 1 2 1 2 5 GL1 A29 ABS SPEED SENSOR REAR LH A30 ABS SPEED SENSOR REAR RH A8 ABS SPEED SENSOR FRONT LH A9 ABS SPEED SENSOR FRONT RH BR BR R- B R- B W- B W- B I J K M OVERALL ELECTRICAL WIRING DIAGRAM 2001 AVALON (EWD431U) 11 AVALON (Cont’ d) V S C (w / T ra c tio n C o ntro l) A B C D E F 12 11 10 LG- B LG- R R- L R- W R- W R- B Y- R 10 1D 4 1C 1 3 R- W FSS SS2 SS1 LBL PKB 62 63 61 40 76 15 LBL 25 VSC+ VSC4 17 CCS 26 PKB2 2 GND 14 11 P RSS 6 LVL2 SS2 18 2 SS1 5 J1 JUNCTION CONNECTOR BR B L 7 8 B W- B 5 4 2D W- B C11 STEERING SENSOR [COMB. SW] To Parking Brake SW<8- 10> To Cruise Control ECU<14- 4> 4 (Shielded) W- B B- W Y- G Y- R O W L- B Y- G W- B (Shielded) B L- B B Y- G O W- B 7 3B R- B W- B A W- B W- B A A 10 2F 4 2F 7 3A W- B R- B W- B W- B W- B W- B J5 JUNCTION CONNECTOR BR B W W- B W- B W- B K J4 JUNCTION CONNECTOR B R- Y 10 D 4 B From Stop Light SW <6- 3> J 8 BR G- W I PKB 83 7 12 ENG+ T5 TRANSLATE ECU A21 ACTIVE LIGHT RELAY EBDWWA 32 22 W- B GND1 28 9 B1 BRAKE FLUID LEVEL WARNING SW GND2 29 8 1H R- W STP V 13 TS IG1 48 15 3B R- W TRC+ ENG- 12 1I G- W 20 TRC- Y- R 7 NEO 15 3A 1 24 TC GR 21 IG1 BR 1 BRL G- W 16 Y- B 1 Y- R R- W R- L 3 W- B 1 R- W Y- R 2 A20 ABS & BA & TRAC & VSC ECU LG- B 4 3 1B LG- R 2 To Engine Control Module<3- 8> 7 IC1 IG1 RELAY 11 3F Y- R 1 1G 10A GAUGE NO. 1 10A ECU- IG NO. 2 Y- R Y- R 2001 AVALON (EWD431U) 18 4H W- R 13 1B W 2 3C R- B 11 3D Y- R 18 4A Y- R R- W Y- R Y- R H R- W From A/T Indicator Light SW [Park/Neutral Position SW] <4- 6><4- 7> G 9 W W- R W- B A Cowl side panel RH W- B W- B J9 JUNCTION CONNECTOR IJ IG Cowl side panel LH Front side of left fender ED 12 AVALON P ow er S ource S hift Lock 1 T urn S ignal and H azard W arning L ight 3 2 4 * 1 : Floor Shift * 2 : Column Shift ACC 3 2 AM1 W- G W- G 2 IJ1 IG1 4 10 1C H7 HAZARD SW 5A ECU- ACC R- B F W- L R- G HAZARD W- R 2 1 3 2 1L 2 1A G- Y G- R 12 1C 9 1C 10 9 STP LH P1 RH 6 IK1 7 3A C C A W- B A J9 JUNCTION CONNECTOR IG Cowl side panel LH Front side of left fender ED IJ Cowl side panel RH C J12 JUNCTION CONNECTOR W- B 22 3C W- B 6 W- B 1 J5 A JUNCTION CONNECTOR W- B A 4 W- B 22 3D 6 W- B W- B 2 4 R8 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] 21 3B 2 W- B IF B SHIFT LOCK ECU W- B W- B Left kick panel L- B 7 4F K3 KEY INTERLOCK SOLENOID W- B W- B 7 4D S3 A , 2 W- B 5 B KLS+ 4 A (*1) 4 B (*2) 7 3G G- Y E 3 A 21 3A 3 R7 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] SLS- BATTERY 7 IK1 G- B 3 F4 FRONT TURN SIGNAL LIGHT RH W- B C9 TURN SIGNAL INDICATOR LIGHT [COMB. METER] F3 FRONT TURN SIGNAL LIGHT LH 21 W- B T7 3 TURN SIGNAL FLASHER RELAY P2 SHIFT LOCK SOLENOID 3 1E G- Y 1 6 1E G- B 2 6 1B G- Y ACC 5 1H G- B IG 2 A (*1) 6 B (*2) 5 1L G- Y 1 B 11 1A G- B 1 A 3 B 4 1D G- W 5 A SHIFT LOCK CONTROL SW IG 2 G- B 8 1C G- Y G- B G- W 7 1L SLS+ Cowl side panel LH TR G- W G- W GR B FL MAIN 3. 0W 1 P , F 8 C , F10 E 1 A F6 A , F 7 B 120A ALT 2 4C 2 W- B 1 E FUSIBLE LINK BLOCK 1 C 1 IC1 2 4D 3 1B W B- L 1 B TB From Stop Light SW <6- 3> 1 1G 10 1D R- B IG1 RELAY B 4 1 2G 15 3D 10A GAUGE NO. 1 1 7. 5A TURN B 3 1 2H TL RH GR 5 10 1L R- B R- Y 4 1C TR G- W 15A HAZ 2001 AVALON (EWD431U) 2 2G 4 15 3C 1 B2 LH 5 4 4D 40A AM1 TL TURN G- R 2 B1 C13 TURN SIGNAL SW [COMB. SW] ON 8 1D 4 4C 5 TB 6 OFF GR 7 2B 7 R- G I15 IGNITION SW R- Y W- L 7 IF1 R- G R- Y BM Back panel center M L B 2001 AVALON (EWD431U) B- L Cowl side panel LH (Shielded) BR G- W B LG 1 A30 ABS SPEED SENSOR REAR RH 2 G (Shielded) 11 IK1 Y 12 IK1 BR W- B EE A A BR A29 ABS SPEED SENSOR REAR LH 2 V (Shielded) 10 IK1 (Shielded) 11 IE1 1 10 IE1 (Shielded) (Shielded) RR- A Front side of left fender J1 JUNCTION CONNECTOR A A7 ABS ACTUATOR AND ECU BR IG LG 21 ID1 (Shielded) 22 ID1 9 IE1 2 RR+ TC 12 7 1H 5 1I ABS 14 4 A (Shielded) (Shielded) R- L Y- R R- B E D C B A (Cont. next page) BR BATTERY 1 (Shielded) V 11 ID1 LG 6 IE1 V 7 IE1 LG- R G FUSIBLE LINK BLOCK 8 IE1 (Shielded) RL8 G Y FL MAIN 3. 0W F 6 A , F 8 C , F10 E 14 IE1 RL+ 9 4 3B 13 3A Y 1 A 120A ALT W 1 E G- W 1 C STP 14 TS 11 6 4H 6 4A LG- R 1 1G 3 1B 4 Y- R 1 IG1 RELAY L +B 17 L BAT 18 LG- B IG1 15 13 IE1 LG- B 3 3 4B 4 3G TC 4 LG- R 1 2G W- L 10A ECU- IG NO. 2 4 1C W- R 2 10A GAUGE NO. 1 Y- R 2 1H 12 4A 22 II2 LG- R 1 40A AM1 Y- R 13 1B 11 II2 TC 11 LG- R 5 60A ABS R- B 10 1D TS 16 D2 DATA LINK CONNECTOR 2 R- L 1 2H L LG- B 5 W- R 3 D1 DATA LINK CONNECTOR 1 LG- B 2 IG1 4 ACC 2 A B S (w /o T raction C ontrol) LG- R 5 W- L 7 IF1 I15 IGNITION SW 2 AM1 1 P ow er S ource LG- R 1 2 13 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM BR BR From Stop Light SW <6- 3> 13 AVALON (Cont’ d) A B S (w /o T raction C ontrol) 5 A B 7 6 8 R- B R- B M3 A , M6 D 4 D Y- R MULTI DISPLAY 6 IL1 R- W 4 4D 15 4H L- O 11 3D 3 D L- O 13 4F 7 A R- L R- B Y- R 5 D 2 3C BRAKE ABS CPU 15 4A 15 4B 18 IE1 R- L L- O R- L 7 IC1 L- O R- L Y- R A21 ACTIVE LIGHT RELAY 2 10 1 R- W A7 ABS ACTUATOR AND ECU SP1 FL- FL+ 6 7 PN 23 (Shielded) GND2 GND1 EBDW 16 19 21 WA 20 PKB 13 6 7 8 5 4 3 W- B Y- G R- Y Y- B B 20 IE1 To Parking Brake SW<8- 10> 4 2D 10 2F W- B B W- B B J1 JUNCTION CONNECTOR B1 BRAKE FLUID LEVEL WARNING SW W- B R- W 1 2 EE 4 2F 8 1H W- B W- B W- B A8 ABS SPEED SENSOR FRONT LH W- B 12 1I W- B 2 15 3B R- W 16 IE1 R- Y B Y- B 1 From A/T Indicator Light SW [Park/Neutral Position SW] <4- 7> A9 ABS SPEED SENSOR FRONT RH G- W 2 15 IE1 BR B- R B- W L (Shielded) 1 3 D5 DIODE (A/T Indicator Light 1) R 1 IE1 1 R- Y L- W 2 IE1 15 3H 15 3A 5 IE1 2 3 IE1 W- B 17 IE1 W- B L B- W (Shielded) (Shielded) B BR Y- B (Shielded) B- R E FR+ 5 R- W D FR4 L- W 2001 AVALON (EWD431U) C R- L R- B Front side of left fender Front side of left fender ED M W- L 5 B B- L 2001 AVALON (EWD431U) B 4 W- B 10A ECU- IG NO. 2 10A GAUGE NO. 1 W W- B FUSIBLE LINK BLOCK F 6 A , F 8 C , F10 E Cowl side panel LH J5 JUNCTION CONNECTOR OD 14 IDL 13 MO 15 II1 15 MC MC MO C4 CRUISE CONTROL ACTUATOR M 2 1 14 II1 7 IJ A P- B W- B W- B P- B 4 3 L SPD 8 2 STP 12 13 II1 Cowl side panel RH J9 JUNCTION CONNECTOR GND 9 II1 4 L 3 W- B IG A A 7 3A To Electronically Controlled Transmission Solenoid<4- 3> W- B W- B C12 CRUISE CONTROL SW [COMB. SW] COAST/SET W W- B BATTERY W CANCEL ECC CRUISE CONTROL INDICATOR LIGHT [MULTI DISPLAY] 20 3A W- B 20 3B 21 II2 G- Y RES/ACC MAIN ECT 6 Y- R (*2) FL MAIN 3. 0W 1 E 5 CCS GND 16 G- Y P 1 A W- L CAN CCS 10 P 120A ALT 3 1 D 3 R 1 C Y- R CAN GR- R 1 2G 1 1G LG- R 3 1B C15 CRUISE CONTROL ECU LG- R Y- R (*1) TC 5 6 4A V- W PI 4 3G 6 4H 22 II2 To Speedometer [Multi Display] <21- 6> 4 13 3B 13 3A LG- R TC 11 G- W B GR- R 17 4A 17 4B M6 D , M7 E 17 4H GR- R 9 4 E 4 D TC 4 D1 DATA LINK CONNECTOR 1 4 * 1 : w/ Traction Control * 2 : w/o Traction Control From Stop Light SW <6- 3> 1 2H IG1 RELAY 2 3D 2 3C 10 A/D D2 DATA LINK CONNECTOR 2 LG- R 1 2 13 1B 13 4F 4 4D 3 From Translate ECU<11- 11> 4 3 10 1D 2 C ruise C ontrol From A/T Indicator Light SW [Park/Neutral Position SW] <4- 6> 1 40A AM1 W- R 4 1C Y- R R- B R- B 5 IG1 4 ACC I15 IGNITION SW 2 AM1 1 P o w er S o urc e LG- R 2 7 IF1 W- L 14 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM S4 STOP LIGHT SW G- B R- B Y GR To Engine Control Module<4- 3> 15 AVALON P ow er S ource SRS 1 3 2 4 W- B LG- B E1 S6 SIDE AIRBAG SENSOR RH IG1 4 1 2 3 4 10 1C 6 LG- R 10 1I 4 3B LG- R 12 1A 4 3G LG- R GR LG L- Y P GR- L LG- B L- W 10 1F P- L 40A AM1 1 1F 4 IJ1 22 II2 B- Y 7 1C I15 IGNITION SW To Body ECU <8- 27> W- R LG- B 2 13 3A 5 II2 B- Y 10A SRS- ACC 5 LG- R 3 TC 4 LG- R W- L B- O 2 TC 11 B- Y IG2 6 7 AM2 M7 SRS WARNING LIGHT [MULTI DISPLAY] W- G 5 1 7 IF1 AB 5 D2 DATA LINK CONNECTOR 2 2 AM1 W- L S5 SIDE AIRBAG SENSOR LH W- G LG- B ACC 3 D1 DATA LINK CONNECTOR 1 3 6 4A 5 1I 4 IF1 1 6 4H 6 1F P- B LG- R B- Y L GR B- O W- R LG- B B C5 A , C6 B , C7 C 1 2H 1 2B 5 B 7 2C 6 B IG2 5A SRS WRN 10A AM2 4 B ACC 7 A GSW E1 E2 D+ D- 27 B 28 B 14 B 13 B P+ 10 B 9 A VUPL P11 B 10 A SSL+ FL+ 5 A SSLFL6 A 12 A ESL FR+ 2 C 12 C VUPR FR1 C 10 C 9 C SSR+ 7 C SSR- +SL 15 B ESR - SL 26 B TC LA +SR 9 B - SR 20 B PL+ 2 A PL1 A PR+ 5 C PR6 C SIL 12 B W 1 IF2 J5 JUNCTION CONNECTOR 3 1F Y 2 IF2 4 1F C Y Y- B Y Y- B C BR W- R 3 1B W B 1 BR- W B- W Y- G Y- R Y- G Y- R Y- G Y- R 1 A F6 A , F 7 B , F 8 C 120A ALT FUSIBLE LINK BLOCK 1 B Y- B B B- L 1 C 19 B CENTER AIRBAG SENSOR ASSEMBLY BR W- R 2 2G 3 B W- B 1 2G W- B 2001 AVALON (EWD431U) 5 1F 5 2 1 2 1 W- B 2 SPIRAL CABLE FL MAIN 3. 0W W- B 1 Cowl side panel LH IG 1 2 1 2 1 2 1 2 7 SIL A27 AIRBAG SQUIB (Steering Wheel Pad) BATTERY 2 A26 AIRBAG SQUIB (Front Passenger Airbag Assembly) S7 SIDE AIRBAG SQUIB LH S8 SIDE AIRBAG SQUIB RH A12 AIRBAG SENSOR FRONT LH A13 AIRBAG SENSOR FRONT RH P16 PRETENSIONER LH P17 D3 PRETENSIONER DATA LINK RH CONNECTOR 3 Surge tank RH EB M M 2 1 2 RCLR R- B BM 1 2 7 M P26 POWER SEAT MOTOR (Front Passenger’ s Seat Rear Vertical Control) R RDWN Back panel center 3 RCLF R- W P19 POWER SEAT CONTROL SW (Front Passenger’ s Seat) Rear quarter inner RH J10 JUNCTION CONNECTOR A A W- B 4 11 BD1 W- B P27 POWER SEAT MOTOR (Front Passenger’ s Seat Reclining Control) 4 8 RUP L- Y 2 6 1 L- B M P28 POWER SEAT MOTOR (Front Passenger’ s Seat Slide Control) SLDR P ow er S eat (F ront P ass enger’ s S eat) E W- B BN M OVERALL ELECTRICAL WIRING DIAGRAM 1 9 SLDF L- O 1 BD1 L- O 3 2 IK1 L L- O 2 1 2 RCLR R- B M P24 POWER SEAT MOTOR (Driver’ s Seat Reclining Control) REAR 3 2 1 8 RDWN R M RCLF P23 POWER SEAT MOTOR (Driver’ s Seat Rear Vertical Control) DOWN 7 P22 POWER SEAT MOTOR (Driver’ s Seat Front Vertical Control) UP 1 2 5 10 FUP L- R Rear quarter inner LH 1 6 2 L- B M P25 POWER SEAT MOTOR (Driver’ s Seat Slide Control) REAR SLDR 2 P18 POWER SEAT CONTROL SW (Driver’ s Seat) FDWN L- W M RUP L- Y UP DOWN REAR 2 3 R- W R- L 4 L- O 1 FRONT 2001 AVALON (EWD431U) 1 A 120A ALT 1 E 1 1G 1 W B BATTERY FL MAIN 3. 0W 30A PWR SEAT 2 8 1I P ow er S ource 16 AVALON L- O F 6 A , F10 E FUSIBLE LINK BLOCK BK J11 JUNCTION CONNECTOR A 11 BC1 R- L 1 9 2 L- O L- O W- B L10 LUMBAR SUPPORT CONTROL MOTOR (Driver’ s Seat) M SLDF W- B W- B L11 LUMBAR SUPPORT CONTROL SW (Driver’ s Seat) 1 BC1 7 ID2 L- O W- B 1 L- O 4 FRONT E B 1 L L- O P ow er S eat (D river’ s S eat w /o D riving P osition M emory ) R- W FRONT 17 AVALON P ow er S ource 1 2 AM1 W- G IG1 4 W- R 4 10 1C L- Y R- B 7 IF1 W- L I15 IGNITION SW B- Y 15A PWR OUTLET NO. 1 13 4D 7 5 5 7 10 1D 7 9 ID2 7 1 IO1 4 ID2 LG (*1) 6 3 RLY IG IG AC1 AC2 3 7 4 IO1 W- B (*1) W- B L (*2) P (*2) B 2 IH1 21 3B 2 IO1 W- B W- B L (*1) L- B (*1) L (*2) P (*2) AC2 AC1 AC2 W- B W- B IG P7 POWER OUTLET IF Left kick panel A A A W- B AC1 4 IA1 W- B (*2) 4 W- B 1 W- B 4 W- B Cowl side panel LH W- B A W- B 1 P6 POWER OUTLET J5 JUNCTION CONNECTOR A A 3 IO1 FL MAIN 3. 0W BATTERY W- B 8 3B 7 4F 1 IH1 3 6 ID2 F 6 A , F 8 C , F10 E FUSIBLE LINK BLOCK 1 1 W- B (*2) 20 4C 1 W- B (*1) 1 A W- B L (*2) P (*2) L- B (*1) 2 ID2 2 W- B 1 E 120A ALT GND E 4 L (*1) W- B 1 C W- B L- Y B- L W 2 C8 CIGARETTE LIGHTER 1 2G 2 P4 POWER OUTLET 3 1B P5 POWER OUTLET 7 1B P8 POWER OUTLET MAIN SW V13 VOLTAGE INVERTER 1 1 1G R- B B- Y GR 2 10A GAUGE NO. 1 4 P LG (*2) W- B GR 1 IG1 RELAY 15A PWR OUTLET NO. 2 B 2001 AVALON (EWD431U) 1 2H 3 LG (*1) 1 5 13 1I LG (*1) 1 3 4 1C 12 1D PWR POINT RELAY R- B 2 15A CIG 2 5 4D 40A AM1 * 1 : Floor Shift * 2 : Column Shift W- G W- L 3 2 ACC 3 C igarette Lighter P ow er O utlet A J11 JUNCTION CONNECTOR J9 JUNCTION CONNECTOR Rear quarter inner LH BK IJ Cowl side panel RH IG Cowl side panel LH M L- B 2001 AVALON (EWD431U) 7 1I L- O B DWN/OPN Roof left W- B UP/CLS W- B Front side of left fender 5 2D 6 2D 2 3 2 1 3 3 4 3 3 4 2F 7 2D 1 M 2 1 2D W- B W- B W- B L- O ED 5 3 3 2 2D 3 2D FAN NO. 2 RELAY A4 A/C SINGLE PRESSURE SW BL 1 2 W- B 1 EC1 W4 WATER TEMP. SW NO. 1 W- B IG E DOWN R- W 2 3 2 EC1 G Cowl side panel LH R- Y UP E 6 2F L G W- B M9 MOON ROOF CONTROL SW 1 7 12 2F 7 2F FAN NO. 1 RELAY G 1 IG1 3 1B 9 DWN 3 3 W- B BATTERY W 1 1G UP 3 2 1 8 2D W- B FL MAIN 3. 0W 1 E 30A CDS 10 G FUSIBLE LINK BLOCK B 1 5 2F 5 3 G 5 4 PCTY 3 9 II2 B- R 2 M 1 3 Y W- R 4 L 1 A 30A RDI 120A ALT B 2 IG DCTY R- B 8 R- L 4 1 M8 MOON ROOF CONTROL ECU To Diode(A/C) <22- 3><23- 6> 3 Y 10 1D R- B 5 1D Y- G F 6 A , F 8 C , F10 E 30A SUN ROOF W- R 4 1C 10 IF1 3 3 A2 A/C CONDENSER FAN MOTOR 1 C 1 R- L 3 IG1 To Door Courtesy SW Front RH<8- 12> O 4 IG1 O 13 IG1 3 3 5 L 1 2G B 4 4D Y- G 2 3 G 1 B 2 3A To Door Courtesy SW Front LH<8- 11> 2 13 4C R- B FAN NO. 3 RELAY 1 Y- G 2 11 3H Y 2 3H Y 1 2H Y 4 IF3 Y 15 IF3 Y Y W- B 6 2E IG1 4 I15 IGNITION SW 2 AM1 3 B 5 40A AM1 W- L Y B L- B R adiator F an and C ondenser F an W- R 1 W- L 5 7 IF1 ACC 2 M oon R oof L- B 2 1 P ow er S ource Y L 5 2E 18 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM R1 RADIATOR FAN MOTOR To Engine Control Module<3- 8> W5 WATER TEMP. SW NO. 2 Y- G W- B L- O 10A GAUGE NO. 1 5A ECU- IG NO. 1 IG1 RELAY 19 AVALON R adio and P lay er (7 S peaker) P ow er S ource 1 ACC 3 2 AM1 R2 RADIO AND PLAYER W- L W- L 9 1J 10 1C BU+B ACC+B 1 15A RADIO AMP+B 11 BEEP 3 FL 17 FR 9 RR 8 RL 18 MUTE 19 S- GND 7 SLD 16 20 (Shielded) L Y W B R G BR W GR L- Y 15 1D GR 1 2C GND 10 5A ECU- ACC W- L W- L 11 1L 5 4 W- G IG1 I15 IGNITION SW 7 IF1 3 2 2 15 3C 30A DCC 3 IM1 18 IM1 19 IM1 6 IM1 5 IM1 17 IM1 15 IM1 20 IM1 15 3D GR L- Y (Shielded) 2 4D 2 4F L Y W B R G W BR L- Y 2 2G B 5 IM3 2 4E B 7 B RR+ SPKR 3 B RR- SPKR 10 B RL+ SPKR 4 B RL- SPKR 11 B 12 A RL IN A 11 A MUTE FL- SPKR 9 B SIG GND WF+ 5 B WF14 B A PWR GND 13 B V P L 10 IM3 A V BR W- B J6 JUNCTION CONNECTOR 3 IB1 4 IB1 V P L 1 2 F13 FRONT DOOR SPEAKER RH 2 1 F12 FRONT DOOR SPEAKER LH 2 1 T9 TWEETER RH T8 TWEETER LH V L P 2 L- R A C 5 IN1 1 A P B L- B C C L J3 JUNCTION CONNECTOR V P L R9 REAR DOOR SPEAKER LH B 4 IN1 LG 2 LG R10 REAR DOOR SPEAKER RH 1 LG 7 BA1 Y 2 13 A RR IN 3 IM3 B D LG Y 6 BA1 B 1 14 A FR IN FL+ SPKR 2 B 11 IM3 D 11 IA1 B W R BATTERY D Y B 12 IA1 FL MAIN 3. 0W 6 A FL IN FR- SPKR 8 B LG Y 7 BB1 5 A BEEP 6 IM3 B 6 BB1 FR+ SPKR 1 B 4 IM3 2 IM3 4 A AMP ON B W 1 A 1 A STEREO COMPONENT AMPLIFIER ACC IN R 120A ALT F 6 A , F 8 C , F10 E 1 B FUSIBLE LINK BLOCK 1 C S 9 A , S10 B 2 A +B 1 2G J3 JUNCTION CONNECTOR GR L- Y 1 2H B- L 2001 AVALON (EWD431U) 1 5 16 IM1 BR L- Y 40A AM1 1 2 W7 WOOFER A W- B Back panel center BM J10 JUNCTION CONNECTOR A Rear quarter inner RH BN Instrument panel brace RH IH M B- L W 2001 AVALON (EWD431U) 30A DCC P 1 P B V LG 1 2 L Instrument panel brace RH BR BR P IH A A BK A J11 JUNCTION CONNECTOR Rear quarter inner RH J10 JUNCTION CONNECTOR BN A 11 BD1 11 BC1 Rear quarter inner LH J3 JUNCTION CONNECTOR C C 1 2 W- B F13 FRONT DOOR SPEAKER RH 1 5 IN1 J14 JUNCTION CONNECTOR 1 2 2 BD1 2 BC1 W- B W- B F12 FRONT DOOR SPEAKER LH V T9 TWEETER RH 2 B R- Y 3 IK1 W- B 2 LG 4 IN1 D E 7 A 4 A15 SEAT HEATER SW [A/C CONTROL ASSEMBLY] W- B 1 V 4 IB1 B L T8 TWEETER LH 2 A D J3 JUNCTION D CONNECTOR B RR- 3 B 26 SHP- SHP+ 13 S13 SEAT HEATER (Front Passenger’ s Seat) BATTERY C A FR5 A L 3 IB1 P J6 JUNCTION C CONNECTOR A FR+ 1 A RR+ 1 B LG 20A SEAT HTR 3 ID2 25 SHD- SHD+ 12 8 1B 1 1G S12 SEAT HEATER (Driver’ s Seat) FL MAIN 3. 0W C FL6 A RADIO AND PLAYER RL- 6 B LG F 6 A , F 7 B , F 8 C , F10 E FL+ 2 A R3 A , R4 B RL+ 2 B 3 S eat H eater R- B FUSIBLE LINK BLOCK L- Y ACC B 120A ALT B 1 B GR 3 A 13 IM2 5 IM2 11 IA1 7 BB1 6 BB1 7 BA1 Y R- Y 1 A B R- W 1 C 2 4F B 12 IA1 R10 REAR DOOR SPEAKER RH 1 2 Y R B 5A ECU- ACC GR GR 2 4D B 6 BA1 Y R W 4 A 8 1D 15 3D 15 3C R9 REAR DOOR SPEAKER LH 1 2 R W R- W 1 2G 11 1L 15A RADIO 10 1C GR W 1 2H 2 2G 9 1J I15 IGNITION SW W- G 2 LG R- Y 1 E 5 40A AM1 1 2C W- L IG1 ACC 3 W R adio a nd P layer (6 S peaker) LG 1 5 W- L 2 7 IF1 2 AM1 1 P ow er S ource W W- L 20 AVALON Back panel center W- B BM M OVERALL ELECTRICAL WIRING DIAGRAM L LG V MEMO 2001 AVALON (EWD431U) W- L 5 W- L B 2001 AVALON (EWD431U) B B- L Front side of left fender 10A ECU- IG NO. 2 Cowl side panel LH W- B W- B B IG ABS W- B ED 3 D 6 E 1 D 2 1 17 IL1 L- Y W- B W1 WASHER LEVEL WARNING SW L- Y BATTERY 5 D 20 4D 10 D 7 E 7 4F 15A IG2 5A SRS WRN W- B IF 7 1D 7. 5A DOME 9 D MULTI DISPLAY Left kick panel 4 E 2 D 10 E M3 A , M4 B , M5 C , M6 D , M7 E 15A RADIO See VSC(w/ Traction Control)System <11- 7><11- 8> VSC FUSIBLE LINK BLOCK 3 1B WASHER F 8 C , F10 E 1 1G 4 3 W- L F6 A , F7 B , W 1 2 5 E 9 1J 7. 5A ECU- B 11 1L VSC OFF FL MAIN 3. 0W 10A AM2 W 4 2F IG1 RELAY 4 D 4 IJ1 9 1B PASSENGER SEAT BELT 1 A 120A ALT 1 E 30A DCC 1 B 2 5 IG2 RELAY 4 1C 10A GAUGE NO. 1 1 C 2 2G W- R 1 2G LG- B 1 2B 10 1D R- B 7 2C Y- R 13 1B 13 4F 4 4D R- B LG- B 1 2C B- O B- W (*1) B- O R- B 1 11 2C 2 2B 2 1J 13 1A W- R 3 7 1C P- L 1 4F 1 4D B- W (*1) B- O Y- R L- Y W- G * 1 : Automatic A/C 2 E 3 E P- L 1 2H 1 W- L 5 ST2 IG2 6 B- O W- R 4 E D C B A (Cont. next page) P- L 2 7 AM2 W- R IG1 4 3 LG- B I15 IGNITION SW 2 AM1 W- L ACC 2 C ombination M eter W- G 4 IF1 1 P ow e r S ourc e L- Y 7 IF1 40A AM1 21 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM DOOR See Multiplex Communication System<8- 24> DRIVER SEAT BELT CRUISE See Cruise Control System <14- 2> SLIP SRS See SRS System <15- 3> BRAKE See ABS(w/o Traction Control) System<13- 8> See VSC(w/ Traction Control) System<11- 7><11- 8> (Cont. next page) 21 AVALON (Cont’ d) C ombination M eter A B C D 7 6 8 W- G A L- Y Y- R 2 3C Y- R 2 3F Y- R Y- R B B- O B- W (*1) 11 3F From Injector NO. 1<3- 7> L (*1) Y- R 8 3C 8 IL1 1 C 16 A L (*1) 21 3F B (*2) V- W 2 A 12 A 1 A 10 A 3 A 6 A BACK LIGHT CIRCUIT POWER SUPPLY MINUTE HOUR ODO/TRIP REVERSE BUZZER E2 PROM SPEED BUZZER W/D LCD ODO TRIP DRIVER DRIVER CPU 9 C 8 A 19 A 9 A 15 A 22 A BR 11 C Y- G 8 C BR 4 C P- B 17 A O 2 C (*2) W- B Y- B 7 C (*2) 4 A (*2) 7 A (*2) 21 A (*1) 11 A (*2) 12 E (*2) 14 E 1 3C From Cruise Control ECU <14- 4> From Engine Control Module <3- 11><4- 4> 18 A CHARGE 6 D 11 E REAR LIGHTS OIL 7 D V- W L- Y 5 A MULTI DISPLAY From A/C Control Assembly<22- 8> V- W B- O M3 A , M4 B , M5 C , M6 D , M7 E MALFUNCTION INDICATOR LAMP 2001 AVALON (EWD431U) B- R 1 3F V- W 10 3C B- W (*1) 5 IJ1 10 3D B See Illumination System<7- 2> B- R See Air Conditioning System<23- 7> B- W (*1) 7 IJ1 From Park/Neutral Position SW<1- 2> From Engine Control Module <3- 9> E 5 W- G * 1 : Automatic A/C * 2 : Manual A/C 12 IJ1 8 IA1 7 IA1 10 IA1 3 FR 1 FE BR W3 WATER TEMP. SENDER 2 FV 11 IJ1 Y- G 1 3 IJ1 BR P- B See Air Conditioning System <22- 5><23- 7><23- 8> O W- B J9 JUNCTION CONNECTOR A A W- B See ABS(w/o Traction Control) System<13- 8> See VSC(w/ Traction Control) System<11- 8> 7 4B See Air Conditioning System<22- 5><23- 8> See Charging System <2- 2> O2 OIL PRESSURE SW See Taillight and Stop Light System<6- 4> Y- B See Engine Control System<3- 5> 1 7 4G F15 FUEL SENDER Front side of right fender EA IJ Cowl side panel RH Surge tank RH EB M B A 9 3 C 2001 AVALON (EWD431U) BR (*1) (*3) B (*1) Y (*1) G (*1) R (*1) W (*1) (*3) 20 IC1 (*3) B (*1) Y (*1) G (*1) R (*1) W (*1) (*3) VY 6 B 8 B 9 B 20 A IH BR VX BR F11 FIELD MAGNETIC SENSOR W (*1) 3 R (*1) 5 G (*1) 4 5 B 7 A 19 A Instrument panel brace RH See Electronically Controlled Transmission and A/T Indicator System<4- 7> VMID Y (*1) 2 4 B 21 A J5 JUNCTION CONNECTOR IG A A 7 3A 7 3G W- B DRIVE SIGNAL 3 B 2 A 3 A 4 A 5 A C 9 A , C10 B COMBINATION METER Cowl side panel LH R GND 6 IG1 BR- W 2 B 1 A See Electronically Controlled Transmission and A/T Indicator System <4- 5><4- 6> 12 6 A 11 A * 5 : w/o Daytime Running Light * 6 : w/ Traction Control * 7 : w/o Traction Control W- B 1 12 IG1 2 IG1 B (*1) 14 IG1 (*3) (*3) 7 IG1 9 B 9 A 10 A TURN LH 15 IG1 2 B SPEEDOMETER 5 IC1 3 B FUEL GAUGE 4 B TEMP. GAUGE 5 B FUEL 6 IC1 L O/D OFF 18 IC1 L- Y ILLUMINATION W- B 17 IC1 6 B P- L P 12 A R- L 16 IC1 8 B L- Y N 5 C 15 A 22 A 16 A Y- R D 7 C L 10 B See Multiplex Communication System<8- 5> 2 6 C W- G 11 B 12 B 14 A See Illumination System <7- 4> HIGH BEAM 2 C 13 B 14 B See Turn Signal and Hazard Warning Light System<12- 3> L 1 C CPU P- L 10 B 12 B 11 B 14 B 13 B L- R P- B 14 3F 5 3C 11 * 1 : Automatic A/C * 3 : Shielded * 4 : w/ Daytime Running Light See Multiplex Communication System(*4)<8- 4> See Headlight System(*5)<5- 2> MULTI DISPLAY 10 C ombination M eter W- G M3 A , M4 B , M5 C , M6 D , M7 E Y- R W- G 21 AVALON (Cont’ d) M OVERALL ELECTRICAL WIRING DIAGRAM See Multiplex Communication System(*4) <8- 4> See Headlight System(*5) <5- 2> TURN RH See Illumination System<7- 4> TACHOMETER BR- W BR G L Y R (*3) W W R Y L G MEMO 2001 AVALON (EWD431U) W- G B W- L 2001 AVALON (EWD431U) B- L B B W- B W- B IG Cowl side panel LH W- B IJ A 1 GND SI 2 L- O Cowl side panel RH J9 JUNCTION CONNECTOR HTR RELAY BATTERY FL MAIN 3. 0W F 6 A , F 7 B , F 8 C , F10 E LG- R FUSIBLE LINK BLOCK L +B 3 L- R VM 4 13 IJ1 2 1 B- W 1 A 120A ALT W 1 E B2 BLOWER MOTOR L- R 1 C 2 1I 3 L- W 1 B W- B 1 L- W 1 1H 2 3 LG- B 16 IF3 1 Y- G M 2 1E From FAN NO. 3 Relay<18- 3> 2 1 1E 1 1K 5 2B 10 3A 1 3A 14 3C 5 3C A3 A/C MAGNETIC CLUTCH AND LOCK SENSOR R- W 1 2G B B L- W 3 2 2C 6 2C 2 Y 1 1G 3 1B 4 3 L- R 1 2 5 10 3H W- G 2 2G 30A DCC IG1 RELAY 3 MG/CLT RELAY IG+ 2 A LOCK 9 B 16 IL1 12 IF3 10 IJ1 L- O B- W W- B HR 19 A ACIN 22 A L- W 1 2H 5 5 B 1 A L- W L- B 1 2C W- L 5 L- B 1 10A HTR 2 1 R- W 50A HTR 5 5 4 2C 14 IF3 R- W Y 9 1J 40A AM1 2 W- R 4 1C 1 5 R- W A/C CONTROL ASSEMBLY A15 A , A16 B 4 L- W 1 2 R- W 11 1I 4 5 R- W R- W 5 IG1 4 ACC 3 W- G 5 I15 IGNITION SW 2 AM1 2 A ir C onditioning (A utoma tic A /C ) C B A (Cont. next page) L- W 9 1B 7 IF1 W- L 1 P ow er S ource L- B 7. 5A ECU- B 22 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM R- W W- G B- W L- B L- B D4 DIODE(A/C) To Engine Control Module<3- 12> L- W A14 A/C BLOWER MOTOR LINEAR CONTROLLER J1 JUNCTION CONNECTOR W- B 22 AVALON (Cont’ d) (Cont. next page) A ir C onditio ning (A utomatic A /C ) 5 7 6 8 A15 A , A16 B A/C CONTROL ASSEMBLY TAMI 21 A BLW 14 A PSW 11 A AMPH 3 A TPP 7 B GND 24 A 1 22 3B 10 4A 1 4A 9 3B 9 3G 1 4H 10 4H W- B BR 22 3A V B- W B- W V 9 3A B- W 4 22 B- W CPU 8 1L W- B W- B V 4 2F A B- W B B- W W- B C V D B- W L- O Surge tank RH EB ED Front side of left fender Left kick panel IF W- B W- B W- B C 7 4F B- W B- W B 9 1H W- B BR A B- W B- W 4 2D 7 4C 1 4B 1 2F 11 IJ1 5 IF1 W- B 1 W- B 2 To Speedometer [Multi Display] <21- 6> 2 1 B- W From Engine Control Module<3- 9> A4 A/C DUAL PRESSURE SW 21 M3 MULTI DISPLAY VER1 15 B W- B 3 A23 AIR MIX CONTROL SERVO MOTOR (Driver Side) 1 5 P 4 SPD 16 A V- W W- B L- R B- Y LG- R 2 4 A19 A/C THERMISTOR 2 13 IC1 G- R 17 AMPC 4 A LG- B L- R P A24 AIR MIX CONTROL SERVO MOTOR (Front Passenger Side) 13 IF3 G- R 16 3 Y B B Y- R Y- G 12 IL1 TE 4 B G- R 5 IF3 5 A17 A/C ROOM TEMP. SENSOR P 11 IL1 TPD 11 B P- B 4 G- R 2001 AVALON (EWD431U) 21 3F AMDH 5 A 20 IF3 1 8 3C AMDC 6 A P- L 2 TR 3 B B Y 21 3C SG 16 B B- W 1 L- R L- O A1 A/C AMBIENT TEMP. SENSOR IGN 17 A B Y- G AC1 10 B Y- R TW 2 B Right kick panel II M 2001 AVALON (EWD431U) V B- W V D 21 4A V 8 4A 21 4B 8 4H 8 V C V 1 8 4B V B V 2 3 SS 8 B V B- W 2 2 3 IL1 2 IL1 TSD 6 B TSP 5 B R 1 3 R- L 4 AIR 10 A L 5 TPI 12 B L- Y AIF 9 A R L A O 3 B- R 5 AOF 7 A 10 A ir C onditio ning (A utomatic A /C ) L 4 TPO 13 B B- Y AOD 8 A A/C CONTROL ASSEMBLY A15 A , A16 B 9 22 AVALON (Cont’ d) 11 12 M OVERALL ELECTRICAL WIRING DIAGRAM A18 A/C SOLAR SENSOR A22 AIR INLET CONTROL SERVO MOTOR V V B- W A25 AIR OUTLET CONTROL SERVO MOTOR V B- W MEMO 2001 AVALON (EWD431U) W- G B W- L 2001 AVALON (EWD431U) B- L B B Cowl side panel LH W- B W- B IG W- B ED L J1 JUNCTION CONNECTOR Front side of left fender L HI 4 B L 1 FRS REC B3 BLOWER RESISTOR 2 3 M2 5 B REC 18 A M1 6 B FRS 17 A 1 A22 AIR INLET CONTROL SERVO MOTOR W- B IJ A H 9 A , H10 B GND 8 A 7 4F 7 4C W- B IF left kick panel HEATER CONTROL SW J9 JUNCTION CONNECTOR +B 2 A E 1 B W- B Cowl side panel RH 4 14 3C 5 3C W- B BATTERY FL MAIN 3. 0W L- B A/CB 5 A IG+ 10 A 2 M L- O 4 2F B2 BLOWER MOTOR L- R M 6 1I LO 8 B 10 3A 1 3B L- B FUSIBLE LINK BLOCK F 6 A , F 7 B , F 8 C , F10 E 4 2D W- B 1 10A A/C 10 3B 4 R- W R- W B A (Cont. next page) W- B 1 A W 120A ALT W- B 2 2 1E 1 1K HTR RELAY 1 E B B L- W 1 C 4 3 16 IF3 1 3A R- W 1 B 1 2 L- W 10 3H 5 IG+ R- L 1 1G 3 1B IG1 RELAY 5 14 IF3 R- W L 1 2G 1 2H 3 5 3 W- G 2 2G 30A DCC 5 10A HTR 5 L- R 1 2C W- L 1 L- B 50A HTR 5 2 5 R- W 9 1J 40A AM1 2 W- R 4 1C 5 R- W 1 2 R- W 11 1I 4 1 R- W 5 IG1 4 R- W R- W R- W 5 I15 IGNITION SW 2 AM1 ACC 2 A ir C onditioning (M anual A /C ) W- G 9 1B 7 IF1 W- L 1 P ow er S ource L- B 7. 5A ECU- B 23 AVALON M OVERALL ELECTRICAL WIRING DIAGRAM L 23 AVALON (Cont’ d) A ir C onditioning (M anual A /C ) 5 A 8 R- W P G- R 7 C 4 A 21 A 9 C 8 C 22 A W- B L- R W- B P B 14 IL1 7 IL1 L- R B P W- B P B 20 IF3 1 1 2F 11 IJ1 4 2F BR W- B L- R L- R P BR 4 A4 A/C DUAL PRESSURE SW J6 JUNCTION CONNECTOR To Engine Control Module<3- 12> B B 1 C M3 A , M5 C CPU MULTI DISPLAY HEATER CONTROL SW 15 IL1 12 IL1 8 4F LG- R H 9 A , H10 B LA/C 11 A 4 IL1 2 C 2 1I A/C6 A 5 IF3 LG- B 4 C 10 IJ1 L- W 11 C 20 IL1 L- B Y 8 4C From Engine Control Module<3- 9> 1 1H FACE 2 G- R 5 IL1 2 12 A 1 LG- B GND 8 2 L- W Y- R D4 DIODE (A/C) 1 1 A1 A/C AMBIENT TEMP. SENSOR G- R L- B L- B L- B B/L 3 LG- R 13 A Y Y- G FOOT 5 2B P 2 A19 A/C THERMISTOR A3 A/C MAGNETIC CLUTCH AND LOCK SENSOR 3 3 B- W B- W 2 9 3B 13 IF3 MG/CLT RELAY W- B 14 A VENT 6 GR F/D BR- W 15 A DEF B/L 5 L- R 16 A FOOT 3 LG- R B- W 2001 AVALON (EWD431U) 1 F/D 9 3G P 13 IJ1 12 IF3 5 2 2C 6 2C 2 P 1 L- B From FAN NO. 3 Relay<18- 3> CONTROL CIRCUIT M A DEF 22 3G 4 2C B 1 P IG 13 IC1 B- W L- B 7 R- W A25 AIR OUTLET CONTROL SERVO MOTOR B- W R- W R- W B 7 6 B Right kick panel II Front side of left fender ED Surge tank RH EB M M OVERALL ELECTRICAL WIRING DIAGRAM 2001 AVALON (EWD431U) [A] : System Title [B] : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red O = Orange LG = Light Green P Y = Pink = Yellow [F] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: GR = Gray G = Green The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Example: ,,,, ,,,, 3C indicates ,,,, that it is inside ,,,, Junction Block ,,,, ,,,,No.3 ,,,, L-Y [G] : Indicates related system. 2001 AVALON (EWD431U) L (Blue) [H] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. Y (Yellow) [C] : The position of the parts is the same as shown in the wiring diagram and wire routing. [D] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example : Numbered in order from upper left to lower right Numbered in order from upper right to lower left Female [I] Male ( ) : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. [J] : Indicates a shielded cable. Female Male The numbering system for the overall wiring diagram is the same as above [E] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example : [K] : Indicates and located on ground point. [L] : The same code occuring on the next page indicates that the wire harness is continuous. Indicates Relay Block No.1 M SYSTEMS LOCATION ABS (w/o Traction Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 Air Conditioning (Automatic A/C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-2 Air Conditioning (Manual A/C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2 Automatic Glare-Resistant EC Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 SYSTEMS LOCATION ∗ Key Reminder and Seat Belt Warning ∗ Light Auto Turn Off ∗ Power Seat (Driver’s Seat w/ Driving Position Memory) ∗ Power Window ∗ Remote Control Mirror (w/ Driving Position Memory) ∗ Theft Deterrent ∗ Wireless Door Lock Control 2001 AVALON (EWD431U) Back-Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Power Seat (Driver’s Seat w/o Driving Position Memory) . . . . . . . . 16-2 Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4 Power Seat (Front Passenger’s Seat) . . . . . . . . . . . . . . . . . . . . . . . . 16-4 Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-2 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1~23-1 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2 Radiator Fan and Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4 Electronically Controlled Transmission and A/T Indicator . . . . . . . . . . 4-2 Radio and Player (6 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Radio and Player (7 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 Engine Immobiliser System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Rear Window Defogger and Mirror Heater . . . . . . . . . . . . . . . . . . . . . . 2-3 Fog Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Remote Control Mirror (w/o Driving Position Memory) . . . . . . . . . . 10-3 Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4 Headlight (w/o Daytime Running Light) . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2 Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Starting and Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Moon Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3 Taillight and Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Multiplex Communication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Turn Signal and Hazard Warning Light . . . . . . . . . . . . . . . . . . . . . . . . 12-3 ∗ Automatic Light Control ∗ Door Lock Control ∗ Headlight (w/ Daytime Running Light) ∗ Interior Light VSC (w/ Traction Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 M OVERALL ELECTRICAL WIRING DIAGRAM SYSTEM INDEX L PART NUMBER OF CONNECTORS Code Part Name Part Number Code Part Name Part Number A1 A/C Ambient Temp. Sensor 90980-11070 C5 Center Airbag Sensor Assembly 90980-11869 A2 A/C Condenser Fan Motor 90980-10928 C6 Center Airbag Sensor Assembly 90980-11872 A3 A/C Magnetic Clutch and Lock Sensor 90980-11016 C7 Center Airbag Sensor Assembly 90980-11867 A4 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) 90980-10943 C8 Cigarette Lighter 90980-11606 C9 Combination Meter 90980-11915 A5 ABS & BA & TRAC & VSC Actuator 90980-11240 C10 Combination Meter 90980-11913 A6 ABS & BA & TRAC & VSC Actuator 90980-11034 C11 Combination SW 90980-11533 A7 ABS Actuator and ECU 90080-98191 C12 Combination SW 90980-11616 A8 ABS Speed Sensor Front LH C13 Combination SW 90980-11672 A9 ABS Speed Sensor Front RH C14 Combination SW 90980-11594 A10 Air Fuel Ratio Sensor (Bank 1 Sensor 1) C15 Cruise Control ECU 90980-11391 A11 Air Fuel Ratio Sensor (Bank 2 Sensor 1) D1 Data Link Connector 1 90980-11195 A12 Airbag Sensor Front LH 90980-11898 D2 Data Link Connector 2 90980-11417 A13 Airbag Sensor Front RH 90980-11856 D3 Data Link Connector 3 90980-11665 A14 A/C Blower Motor Linear Controller 90980-11676 D4 Diode (A/C) A15 A/C Control Assembly 90980-11390 D5 Diode (A/T Indicator Light 1) A16 A/C Control Assembly 90980-11391 D6 Diode (A/T Indicator Light 2) A17 A/C Room Temp. Sensor 90980-11918 D7 Diode (Luggage Compartment Light) 90980-10962 A18 A/C Solar Sensor 90980-11987 D8 Door Control Receiver 90980-11909 A19 A/C Thermistor 90980-11918 D9 Door Courtesy Light Front LH A20 ABS & BA & TRAC & VSC ECU 90080-98201 D10 Door Courtesy Light Front RH A21 Active Light Relay 90980-11533 D11 Door Courtesy SW Front LH A22 Air Inlet Control Servo Motor D12 Door Courtesy SW Front RH A23 Air Mix Control Servo Motor (Driver Side) D13 Door Courtesy SW Rear LH A24 Air Mix Control Servo Motor (Front Passenger Side) D14 Door Courtesy SW Rear RH D15 Door Lock Motor Rear LH D16 Door Lock Motor Rear RH D17 Door Lock Motor,Door Key Lock and Unlock SW and Door Unlock Detection SW Front LH D18 Door Lock Motor,Door Key Lock and Unlock SW and Door Unlock Detection SW Front RH D19 Driver Door ECU 90980-11877 E1 Electronically Controlled Transmission Solenoid 90980-10854 E2 Engine Coolant Temp. Sensor 90980-10737 E3 Engine Hood Courtesy SW 90980-11189 E4 Engine Control Module 90980-11421 E5 Engine Control Module 90980-11476 E6 Engine Control Module 90980-11586 E7 Engine Control Module 90980-11637 E8 Engine Control Module 90980-11638 F1 Front Fog Light LH F2 Front Fog Light RH F3 Front Turn Signal Light and Parking Light LH F4 Front Turn Signal Light and Parking Light RH A25 90980-10869 90980-11909 Air Outlet Control Servo Motor (Automatic A/C) Air Outlet Control Servo Motor (Manual A/C) A26 90980-11075 Airbag Squib (Front Passenger Airbag Assembly) 90980-11989 90980-11886 A27 Airbag Squib (Steering Wheel Pad) 90980-10850 A28 Automatic Light Control Sensor 90980-11107 A29 ABS Speed Sensor Rear LH 90980-11060 A30 ABS Speed Sensor Rear RH B1 Brake Fluid Level Warning SW 90980-11207 B2 Blower Motor 90980-10903 B3 Blower Resistor 90980-11136 B4 Body ECU 90980-11058 B5 Body ECU 90980-11877 B6 Back-Up Light LH B7 Back-Up Light RH B8 Buckle SW LH B9 Buckle SW RH C1 Camshaft Position Sensor LH C2 Camshaft Position Sensor RH C3 Crankshaft Position Sensor C4 Cruise Control Actuator 90980-11148 90980-11212 90980-10947 90980-10947 90980-11150 Note: Not all of the above part numbers of the connector are established for the supply. 308 2001 AVALON (EWD431U) 90980-11071 90980-10935 90980-10871 90980-11150 90980-11858 90980-11660 90980-11020 L Code Part Name F5 Front Wiper Motor F6 Fusible Link Block F7 Fusible Link Block F8 Fusible Link Block Part Number Code 90980-11599 J1 Junction Connector J2 Junction Connector J3 Junction Connector J4 Junction Connector J5 Junction Connector 99141-14005 99141-14006 Part Name Part Number 90980-11542 F9 Fusible Link Block F10 Fusible Link Block 90980-11881 J6 Junction Connector F11 Field Magnetic Sensor 90980-11909 J7 Junction Connector F12 Front Door Speaker LH J8 Junction Connector F13 Front Door Speaker RH J9 Junction Connector F14 Front Passenger Door ECU 90980-11469 J10 Junction Connector F15 Fuel Pump and Sender 90980-11077 J11 Junction Connector G1 Generator 90980-11349 J12 Junction Connector 90980-11542 G2 Generator 90980-09213 J13 Junction Connector 90980-10799 G3 Glove Box Light SW 90980-11098 J14 Junction Connector 90980-11542 H1 Headlight High LH K1 Knock Sensor 1 K2 Knock Sensor 2 K3 Key Interlock Solenoid L1 Luggage Compartment Door Opener Main SW L2 Luggage Compartment Door Opener SW L3 License Plate Light LH L4 License Plate Light RH L5 Light Failure Sensor 90980-10803 L6 Luggage Compartment Door Key Unlock SW 90980-11212 L7 Luggage Compartment Door Unlock Motor 90980-11315 L8 Luggage Compartment Light 90980-11148 L9 Luggage Compartment Light SW 90980-11097 L10 Lumbar Support Control Motor (Driver’s Seat) 90980-10935 L11 Lumbar Support Control SW (Driver’s Seat) 90980-10601 H2 Headlight High RH H3 Headlight Low LH H4 Headlight Low RH H5 Horn LH H6 Horn RH 90980-10935 90980-11095 90980-11660 90980-10619 H7 Hazard SW 90980-10801 H8 Heated Oxygen Sensor (Bank 1 Sensor 2) 90980-11028 H9 Heater Control SW 90980-11913 H10 Heater Control SW 90980-10877 H11 High Mounted Stop Light 90980-11148 I1 Idle Air Control Valve 90980-11145 I2 Ignition Coil and Igniter No.1 I3 Ignition Coil and Igniter No.2 I4 Ignition Coil and Igniter No.3 90980-11885 90980-10976 90980-11166 90980-10825 90980-11148 I5 Ignition Coil and Igniter No.4 I6 Ignition Coil and Igniter No.5 M1 Mass Air Flow Meter 90980-11317 I7 Ignition Coil and Igniter No.6 M2 Masster Cylinder Pressure Sensor 90080-98200 I8 Injector No.1 M3 Multi Display 90980-11915 I9 Injector No.2 M4 Multi Display 90980-11913 I10 Injector No.3 M5 Multi Display 90980-11971 90980-11153 I11 Injector No.4 M6 Multi Display 90980-11116 I12 Injector No.5 M7 Multi Display 90980-11113 I13 Injector No.6 M8 Moon Roof Control ECU 90980-10997 I14 Ignition Key Cylinder Light 90980-10906 M9 Moon Roof Control SW 90980-10908 I15 Ignition SW 90980-11615 N1 Noise Filter (Ignition) 90980-10843 I16 Inner Mirror 90980-12039 N2 Noise Filter (Rear Window Defogger) 90980-11259 I17 Interior Light 90980-10121 2001 AVALON (EWD431U) 309 L PART NUMBER OF CONNECTORS Code Part Name Part Number Noise Filter (Stop Light and Luggage Compartment Light) 90980-10860 O1 O/D Direct Clutch Speed Sensor 90980-11156 O2 Oil Pressure SW 90980-11363 O/D Main SW (Floor Shift) 90980-10795 O/D Main SW (Column Shift) 990980-11471 P1 Park/Neutral Position SW,A/T Indicator Light SW and Back-Up Light SW 90980-11332 P2 Power Steering Oil Pressure SW 90980-11428 P3 Parking Brake SW 90980-10871 P4 Power Outlet 90980-10860 P5 Power Outlet 90980-10760 P6 Power Outlet N3 O3 Power Outlet P8 Power Outlet Main SW 90980-10797 P9 Personal Light 90980-10908 P10 Power Window Control SW Rear LH P11 Power Window Control SW Rear RH P12 Power Window Motor Front LH Power Window Motor Front RH P14 Power Window Motor Rear LH P15 Power Window Motor Rear RH P16 Pretensioner LH Power Seat Control SW (Front Passenger’s Seat) 90980-10997 P20 Power Seat ECU 90980-11527 Power Seat Motor (Driver’s Seat Front Vertical Control) P23 Power Seat Motor (Driver’s Seat Rear Vertical Control) P24 Power Seat Motor (Driver’s Seat Reclining Control) P25 Power Seat Motor (Driver’s Seat Slide Control) P26 Power Seat Motor (Front Passenger’s Seat Rear Vertical Control) P27 Power Seat Motor (Front Passenger’s Seat Reclining Control) 90980-11877 90980-10825 P28 Power Seat Motor (Front Passenger’s Seat Slide Control) P29 Power Seat Position Sensor (Driver’s Seat Front Vertical Control) 90980-11296 Power Seat Position Sensor (Driver’s Seat Rear Vertical Control) 90980-10908 P30 P31 P32 Power Seat Position Sensor (Driver’s Seat Reclining Control) Power Seat Position Sensor (Driver’s Seat Slide Control) R3 Radio and Player 90980-10997 R4 Radio and Player 90980-10996 R5 Remote Control Mirror SW 90980-11657 R6 Rheostat 90980-10908 R7 Rear Combination Light LH R8 Rear Combination Light RH R9 Rear Door Speaker LH R10 Rear Door Speaker RH R11 Rear Interior Light LH R12 Rear Interior Light RH 90980-10908 90980-10935 90980-11580 Remote Control Mirror LH (w/o Driving Position Memory and w/ Mirror Heater) 90980-11487 Remote Control Mirror LH (w/o Driving Position Memory and w/o Mirror Heater) 90980-11470 Remote Control Mirror LH (Taiwan) 90980-12059 Remote Control Mirror RH (w/ Driving Position Memory) 90980-11580 Remote Control Mirror RH (w/o Driving Position Memory and w/ Mirror Heater) 90980-11487 Remote Control Mirror RH (w/o Driving Position Memory and w/o Mirror Heater) 90980-11470 Remote Control Mirror RH (Taiwan) 90980-12059 S1 Starter 90980-11400 S2 Starter 90980-09689 Shift Lock ECU (Floor Shift) 90980-11319 R13 S3 Shift Lock ECU (Column Shift) 90980-11488 S4 Stop Light SW 90980-11118 S5 Side Airbag Sensor LH S6 Side Airbag Sensor RH S7 Side Airbag Squib LH S8 Side Airbag Squib RH S9 Stereo Component Amplifier 90980-10807 S10 Stereo Component Amplifier 90980-10848 S11 Seat Belt Warning Occupant Detection Sensor 90980-10860 S12 Seat Heater (Driver’s Seat) S13 Seat Heater (Front Passenger’s Seat) S14 Seat Memory SW T1 Theft Deterrent Buzzer 90980-11051 T2 Theft Deterrent Horn 90980-10619 T3 Throttle Position Sensor 90980-11261 T4 Theft Deterrent ECU 90980-11423 T5 Translate ECU 90980-11390 T6 Transponder Key Amplifier 90980-10789 Note: Not all of the above part numbers of the connector are established for the supply. 310 90980-11587 Remote Control Mirror LH (w/ Driving Position Memory) 90980-11862 P19 P22 90980-11971 R14 Power Seat Control SW (Driver’s Seat) Power Seat ECU 90980-10928 Radio and Player 90980-10860 P18 P21 Radiator Fan Motor 90980-11011 Pretensioner RH Part Number R2 90980-10797 P17 Part Name R1 90980-10601 P7 P13 Code 2001 AVALON (EWD431U) 90980-11857 90980-11864 90980-10860 90980-11013 L Code Part Name T7 Turn Signal Flasher Relay T8 Tweeter LH T9 Tweeter RH U1 Unlock Warning SW V1 VSV (ACIS No.1) Part Number Code 82751-07010 V10 Vanity Light LH and Garage Door Opener V11 Vanity Light RH V12 Vapor Pressure Sensor 90980-11860 V13 Voltage Inverter 90980-10799 V14 VSV (Pressure Switching Valve) 90980-11859 90980-10825 90980-10860 90980-11149 Part Name Part Number 90980-10621 V2 VSV (ACIS No.2) W1 Washer Level Warning SW 90980-11068 V3 VSV (ACM) 90980-11156 W2 Washer Motor 90980-10981 V4 VSV (Canister Closed Valve) 90980-11162 W3 Water Temp. Sender 90980-11428 V5 VSV (EVAP) 90980-11156 W4 Water Temp. SW No.1 90980-11235 V6 VVT Solenoid LH W5 Water Temp. SW No.2 90980-11243 90980-11162 V7 VVT Solenoid RH W6 Wireless Door Lock Buzzer 90980-11142 V8 VSC Off SW 90980-11013 W7 Woofer 90980-10935 V9 VSC Warning Buzzer 90980-10906 Y1 Yaw Rate Sensor 90080-98199 2001 AVALON (EWD431U) 311 L PART NUMBER OF CONNECTORS Code Part Name Part Number Code Part Name Part Number A1 A/C Ambient Temp. Sensor 90980-11070 C5 Center Airbag Sensor Assembly 90980-11869 A2 A/C Condenser Fan Motor 90980-10928 C6 Center Airbag Sensor Assembly 90980-11872 A3 A/C Magnetic Clutch and Lock Sensor 90980-11016 C7 Center Airbag Sensor Assembly 90980-11867 A4 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) 90980-10943 C8 Cigarette Lighter 90980-11606 C9 Combination Meter 90980-11915 A5 ABS & BA & TRAC & VSC Actuator 90980-11240 C10 Combination Meter 90980-11913 A6 ABS & BA & TRAC & VSC Actuator 90980-11034 C11 Combination SW 90980-11533 A7 ABS Actuator and ECU 90080-98191 C12 Combination SW 90980-11616 A8 ABS Speed Sensor Front LH C13 Combination SW 90980-11672 A9 ABS Speed Sensor Front RH C14 Combination SW 90980-11594 A10 Air Fuel Ratio Sensor (Bank 1 Sensor 1) C15 Cruise Control ECU 90980-11391 A11 Air Fuel Ratio Sensor (Bank 2 Sensor 1) D1 Data Link Connector 1 90980-11195 A12 Airbag Sensor Front LH 90980-11898 D2 Data Link Connector 2 90980-11417 A13 Airbag Sensor Front RH 90980-11856 D3 Data Link Connector 3 90980-11665 A14 A/C Blower Motor Linear Controller 90980-11676 D4 Diode (A/C) A15 A/C Control Assembly 90980-11390 D5 Diode (A/T Indicator Light 1) A16 A/C Control Assembly 90980-11391 D6 Diode (A/T Indicator Light 2) A17 A/C Room Temp. Sensor 90980-11918 D7 Diode (Luggage Compartment Light) 90980-10962 A18 A/C Solar Sensor 90980-11987 D8 Door Control Receiver 90980-11909 A19 A/C Thermistor 90980-11918 D9 Door Courtesy Light Front LH A20 ABS & BA & TRAC & VSC ECU 90080-98201 D10 Door Courtesy Light Front RH A21 Active Light Relay 90980-11533 D11 Door Courtesy SW Front LH A22 Air Inlet Control Servo Motor D12 Door Courtesy SW Front RH A23 Air Mix Control Servo Motor (Driver Side) D13 Door Courtesy SW Rear LH A24 Air Mix Control Servo Motor (Front Passenger Side) D14 Door Courtesy SW Rear RH D15 Door Lock Motor Rear LH D16 Door Lock Motor Rear RH D17 Door Lock Motor,Door Key Lock and Unlock SW and Door Unlock Detection SW Front LH D18 Door Lock Motor,Door Key Lock and Unlock SW and Door Unlock Detection SW Front RH D19 Driver Door ECU 90980-11877 E1 Electronically Controlled Transmission Solenoid 90980-10854 E2 Engine Coolant Temp. Sensor 90980-10737 E3 Engine Hood Courtesy SW 90980-11189 E4 Engine Control Module 90980-11421 E5 Engine Control Module 90980-11476 E6 Engine Control Module 90980-11586 E7 Engine Control Module 90980-11637 E8 Engine Control Module 90980-11638 F1 Front Fog Light LH F2 Front Fog Light RH F3 Front Turn Signal Light and Parking Light LH F4 Front Turn Signal Light and Parking Light RH A25 90980-10869 90980-11909 Air Outlet Control Servo Motor (Automatic A/C) Air Outlet Control Servo Motor (Manual A/C) A26 90980-11075 Airbag Squib (Front Passenger Airbag Assembly) 90980-11989 90980-11886 A27 Airbag Squib (Steering Wheel Pad) 90980-10850 A28 Automatic Light Control Sensor 90980-11107 A29 ABS Speed Sensor Rear LH 90980-11060 A30 ABS Speed Sensor Rear RH B1 Brake Fluid Level Warning SW 90980-11207 B2 Blower Motor 90980-10903 B3 Blower Resistor 90980-11136 B4 Body ECU 90980-11058 B5 Body ECU 90980-11877 B6 Back-Up Light LH B7 Back-Up Light RH B8 Buckle SW LH B9 Buckle SW RH C1 Camshaft Position Sensor LH C2 Camshaft Position Sensor RH C3 Crankshaft Position Sensor C4 Cruise Control Actuator 90980-11148 90980-11212 90980-10947 90980-10947 90980-11150 Note: Not all of the above part numbers of the connector are established for the supply. 308 2001 AVALON (EWD431U) 90980-11071 90980-10935 90980-10871 90980-11150 90980-11858 90980-11660 90980-11020 L Code Part Name F5 Front Wiper Motor F6 Fusible Link Block F7 Fusible Link Block F8 Fusible Link Block Part Number Code 90980-11599 J1 Junction Connector J2 Junction Connector J3 Junction Connector J4 Junction Connector J5 Junction Connector 99141-14005 99141-14006 Part Name Part Number 90980-11542 F9 Fusible Link Block F10 Fusible Link Block 90980-11881 J6 Junction Connector F11 Field Magnetic Sensor 90980-11909 J7 Junction Connector F12 Front Door Speaker LH J8 Junction Connector F13 Front Door Speaker RH J9 Junction Connector F14 Front Passenger Door ECU 90980-11469 J10 Junction Connector F15 Fuel Pump and Sender 90980-11077 J11 Junction Connector G1 Generator 90980-11349 J12 Junction Connector 90980-11542 G2 Generator 90980-09213 J13 Junction Connector 90980-10799 G3 Glove Box Light SW 90980-11098 J14 Junction Connector 90980-11542 H1 Headlight High LH K1 Knock Sensor 1 K2 Knock Sensor 2 K3 Key Interlock Solenoid L1 Luggage Compartment Door Opener Main SW L2 Luggage Compartment Door Opener SW L3 License Plate Light LH L4 License Plate Light RH L5 Light Failure Sensor 90980-10803 L6 Luggage Compartment Door Key Unlock SW 90980-11212 L7 Luggage Compartment Door Unlock Motor 90980-11315 L8 Luggage Compartment Light 90980-11148 L9 Luggage Compartment Light SW 90980-11097 L10 Lumbar Support Control Motor (Driver’s Seat) 90980-10935 L11 Lumbar Support Control SW (Driver’s Seat) 90980-10601 H2 Headlight High RH H3 Headlight Low LH H4 Headlight Low RH H5 Horn LH H6 Horn RH 90980-10935 90980-11095 90980-11660 90980-10619 H7 Hazard SW 90980-10801 H8 Heated Oxygen Sensor (Bank 1 Sensor 2) 90980-11028 H9 Heater Control SW 90980-11913 H10 Heater Control SW 90980-10877 H11 High Mounted Stop Light 90980-11148 I1 Idle Air Control Valve 90980-11145 I2 Ignition Coil and Igniter No.1 I3 Ignition Coil and Igniter No.2 I4 Ignition Coil and Igniter No.3 90980-11885 90980-10976 90980-11166 90980-10825 90980-11148 I5 Ignition Coil and Igniter No.4 I6 Ignition Coil and Igniter No.5 M1 Mass Air Flow Meter 90980-11317 I7 Ignition Coil and Igniter No.6 M2 Masster Cylinder Pressure Sensor 90080-98200 I8 Injector No.1 M3 Multi Display 90980-11915 I9 Injector No.2 M4 Multi Display 90980-11913 I10 Injector No.3 M5 Multi Display 90980-11971 90980-11153 I11 Injector No.4 M6 Multi Display 90980-11116 I12 Injector No.5 M7 Multi Display 90980-11113 I13 Injector No.6 M8 Moon Roof Control ECU 90980-10997 I14 Ignition Key Cylinder Light 90980-10906 M9 Moon Roof Control SW 90980-10908 I15 Ignition SW 90980-11615 N1 Noise Filter (Ignition) 90980-10843 I16 Inner Mirror 90980-12039 N2 Noise Filter (Rear Window Defogger) 90980-11259 I17 Interior Light 90980-10121 2001 AVALON (EWD431U) 309 L PART NUMBER OF CONNECTORS Code Part Name Part Number Noise Filter (Stop Light and Luggage Compartment Light) 90980-10860 O1 O/D Direct Clutch Speed Sensor 90980-11156 O2 Oil Pressure SW 90980-11363 O/D Main SW (Floor Shift) 90980-10795 O/D Main SW (Column Shift) 990980-11471 P1 Park/Neutral Position SW,A/T Indicator Light SW and Back-Up Light SW 90980-11332 P2 Power Steering Oil Pressure SW 90980-11428 P3 Parking Brake SW 90980-10871 P4 Power Outlet 90980-10860 P5 Power Outlet 90980-10760 P6 Power Outlet N3 O3 Power Outlet P8 Power Outlet Main SW 90980-10797 P9 Personal Light 90980-10908 P10 Power Window Control SW Rear LH P11 Power Window Control SW Rear RH P12 Power Window Motor Front LH Power Window Motor Front RH P14 Power Window Motor Rear LH P15 Power Window Motor Rear RH P16 Pretensioner LH Power Seat Control SW (Front Passenger’s Seat) 90980-10997 P20 Power Seat ECU 90980-11527 Power Seat Motor (Driver’s Seat Front Vertical Control) P23 Power Seat Motor (Driver’s Seat Rear Vertical Control) P24 Power Seat Motor (Driver’s Seat Reclining Control) P25 Power Seat Motor (Driver’s Seat Slide Control) P26 Power Seat Motor (Front Passenger’s Seat Rear Vertical Control) P27 Power Seat Motor (Front Passenger’s Seat Reclining Control) 90980-11877 90980-10825 P28 Power Seat Motor (Front Passenger’s Seat Slide Control) P29 Power Seat Position Sensor (Driver’s Seat Front Vertical Control) 90980-11296 Power Seat Position Sensor (Driver’s Seat Rear Vertical Control) 90980-10908 P30 P31 P32 Power Seat Position Sensor (Driver’s Seat Reclining Control) Power Seat Position Sensor (Driver’s Seat Slide Control) R3 Radio and Player 90980-10997 R4 Radio and Player 90980-10996 R5 Remote Control Mirror SW 90980-11657 R6 Rheostat 90980-10908 R7 Rear Combination Light LH R8 Rear Combination Light RH R9 Rear Door Speaker LH R10 Rear Door Speaker RH R11 Rear Interior Light LH R12 Rear Interior Light RH 90980-10908 90980-10935 90980-11580 Remote Control Mirror LH (w/o Driving Position Memory and w/ Mirror Heater) 90980-11487 Remote Control Mirror LH (w/o Driving Position Memory and w/o Mirror Heater) 90980-11470 Remote Control Mirror LH (Taiwan) 90980-12059 Remote Control Mirror RH (w/ Driving Position Memory) 90980-11580 Remote Control Mirror RH (w/o Driving Position Memory and w/ Mirror Heater) 90980-11487 Remote Control Mirror RH (w/o Driving Position Memory and w/o Mirror Heater) 90980-11470 Remote Control Mirror RH (Taiwan) 90980-12059 S1 Starter 90980-11400 S2 Starter 90980-09689 Shift Lock ECU (Floor Shift) 90980-11319 R13 S3 Shift Lock ECU (Column Shift) 90980-11488 S4 Stop Light SW 90980-11118 S5 Side Airbag Sensor LH S6 Side Airbag Sensor RH S7 Side Airbag Squib LH S8 Side Airbag Squib RH S9 Stereo Component Amplifier 90980-10807 S10 Stereo Component Amplifier 90980-10848 S11 Seat Belt Warning Occupant Detection Sensor 90980-10860 S12 Seat Heater (Driver’s Seat) S13 Seat Heater (Front Passenger’s Seat) S14 Seat Memory SW T1 Theft Deterrent Buzzer 90980-11051 T2 Theft Deterrent Horn 90980-10619 T3 Throttle Position Sensor 90980-11261 T4 Theft Deterrent ECU 90980-11423 T5 Translate ECU 90980-11390 T6 Transponder Key Amplifier 90980-10789 Note: Not all of the above part numbers of the connector are established for the supply. 310 90980-11587 Remote Control Mirror LH (w/ Driving Position Memory) 90980-11862 P19 P22 90980-11971 R14 Power Seat Control SW (Driver’s Seat) Power Seat ECU 90980-10928 Radio and Player 90980-10860 P18 P21 Radiator Fan Motor 90980-11011 Pretensioner RH Part Number R2 90980-10797 P17 Part Name R1 90980-10601 P7 P13 Code 2001 AVALON (EWD431U) 90980-11857 90980-11864 90980-10860 90980-11013 L Code Part Name T7 Turn Signal Flasher Relay T8 Tweeter LH T9 Tweeter RH U1 Unlock Warning SW V1 VSV (ACIS No.1) Part Number Code 82751-07010 V10 Vanity Light LH and Garage Door Opener V11 Vanity Light RH V12 Vapor Pressure Sensor 90980-11860 V13 Voltage Inverter 90980-10799 V14 VSV (Pressure Switching Valve) 90980-11859 90980-10825 90980-10860 90980-11149 Part Name Part Number 90980-10621 V2 VSV (ACIS No.2) W1 Washer Level Warning SW 90980-11068 V3 VSV (ACM) 90980-11156 W2 Washer Motor 90980-10981 V4 VSV (Canister Closed Valve) 90980-11162 W3 Water Temp. Sender 90980-11428 V5 VSV (EVAP) 90980-11156 W4 Water Temp. SW No.1 90980-11235 V6 VVT Solenoid LH W5 Water Temp. SW No.2 90980-11243 90980-11162 V7 VVT Solenoid RH W6 Wireless Door Lock Buzzer 90980-11142 V8 VSC Off SW 90980-11013 W7 Woofer 90980-10935 V9 VSC Warning Buzzer 90980-10906 Y1 Yaw Rate Sensor 90080-98199 2001 AVALON (EWD431U) 311 J POWER SOURCE (Current Flow Chart) 2001 AVALON (EWD431U) 290 J 2001 AVALON (EWD431U) 291 J POWER SOURCE (Current Flow Chart) Driver Side J/B (See Page 26) Fuse 5A ECU-ACC System Page ABS (w/o Traction Control) Back-Up Light Cruise Control Electronically Controlled Transmission and A/T Indicator 200 152 210 216 Multiplex Communication System Radio and Player (6 Speaker) Radio and Player (7 Speaker) Remote Control Mirror (w/o Driving Position Memory) 108 254 250 246 Shift Lock VSC (w/ Traction Control) 222 190 5A ECU-IG NO.1 Charging Radiator Fan and Condenser Fan 80 266 5A PANEL Combination Meter Illumination 256 142 DOME Combination Meter Garage Door Opener Interior Light Wireless Door Lock Control 256 238 136 178 Air Conditioning (Automatic A/C) Air Conditioning (Manual A/C) Automatic Light Control Combination Meter 268 276 130 256 Door Lock Control Headlight (w/ Daytime Running Light) Interior Light Key Reminder and Seat Belt Warning 172 98 136 154 Light Auto Turn Off Multiplex Communication System Power Seat (w/ Driving Position Memory) Power Window 132 108 224 166 Remote Control Mirror (w/ Driving Position Memory) Theft Deterrent Wireless Door Lock Control 242 184 178 7.5A 7.5A ECU-B 7.5A OBD-II Engine Control 82 7.5A TURN Turn Signal and Hazard Warning Light 146 10A A/C Air Conditioning (Manual A/C) 276 Combination Meter Cruise Control Door Lock Control Electronically Controlled Transmission and A/T Indicator 256 210 172 216 Interior Light Key Reminder and Seat Belt Warning 136 154 10A ECU-IG NO.2 ∗ These are the page numbers of the first page on which the related system is shown. 2001 AVALON (EWD431U) 292 J Fuse 10A 10A 10A ECU-IG NO.2 GAUGE NO.1 GAUGE NO.2 System Page Multiplex Communication System Theft Deterrent VSC (w/ Traction Control) Wireless Door Lock Control 108 184 190 178 ABS (w/o Traction Control) Automatic Glare-Resistant EC Mirror Combination Meter Cruise Control 200 240 256 210 Engine Control Key Reminder and Seat Belt Warning Moon Roof Multiplex Communication System 82 154 236 108 Power Outlet Power Seat (w/ Driving Position Memory) Power Window Rear Window Defogger and Mirror Heater 162 224 166 248 Remote Control Mirror (w/ Driving Position Memory) Shift Lock Taillight and Stop Light VSC (w/ Traction Control) 242 222 148 190 ABS (w/o Traction Control) Back-Up Light Cruise Control Electronically Controlled Transmission and A/T Indicator 200 152 210 216 VSC (w/ Traction Control) 190 10A HTR Air Conditioning (Automatic A/C) Air Conditioning (Manual A/C) 268 276 10A MIR HTR Engine Control Rear Window Defogger and Mirror Heater 82 248 10A SRS-ACC SRS 205 10A TAIL Engine Control Taillight and Stop Light 82 148 15A CIG Cigarette Lighter 160 15A ECU-IG NO.2 ABS (w/o Traction Control) 200 15A FOG Fog Light 104 15A PWR OUTLET NO.1 Power Outlet 162 15A PWR OUTLET NO.2 Power Outlet 162 15A RADIO Combination Meter Radio and Player (6 Speaker) Radio and Player (7 Speaker) 256 254 250 15A STOP ABS (w/o Traction Control) Cruise Control Electronically Controlled Transmission and A/T Indicator 200 210 216 ∗ These are the page numbers of the first page on which the related system is shown. 2001 AVALON (EWD431U) 293 J POWER SOURCE (Current Flow Chart) Fuse System Page 15A STOP Engine Control Shift Lock Taillight and Stop Light VSC (w/ Traction Control) 20A FR P/W Multiplex Communication System Power Window 108 166 20A RL P/W Multiplex Communication System Power Window 108 166 20A RR P/W Multiplex Communication System Power Window 108 166 20A SEAT HEATER Seat Heater 234 Door Lock Control Interior Light Multiplex Communication System Theft Deterrent 172 136 108 184 Wireless Door Lock Control 178 25A DOOR NO.1 82 222 148 190 25A FL P/W Multiplex Communication System Power Window 108 166 25A WIP Wiper and Washer 158 30A PWR SEAT Multiplex Communication System Power Seat (w/ Driving Position Memory) Power Seat (w/o Driving Position Memory) Remote Control Mirror (w/ Driving Position Memory) 108 224 230 242 30A SUN ROOF Moon Roof 236 40A DEF Rear Window Defogger and Mirror Heater 248 Engine Room J/B (See Page 30) Fuse System Page 5A ALT-S Charging 80 5A SRS WRN Combination Meter SRS 256 205 7.5A EFI NO.2 Electronically Controlled Transmission and A/T Indicator Engine Control Engine Immobiliser System 216 82 94 Charging Combination Meter Electronically Controlled Transmission and A/T Indicator Engine Control 80 256 216 82 Engine Immobiliser System SRS Starting and Ignition 94 205 76 10A AM2 Horn Multiplex Communication System Theft Deterrent ∗ These are the page numbers of the first page on which the related system is shown. 10A HORN 2001 AVALON (EWD431U) 294 164 108 184 J Fuse System Page 15A DOOR NO.2 Door Lock Control Interior Light Multiplex Communication System Wireless Door Lock Control 15A EFI NO.1 Electronically Controlled Transmission and A/T Indicator Engine Control Engine Immobiliser System 216 82 94 15A HAZ Turn Signal and Hazard Warning Light 146 15A IG2 Combination Meter Engine Control Starting and Ignition 256 82 76 25A A/F Engine Control 82 25A ABS NO.2 VSC (w/ Traction Control) 190 25A ABS NO.3 VSC (w/ Traction Control) 190 30A CDS Radiator Fan and Condenser Fan 266 30A RDI Radiator Fan and Condenser Fan 266 Automatic Light Control Headlight (w/ Daytime Running Light) Headlight (w/o Daytime Running Light) Light Auto Turn Off 130 98 102 132 Multiplex Communication System Starting and Ignition 108 76 40A MAIN 172 136 108 178 Engine Room R/B No.2 (See Page 24) Fuse System Page 10A HEAD LH UPR Headlight (w/ Daytime Running Light) Multiplex Communication System 98 108 10A HEAD RH UPR Headlight (w/ Daytime Running Light) Multiplex Communication System 98 108 Engine Room R/B No.5 (See Page 25) Fuse System Page 5A ABS NO.4 VSC (w/ Traction Control) 190 7.5A DRL Headlight (w/ Daytime Running Light) Multiplex Communication System 98 108 15A HEAD LH Fog Light Headlight (w/o Daytime Running Light) 104 102 15A HEAD LH LWR Fog Light Headlight (w/ Daytime Running Light) Multiplex Communication System 104 98 108 15A HEAD RH Combination Meter Headlight (w/o Daytime Running Light) 256 102 15A HEAD RH LWR Headlight (w/ Daytime Running Light) Multiplex Communication System 98 108 ∗ These are the page numbers of the first page on which the related system is shown. 2001 AVALON (EWD431U) 295 J POWER SOURCE (Current Flow Chart) Fuse System Page 50A HTR Air Conditioning (Automatic A/C) Air Conditioning (Manual A/C) 268 276 60A ABS ABS (w/o Traction Control) VSC (w/ Traction Control) 200 190 Fusible Link Block (See Page 23) Fuse 120A ALT System Page Automatic Light Control Charging Illumination Light Auto Turn Off 130 80 142 132 Power Window Rear Window Defogger and Mirror Heater Taillight and Stop Light 166 248 148 ∗ These are the page numbers of the first page on which the related system is shown. 2001 AVALON (EWD431U) 296 MEMO 2001 AVALON (EWD431U) 297 F RELAY LOCATIONS [Engine Compartment] [Body] 2001 AVALON (EWD431U) 20 F [Instrument Panel] (Column Shift) (Floor Shift) 2001 AVALON (EWD431U) 21 F RELAY LOCATIONS [Seat] (Column Shift) (Floor Shift) 2001 AVALON (EWD431U) 22 F Fusible Link Block Engine Compartment Left (See Page 20) [Inside Engine Room J/B] 2001 AVALON (EWD431U) 23 F RELAY LOCATIONS 2 : Engine Room R/B No.2 Engine Compartment Right (See Page 20) 3 : Engine Room R/B No.3 Near the Radiator Fan (See Page 20) 2001 AVALON (EWD431U) 24 F 5 : Engine Room R/B No.5 Engine Compartment Left (See Page 20) [Inside Engine Room J/B] 2001 AVALON (EWD431U) 25 F RELAY LOCATIONS ,,, ,,, ,,,: Driver Side J/B Lower Finish Panel (See Page 21) 2001 AVALON (EWD431U) 26 F 2001 AVALON (EWD431U) 27 F RELAY LOCATIONS [Driver Side J/B Inner Circuit] 2001 AVALON (EWD431U) 28 MEMO 2001 AVALON (EWD431U) 29 F RELAY LOCATIONS ,,, ,,, ,,,: Engine Room J/B Engine Compartment Left (See Page 20) 2001 AVALON (EWD431U) 30 F 2001 AVALON (EWD431U) 31 F RELAY LOCATIONS [Engine Room J/B Inner Circuit] 2001 AVALON (EWD431U) 32 MEMO 2001 AVALON (EWD431U) 33 F RELAY LOCATIONS ,,, ,,, ,,,: J/B No.3 Left Kick Panel (See Page 21) 2001 AVALON (EWD431U) 34 F 2001 AVALON (EWD431U) 35 F RELAY LOCATIONS [J/B No.3 Inner Circuit] 2001 AVALON (EWD431U) 36 F 2001 AVALON (EWD431U) 37 F RELAY LOCATIONS ,,, ,,, ,,,: J/B No.4 Right Kick Panel (See Page 21) 2001 AVALON (EWD431U) 38 F 2001 AVALON (EWD431U) 39 F RELAY LOCATIONS [J/B No.4 Inner Circuit] 2001 AVALON (EWD431U) 40 F 2001 AVALON (EWD431U) 41 F RELAY LOCATIONS 6 : Driver Side R/B No.6 Left Kick Panel (See Page 21) 7 : Front Passenger Side R/B No.7 Right Kick Panel (See Page 21) 2001 AVALON (EWD431U) 42 MEMO 2001 AVALON (EWD431U) 43 POWER SOURCE B- L 1 2G 1 2H B 1 5 2 L- B 5 30A CDS 1 50A HTR 2 1 L (* 2) 2 W 5 (* 1) 30A RDI 1 60A ABS 2 1 2 5 W- L 25A ABS NO. 2 40A AM1 25A ABS NO. 3 W- L 10A GAUGE NO. 2 W G2 GENERATOR 1 1G 15A FOG 10A HTR 20A SEAT HTR 25A WIP 15A PWR OUTLET NO. 2 7. 5A TURN 5A OPNER 5A ECU- IG NO. 1 1 2 3 4 10A GAUGE NO. 1 B W- R 10A ECU- IG NO. 2 IG1 RELAY 4 1C 1 1 D 1 C 5 1 2 10A MIR HTR 40A DEF W B- L B- L DEF RELAY 3 1 PWR RELAY 1 E 5 3 1 2 20A FR P/W 20A RR P/W F6 A , F7 B , F8 C , F9 D , 120A ALT 20A RL P/W F10 E FUSIBLE LINK BLOCK TAIL RELAY 1 2 10A TAIL 5 3 5A PANEL 1 B 30A PWR SEAT B B 1 A 2 7. 5A OBD- II 1 2 25A DOOR NO. 1 FL MAIN 3. 0W 25A FL P/W 30A SUN ROOF 15A STOP B L 2 BATTERY 3 1 10A HEAD LH UPR R 2 2 1 10A HEAD RH UPR 2001 AVALON (EWD431U) 72 2 R- B * * * * 1 : W/ TRACTION CONTROL 2 : W/O TRACTION CONTROL 3 : W/ DAYTIME RUNNING LIGHT 4 : W/O DAYTIME RUNNING LIGHT 4 L- B L- B R- W W 3 (* 1) GR- R 3 ABS MTR RELAY 1 2 3 5 5 1 2 5 3 L 3 4 GR- L 3 7 IF1 W- L 1 1K L- R 5 10A A/C L- W 5 HTR RELAY L 5 1 I15 IGNITION SW W- L W- B 5 2 O 5 5A ABS NO. 4 ACC 3 W- G IG1 4 W- R 2 AM1 10 1C 15A PWR OUTLET NO. 1 5A ECU- ACC 15A CIG 10A SRS- ACC 4 IF1 W- R 7 AM2 IG2 6 ST2 8 B- O B- W B- O W- R 7 1C W- R 15A RADIO 9 1J 7. 5A ECU- B 2 1J 7 2C 10A AM2 B- O W- L 7. 5A DOME 1 2C 30A DCC 11 2C 1 B- O 2 15A HEAD RH LWR (* 3) 15A HEAD RH (* 4) G- W 15A IG2 5 (* 3) 3 R- W 5 (* 4) 1 3 1 5 IG2 RELAY B- R 15A DOOR NO. 2 5A ALT- S 5A SRS WRN 15A HAZ 10A HORN R- B 5 15A HEAD LH LWR (* 3) 15A HEAD LH (* 4) 25A A/F 15A EFI NO. 1 2 EFI RELAY 5 3 7. 5A EFI NO. 2 HEAD RELAY 1 4 2 1 5 R- B R 5 3 2 1 2E R- B 4 2E R- B 5 B- R 5 40A MAIN B 2 2G 1 R- B R- B 2 2 2 3 4 2 1 2 2 R E1 (*3) R- L 8 IF1 (*3) 6 EA1 R R 7. 5A DRL R W- R DRL NO. 2 RELAY 5 2 1 5 R- L (*3) 2001 AVALON (EWD431U) 73 POWER SOURCE SERVICE HINTS HEAD RELAY 1-2 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position TAIL RELAY 5-3 : Closed with the light control SW at TAIL or HEAD position I15 IGNITION SW 2-3 : Closed with the ignition key at ACC or ON position 2-4 : Closed with the ignition key at ON or ST position 7-6 : Closed with the ignition key at ON or ST position 7-8 : Closed with the ignition key at ST position : PARTS LOCATION Code See Page Code See Page F6 A 44 F9 D 44 F7 B 44 F10 E 44 F8 C 44 G2 Code I15 See Page 47 (Column Shift) 49 (Floor Shift) 44 : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 2 24 Engine Room R/B No.2 (Engine Compartment Right) 3 24 Engine Room R/B No.3 (Near the Radiator Fan) 5 25 Engine Room R/B No.5 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1C See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 27 Engine g Room Main Wire and Driver Side J/B ((Lower Finish Panel)) 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2G 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 2H 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 1G 1J 1K 2C 2E : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EA1 IF1 See Page 54 Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Engine Room No.2 Wire (Near the Engine Room R/B No.2) 56 (Column Shift) 60 (Floor Shift) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) : SPLICE POINTS Code E1 See Page 54 Wire Harness with Splice Points Code Engine Room No.2 Wire 2001 AVALON (EWD431U) 74 See Page Wire Harness with Splice Points MEMO 2001 AVALON (EWD431U) 75 STARTING AND IGNITION ACC B- W AM1 IG1 B- W 7 AM2 IG2 6 B- O ST2 8 B- W B- W W- R B- W I14 7 1C IF1 I15 IGNITION SW B- W 11 2C 8 2B 10A AM2 40A MAIN 2 15A IG2 1 1 ST RELAY 5 3 2 6 2A 4 2D 4 2F B- R W- B W- B W- B B- R 3 2B B- R 2 8 2A 10 2C B 1 5 P N 6 IG2 RELAY 3 2 2G 5 II1 B- W B- O 7 2C P1 PARK/NEUTRAL POSITION SW W- R 7 2 1J B- R 4 1 B I19 B- R FUSIBLE LINK BLOCK B- R F6 A , F7 B 4 B- R FL MAIN 3. 0W B- R 1 A 1 B W- B II2 B- W B- R B TO COMBINATION METER 1 A B- R B B W- B J1 JUNCTION CONNECTOR M BATTERY W- B S1 A , S2 B STARTER ED 2001 AVALON (EWD431U) 76 STA NSW B- Y B- R LG- B L- Y L LG 20 D GR 2 3 B- W 4 1 2 3 B- Y B- R B- Y IGT1 IGF 1 2 3 LG- B E2 B- Y IGT2 1 2 3 L- Y E2 B- Y IGT3 B- W 4 1 2 E2 B- Y IGT4 W- B E5 1 4 3 2 3 IGT5 LG B- W 4 B- Y W- B W- B W- B L B- W B- W I7 IGNITION COIL AND IGNITER NO. 6 W- B B- W B- Y 4 I6 IGNITION COIL AND IGNITER NO. 5 B- W E4 B- Y E5 W- B B- W I5 IGNITION COIL AND IGNITER NO. 4 B- W 4 B- Y W- B W- B B- W B- W I4 IGNITION COIL AND IGNITER NO. 3 W- B I3 IGNITION COIL AND IGNITER NO. 2 1 GR B- W E5 W- B 7 E B- W 1 B- Y I2 IGNITION COIL AND IGNITER NO. 1 N1 NOISE FILTER (IGNITION) B- W B- W B- W E4 W- B E2 B- W B- R 11 A 25 A 12 A 13 A 14 A 15 A 16 A IGT6 ENGINE CONTROL MODULE E4 A , E7 D , E8 E EC 2001 AVALON (EWD431U) 77 STARTING AND IGNITION SERVICE HINTS I15 IGNITION SW 7-6 : Closed with the ignition SW at ON or ST position 7-8 : Closed with the ignition SW at ST position P1 PARK/NEUTRAL POSITION SW 5-6 : Closed with the A/T shift lever in P or N position S1 (A), S2 (B) STARTER Points closed with the Park/Neutral position SW at P or N position and the ignition SW at ST position : PARTS LOCATION Code E4 See Page A E7 D Code See Page Code See Page 46 (Column Shift) I2 45 48 (Floor Shift) I3 45 46 (Column Shift) I4 45 N1 48 (Floor Shift) I5 45 P1 46 (Column Shift) I6 45 S1 A 45 48 (Floor Shift) I7 45 S2 B 45 E8 E F6 A 44 F7 B 44 I15 47 (Column Shift) J1 49 (Floor Shift) 45 45 47 (Column Shift) 49 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1C 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1J 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 30 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 2A 2B 2C 2D 2F 2G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IF1 II1 II2 See Page 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Engine Wire and Cowl Wire (Behind the Glove Box) 62 (Floor Shift) : GROUND POINTS Code See Page Ground Points Location EC 54 Rear Side of Surge Tank ED 54 Front Side of Left Fender : SPLICE POINTS Code See Page Wire Harness with Splice Points E2 E4 I14 54 Engine g Wire E5 I14 Code 58 (Column Shift) I19 See Page 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Cowl Wire 2001 AVALON (EWD431U) 78 Wire Harness with Splice Points Cowl Wire Engine Wire MEMO 2001 AVALON (EWD431U) 79 CHARGING B- L FROM POWER SOURCE SYSTEM (SEE PAGE 72) ACC AM1 IG1 5A ECU- IG NO. 1 7 AM2 IG2 6 B- O 5 1D ST2 W- R I15 IGNITION SW Y 7 1C 13 1A W- R M7 CHARGE WARNING LIGHT [MULTI DISPLAY] B- O IF1 W- R 4 11 7 2C 11 2B 2 3A 11 3A 12 5A ALT- S Y R- L 10A AM2 I8 R- L 16 II1 6 6 IJ1 Y ALTL R- L 120A ALT F6 A , F7 B , F9 D FUSIBLE LINK BLOCK B5 BODY ECU 3 A 1 A 2 A 1 B B- L 1 B (*1) B 1 D R- L B- L 2 2G W- R 1 A B G1 A , G2 B IG FL MAIN 3. 0W L S * 1 : W/ DAYTIME RUNNING LIGHT IC REGULATOR BATTERY 2001 AVALON (EWD431U) 80 B GENERATOR SERVICE HINTS G1 (A) GENERATOR (A) 3-GROUND : 13.9- 15.1 volts with the engine running at 2000 rpm and 25°C (77°F) 13.5- 14.3 volts with the engine running at 5000 rpm and 115°C (239°F) (A) 1-GROUND : 0- 4 volts with the ignition SW at ON position and the engine not running : PARTS LOCATION Code See Page B5 Code See Page 46 (Column Shift) F9 D 44 48 (Floor Shift) G1 A 44 F6 A 44 G2 B 44 F7 B 44 I15 Code I15 M7 See Page 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A 1C 1D See Page Junction Block and Wire Harness (Connector Location) 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 2B 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 2C 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2G 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 3A 34 Cowl Wire and J/B No.3 (Left Kick Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IF1 II1 IJ1 See Page 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) Engine Wire and Cowl Wire (Behind the Glove Box) Engine Wire and Instrument Panel Wire (Right Kick Panel) : SPLICE POINTS Code See Page I8 58 (Column Shift) Wire Harness with Splice Points Instrument Panel Wire Code I8 See Page 62 (Floor Shift) Wire Harness with Splice Points Instrument Panel Wire 2001 AVALON (EWD431U) 81 ENGINE CONTROL L- O B- W 7 AM2 IG2 6 B- W ST2 8 B- W B- W B- W B- O W- R B- W I15 IGNITION SW B- O IF1 I7 B- O B- W B- W B- W B- W B- W B- W 4 2B 9 2B 1 2A 6 2B 2 2F 2 2A B- O B- O L- O W- R 4 B- R 7 2C 11 2C 2 1J 7 1C 2 13 2C 4 2F 12 2B 13 2B 2 2B B- W B- W B- W 5 2 3 B- O 15A IG2 3 B 5 1 3 2 IG2 RELAY 2 2G 1 A/F RELAY 1 W- B 25A A/F 7. 5A EFI NO. 2 5 EFI RELAY 10A AM2 B- R 15A EFI NO. 1 12 1B 10 2B B- R FUSIBLE LINK BLOCK F6 A , F7 B 1 B 1 A 8 II1 1 IF1 B B- O B- R B- R FL MAIN 3. 0W B- R B- W B- W B- R BATTERY B- W ED 2001 AVALON (EWD431U) 82 L- O B- W B- W E2 B- W B- W B- W BR B- W B- W B- W B- W 2 B- W B- R G- B 7 B 26 A EVP1 6 V1 VSV (ACIS NO. 1) B- W L- O 3 8 E 17 A BR RSO MREL ACIS E4 A , E5 B , E6 C , E7 D , E8 E ENGINE CONTROL MODULE B- W B- W G- B L- B 6 16 E +B II1 2 1 20 D NSW 2 B- W 3 1 17 B- W 1 BR 2 R- Y 6 C/OPN RELAY 5 1 L- O 6 IF1 V5 VSV (EVAP) 6 B- W B- R I1 IDLE AIR CONTROL VALVE B- W B- W B- W B- O Y #30 1 A W # 40 2 A G # 50 3 A G #60 4 A B- R STA 7 E B- R BATT 1 E B- O IGSW 2 E G- B FC 3 E 1 1 1 1 I10 INJECTOR NO. 3 2 2 B- W 2 B- W B- W B- W 2 I11 INJECTOR NO. 4 W- B B- O B- W 5 I13 INJECTOR NO. 6 M I12 INJECTOR NO. 5 4 TO ST RELAY F15 FUEL PUMP L- B 1 ID2 B- W B- R E5 B- W B- W E5 B- W E5 B- W W- B B- W A B- W J11 JUNCTION CONNECTOR BK 2001 AVALON (EWD431U) 83 84 W 3 E2G 2 10 B 19 B 22 B THA 23 B 4 1 5 II1 5 D TC VTA1 I23 1 15 2 3 VTA VC 1 E2 2 B- W 14 W 2001 AVALON (EWD431U) E2 W BR 8 8 IK2 9 D HTS 2 B VC II2 E2 E2 BR B (* 1) HT B TE1 1 19 IK2 I14 17 E PTNK L- R 5 ID1 2 4 ID1 3 2 VCC PTNK 20 ID1 W E2 W TBP +B W- B B- W BR H8 HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) LG B- W 2 E2 ENGINE COOLANT TEMP. SENSOR 3 D E1 G- Y VG D1 DATA LINK CONNECTOR 1 16 IK2 W ACI1 12 +B 3 P 6 ID1 12 B- W 16 II2 (*1) 1 LG- R B- W V14 VSV (PRESSURE SWITCHING VALVE) B- W 2 LG P- B 2 W- R V2 VSV (ACIS NO. 2) B- W 3 ID1 B- W P 15 B E2 V12 VAPOR PRESSURE SENSOR 1 PS L- R D 9 B L- R # 10 L- R D 1 L P- B G B- W B- W W 5 B LG # 20 L- R 6 B L- B CCV R- B 10 E E2 E2 T3 THROTTLE POSITION SENSOR W 1 II1 R G 1 B- R ACM1 B- W M1 MASS AIR FLOW METER E5 V4 VSV (CANISTER CLOSED VALVE) V3 VSV (ACM) B- W W B- W 18 J8 JUNCTION CONNECTOR L 2 2 P2 POWER STEERING OIL PRESSURE SW L 11 C E2 W 2 B- W B- W W- L 1 I8 INJECTOR NO. 1 L R BR B- W I9 INJECTOR NO. 2 E2 TO MULTI DISPLAY B- W ENGINE CONTROL BR B- W B- W B- W B- W W- B B- W BR B- W BR 21 IK2 4 E1 3 OX B5 18 IK2 BR 8 D OXS ENGINE CONTROL MODULE E4 A , E5 B , E6 C , E7 D , E8 E 14 B THW 18 B E2 D 1 1 II2 W BR BR B- W (*1) B- W (*1) W- B W- B BR BR BR BR L 2 1 3 1 AFR- HAFL V6 VVT SOLENOID LH V7 VVT SOLENOID RH 2 10A TAIL 2 1B L R- B R R- L R- W G 1 B- W 4 B AFR+ (* 1) 20 B (* 1) 11 B HAFR (* 1) B- W 4 B- R 3 B A11 AIR FUEL RATIO SENSOR (BANK 2 SENSOR 1) 3 (* 1) 1 2 BR BR 4 B- R B- W 2 B- R A10 AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) FROM POWER SOURCE SYSTEM (SEE PAGE 72) 12 B 21 B 6 A 5 A 29 A 18 A 4 D AFL+ AFL- OC1+ OC1- OC2+ OC2- ELS E4 A , E5 B , E6 C , E7 D , E8 E ENGINE CONTROL MODULE IMLD 22 E KSW 23 D THWO A/C 14 D KNKL 7 D KNKR 28 A NEO 27 A 16 D ENG+ 14 E ENG21 E TRC+ 13 E TRC20 E CF 26 D (*1) 4 EB1 1 EB1 G G- W BR GR V Y- B 3 EB1 6 IF3 W (* 1) W 1 K1 KNOCK SENSOR 1 1 FROM TRANSLATE ECU FROM FAN NO. 1 RELAY (* 1) K2 KNOCK SENSOR 2 TO MULTI DISPLAY TO A/C CONTROL ASSEMBLY TO UNLOCK WARNING SW TO SECURITY INDICATOR LIGHT [COMB. METER] G 2 EB1 (* 1) W (* 1) W (*3) Y- R (*2) Y- R (*2) Y- G R- Y V- W (*1) * 1 : SHIELDED * 2 : AUTOMATIC A/C * 3 : MANUAL A/C 2001 AVALON (EWD431U) 85 ENGINE CONTROL BR BR (*1) (*1) (*1) (*1) W- B W- B BR BR BR BR FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A MIR HTR G- W 5 1B 3 3C 3 1D 3 3F 11 1D G- W 11 1B G- W 15A STOP 1 FROM IGNITION COIL AND IGNITERS B R TO MULTI DISPLAY B- Y GR B- R LG- B L- Y L LG V- W B S4 STOP LIGHT SW 16 4F 25 A 11 A 12 A 13 A 14 A 15 A 16 A 22 D 27 D 16 4C G- W 2 13 D 15 E ELS2 STP IGF IGT1 IGT2 IGT3 IGT4 IGT5 IGT6 TACH SPD E4 A , E5 B , E6 C , E7 D , E8 E ENGINE CONTROL MODULE VV1+ 10 A NE- VV2+ NE+ 22 A 24 B 16 B EO1 21 A EO2 EO3 31 A 30 A EO4 1 B EO5 8 B W 6 E B- Y W- B C I23 I22 B- W B- Y W- B 1 (*1) BR W- B BR 2 W- B W- B 2 C3 CRANKSHAFT POSITION SENSOR (*1) 1 L (* 1) B- W C1 CAMSHAFT POSITION SENSOR LH L (* 1) C 1 2 B- W C L B- W C (*1) C2 CAMSHAFT POSITION SENSOR RH (* 1) J8 JUNCTION CONNECTOR L L W- B (*1) W- B (*1) W- B (*1) W- B (*1) (*1) (*1) (*1) EB 2001 AVALON (EWD431U) 86 FROM POWER SOURCE SYSTEM (SEE PAGE 72) BR (* 1) (* 1) 10A GAUGE NO. 1 7. 5A OBD- II W- B BR BR 10 1D B R- B 1 1I B B R- B B 13 4F W B SIL BR BR (*1) (*1) 4 E ACMG W- B W 6 D BR LG- R J5 B JUNCTION CONNECTOR 5 7 16 SG SIL BAT E4 A , E5 B , E6 C , E7 D , E8 E 10 4 7 B- Y ENGINE CONTROL MODULE M6 MALFUNCTION INDICATOR LAMP [MULTI DISPLAY] C BR J5 JUNCTION CONNECTOR BR FROM DIODE (A/C) C BR W 4 4D II2 CG E1 D3 DATA LINK CONNECTOR 3 4 17 B W- B BR (* 1) 4 IC1 (* 1) (* 1) BR BR (* 1) (* 1) A A A A A A A A A A A BR (* 1) (* 1) (* 1) BR B- Y (* 1) BR A J7 JUNCTION CONNECTOR * 1 : SHIELDED B- Y W- B W- B BR 20 4B W- B 7 4B W- B BR (* 1) W- B (* 1) (* 1) A EC J9 JUNCTION CONNECTOR IJ 2001 AVALON (EWD431U) 87 ENGINE CONTROL SYSTEM OUTLINE This system utilizes an engine control module and maintains overall control of the engine, transmission and so on. An outline of the engine control is explained here. 1. INPUT SIGNALS (1) Engine coolant temp. signal circuit The engine coolant temp. sensor detects the engine coolant temp. and has a built-in thermistor with a resistance which varies according to the water temp. is input into TERMINAL THW of the engine control module as a control signal. (2) Intake air temp. signal circuit The intake air temp. sensor is installed in the mass air flow meter and detects the intake air temp., which is input as a control signal into TERMINAL THA of the engine control module. (3) RPM signal system Camshaft position and crankshaft position are detected by the camshaft position sensor and crankshaft position sensor. The camshaft position is input as a control signal to TERMINAL VV2+ of the engine control module, and the engine RPM is input into TERMINAL NE+. (4) Throttle signal circuit The throttle position sensor detects the throttle valve opening angle as a control signal, which is input into TERMINAL VTA1 of the engine control module. (5) Vehicle speed signal system The vehicle speed sensor, installed inside the transmission, detects the vehicle speed and inputs a control signal into TERMINAL SPD of the engine control module. (6) Park/Neutral position SW signal system The Park/Neutral position SW detects whether the shift position is in neutral, parking or not, and inputs a control signal into TERMINAL STA of the engine control module. (7) A/C SW signal system The A/C amplifier inputs the A/C operations into TERMINAL A/C of the engine control module as a control signal. (8) Battery signal circuit Voltage is always supplies to TERMINAL BATT of the engine control module. If you turn on the ignition SW, the current goes from TERMINAL MREL of the engine control module to the EFI relay and put on the relay, and the voltage related to the engine control module operation is supplied to TERMINAL +B of the engine control module through the EFI relay. (9) Intake air volume signal circuit Intake air volume is detected by the mass air flow meter and a signal is input into TERMINAL VG of the engine control module as a control signal. (10) NSW signal circuit To confirm whether the engine is cranking, the voltage applied to the starter motor during cranking is detected and the signal is input into TERMINAL NSW of the engine control module as a control signal. (11) Engine knock signal circuit Engine knocking is detected by the knock sensor 1 and 2, then the signals are input into TERMINALS KNKR and KNKL of the engine control module as a control signal. (12) Air fuel ratio signal system The air fuel ratio is detected and input as a control signal into TERMINALS AFL+, AFR+ of the engine control module. 2001 AVALON (EWD431U) 88 2. CONTROL SYSTEM ∗ SFI (Sequential multiport Fuel Injection) system The SFI system monitors the engine condition through the signals, which are input from each sensor (Input signals (1) to (12) ). The best fuel injection volume is decided based on this data and the program memorized by the engine control module, and the control signal is output to TERMINALS #10, #20, #30, #40, #50 and #60 of the engine control module to operate the injector (Inject the fuel). The SFI system produces control of fuel injection operation by the engine control module in response to the driving conditions. ∗ ESA (Electronic Spark Advance) system The ESA system monitors the engine condition through the signals, which are input to the engine control module from each sensor (Input signals from 1, 3, 11). The best ignition timing is decided according to this data and the memorized data in the engine control module and the control signal is output to TERMINALS IGT1, IGT2, IGT3, IGT4, IGT5 and IGT6. This signal controls the igniter to provide the best ignition timing for the driving conditions. ∗ Idle air control system The idle air control system (Rotary solenoid type) increases the rpm and provides idle stability for fast idle-up when the engine is cold, and when the idle speed has dropped due to electrical load and so on, the engine control module evaluates the signals from each sensor (Input signals from 1, 3, 4, 7, 8), current is output to TERMINAL RSO to control idle air control valve. ∗ ACIS (Acoustic Control Induction System) ACIS includes a valve in the bulkhead separating the surge tank into two parts. This valve is opened and closed in accordance with the driving conditions to control the intake manifold length in two stages for increased engine output in all ranges from low to high speeds. The engine control module judges the engine speed by the signals ( (3), (4) ) from each sensor and outputs signals to the TERMINALS ACIS and ACI1 to control the VSV (ACIS No.1 or No.2). 3. DIAGNOSIS SYSTEM With the diagnosis system, when there is a malfunction in the engine control module signal system, the malfunctioning system is recorded in the memory. 4. FAIL-SAFE SYSTEM When a malfunction occurs in any systems, if there is a possibility of engine trouble being caused by continued control based on the signals from that system, the fail-safe system either controls the system by using data (Standard values) recorded in the engine control module memory or else stops the engine. 2001 AVALON (EWD431U) 89 ENGINE CONTROL SERVICE HINTS C/OPN RELAY 3-5 : Closed with the starter running and engine running EFI RELAY 5-3 : Closed with the ignition SW at ON or ST position E4 (A), E5 (B), E6 (C), E7 (D), E8 (E) ENGINE CONTROL MODULE Voltage at engine control module wiring connector BATT-E1 : Always 9.0- 14.0 volts +B-E1 : 9.0- 14.0 volts (Ignition SW at ON position) VC-E1 : Always 4.5- 5.5 volts (Ignition SW at ON position) VTA1-E1 : 0.3- 0.8 volts (Ignition SW on and throttle valve fully closed) 3.2- 4.9 volts (Ignition SW on and throttle valve fully open) VG-E1 : 4.0- 5.5 volts (Ignition SW at ON position) THA-E1 : 0.5- 3.4 volts (Ignition SW on and intake air temp. 20°C,68°F) THW-E1 : 0.2- 1.0 volts (Engine idling and coolant temp. 80°C,176°F) IGF-E1 : 4.5- 5.5 volts (Ignition SW at ON position) Pulse generation (Engine idling) STA-E1 : 9.0- 14.0 volts (Ignition SW on and other shift position in P or N position) Below 3.0 volts (Ignition SW on and shift position in P or N position) SPD-E1 : Pulse generation (Ignition SW on and rotate driving wheel slowly) W-E1 : Below 3.0 volts (Malfunction indicator lamp on) 9.0- 14.0 volts (Malfunction indicator lamp off and engine running) A/C-E1 : Below 1.5 volts (Engine idling and A/C SW on) 7.5- 14.0 volts (A/C SW off) ACT-E1 : 9.0- 14.0 volts (Engine idling and A/C SW on) Below 1.5 volts (A/C SW off) ACIS-E01 : 9.0- 14.0 volts (Ignition SW at ON position) NSW-E1 : 6.0 volts or more (Engine cranking) RSO-E1 : Pulse generation (Engine idling and A/C operation) KNKL, KNKR-E1 : Pulse generation (Engine idling) HTS, HAFL, HAFR-E01 : 9.0- 14.0 volts (Ignition SW at ON position) 0- 3.0 volts (Engine idling) OXS, AFL+, AFR+-E1 : Pulse generation (Maintain engine speed at 2500 rpm for two minutes after warning up) IGT1, IGT2, IGT3, IGT4, IGT5, IGT6-E1 : Pulse generation (Engine idling) #10, #20, #30, #40, #50, #60-E01 : 9.0- 14.0 volts (Ignition SW at ON position) Pulse generation (Engine idling) I8, I9, I10, I11, I12, I13 INJECTOR 2-1 : Approx. 13.8 Ω T3 THROTTLE POSITION SENSOR 2-1 : 3.75 kΩ 2001 AVALON (EWD431U) 90 : PARTS LOCATION Code See Page A10 44 A11 44 C1 44 C2 44 C3 44 D1 44 D3 E2 E4 A E5 B E6 C E7 D E8 E F6 A Code See Page See Page J9 49 (Floor Shift) 50 J11 50 47 (Column Shift) K1 45 49 (Floor Shift) K2 45 I1 45 M1 45 I8 45 46 (Column Shift) I9 45 48 (Floor Shift) I10 45 44 I11 45 46 (Column Shift) I12 45 48 (Floor Shift) I13 45 T3 45 47 (Column Shift) V1 45 49 (Floor Shift) V2 45 47 (Column Shift) V3 45 49 (Floor Shift) V4 45 47 (Column Shift) V5 45 49 (Floor Shift) V6 45 47 (Column Shift) V7 45 49 (Floor Shift) V12 51 47 (Column Shift) V14 51 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 44 B Code 44 46 (Column Shift) F7 F15 H8 I15 J5 J7 J8 J9 M6 P2 S4 47 (Column Shift) 49 (Floor Shift) 45 47 (Column Shift) 49 (Floor Shift) : RELAY BLOCKS Code 6 See Page 42 Relay Blocks (Relay Block Location) Driver Side R/B No.6 (Left Kick Panel) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1C 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2G 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 3C 34 Cowl Wire and J/B No.3 (Left Kick Panel) 3F 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No.4 ((Right g Kick Panel)) 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) 1D 1I 1J 2A 2B 2C 2F 4B 4C 4D 4F 2001 AVALON (EWD431U) 91 ENGINE CONTROL : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EB1 IC1 ID1 ID2 IF1 IF3 II1 II2 IK2 See Page 54 Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Sensor Wire (LH Bank of the Cylinder Head) 56 (Column Shift) 60 (Floor Shift) Cowl Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Engine Wire and Cowl Wire (Behind the Glove Box) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location EB 54 Surge Tank RH EC 54 Rear Side of Surge Tank ED 54 Front Side of Left Fender IJ BK 56 (Column Shift) 60 (Floor Shift) 64 Cowl Side Panel RH Rear Quarter Inner LH : SPLICE POINTS Code E2 E5 I7 I14 See Page 54 Wire Harness with Splice Points Engine Wire 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Code I22 I23 Cowl Wire B5 See Page 62 (Floor Shift) 58 (Column Shift) Engine Wire 62 (Floor Shift) 64 62 (Floor Shift) 2001 AVALON (EWD431U) 92 Wire Harness with Splice Points 58 (Column Shift) Floor No.2 Wire MEMO 2001 AVALON (EWD431U) 93 ENGINE IMMOBILISER SYSTEM ACC B- O FROM POWER SOURCE SYSTEM (SEE PAGE 72) IG1 B- O AM1 7 1C 15A EFI NO. 1 IG2 6 10 2B ST2 4 2B I15 IGNITION SW IF1 5 W- R 1 EFI RELAY 2 L- O 4 12 1B B- O 7 AM2 B- R W- R 3 7 2C 8 II1 L- O 7. 5A EFI NO. 2 10A AM2 II1 B- R 17 E7 D , E8 E 8 E 1 E RXCK 19 D TXCT EOM 18 D 22 E 10 IC1 11 4B BR B- W V V- W B 1 A 1 2 3 CODE RXCK 4 TXCT 2 4B 10 II2 GND 1 2 5 FL MAIN 3. 0W T6 TRANSPONDER KEY AMPLIFIER BR ANT2 W- B ANT1 8 4D U1 UNLOCK WARNING SW B R- Y +B 2 B A A J6 JUNCTION CONNECTOR II EC A W- B A EB W- B BR BR W- B W- B 9 3D 7 3A 22 3D 2001 AVALON (EWD431U) 94 21 A B ED J7 JUNCTION CONNECTOR W- B 8 4F 22 7 3G 1 TRANSPONDER KEY COIL C9 SECURITY INDICATOR LIGHT [COMB. METER] B- W J5 JUNCTION CONNECTOR W- B L- Y B FUSIBLE LINK BLOCK BATTERY IMLD 23 D J5 JUNCTION CONNECTOR I13 L- O P- G 1 B F6 A , F7 B KSW 1 D IF1 B- W B 6 CODE 28 D W- B B- W +B 16 E IGSW R- Y 2 2F 2 E BATT BR 4 2F W- B MREL 2 2G ENGINE CONTROL MODULE IG W- B SERVICE HINTS T6 TRANSPONDER KEY AMPLIFIER 1-GROUND : Always approx. 12 volts 5-GROUND : Always continuity U1 UNLOCK WARNING SW 1-2 : Closed with the ignition key in cylinder : PARTS LOCATION Code See Page 46 (Column Shift) C9 E7 Code F7 48 (Floor Shift) D E8 E F6 A I15 46 (Column Shift) 48 (Floor Shift) J5 46 (Column Shift) 48 (Floor Shift) J6 44 See Page B Code 44 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) J7 T6 U1 See Page 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 49 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1C 2B 2C 2F 2G 3A 3D 3G 4B 4D See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC1 IF1 II1 II2 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Engine Wire and Cowl Wire (Behind the Glove Box) 62 (Floor Shift) : GROUND POINTS Code See Page Ground Points Location EB 54 Surge Tank RH EC 54 Rear Side of Surge Tank ED 54 Front Side of Left Fender IG II 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Cowl Side Panel LH Right Kick Panel 2001 AVALON (EWD431U) 95 ENGINE IMMOBILISER SYSTEM : SPLICE POINTS Code See Page I13 58 (Column Shift) Wire Harness with Splice Points Cowl Wire Code I13 See Page 62 (Floor Shift) 2001 AVALON (EWD431U) 96 Wire Harness with Splice Points Cowl Wire MEMO 2001 AVALON (EWD431U) 97 HEADLIGHT (w/ DAYTIME RUNNING LIGHT) R R R- B R- B R 5 2 5 5 3 5 HEAD RELAY R 1 1 4 7. 5A DRL 5 6 EA1 R- L E3 G G IF1 10 IF3 1 2 15A HEAD RH LWR 40A MAIN 1 2 15A HEAD LH LWR 5 4 DRL NO. 4 RELAY 2 3 2 5 2 2 2 R- W 2 W- B 9 EA1 R- W I9 R- B W- B W- B G- W W- B IF1 W- B W- B 1 11 EA1 R- W 11 12 R- L 1 W- B FL MAIN 3. 0W 2 H3 HEADLIGHT LOW LH 2 W- B B 1 A H4 HEADLIGHT LOW RH 9 IC1 G- W F6 A , F7 B FUSIBLE LINK BLOCK 2 1 DRL NO. 3 RELAY 2 B 2 4 3 5 3 2 1 3 2 2G 2 1 R- W 2 W- R W- R R 1 B 1 5 R- W 1 2E G 5 EA1 4 2E H2 HEADLIGHT HIGH RH W- R R- B 2 EA1 C9 HIGH BEAM INDICATOR LIGHT [COMB. METER] 8 G 5 R- L R R- B B- R 2 8 IC1 BATTERY W- B EA : *1 EB : *2 ED EA 2001 AVALON (EWD431U) 98 FROM POWER SOURCE SYSTEM (SEE PAGE 72) R R R- B R 7. 5A ECU- B E1 R R * 1 : EXCEPT CANADA * 2 : CANADA 2 1 W- G 9 1B 2 4 5 3C G1 GENERATOR DRL NO. 2 RELAY G 2 L 3 14 3D R R- L R- B R- B 6 IF1 2 2 4 1J B4 A , B5 B 8 10 A DRL BODY ECU 24 A HRLY B 6 B ALTL 3 L 1 R- L 1 10A HEAD LH UPR 2 R- B 2 1 10A HEAD RH UPR H1 HEADLIGHT HIGH LH G 8 EA1 IJ1 W- G 2 2 R- B 2 1 2 GND2 11 A W- B P PKB 15 A Y- G R- Y TAIL 14 A B- W HEAD 3 A IF1 L L 9 HF 2 A B- R HU 13 A 10 EA1 5 3A 8 13 14 5 3B Y- G TAIL HEAD HIGH FLASH C13 COMBINATION SW 16 1 B J4 JUNCTION CONNECTOR P3 PARKING BRAKE SW LOW W- B DIMMER SW L LIGHT CONTROL SW 7 OFF W- B I16 W- B W- B B IG 2001 AVALON (EWD431U) 99 HEADLIGHT (w/ DAYTIME RUNNING LIGHT) SYSTEM OUTLINE DAYTIME RUNNING LIGHT OPERATION When the engine is started, a signal from the generator is input into TERMINAL (B)6 of the body ECU. At this time, if the parking brake pedal is depressed (Parking brake SW ON), the body ECU is not activated, and the daytime running light system does not operate. When the parking brake pedal is released (Parking brake SW OFF), a signal is input into TERMINAL (A)15 of the body ECU. This activates the body ECU and the headlight turns on. SERVICE HINTS HEAD RELAY 1-2 : Closed with the light control SW at HEAD position or dimmer SW at FLASH position Closed with the engine running and the parking brake pedal depressed (Parking brake SW off) B4 (A), B5 (B) BODY ECU (A)24-GROUND : Always approx. 12 volts (B) 6-GROUND : Approx. 12 volts with engine running (A)15-GROUND : Continuity with parking brake pedal depressed (A)13-GROUND : Continuity with the dimmer SW at HIGH or FLASH position (A)14-GROUND : Continuity with the light control SW at TAIL or HEAD position (A)11-GROUND : Always continuity : PARTS LOCATION Code B4 See Page A B5 B C9 C13 Code 46 (Column Shift) See Page C13 48 (Floor Shift) 48 (Floor Shift) F6 A 44 46 (Column Shift) F7 B 44 48 (Floor Shift) G1 44 46 (Column Shift) H1 44 48 (Floor Shift) H2 44 46 (Column Shift) H3 44 Code H4 J4 P3 : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 2 24 Engine Room R/B No.2 (Engine Compartment Right) 5 25 Engine Room R/B No.5 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1J 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 2E 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2G 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 3A 3B 3C 3D 2001 AVALON (EWD431U) 100 See Page 44 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EA1 IC1 IF1 IF3 IJ1 See Page 54 Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Engine Room No.2 Wire (Near the Engine Room R/B No.2) 56 (Column Shift) 60 (Floor Shift) Cowl Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Engine Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location EA 54 Front Side of Right Fender EB 54 Surge Tank RH ED 54 Front Side of Left Fender IG 56 (Column Shift) 60 (Floor Shift) Cowl Side Panel LH : SPLICE POINTS Code See Page E1 54 E3 54 I9 58 (Column Shift) Wire Harness with Splice Points Code Engine Room No.2 Wire I9 Cowl Wire I16 See Page Wire Harness with Splice Points 62 (Floor Shift) 58 (Column Shift) Cowl Wire 62 (Floor Shift) 2001 AVALON (EWD431U) 101 HEADLIGHT (w/o DAYTIME RUNNING LIGHT) R- B R B- R 5 3 5 5 2 1 1 HEAD RELAY 15A HEAD RH 4 15A HEAD LH 1 2 5 5 5 R- W R- B R- B B- R 3 IF1 4 1J 8 HRLY B4 A I9 BODY ECU R- B R- B W- B R- L R- L 2 R- L FUSIBLE LINK BLOCK I16 B- W I16 R- L 8 7 OFF TAIL HEAD LOW FLASH C13 COMBINATION SW W- B 16 W- B HIGH W- B LIGHT CONTROL SW 13 DIMMER SW R- L IF1 R- L B B- Y BATTERY 1 8 IC1 1 A FL MAIN 3. 0W 1 2 12 1 B F6 A , F7 B 1 2 IG EA 2001 AVALON (EWD431U) 102 ED H3 HEADLIGHT LOW LH 1 2 H1 HEADLIGHT HIGH LH 2 H4 HEADLIGHT LOW RH R- W 11 R- L B- W B C9 HIGH BEAM INDICATOR LIGHT [COMB. METER] 9 IC1 B- Y 2 2G R- W 2 A 1 W- B 3 A I9 HF H2 HEADLIGHT HIGH RH HEAD R- W R- W 40A MAIN R- W 2 R- W 1 2E 3 5 SERVICE HINTS HEAD RELAY 2-1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position C13 LIGHT CONTROL SW [COMB. SW] 13-16 : Closed with the light control SW at HEAD position C13 DIMMER SW [COMB. SW] 8-16 : Closed with the dimmer SW at FLASH position 7-16 : Closed with the dimmer SW at HIGH or FLASH position : PARTS LOCATION Code B4 See Page A C9 Code 46 (Column Shift) See Page C13 48 (Floor Shift) Code See Page 46 (Column Shift) H1 44 48 (Floor Shift) H2 44 46 (Column Shift) F6 A 44 H3 44 48 (Floor Shift) F7 B 44 H4 44 : RELAY BLOCKS Code 5 See Page 25 Relay Blocks (Relay Block Location) Engine Room R/B No.5 (Engine Compartment Left) ,,, ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1J 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 2E 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2G 30 Engine Wire and Engine Room J/B (Engine Compartment Left) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC1 IF1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) : GROUND POINTS Code See Page Ground Points Location EA 54 Front Side of Right Fender ED 54 Front Side of Left Fender IG 56 (Column Shift) 60 (Floor Shift) Cowl Side Panel LH : SPLICE POINTS Code I9 See Page 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Cowl Wire Code I16 See Page 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Cowl Wire 2001 AVALON (EWD431U) 103 FOG LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 72) 15A HEAD LH LWR (*1) 15A HEAD RH (* 2) 15A FOG 3 (*1) 2 5 (* 2) 3 1H 1 3 2 1C 4 1B G- R FOG RELAY R- Y R- W R- B 5 10 1H R- B * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT 1 1 W- B R- Y W- B 2 W- B 2 F1 FRONT FOG LIGHT LH (* 2) G- R (* 1) F2 FRONT FOG LIGHT RH R- W B LIGHT CONTROL SW 17 10 OFF B TAIL W- B HEAD DIMMER SW LOW HIGH 4 2D OFF ON 16 IG EA 2001 AVALON (EWD431U) W- B W- B 4 2F W- B FOG LIGHT SW FLASH C13 COMBINATION SW 104 J1 JUNCTION CONNECTOR 11 ED SERVICE HINTS FOG RELAY 5-3 : Closed with the light control SW at HEAD position, dimmer SW at LOW position and the fog light SW ON position : PARTS LOCATION Code C13 See Page Code See Page 46 (Column Shift) F1 44 48 (Floor Shift) F2 44 Code J1 See Page 47 (Column Shift) 49 (Floor Shift) : RELAY BLOCKS Code 5 See Page 25 Relay Blocks (Relay Block Location) Engine Room R/B No.5 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1C 1H 2D 2F See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) : GROUND POINTS Code See Page Ground Points Location EA 54 Front Side of Right Fender ED 54 Front Side of Left Fender IG 56 (Column Shift) 60 (Floor Shift) Cowl Side Panel LH 2001 AVALON (EWD431U) 105 MULTIPLEX COMMUNICATION SYSTEM (COMMUNICATION BUS) T4 THEFT DETERRENT ECU R- Y 20 MPX1 9 IB1 MPX1 10 D19 DRIVER DOOR ECU MPX2 R- Y 23 A 9 B G V 8 MPX2 MPX4 G IB1 8 IN1 10 ID1 9 IN1 G- W G G- B 21 B G- W 9 A 8 B4 A , B5 B MPX3 BODY ECU MPX1 11 8 BC1 MPX2 G- W MPX1 10 14 MPX1 P21 POWER SEAT ECU G- B 2001 AVALON (EWD431U) 106 F14 FRONT PASSENGER DOOR ECU SYSTEM OUTLINE This is a multiplex system comprised of the body ECU, driver door ECU, front passenger door ECU, theft deterrent ECU and power seat ECU. THE MULTIPLEX COMMUNICATION SYSTEM INCLUDES THE FOLLOWING SYSTEMS ∗ AUTOMATIC LIGHT CONTROL ∗ DOOR LOCK CONTROL ∗ HEADLIGHT (w/ DAYTIME RUNNING LIGHT) ∗ INTERIOR LIGHT ∗ KEY REMINDER AND SEAT BELT WARNING ∗ LIGHT AUTO TURN OFF ∗ POWER SEAT (w/ DRIVING POSITION MEMORY) ∗ POWER WINDOW ∗ REMOTE CONTROL MIRROR (w/ DRIVING POSITION MEMORY) ∗ THEFT DETERRENT ∗ WIRELESS DOOR LOCK CONTROL 2001 AVALON (EWD431U) 107 MULTIPLEX COMMUNICATION SYSTEM W R R- B R R- B R 5 2 5 5 * 11 : EXCEPT CANADA * 12 : CANADA 3 5 R HEAD RELAY 1 4 1 6 EA1 7. 5A DRL 5 E3 R R- L IF1 10 IF3 2 DRL NO. 3 RELAY 3 3 2 R- W W- B W- B R- B W- B 9 EA1 L IF1 2 R- W I9 W- B 10 EA1 R- W 11 12 R- L C9 HIGH BEAM INDICATOR LIGHT [COMB. METER] 11 EA1 W- B H3 HEADLIGHT LOW LH 1 W- B W- B 1 2 8 IC1 L W- B BATTERY EA : *11 EB : *12 ED EA 2001 AVALON (EWD431U) 108 9 2 2 W- B H4 HEADLIGHT LOW RH 2 FL MAIN 3. 0W 2 2 G- W B 1 A DRL NO. 4 RELAY 9 IC1 G- W B F 6 A , F 7 B , F10 E FUSIBLE LINK BLOCK W 2 IF1 2 1 L 4 5 2 4 3 5 3 2 1 2 R- W 5 1 L 2 15A HEAD LH LWR H1 HEADLIGHT HIGH LH W- R 2 2 2G 2 1 15A HEAD RH LWR 1 W- R 1 R- W 1 40A MAIN 120A ALT G 5 2 1 B H2 HEADLIGHT HIGH RH G W- R R- B 1 2E R 1 E IF1 2 EA1 5 EA1 4 2E G R- L 8 G 5 G R- B B- R 2 FROM POWER SOURCE SYSTEM (SEE PAGE 72) W R- B R L- R R- B W- G R 10A HORN R Y- R 1 5 2C 18 4H B- R 2 18 4B 2 4 7 2 3 SH V R- B R 24 Y- R T4 THEFT DETERRENT ECU 2 W- G 2 B- R 2 2 IF3 L- R DRL NO. 2 RELAY W V R R E1 1 2 14 10 +B2 +B1 MPX1 IG W- B 21 2 B B 1 20 4A 2 7 4B B B 4 2D W- B 7 3A W- B 1 4 IF3 W- B 7 3G A W- B L6 LUGGAGE COMPARTMENT DOOR KEY UNLOCK SW W R- B 2 L 18 IK2 G- W 3 KSW W- B 22 1 E 12 1 C9 SECURITY INDICATOR LIGHT [COMB. METER] 10A HEAD LH UPR V 1 T2 THEFT DETERRENT HORN 10 IC1 6 W V- W G- W 1 DSWH R- Y SH25 W- B IND 12 E3 ENGINE HOOD COURTESY SW LUG 3 J1 JUNCTION CONNECTOR 10A HEAD RH UPR 2 J5 JUNCTION CONNECTOR R- Y 4 2F W- B A W L R- B W- B I16 A J10 JUNCTION CONNECTOR W- B W- B W- B W- B BN ED A A IJ J9 JUNCTION CONNECTOR W- B EA 2001 AVALON (EWD431U) 109 MULTIPLEX COMMUNICATION SYSTEM R- B FROM POWER SOURCE SYSTEM (SEE PAGE 72) L- R W- G 15A DOOR NO. 2 Y- R 25A DOOR NO. 1 10A ECU- IG NO. 2 B4 A , B5 B BODY ECU V BDR1 SIG BDR2 HRLY TRLY 1 8 9 2 7 5 1J 4 1J R- B L- R 13 1B L- R 10 1B Y- R 12 2C L- R L- O 2 3C P- B 8 1A 12 1L 25A FL P/W L- O Y- R 11 3F 3 1 5 TAIL RELAY 2 1 1G W- G V R- Y W R- Y W R- B R- B W- B W- B 2001 AVALON (EWD431U) 110 * 1 : AUTOMATIC A/C * 2 : MANUAL A/C B4 A , B5 B BODY ECU GND2 17 A W- B R- Y KSW 11 A Y- G PKB 15 A G- O AUTO 4 A P TAIL 14 A R- Y HEAD 3 A B- W HF 2 A B- R HU 13 A R- B DRL 10 A V MPX1 23 A L- O L- O P- B P- B L LG P W- G R- Y P 14 R- Y W- B Y- G B- W 13 G- O B- R 8 1 2 4B 2 1 12 OFF LIGHT CONTROL SW PWR RELAY R- B 3 7 2 4A U1 UNLOCK WARNING SW W- B R- Y 20A RL P/W 2 8 EA1 P3 PARKING BRAKE SW P 10 1A 11 4A 5 3B R- B LG 1 1L 20A RR P/W 9 1L 20A FR P/W L 5 3A 9 3D TAIL HEAD 22 3D AUTO W- G W- B 5 DIMMER SW 1 LOW HIGH FLASH 16 V C13 COMBINATION SW J4 JUNCTION CONNECTOR W- B R- Y R- B W- B B W- B B I9 W- B W- B W- B B W- B IG 2001 AVALON (EWD431U) 111 MULTIPLEX COMMUNICATION SYSTEM B4 A , B5 B BODY ECU TKU 18 A R- W LG- R TC 16 B O RCTY 3 B R- L PCTY 5 A L DCTY 25 A L TR+ 20 B Y- B CLTB 7 B LG CLTE 8 B P- L CLTS 20 A L- B BZ 18 B P- B L L LG LG P P W- G W- G LG 1 L P- B Y- B L- O 4 3 1 CLTS CLTE CLTB LG- R 4 IK1 17 3D 17 4F 5 4F 17 3E 17 4E 14 4F O A28 AUTOMATIC LIGHT CONTROL SENSOR R- L P- L 2 L2 LUGGAGE COMPARTMENT DOOR OPENER SW W- B L L1 LUGGAGE COMPARTMENT DOOR OPENER MAIN SW L- O 4 3A 4 3G 6 4H 1 W- B 1 LG- R LG- R 22 II2 LG- R 1 D14 DOOR COURTESY SW REAR RH 1 D13 DOOR COURTESY SW REAR LH W- B M 4 TC D2 DATA LINK CONNECTOR 2 11 TC D1 DATA LINK CONNECTOR 1 W- B A J9 JUNCTION CONNECTOR A IJ 2001 AVALON (EWD431U) 112 6 4A R- W R- W 1 D12 DOOR COURTESY SW FRONT RH I14 2 IA1 D11 DOOR COURTESY SW FRONT LH W- B 7 4B 13 3A 1 L7 LUGGAGE COMPARTMENT DOOR UNLOCK MOTOR 1 5 4E 2 L 2 T1 THEFT DETERRENT BUZZER W- B P- L BUZZER 7 4H W6 WIRELESS DOOR LOCK BUZZER W- B P- L BUZZER 2 I9 R- W 1 B4 A , B5 B BODY ECU LGC 10 B R- B G- B RRU 22 B G- Y RRD 22 A Y- R RLU 8 A R RLD 6 A L LG W- G P 18 ID1 17 ID1 1 IM2 W- G Y- R G- Y L- W R- B G- B 1 BA1 3 BA1 2 BB1 1 BB1 3 BB1 Y- R G- Y L- W R- B G- B 6 DOWN 4 B 1 UP 6 DOWN 4 B UP 3 4E DOWN 5 12 BB1 2 1 P14 POWER WINDOW MOTOR REAR LH W- B M U 2 G R 1 D R 5 G U 2 3 E W- B W- B D 12 BA1 W- B L9 LUGGAGE COMPARTMENT LIGHT SW R- W R- W 3 E UP P11 POWER WINDOW CONTROL SW REAR RH UP P10 POWER WINDOW CONTROL SW REAR LH DOWN 1 3 IM2 2 BA1 1 12 4E 4 IM2 L- Y 12 4C IA1 P 1 G- B L R- B P- B LG P- B G- Y L- O Y- R L- O M 2 P15 POWER WINDOW MOTOR REAR RH R- W W- B W- B W- B W- B 2001 AVALON (EWD431U) 113 MULTIPLEX COMMUNICATION SYSTEM B4 A , B5 B BODY ECU L ACT15 B L- O LSR 5 B L- O L- O P- B P- B L L W- G W- G 6 3F 19 3F L- B L- O 6 3E F14 FRONT PASSENGER DOOR ECU 10 IN1 4 1 1 1 3 13 L- W Y B 5 1 2 3 4 M L- R L L L W- B L- R L 6 W- B KEYE 4 LOCK 10 BA1 LSWP L- Y 10 BB1 KL 3 L- B L 5 IA1 J3 JUNCTION CONNECTOR L 11 IM2 KUL 2 UNLOCK M C L M C L- B 4 C L 2 C L- B 2 D16 DOOR LOCK MOTOR REAR RH L- R L- O 3 D15 DOOR LOCK MOTOR REAR LH L- O 9 BB1 L- R 9 BA1 L- O L- O 10 IM2 D18 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH L- R L- R L- R 8 BA1 8 BB1 W- B R- W W- B R- W W- B W- B W- B W- B W- B W- B BM 2001 AVALON (EWD431U) 114 B4 A , B5 B BODY ECU ACT+ MPX4 21 B 2 B G- B W- L L- O L- O W- G W- G 12 11 A MPX1 CPUB MPX2 19 M 1 L- O G- O G- Y Y- B 3 2 1 6 9 8 7 MV M+ MH M Y- G LG PVC M 12 IM2 13 IA1 A GND 8 L- R 14 13 IN1 11 IN1 5 BB1 5 BA1 L- R 15 L- R HSSR 7 2 GND2 L- R VSSR 17 A L- R PMHR 18 W- B PM+R 16 LG- B PMVR 1 A W- B 1 DWN2 P13 POWER WINDOW MOTOR FRONT RH R- L 2 UP2 9 G 5 R CTYE 6 D10 DOOR COURTESY LIGHT FRONT RH CTYB R L- R A 3 IB2 L- R BDR J2 JUNCTION CONNECTOR L- R 10 L- R 20 L- R F14 FRONT PASSENGER DOOR ECU L- R 8 IN1 G 7 IN1 W- G 9 IN1 G- B 6 IN1 L G G W- L L G- B P- B L P- B R14 REMOTE CONTROL MIRROR RH L- R L- R L- R W- B R- W R- W W- B W- B W- B W- B W- B W- B 2001 AVALON (EWD431U) 115 MULTIPLEX COMMUNICATION SYSTEM B4 A , B5 B BODY ECU ACTD 1 B W- L W- L L- O P- B G 2 IB1 L- O 6 IB2 P- B IB1 G 8 L- O W- G P- B W- G 8 7 25 WLSW BDR CTYE DWN2 UP2 PLS LMT 9 5 6 14 1 3 2 4 LG R B R- L R G P Y W 6 5 4 3 2 1 2 3 4 5 W- B LIMIT SW M D17 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH B B B B W- B W- B P12 POWER WINDOW MOTOR FRONT LH J6 JUNCTION CONNECTOR W- B B W- B L- R 2 1 GND 13 11 IB1 PULSE SENSOR M UNLOCK L- B 1 E W- B CTYB 24 9 IB2 KL D9 DOOR COURTESY LIGHT FRONT LH KEYE 22 L- W KUL LOCK LSWD 10 L L- W MPX2 D19 DRIVER DOOR ECU L- R W- B R- W R- W W- B W- B W- B W- B W- B W- B W- B W- B II 2001 AVALON (EWD431U) 116 B4 A , B5 B BODY ECU P MPX3 B 9 B 24 A W- G 1 A W- G R- B G- W W- L W- G R- Y W- L FROM POWER SOURCE SYSTEM (SEE PAGE 72) 2 1D E2 12 W- L 5 3F VSSR HSSR 18 19 DVC 11 SIG W- G W- G 5 3D W- G W- L 14 3F CPUB 14 3D 14 3E 5 3C 9 1B 10 1D R- B DMHR 16 23 MPX1 W- G DM+R 15 20 10A GAUGE NO. 1 7. 5A ECU- B W- G DMVR 17 1 IB1 W- G D19 DRIVER DOOR ECU IB1 R- Y 9 FROM PARK/NEUTRAL POSITION SW 21 8 7 M M 4 4F 13 4F R- B GR 9 R- B GR- L 6 R- B LG- B 1 MH 5 IB1 R- B LG- R 2 M+ Y- G 3 MV BR- Y BR- W 4 4D R13 REMOTE CONTROL MIRROR LH W- B W- B W- B W- B R- W R- W W- B W- B W- B W- B W- B W- B 2001 AVALON (EWD431U) 117 MULTIPLEX COMMUNICATION SYSTEM B4 A , B5 B BODY ECU DBEW 23 B PBEW 11 B AJAR 25 B CLTC RDA GND1 13 B 14 B PRG 21 A ALTL 7 A 6 B GSW ILL 19 A 5 3 1C G- R L- W (* 3) R G- R G- R L R- L R- B W- B R- B W- B W- G G- W W- G P- L P- L 3 RDA PRG E +B 1 5 W- B P- L 8 4E W- B 3 E W- B 4 D 8 4F FROM GENERATOR 2 D8 DOOR CONTROL RECEIVER OPEN DOOR IK2 21 4F P- L MULTI DISPLAY 2 E R- B M6 D , M7 E 10 E PASSENGER SEAT BELT DRIVER SEAT BELT 2 D 20 G- R L- W 9 IK2 4 GSW C6 CENTER AIRBAG SENSOR ASSEMBLY R- B W- B W- B R- W I6 W- B W- B R- W G- R W- B W- B W- B W- B W- B W- B W- B IF 2001 AVALON (EWD431U) 118 W- B * 3 : TAIWAN B4 A , B5 B BODY ECU HORN STOP 10 11 1 1J 3 1D W- G W- G R- B R- B P- L P- L P- L P- L FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 4D 10 4E 10 4D R- L G- B P- L 1 4F P- L 1 4E P- L P- L 15A STOP 10A HORN 5 1 1 4C 10 4C P- L P- L P- L P- L 3 2C W- B 17 IG1 W- B G- B P- L W- B 1 W- B 1 W- B V10 VANITY LIGHT LH V11 VANITY LIGHT RH P- L P9 PERSONAL LIGHT P- L 2 B4 W- B (* 4) G- R 1 G- R DOOR ON OFF G- R 11 IG1 OFF ON 2 DOOR 2 I17 INTERIOR LIGHT P- L 3 1 G- R P- L B4 W- B I7 P- L B3 1 2 8 IG1 G- R 2 I14 IGNITION KEY CYLINDER LIGHT 1 G- R L8 LUGGAGE COMPARTMENT LIGHT R- L B3 R- W W- B W- B W- B W- B W- B 2 5 IG1 2 1 W- B 3 S4 STOP LIGHT SW D7 DIODE(LUGGAGE COMPARTMENT LIGHT) P- L 1 2 G- R HORN RELAY 2 B11 P- L 2 N3 NOISE FILTER (LUGGAGE COMPARTMENT LIGHT) P- L 1 4E P- L R 11 1D W- B 4 IA1 W- B W- B BL 2001 AVALON (EWD431U) 119 A W- B A W- B A W- B A BK 120 J11 JUNCTION CONNECTOR A A W- B J10 JUNCTION CONNECTOR BN 2001 AVALON (EWD431U) B7 W- B C C 11 BC1 (* 7) B15 (* 9) (* 6) R- W 6 BC1 W- B (* 5) R- W (*5) R- W 2 IM2 (*10) (* 6) W- R (*5) R- W 16 A G W- R R- W SEAT W- B 2 B8 BUCKLE SW LH (* 5) 4 B (* 7) W- B (*5) G (*5) 17 B (*7) W- B (* 5) (*8) W- B W- B 2 (* 6) 1 S11 SEAT BELT WARNING OCCUPANT DETECTION SENSOR W- B W- R G (* 6) 8 BD1 W- B 1 (* 5) G (* 5) 6 IM2 W- B 7 ID1 W- B B9 BUCKLE SW RH W- G (* 5) W- B (* 6) W- B P- L P- L PBKL (*5) 1 R12 REAR INTERIOR LIGHT RH W- B P- L 6 BD1 W- B B6 2 (*6) 1 R11 REAR INTERIOR LIGHT LH W- B 2 W- B W- B MULTIPLEX COMMUNICATION SYSTEM BODY ECU B4 A , B5 B DBKL W- G R- B R- B P- L P- L P- L P- L 9 ID1 1 2 B13 B13 11 BD1 C J14 JUNCTION CONNECTOR W- B (*7) W- B (*7) * 4 : W/ MOON ROOF * 5 : W/ POWER SEAT * 6 : W/O POWER SEAT * 7 : W/ DRIVING POSITION MEMORY * 8 : W/O DRIVING POSITION MEMORY * 9 : FLOOR SHIFT W/ DRIVING POSITION MEMORY * 10 : COLUMN SHIFT W/ DRIVING POSITION MEMORY B4 A , B5 B BODY ECU W- G W- G R- B R- B P- L P- L L- O L- O (* 9) (*9) 3 1 7 8 R- Y 9 R- W 6 B 10 B- R (* 9) W- B (*9) 5 B- Y M L10 LUMBAR SUPPORT CONTROL MOTOR (DRIVER’ S SEAT) R- W (*9) (*9) R- L W- B 2 3 R- B 2 1 G- B 4 G 2 P18 POWER SEAT CONTROL SW (DRIVER’ S SEAT) L11 LUMBAR SUPPORT CONTROL SW (DRIVER’ S SEAT) 1 12 B 10 B 24 B 23 B 8 B 6 B 22 B 11 B RCLR RCLF FDWN FUP SLDR SLDF LUP LDWN P20 A , P21 B (*9) GND Y- G 3 BC1 4 BC1 3 Y- G 10 BC1 IA1 15 IA1 9 8 E MSW 14 IA1 Y- G (*7) MIRG 2 B P W- B (*7) MIRB 1 B W- L W- B MIRE 18 B W- L 7 A P B12 P (*9) POWER SEAT ECU W- B W- L W- B R5 REMOTE CONTROL MIRROR SW 7 M+ UP RIGHT RIGHT LEFT DOWN RIGHT LEFT LEFT SELECT SW OPERATION SW 2001 AVALON (EWD431U) 121 MULTIPLEX COMMUNICATION SYSTEM FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 5A ECU- ACC B4 A , B5 B 30A PWR SEAT 7. 5A DOME BODY ECU 2 ACC MPX2 9 A 8 1I G- W L- O 3 W- G 7 1D L- O I6 L- O P- L R- B P- L L- O 7 ID2 G- W W- G R- B L- O (*9) L- O 1 BC1 10 ID1 R- B G- W 13 B 25 B 14 B IG B12 (* 9) SYSB L- O 8 BC1 W- G 5 BC1 R- B 7 BC1 L- O G- W 8 ID1 8 A +B MPX1 P20 A , P21 B POWER SEAT ECU R PVCC 5 B L SSRS 3 B L- R SSRR 16 B BR SGND 19 B R A 2 9 IA1 BR 9 BC1 BR BR J3 JUNCTION CONNECTOR A BR BR 2 B B BR 2001 AVALON (EWD431U) R 3 2 B J14 JUNCTION CONNECTOR IH 1 B B A 122 3 L R 1 BR 2 M A P31 POWER SEAT POSITION SENSOR (DRIVER’ S SEAT RECLINING CONTROL) 2 M 1 P23 POWER SEAT MOTOR (DRIVER’ S SEAT REAR VERTICAL CONTROL) 1 M 1 P25 POWER SEAT MOTOR (DRIVER’ S SEAT SLIDE CONTROL) M 1 P22 POWER SEAT MOTOR (DRIVER’ S SEAT FRONT VERTICAL CONTROL) 2 P24 POWER SEAT MOTOR (DRIVER’ S SEAT RECLINING CONTROL) A J14 JUNCTION CONNECTOR R A P32 POWER SEAT POSITION SENSOR (DRIVER’ S SEAT SLIDE CONTROL) LFT5 A L- Y LFT+ 6 A L SLD+ 4 A L- B SLD3 A L- R FRV+ 10 A L- W FRV9 A R- W RCL+ 2 A R- B RCL1 A BR BR 3 3 1 RUP RDWN RCLF RCLR E 6 8 7 3 2 4 1 M 2 2 M 1 1 M 2 BM W- B W- B G- Y G- W Y L- O 20 B 1 P27 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT RECLINING CONTROL) SLDR 9 R- B B12 SLDF R- W 4 P26 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT REAR VERTICAL CONTROL) SSFV R 4 B L- Y 2 3 B12 W- B A A J10 JUNCTION CONNECTOR 1 SW1 L- B 1 1 21 B L MMRY P30 POWER SEAT POSITION SENSOR (DRIVER’ S SEAT REAR VERTICAL CONTROL) MMRY 2 9 B L- W SWE R R E W- B 2 BR R L- B 7 B P29 POWER SEAT POSITION SENSOR (DRIVER’ S SEAT FRONT VERTICAL CONTROL) L- B L- O S14 SEAT MEMORY SW P28 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT SLIDE CONTROL) 2 BR L- O * 7 : W/ DRIVING POSITION MEMORY * 9 : FLOOR SHIFT W/ DRIVING POSITION MEMORY L- O 2 IK1 1 BD1 P19 POWER SEAT CONTROL SW (FRONT PASSENGER’ S SEAT) SW2 POWER SEAT ECU P20 A , P21 B 17 B SSRL 11 BD1 BN 2001 AVALON (EWD431U) 123 MULTIPLEX COMMUNICATION SYSTEM SERVICE HINTS T4 THEFT DETERRENT ECU 1-GROUND : Always approx. 12 volts 2-GROUND : Always approx. 12 volts 14-GROUND : Approx. 12 volts with ignition SW at ON or ST position 24-GROUND : Always approx. 12 volts 12-GROUND : Always continuity B4 (A), B5 (B) BODY ECU 1-GROUND : Always approx. 12 volts 2-GROUND : Approx. 12 volts with ignition SW at ON or ST position 3-GROUND : Approx. 12 volts with ignition SW at ACC or ON position 7-GROUND : Always approx. 12 volts (A)24-GROUND : Always approx. 12 volts (A)11-GROUND : Always continuity (B)14-GROUND : Always continuity D19 DRIVER DOOR ECU 13-GROUND : Always continuity 21-GROUND : Approx. 12 volts with ignition SW at ON or ST position 23-GROUND : Always approx. 12 volts 24-GROUND : Always approx. 12 volts F14 FRONT PASSENGER DOOR ECU 8-GROUND : Always continuity 12-GROUND : Always approx. 12 volts P20 (A), P21 (B) (A) 7-GROUND (A) 8-GROUND (B)13-GROUND (B)19-GROUND POWER SEAT ECU : Always continuity : Always approx. 12 volts : Approx. 12 volts with ignition SW at ON or ST position : Always continuity 2001 AVALON (EWD431U) 124 : PARTS LOCATION Code See Page A28 B4 B 46 (Column Shift) 48 (Floor Shift) 48 (Floor Shift) 53 (Floor Shift w/ Power Seat) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 48 (Floor Shift) J10 50 46 (Column Shift) J11 50 48 (Floor Shift) 46 (Column Shift) 52 (Column Shift) J14 48 (Floor Shift) 53 (Floor Shift) 47 (Column Shift) L1 44 46 (Column Shift) D2 47 (Column Shift) J9 46 (Column Shift) D1 49 (Floor Shift) J6 52 (Column Shift w/ Power Seat) C13 47 (Column Shift) J5 50 (w/o Power Seat) C9 49 (Floor Shift) J4 53 (Floor Shift w/ Power Seat) C6 47 (Column Shift) J3 46 (Column Shift) 52 (Column Shift w/ Power Seat) B9 49 (Floor Shift) J2 50 (w/o Power Seat) B8 See Page J1 48 (Floor Shift) A B5 Code 46 (Column Shift) 49 (Floor Shift) 47 (Column Shift) L2 48 (Floor Shift) 49 (Floor Shift) D7 50 L6 50 D8 50 L7 50 Code P21 B P22 P23 P24 P25 P26 P27 P28 P29 P30 P31 P32 See Page 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) D9 50 L8 50 D10 50 L9 50 D11 50 L10 53 (Floor Shift) D12 50 L11 53 (Floor Shift) R11 51 D13 50 47 (Column Shift) R12 51 D14 50 49 (Floor Shift) R13 51 D15 50 47 (Column Shift) R14 51 D16 50 D17 50 D18 50 D19 50 E3 44 P9 51 M6 D M7 E N3 49 (Floor Shift) 51 R5 S4 47 (Column Shift) P3 49 (Floor Shift) 53 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 51 (w/o Power Seat) S11 52 (Column Shift w/ Power Seat) 53 (Floor Shift w/ Power Seat) F6 A 44 P10 51 F7 B 44 P11 51 F10 E 44 P12 51 T1 45 F14 50 P13 51 T2 45 H1 44 P14 51 H2 44 P15 51 H3 44 H4 44 I14 47 (Column Shift) 49 (Floor Shift) I17 50 J1 47 (Column Shift) 52 (Column Shift) P18 53 (Floor Shift) P19 P20 A S14 T4 U1 52 (Column Shift) 53 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 52 (Column Shift) V10 51 53 (Floor Shift) V11 51 52 (Column Shift) W6 45 53 (Floor Shift) : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 2 24 Engine Room R/B No.2 (Engine Compartment Right) 5 25 Engine Room R/B No.5 (Engine Compartment Left) 2001 AVALON (EWD431U) 125 MULTIPLEX COMMUNICATION SYSTEM ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A See Page Junction Block and Wire Harness (Connector Location) 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 1G 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1I 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1J 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1L 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 1B 1C 1D 2C 2D 2E 2F 2G 3A 3B 3C 3D 3E 3F 3G 4A 4B 4C 4D 4E 4F 4H 2001 AVALON (EWD431U) 126 : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EA1 IA1 IB1 IB2 IC1 ID1 ID2 IF1 IF3 IG1 II2 IK1 IK2 IM2 IN1 See Page 54 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Engine Room No.2 Wire (Near the Engine Room R/B No.2) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Cowl Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Roof Wire and Cowl Wire (Front Left Pillar) Engine Wire and Cowl Wire (Behind the Glove Box) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Floor No.2 No 2 Wire and Instrument Panel Wire (Right Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 64 Rear Door No.2 Wire and Floor No.1 Wire (Under the Left Center Pillar) BB1 64 Rear Door No.1 Wire and Floor No.2 Wire (Under the Right Center Pillar) BC1 BD1 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) Floor No No.1 1 Wire and Seat No No.1 1 Wire (Under the Driver’s Seat) Floor No No.2 2 Wire and Seat No No.2 2 Wire (Under the Front Passenger’s Seat) 2001 AVALON (EWD431U) 127 MULTIPLEX COMMUNICATION SYSTEM : GROUND POINTS Code See Page Ground Points Location EA 54 Front Side of Right Fender EB 54 Surge Tank RH ED 54 Front Side of Left Fender IF IG IH II IJ 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Left Kick Panel Cowl Side Panel LH Instrument Panel Brace RH Right Kick Panel Cowl Side Panel RH BK 64 Rear Quarter Inner LH BL 64 Roof Letf BM 64 Back Panel Center BN 64 Rear Quarter Inner RH : SPLICE POINTS Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points E1 54 Engine Room No.2 Wire B3 64 Floor No.1 Wire E3 54 Cowl wire B4 64 Roof Wire 58 (Column Shift) B6 64 Floor No.1 Wire 62 (Floor Shift) B7 58 (Column Shift) B11 64 Floor No No.2 2 Wire I6 I7 I9 I14 I16 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) B12 Cowl Wire B13 B15 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) 62 (Floor Shift) 2001 AVALON (EWD431U) 128 Seat No.1 No 1 Wire Seat No.2 No 2 Wire MEMO 2001 AVALON (EWD431U) 129 AUTOMATIC LIGHT CONTROL B W 2 2G FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 1 1G 40A MAIN 7. 5A ECU- B 5 2 2 1 2E 9 1B W- G TAIL RELAY 3 R- B 1 R A28 AUTOMATIC LIGHT CONTROL SENSOR 5 5 2 14 3D CLTS CLTE CLTB 4 3 1 3 HEAD RELAY LG Y- B L 24 A 8 B 7 B 20 B CLTS CLTE CLTB W DCTY 4 A HRLY 8 14 LIGHT CONTROL SW OFF 1 A R- L B 17 3E C13 LIGHT CONTROL SW [COMB. SW] BATTERY 16 W- B 1 HEAD AUTO D11 DOOR COURTESY SW FRONT LH FL MAIN 3. 0W TAIL * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT R- B IG 2001 AVALON (EWD431U) 130 TO ” DRL” FUSE 12 17 3D TO ” HEAD LH, HEAD RH” FUSE (*2) TO ” HEAD LH LWR, HEAD RH LWR” FUSE (*1) 13 R- B G- O P R- L F 6 A , F 7 B , F10 E AUTO 3 A 4 1J FUSIBLE LINK BLOCK 1 E 120A ALT 1 B HEAD TAIL 14 A R- Y B B4 A , B5 B BODY ECU 5 A 5 (* 1) B 5 B- R TRLY 4 R- L 9 W- G 1 R- B 5 3C SERVICE HINTS C13 LIGHT CONTROL SW [COMB. SW] 14-16 : Closed with light control SW at TAIL or HEAD position 13-16 : Closed with light control SW at HEAD position 12-16 : Closed with light control SW at AUTO position D11 DOOR COURTESY SW FRONT LH 1-GROUND : Closed with driver door open : PARTS LOCATION Code See Page 46 (Column Shift) A28 B4 B5 48 (Floor Shift) A Code 46 (Column Shift) C13 48 (Floor Shift) See Page B Code 46 (Column Shift) D11 See Page 50 48 (Floor Shift) F6 A 44 46 (Column Shift) F7 B 44 48 (Floor Shift) F10 E 44 : RELAY BLOCKS Code 5 See Page 25 Relay Blocks (Relay Block Location) Engine Room R/B No.5 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 2E 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2G 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 1G 1J 3C 3D 3E : GROUND POINTS Code IG See Page 56 (Column Shift) 60 (Floor Shift) Ground Points Location Cowl Side Panel LH 2001 AVALON (EWD431U) 131 LIGHT AUTO TURN OFF B FROM POWER SOURCE SYSTEM (SEE PAGE 72) W 1 1G 1 7. 5A ECU- B 5 9 1B 2 W- G TAIL RELAY 3 5 3C W- G 14 3D 9 24 A TRLY B G- O 14 13 RCTY 16 B 17 4F 5 4F 17 4E 14 4F 12 OFF TAIL HEAD 5 4E R- W R- W O R- L AUTO 16 IA1 IG 2001 AVALON (EWD431U) 1 D13 DOOR COURTESY REAR LH 1 D12 DOOR COURTESY FRONT RH R- W 2 W- B D11 DOOR COURTESY SW FRONT LH C13 COMBINATION SW 1 D14 DOOR COURTESY REAR RH LIGHT CONTROL SW B 1 132 PCTY 3 B R- W R- Y 17 3D 17 3E BATTERY AUTO 4 A 1 A FL MAIN 3. 0W HEAD 3 A P TAIL 14 A R- L F 6 A , F 7 B , F10 E 1 E 120A ALT 1 B FUSIBLE LINK BLOCK DCTY 5 A O W B B4 A , B5 B BODY ECU FROM POWER SOURCE SYSTEM (SEE PAGE 72) B 7. 5A DOME 2 2G 1 * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT 40A MAIN 7 1D 2 P- L R- B 1 2E R 5 5 1 4D 3 1 4 HEAD RELAY 2 1 4E 5 P- L 5 R- B (* 1) R- L B- R 5 D8 DOOR CONTROL RECEIVER +B B4 A , B5 B 9 IK2 3 E 1 W- B R- B PRG 2 8 4E 8 4F W- B 20 IK2 L- W G- R 4 1J RDA R- B B L- W J6 JUNCTION CONNECTOR B G- R W- B 8 G- R HRLY TO ” DRL” FUSE RDA 21 A TO ” HEAD LH, HEAD RH” FUSE (* 2) TO ” HEAD LH LWR, HEAD RH LWR” FUSE (*1) PRG 7 A L- W BODY ECU II 2001 AVALON (EWD431U) 133 LIGHT AUTO TURN OFF SYSTEM OUTLINE When the ignition SW is turned from ON or ST position to ACC or OFF position while the taillight or headlight is ON, approximately 30 seconds after any door is opened and then closed, the taillights and headlights are turned OFF automatically. Also, if the doors are locked with the wireless door lock within approximately 30 seconds, the taillights and headlights are turned OFF automatically. SERVICE HINTS C13 COMBINATION SW 14-16 : Closed with light control SW at TAIL or HEAD position 13-16 : Closed with light control SW at HEAD position 12-16 : Closed with light control SW at AUTO position D8 DOOR CONTROL RECEIVER 5-GROUND : Always approx. 12 volts 1-GROUND : Always continuity D11, D12, D13, D14 DOOR COURTESY SW FRONT LH, RH, REAR LH, RH 1-GROUND : Closed with the door open : PARTS LOCATION Code B4 See Page A B5 B C13 Code See Page Code 46 (Column Shift) D8 50 F7 B 44 48 (Floor Shift) D11 50 F10 E 44 46 (Column Shift) D12 50 48 (Floor Shift) D13 50 46 (Column Shift) D14 50 48 (Floor Shift) F6 A J6 44 : RELAY BLOCKS Code 5 See Page 25 Relay Blocks (Relay Block Location) Engine Room R/B No.5 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 2E 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2G 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 1D 1G 1J 3C 3D 3E 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 4D 38 Cowl Wire and J/B No.4 (Right Kick Panel) 4E 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 4F 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IK2 See Page 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) 2001 AVALON (EWD431U) 134 See Page 47 (Column Shift) 49 (Floor Shift) : GROUND POINTS Code IG II See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Cowl Side Panel LH Right Kick Panel 2001 AVALON (EWD431U) 135 INTERIOR LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A ECU- IG NO. 2 7. 5A ECU- B W- G 9 1B 5 3C W- L 14 3F R- Y G G W- G G- B G- B R- Y W- G 12 10 21 B 9 B 24 A MPX2 CPUB MPX1 GND 5 8 2 IB1 CLTC W- B GND1 14 B (TAIWAN) W- B SIG B4 A , B5 B DCTY 5 A 21 4F 17 3D 8 4F 17 3E R- L W- B (TAIWAN) B 1 B B B J6 JUNCTION CONNECTOR W- B B II 2001 AVALON (EWD431U) W- B I5 W- B W- B 136 2 W- B 1 B BODY ECU 13 B 13 IN1 MPX3 W- B CTYE 6 MPX4 F14 FRONT PASSENGER DOOR ECU CTYB 13 W- B 1 11 GND 11 9 IN1 8 MPX2 D10 DOOR COURTESY LIGHT FRONT RH 2 7 IN1 R- L 6 8 IN1 R CTYE 5 D9 DOOR COURTESY LIGHT FRONT LH CTYB IB1 D19 DRIVER DOOR ECU MPX1 R- L 20 CPUB R 23 8 G IB1 W- B 9 R- Y IB1 W- G 1 IF D11 DOOR COURTESY SW FRONT LH 5 3F R- L W- G W- L 14 3D 2 1 G- R R- W 14 4F IA1 5 4F 12 4C 5 4E 12 4E 1 1 G- R LGC 11 A GND2 B B AJAR B4 A , B5 B ILL B W- B BODY ECU 2 5 1 G- R 17 IG1 2 1 2 I7 G- R DOOR P- L P- L 1 4D 10 4E 10 4D 1 4C 10 4C 3 4E I17 INTERIOR LIGHT P- L 1 ON OFF 5 1J B11 P- L P- L 1 4E I14 IGNITION KEY CYLINDER LIGHT P- L D7 DIODE(LUGGAGE COMPARTMENT LIGHT) 3 P- L P- L G- R 17 4F 6 A 2 N3 NOISE FILTER (LUGGAGE COMPARTMENT LIGHT) 1 4F L8 LUGGAGE COMPARTMENT LIGHT 25 B P- L 2 M7 OPEN DOOR WARNING LIGHT [MULTI DISPLAY] P- L R- W G- R RCTY W- B R- L L- R 15A DOOR NO. 2 L9 LUGGAGE COMPARTMENT LIGHT SW R 7 BDR2 R- W 1 BDR1 R- W 16 B R- W 12 2C D14 DOOR COURTESY SW REAR RH 17 4E D13 DOOR COURTESY SW REAR LH R- W PCTY R- W 3 B O 25A DOOR NO. 1 W- B 1 D12 DOOR COURTESY SW FRONT RH O FROM POWER SOURCE SYSTEM (SEE PAGE 72) 7. 5A DOME P- L 7 1D P- L 5 IG1 B3 P- L 2 3 1C 1 G- R 8 IG1 G- R 11 IG1 W- B J4 JUNCTION CONNECTOR IG 2001 AVALON (EWD431U) 137 138 BL 3 2 2 2 1 1 A BK 2001 AVALON (EWD431U) R11 REAR INTERIOR LIGHT LH P- L J11 JUNCTION CONNECTOR 2 1 A BN R12 REAR INTERIOR LIGHT RH P- L P- L P- L W- B W- B P- L B4 V11 VANITY LIGHT RH V10 VANITY LIGHT LH P- L P- L W- B 1 W- B P9 PERSONAL LIGHT OFF ON DOOR B3 W- B W- B 2 W- B P- L (W/ MOON ROOF) G- R 1 G- R INTERIOR LIGHT P- L P- L 7 ID1 B4 J10 JUNCTION CONNECTOR SYSTEM OUTLINE In this system, the following functions operate through the communication control among the body ECU: When any door is opened, the lights come on. With the ignition SW OFF, when a door is closed remaining no door open, the lights come on for approximately 15 seconds. With all the doors are closed and locked, when the driver’s side or front passenger’s side door is unlocked either using the ignition key or the transmitter, the lights come on for approximately 15 seconds. SERVICE HINTS D11, D12, D13, D14 DOOR COURTESY SW FRONT LH, RH REAR LH, RH 1-GROUND : Closed with door open B4 (A), B5 (B) BODY ECU 1-GROUND : Always approx. 12 volts 2-GROUND : Approx. 12 volts with ignition SW at ON or ST position 7-GROUND : Always approx. 12 volts (A)24-GROUND : Always approx. 12 volts (A)11-GROUND : Always continuity (B)14-GROUND : Always continuity : PARTS LOCATION Code B4 A B5 B See Page Code See Page Code See Page 46 (Column Shift) D19 50 L8 50 48 (Floor Shift) F14 50 L9 50 46 (Column Shift) 48 (Floor Shift) D7 50 D9 50 D10 50 D11 50 D12 50 D13 50 D14 50 I14 I17 47 (Column Shift) 49 (Floor Shift) M7 47 (Column Shift) 49 (Floor Shift) 50 N3 51 47 (Column Shift) P9 51 49 (Floor Shift) R11 51 47 (Column Shift) R12 51 49 (Floor Shift) V10 51 J10 50 V11 51 J11 50 J4 J6 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1C 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 1J 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 2C 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 3E 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 3F 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 4E 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 4F 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) 1D 3C 3D 4C 4D 2001 AVALON (EWD431U) 139 INTERIOR LIGHT : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IB1 ID1 IG1 IN1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Roof Wire and Cowl Wire (Front Left Pillar) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code IF IG II See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Left Kick Panel Cowl Side Panel LH Right Kick Panel BK 64 Rear Quarter Inner LH BL 64 Roof Left BN 64 Rear Quarter Inner RH : SPLICE POINTS Code I5 I7 See Page 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Instrument Panel Wire Cowl Wire Code See Page 64 Floor No.1 Wire B4 64 Roof Wire B11 64 Floor No.2 Wire 2001 AVALON (EWD431U) 140 Wire Harness with Splice Points B3 MEMO 2001 AVALON (EWD431U) 141 ILLUMINATION W 1 1G G 1 5 J2 JUNCTION CONNECTOR TAIL RELAY 2 3 B B B B B B G 9 B4 A G G G G 5A PANEL TAIL 14 A P W BODY ECU TRLY 4 1A 14 OFF C13 LIGHT CONTROL SW [COMB. SW] 6 4 11 W- G 10 13 4H 13 4G 7 4G 13 4B P8 POWER OUTLET MAIN SW 1 BACK LIGHT CIRCUIT W- B FL MAIN 3. 0W 3 5 W- B B 4 4H M3 MULTI DISPLAY ILLUMINATION [MULTI DISPLAY] W- G 12 A (* 1) 5 C (* 2) W- G 1 A 2 A (* 1) 10 B (* 2) W- G F 6 A , F10 E FUSIBLE LINK BLOCK 120A ALT 1 E R5 REMOTE CONTROL MIRROR SW R2 A , R3 B , R4 C 16 22 4D RADIO AND PLAYER HEAD G TAIL BATTERY W- B W- B W- B I9 IG 2001 AVALON (EWD431U) 142 * * * * * 1 : 7 SPEAKER 2 : 6 SPEAKER 3 : MANUAL A/C 4 : AUTOMATIC A/C 5 : FLOOR SHIFT G G 3 3A 22 4F 9 4F 12 3A G 12 3G 4 4B W- G C9 COMBINATION METER ILLUMINATION [COMB. METER] G (*4) 23 W- G (* 4) 19 4 3F 13 3C 4 4A 16 15 W- G A15 A/C SW [A/C CONTROL ASSEMBLY] 9 G (* 3) G 13 4A (* 5) 3 (* 3) 20 4H H9 A/C SW [HEATER CONTROL SW] W- G G 4 4G 1 (* 5) 4 3 3G 3 3B 1 W- G 2 12 3B O3 O/D MAIN SW 2 W- B 9 G3 GLOVE BOX LIGHT SW 8 W- G H7 HAZARD SW 1 C8 CIGARETTE LIGHTER W- G G G 9 4C G G G 4 3C 13 3F W- G 7 4B 2 1 T W- B ILL- E W- B W- B A J5 JUNCTION CONNECTOR A A W- B 7 3A 20 3G R6 RHEOSTAT W- B 3 W- B J9 JUNCTION CONNECTOR IJ 2001 AVALON (EWD431U) 143 ILLUMINATION SERVICE HINTS TAIL RELAY 5-3 : Closed with the light control SW at TAIL or HEAD position C13 LIGHT CONTROL SW [COMB. SW] 14-16 : Closed with the light control SW at TAIL or HEAD position : PARTS LOCATION Code See Page A15 B4 H7 48 (Floor Shift) A 46 (Column Shift) H9 48 (Floor Shift) 46 (Column Shift) C8 J2 48 (Floor Shift) 46 (Column Shift) C9 J5 48 (Floor Shift) 46 (Column Shift) C13 J9 48 (Floor Shift) F6 A 44 F10 E 44 G3 Code 46 (Column Shift) M3 47 (Column Shift) O3 49 (Floor Shift) See Page Code 47 (Column Shift) P8 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 49 (Floor Shift) R2 A R3 B R4 C 47 (Column Shift) R5 49 (Floor Shift) 47 (Column Shift) R6 49 (Floor Shift) See Page 47 (Column Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1A 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 1G 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 34 Cowl Wire and J/B No.3 ((Left Kick Panel)) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 (Right ( g Kick Panel)) 3A 3B 3C 3F 3G 4A 4B 4C 4D 4F 4G 4H : GROUND POINTS Code IG IJ See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Cowl Side Panel LH Cowl Side Panel RH : SPLICE POINTS Code See Page I9 58 (Column Shift) Wire Harness with Splice Points Cowl Wire Code I9 See Page 62 (Floor Shift) 2001 AVALON (EWD431U) 144 Wire Harness with Splice Points Cowl Wire MEMO 2001 AVALON (EWD431U) 145 TURN SIGNAL AND HAZARD WARNING LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 72) 7. 5A TURN 15A HAZ 10 1L 7 2B R- Y R- G H7 HAZARD SW 7 2 IJ1 R- G C13 TURN SIGNAL SW [COMB. SW] 6 OFF RH HAZARD TURN G- Y 3 2 1A 12 1C 9 1C 6 1B 6 1E 3 1E G- Y 5 1L G- W 11 1A 2 G- B 2 1L 1 G- B 2 G- Y 1 G- Y 4 G- B 5 G- W LH G- R ON 6 IK1 7 IK1 7 3A F4 FRONT TURN SIGNAL LIGHT RH F3 FRONT TURN SIGNAL LIGHT LH 2 C9 TURN SIGNAL INDICATOR LIGHT [COMB. METER] 4 4 6 6 W- B W- B R7 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] 21 3B 3 W- B 7 3G 2 W- B 21 3A RH LH 21 W- B 3 3 A C A IG ED 2001 AVALON (EWD431U) 146 C A W- B J5 JUNCTION CONNECTOR J9 JUNCTION CONNECTOR W- B A C IJ BM J12 JUNCTION CONNECTOR R8 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] 9 G- Y G- Y 10 W- B T7 TURN SIGNAL FLASHER RELAY 2 W- B G- B 1 5 1H G- R 1 IC1 G- W 4 1D W- B 8 1C G- B 7 1L G- B G- W SERVICE HINTS T7 TURN SIGNAL FLASHER RELAY 2-GROUND : Approx. 12 volts with the ignition SW on or the hazard SW on 1-GROUND : Changes from 12 to 0 volts with the ignition SW on and the turn signal SW at LH or RH position and with the hazard SW on 3-GROUND : Always continuity : PARTS LOCATION Code C9 C13 See Page Code 46 (Column Shift) H7 48 (Floor Shift) 46 (Column Shift) J5 48 (Floor Shift) F3 44 F4 44 J9 See Page Code See Page 47 (Column Shift) J12 50 49 (Floor Shift) R7 51 47 (Column Shift) R8 51 49 (Floor Shift) 47 (Column Shift) T7 47 (Column Shift) 49 (Floor Shift) 49 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A See Page Junction Block and Wire Harness (Connector Location) 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1H 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1L 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 2B 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 1B 1C 1D 1E 3A 3B 3G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC1 IJ1 IK1 See Page 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Engine Wire and Instrument Panel Wire (Right Kick Panel) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) : GROUND POINTS Code ED IG IJ BM See Page 54 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 64 Ground Points Location Front Side of Left Fender Cowl Side Panel LH Cowl Side Panel RH Back Panel Center 2001 AVALON (EWD431U) 147 TAILLIGHT AND STOP LIGHT W G 1 1G 1 1B 1 5 G 1 IK1 TAIL RELAY A A B4 A BODY ECU G 9 A A G J13 JUNCTION CONNECTOR A W G 3 G 2 TRLY 10A TAIL TAIL 14 A P B8 4 1H 2 1B 14 OFF TAIL HEAD G G G G G C13 16 LIGHT CONTROL SW [COMB. SW] LG 1 1 LG G- R R7 REAR COMBINATION LIGHT LH STOP G 3 TAIL SIDE MARKER 2 1 6 B8 W- B W- B FL MAIN 3. 0W 2 5 W- B 2 L4 LICENSE PLATE LIGHT RH 1 W- B 2 L3 LICENSE PLATE LIGHT LH 1 F4 FRONT PARKING LIGHT RH F3 FRONT PARKING LIGHT LH W- B B 1 A W- B F 6 A , F10 E G- R FUSIBLE LINK BLOCK 120A ALT 1 E W- B W- B BATTERY A IG ED J9 JUNCTION CONNECTOR IJ A J10 JUNCTION CONNECTOR A BN 2001 AVALON (EWD431U) 148 W- B FROM POWER SOURCE SYSTEM (SEE PAGE 72) G- W 1 10A GAUGE NO. 1 15A STOP 3 1D 11 1D 10 1D R- B G R 5 IK1 4 D 4 4E 13 4F R- B G- W 3 7 R- B 8 17 IM2 Y- G 4 4D M6 D , M7 E 14 E 2 REAR LIGHTS WARNING LIGHT [MULTI DISPLAY] G- W 4 1E S4 STOP LIGHT SW Y- G 4 RELAY HOLD LG G- R 5 1 3 1 TAIL STOP 2 H11 HIGH MOUNTED STOP LIGHT G B SIDE MARKER W- B 11 R- W B B R- W A G- R L5 LIGHT FAILURE SENSOR B10 J12 JUNCTION CONNECTOR A 1 J12 JUNCTION CONNECTOR LG A LG 2 R- W 9 G G- R DELAY N3 NOISE FILTER (STOP LIGHT) W- B 6 W- B 1 R8 REAR COMBINATION LIGHT RH C W- B C C C W- B W- B W- B J12 JUNCTION CONNECTOR W- B BM 2001 AVALON (EWD431U) 149 TAILLIGHT AND STOP LIGHT SYSTEM OUTLINE TAILLIGHT DISCONNECTION WARNING If any of the taillights are disconnected when the light control SW is at TAIL or HEAD while the ignition SW is ON, the light failure sensor detects the voltage difference, and blinks the rear lights warning light to warn the driver. STOP LIGHT DISCONNECTION WARNING If any of the stop lights are disconnected when the brake pedal is depressed while the ignition SW is ON, the light failure sensor detects the voltage difference, and blinks the rear lights warning light to warn the driver. SERVICE HINTS TAIL RELAY 5-3 : Closed with the light control SW at TAIL or HEAD position L5 LIGHT FAILUER SENSOR 7-GROUND : Approx. 12 volts with stop light SW on 3-GROUND : Approx. 12 volts with the light control SW at TAIL or HEAD position 4, 8-GROUND : Approx. 12 volts with the ignition SW at ON position 11-GROUND : Always continuity S4 STOP LIGHT SW 1-2 : Closed with brake pedal depressed : PARTS LOCATION Code B4 See Page A Code 46 (Column Shift) See Page 47 (Column Shift) J9 48 (Floor Shift) 49 (Floor Shift) Code M6 D M7 E See Page 49 (Floor Shift) 47 (Column Shift) 46 (Column Shift) J10 50 48 (Floor Shift) J12 50 N3 51 F3 44 J13 50 R7 51 F4 44 L3 50 R8 51 A 44 L4 50 E 44 C13 F6 F10 H11 50 L5 M6 50 D 47 (Column Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1D 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 4D 38 Cowl Wire and J/B No.4 (Right Kick Panel) 4E 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 4F 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) 1E 1G 1H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IK1 IM2 See Page 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Floor No.2 No 2 Wire and Instrument Panel Wire (Right Kick Panel) 2001 AVALON (EWD431U) 150 S4 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) : GROUND POINTS Code ED IG IJ See Page 54 Ground Points Location Front Side of Left Fender 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Cowl Side Panel LH Cowl Side Panel RH BM 64 Back Panel Center BN 64 Rear Quarter Inner RH : SPLICE POINTS Code B8 See Page 64 Wire Harness with Splice Points Floor No.2 Wire Code B10 See Page 64 Wire Harness with Splice Points Floor No.2 Wire 2001 AVALON (EWD431U) 151 BACK-UP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A GAUGE NO. 2 5A ECU- ACC 8 1D R- L 1 1C (* 2) GR * 1 : FLOOR SHIFT * 2 : COLUMN SHIFT 15 3C 7 3C 15 3D 20 3D 20 3C R- L GR (*2) 6 1 5 BK/UP LP RELAY R- L 2 R- L 2 (*2) (* 1) 3 6 6 II1 R- B P1 BACK- UP LIGHT SW [PARK/NEUTRAL POSITION SW] R- B R- L 20 R- B (* 1) 8 IK1 R- B (* 2) W- B 2 D 8 J12 JUNCTION CONNECTOR 8 3A D II1 R- B 1 (* 2) R- B R- B (* 2) A J5 JUNCTION CONNECTOR R- B (* 1) 2 A B8 2 1 W- B W- B (* 2) W- B 1 W- B R- B B8 (* 2) W- B 21 3B A J10 JUNCTION CONNECTOR IG 2001 AVALON (EWD431U) 152 BN B7 BACK- UP LIGHT RH 11 4C GR R- L 6 B6 BACK- UP LIGHT LH D6 DIODE (A/T INDICATOR LIGHT 2) 3 (* 2) GR (* 2) R- B (*2) 1 2 4D (* 2) R- L (*1) (*2) SERVICE HINTS BACK-UP RELAY 5-3 : Closed with the ignition SW at ON position and the shift lever at R position (Column shift) P1 BACK-UP LIGHT SW [PARK/NEUTRAL POSITION SW] 2-8 : Closed with the shift lever at R position : PARTS LOCATION Code See Page B6 50 B7 50 D6 46 (Column Shift) Code J5 J10 See Page Code See Page 47 (Column Shift) J12 50 49 (Floor Shift) P1 45 50 : RELAY BLOCKS Code 6 See Page 42 Relay Blocks (Relay Block Location) Driver Side R/B No.6 (Left Kick Panel) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1C 1D See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 3A 3B 3C 3D 4C 4D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code II1 IK1 See Page 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Cowl Wire (Behind the Glove Box) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) : GROUND POINTS Code IG BN See Page 56 (Column Shift) 60 (Floor Shift) 64 Ground Points Location Cowl Side Panel LH Rear Quater Inner RH : SPLICE POINTS Code B8 See Page 64 Wire Harness with Splice Points Code See Page Wire Harness with Splice Points Floor No.2 Wire 2001 AVALON (EWD431U) 153 154 B B II IF A A BK 2001 AVALON (EWD431U) A BN 2 W- B (* 1) 11 BC1 J10 JUNCTION CONNECTOR 8 BD1 1 2 B15 C 11 BD1 B7 IA1 (*2) W- R 2 IM2 W- R (* 1) R- W 6 IM2 (*2) (* 1) G 9 ID1 W- B (*1) G (* 1) PBKL (*1) 1 S11 SEAT BELT WARNING OCCUPANT DETECTION SENSOR W- R W- B (*2) G 6 BD1 W- B G (* 1) (*2) R- W 17 B (* 1) 2 B9 BUCKLE SW RH 1 (*2) (* 4) 6 BC1 W- B C W- B DBKL W- B 4 R- W 16 A (* 2) W- B I5 (* 1) R- W GND1 (* 1) R- W 14 B (*3) 21 4F B8 BUCKLE SW LH CLTC (*3) W- B 8 4F J14 JUNCTION CONNECTOR W- B 14 3D W- B W- B 13 B W- B W- B W- G 7. 5A ECU- B J11 JUNCTION CONNECTOR B J6 JUNCTION CONNECTOR W- B W- B (TAIWAN) B W- B W- B W- B 24 A (TAIWAN) W- G KEY REMINDER AND SEAT BELT WARNING FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A ECU- IG NO. 2 9 1B 5 3C 2 SIG BODY ECU B4 A , B5 B 4 B SEAT * * * * FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 : W/ POWER SEAT 2 : W/O POWER SEAT 3 : W/ DRIVING POSITION MEMORY 4 : W/O DRIVING POSITION MEMORY 10A GAUGE NO. 1 R- B 10 1D 4 4D 13 4F B4 A , B5 B BODY ECU W- B 1 R- B M6 D , M7 E 10 E SEAT BELT WARNING LIGHT [MULTI DISPLAY] R- Y 2 G- R R- L 1 2 D PASSENGER SEAT BELT 2 4B PBEW 11 B G- W 17 3E DRIVER SEAT BELT R- Y 11 4A DBEW 23 B 4 D W- B R- L 17 3D 9 3D 22 3D B W- B J4 JUNCTION CONNECTOR B W- B D11 DOOR COURTESY SW FRONT LH GND2 11 A W- B KSW 17 A U1 UNLOCK WARNING SW DCTY 5 A IG 2001 AVALON (EWD431U) 155 KEY REMINDER AND SEAT BELT WARNING SYSTEM OUTLINE 1. SEAT BELT WARNING SYSTEM When the driver has not fastened the seat belt while the ignition SW is ON, the driver seat belt warning light blinks, and a warning buzzer comes on. Also, in the front passenger seat, a sensor recognizes a passenger, and when the passenger has not fastened the seat belt, the front passenger seat belt warning light blinks. 2. KEY REMINDER SYSTEM When the ignition key is remaining in the key cylinder with the ignition SW at ACC of OFF position (Unlock warning SW ON), and the driver’s door is opened, a buzzer comes on, and reminds the driver that the ignition key is in the key cylinder. SERVICE HINTS D11 DOOR COURTESY SW FRONT LH 1-GROUND : Closed with the door open U1 UNLOCK WARNING SW 1-2 : Closed with the ignition key in cylinder S11 SEAT BELT WARNING OCCUPANT DETECTION SENSOR 1-2 : Closed with passenger sit on the front passenger seat : PARTS LOCATION Code B4 A B5 B See Page 46 (Column Shift) Code D11 48 (Floor Shift) 48 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) J6 49 (Floor Shift) J10 50 53 (Floor Shift w/ Power Seat) J11 50 52 (Column Shift w/ Power Seat) 53 (Floor Shift w/ Power Seat) 52 (Column Shift) J14 M6 53 (Floor Shift) D 47 (Column Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1D 3C 3D 3E See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No.4 ((Right g Kick Panel)) 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) 4A 4B 4D 4F 2001 AVALON (EWD431U) 156 Code M6 D M7 E 47 (Column Shift) 52 (Column Shift w/ Power Seat) 50 (w/o Power Seat) B9 50 J4 46 (Column Shift) 50 (w/o Power Seat) B8 See Page See Page 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 51 (w/o Power Seat) S11 52 (Column Shift w/ Power Seat) 53 (Floor Shift w/ Power Seat) U1 47 (Column Shift) 49 (Floor Shift) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 ID1 IM2 BC1 BD1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Floor No.2 No 2 Wire and Instrument Panel Wire (Right Kick Panel) Floor No No.1 1 Wire and Seat No No.1 1 Wire (Under the Driver’s Seat) Floor No No.2 2 Wire and Seat No No.2 2 Wire (Under the Front Passenger’s Seat) : GROUND POINTS Code IF IG II See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Left Kick Panel Cowl Side Panel LH Right Kick Panel BK 64 Rear Quarter Inner LH BN 64 Rear Quater Inner RH : SPLICE POINTS Code I5 B7 See Page 58 (Column Shift) 62 (Floor Shift) 64 Wire Harness with Splice Points Instrument Panel Wire Code B15 See Page 66 (Column Shift) 68 (Floor Shift) Wire Harness with Splice Points Seat No.2 No 2 Wire Floor No.2 Wire 2001 AVALON (EWD431U) 157 WIPER AND WASHER FROM POWER SOURCE SYSTEM (SEE PAGE 72) 25A WIP L 5 1C WF WIPER SW EW WASHER SW OFF W2 WASHER MOTOR 1 2 M HI INT LO WF E 11 L- W L I25 2 INT1 W- B L INT2 B1 OFF ON L- Y +1 7 L- B +2 8 L- O +B 17 L +S 16 +B +2 +1 +S I9 L C14 FRONT WIPER AND WASHER SW [COMB. SW] 3 5 2 1 +2 +1 B +S M E IG 2001 AVALON (EWD431U) 158 4 W- B W- B F5 FRONT WIPER MOTOR EA SYSTEM OUTLINE When the ignition SW is turned ON, the current flows from WIP fuse to wiper and washer SW TERMINAL 17, washer motor TERMINAL 2, and front wiper motor TERMINAL 2. 1. LO POSITION When the wiper and washer SW is at LO position, the current flows from wiper and washer SW TERMINAL 17 to TERMINAL 7 to front wiper motor TERMINAL 5 to TERMINAL 4 to GROUND, and the front wiper motor runs at low speed. 2. HI POSITION When the wiper and washer SW is at HI position, the current flows from wiper and washer SW TERMINAL 17 to TERMINAL 8 to front wiper motor TERMINAL 3 to TERMINAL 4 to GROUND, and the front wiper motor runs at high speed. 3. INT POSITION When the wiper and washer SW is at INT position, the wiper relay is activated and the current flows from wiper and washer SW TERMINAL 17 to TERMINAL 2 to GROUND. This current activates the intermittent circuit, and the current flows from wiper and washer SW TERMINAL 17 to TERMINAL 7 to front wiper motor TERMINAL 5 to TERMINAL 4 to GROUND, and operates the front wipers. 4. WASHER CONTINUOUS OPERATION When the wiper and washer SW is pulled to WASHER position (Washer SW ON posiiton), the current from the WIP fuse flows to washer motor TERMINAL 2 to TERMINAL 1 to wiper and washer SW TERMINAL 11 to TERMINAL 2 to GROUND, and operates the washer motor to emitt a water spray. At the same time, the current flows from the WIP fuse to wiper and washer SW TERMINAL 17 to TERMINAL 7 to front wiper motor TERMINAL 5 to TERMINAL 4 to GROUND, and operates the front wiper motor. SERVICE HINTS C14 FRONT WIPER AND WASHER SW 2-GROUND : Always continuity 7-GROUND : Approx. 12 volts with the front wiper and washer SW at LO position Approx. 2 to 12 seconds intermittently with the front wiper and washer SW at INT position 8-GROUND : Approx. 12 volts with the front wiper and washer SW at HI position 16-GROUND : Approx. 12 volts with the ignition SW on unless the front wiper motor at STOP position 17-GROUND : Approx. 12 volts the ignition SW at ON or ST position F5 FRONT WIPER MOTOR 2-1 : Closed unless the wiper motor at STOP position : PARTS LOCATION Code C14 See Page Code See Page 46 (Column Shift) F5 44 48 (Floor Shift) W2 45 Code See Page ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1C See Page 27 Junction Block and Wire Harness (Connector Location) Cowl Wire and Driver Side J/B (Lower Finish Panel) : GROUND POINTS Code EA IG See Page 54 Ground Points Location Front Side of Right Fender 56 (Column Shift) 60 (Floor Shift) Cowl Side Panel LH : SPLICE POINTS Code I9 See Page 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Cowl Wire Code I25 See Page 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Cowl Wire 2001 AVALON (EWD431U) 159 CIGARETTE LIGHTER FROM POWER SOURCE SYSTEM (SEE PAGE 72) 15A CIG P 13 1I 1 C8 CIGARETTE LIGHTER W- B W- B 3 IG 2001 AVALON (EWD431U) 160 SERVICE HINTS C8 CIGARETTE LIGHTER 1-GROUND : Approx. 12 volts with the ignition SW ON or ACC position 3-GROUND : Always continuity : PARTS LOCATION Code C8 See Page 46 (Column Shift) Code C8 See Page Code See Page 48 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1I See Page 27 Junction Block and Wire Harness (Connector Location) Cowl Wire and Driver Side J/B (Lower Finish Panel) : GROUND POINTS Code IG See Page 56 (Column Shift) 60 (Floor Shift) Ground Points Location Cowl Side Panel LH 2001 AVALON (EWD431U) 161 POWER OUTLET FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A GAUGE NO. 1 15A PWR OUTLET NO. 1 10 1D 15A PWR OUTLET NO. 2 7 1B L- Y 12 1D LG * 1 : FLOOR SHIFT * 2 : COLUMN SHIFT (* 1) R- B B- Y 7 7 5 2 PWR POINT RELAY 3 1 GR LG 4 ID2 (* 1) LG 9 ID2 (* 2) 5 4D 13 4D 1 IO1 2 RLY GND P8 POWER OUTLET MAIN SW 1 V13 VOLTAGE INVERTER 1 IG E 1 4 AC1 AC2 3 7 J5 JUNCTION CONNECTOR A A (* 2) L L 20 4C (* 2) 2 IH1 L P 1 IH1 6 ID2 7 4F (* 2) P 2 ID2 P L (*1) (*1) L- B W- B (*1) W- B (*2) W- B W- B 21 3B (* 2) L 3 IO1 (* 2) 2 IO1 (* 1) (* 1) L- B 4 IO1 (* 2) 8 3B (* 1) W- B W- B W- B 2 7 GR 2 P4 POWER OUTLET IG LG 6 (* 1) B- Y 3 P5 POWER OUTLET R- B 7 1 4 1 4 AC1 AC2 AC1 AC2 B1 A A J9 JUNCTION CONNECTOR A IG IJ J11 JUNCTION CONNECTOR W- B A A BK 2001 AVALON (EWD431U) 162 P6 POWER OUTLET W- B W- B W- B P7 POWER OUTLET W- B 4 IA1 W- B IF SERVICE HINTS P8 POWER OUTLET MAIN SW 3-GROUND : Approx. 12 volts with the ignition SW at ON position 2-GROUND : Always continuity P4, P5 POWER OUTLET 2-GROUND : Approx. 12 volts with the ignition SW ON or ACC position 1-GROUND : Always continuity : PARTS LOCATION Code J5 J9 See Page Code See Page 47 (Column Shift) J11 50 49 (Floor Shift) P4 47 (Column Shift) 47 (Column Shift) P5 49 (Floor Shift) 49 (Floor Shift) P6 47 (Column Shift) Code P7 See Page 49 (Floor Shift) 47 (Column Shift) P8 49 (Floor Shift) V13 51 : RELAY BLOCKS Code 7 See Page 42 Relay Blocks (Relay Block Location) Front Passenger Side R/B No.7 (Right Kick Panel) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1D 3B 4C 4D 4F See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 34 Cowl Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 ID2 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) IH1 58 (Column Shift) Cowl Wire and Cowl No.2 Wire (Behind the Center Cluster) IO1 62 (Floor Shift) Floor No.3 Wire and Floor No.1 Wire (Under the Console Box) : GROUND POINTS Code IF IG IJ BK See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 64 Ground Points Location Left Kick Panel Cowl Side Panel LH Cowl Side Panel RH Rear Quarter Inner LH : SPLICE POINTS Code B1 See Page 64 Wire Harness with Splice Points Code See Page Wire Harness with Splice Points Floor No.1 Wire 2001 AVALON (EWD431U) 163 HORN FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A HORN 5 1 HORN RELAY 3 2 3 2F 3 2C G- B G- W 1 1J G- B 11 1C G- W 1 H5 HORN LH 6 1 H6 HORN RH 2001 AVALON (EWD431U) 164 C12 HORN SW [COMB. SW] SERVICE HINTS HORN RELAY 5-3 : Closed with the horn SW on : PARTS LOCATION Code C12 See Page Code See Page 46 (Column Shift) H5 44 48 (Floor Shift) H6 44 Code See Page ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1C 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1J 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2C 2F 2001 AVALON (EWD431U) 165 POWER WINDOW LG P L L P- B L- O 10 1A 9 1L 12 1L 8 1A 9 1B W- G W- G 10 1D 4 4D 5 3C 14 3D 4 4F 14 3F 5 3F 2 1 2 IB1 5 IB1 W- L W- L R- B 6 IB2 L- O P- B PWR RELAY 5 7. 5A ECU- B R- B 3 10A GAUGE NO. 1 25A FL P/W 20A RL P/W 20A FR P/W P 1 1L 20A RR P/W LG FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 IB1 BDR W- G 25 R- B D19 DRIVER DOOR ECU P- B W L- O 1 1G 7 21 23 WLSW SIG CPUB UP2 PLS LMT 1 3 2 4 13 G P Y W W- B E GND B 1 A FL MAIN 3. 0W MPX1 MPX2 20 8 1 2 3 4 9 IB1 G R- Y DWN2 14 R F 6 A , F10 E FUSIBLE LINK BLOCK 120A ALT 1 E 8 IB1 5 11 IB1 W- B LIMIT SW M PULSE SENSOR G R- Y B BATTERY B W- B B W- B (* 1) P12 POWER WINDOW MOTOR FRONT LH W- B B J6 JUNCTION CONNECTOR B IF 2001 AVALON (EWD431U) 166 W- B W- B W- B I5 II W- B LG LG P P L * 1 : TAIWAN W- G G- B R- B L G- Y Y- R W- L G- B L G- B G- B W- G G- B R- B G- Y Y- R 12 20 10 21 B 24 A 10 B 22 B 22 A 8 A CPUB BDR MPX1 MPX4 B RRU RRD RLU RLD B4 A , B5 B 9 B 13 B W- B R- Y W- B TC 18 A GND2 11 A LG- R 13 IN1 4 3A 8 4F 13 3A 4 3G 6 4H 6 4A II2 W- B (*1) W- B 4 TC 11 B TC J4 JUNCTION CONNECTOR 22 LG- R B W- B D2 DATA LINK CONNECTOR 2 D1 DATA LINK CONNECTOR 1 W- B R- Y (*1) LG- R 21 4F W- B 2 GND1 14 B LG- R M CLTC W- B 1 MPX3 LG- R 8 W- B 1 W- B DWN2 (* 1) GND 9 G MPX2 P13 POWER WINDOW MOTOR FRONT RH UP2 11 R BODY ECU 8 IN1 G 9 IN1 W- G 6 IN1 G F14 FRONT PASSENGER DOOR ECU 7 IN1 IG 2001 AVALON (EWD431U) 167 POWER WINDOW LG P G- B R- B G- Y G- Y LG R- B G- B 18 ID1 17 ID1 1 IM2 4 IM2 3 IM2 P Y- R Y- R L- Y Y- R G- Y L- W R- B G- B 2 BA1 1 BA1 3 BA1 2 BB1 1 BB1 3 BB1 Y- R G- Y LG R- B G- B IA1 P 1 6 1 DOWN UP W- B 3 E D U 2 5 W- B R A BK 1 M 2 P14 POWER WINDOW MOTOR REAR LH 4 B UP 3 E 12 BB1 G D U 2 5 R J11 JUNCTION CONNECTOR BM 2001 AVALON (EWD431U) 168 UP DOWN W- B 12 BA1 6 DOWN W- B 4 B UP P10 POWER WINDOW CONTROL SW REAR LH DOWN P11 POWER WINDOW CONTROL SW REAR RH 1 1 M 2 P15 POWER WINDOW MOTOR REAR RH G SYSTEM OUTLINE 1. MANUAL DOWN OR UP OPERATION When the power window master SW (Driver’s) is pushed one step, the motor rotates to open the window. When the power window master SW (Driver’s) is pulled up one step, the motor rotates in the opposite direction, to close the window. All the other windows can be opened/closed as well, by the operation of the power window master SW or respective power window SW. 2. AUTO DOWN OR UP OPERATION When the power window master SW (Driver’s) is pushed two steps, the motor rotates to open the window automatically. When the power window master SW (Driver’s) is pulled up two steps, the motor rotates to close the window automatically. 3. JAM PROTECTION FUNCTION When any foreign object gets caught during power window UP operation, the motor rotates in the opposite direction to open the window. SERVICE HINTS B4 (A), B5 (B) BODY ECU (A)24-GROUND : Always approx. 12 volts (A)11-GROUND : Always continuity (B)14-GROUND : Always continuity D19 DRIVER DOOR ECU 13-GROUND : Always continuity 21-GROUND : Approx. 12 volts with ignition SW at ON or ST position 23-GROUND : Always approx. 12 volts F14 FRONT PASSENGER DOOR ECU 8-GROUND : Always continuity 12-GROUND : Always approx. 12 volts : PARTS LOCATION Code B4 A B5 B D1 D2 D19 See Page Code 46 (Column Shift) F6 48 (Floor Shift) F10 46 (Column Shift) 48 (Floor Shift) 44 46 (Column Shift) 48 (Floor Shift) 50 F14 J4 J6 J11 See Page A 44 E Code See Page P10 51 44 P11 51 50 P12 51 47 (Column Shift) P13 51 49 (Floor Shift) P14 51 47 (Column Shift) P15 51 49 (Floor Shift) 50 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A See Page Junction Block and Wire Harness (Connector Location) 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1G 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1L 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 34 Cowl Wire and J/B No.3 ((Left Kick Panel)) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 1B 1D 3A 3C 3D 3F 3G 4A 4D 4F 4H 2001 AVALON (EWD431U) 169 POWER WINDOW : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IB1 IB2 ID1 II2 IM2 IN1 See Page 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Engine Wire and Cowl Wire (Behind the Glove Box) Floor No.2 No 2 Wire and Instrument Panel Wire (Right Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 64 Rear Door No.2 Wire and Floor No.1 Wire (Under the Left Center Pillar) BB1 64 Rear Door No.1 Wire and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code IF IG II See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Left Kick Panel Cowl Side Panel LH Right Kick Panel BK 64 Rear Quarter Inner LH BM 64 Back Panel Center : SPLICE POINTS Code See Page I5 58 (Column Shift) Wire Harness with Splice Points Instrument Panel Wire Code I5 See Page 62 (Floor Shift) 2001 AVALON (EWD431U) 170 Wire Harness with Splice Points Instrument Panel Wire MEMO 2001 AVALON (EWD431U) 171 DOOR LOCK CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 72) L- O G- B 10A ECU- IG NO. 2 25A DOOR NO. 1 15A DOOR NO. 2 L- R 12 2C 5 1J L- O G- B W- G W- G 5 B 21 B 24 A 2 1 7 SIG BDR1 BDR2 MPX4 LSR B B4 A , B5 B BODY ECU 11 4A 17 3E 17 4E 2 4B R- Y IK1 1 W- B W- B 2 L- R L- W ACTD 1 B L W- B (TAIWAN) ACT+ 2 B L- W 21 4F 8 4F L- R L W- B 7 4H W- B 9 3D J6 JUNCTION CONNECTOR B 7 4B B IG I5 A IJ 2001 AVALON (EWD431U) W- B B W- B B IF B W- B J9 JUNCTION CONNECTOR W- B W- B 22 3D 172 ACT15 B L B J4 JUNCTION CONNECTOR B 1 W- B 1 D12 DOOR COURTESY SW FRONT RH M 1 D11 DOOR COURTESY SW FRONT LH 1 L7 LUGGAGE COMPARTMENT DOOR UNLOCK MOTOR 2 U1 UNLOCK WARNING SW L 2 CLTC 13 B W- B L- B 17 4F O 4 17 3D R- L 1 GND1 14 B L1 LUGGAGE COMPARTMENT DOOR OPENER MAIN SW W- B TKU 18 B R- Y GND2 11 A O KSW 17 A R- L PCTY 3 B L DCTY 5 A L2 LUGGAGE COMPARTMENT DOOR OPENER SW TR+ 25 A II L W- B W- B L- O L- O G- B FROM POWER SOURCE SYSTEM (SEE PAGE 72) * 1 : AUTOMATIC A/C * 2 : MANUAL A/C 7. 5A ECU- B W- G 9 1B 5 3C W- G 14 3D W- G 5 3F W- L G G- B KUL W- B L- R KEYE GND 2 3 KL LSWP 4 13 8 11 IB1 6 1 11 IN1 2 M 3 4 LOCK 3 L- R M 4 13 IN1 UNLOCK 5 UNLOCK 6 W- B 1 W- B B GND 13 W- B 9 B W- G MPX1 Y 10 CPUB L- W G 12 MPX2 L- Y 11 F14 FRONT PASSENGER DOOR ECU 24 LG L- B KL LOCK 9 IB2 KEYE 22 L- W KUL L- W LSWD 10 9 IN1 8 MPX2 L CPUB 7 IN1 G D19 DRIVER DOOR ECU 23 8 IN1 G- B 8 IB1 W- G 1 IB1 W- L W- L 14 3F D17 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH 5 L- B L- R 2 3 IB2 D18 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH 10 IN1 A L- R A A A A L- R L- R L- R L- R J2 JUNCTION CONNECTOR L L- R L- R C L W- B L L L L L C C C J3 JUNCTION CONNECTOR W- B 2001 AVALON (EWD431U) 173 DOOR LOCK CONTROL L- O 6 3F 19 3F L- O L- O 6 3E 10 IM2 L- O L- O 9 BA1 3 M 2 M W- B 5 IA1 L L- R 13 IA1 12 IM2 11 IM2 W- B L 8 BB1 L- B 10 BB1 L L- R 5 BB1 L- R 8 BA1 L- R W- B 10 BA1 L- R 5 BA1 W- B 1 L 3 L- B 4 L- R 1 4 D15 DOOR LOCK MOTOR REAR LH 2 L- R L- R L A BK W- B W- B L J11 JUNCTION CONNECTOR BM 2001 AVALON (EWD431U) 174 D16 DOOR LOCK MOTOR REAR RH L- O 9 BB1 SYSTEM OUTLINE 1. MANUAL UNLOCK OPERATION When the door lock control SW of the driver’s or passenger’s side door is pushed to UNLOCK, the door lock will unlock. 2. MANUAL LOCK OPERATION When the door lock control SW of the driver’s or passenger’s side door is pushed to LOCK, the door lock will lock. 3. DOOR KEY UNLOCK OPERATION ∗ Unlock operation from driver’s side door When the driver’s side door is unlocked once using the ignition key, only the driver’s side door is unlocked. If this operation is repeated within 3 seconds, all the other doors are unlocked. ∗ Unlock operation from front passenger’s side door When the front passenger’s side door is unlocked using the ignition key, all the other doors are unlocked, too. SERVICE HINTS B4 (A), B5 (B) BODY ECU 1-GROUND : Always approx. 12 volts 2-GROUND : Approx. 12 volts with ignition SW at ON or ST position 3-GROUND : Approx. 12 volts with ignition SW at ACC or ON position 7-GROUND : Always approx. 12 volts (A)24-GROUND : Always approx. 12 volts (A)11-GROUND : Always continuity (B)14-GROUND : Always continuity D19 DRIVER DOOR ECU 13-GROUND : Always continuity 23-GROUND : Always approx. 12 volts F14 FRONT PASSENGER DOOR ECU 8-GROUND : Always continuity 12-GROUND : Always approx. 12 volts : PARTS LOCATION Code B4 A B5 B See Page Code See Page 46 (Column Shift) D19 50 48 (Floor Shift) F14 50 46 (Column Shift) 48 (Floor Shift) D11 50 D12 50 D15 50 D16 50 D17 50 D18 50 J2 J3 J4 J6 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) Code J9 J11 L1 L2 L7 U1 See Page 47 (Column Shift) 49 (Floor Shift) 50 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 50 47 (Column Shift) 49 (Floor Shift) 2001 AVALON (EWD431U) 175 DOOR LOCK CONTROL ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1J 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 2C 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 3E 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 3F 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 3C 3D 4A 4B 4E 4F 4H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IB1 IB2 IK1 IM2 IN1 See Page 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Floor No.2 No 2 Wire and Instrument Panel Wire (Right Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 64 Rear Door No.2 Wire and Floor No.1 Wire (Under the Left Center Pillar) BB1 64 Rear Door No.1 Wire and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code IF IG II IJ See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Left Kick Panel Cowl Side Panel LH Right Kick Panel Cowl Side Panel RH BK 64 Rear Quarter Inner LH BM 64 Back Panel Center : SPLICE POINTS Code See Page I6 58 (Column Shift) Wire Harness with Splice Points Cowl Wire Code I6 See Page 62 (Floor Shift) 2001 AVALON (EWD431U) 176 Wire Harness with Splice Points Cowl Wire MEMO 2001 AVALON (EWD431U) 177 WIRELESS DOOR LOCK CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 72) L- O G- B 15A DOOR NO. 2 10A ECU- IG NO. 2 W- G 25A DOOR NO. 1 7. 5A DOME 7 1D W- B 5 1 +B E RDA PRG 2 3 L- W L- R D8 DOOR CONTROL RECEIVER 1 4E G- R 1 4D P- L P- L 12 2C BDR1 W- G 1 SIG G- B 2 IK2 G- R 7 BDR2 20 L- W 5 1J IK2 L- O 9 5 B 21 A 7 A 21 B 24 A LSR RDA PRG MPX4 B B4 A , B5 B BODY ECU IK1 1 B L- W ACTD 2 B L- R W- B L ACT+ (TAIWAN) W- B GND2 13 B L- W L- R L 8 4E 21 4F 1 8 4F W- B 2 2 BUZZER B 1 W- B R- Y W- B 1 B J4 JUNCTION CONNECTOR O L 7 4H W- B 9 3D W- B B 7 4B IG J9 JUNCTION CONNECTOR W- B I5 A A IJ 2001 AVALON (EWD431U) 178 W- B W- B 22 3D IF W- B B B W- B J6 JUNCTION CONNECTOR B W- B W- B 1 D12 DOOR COURTESY SW FRONT RH M 1 D11 DOOR COURTESY SW FRONT LH 1 L7 LUGGAGE COMPARTMENT DOOR UNLOCK MOTOR 2 W- B 2 4B U1 UNLOCK WARNING SW 17 4E R- L L 2 17 3E ACT15 B W- B 11 4A W6 WIRELESS DOOR LOCK BUZZER 4 17 4F L2 LUGGAGE COMPARTMENT DOOR OPENER SW 17 3D GND1 14 B P- L 1 BZ 20 A L1 LUGGAGE COMPARTMENT DOOR OPENER MAIN SW L- B TKU 18 B W- B GND2 11 A R- Y KSW 17 A O PCTY 3 B R- L DCTY 5 A L TR+ 25 A II L- O L- O G- B W- G FROM POWER SOURCE SYSTEM (SEE PAGE 72) 7. 5A ECU- B W- G 9 1B 5 3C 14 3D W- G 5 3F W- L G- B 7 IN1 9 IN1 W- L W- L G 14 3F 8 IB1 G- B MPX1 GND KUL 13 L- R KEYE GND 2 3 KL LSWP 4 13 8 11 IB1 W- B 9 W- B KL B W- G 10 CPUB Y 12 MPX2 L- W G 11 L- Y 24 B L- B KEYE 22 LG 9 IB2 LSWD 10 L- W KUL L- W 8 MPX2 L CPUB F14 FRONT PASSENGER DOOR ECU D19 DRIVER DOOR ECU 23 8 IN1 G W- G 1 IB1 13 IN1 L- R 1 2 4 L- R M 3 W- B 6 11 IN1 LOCK 3 LOCK M 4 UNLOCK 5 UNLOCK 6 W- B 1 D17 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH 5 L- B L- R 2 3 IB2 D18 DOOR LOCK MOTOR, DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH 10 IN1 L A L- R A A A A L- R L- R L- R L- R J2 JUNCTION CONNECTOR L L- R L- R C L W- B W- B L L L L C C C J3 JUNCTION CONNECTOR 2001 AVALON (EWD431U) 179 WIRELESS DOOR LOCK CONTROL L- O 6 3F 19 3F L- O L- O 6 3E 10 IM2 L- O L- O 9 BA1 3 M 2 M W- B 5 IA1 L L- R 13 IA1 12 IM2 11 IM2 W- B L 8 BB1 L- B 10 BB1 L L- R 5 BB1 L- R 8 BA1 L- R W- B 10 BA1 L- R 5 BA1 W- B 1 L 3 L- B 4 L- R 1 4 D15 DOOR LOCK MOTOR REAR LH 2 L- R L- R L A BK W- B W- B L J11 JUNCTION CONNECTOR BM 2001 AVALON (EWD431U) 180 D16 DOOR LOCK MOTOR REAR RH L- O 9 BB1 SYSTEM OUTLINE In this system, the door control receiver receives the weak radio wave transmitted from the transmitter inside the ignition SW, and controls remotely the lock/unlock of all the doors and the luggage door, through the communication control of the body ECU. 1. NORMAL OPERATION ∗ Lock operation When the lock SW of the transmitter is pushed, all the doors are locked. The answer back buzzer will beep once and the tail lamps will flash once synchronously. ∗ Unlock operation When the unlock SW of the transmitter is pushed once, only the driver’s side door is unlocked. The answer back buzzer will beep twice and the tail lamps will flash twice synchronously. When the unlock SW is pushed again within 3 seconds, all the doors are unlocked. After the unlock button is pressed the 2nd time, there will be 2 quick beeps (Answer back buzzer) and 2 quick flashes the tail lamps. ∗ Luggage door unlock operation When the luggage door unlock SW is pushed for a second, the luggage door will open. The answer back buzzer will make a single, long beep. 2. AUTO LOCK FUNCTION When the doors are unlocked by the transmitter, but are not actually opened within 30 seconds, all the doors will be locked again automatically. 3. PANIC MODE FUNCTION When the panic SW of the transmitter is pushed, the horn comes on, and the headlight and taillight flashes. 4. REPEAT FUNCTION In case an appropriate lock detection signal is not received after outputting a lock signal when pushing the lock button (Transmitter), the body ECU output the lock signal again. SERVICE HINTS B4 (A), B5 (B) BODY ECU 1-GROUND : Always approx. 12 volts 2-GROUND : Approx. 12 volts with ignition SW at ON or ST position 3-GROUND : Approx. 12 volts with ignition SW at ACC or ON position 7-GROUND : Always approx. 12 volts (A)24-GROUND : Always approx. 12 volts (A)11-GROUND : Always continuity (B)14-GROUND : Always continuity D19 DRIVER DOOR ECU 13-GROUND : Always continuity 23-GROUND : Always approx. 12 volts F14 FRONT PASSENGER DOOR ECU 8-GROUND : Always continuity 12-GROUND : Always approx. 12 volts : PARTS LOCATION Code B4 A B5 B See Page Code See Page Code See Page 46 (Column Shift) D19 50 J9 49 (Floor Shift) 48 (Floor Shift) F14 50 J11 50 46 (Column Shift) 48 (Floor Shift) D8 50 D11 50 D12 50 D15 50 D16 50 D17 50 D18 50 J2 J3 J4 J6 J9 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) L1 L2 L7 U1 W6 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 50 47 (Column Shift) 49 (Floor Shift) 45 47 (Column Shift) 2001 AVALON (EWD431U) 181 WIRELESS DOOR LOCK CONTROL ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1J 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 2C 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 3E 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 3F 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No.4 ((Right g Kick Panel)) 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 1D 3C 3D 4A 4B 4D 4E 4F 4H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IB1 IB2 IK1 IK2 IM2 IN1 See Page 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Floor No.2 No 2 Wire and Instrument Panel Wire (Right Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 64 Rear Door No.2 Wire and Floor No.1 Wire (Under the Left Center Pillar) BB1 64 Rear Door No.1 Wire and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code IF IG II IJ See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Left Kick Panel Cowl Side Panel LH Right Kick Panel Cowl Side Panel RH BK 64 Rear Quarter Inner LH BM 64 Back Panel Center : SPLICE POINTS Code See Page I6 58 (Column Shift) Wire Harness with Splice Points Cowl Wire Code I6 See Page 62 (Floor Shift) 2001 AVALON (EWD431U) 182 Wire Harness with Splice Points Cowl Wire MEMO 2001 AVALON (EWD431U) 183 THEFT DETERRENT FROM POWER SOURCE SYSTEM (SEE PAGE 72) W- L W- L 25A DOOR NO. 1 10A HORN 7. 5A ECU- B Y- R L- R IF3 W- L 5 3C 5 3F 14 3F W- G 14 3D 5 3D W- G 7 W- L 9 1B W- G 10 1B B- R 5 2C T4 THEFT DETERRENT ECU SH SH- 1 2 14 +B2 +B1 KSW 4 2 4A IG DSWH E 6 MPX1 12 10 V B R- Y 25 W 12 V- W IND 3 G- W LUG Y- R 24 W- G B- R Y- R 18 IF3 E3 ENGINE HOOD COURTESY SW 20 4A 7 4B B J1 JUNCTION CONNECTOR 2 W- B U1 UNLOCK WARNING SW 2 1 1 1 W- B W- B B 22 3D 4 2F W- B 4 2D W- B 9 3D A A J5 JUNCTION CONNECTOR W- B IG W- B 7 3A W- B A BN ED 2001 AVALON (EWD431U) 184 W- B 7 3G W- B J10 JUNCTION CONNECTOR C9 SECURITY INDICATOR LIGHT [COMB. METER] W- B 21 W- B L6 LUGGAGE COMPARTMENT DOOR KEY UNLOCK SW 2 2 4B R- Y 22 V 10 IC1 G- W 1 1 IK2 T2 THEFT DETERRENT HORN B W- B V A A J9 JUNCTION CONNECTOR A IJ W- B EA W- L W- L W- L W- L FROM POWER SOURCE SYSTEM (SEE PAGE 72) Y- R 10A ECU- IG NO. 2 18 4B W- G Y- R 18 4H G- B 11 3F R- Y 2 3C IB1 R- Y 13 1B 9 G- B W- G Y- R 9 IN1 21 B 9 B B4 A , B5 B 2 SIG MPX1 DCTY PCTY 5 A RCTY CLTC GND1 13 B 14 B R- L O R- W W- B 17 3D 17 4F 5 4F 21 4F 2 17 3E 14 4F 14 4F O BUZZER 1 R- L 16 B P- L 3 B MPX3 W- B 5 4E 8 4F W- B (TAIWAN) W- B 1 D14 DOOR COURTESY SW REAR RH R- W 1 D13 DOOR COURTESY SW REAR LH B J6 JUNCTION CONNECTOR B W- B I5 W- B B W- B 1 D12 DOOR COURTESY SW FRONT RH 2 IA1 D11 DOOR COURTESY SW FRONT LH 1 W- B R- W R- W V BZ 20 A T1 THEFT DETERRENT BUZZER 23 A MPX4 W- B B BODY ECU (TAIWAN) 24 A II IF 2001 AVALON (EWD431U) 185 THEFT DETERRENT W- L W- L W- L W- L G- B G- B W- G 10 12 MPX2 MPX1 CPUB 8 1 2 3 4 W- B LOCK W- B D17 DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT LH B B J6 JUNCTION CONNECTOR B W- B W- B W- B IF 2001 AVALON (EWD431U) 186 LSWP 13 IN1 D18 DOOR KEY LOCK AND UNLOCK SW AND DOOR UNLOCK DETECTION SW FRONT RH B II KL W- B 13 IB1 KUL W- B GND 11 4 W- B 3 3 Y 4 GND 2 L- W 5 KEYE 13 F14 FRONT PASSENGER DOOR ECU G 11 LOCK 6 UNLOCK 9 W- B KEYE LG LSWD 24 L- W KL 22 L KUL 8 MPX2 10 7 IN1 L- Y CPUB 8 IN1 UNLOCK 23 MPX1 IB1 D19 DRIVER DOOR ECU 20 8 G W- G IB1 R- Y 1 G W- B R- Y SERVICE HINTS D11, D12, D13, D14 DOOR COURTESY SW FRONT LH, RH REAR LH, RH 1-GROUND : Closed with the door open D17 DOOR KEY LOCK AND UNLOCK SW FRONT LH 5-3 : Closed with the door lock cylinder locked with the key 6-3 : Closed with the door lock cylinder unlocked with the key D18 DOOR KEY LOCK AND UNLOCK SW FRONT RH 2-4 : Closed with the door lock cylinder locked with the key 1-4 : Closed with the door lock cylinder unlocked with the key E3 ENGINE HOOD COURTESY SW 1-2 : Open with the engine hood open L6 LUGGAGE COMPARTMENT DOOR KEY UNLOCK SW 2-1 : Closed with the door lock cylinder unlocked with the key T4 THEFT DETERRENT ECU 3-GROUND : Continuity with the luggage compartment door to UNLOCK position 6-GROUND : Continuity with the engine hood close 1, 2, 24-GROUND : Always approx. 12 volts 12-GROUND : Always continuity 14-GROUND : Approx. 12 volts with the ignition SW at ON position B4 (A), B5 (B) BODY ECU 2-GROUND : Approx. 12 volts with the ignition SW at ON position (A)24-GROUND : Always approx. 12 volts (A) 5-GROUND : Continuity with the front door LH open (B) 3-GROUND : Continuity with the front door RH open (B)16-GROUND : Continuity with the rear door LH, RH open (B)14-GROUND : Always continuity : PARTS LOCATION Code B4 A B5 B C9 See Page Code See Page Code See Page 46 (Column Shift) D18 50 J9 49 (Floor Shift) 48 (Floor Shift) D19 50 J10 50 46 (Column Shift) E3 44 L6 50 48 (Floor Shift) F14 50 T1 45 47 (Column Shift) T2 45 46 (Column Shift) 48 (Floor Shift) D11 50 D12 50 D13 50 D14 50 D17 50 J1 J5 J6 J9 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) T4 U1 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 49 (Floor Shift) 47 (Column Shift) 2001 AVALON (EWD431U) 187 THEFT DETERRENT ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 30 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 34 Cowl Wire and J/B No.3 ((Left Kick Panel)) 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 2C 2D 2F 3A 3C 3D 3E 3F 3G 4A 4B 4E 4F 4H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IB1 IC1 IF3 IK2 IN1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location EA 54 Front Side of Right Fender ED 54 Front Side of Left Fender IF IG II IJ BN 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 64 Left Kick Panel Cowl Side Panel LH Right Kick Panel Cowl Side Panel RH Rear Quarter Inner RH : SPLICE POINTS Code See Page I5 58 (Column Shift) Wire Harness with Splice Points Instrument Panel Wire Code I5 See Page 62 (Floor Shift) 2001 AVALON (EWD431U) 188 Wire Harness with Splice Points Instrument Panel Wire MEMO 2001 AVALON (EWD431U) 189 VSC (w/ TRACTION CONTROL) FROM POWER SOURCE SYSTEM (SEE PAGE 72) A4 A , A5 B 1 ABS & BA & TRAC & VSC ACTUATOR 25A ABS NO. 2 60A ABS L 2 2 GR G- O 5 IE1 6 IE1 3 55 5 3 SFRH SFRR SFLH SFLR 17 IE1 GR G- O W- R 26 GR- R R 6 SRRH 19 3H A20 ABS & BA & TRAC & VSC ECU MR CSW 27 7 44 W- L MT 36 GR- L GR- R R- B SR 2 O R+ 6 3A R W- B IE1 W- G 3 R O 4 GR- R GR- L W- R W- G 3 IE1 L L IE1 6 19 3A 4 V8 VSC OFF SW IF3 O GR- L SRRH 4 A B- W 3 5A ABS NO. 4 3 SFLR 8 A IF3 W- L 3 21 5 IE1 SFLH 7 A 4 3 5 6 SFRR 11 A B- W 3 ABS SOL RELAY ABS MTR RELAY 1 2 3 W- L 3 1 4 SFRH 9 A GR- R 3 3 6 A W GR- R 3 BM 2 A 8 2F W 5 BS 10 A W- B GND 2 W- B 1 21 4D J6 JUNCTION CONNECTOR W- B 8 4F B B R- B EE 2001 AVALON (EWD431U) 190 W- B W- B W- B II FROM POWER SOURCE SYSTEM (SEE PAGE 72) A4 A , A5 B ABS & BA & TRAC & VSC ACTUATOR 15A STOP G- W ML+ 6 B 3 3C 5 1B 3 3F 3 1D G- W 11 1D R B- Y ML- 1 B G- W SRC2 4 B V SRC1 5 B W- R SMC2 2 B R- B SMC1 3 B L- Y Y- B G- R SRLR 3 A V- W SRLH 1 A G- Y SRRR 5 A 1 10 IE1 11 IE1 12 IE1 13 IE1 14 IE1 15 IE1 8 IE1 9 IE1 16 4F S4 STOP LIGHT SW 7 IE1 G- W V W- R R- B B- Y V- W G- Y L- Y Y- B G- R 16 4D 2 4 SRRR 53 25 49 50 54 52 SRLH SRLR SMC1 SMC2 SRC1 SRC2 22 24 ML+ 48 ML- STP A20 ABS & BA & TRAC & VSC ECU VCM PMC 67 E2 68 YD 69 77 GYAW 78 YAW 79 YIGA 34 YGNA 80 GL1 18 BR BR 3 2 1 Y L R W G 1 ID1 2 ID1 12 ID1 13 ID1 14 ID1 16 ID1 I4 BR- W BR BR BR- W 15 ID1 A A A BR- W A A A G BR BR BR- W W R L Y BR- W BR (SHIELDED) IF3 BR 2 (SHIELDED) IF3 BR- Y R- L 9 R- L P- L IF3 P- L 8 BR- Y (SHIELDED) I15 I1 2 YD 1 GYW2 4 YAW2 3 IGA 6 GNDA J4 JUNCTION CONNECTOR 5 GL1 BR- W M2 MASTER CYLINDER PRESSURE SENSOR BR Y1 YAW RATE SENSOR BR R- B R- B W- B W- B 2001 AVALON (EWD431U) 191 VSC (w/ TRACTION CONTROL) FROM POWER SOURCE SYSTEM (SEE PAGE 72) LG- B 11 22 II2 12 4B 19 4B 13 3A 6 4H 4 3G LG- B II2 TC LG- B LG- B LG- R J5 JUNCTION CONNECTOR 14 I20 1 IE1 C ABS 4 R- L 11 W W- L 9 2F R- L TC 16 LG- R TS D2 DATA LINK CONNECTOR 2 LG- R TS 14 LG- R SIL 7 LG- B 25A ABS NO. 3 LG- R D1 DATA LINK CONNECTOR 1 LG- B D3 DATA LINK CONNECTOR 3 12 4A 6 4A 3 4A 19 4A W- L W LG- B LG- R C 51 46 42 86 BAT D/G TS LG- R TC A20 ABS & BA & TRAC & VSC ECU RL- BR RR+ 14 RR- 11 (SHIELDED) FL+ 10 8 (SHIELDED) B- R Y BR- W I15 G I15 (SHIELDED) I15 V LG BR- W FL- 12 BR RL+ 13 BR I4 11 (SHIELDED) 2 A29 ABS SPEED SENSOR REAR LH Y IK1 1 2 A30 ABS SPEED SENSOR REAR RH 20 IE1 19 IE1 18 IE1 (SHIELDED) BR IK1 G V 1 BR- W 12 21 ID1 (SHIELDED) LG 22 ID1 B- R 10 IK1 11 ID1 1 2 A8 ABS SPEED SENSOR FRONT LH BR BR BR BR R- B R- B W- B W- B 2001 AVALON (EWD431U) 192 LG- B LG- B LG- R LG- R R- L R- L 15 4A 7 IC1 R- W 15 4B R- W R- W I9 Y- R Y- R FROM POWER SOURCE SYSTEM (SEE PAGE 72) R- L R- W 15 4H 10A GAUGE NO. 1 M3 A , M6 D , M7 E MULTI DISPLAY 3 D 10A ECU- IG NO. 2 I15 Y- R 5 D BRAKE Y- R V L- O 15 4F 16 4H 18 IL1 6 Y- R V L- O 16 4A IL1 P- B 15 4C 72 71 31 70 VSCW 2 13 4F WT IND 4 4D 18 4H I7 4 D Y- R 7 A V9 VSC WARNING BUZZER L- W BUZZER 9 D R- B 7 E P- B Y- R 10 D Y- R CPU 18 4A Y- R SLIP R- B VSC OFF VSC 13 1B Y- R 10 1D Y- R ABS 11 3D 2 3C 1 11 3F 88 SP1 1 BZ IG1 R- W R- L WA 83 Y- R EBDW 32 B 76 R- Y 40 8 7 2 3 1 I15 I15 W- B A9 ABS SPEED SENSOR FRONT RH A A21 ACTIVE LIGHT RELAY Y- G W O A W- B I15 W- B BR 4 L- B A W- B 2 B BR W- B 1 J5 JUNCTION CONNECTOR B W- B W- B B J4 JUNCTION CONNECTOR B W- B (SHIELDED) L BR 61 Y- G SS2 SS1 LBL PKB 63 L- B FSS 62 W 28 O GND1 29 W- B FR+ (SHIELDED) GND2 17 W- B FR16 B- W A20 ABS & BA & TRAC & VSC ECU W- B R- B R- B W- B W- B A J9 JUNCTION CONNECTOR IJ IG 2001 AVALON (EWD431U) 193 VSC (w/ TRACTION CONTROL) LG- B LG- R R- W Y- R R- W E7 D , E8 E C15 CRUISE CONTROL ECU R- W ENGINE CONTROL MODULE ENG+ ENG- TRC+ TRC- NEO D 15 3B 9 20 7 13 26 11 TRC+ TRC- R- W 22 Y- R 24 Y- B 21 G- W 16 BR 1 15 3A GR 3 V 16 D LG- B 20 E LG- R 13 E R- W 21 E Y- R 14 E IG1 BRL TC TS ENG+ ENG- CCS NEO LVL2 SS2 6 P 10 D 12 1 4 5 7 8 Y- R Y- G 15 I24 G- W Y- G (SHIELDED) W 5 3B P3 PARKING BRAKE SW L- B 5 3A PKB RSS W- B 14 3A B4 BODY ECU Y- G SS1 5 BR 18 C11 STEERING SENSOR [COMB. SW] O GND 14 L 2 R- B 17 B- W PKB2 4 W LBL W- B VSC- 25 L- B PKB Y- G VSC+ 15 Y- G T5 TRANSLATE ECU 18 3B 6 4D 18 3A 6 4C Y- R G- W 7 3B O W- B 7 3A W- B R- B W- B W- B 2001 AVALON (EWD431U) 194 FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A GAUGE NO. 2 * 1 : FLOOR SHIFT * 2 : COLUMN SHIFT 5A ECU- ACC 1 1C 8 1D R- L GR 2 4D 15 3D 20 3C 20 3D 11 4C 15 3C R- L GR (*2) 12 1I (*1) R- W GR 7 3C R- L R- W 3 1 D6 DIODE (A/T INDICATOR LIGHT 2) 8 1H (* 2) II1 R- L 20 2 2 P W- B 1 B1 BRAKE FLUID LEVEL WARNING SW R- W R- L 2 D P1 PARK/NEUTRAL POSITION SW Y- R G- W 7 4 II1 3 II2 W- B B J1 JUNCTION CONNECTOR 10 B Y- R G- W 4 2D 10 2F 4 2F W- B W- B ED 2001 AVALON (EWD431U) 195 VSC (w/ TRACTION CONTROL) SYSTEM OUTLINE The vehicle could be in an extreme over steering or under steering tendency due to unexpected accidents, road conditions, vehicle speed, or by other external factors. In such a case, this system automatically controls the engine output and the braking to each wheel, to decrease the extreme over steering and under steering. ∗ To decrease extreme over steering tendency When the system determines that the over steering tendency is large, the system applies brakes to the outer wheels according to the degree of over steering, and creates a moment towards the outer side of the vehicle, to decrease the tendency of over steering. Also, when the brakes are applied, the vehicle speed decreases while the stability increases. ∗ To decrease extreme under steering tendency When the system determines that the under steering tendency is large, the system applies brakes to the front or rear wheels according to the degree of under steering, to decrease the tendency of under steering. ∗ VSC OFF SW The SW to send the VSC system into OFF mode. When the SW is pushed after starting the engine, the system will be in OFF mode, and the VSC off indicator light will turn on. When the SW is pushed again, the system will be in standby mode. When the engine is stopped and re-started, regardless of the VSC OFF SW, the system will be in standby mode. Information to the driver The VSC system informs the driver when the tire grip is about to exceed its grip capacity, by blinking the slip indicator light and turning on the buzzer. Accordingly, the driver is informed to drive more gently. SERVICE HINTS A8, A9 ABS SPEED SENSOR FRONT LH, RH 1-2 : 1.5 - 1.7 kΩ (20°C, 68°F) A29, A30 ABS SPEED SENSOR REAR LH, RH 1-2 : 1.5 - 1.7 kΩ (20°C, 68°F) A20 ABS & BA & TRAC & VSC ECU 51-GROUND : Always approx. 12 volts 48-GROUND : Approx. 12 volts with the stop light SW on 28, 29-GROUND : Always continuity S4 STOP LIGHT SW 2-1 : Closed with brake pedal depressed : PARTS LOCATION Code See Page A4 A 44 A5 B 44 A8 44 A9 44 A20 A21 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) A29 50 A30 50 B1 44 B4 C11 C15 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) D1 44 D2 46 (Column Shift) Code See Page D2 48 (Floor Shift) 46 (Column Shift) D3 48 (Floor Shift) D6 E7 46 (Column Shift) D E8 E J1 J4 J5 J6 J9 M2 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 45 2001 AVALON (EWD431U) 196 Code M3 A M6 D M7 E P1 P3 S4 T5 V8 V9 Y1 See Page 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 45 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 3 24 Engine Room R/B No.3 (Near the Radiator Fan) 5 25 Engine Room R/B No.5 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1C 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 1H 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1I 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 35 Cowl Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 1D 2D 2F 3A 3B 3C 3D 3F 3G 3H 4A 4B 4C 4D 4F 4H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC1 ID1 IE1 IF3 II1 II2 IK1 IL1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Behind the Driver Side J/B) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Engine Wire and Cowl Wire (Behind the Glove Box) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Cowl Wire and Instrument Panel Wire (Right Kick Panel) 2001 AVALON (EWD431U) 197 VSC (w/ TRACTION CONTROL) : GROUND POINTS Code ED EE IG II IJ See Page 54 Ground Points Location Front Side of Left Fender 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Cowl Side Panel LH Right Kick Panel Cowl Side Panel RH : SPLICE POINTS Code I1 I4 I7 I9 See Page 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Floor Wire 62 (Floor Shift) 62 (Floor Shift) 58 (Column Shift) I9 I15 58 (Column Shift) 58 (Column Shift) Code Cowl Wire I20 I24 See Page 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 2001 AVALON (EWD431U) 198 Wire Harness with Splice Points 62 (Floor Shift) Cowl Wire MEMO 2001 AVALON (EWD431U) 199 ABS (w/o TRACTION CONTROL) FROM POWER SOURCE SYSTEM (SEE PAGE 72) D1 DATA LINK CONNECTOR 1 1 15A STOP 10A ECU- IG NO. 2 60A ABS TS 5 2 1H 13 1B LG- R II2 2 3C 12 4A 6 4A 11 3D 3 4B 6 4H LG- R 22 LG- B Y- R L L S4 STOP LIGHT SW II2 LG- B Y- R R 11 2 11 LG- R 11 1D TC 16 LG- B 2 1 Y- R R- L LG- R 3 1D 18 5 1B 17 BAT 15 +B IE1 LG- B 13 Y- R 11 TS IG1 A7 ABS ACTUATOR AND ECU STP 14 RL+ RL- RR+ RR- 9 8 2 1 (SHIELDED) Y E6 (SHIELDED) 6 IE1 IE1 10 IE1 11 IE1 22 ID1 21 ID1 10 IK1 12 IK1 BR Y G (SHIELDED) (SHIELDED) (SHIELDED) I4 16 4F 9 11 ID1 11 IK1 R- L A BR A (SHIELDED) BR A BR Y G V LG BR A 1 A (SHIELDED) B2 2 A29 ABS SPEED SENSOR REAR LH 2001 AVALON (EWD431U) 200 BR IE1 BR 7 V (SHIELDED) G- W IE1 16 4D 3 3F G V LG (SHIELDED) IE1 8 3 3C (SHIELDED) LG 14 (SHIELDED) R- L G- W E6 1 2 A30 ABS SPEED SENSOR REAR RH EE J1 JUNCTION CONNECTOR D2 DATA LINK CONNECTOR 2 R- L ABS 14 LG- R TC 4 13 3A 4 3B LG- R 4 3G 5 1I LG- R R- L 7 1H LG- R L- O L- O 12 10 Y- R TC Y- R SP1 A7 ABS ACTUATOR AND ECU GND2 GND1 16 19 (SHIELDED) PN EBDW WA PKB 23 21 20 13 Y- B FL+ 7 B FL6 R- Y FR+ 5 L- W FR4 (SHIELDED) E6 (SHIELDED) L B- W E6 W- B B (SHIELDED) R- Y 3 IE1 2 IE1 BR B- R BR BR W- B Y- B 1 IE1 17 IE1 L- W 10 2F 2 A9 ABS SPEED SENSOR FRONT RH 1 4 2D W- B W- B 1 4 2F W- B B- W L BR (SHIELDED) BR 2 A8 ABS SPEED SENSOR FRONT LH EE J1 JUNCTION CONNECTOR B B W- B ED 2001 AVALON (EWD431U) 201 ABS (w/o TRACTION CONTROL) M3 A , M6 D 15 4H BRAKE 3 D 7 3C 15 3C 20 3D 15 3D IL1 20 3C R- B 18 IE1 7 IC1 GR 15 4B A21 ACTIVE LIGHT RELAY GR R- L 2 5 4 3 B R- Y Y- G W- B R- W 14 3B 5 IE1 15 IE1 16 15 3H 15 3B IE1 20 IE1 Y- B N 3 18 3A G- W 18 3H G- W R- W 1 B1 BRAKE FLUID LEVEL WARNING SW 1 P3 PARKING BRAKE SW 1 II2 19 II2 W- B Y- G 8 1H 18 3B R 2 3 P G- W D5 DIODE (A/T INDICATOR LIGHT 1) 1 PKB R 15 3A Y- G B4 BODY ECU 15 9 G- W 5 3B 12 1I G- W 2 W- B W- B W- B ED 2001 AVALON (EWD431U) 202 2 P R- W 5 3A R- Y L- W II1 7 B 11 4C R- L 8 P1 PARK/NEUTRAL POSITION SW 7 R- W 6 Y- B 20 (* 2) 2 4D R 1 2 1 3 (*2) R- L Y- R (*1) L- O D6 DIODE (A/T INDICATOR LIGHT 2) L- O R- L R- L (* 2) 15 4A R- L 4 4D (* 2) L- O 6 8 1D GR R- L 13 4F 7 A R- W R- B 5 D 5A ECU- ACC 1 1C L- O CPU ABS 10 1D R- B 10A GAUGE NO. 2 MULTI DISPLAY 4 D (* 2) R- B 10A GAUGE NO. 1 FROM POWER SOURCE SYSTEM (SEE PAGE 72) * 1 : FLOOR SHIFT * 2 : COLUMN SHIFT R- L FROM POWER SOURCE SYSTEM (SEE PAGE 72) SYSTEM OUTLINE ABS is a brake system designed for the purpose to improve the operating ability securing the stability of the vehicle by preventing the locking-up of the vehicle controlling the wheel cylinder pressure of all the four wheels at the time of sudden braking. 1. INPUT SIGNALS (1) Speed sensor signal The speed of the wheels is detected and input to TERMINALS FL+, FR+, RL+, and RR+ of the ABS actuator and ECU. (2) Stop light SW signal A signal is input to TERMINAL STP of the ABS actuator and ECU when brake pedal is depressed. 2. SYSTEM OPERATION When the wheels are to be locked-up, the solenoid inside the actuator will be controlled by the signal from the ABS actuator and ECU and the brake fluid in the wheel cylinder will flow through the reservoir and reduce the hydraulic pressure. While the ABS is in operation, as the ABS actuator and ECU always outputs the operation signal to the pump inside the actuator, brake fluid stored inside the reservoir will be sucked up by the pump inside the actuator and returned to the master cylinder. When the hydraulic pressure of the wheel cylinder is decompressed or increased until the necessary hydraulic pressure, the solenoid inside the actuator is controlled by the control signal from the ABS actuator and ECU and as a result, hydraulic pressure of the wheel cylinder will be closed at both routes of the master cylinder and reservoir sides and the hydraulic pressure of the wheel cylinder will become to be in the holding condition. If the increase of hydraulic pressure volume of the wheel cylinder becomes necessary, with the control signal from the ABS actuator and ECU, the solenoid inside the actuator will be controlled and become the same condition as usual and the brake fluid of the master cylinder will be sent to the wheel cylinder and will increase the hydraulic pressure of the wheel cylinder. At this time, in the case that the brake fluid stays left in the reservoir, it will be suctioned up by the pump inside the actuator and will be sent to the wheel cylinder. Also, increasing speed of the hydraulic pressure is controlled by outputting the increasing and the said holding one after another. SERVICE HINTS A8, A9 ABS SPEED SENSOR FRONT LH, RH 1-2 : 1.5 - 1.7 kΩ (20°C, 68°F) A29, A30 ABS SPEED SENSOR REAR LH, RH 1-2 : 1.5 - 1.7 kΩ (20°C, 68°F) A7 ABS ACTUATOR AND ECU 17, 18-GROUND : Always approx. 12 volts 14-GROUND : Approx. 12 volts with the stop light SW on 15-GROUND : Approx. 12 volts with the ignition SW at ON position 16, 19-GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page A7 44 B4 48 (Floor Shift) A8 44 D1 44 A9 44 A21 46 (Column Shift) 48 (Floor Shift) A29 50 A30 50 B1 44 B4 46 (Column Shift) D2 D5 D6 J1 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 47 (Column Shift) 49 (Floor Shift) Code M3 A M6 D P1 P3 S4 See Page 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 45 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) : RELAY BLOCKS Code 5 See Page 25 Relay Blocks (Relay Block Location) Engine Room R/B No.5 (Engine Compartment Left) 2001 AVALON (EWD431U) 203 ABS (w/o TRACTION CONTROL) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1C 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 1H 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1I 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 35 Cowl Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 1D 2D 2F 3A 3B 3C 3D 3F 3G 3H 4A 4B 4C 4D 4F 4H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC1 ID1 IE1 II1 II2 IK1 IL1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Behind the Driver Side J/B) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Engine Wire and Cowl Wire (Behind the Glove Box) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Cowl Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code ED EE See Page 54 Ground Points Location Front Side of Left Fender : SPLICE POINTS Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points E6 54 Engine Room Main Wire I4 62 (Floor Shift) Cowl Wire I4 58 (Column Shift) Cowl Wire B2 64 Floor No.1 Wire 2001 AVALON (EWD431U) 204 SRS NOTICE: When inspecting or repairing the SRS, perform the operation in accordance with the following precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model year.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.
Work must be started after 90 seconds from when the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back-up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.
Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, airbag sensor assembly, front airbag sensor assembly or side airbag sensor assembly directly to hot air or flames.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, airbag sensor assembly, front airbag sensor assembly and side airbag sensor assembly should be inspected.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, airbag sensor assembly, front airbag sensor assembly or side airbag sensor assembly in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, airbag sensor assembly, front airbag sensor assembly or side airbag sensor assembly has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones.
Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.
After work on the SRS is completed, perform the SRS warning light check.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section of the Repair Manual. 2001 AVALON (EWD431U) 205 SRS FROM POWER SOURCE SYSTEM (SEE PAGE 72) ACC AM1 10A SRS- ACC IG1 10 1F IG2 6 GR 7 AM2 B- O ST2 W- R I15 IGNITION SW B4 BODY ECU 7 1C 4 S5 SIDE AIRBAG SENSOR LH IF1 W- R GSW 1 1F L- W LG- B GR- L 4 P- L 3 L 2 GR 1 B- O 7 2C 19 5 B 6 B 4 B 7 A 9 A 10 A 12 A IG2 ACC GSW VUPL SSL+ SSL- ESL 10A AM2 C5 A , C6 B , C7 C CENTER AIRBAG SENSOR ASSEMBLY E2 D- P+ P- 28 B 14 B 13 B 10 B 11 B 5 A 6 A 2 C 1 C W- B Y- B Y Y- R Y- G Y- R Y- G Y- R Y- G 1 B E1 27 B W- B B 2 2G D+ FL+ FL- FR+ FR- 3 1F 4 1F 1 2 1 2 1 2 1 2 F6 A , F7 B FUSIBLE LINK BLOCK 1 A B 3 1B SPIRAL CABLE W- B FL MAIN 3. 0W A27 AIRBAG SQUIB (STEERING WHEEL PAD) BATTERY A26 AIRBAG SQUIB (FRONT PASSENGER AIRBAG ASSEMBLY) IG 2001 AVALON (EWD431U) 206 S7 SIDE AIRBAG SQUIB LH S8 SIDE AIRBAG SQUIB RH FROM POWER SOURCE SYSTEM (SEE PAGE 72) W- B D1 DATA LINK CONNECTOR 1 3 E1 D2 DATA LINK CONNECTOR 2 1 2B B- Y M7 SRS WARNING LIGHT [MULTI DISPLAY] IJ1 5 II2 22 II2 13 3A LG- R 6 B- Y 5 B- Y LG- B TC 4 LG- R 4 TC 11 LG- R LG- B AB 5 12 1A 10 1I 6 4A 4 3G 3 5 1I LG- R 2 4 3B LG- R S6 SIDE AIRBAG SENSOR RH 1 4 LG GR B- Y P- B 6 1F L- Y 6 4H P 5 1F 12 C 10 C 9 C 7 C 3 B 19 B VUPR SSR+ W- B 5A SRS WRN SSR- ESR TC LA C5 A , C6 B , C7 C CENTER AIRBAG SENSOR ASSEMBLY W SIL 12 B Y PR6 C Y- B PR+ 5 C Y PL1 A Y- B PL+ 2 A BR- W - SR 20 B B- W +SR 9 B BR - SL 26 B W- R +SL 15 B C 1 IF2 2 IF2 J5 JUNCTION CONNECTOR BR 2 1 W W- R C 7 1 SIL 1 A12 AIRBAG SENSOR FRONT LH A13 AIRBAG SENSOR FRONT RH 2 P16 PRETENSIONER LH 1 2 D3 DATA LINK CONNECTOR 3 W- B 2 P17 PRETENSIONER RH EB 2001 AVALON (EWD431U) 207 SRS SYSTEM OUTLINE The SRS is a driver and front passenger protection device which has a supplemental role to the seat belts. When the ignition SW is turned to ACC or ON, current from the SRS-ACC fuse flows to TERMINAL (A) 6 of the center airbag sensor assembly. If an accident occurs while driving, when the frontal impact exceeds a set level, current from the SRS-ACC fuse flows to TERMINALS (A) 2, (B) 10, (B) 14 and (C) 5 of the center airbag sensor assembly to TERMINAL 1 of the airbag squibs and the pretensioners to TERMINAL 2 to TERMINALS (A) 1, (B) 11, (B) 13 and (C) 6 of the center airbag sensor assembly to TERMINAL (B) 27, (B) 28 or BODY GROUND to GROUND, so that current flows to the airbag squibs and the pretensioners and causes them to operate. When the side impact also exceeds a set level, current from the SRS-ACC fuse flows to TERMINALS (A) 2, (A) 5, (C) 2 and (C) 5 of the center airbag sensor assembly to TERMINAL 1 of the side airbag squibs and the pretensioners to TERMINAL 2 to TERMINALS (A)1, (A) 6, (C) 1, and (C) 6 of the center airbag sensor assembly to TERMINAL (B) 27, (B) 28 or BODY GROUND to GROUND, causing side airbag squibs and the pretensioners to operate. The airbag stored inside the steering wheel pad is instantaneously expanded to soften the shock to the driver. The airbag stored inside the passenger’s instrument panel is instantaneously expanded to soften the shock to the front passenger. Side airbags are instantaneously expanded to soften the shock of side to the driver and front passenger. The pretensioners make sure of the seat belt restrainability. : PARTS LOCATION Code See Page A12 44 A13 44 46 (Column Shift) A26 Code B C7 C 48 (Floor Shift) D1 46 (Column Shift) A27 46 (Column Shift) C5 A C6 B 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) D3 48 (Floor Shift) 48 (Floor Shift) 44 D2 48 (Floor Shift) B4 See Page C6 I15 J5 M7 51 51 48 (Floor Shift) S5 51 F6 A 44 S6 51 48 (Floor Shift) F7 B 44 S7 51 47 (Column Shift) S8 51 46 (Column Shift) I15 See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 2B 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 2C 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 2G 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 3G 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 4A 38 Cowl Wire and J/B No.4 (Right Kick Panel) 4H 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) 1I 2001 AVALON (EWD431U) 208 49 (Floor Shift) P17 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 3B 47 (Column Shift) 46 (Column Shift) 1B 3A 49 (Floor Shift) P16 26 1F 47 (Column Shift) 46 (Column Shift) Code 1C See Page 49 (Floor Shift) 48 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, 1A Code : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IF1 IF2 II2 IJ1 See Page Joining Wire Harness and Wire Harness (Connector Location) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Engine Wire and Cowl Wire (Behind the Glove Box) Engine Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code EB IG See Page 54 56 (Column Shift) 60 (Floor Shift) Ground Points Location Surge Tank RH Cowl Side Panel LH 2001 AVALON (EWD431U) 209 CRUISE CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A ECU- IG NO. 2 10A GAUGE NO. 2 5A ECU- ACC 8 1D P1 PARK/NEUTRAL POSITION SW 15 3C 10 II1 Y- R R- L GR 2 3C 4 1 1C (* 4) Y- R 13 1B TO SPEEDOMETER [MULTI DISPLAY] Y- R D 7 3C 2 15 3D 20 3D 20 3C 6 4D 2 Y- R R- L 9 12 D CCS 10 GND C15 CRUISE CONTROL ECU 3 ECT 16 6 5 IDL 13 21 II2 RES/ACC COAST/SET ECC A C12 CRUISE CONTROL SW [COMB. SW] J5 JUNCTION CONNECTOR A W- B W- B 24 25 7 3A W- B 20 3A Y G- Y 20 3B MAIN GR CCS IG 2001 AVALON (EWD431U) TO ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID CAN OD 14 W- B W W- L 1 SPD G- Y CAN CANCEL (*2) 3 B 10 3C CCS 26 (*4) 210 D V- W 11 4C 12 Y- R D6 DIODE (A/T INDICATOR LIGHT 2) (* 4) GR 3 (* 1) Y- R (*3) 1 4 19 4C (*1) (* 4) R- L R- L 2 4D Y- R II1 1 3F (* 4) GR 20 T5 TRANSLATE ECU 2 3D V- W R- L 6 4C OD1 IDLO E7 ENGINE CONTROL MODULE FROM POWER SOURCE SYSTEM (SEE PAGE 72) * 1 : W/ TRACTION CONTROL * 2 : W/O TRACTION CONTROL * 3 : FLOOR SHIFT * 4 : COLUMN SHIFT 10A GAUGE NO. 1 15A STOP D2 DATA LINK CONNECTOR 2 D1 DATA LINK CONNECTOR 1 11 1D R- B 10 1D LG- R TC 4 GR- R A/D 10 17 4B 13 3A TC 11 22 R LG- R 4 4D II2 M6 D , M7 E 4 D CRUISE CONTROL INDICATOR LIGHT [MULTI DISPLAY] R- B LG- R 13 4F 6 4A G- W 17 4H 17 4A 13 3B 4 3G 6 4H 4 E LG- R GR- R GR- R LG- R 4 5 3 3D 3 3C TC STP G- W PI 2 5 1B 15 7 R MC P MO L C15 CRUISE CONTROL ECU 8 3 1D 15 II1 14 II1 R- B 1 2 MO 3 3 MC G- W G- B P P- B 1 L 13 II1 S4 STOP LIGHT SW M 4 2 GND C4 CRUISE CONTROL ACTUATOR P- B R W- B 4 II1 W- B 9 A J9 JUNCTION CONNECTOR IJ 2001 AVALON (EWD431U) 211 CRUISE CONTROL SYSTEM OUTLINE The cruise control system allows to travel at a constant speed, by the operation of the switch, without having to depress the accelerator pedal. In this system, the engine throttle valve opening angle is adjusted automatically to control the vehicle at a constant speed. 1. SET CONTROL When the SET/COAST SW is operated while traveling with the main SW ON, the speed when the SW is operated to OFF (SW released) is memorized, and the vehicle speed is controlled at that speed. 2. COAST CONTROL When the SET/COAST SW is operated to ON, the motor in the actuator rotates the throttle valve until it is closed fully to decrease the vehicle speed, and the speed when the SW is operated to OFF is memorized, and the vehicle speed is controlled at that speed. Furthermore, every time the SET/COAST SW is operated momentarily (Approximately 0.5 sec.) to ON, the memorized vehicle speed is decreased by approximately 1.5km/h. 3. ACCEL CONTROL When the RESUME/ACCEL SW is operated to ON, the motor in the actuator rotates the throttle valve to open direction to increase the vehicle speed, and the speed when the SW is operated to OFF is memorized, and the vehicle speed is controlled at that speed. Furthermore, every time the RESUME/ACCEL SW is operated momentarily (Approximately 0.5 sec.) to ON, the memorized vehicle speed is increased by approximately 1.5km/h. 4. MANUAL CANCEL MECHANISM If any of the following signals are input during cruise control traveling, the magnetic clutch of the actuator is turned off, and the current to the motor flows in the direction to close the throttle valve, and cancel the cruise control. (1) Stop lamp SW is ON (Brake pedal is depressed) (2) The CANCEL SW of the control SW is ON (3) MAIN SW is OFF 5. RESUME CONTROL After canceling the cruise control (Except when the main SW is OFF) if the vehicle speed is above the minimum speed limit (Approximately 40km/h, 25mph), operating the RESUME/ACCEL SW from OFF to ON will cause the system to accelerate and resume to the vehicle speed before manual cancellation. 6. OVERDRIVE FUNCTION The overdrive may be cut on an uphill grade, while traveling with the cruise control. After the overdrive is cut, if the vehicle speed reaches the overdrive resume speed (Set speed minus 2km/h), and if the system determines that the uphill grade has finished, the overdrive will resume after the overdrive timer operation. 7. AUTO CANCEL OPERATION If any of the following conditions are detected, the set speed is erased and the control is canceled. (1) The motor does not operate (2) Short in the magnetic clutch (3) Disconnection in the magnetic clutch (Includes blown STOP fuse) (4) No vehicle speed signal input (5) The actual vehicle speed becomes slower than the minimum speed limit 2001 AVALON (EWD431U) 212 SERVICE HINTS C12 CRUISE CONTROL SW [COMB. SW] 3-4 : Continuity with the CANCEL SW on 5-4 : Approx. 0 Ω with the CRUISE SW on Approx. 240 Ω with the RES/ACC SW on Approx. 630 Ω with the COAST/SET SW on C15 CRUISE CONTROL ECU 9-GROUND : Approx. 12 volts with the ignition SW at ON position 1-GROUND : Approx. 12 volts with the CANCEL SW on 10-GROUND : Approx. 0 Ω with the CRUISE SW on Approx. 240 Ω with the RES/ACC SW on Approx. 630 Ω with the COAST/SET SW on 16-GROUND : Always continuity C4 CRUISE CONTROL ACTUATOR 3-4 : Approx. 38.5 Ω : PARTS LOCATION Code C4 C12 C15 D1 D2 See Page Code 44 46 (Column Shift) 46 (Column Shift) 46 (Column Shift) E7 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 47 (Column Shift) J5 48 (Floor Shift) 44 49 (Floor Shift) 47 (Column Shift) J9 46 (Column Shift) 48 (Floor Shift) See Page D6 M6 49 (Floor Shift) D 47 (Column Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Code M6 D M7 E P1 S4 T5 See Page 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 45 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) Junction Block and Wire Harness (Connector Location) 1B 1C 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 1D 3A 3B 3C 3D 3F 3G 4A 4B 4C 4D 4F 4H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code II1 II2 See Page Joining Wire Harness and Wire Harness (Connector Location) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Engine Wire and Cowl Wire (Behind the Glove Box) 62 (Floor Shift) 2001 AVALON (EWD431U) 213 CRUISE CONTROL : GROUND POINTS Code IG IJ See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Cowl Side Panel LH Cowl Side Panel RH 2001 AVALON (EWD431U) 214 MEMO 2001 AVALON (EWD431U) 215 ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR FROM POWER SOURCE SYSTEM (SEE PAGE 72) ACC IG1 15A STOP IG2 6 11 1D R ST2 8 1 5 2 2 S4 STOP LIGHT SW EFI RELAY B- O W- R I15 IGNITION SW 3 IF1 B- W W- R 12 1B 4 2F 2 2F 3 3F 1 G- W 4 7. 5A EFI NO. 2 7 1C 3 3C 4 2B G- W 7 AM2 15A EFI NO. 1 G- W AM1 3 1D 16 4F 5 1B 16 4C 10 2B B- R L- O B- W 7 2C W- B 6 2 E 16 E 8 E 1 E 15 E IGSW B NSW +B MREL S2 S1 SL 1 C 7 A 15 C 19 A 20 A P- L ENGINE CONTROL MODULE SLN- SLN+ NC223 A G- Y II2 FL MAIN 3. 0W 13 BATTERY IDL 14 OD 6 3 2 4 1 S2 S1 SL SLN- SLN+ 6 ECT W- B C15 CRUISE CONTROL ECU ED 1 G G- Y 21 E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 2001 AVALON (EWD431U) G R 2 O1 O/D DIRECT CLUTCH SPEED SENSOR GR B B Y B J8 JUNCTION CONNECTOR P B G- Y 1 A 216 NC2+ 24 A G- Y FUSIBLE LINK BLOCK F6 A , F7 B OD1 24 D STP Y IDLO 25 D BATT G- W E4 A , E5 B , E6 C , E7 D , E8 E 1 B II1 G- W 8 B- R II1 L- O 17 B- W 20 D 2 2G IF1 B- O 10A AM2 FROM POWER SOURCE SYSTEM (SEE PAGE 72) R- L * 1 : FLOOR SHIFT * 2 : COLUMN SHIFT 10A GAUGE NO. 2 5A ECU- ACC 20 1 1C II1 R- L 8 1D GR (* 2) 2 4D T3 THROTTLE POSITION SENSOR 15 3C 11 4C 1 GR 3 GR (* 2) (* 2) (* 2) W W E2 R- L W TO SPEEDOMETER [MULTI DISPLAY] 2 E2 ENGINE COOLANT TEMP. SENSOR 20 3D 2 1 E2 VC VTA 1 3 20 3C 7 3C R- L 2 Y G- Y V- W G- Y W LG L- R (* 1) 15 3D D6 DIODE (A/T INDICATOR LIGHT 2) R- L GR (*2) R- L (* 2) R- B 2 B 23 B VC 18 B VTA1 14 B E2 22 D THW SPD E4 A , E5 B , E6 C , E7 D , E8 E EO1 21 A EO2 31 A E1 EO3 17 B 30 A EO4 1 B ENGINE CONTROL MODULE EO5 8 B ODMS 12 C ODLP 9 E R 2 L 8 C 14 C 13 C 6 II2 7 II2 18 II2 G- O G- O W- B W- B W- B BR W- B W- B Y G- Y W- B A A G- O A W- B G- O BR BR J7 JUNCTION CONNECTOR W- B EB R- B I22 W- B I23 EC 2001 AVALON (EWD431U) 217 ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR R- L R- L P1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] FROM POWER SOURCE SYSTEM (SEE PAGE 72) * 1 : FLOOR SHIFT * 2 : COLUMN SHIFT 2 C DL NL RL PL 3 10 9 8 7 R- B R Y- R G- W 2L 4 G- Y LL Y 10A ECU- IG NO. 2 13 1B II2 2 II2 4 II1 19 II2 1 II1 3 II2 R- B G- W 18 3C 18 3A 18 3F 18 3G Y- R Y G- Y R Y- R 1 15 IC1 17 3B 17 3G Y 17 3A 16 3D 6 4C 16 3F 6 4F 18 3D 1 Y G- W R- B R- B R Y- R G- Y P G- Y R- B Y- G Y B4 BODY ECU 15 6 O/D OFF 5 L 2 4 D 3 N G- O W- B 16 3G 7 3G W- B 7 4A O3 A , 8 II2 W- B 4 A (* 1) 1 B (* 2) 7 4B A B O/D MAIN SW A A J9 JUNCTION CONNECTOR 2 A (* 1) 3 B (* 2) G- O J5 JUNCTION CONNECTOR IJ W- B G- O 7 3A W- B 16 3A G- O IG 2001 AVALON (EWD431U) 2 R 1 P C9 COMBINATION METER 21 W- B 7 218 18 3H G- W 2 3F 16 3C G- Y 2 3C SYSTEM OUTLINE Previous automatic transaxle have selected each gear shift using the mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock-up hydraulic pressure. The electronically controlled transmission, however, electrically controls the line pressure and lock-up pressure etc., through the solenoid valve. Engine control module control of the solenoid valve based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at theat time. 1. GEAR SHIFT OPERATION During driving, the engine control module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the engine coolant temp. sensor to TERMINAL THW of the engine control module, and also the input signals to TERMINAL NC2+ of the engine control module from the vehicle speed sensor devoted to the electronically controlled transmission. Current is then output to the electronically controlled transmission solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 3 of the electronically controlled transmission solenoid to GROUND, and continuity to the No.1 solenoid causes the shift. For the 2nd speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 3 of the electronically controlled transmission solenoid to GROUND, and from TERMINAL S2 of the engine control module to TERMINAL 6 of the electronically controlled transmission solenoid to GROUND, and continuity to solenoids No.1 and No.2 cause the shift. For the 3rd speed, there is no continuity to No.1 solenoid, only to No.2, causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 solenoid. 2. LOCK -UP OPERATION When the engine control module judges from each signal that lock-up operation conditions have been met, current flows from TERMINAL SL of the engine control module to TERMINAL 2 of the electronically controlled transmission solenoid to GROUND, causing continuity to the lock-up solenoid and causing lock-up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock-up condition, a signal is input to TERMINAL STP of the engine control module, the engine control module operates and continuity to the lock-up solenoid is cut. 4. OVERDRIVE CIRCUIT ∗ O/D main SW on When the O/D main SW is turned on (SW point is open), a signal is input to TERMINAL ODMS of the engine control module and engine control module operation causes gear shift when the conditions for overdrive are met. ∗ O/D main SW off When the O/D main SW is turned off (SW point is closed), a signal is input into TERMINAL ODMS of the engine control module, and turns on the O/D off indicator light. This activates the ECU, and the transmission system is controlled not to shift to overdrive. SERVICE HINTS E4 (A), E5 (B), E6 (C), E7 (D), E8 (E) ENGINE CONTROL MODULE S1,S2-E1 : 9.0- 14.0 volts with the electronically controlled transmission solenoid on 0- 1.5 volts with the electronically controlled transmission solenoid off L-E1 : 7.5- 14.0 volts with the ignition SW on and shift lever at L position 2-E1 : 7.5- 14.0 volts with the ignition SW on and shift lever at 2 position R-E1 : 7.5- 14.0 volts with the ignition SW on and shift lever at R position STP-E1 : 9.0- 14.0 volts with the ignition SW on and brake pedal depressed THW-E2 : 0.2- 1.0 volts with the engine idling and the engine coolant temp. 80°C (176°F) VTA1-E2 : 0.3- 0.8 volts with the ignition SW on and throttle valve fully closed 3.2- 4.9 volts with the ignition SW on and throttle valve fully open VC-E2 : 4.5- 5.5 volts with the ignition SW at ON position OD1-E1 : 4.5- 5.5 volts with the ignition SW at ON position OD2-E1 : 9.0- 14.0 volts with the ignition SW on and O/D main SW off 0- 3.0 volts with the ignition SW on and O/D main SW on +B-E1 : 9.0- 14.0 volts with the ignition SW at ON position E1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 2, 3, 6-GROUND : Each 11- 15 Ω O3 (A), (B) O/D MAIN SW (A) 2-(A) 4 : Closed with the O/D main SW off, open with the O/D main SW on (Floor shift) (B) 3-(B) 1 : Closed with the O/D main SW off, open with the O/D main SW on (Column shift) 2001 AVALON (EWD431U) 219 ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR : PARTS LOCATION Code See Page 46 (Column Shift) B4 48 (Floor Shift) 46 (Column Shift) C9 48 (Floor Shift) Code See Page E6 C E7 D 46 (Column Shift) 48 (Floor Shift) F6 A 44 D6 46 (Column Shift) F7 B 44 E1 44 E2 44 E4 A E5 B E6 C 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) I15 J5 J7 J8 See Page B 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) P1 S4 T3 49 (Floor Shift) 47 (Column Shift) Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 30 Engine Room Main Wire and Engine Room J/B (Engine Compartment Left) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 35 Cowl Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) 1D 2B 2C 2F 2G 3A 3B 3C 3D 3F 3G 3H 4A 4B 4C 4D 4F : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC1 IF1 II1 II2 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Engine Wire and Cowl Wire (Behind the Glove Box) 62 (Floor Shift) 2001 AVALON (EWD431U) 220 45 O3 1B 1C 49 (Floor Shift) A ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 47 (Column Shift) O1 48 (Floor Shift) See Page 49 (Floor Shift) J9 48 (Floor Shift) E C15 J8 46 (Column Shift) E8 46 (Column Shift) Code 48 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 45 47 (Column Shift) 49 (Floor Shift) 45 : GROUND POINTS Code See Page Ground Points Location EB 54 Surge Tank RH EC 54 Rear Side of Surge Tank ED 54 Front Side of Left Fender IG IJ 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Cowl Side Panel LH Cowl Side Panel RH : SPLICE POINTS Code E2 I22 See Page Wire Harness with Splice Points 54 58 (Column Shift) Engine g Wire Code I23 See Page 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Engine Wire 62 (Floor Shift) 2001 AVALON (EWD431U) 221 SHIFT LOCK FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A GAUGE NO. 1 5A ECU- ACC 15A STOP 10 1D 11 1D R 8 1D * 1 : FLOOR SHIFT * 2 : COLUMN SHIFT GR 2 R- B S4 STOP LIGHT SW 15 3C R- L 1 2 4D 4 4D 3 3C 3 1D 2 4C 4 4C 12 3C 5 1B GR R- B G- W R- L GR 15 3D 1 A 1 B 5 A 3 B ACC R- L 2 A (* 1) 6 B (* 2) IG STP P1 P P2 S3 A , B SHIFT LOCK ECU SHIFT LOCK CONTROL SW SLS+ SLSKLS+ E 3 A (* 1) 5 B (* 2) W- B L- B 4 A 4 B 2 K3 KEY INTERLOCK SOLENOID 7 4D 7 4F 22 3D W- B 22 3C W- B W- B 1 IG IF 2001 AVALON (EWD431U) 222 SHIFT LOCK SOLENOID SYSTEM OUTLINE When the ignition SW is at ACC position, the current flows from ECU-ACC fuse to shift lock ECU TERMINAL ACC, and at ON position, the current flows from GAUGE NO.1 fuse to shift lock ECU TERMINAL 3. 1. SHIFT LOCK MECHANISM When the signals that the brake pedal is depressed (Stop light SW ON) and the shift lever is placed in P position is input into the shift lock ECU while the ignition SW is ON, the shift lock ECU is activated and the current flows from shift lock ECU TERMINAL IG to shift lock ECU TERMINAL SLS+ to shift lock solenoid to shift lock ECU TERMINAL SLS- to shift lock ECU TERMINAL E to GROUND. As a result, the shift lock solenoid is turned on and (Plate stopper is released) the shift lever can be placed in a position other than P position. 2. KEY INTERLOCK MECHANISM When the shift lever is placed to P position with the ignition SW ON or at ACC position, the current from shift lock ECU TERMINAL KLS+ to key interlock solenoid is cut off. As a result, the key interlock solenoid is turned off (The lock lever is released from lock position) and the ignition key can be placed to LOCK position from ACC. SERVICE HINTS S3 (A) SHIFT LOCK ECU (FLOOR SHIFT) (A) 1-GROUND : Approx. 12 volts with the ignition SW at ACC or ON position (A) 5-GROUND : Approx. 12 volts with the ignition SW at ON position (A) 3-GROUND : Always continuity (A) 2-GROUND : Approx. 12 volts with the brake pedal depressed S3 (B) SHIFT LOCK ECU (COLUMN SHIFT) (B) 1-GROUND : Approx. 12 volts with the ignition SW at ACC or ON position (B) 3-GROUND : Approx. 12 volts with the ignition SW at ON position (B) 5-GROUND : Always continuity (B) 6-GROUND : Approx. 12 volts with the brake pedal depressed S4 STOP LIGHT SW 2-1 : Closed with the brake pedal depressed : PARTS LOCATION Code See Page K3 S3 Code 47 (Column Shift) 49 (Floor Shift) A See Page A S3 47 (Column Shift) B 49 (Floor Shift) 47 (Column Shift) Code S4 See Page 47 (Column Shift) 49 (Floor Shift) 49 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1D 3C 3D 4C 4D 4F See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) : GROUND POINTS Code IF IG See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Left Kick Panel Cowl Side Panel LH 2001 AVALON (EWD431U) 223 POWER SEAT (w/ DRIVING POSITION MEMORY) FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 10A GAUGE NO. 1 L- O L- O 30A PWR SEAT 7. 5A ECU- B (* 1) 2 9 1B 8 1I W- G L- O 2 1D B4 BODY ECU L- O R- B MPX2 5 3C L- O I6 9 14 3E L- O G- W 7 ID2 S14 SEAT MEMORY SW L- O 8 BC1 L- O 7 B 9 B 21 B 20 B 13 B 25 B 14 B 8 A SWE MMRY SW1 SW2 IG MPX1 SYSB L- O B12 G- W 5 BC1 W- G 7 BC1 R- B 4 Y 2 3 G- W 1 1 G- Y MMRY 2 1 BC1 W- B E 10 ID1 G- W R- B W- G 8 ID1 (*1) +B P20 A , P21 B POWER SEAT ECU SSRR SSRS 16 B PVCC 3 B 5 B R A 2 L- R 9 IA1 BR 9 BC1 BR BR J3 JUNCTION CONNECTOR A BR BR 2 B B BR 2001 AVALON (EWD431U) R 3 2 B J14 JUNCTION CONNECTOR IH 1 B B A 224 3 L R 1 BR 2 M A P31 POWER SEAT POSITION SENSOR (DRIVER’ S SEAT RECLINING CONTROL) 2 M 1 P23 POWER SEAT MOTOR (DRIVER’ S SEAT REAR VERTICAL CONTROL) 1 M 1 P25 POWER SEAT MOTOR (DRIVER’ S SEAT SLIDE CONTROL) M 1 P22 POWER SEAT MOTOR (DRIVER’ S SEAT FRONT VERTICAL CONTROL) 2 P24 POWER SEAT MOTOR (DRIVER’ S SEAT RECLINING CONTROL) BR A J14 JUNCTION CONNECTOR A R P32 POWER SEAT POSITION SENSOR (DRIVER’ S SEAT SLIDE CONTROL) SGND 19 B L R LFT5 A L- Y LFT+ 6 A L SLD+ 4 A L- B SLD3 A L- R FRV+ 10 A L- W FRV9 A R- W RCL+ 2 A R- B RCL1 A BR W- B BR R 1 3 2 R- Y 6 B SSFV 17 B SSRL 3 1 SLDF 22 B LUP 11 B LDWN 1 POWER SEAT ECU P20 A , P21 B GND 2 B12 B12 C C A W- B (*1) L11 LUMBAR SUPPORT CONTROL SW (DRIVER’ S SEAT) R- W 8 B 4 2 M 1 (* 1) B 23 B L10 LUMBAR SUPPORT CONTROL MOTOR (DRIVER’ S SEAT) B- R 24 B R- W B- Y 10 B (* 1) L- O 1 W- B R- B 12 B 8 (* 1) 4 B SLDR 7 R- L W- B FUP 9 W- B FDWN 6 W- B G- B 10 W- B G 5 P30 POWER SEAT POSITION SENSOR (DRIVER’ S SEAT REAR VERTICAL CONTROL) L- W R RCLF R L- B RCLR 3 P29 POWER SEAT POSITION SENSOR (DRIVER’ S SEAT FRONT VERTICAL CONTROL) L- B 2 BR BR * 1 : FLOOR SHIFT L- O L- O L- O (*1) P18 POWER SEAT CONTROL SW (DRIVER’ S SEAT) 7 A 3 J14 JUNCTION CONNECTOR C 2 11 BC1 B12 J11 JUNCTION CONNECTOR BK 2001 AVALON (EWD431U) 225 226 W- B 1 M 2 2 M 1 P26 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT REAR VERTICAL CONTROL) 1 M 2 BM P27 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT RECLINING CONTROL) RUP RDWN RCLF RCLR E 6 8 7 3 2 4 L- Y R R- W R- B W- B SLDR 9 L- B 1 P28 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT SLIDE CONTROL) SLDF L L- O L- O POWER SEAT (w/ DRIVING POSITION MEMORY) L- O 2 IK1 1 BD1 P19 POWER SEAT CONTROL SW (FRONT PASSENGER’ S SEAT) 11 BD1 W- B A A BN 2001 AVALON (EWD431U) J10 JUNCTION CONNECTOR SERVICE HINTS P20 (A), P21 (B) POWER SEAT ECU (B)13-GROUND : Approx. 12 volts with the ignition SW at ON position (B) 6-GROUND : Approx. 12 volts with the driver’s seat at front slide operation (B) 8-GROUND : Approx. 12 volts with the driver’s seat at rear slide operation (B)11-GROUND : Approx. 12 volts with the driver’s seat at rear vertical down operation (B)22-GROUND : Approx. 12 volts with the driver’s seat at rear vertical up operation (B)24-GROUND : Approx. 12 volts with the driver’s seat at front vertical down operation (B)23-GROUND : Approx. 12 volts with the driver’s seat at front vertical up operation (B)10-GROUND : Approx. 12 volts with the driver’s seat at front reclining operation (B)12-GROUND : Approx. 12 volts with the driver’s seat at rear reclining operation P18 POWER SEAT CONTROL SW (DRIVER’S SEAT) 3-1 : Closed with the driver’s seat at front reclining operation 2-1 : Closed with the driver’s seat at rear reclining operation 5-1 : Closed with the driver’s seat at front vertical down operation 10-1 : Closed with the driver’s seat at front vertical up operation 8-1 : Closed with the driver’s seat at rear vertical down operation 7-1 : Closed with the driver’s seat at rear vertical up operation 9-1 : Closed with the driver’s seat at front slide operation 6-1 : Closed with the driver’s seat at rear slide operation : PARTS LOCATION Code B4 J3 See Page 46 (Column Shift) 48 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) J10 50 J11 50 J14 52 (Column Shift) 53 (Floor Shift) L10 53 (Floor Shift) L11 53 (Floor Shift) P18 P19 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) Code P20 P21 P22 P23 P24 P25 P26 See Page A B 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Code P27 P28 P29 P30 P31 P32 S14 See Page 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) Junction Block and Wire Harness (Connector Location) 1B 1D 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 3C 34 Cowl Wire and J/B No.3 (Left Kick Panel) 3E 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 1I 2001 AVALON (EWD431U) 227 POWER SEAT (w/ DRIVING POSITION MEMORY) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 ID1 ID2 IK1 BC1 BD1 See Page 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Floor No No.1 1 Wire and Seat No No.1 1 Wire (Under the Driver’s Seat) Floor No No.2 2 Wire and Seat No No.2 2 Wire (Under the Front Passenger’s Seat) : GROUND POINTS Code IH See Page 56 (Column Shift) 60 (Floor Shift) Ground Points Location Instrument Panel Brace RH BK 64 Rear Quarter Inner LH BM 64 Back Panel Center BN 64 Rear Quarter Inner RH : SPLICE POINTS Code I6 See Page 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Cowl Wire Code B12 See Page 66 (Column Shift) 68 (Floor Shift) 2001 AVALON (EWD431U) 228 Wire Harness with Splice Points Seat No.1 No 1 Wire MEMO 2001 AVALON (EWD431U) 229 230 W- B 2 M 1 A SLDF SLDR FUP FDWN RUP RDWN RCLF RCLR 4 9 6 10 5 7 8 3 2 L- R B12 2 M 1 L- W L- Y R 2 M 1 11 BC1 J11 JUNCTION CONNECTOR BK 2001 AVALON (EWD431U) 1 M 2 P23 POWER SEAT MOTOR (DRIVER’ S SEAT REAR VERTICAL CONTROL) R- W R- B REAR L- O L- O L- O L- O 1 M 2 P24 POWER SEAT MOTOR (DRIVER’ S SEAT RECLINING CONTROL) FRONT DOWN DOWN UP 1 P22 POWER SEAT MOTOR (DRIVER’ S SEAT FRONT VERTICAL CONTROL) UP REAR FRONT L11 LUMBAR SUPPORT CONTROL SW (DRIVER’ S SEAT) P25 POWER SEAT MOTOR (DRIVER’ S SEAT SLIDE CONTROL) E L- B 3 L 4 W- B 1 W- B REAR B12 W- B L- O I6 L10 LUMBAR SUPPORT CONTROL MOTOR (DRIVER’ S SEAT) FRONT L- O 8 R- W R- L POWER SEAT (w/o DRIVING POSITION MEMORY) FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 30A PWR SEAT 2 1I L- O 7 ID2 1 BC1 L- O P18 POWER SEAT CONTROL SW (DRIVER’ S SEAT) B 2 M 2 2 M 1 P26 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT REAR VERTICAL CONTROL) 1 M 2 P27 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT RECLINING CONTROL) RUP RDWN RCLF RCLR E 6 8 7 3 2 4 L- Y R R- W R- B W- B SLDR 9 L- B 1 W- B 1 P28 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT SLIDE CONTROL) SLDF L L- O L- O L- O 2 IK1 1 BD1 P19 POWER SEAT CONTROL SW (FRONT PASSENGER’ S SEAT) 11 BD1 W- B BM A A J10 JUNCTION CONNECTOR BN 2001 AVALON (EWD431U) 231 POWER SEAT (w/o DRIVING POSITION MEMORY) SERVICE HINTS P19 POWER SEAT CONTROL SW (DRIVER’S SEAT) 1-GROUND : Always approx. 12 volts 4-GROUND : Always continuity P18 POWER SEAT CONTROL SW (FRONT PASSENGER’S SEAT) 1-GROUND : Always approx. 12 volts 4-GROUND : Always continuity : PARTS LOCATION Code See Page J10 50 J11 50 L10 53 (Floor Shift) L11 53 (Floor Shift) P18 P19 Code P22 P23 52 (Column Shift) P24 53 (Floor Shift) 52 (Column Shift) P25 53 (Floor Shift) See Page Code 52 (Column Shift) P26 53 (Floor Shift) 52 (Column Shift) P27 53 (Floor Shift) 52 (Column Shift) P28 53 (Floor Shift) See Page 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1I See Page 27 Junction Block and Wire Harness (Connector Location) Cowl Wire and Driver Side J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code ID2 IK1 BC1 BD1 See Page 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Floor No No.1 1 Wire and Seat No No.1 1 Wire (Under the Driver’s Seat) Floor No No.2 2 Wire and Seat No No.2 2 Wire (Under the Front Passenger’s Seat) : GROUND POINTS Code See Page Ground Points Location BK 64 Rear Quarter Inner LH BM 64 Back Panel Center BN 64 Rear Quarter Inner RH : SPLICE POINTS Code I6 See Page 58 (Column Shift) 62 (Floor Shift) Wire Harness with Splice Points Cowl Wire Code B12 See Page 66 (Column Shift) 68 (Floor Shift) 2001 AVALON (EWD431U) 232 Wire Harness with Splice Points Seat No.1 No 1 Wire MEMO 2001 AVALON (EWD431U) 233 SEAT HEATER FROM POWER SOURCE SYSTEM (SEE PAGE 72) 20A SEAT HTR 10A HTR 11 1I LG R- W 8 1B 1 3A LG 10 3A 12 13 2 SHD+ SHP+ IG+ R- W LG I18 SHD- SHP- 25 26 R- W R- Y A15 SEAT HEATER CONTROL SW [A/C CONTROL ASSEMBLY] R- Y R- Y 2 2 S12 SEAT HEATER (DRIVER’ S SEAT) R- W 2 BD1 R- B IK1 2 BC1 1 W- B 1 W- B S13 SEAT HEATER (FRONT PASSENGER’ S SEAT) 3 3 ID2 GND 24 C W- B J14 JUNCTION CONNECTOR W- B W- B C 11 BD1 BK J11 JUNCTION CONNECTOR J10 JUNCTION CONNECTOR A 7 4F A BN W- B W- B A 7 4C W- B W- B 11 BC1 BM 2001 AVALON (EWD431U) 234 IF SERVICE HINTS A15 SEAT HEATER CONTROL SW [A/C CONTROL ASSEMBLY] 2-GROUND : Approx. 12 volts with the ignition SW at ON position 12, 13-GROUND : Always approx. 12 volts 24-GROUND : Always continuity : PARTS LOCATION Code A15 See Page 46 (Column Shift) J14 48 (Floor Shift) J10 50 J11 50 Code S12 See Page Code 52 (Column Shift) S13 53 (Floor Shift) See Page 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) 53 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1I See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 3A 34 Cowl Wire and J/B No.3 (Left Kick Panel) 4C 38 Cowl Wire and J/B No.4 (Right Kick Panel) 4F 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code ID2 IK1 BC1 BD1 See Page 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Floor No.2 No 2 Wire and Cowl Wire (Right Kick Panel) Floor No No.1 1 Wire and Seat No No.1 1 Wire (Under the Driver’s Seat) Floor No No.2 2 Wire and Seat No No.2 2 Wire (Under the Front Passenger’s Seat) : GROUND POINTS Code IF See Page 56 (Column Shift) 60 (Floor Shift) Ground Points Location Left Kick Panel BK 64 Rear Quarter Inner LH BM 64 Back Panel Center BN 64 Rear Quarter Inner RH : SPLICE POINTS Code See Page I18 58 (Column Shift) Wire Harness with Splice Points Cowl Wire Code I18 See Page 62 (Floor Shift) Wire Harness with Splice Points Cowl Wire 2001 AVALON (EWD431U) 235 MOON ROOF FROM POWER SOURCE SYSTEM (SEE PAGE 72) 10A GAUGE NO. 1 7 1I 13 4C 1 IG1 L- O R- B 4 4D L- O R- B 10 1D 30A SUN ROOF R- B 13 IG1 8 M8 MOON ROOF CONTROL ECU 5 B 1 3 PCTY 3 4 4 IG1 3 IG1 UP/CLS DWN/OPN O DOWN R- L UP DCTY O 7 W- B E 9 R- W DWN R- Y UP 10 R- L IG 17 3C 17 4C 17 3E 17 4E E BL 2001 AVALON (EWD431U) 236 1 D12 DOOR COURTESY SW FRONT RH 1 O R- L W- B W- B B4 D11 DOOR COURTESY SW FRONT LH 2 W- B M9 MOON ROOF CONTROL SW SERVICE HINTS M9 MOON ROOF CONTROL SW 3-2 : Closed with the moon roof control SW at TILT DOWN or OPEN position 1-2 : Closed with the moon roof control SW at TILT UP or CLOSE position : PARTS LOCATION Code See Page Code See Page D11 50 M8 51 D12 50 M9 51 Code See Page ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1D See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 3C 34 Cowl Wire and J/B No.3 (Left Kick Panel) 3E 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 1I 4C 4D 4E : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IG1 See Page 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Roof Wire and Cowl Wire (Front Left Pillar) : GROUND POINTS Code BL See Page 64 Ground Points Location Roof Left : SPLICE POINTS Code B4 See Page 64 Wire Harness with Splice Points Code See Page Wire Harness with Splice Points Roof Wire 2001 AVALON (EWD431U) 237 GARAGE DOOR OPENER FROM POWER SOURCE SYSTEM (SEE PAGE 72) 7. 5A DOME P- L 7 1D 1 4D P- L 10 4C P- L 5 IG1 2 V10 GARAGE DOOR OPENER [VANITY LIGHT LH] W- B 1 17 IG1 W- B W- B (W/ MOON ROOF) W- B B4 B J4 JUNCTION CONNECTOR W- B B BL IG 2001 AVALON (EWD431U) 238 SERVICE HINTS V10 GARAGE DOOR OPENER [VANITY LIGHT LH] 2-GROUND : Always approx. 12 volts 1-GROUND : Always continuity : PARTS LOCATION Code J4 See Page 47 (Column Shift) Code J4 See Page Code 49 (Floor Shift) V10 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1D 4C 4D See Page See Page 51 Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IG1 See Page 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Roof Wire and Cowl Wire (Front Left Pillar) : GROUND POINTS Code IG BL See Page 56 (Column Shift) 60 (Floor Shift) 64 Ground Points Location Cowl Side Panel LH Roof Left : SPLICE POINTS Code B4 See Page 64 Wire Harness with Splice Points Code See Page Wire Harness with Splice Points Roof Wire 2001 AVALON (EWD431U) 239 AUTOMATIC GLARE-RESISTANT EC MIRROR FROM POWER SOURCE SYSTEM (SEE PAGE 72) * 1 : W/ DRIVING POSITION MEMORY * 2 : W/O DRIVING POSITION MEMORY 10A GAUGE NO. 1 R- B 10 1D 4 4D R- B 13 4C R- B 13 IG1 2 I16 INNER MIRROR 1 W- B (* 2) W- B (*1) (*2) W- B 17 IG1 B J4 JUNCTION CONNECTOR IG 2001 AVALON (EWD431U) 240 (*1) W- B (*2) W- B B BL SERVICE HINTS I16 INNER MIRROR 2-GROUND : Approx. 12 volts with the ignition SW at ON position 1-GROUND : Always continuity : PARTS LOCATION Code I16 See Page 50 Code J4 See Page 47 (Column Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1D 4C 4D See Page Code J4 See Page 49 (Floor Shift) Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IG1 See Page 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Roof Wire and Cowl Wire (Front Left Pillar) : GROUND POINTS Code IG BL See Page 56 (Column Shift) 60 (Floor Shift) 64 Ground Points Location Cowl Side Panel LH Roof Left 2001 AVALON (EWD431U) 241 REMOTE CONTROL MIRROR (w/ DRIVING POSITION MEMORY) FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 10A GAUGE NO. 1 30A PWR SEAT 7. 5A ECU- B W- L 2 1I 2 1D W- L 9 1B W- G 8 L- O S14 SEAT MEMORY SW 5 3F 14 3F R- B 5 3C G- W 14 3E 7 B SW2 SWE R- B W- G G- W 5 BC1 8 BC1 G- W 20 B SW1 7 BC1 W- G 21 B MMRY 1 BC1 R- B 9 B 10 ID1 L- O 2 W- B E 4 Y 2 3 G- W 1 1 G- Y MMRY 8 ID1 L- O 7 ID2 8 A 13 B 25 B 14 B +B IG SYSB MPX1 P20 A , P21 B POWER SEAT ECU Y- G 15 IA1 14 SGND 19 B C J14 JUNCTION CONNECTOR B C B 9 BC1 11 BC1 9 IA1 J14 JUNCTION CONNECTOR IA1 Y- G R5 REMOTE CONTROL MIRROR SW E 8 7 MSW M+ BR UP BR 9 P W- L BR 3 IA1 Y- G P 4 BC1 P W- L 3 BC1 W- L 10 BC1 GND 7 A BR MIRG 2 B W- B MIRB 1 B W- B MIRE 18 B RIGHT RIGHT A W- B LEFT DOWN A BR RIGHT LEFT LEFT SELECT SW A OPERATION SW BK 2001 AVALON (EWD431U) 242 J11 JUNCTION CONNECTOR IH J3 JUNCTION CONNECTOR W- L W- L W- L B4 A , B5 B BODY ECU 9 A MPX2 MPX4 21 B 9 IN1 G- B G- B G- B MPX3 R- Y W- L 9 B 1 IB1 W- G IB1 R- Y 9 D19 DRIVER DOOR ECU 20 23 DMVR DM+R DMHR VSSR HSSR 17 15 16 12 18 19 11 BR- W LG- R LG- B GR- L GR CPUB Y- G MPX1 BR- Y DVC GND MPX2 13 8 11 1 MH M 6 9 8 8 IB1 7 G M W- B 2 M+ IB1 R13 REMOTE CONTROL MIRROR LH J6 JUNCTION CONNECTOR B B B W- B B IF W- B 3 MV G W- B E2 W- B G- W II 2001 AVALON (EWD431U) 243 REMOTE CONTROL MIRROR (w/ DRIVING POSITION MEMORY) W- L W- L G- B G- B W- G 7 IN1 F14 FRONT PASSENGER DOOR ECU 10 PMVR PM+R PMHR VSSR HSSR 16 18 17 7 15 14 19 Y- G LG L- O G- O G- Y Y- B GND2 PVC 8 G 13 IN1 3 2 1 MV M+ MH 6 9 8 7 M R14 REMOTE CONTROL MIRROR RH W- B 2001 AVALON (EWD431U) W- B M 244 GND W- B MPX2 11 8 IN1 G 12 CPUB LG- B MPX1 SERVICE HINTS R4 REMOTE CONTROL MIRROR SW 7-9 : Approx. 800 Ω with select SW at RH position and operation SW at LEFT position 7-9 : Approx. 250 Ω with select SW at RH position and operation SW at RIGHT position 7-9 : Approx. 100 Ω with select SW at RH position and operation SW at UP position 7-9 : Approx. 470 Ω with select SW at RH position and operation SW at DOWN position 7-9 : Approx. 900 Ω with select SW at LH position and operation SW at LEFT position 7-9 : Approx. 350 Ω with select SW at LH position and operation SW at RIGHT position 7-9 : Approx. 200 Ω with select SW at LH position and operation SW at UP position 7-9 : Approx. 570 Ω with select SW at LH position and operation SW at DOWN position : PARTS LOCATION Code B4 See Page A B5 B 46 (Column Shift) F14 50 49 (Floor Shift) J11 48 (Floor Shift) 50 See Page 47 (Column Shift) J6 48 (Floor Shift) D19 J3 Code 46 (Column Shift) 50 J14 47 (Column Shift) 49 (Floor Shift) P20 A P21 B Code P21 R5 B See Page 53 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 52 (Column Shift) R13 51 53 (Floor Shift) R14 51 52 (Column Shift) 53 (Floor Shift) S14 52 (Column Shift) 53 (Floor Shift) 52 (Column Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1D 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 3C 34 Cowl Wire and J/B No.3 (Left Kick Panel) 3E 35 Floor No.1 Wire and J/B No.3 (Left Kick Panel) 3F 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 1I : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IB1 ID1 ID2 IN1 BC1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 66 (Column Shift) 68 (Floor Shift) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) Floor No No.1 1 Wire and Seat No No.1 1 Wire (Under the Driver’s Seat) : GROUND POINTS Code IF IH II BK See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 64 Ground Points Location Left Kick Panel Instrument Panel Brace RH Right Kick Panel Rear Quarter Inner LH 2001 AVALON (EWD431U) 245 REMOTE CONTROL MIRROR (w/o DRIVING POSITION MEMORY) * * * * FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1: 2: 3: 4: TAIWAN EXCEPT TAIWAN W/ MIRROR HEATER W/O MIRROR HEATER 5A ECU- ACC GR 8 1D 15 3C GR 15 3D 2 4D GR 11 4F R5 REMOTE CONTROL MIRROR SW 4 OPERATION SW SELECT SW RIGHT/ DOWN LEFT/ UP MV LG- B M+ E 7 8 W- B 2 BR- Y VR 3 LG VL 10 BR- W HR 9 Y- G MH HL DOWN UP LEFT RIGHT B 9 4H 22 4H Y- G LG- B Y- G 5 IB2 3 IN1 12 IN1 2 IN1 Y- G 7 A (*1) 2 B (*2 * 3) 2 C (*2 * 4) MV M+ MH M R13 A , M B , 6 A 1 B 1 C 3 A 4 B 3 C 7 A (*1) 2 B (*2 * 3) 2 C (*2 * 4) MV M+ MH M C REMOTE CONTROL MIRROR LH R14 A , M B , C REMOTE CONTROL MIRROR RH 2001 AVALON (EWD431U) 246 20 4F 7 4F W- B 3 A 4 B 3 C Y- G 6 A 1 B 1 C LG- B LG IB2 LG 2 BR- Y IB2 BR- W 4 Y- G BR- Y 9 4G IF SERVICE HINTS R5 REMOTE CONTROL MIRROR SW 7-8 : Continuity with the operation SW at UP or LEFT position 4-7 : Continuity with the operation SW at DOWN or RIGHT position 4-GROUND : Approx. 12 volts with the ignition SW at ACC or ON position : PARTS LOCATION Code See Page 47 (Column Shift) R5 R13 R13 49 (Floor Shift) A Code 51 R14 See Page B 51 C 51 A 51 Code R14 See Page B 51 C 51 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1D 3C 3D 4D See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 38 Cowl Wire and J/B No.4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 (Right ( g Kick Panel)) 4F 4G 4H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IB2 IN1 See Page 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code IF See Page 56 (Column Shift) 60 (Floor Shift) Ground Points Location Left Kick Panel 2001 AVALON (EWD431U) 247 REAR WINDOW DEFOGGER AND MIRROR HEATER FROM POWER SOURCE SYSTEM (SEE PAGE 72) W 1 1G 10A GAUGE NO. 1 3 2 DEF RELAY 5 40A DEF 10A MIR HTR 2 W 2 1 NOISE FILTER 2 1 NOISE FILTER 1 1 1 B 4 1I 3 1L B 5 1E W- B 2 3 1B 5 4H B B 14 4H 1 IB2 1 IN1 (*2) (*1) B R- B 5 4G R- B 8 ID2 B C B , 10 A (* 3) 6 B (* 4 * 5) 1 C (* 4 * 6) 11 IB1 13 IN1 J6 JUNCTION CONNECTOR W- B W- B R14 A , C B , MIRROR HEATER LH [REMOTE CONTROL MIRROR LH] R13 A , (*2) 10 A (*3) 6 B (*4 * 5) 1 C (*4 * 6) MIRROR HEATER RH [REMOTE CONTROL MIRROR RH] B 7 4C GND 24 5 A (* 3) 3 B (* 4 * 5) 2 C (* 4 * 6) W- B 1 : MANUAL A/C 2 : AUTOMATIC A/C 3 : W/ DRIVING POSITION MEMORY 4 : W/O DRIVING POSITION MEMORY 5 : EXCEPT TAIWAN 6 : TAIWAN RDEF 5 A (*3) 3 B (*4 * 5) 2 C (*4 * 6) W- B BATTERY * * * * * * 18 W- B 8 W- B FL MAIN 3. 0 GND A15 REAR WINDOW DEFOGGER SW [A/C CONTROL ASSEMBLY] N2 NOISE FILTER (REAR WINDOW DEFOGGER) 4 RDEF (*1) B 1 A H9 REAR WINDOW DEFOGGER SW [HEATER CONTROL SW] REAR WINDOW DEFOGGER F 6 A , F10 E 1 FUSIBLE LINK BLOCK 120A ALT 1 E B 7 4F IG IF 2001 AVALON (EWD431U) 248 B W- B W- B W- B B II SERVICE HINTS DEF RELAY 5-3 : Closed with the ignition SW at ON position and rear window defogger SW at ON position A15 REAR WINDOW DEFOGGER SW [A/C CONTROL ASSEMBLY] (AUTOMATIC A/C) 18-GROUND : Continuity with the ignition SW at ON position and rear window defogger SW at ON position 24-GROUND : Always continuity H9 REAR WINDOW DEFOGGER SW [HEATER CONTROL SW] (MANUAL A/C) 4-GROUND : Continuity with the ignition SW at ON position and rear window defogger SW at ON position 8-GROUND : Always continuity : PARTS LOCATION Code See Page Code 46 (Column Shift) A15 48 (Floor Shift) F6 A 44 F10 E 44 H9 See Page H9 49 (Floor Shift) 47 (Column Shift) J6 R13 51 A 51 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page R13 49 (Floor Shift) N2 47 (Column Shift) Code R14 See Page B 51 C 51 A 51 B 51 C 51 Junction Block and Wire Harness (Connector Location) 1B 27 1E and Cowl Wire and Driver Side J/B (Lower Finish Panel) 1G 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1I 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1L 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 4C 38 Cowl Wire and J/B No.4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 (Right ( g Kick Panel)) 4F 4G 4H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IB1 IB2 ID2 IN1 See Page Joining Wire Harness and Wire Harness (Connector Location) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Floor No.1 No 1 Wire and Cowl Wire (Left Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code IF IG II See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Ground Points Location Left Kick Panel Cowl Side Panel LH Right Kick Panel 2001 AVALON (EWD431U) 249 RADIO AND PLAYER (7 SPEAKER) FROM POWER SOURCE SYSTEM (SEE PAGE 72) 15A RADIO R2 RADIO AND PLAYER 5A ECU- ACC 8 1D GR 11 1L ACC+B BU+B 11 1 AMP+B BEEP 3 FL 17 FR 9 8 L- Y 15 3C L- Y 2 4D R G BR W L- Y GR GR 15 3D (SHIELDED) (SHIELDED) L- Y I12 (SHIELDED) 2 4F 5 IM3 3 IM1 16 IM1 18 IM1 19 IM1 2 4E 7 B +B 2 A 1 A ACC IN AMP ON R G BR (SHIELDED) GR L- Y W (SHIELDED) (SHIELDED) 4 A 5 A BEEP 6 A FL IN FR IN S 9 A , S10 B STEREO COMPONENT AMPLIFIER RL- SPKR FR+ SPKR FR- SPKR L 6 IM3 4 IM3 11 IM3 L D B 2 IM3 Y LG 8 B LG 1 B Y 11 B B 4 B D 12 IA1 11 B IA1 LG 4 IN1 Y J3 JUNCTION CONNECTOR 1 2 F13 FRONT DOOR SPEAKER RH 1 2 R10 REAR DOOR SPEAKER RH 1 2 R9 REAR DOOR SPEAKER LH 2001 AVALON (EWD431U) 250 B 5 IN1 LG Y 7 BA1 LG B 6 BA1 B R W D L 7 BB1 L 6 BB1 2 1 T9 TWEETER RH L RL+ SPKR B 10 B W RR- SPKR 3 B R RR+ SPKR R2 RADIO AND PLAYER RR RL 18 MUTE 19 S- GND 7 SLD 16 GND 10 20 Y L 5 IM1 17 IM1 15 IM1 (SHIELDED) BR W 6 IM1 (SHIELDED) B (SHIELDED) A J3 JUNCTION CONNECTOR 20 IM1 A Y L 13 A 12 A 11 A (SHIELDED) RR IN RL IN MUTE BR W 14 A (SHIELDED) B (SHIELDED) SIG GND S 9 A , S10 B STEREO COMPONENT AMPLIFIER V 10 IM3 P V C A WF- 5 B PWR GND 14 B L- B P 3 IM3 C 13 B A J6 JUNCTION CONNECTOR F12 FRONT DOOR SPEAKER LH 2 1 2 W7 WOOFER 1 BR 2 W- B 1 V IB1 V 4 P 3 IB1 A V P C P WF+ 9 B W- B FL- SPKR 2 B L- R FL+ SPKR A T8 TWEETER LH W- B J10 JUNCTION CONNECTOR A BM BN IH 2001 AVALON (EWD431U) 251 RADIO AND PLAYER (7 SPEAKER) SERVICE HINTS S9 (A), S10 (B) STEREO COMPONENT AMPLIFIER (A) 2-GROUND : Approx. 12 volts with the ignition SW ON or ACC position (B) 7-GROUND : Always approx. 12 volts (B)13-GROUND : Always continuity : PARTS LOCATION Code See Page F12 50 F13 50 J3 J6 Code See Page J10 R9 51 47 (Column Shift) R10 51 S9 A T9 51 W7 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1L 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 4D 38 Cowl Wire and J/B No.4 (Right Kick Panel) 4E 39 Floor No.2 Wire and J/B No.4 (Right Kick Panel) 4F 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) 3D See Page 51 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 51 Junction Block and Wire Harness (Connector Location) 1D 3C B T8 49 (Floor Shift) 49 (Floor Shift) 49 (Floor Shift) S10 47 (Column Shift) R2 47 (Column Shift) Code 50 : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IB1 IM1 IM3 IN1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Floor No.2 No 2 Wire and Instrument Panel Wire (Right Kick Panel) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 64 Rear Door No.2 Wire and Floor No.1 Wire (Under the Left Center Pillar) BB1 64 Rear Door No.1 Wire and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code IH See Page 56 (Column Shift) 60 (Floor Shift) Ground Points Location Instrument Panel Brace RH BM 64 Back Panel Center BN 64 Rear Quarter Inner RH : SPLICE POINTS Code See Page I12 58 (Column Shift) Wire Harness with Splice Points Instrument Panel Wire Code I12 2001 AVALON (EWD431U) 252 See Page 62 (Floor Shift) Wire Harness with Splice Points Instrument Panel Wire MEMO 2001 AVALON (EWD431U) 253 RADIO AND PLAYER (6 SPEAKER) FROM POWER SOURCE SYSTEM (SEE PAGE 72) 5A ECU- ACC R9 REAR DOOR SPEAKER LH 1 2 11 1L GR 8 1D 15A RADIO R10 REAR DOOR SPEAKER RH 1 2 W 7 BB1 W 2 B 6 B 1 B 3 B RL- FR+ 6 A R3 A , R4 B A A LG 1 2 J3 B JUNCTION CONNECTOR 1 4 IB1 4 IN1 LG T9 TWEETER RH V P 1 E 7 A B 2 T8 TWEETER LH 3 IB1 B D V V 2 D D J6 A JUNCTION CONNECTOR P P C 5 A 5 IN1 L V C C FR- 1 A L P RADIO AND PLAYER RR- L FL- RR+ BR RL+ LG FL+ 2 A 13 IM2 L B 5 IM2 R 4 A ACC IA1 LG 3 A 11 Y 12 IA1 B 2 4F GR 2 4D W R 6 BB1 R Y 7 BA1 Y 6 BA1 B GR L- Y 15 3D B 15 3C 1 2 A F13 FRONT DOOR SPEAKER RH A BR F12 FRONT DOOR SPEAKER LH IH 2001 AVALON (EWD431U) 254 J3 JUNCTION CONNECTOR SERVICE HINTS R3 (A) RADIO AND PLAYER (A) 4-GROUND : Always approx. 12 volts (A) 3-GROUND : Approx. 12 volts with the ignition SW ON or ACC position (A) 7-GROUND : Always continuity : PARTS LOCATION Code See Page F12 50 F13 50 J3 J6 Code R3 47 (Column Shift) A R4 49 (Floor Shift) See Page B Code 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) R9 51 49 (Floor Shift) R10 51 T8 T9 See Page 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1D 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1L 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 34 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) 4D 38 Cowl Wire and J/B No.4 (Right Kick Panel) 4F 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IB1 IM2 IN1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) Floor No.2 No 2 Wire and Instrument Panel Wire (Right Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 64 Rear Door No.2 Wire and Floor No.1 Wire (Under the Left Center Pillar) BB1 64 Rear Door No.1 Wire and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code IH See Page 56 (Column Shift) 60 (Floor Shift) Ground Points Location Instrument Panel Brace RH 2001 AVALON (EWD431U) 255 COMBINATION METER B- O ACC AM1 B- W IG1 7 AM2 7 II1 B- W FROM POWER SOURCE SYSTEM (SEE PAGE 72) 7. 5A DOME IG2 6 10A GAUGE NO. 1 R- B 10 1D 1 4D 4 4D 1 4F 13 4F P- L R- B IF1 W- R 4 7 1D I15 IGNITION SW P- L W- R ST2 8 3 E 4 D 5 D R- W 1 D 4 E 10 D 7 E 9 D V 3 D Y- R 2 E P- B 10 E GR- R 2 D FUSIBLE LINK BLOCK 15 3G 17 IL1 L- Y R- L G- B G- W 1 A 25 12 1I AJAR TO ABS & BA & TRAC & VSC ECU PBEW TO CRUISE CONTROL ECU 11 DBEW 1 TO ACTIVE LIGHT RELAY 23 W1 WASHER LEVEL WARNING SW R- W B 15 3A FL MAIN 3. 0W 2 W- B 8 1H J1 JUNCTION CONNECTOR B W- B 1 4 2F 7 4F W- B W- B ED 2 2001 AVALON (EWD431U) 256 20 4D 4 2D B W- B B1 BRAKE FLUID LEVEL WARNING SW R- W B5 BODY ECU BATTERY SLIP VSC OFF VSC CRUISE ABS WASHER BRAKE DOOR PASSENGER SEAT BELT DRIVER SEAT BELT F6 A , F7 B R- L 1 B L- Y B 2 2G MULTI DISPLAY 10A AM2 M3 A , M4 B , M5 C , M6 D , M7 E 7 2C IF FROM POWER SOURCE SYSTEM (SEE PAGE 72) B- O B- W B- R 5A SRS WRN 6 2A 3 2B C15 CRUISE CONTROL ECU A15 A/C CONTROL ASSEMBLY SPD 1 2B SPD 6 SPD TACH B 27 V- W 22 V- W 16 V- W LG- B B- O B- R 12 5 E7 ENGINE CONTROL MODULE 10 3C 10 3D 1 3C 8 3C 7 1C 5 P IJ1 4 IJ1 N 1 3F 21 3F 13 1A P1 PARK/NEUTRAL POSITION SW B- R B- O LG- B V- W B 5 A 11 E 5 E 18 A B- Y MINUTE HOUR ODO/TRIP 11 A 21 A B- W 6 E W- B 12 E R- L SRS CHARGE REAR LIGHTS 14 E IJ1 TO CENTER AIRBAG SENSOR ASSEMBLY 7 4G 7 4B W- B TO GENERATOR FROM A/C MAGNETIC CLUTCH AND LOCK SENSOR FROM A/C THERMISTOR FROM A/C AMBIENT TEMP. SENSOR O2 OIL PRESSURE SW TO LIGHT FAILURE SENSOR TO ENGINE CONTROL MODULE Y- B 12 6 D Y- G B- Y 7 D Y- B OIL MALFUNCTION INDICATOR LAMP M3 A , M4 B , M5 C , M6 D , M7 E MULTI DISPLAY 1 A W- B EA J9 JUNCTION CONNECTOR A IJ 2001 AVALON (EWD431U) 257 258 2001 AVALON (EWD431U) 8 A 1 FV 10 2 FR F15 FUEL SENDER Y- G E2 PROM Y- G MULTI DISPLAY REVERSE BUZZER 9 A IA1 3 FE 3 1 W3 WATER TEMP. SENDER 8 IA1 BR 19 A BR P- B 7 IA1 P- B 9 C O BACK LIGHT CIRCUIT O 11 C P TO A/C DUAL PRESSURE SW TO RHEOSTAT FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 C SPEED BUZZER W/D CPU 15 A IJ1 (*2) L- B 10 A (*2) W- G 3 A TO HEATER CONTROL SW 8 C Y 1 A (*2) G M3 A , M4 B , M5 C , M6 D , M7 E Y- R L- Y 11 1L TO ENGINE CONTROL MODULE POWER SUPPLY (*2) 4 C B (*2) L- B (*1) Y (*2) L- W 17 A FROM HEATER CONTROL SW L- W 12 A FROM MG/CLT RELAY G- R 2 C TO A/C CONTROL ASSEMBLY 7 C TO A/C MAGNETIC CLUTCH AND LOCK SENSOR 4 A (*2) 7 A L- O 16 A TO A/C THERMISTOR TO A/C AMBIENT TEMP. SENSOR TO ABS ACTUATOR AND ECU (*7) TO ABS & BA & TRAC & VSC ECU (*6) COMBINATION METER G Y- R 15A RADIO B G G Y- R Y- R FROM POWER SOURCE SYSTEM (SEE PAGE 72) * 1 : AUTOMATIC A/C * 2 : MANUAL A/C * 3 : SHIELDED L 15A IG2 L- R D J8 JUNCTION CONNECTOR 2 2 2B P- B L (* 1) L D (* 1) B- W P- L (*1) 2 L- Y (*1) 1 IG2 RELAY 5 L 1 L L- Y P- L L- R P- B I8 INJECTOR NO. 1 IL1 L (*1) 8 (*1) IJ1 B- W 7 10 B 12 B 11 B 14 B 13 B M3 A , M4 B , M5 C , M6 D , M7 E 2 A MULTI DISPLAY 6 A LCD ODO TRIP DRIVER DRIVER 8 B 6 B 5 B 4 B 3 B 2 B 9 B W BR- W 3 C R 5 C Y 7 C L 6 C G 2 C BR 1 C (*1) 22 A BR CPU BR- W (* 3) (* 1) B Y (* 1) G (* 1) R (* 1) W (* 1) (* 3) BR I10 W 16 IC1 IJ1 17 IC1 18 IC1 6 IC1 5 IC1 20 IC1 (* 3) (* 1) B Y (* 1) G (* 1) R (* 1) W (* 1) (* 3) R Y L 15 IG1 7 IG1 14 IG1 6 IG1 2 IG1 12 IG1 G 1 DRIVE SIGNAL 2 4 GND VMID 5 VX (*3) (*1) B Y (*1) G (*1) R (*1) W (*1) (*3) BR BR 11 3 VY F11 FIELD MAGNETIC SENSOR EB 2001 AVALON (EWD431U) 259 COMBINATION METER G G FROM POWER SOURCE SYSTEM (SEE PAGE 72) Y- R L FROM POWER SOURCE SYSTEM (SEE PAGE 72) L- Y 10A ECU- IG NO. 2 P- L L- R 7. 5A ECU- B Y- R 13 1B Y- R P- B 11 3F 2 3C W- G 9 1B P- L L- Y W- G 14 B 11 B 12 B 14 A 2 3F Y- R L- R 13 B 5 3C L P- B 14 3F 10 B 15 A C 9 A , C10 B BR- W I10 9 B (* 3) 20 A TACHOMETER O/D OFF FUEL 7 A G- O 8 B BR Y 6 B BR- W R 5 B BR 4 B G 3 B L 2 B W SPEEDOMETER FUEL GAUGE TEMP. GAUGE COMBINATION METER I10 W R TO ENGINE CONTROL MODULE Y L G BR BR IH 2001 AVALON (EWD431U) 260 FROM POWER SOURCE SYSTEM (SEE PAGE 72) G 5A PANEL G 4 1A B FROM A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] G B G (* 5) R- W B R- W J2 JUNCTION CONNECTOR IF1 FROM HAZARD SW OR TURN SIGNAL SW [COMB. SW] (*5) R- W 5 3 * 3 : SHIELDED * 4 : W/ DAYTIME RUNNING LIGHT * 5 : W/O DAYTIME RUNNING LIGHT FROM THEFT DETERRENT ECU 15A HEAD RH 12 3G (* 4) G- Y Y 3 A 4 A 5 A 6 A 16 A ILLUMINATION L TURN RH SECURITY 12 A G Y- R 2 A 2 R 1 A D R- B 10 A N G- W 9 A R G- B 22 A P G- Y 11 A TURN LH V 3 3G HIGH BEAM R- W 9 IC1 21 A C 9 A , C10 B 19 A R- L W- B W- G COMBINATION METER 7 3G 8 IC1 R- L (*5) TO COMBINATION SW (*4) W- B TO RHEOSTAT 7 3A A J5 JUNCTION CONNECTOR A W- B W- B W- B FROM DRL NO. 3 RELAY FROM POWER SOURCE SYSTEM (SEE PAGE 72) (* 4) IG 2001 AVALON (EWD431U) 261 COMBINATION METER SERVICE HINTS B1 BRAKE FLUID LEVEL WARNING SW 1-2 : Closed with the float down M3 (A), M4 (B), M5 (C), M6 (D), M7 (E) MULTI DISPLAY (B)7-GROUND : Approx. 12 volts with the ignition SW at ST position and the shift lever at P or N position (D)4-GROUND : Approx. 12 volts with the ignition SW at ON position (A) 12, (E) 3-GROUND : Always approx. 12 volts (A)11, (A)22-GROUND : Always continuity O2 OIL PRESSURE SW 1-GROUND : Closed with the oil pressure above approx. 20 kpa (2.8 psi, 0.2 kgf/cm2) W3 WATER TEMP. SENDER 1-GROUND : Approx. 160- 240 Ω (50°C ,122°F) Approx. 17.1- 20.4 Ω (120°C,288°F) C9 (A), C10 (B) COMBINATION METER (A)14, (A) 16-GROUND : Always approx. 12 volts (A)15-GROUND : Approx. 12 volts with the ignition SW at ON position (A)21-GROUND : Always continuity : PARTS LOCATION Code See Page A15 B1 C9 C10 50 48 (Floor Shift) F15 50 I8 45 46 (Column Shift) 48 (Floor Shift) A B 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) C15 48 (Floor Shift) 46 (Column Shift) E7 See Page F11 44 B5 Code 46 (Column Shift) 48 (Floor Shift) F6 A 44 F7 B 44 I15 J1 J2 J5 J8 J9 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 5 See Page 25 A M4 B M5 C M6 D M7 E 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 45 47 (Column Shift) P1 45 49 (Floor Shift) W1 45 47 (Column Shift) W3 45 49 (Floor Shift) Relay Blocks (Relay Block Location) Engine Room R/B No.5 (Engine Compartment Left) 2001 AVALON (EWD431U) 262 M3 See Page 47 (Column Shift) O2 : RELAY BLOCKS Code Code ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A See Page Junction Block and Wire Harness (Connector Location) 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 27 Cowl Wire and Driver Side J/B (Lower ( Finish Panel)) 1H 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1I 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1L 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 30 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 34 Cowl Wire and J/B No.3 ((Left Kick Panel)) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 38 Cowl Wire and J/B No No.4 4 (Right Kick Panel) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 1B 1C 1D 2A 2B 2C 2D 2F 2G 3A 3C 3D 3F 3G 4B 4D 4F 4G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IA1 IC1 IF1 IG1 II1 IJ1 IL1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Floor No.1 No 1 Wire and Instrument Panel Wire (Left Kick Panel) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) Roof Wire and Cowl Wire (Front Left Pillar) Engine Wire and Cowl Wire (Behind the Glove Box) Engine Wire and Instrument Panel Wire (Right Kick Panel) Cowl Wire and Instrument Panel Wire (Right Kick Panel) 2001 AVALON (EWD431U) 263 COMBINATION METER : GROUND POINTS Code See Page Ground Points Location EA 54 Front Side of Right Fender EB 54 Surge Tank RH ED 54 Front Side of Left Fender IF IG IH IJ 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Left Kick Panel Cowl Side Panel LH Instrument Panel Brace RH Cowl Side Panel RH : SPLICE POINTS Code See Page I10 58 (Column Shift) Wire Harness with Splice Points Instrument Panel Wire Code I10 See Page 62 (Floor Shift) 2001 AVALON (EWD431U) 264 Wire Harness with Splice Points Instrument Panel Wire MEMO 2001 AVALON (EWD431U) 265 RADIATOR FAN AND CONDENSER FAN FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 5A ECU- IG NO. 1 1 2 2 5 2E 6 2E L- B Y 5 1D 30A RDI B 30A CDS 2 3A 4 Y 2 3H Y 11 3H IF3 15 W- R IF3 Y 5 1 FAN NO. 3 RELAY 2 3 3 3 1 FAN NO. 1 RELAY 5 3 3 FAN NO. 2 RELAY 2 5 2 3 B- R 4 3 3 G 3 W- B L Y- G Y- G 3 1 3 3 W- R 3 G 2 M 3 L 3 A2 A/C CONDENSER FAN MOTOR 1 W- R 3 Y L- B Y Y B 7 2F 2 2D 3 2D L 3 2 R1 RADIATOR FAN MOTOR 6 2D 7 2D 8 2D 1 EC1 W- B E7 ENGINE CONTROL MODULE G 6 1 2 W- B W- B 1 M W- B IF3 A4 A/C SINGLE PRESSURE SW 6 W- B 2 W4 WATER TEMP. SW NO. 1 Y- G LG- R 1I CF 1 2D 2 EC1 II2 1 ACMG 6 2F G 12 2F G 9 1 1H 2 5 2F G LG- B 2 G IF1 Y- G 10 W5 WATER TEMP. SW NO. 2 D4 DIODE (A/C) 1 26 G 5 2D W- B 4 2F ED 2001 AVALON (EWD431U) 266 SYSTEM OUTLINE The radiator fan motor and A/C condenser fan motor operates according to the water temp. SW NO.1, water temp. SW NO.2, A/C single pressure SW, and the A/C system condition. The FAN NO.1 relay, FAN NO.2 relay, FAN NO.3 relay are turned on/off, to operate the fan motors at low speed (In series), or high speed (In parallel). 1. LOW SPEED OPERATION Either when the A/C system is operating, or when the water temp. SW NO.2 is on, the radiator fan motor and A/C condenser fan motor operates at low speed. 2. HIGH SPEED OPERATION Either when the A/C system is operating, or when the water temp. SW NO.2 is on, if the water temp. SW NO.1 or A/C single pressure SW is on, the radiator fan motor and A/C condenser fan motor operates at high speed. SERVICE HINTS A3 A/C SINGLE PRESSURE SW 3-2 : Open above approx. 15.5 kgf/cm2 (224 psi, 1520 kpa) Close below approx. 12.5 kgf/cm2 (181 psi, 1225 kpa) : PARTS LOCATION Code See Page A2 44 A4 44 D4 46 (Column Shift) Code D4 E7 See Page Code See Page 48 (Floor Shift) R1 45 46 (Column Shift) W4 45 48 (Floor Shift) W5 45 : RELAY BLOCKS Code 3 See Page 24 Relay Blocks (Relay Block Location) Engine Room R/B No.3 (Near the Radiator Fan) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1D 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1H 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1I 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 30 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 2D 2E 2F 3A 34 3H 35 Cowl Wire and J/B No.3 No 3 (Left Kick Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EC1 IF1 IF3 II2 See Page 54 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Engine Room No.3 Wire (Near the Radiator Fan) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Engine Wire and Cowl Wire (Behind the Glove Box) : GROUND POINTS Code ED See Page 54 Ground Points Location Front Side of Left Fender 2001 AVALON (EWD431U) 267 AIR CONDITIONING (AUTOMATIC A/C) FROM POWER SOURCE SYSTEM (SEE PAGE 72) 1 50A HTR 10A HTR 7. 5A ECU- B 2 5 11 1I 14 IF3 R- W W- G L- W R- W L- B 9 1B R- W 1 3A 5 3C 10 3A 14 3C R- W 10 3H 4 2C 5 1 5 5 1 4 5 HTR RELAY 2 MG/CLT RELAY 3 2 W- G 3 R- W 5 5 5 16 IF3 L- R W- B 2 2C 5 2B Y L- W L- W 6 2C L- B L- B L- B L- W 1 1K D4 DIODE (A/C) 1 A3 A/C MAGNETIC CLUTCH AND LOCK SENSOR M LG- B B- W 2 13 IJ1 2 1I L 1 1 1H B- W 2 2 1E B2 BLOWER MOTOR L- R 1 1E W- B 3 2 L- R B 3 J1 JUNCTION CONNECTOR B 4 LG- R 3 VM +B LG- R B- W A14 A/C BLOWER MOTOR LINEAR CONTROLLER GND SI 1 2 L- O L- O W- B W- B A J9 JUNCTION CONNECTOR IJ 2001 AVALON (EWD431U) 268 A15 A , A16 B A/C CONTROL ASSEMBLY IF3 16 BLW PSW 11 A L- R 14 A L- O IGN 17 A B Y- R IL1 21 3C L- W W- G AC1 10 B 8 3C 20 IF3 L- R 12 TW 2 B Y- G LOCK 9 B L- W ACIN 22 A Y L- W HR 19 A R- W IG+ 2 A W- G B 1 A 21 3F R- W L- B 10 B IJ1 B L- W L- W Y- G Y- R B 6 14 7 27 THWO A/C TACH ACMG 1 E7 ENGINE CONTROL MODULE W- B 4 A4 A/C DUAL PRESSURE SW LG- R L- W LG- R B- W B- W L- O 1 2F W- B W- B 4 2D W- B 4 2F ED 2001 AVALON (EWD431U) 269 AIR CONDITIONING (AUTOMATIC A/C) A15 A , A16 B 6 A 5 A 11 B P- B G- R A1 A/C AMBIENT TEMP. SENSOR AMDH 3 B P- L SG Y AMDC 16 B B TAMI 21 A B- W A/C CONTROL ASSEMBLY TR TPD 4 5 3 2 13 IF3 A17 A/C ROOM TEMP. SENSOR P G- R B 12 IL1 13 IC1 1 21 2 1 B- W 4 B- W P 17 B- W G- R 16 Y 2 V IF3 IL1 A24 AIR MIX CONTROL SERVO MOTOR (FRONT PASSENGER SIDE) 5 11 P G- R 1 9 3A 22 3A 22 3B 9 3B 9 3G CPU M3 MULTI DISPLAY B- W BR 22 B- W B- W B- W B- W V IJ1 BR 11 EB 2001 AVALON (EWD431U) 270 A15 A , A16 B AMPH 4 A 3 A 7 B 8 A 7 A 13 B LG- R B- Y L- R O B- R B- Y 4 5 3 4 5 3 AOD AOF TPO 2 1 1 2 B- W B- W V B- W V 1 A25 AIR OUTLET CONTROL SERVO MOTOR 2 TPP A19 A/C THERMISTOR TE A23 AIR MIX CONTROL SERVO MOTOR (DRIVER SIDE) AMPC 4 B LG- B A/C CONTROL ASSEMBLY 10 4A 1 4A V 10 4H B- W 1 4H B- W 1 4B B- W B- W B- W B- W V V V 2001 AVALON (EWD431U) 271 AIR CONDITIONING (AUTOMATIC A/C) A15 A , A16 B A/C CONTROL ASSEMBLY 1 W- B IF1 A18 A/C SOLAR SENSOR W- B 3 W- B V- W 2 5 TO SPEEDOMETER [MULTI DISPLAY] IL1 VER1 15 B 8 V B- W 2 GND 24 A L 3 SPD 16 A 3 A22 AIR INLET CONTROL SERVO MOTOR 4 IL1 S5 8 B V R 2 I13 V V 8 4H 8 4B V V V 5 TSD 6 B L TSP 5 B R L- Y TPI 12 B L AIR 10 A R- L AIF 9 A 21 4B B- W 21 4A 8 4A V W- B W- B 7 4C 9 1H 7 4F 8 1L W- B W- B V IF 2001 AVALON (EWD431U) 272 II SERVICE HINTS A3 A/C DUAL PRESSURE SW 1-4 : Open above approx. 2.0 kgf/cm2 (29 psi, 196 kpa) or 32 kgf/cm2 (464 psi, 3140 kpa) A15 (A), A16 (B) (A) 1-GROUND (A) 2-GROUND (A)24-GROUND A/C CONTROL ASSEMBLY : Always approx. 12 volts : Approx. 12 volts with the ignition SW at ON position : Always continuity : PARTS LOCATION Code See Page A1 44 A3 44 A4 44 46 (Column Shift) A14 48 (Floor Shift) A15 A A16 B A17 A18 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) Code A18 A19 A22 A23 A24 A25 B2 See Page 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) Code B2 D4 E7 J1 J9 M3 See Page 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 46 (Column Shift) : RELAY BLOCKS Code 5 See Page 25 Relay Blocks (Relay Block Location) Engine Room R/B No.5 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1H 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1I 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1K 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1L 26 Instrument Panel Wire and Driver Side J/B (Lower Finish Panel) 2B 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 30 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 34 Cowl Wire and J/B No.3 ((Left Kick Panel)) 35 Instrument Panel Wire and J/B No.3 No 3 (Left Kick Panel) 35 Cowl Wire and J/B No.3 (Left Kick Panel) 38 Cowl Wire and J/B No.4 ((Right g Kick Panel)) 39 Instrument Panel Wire and J/B No.4 No 4 (Right Kick Panel) 1E 2C 2D 2F 3A 3B 3C 3F 3G 3H 4A 4B 4C 4F 4H 2001 AVALON (EWD431U) 273 AIR CONDITIONING (AUTOMATIC A/C) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC1 IF1 IF3 IJ1 IL1 See Page 56 (Column Shift) 60 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Instrument Panel Wire (Left Kick Panel) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Engine Wire and Instrument Panel Wire (Right Kick Panel) Cowl Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location EB 54 Surge Tank RH ED 54 Front Side of Left Fender IF II IJ 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Left Kick Panel Right Kick Panel Cowl Side Panel RH : SPLICE POINTS Code See Page I13 58 (Column Shift) Wire Harness with Splice Points Cowl Wire Code I13 See Page 62 (Floor Shift) 2001 AVALON (EWD431U) 274 Wire Harness with Splice Points Cowl Wire MEMO 2001 AVALON (EWD431U) 275 AIR CONDITIONING (MANUAL A/C) FROM POWER SOURCE SYSTEM (SEE PAGE 72) R- W 1 R- W 50A HTR 10A HTR FROM POWER SOURCE SYSTEM (SEE PAGE 72) 2 5 11 1I 7. 5A ECU- B L- B R- W R- W 9 1B R- W 5 IF3 2 W- G R- W M 10 3H 1 3A 10 3B 1 3B 5 L- W 5 L- R 10 3A FRS 16 IF3 2 5 3C 14 3C 1 1 1K 10 A 17 A 18 A W- G L L- W R- L B REC R- W W- B IG+ 3 5 J1 JUNCTION CONNECTOR R- W 4 R- W 5 R- W 5 HTR RELAY 1 14 A22 AIR INLET CONTROL SERVO MOTOR 5 B W- B 8 B LO IG+ FRS 10A A/C 2 A REC +B H 9 A , H10 B HEATER CONTROL SW W- B L- B GND 8 A W- B L- B E 1 B L- O M2 5 B 7 4C L L 2 3 1 4 W- B 4 2F I13 W- B W- B B3 BLOWER RESISTOR 7 4F W- B L 4 2D W- B I20 M1 6 B L- B L W- B 1 HI 4 B L- O M 5 A B2 BLOWER MOTOR L- R 2 6 1I L A/CB 2 1E J9 JUNCTION CONNECTOR ED IJ 2001 AVALON (EWD431U) 276 A IF L- B R- W L- B R- W R- W R- W A25 AIR OUTLET CONTROL SERVO MOTOR 7 4 2C IG CONTROL CIRCUIT B 1 5 MG/CLT RELAY M 2 3 2 2C 6 2C A 5 2B Y L- B 3 L- B D4 DIODE (A/C) 2 6 GR 14 A 13 A 12 A FOOT B/L 2 1I H 9 A , H10 B HEATER CONTROL SW 8 4F P 14 A/C E7 ENGINE CONTROL MODULE IL1 P P B B W- B IL1 W- B 11 A 7 B J6 JUNCTION CONNECTOR B W- B 15 6 A IL1 6 ACMG LA/C B A/C- 5 8 4C FACE Y- R BR- W 15 A F/D 8 Y 1 1H 16 A DEF GND LG- R 5 L- R 3 VENT LG- R 2 B/L LG- R FOOT B- W 1 F/D W- B DEF II 2001 AVALON (EWD431U) 277 AIR CONDITIONING (MANUAL A/C) L- B P B- W L- B 22 3G 9 3G P P P P IL1 8 C 7 C 21 A 4 A 22 A M3 A , M5 C BR L- R B P MULTI DISPLAY L- R IL1 11 IJ1 B 20 BR L- R 1 P A4 A/C DUAL PRESSURE SW IF3 4 W- B L- R 1 2F ED 2001 AVALON (EWD431U) BR W- B 4 2F 278 IL1 2 C 1 C 7 12 G- R 2 CPU 9 C IF3 P 4 5 1 G- R 2 LG- B 4 C IJ1 IF3 G- R L- W 10 13 L- W L- B Y 1 LG- B 1 11 C 13 IC1 A1 A/C AMBIENT TEMP. SENSOR 2 B- W 3 9 3B A19 A/C THERMISTOR IL1 A3 A/C MAGNETIC CLUTCH AND LOCK SENSOR 20 IJ1 B- W 13 L- B IF3 L- B 12 I4 EB SERVICE HINTS A3 A/C DUAL PRESSURE SW 1-4 : Open above approx. 2.0 kgf/cm2 (29 psi, 196 kpa) or 32 kgf/cm2 (464 psi, 3140 kpa) H9 (A), H10 (B) HEATER CONTROL SW +B-GROUND : Always approx. 12 volts IG+-GROUND : Approx. 12 volts with the ignition SW at ON position REC-GROUND : Approx. 12 volts with RECIRC SW on FRS-GROUND : Approx. 12 volts with FRESH SW on E-GROUND : Always continuity GND-GROUND : Always continuity : PARTS LOCATION Code See Page A1 44 A3 44 A4 44 A19 A22 A25 B2 Code B3 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) 46 (Column Shift) 48 (Floor Shift) H9 48 (Floor Shift) B J1 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) J9 46 (Column Shift) See Page 49 (Floor Shift) J6 48 (Floor Shift) A H10 J1 46 (Column Shift) E7 46 (Column Shift) Code 48 (Floor Shift) D4 46 (Column Shift) 48 (Floor Shift) See Page 46 (Column Shift) 49 (Floor Shift) M3 A M5 C 47 (Column Shift) 49 (Floor Shift) 47 (Column Shift) 49 (Floor Shift) 49 (Floor Shift) 47 (Column Shift) : RELAY BLOCKS Code 5 See Page 25 Relay Blocks (Relay Block Location) Engine Room R/B No.5 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1H 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 1I 27 Cowl Wire and Driver Side J/B (Lower Finish Panel) 1K 27 Engine Room Main Wire and Driver Side J/B (Lower Finish Panel) 2B 30 Engine Wire and Engine Room J/B (Engine Compartment Left) 30 Engine g Room Main Wire and Engine g Room J/B (Engine ( g Compartment Left)) 34 Cowl Wire and J/B No.3 ((Left Kick Panel)) 3G 35 Instrument Panel Wire and J/B No.3 (Left Kick Panel) 3H 35 Cowl Wire and J/B No.3 (Left Kick Panel) 4C 38 Cowl Wire and J/B No.4 (Right Kick Panel) 4F 39 Instrument Panel Wire and J/B No.4 (Right Kick Panel) 1E 2C 2D 2F 3A 3B 3C 2001 AVALON (EWD431U) 279 AIR CONDITIONING (MANUAL A/C) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC1 IF3 IJ1 IL1 See Page 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) 62 (Floor Shift) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Instrument Panel Wire (Left Kick Panel) Engine Room Main Wire and Cowl Wire (Left Side of Instrument Panel) Engine Wire and Instrument Panel Wire (Right Kick Panel) Cowl Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location EB 54 Surge Tank RH ED 54 Front Side of Left Fender IF II IJ 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) 56 (Column Shift) 60 (Floor Shift) Left Kick Panel Right Kick Panel Cowl Side Panel RH : SPLICE POINTS Code I4 I13 See Page Wire Harness with Splice Points 58 (Column Shift) 62 (Floor Shift) 58 (Column Shift) Code I13 Cowl Wire I20 See Page 58 (Column Shift) 62 (Floor Shift) 2001 AVALON (EWD431U) 280 Wire Harness with Splice Points 62 (Floor Shift) Cowl Wire MEMO 2001 AVALON (EWD431U) 281 C TROUBLESHOOTING To Ignition SW IG Terminal Fuse [A] SW 1 Voltmeter [B] VOLTAGE CHECK (a) Establish conditions in which voltage is present at the check point. Example: [A] - Ignition SW on [B] - Ignition SW and SW 1 on [C] - Ignition SW, SW 1 and Relay on (SW 2 off) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Relay [C] Solenoid SW 2 CONTINUITY AND RESISTANCE CHECK (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Ohmmeter SW If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Ohmmeter Diode (c) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. Digital Type Analog Type 2001 AVALON (EWD431U) 12 C To Ignition SW IG Terminal Test Light Fuse Case Short [A] SW 1 Short [B] Disconnect Disconnect Light (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: [A] - Ignition SW on [B] - Ignition SW and SW 1 on [C] - Ignition SW, SW 1 and Relay on (Connect the Relay) and SW 2 off (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: Relay Short [C] Disconnect SW 2 FINDING A SHORT CIRCUIT (a) Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (b) When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Solenoid DISCONNECTION OF MALE AND FEMALE CONNECTORS To pull apart the connectors, pull on the connector itself, not the wire harness. HINT : Check to see what kind of connector you are disconnecting before pulling apart. Pull Up Pull Up Press Down Press Down 2001 AVALON (EWD431U) 13 C TROUBLESHOOTING HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Reference: 1. PREPARE THE SPECIAL TOOL 10 3 1 HINT : To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. DISCONNECT CONNECTOR 1 Example: (Case 1) 0.2 (mm) Up Tool 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTICE: Do not remove the terminal retainer from connector body. Terminal Retainer [A] Terminal Retainer For Non-Waterproof Type Connector HINT : The needle insertion position varies according to the connector’s shape (number of terminals etc.), so check the position before inserting it. [Retainer at Full Lock Position] Stopper ”Case 1” Raise the terminal retainer up to the temporary lock position. Terminal Retainer [Retainer at Temporary Lock Position] Example: (Case 2) Secondary Locking Device ”Case 2” Open the secondary locking device. 2001 AVALON (EWD431U) 14 C Tool Tab Tab Example: (Case 1) [B] Terminal Retainer Tool [Male] Access Hole ( Mark) Tool For Waterproof Type Connector HINT : Terminal retainer color is different according to connector body. Example: Terminal Retainer Black or White Black or White Gray or White : Connector Body : Gray : Dark Gray : Black [Female] ”Case 1” Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (
Mark) and pull the terminal retainer up to the temporary lock position. HINT : The needle insertion position varies according to the connector’s shape (Number of terminals etc.), so check the position before inserting it. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] Example: (Case 2) [Female] ”Case 2” Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Tool Tool [Male] Press Down Press Down [Female] 2001 AVALON (EWD431U) 15 C TROUBLESHOOTING Push the terminal retainer down to the temporary lock position. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] [Female] (c) Release the locking lug from terminal and pull the terminal out from rear. Locking Lug Tool 4. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR 2001 AVALON (EWD431U) 16 AC-73 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY (Auto A/C) AIR CONDITIONING CONTROL ASSEMBLY (Auto A/C) AC2GH-01 COMPONENTS Instrument Panel Register Bracket Radio Bucket seat type: Flash Receptacle Bench seat type: Instrument Lower Cover Bracket A/C Control Assembly A/C Control Panel Case Bulb (Panel Lighting) A/C Amplifier Holder Bulb (Panel Lighting) Bulb (LCD Lighting) I12960 I12956 A/C Control Panel I12969 2001 AVALON (RM808U) Author
: Date
: 1995 AC-74 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY (Auto A/C) AC2GI-01 DISASSEMBLY 1. REMOVE A/C CONTROL PANEL (a) Remove the 4 screws. (b) Using a screwdriver, release the 4 claws. HINT: Tape the screwdriver tip before use. (c) Unlock the connector’s lock and pull out the flat harness from the A/C control panel. I12931 2. (a) (b) REMOVE A/C AMPLIFIER Release the 2 claws and remove the holder. Hold the connector of amplifier and pull out the amplifier. I14061 3. REMOVE BULB Using a screwdriver, turn the bulb to the left and pull out the bulb. I12932 2001 AVALON (RM808U) Author
: Date
: 1996 AC-75 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY (Auto A/C) AC2GJ-01 INSPECTION 1. INSPECT ILLUMINATION OPERATION Connect the positive (+) lead from the battery to terminal 31 and the negative (-) lead to terminal 39, then check that the illumination lights up. If there is bulb not light up, replace the bulb only. If all bulbs do not light up, replace the A/C control panel. 2. INSPECT A/C CONTROL AMPLIFIER CIRCUIT (See page DI-759 ) : Bulb 39 31 I12984 2001 AVALON (RM808U) Author
: Date
: 1997 AC-76 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY (Auto A/C) AC2GK-01 REASSEMBLY 1. (a) (b) INSTALL BULB Install the bulb to the A/C control panel. Using a screwdriver, turn the bulb to the right and lock the bulb. 2. (a) INSTALL A/C AMPLIFIER Hold the connector of supply parts amplifier and pull out the amplifier from electrostatic prevention bag. (b) (c) (d) Hold the connector of amplifier and install the amplifier to the A/C control panel case. Install the holder. Check the fitting for connector of amplifier. 3. (a) (b) (c) (d) INSTALL A/C CONTROL PANEL Unlock the connector’s lock and push into the flat cable. INstall the A/C control panel. Check the fitting for 4 claws. INstall the 4 screws. I12932 I14062 I12931 2001 AVALON (RM808U) Author
: Date
: 1998 AC-79 AIR CONDITIONING - AIR CONDITIONING AMPLIFIER (Manual A/C) AC10F-02 INSTALLATION Installation is in the reverse order of removal (See page AC-78 ). 2001 AVALON (RM808U) Author
: Date
: 2001 AC-77 AIR CONDITIONING - AIR CONDITIONING AMPLIFIER (Manual A/C) AIR CONDITIONING AMPLIFIER (Manual A/C) AC2GL-01 ON-VEHICLE INSPECTION I12987 INSPECT A/C AMPLIFIER CIRCUIT (a) Remove the multi display with connectors still connected. (b) Inspect wire harness side connector from the back side, as shown in the chart below. Test conditions:
Running engine at idle speed
A/C switch ON
Temperature control dial ”MAX COOL” position
Blower speed control switch at ”HI” position
Set on manifold gauge set Tester connection Condition Specified condition Refrigerant pressure at 196 - 3,140 kPa Below 1.0 V 1 - Ground Refrigerant pressure less than 196 kPa or more than 3,140 kPa Battery positive voltage 2 - Ground Constant Pulse generation 5 - Ground A/C switch ON Battery positive voltage 7 - Ground Evaporator temperature at 25 °C (77 °F) Approx. 1.5 kΩ A/C switch ON Battery positive voltage A/C switch OFF Below 1.0 V A/C switch ON Below 2.0 V A/C switch OFF No voltage Constant Battery positive voltage Engine speed at idle-up speed Below 1.0 V A/C switch OFF Battery positive voltage A/C switch ON Below 0.7 V Magnetic clutch is engaged Below 1.0 V Magnetic clutch is not engaged Battery positive voltage 8 - Ground G d 9 - Ground G d 10 - Ground G d 11 - Ground G d 11 - Ground G d If the circuit is not as specified, inspect the circuits connected to other parts. 2001 AVALON (RM808U) Author
: Date
: 1999 AC-78 AIR CONDITIONING - AIR CONDITIONING AMPLIFIER (Manual A/C) AC2GM-01 REMOVAL REMOVE MULTI DISPLAY (Built into the A/C amplifier) (See page BO-90 ) 2001 AVALON (RM808U) Author
: Date
: 2000 AC-12 AIR CONDITIONING - AIR CONDITIONING SYSTEM AC20C-02 CHARGING 1. INSTALL CHARGING CYLINDER HINT: When handling the charging cylinder, always follow the directions given in the instruction manual. (a) Charge the proper amount of refrigerant into the charging cylinder. (b) Connect the center hose to the charging cylinder. CAUTION: Do not open both high and low hand valves of manifold gauge set. (c) Open the valve of charging cylinder. (d) Press the valve core on the side of manifold gauge and expel the air inside of the center hose. Push Air Low Pressure Service Valve High Pressure Service Valve Charging Cylinder N13793 2. (a) INSPECT REFRIGERATION SYSTEM FOR LEAKS Open the high pressure hand valve and charge refrigerant. (b) When the low pressure gauge indicates 98 kPa (1 kgf/cm2, 14 psi) close the high pressure hand valve. (c) Using a gas leak detector, check the system for leakage. If leak is found, repair the faulty component or connection. CAUTION: Use the refrigerant recovery/ recycling machine to recover the refrigerant whenever replacing parts. Gas Leak Detector N13792 2001 AVALON (RM808U) Author
: Date
: 1934 AC-13 AIR CONDITIONING - AIR CONDITIONING SYSTEM 3. Low Pressure Service Valve High Pressure Service Valve N13790 CHARGE REFRIGERANT INTO REFRIGERANT SYSTEM If there is no leak after refrigerant leak check, charge the proper amount of refrigerant into refrigeration system. CAUTION:
Never run the engine when charging the system through the high pressure side.
Do not open the low pressure hand a valve when the system is being charged with liquid refrigerant. (a) Open the high pressure hand valve fully. (b) Charge specified amount of refrigerant, then close the high pressure hand valve. HINT: A fully charged system is indicated by the sight glass being free of any bubbles. (c) Charge partially refrigeration system with refrigerant. (1) Set vehicle in these conditions:
Running engine at 1,500 rpm
Blower speed control set at ”HI”
Temperature control set at ”MAX. COOL”
Air inlet control set at ”RECIRC”
Fully open doors (Sliding roof: closed) (2) Open the low pressure hand valve. CAUTION: Do not open the high pressure hand valve. (d) (e) Charge refrigerant until bubbles disappear and check the pressure on the gauge through the sight glass. Replenishment to be 100 ± 50 g after bubbles disapper. Properly Charged Insufficiently Charged I12287 2001 AVALON (RM808U) Author
: Date
: 1935 AC-1 1 AIR CONDITIONING - AIR CONDITIONING SYSTEM AC0YC-02 EVACUATING Quick Disconnect Adapter 1. Charging Hose 2. 3. (a) (b) Service Valve N13795 CONNECT QUICK DISCONNECT ADAPTER TO CHARGING HOSES REMOVE CAPS FROM SERVICE VALVES ON REFRIGERANT LINES SET ON MANIFOLD GAUGE SET Close both hand valves of manifold gauge set. Connect the quick disconnect adapters to the service valves. 4. (a) EVACUATE AIR FROM REFRIGERATION SYSTEM Connect the vacuum pump adapter to the vacuum pump. (b) Connect the center hose of the manifold gauge set to the vacuum pump adapter. Open both the high and low hand valves and run the vacuum pump. After 10 minutes or more, check that the low pressure gauge indicates 750 mmHg (30 in. Hg) or more. Vacuum Pump Vacuum Pump Adapter N13794 Manifold Gauge Set (c) (d) HINT: If the reading is 750 mmHg (30 in. Hg) or more, close both hand valves of manifold gauge set and stop the vacuum pump. Check the system for leaks and repair if necessary. (e) Close both the high and low hand valves and stop the vacuum pump. (f) Leave the system in this condition for 5 minutes or more and check that there is no gauge indicator. Low Pressure Service Valve High Pressure Service Valve Vacuum Pump Adapter N13791 2001 AVALON (RM808U) Author
: Date
: 1933 AC-14 AIR CONDITIONING - AIR CONDITIONING SYSTEM AC0YE-02 LOCATION Compressor Relay Block No. 8
No. 2 Cooling Fan Relay
No. 3 Cooling Fan Relay Pressure Switch Junction Block No. 8
Heater Main Relay
Magnetic Clutch Relay Auto A/C: Ambient Temperature Sensor Condenser Fan Condenser Auto A/C: Solar Sensor A/C Control Assembly
Manual A/C:
Auto A/C: Blower Speed Control Switch A/C Amplifier
Manual A/C:
Manual A/C: Mode Control Switch A/C Switch Manual A/C: Multi Display (Built into the A/C amplifier) Auto A/C: Room Temperature Sensor I12946 I12953 A/C Unit
Heater Radiator
Evaporator
Expansion Valve
Evaporator Temp. Sensor
Auto A/C Air Mix Servomotor
Air Outlet Servomotor Blower Unit
Blower Motor
Manual A/C: Blower Resistor
Auto A/C: Blower Motor Linear Controller
Air inlet Servomotor I12964 2001 AVALON (RM808U) Author
: Date
: 1936 AC-3 AIR CONDITIONING - AIR CONDITIONING SYSTEM AC0YB-02 ON-VEHICLE INSPECTION ight Glass I12286 Item 1. INSPECT REFRIGERANT VOLUME Observe the sight glass on the liquid tube. Test conditions:  Running engine at 1,500 rpm  Blower speed control switch at ”HI” position  A/C switch ON  Temperature control dial at ”COOL” position  Fully open the doors Symptom Amount of refrigerant Remedy 1 Bubbles present in sight glass Insufficient* (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 2 No bubbles present in sight glass None, sufficient or too much Refer item 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 4 Temperature between compressor inlet and outlet is noticeably different Correct or too much Refer to items 5 and 6 5 Immediately after air conditioning is turned off, refrigerant in sight glass stays clear Too much (1) Discharge refrigerant (2) Evacuate air and charge proper amount of purified refrigerant 6 When air conditioning is turned off, refrigerant foams and then stays clear Correct - *: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient. 2001 AVALON (RM808U) Author
: Date
: 1925 AC-4 AIR CONDITIONING - AIR CONDITIONING SYSTEM 2. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the these conditions are established. Test conditions:  Temperature at the air inlet with the switch set at RECIRC is 30 - 35 °C (86 - 95 °F)  Engine running at 1500 rpm  Blower speed control switch at ”HI” position  Temperature control dial on ”COOL” position HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions. (1) Normally functioning refrigeration system. Gauge reading: Low pressure side: 0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm2) High pressure side: 1.37 - 1.57 MPa (14 - 16 kgf/cm2) I01386 2001 AVALON (RM808U) Author
: Date
: 1926 AC-5 AIR CONDITIONING - (2) AIR CONDITIONING SYSTEM Moisture present in refrigeration system. Condition : Periodically cools and then fails to cool I01387 Symptom seen in refrigeration system Probable cause During operation, pressure on low pressure side sometimes become a vacuum and sometime normal Moisture entered in refrigeration system freezes at expansion valve orifice and temporarily stops cycle, by normal state is restored after a time when the ice melts Diagnosis (3)  Drier oversaturated state  Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant Remedy (1) Replace condenser (2) Remove moisture in cycle through repeatedly evacuating air (3) Charge proper amount of new refrigerant Insufficient cooling Condition: Insufficient cooling I01388 Symptom seen in refrigeration system  Pressure low on both low and high pressure sides  Bubbles seen in sight glass continuously  Insufficient cooling performance Probable cause Gas leakage at some place in refrigeration system Diagnosis  Insufficient refrigerant in system  Refrigerant leaking Remedy (1) Check for gas leakage with gas leak detector and repair if necessary (2) Charge proper amount of refrigerant (3) If indicated pressure value is near 0 when connected to gauge, create the vacuum after inspecting and repairing the location of the leak 2001 AVALON (RM808U) Author
: Date
: 1927 AC-6 AIR CONDITIONING (4) - AIR CONDITIONING SYSTEM Poor circulation of refrigerant Condition: Insufficient cooling I01389 Symptom seen in refrigeration system  Pressure low in both low and high pressure sides  Frost on tube from receiver to unit Probable cause Diagnosis Refrigerant flow obstructed by dirt in receiver (5) Receiver clogged Remedy Replace condenser Refrigerant does not circulate Condition: Does not cool (Cools from time to time in some cases) I01449 Symptom seen in refrigeration system  Vacuum indicated on low pressure side, very low pressure indicated on high pressure side  Frost or dew seen on piping before and after condenser/ drier or expansion valve Probable cause Diagnosis  Refrigerant flow obstructed by moisture or dirt in refrigeration system Refrigerant does not circulate  Refrigerant flow obstructed by gas leakage from expansion valve Remedy (1) Check expansion valve (2) Clean out dirt in expansion valve by blowing with air (3) Replace condenser (4) Evacuate air and charge new refrigerant to proper amount (5) For gas leakage from expansion valve, replace expansion valve 2001 AVALON (RM808U) Author
: Date
: 1928 AC-7 AIR CONDITIONING - (6) AIR CONDITIONING SYSTEM Refrigerant overcharged or insufficient cooling of condenser Condition: Insufficient cooling I01390 Symptom seen in refrigeration system  Pressure too high on both low and high pressure sides  No air bubbles seen through the sight glass even when the engine rpm is lowered Probable cause Diagnosis Remedy  Unable to develop sufficient performance due to excessive refrigeration system  Insufficient cooling of condenser  Excessive refrigerant in cycle → refrigerant over charged  Condenser cooling → condenser fins clogged of condenser fan faulty (1) Clean condenser (2) Check condenser fan motor operation (3) If (1) and (2) are in normal state, check amount of refrigerant Charge proper amount of refrigerant (7) Air present in refrigeration system Condition: Insufficient cooling NOTE : These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without vacuum purging. I01392 Symptom seen in refrigeration system  Pressure too high on both low and high pressure sides  The low pressure piping hot to touch  Bubbles seen in sight glass Probable cause Air entered in refrigeration system Diagnosis  Air present in refrigeration system  Insufficient vacuum purging Remedy (1) Check compressor oil to see if it is dirty or insufficient (2) Evacuate air and charge new refrigerant 2001 AVALON (RM808U) Author
: Date
: 1929 AC-8 AIR CONDITIONING (8) - AIR CONDITIONING SYSTEM Expansion valve improperly Condition: Insufficient cooling I01450 Symptom seen in refrigeration system  Pressure too high on both low and high pressure sides  Frost or large amount of dew on piping on low pressure side Probable cause Diagnosis  Excessive refrigerant in low pressure piping  Expansion valve opened too wide Trouble in expansion valve (9) Remedy Check expansion valve Replace if defective Defective compression compressor Condition : Does not cool I01393 Symptom seen in refrigeration system  Pressure too high on low and high pressure sides  Pressure too low on high pressure side Probable cause Internal leak in compressor Diagnosis  Compression defective  Valve leaking or broken sliding parts Remedy Repair or replace compressor 2001 AVALON (RM808U) Author
: Date
: 1930 AC-9 AIR CONDITIONING - AIR CONDITIONING SYSTEM 3. (a) INSPECT FOR LEAKAGE OF REFRIGERANT Perform in these conditions:  Stop engine.  Secure good ventilation (If the gas leak detector may not react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas.)  Repeat the test 2 or 3 times.  Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is OFF: approx. 392 - 588 kPa (4 - 6 kgf/ cm2, 57 - 85 psi) (b) Bring the gas leak detector close to the drain hose before performing the test. Drain Hose HINT:  N14519 After the blower motor has stopped, leave the cooling unit for more than 15 minutes.  Expose the gas leak detector sensor under the drain hose.  When bring the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. If such reaction is unavoidable, the vehicle must be lifted up. (c) If gas leak is not detected on the drain hose, remove the blower resistor from the cooling unit. Then insert the gas leak detector sensor into the unit and perform the test. (d) Disconnect the connector and leave the pressure switch for approx. 20 minutes. Then bring the gas leak detector close to the pressure switch and perform the test. (e) Bring the gas leak detector close to the refrigerant lines and perform the test. 2001 AVALON (RM808U) Author
: Date
: 1931 AC-10 AIR CONDITIONING 4. (a) (b) - AIR CONDITIONING SYSTEM INSPECT IDLE-UP SPEED Warm up engine. Inspect idle-up speed when the these conditions are established. Test conditions:  Idle speed set correctly.  Steering wheel straight ahead  Blower speed control switch at HI  A/C switch ON  Steering wheel straight ahead Magnetic clutch condition Idle speed Magnetic clutch not engaged 700 ±50 rpm Magnetic clutch engaged 700 ±50 rpm If idle speed is not as specified, check the IAC valve and idle control system (See page SF-43 ,DI-102 ). 2001 AVALON (RM808U) Author
: Date
: 1932 AC-1 AIR CONDITIONING - AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM AC0Y9-02 PRECAUTION 1. 2. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR WEAR EYE PROTECTION ALWAYS WEAR EYE PROTECTION AC2810 3. AC2811 Wrong LO HI 6. Okay LO BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin. (a) Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a physician or hospital for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT HI N11084 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERATION SYSTEM If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so that care to avoid this, necessary care should be taken. 7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATE If the high pressure valve is opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. 2001 AVALON (RM808U) Author
: Date
: 1923 AC-2 AIR CONDITIONING - AIR CONDITIONING SYSTEM 9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The AVALON is equipped with an SRS (Supplemental Restraint System) such as the driver and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing ( including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 2001 AVALON (RM808U) Author
: Date
: 1924 AC-26 AIR CONDITIONING - AIR CONDITIONING UNIT AC2FY-01 COMPONENTS Instrument Panel Reinforcement No. 3 Heater to Register Duct Duct Brace Brace Suction Tube
O-Ring Piping Clamp Liquid Tube Piping Clamp
O-Ring A/C Unit Blower Unit Rear Heater Duct N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part I12951 2001 AVALON (RM808U) Author
: Date
: 1948 AC-27 AIR CONDITIONING - AIR CONDITIONING UNIT Expansion Valve Heater Radiator Unit Case LH Air Duct Evaporator Unit Case RH
O-Rings
O-Rings Liquid and Suction Tube x 10 5.4 (55, 48 in.·lbf) Air Outlet Servomotor Aspirator Auto A/C: Air Mix Servomotor (Passenger side) Air Vent Duct Plate Auto A/C Air Mix Servomotor (Driver side) Auto A/C: Aspirator Hose Drain Hose Evaporator Temp. Sensor Air Duct N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part I12952 2001 AVALON (RM808U) Author
: Date
: 1949 AC-30 AIR CONDITIONING - AIR CONDITIONING UNIT AC2HX-01 DISASSEMBLY 1. REMOVE AIR VENT DUCT 2. REMOVE EVAPORATOR TEMP. SENSOR Pull out the sensor. 3. REMOVE EXPANSION VALVE Using a hexagon wrench, remove the 2 bolts and separate the evaporator, expansion valve, liquid and suction tube. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) HINT: At the time of reassembly, please refer to the following item. Lubricate 4 new O-rings with compressor oil and install them to the valve. I14049 4. Auto A/C only: REMOVE BLOWER MOTOR LINEAR CONTROLLER Remove the 2 screws and controller. 5. REMOVE BLOWER RESISTOR Remove the 2 screws and blower resistor. 6. Auto A/C only: REMOVE AIR MIX SERVOMOTOR (Driver side) Remove the 3 screws and servomotor. 7. Auto A/C only: REMOVE AIR MIX SERVOMOTOR (Passenger side) Remove the 3 screws and servomotor. 8. REMOVE AIR OUTLET SERVOMOTOR Remove the 3 screws and servomotor. 9. REMOVE ASPIRATOR Remove the screw and aspirator. 10. (a) (b) (c) REMOVE HEATER RADIATOR Remove the air duct. Remove the 2 screws and 2 clamps. Pull out the heater radiator. I14050 2001 AVALON (RM808U) Author
: Date
: 1952 AC-31 AIR CONDITIONING - AIR CONDITIONING UNIT 11. REMOVE EVAPORATOR (a) Remove the 10 screws and separate the A/C unit case. (b) Pull out the evaporator. HINT: At the time of reassembly, please refer to the following item. If evaporator is replaced, add compressor oil to evaporator. Add 40 cc (1.4 fl.oz.) Compressor oil: ND-OIL 8 or equivalent 2001 AVALON (RM808U) Author
: Date
: 1953 AC-32 AIR CONDITIONING - AIR CONDITIONING UNIT AC2G0-01 INSPECTION 1. CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. NOTICE: Never use water to clean the evaporator. 2. CHECK FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary. 3. (a) Sensor Ice INSPECT EVAPORATOR TEMPERATURE SENSOR Place the sensor in cold water, and while changing the temperature of water, measure resistance at the connector and at the same time, measure temperature of water with a thermometer. 10 cm (0.39 in.) Ohmmeter I03338 Thermistor (Ω) 5,000 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1,000 500 0 0 32 (b) Compare the 2 readings on the chart. If resistance is not as specified, replace the thermistor. 5 41 10 50 15 59 20 68 25(°C) 77 (°F) Z04352 2001 AVALON (RM808U) Author
: Date
: 1954 AC-34 AIR CONDITIONING - AIR CONDITIONING UNIT AC0YR-02 INSTALLATION Installation is in the reverse order of removal (See page AC-28 ). 2001 AVALON (RM808U) Author
: Date
: 1956 AC-25 AIR CONDITIONING - AIR CONDITIONING UNIT AIR CONDITIONING UNIT AC2FX-01 ON-VEHICLE INSPECTION INSPECT FOR LEAKAGE OF REFRIGERANT (a) Remove the glove compartment door (See page BO-90 ). (b) Remove the blower resister. (c) Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints or check the evaporator. 2001 AVALON (RM808U) Author
: Date
: 1947 AC-33 AIR CONDITIONING - AIR CONDITIONING UNIT AC2HI-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC-30 ). 2001 AVALON (RM808U) Author
: Date
: 1955 AC-28 AIR CONDITIONING - AIR CONDITIONING UNIT AC2KB-01 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant. 3. (a) DISCONNECT LIQUID AND SUCTION TUBES Using SST, remove the 2 piping clamps. SST 09870-00015 (Suction tube) 09870-00025 (Liquid tube) I12289 (1) Insert SST to piping clamp. HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label. SST I03838 Push SST (2) Push down SST and release the clamp lock. NOTICE: Be careful not to deform the tubes, when pushing SST. (3) Pull SST slightly and push the release lever, then remove the piping clamp with SST. (4) Remove the piping clamp from SST. (b) Disconnect the both tubes. Pull SST Release Lever I03839 2001 AVALON (RM808U) Author
: Date
: 1950 AC-29 AIR CONDITIONING - AIR CONDITIONING UNIT NOTICE:
Do not use tools like screwdriver to remove the tube.
Cap the open fittings immediately to keep moisture or dirt out of the system. 4. REMOVE INSTRUMENT PANEL AND REINFORCEMENT (See page BO-90 ) Disconnect the tube using hand Screw Driver Tube I06919 5. (a) (b) DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES Using pliers, grip the claw of the hose clip and slide the hose clip along the hose. Disconnect the water hoses. I12290 Water Hose 45 ± 10° Heater Radiator LH Pipe Upper RH HINT: At the time of installation, please refer to the following item. Push the water hose onto the heater radiator pipe as far as second ridge on the pipe and install the hose clip. 6. REMOVE BLOWER UNIT (See page AC-37 ) RH LH Second Ridge Hose Clip Lower I12291 7. (a) (b) (c) REMOVE A/C UNIT Remove the duct. Disconnect the connectors. Remove the 2 nuts and A/C unit. I12292 2001 AVALON (RM808U) Author
: Date
: 1951 AC-59 AIR CONDITIONING - AIR MIX SERVOMOTOR (Auto A/C) AIR MIX SERVOMOTOR (Auto A/C) AC2GB-01 INSPECTION 1. I12301 (a) (b) (c) (d) 2. 3. 4. (a) (b) (c) 5. 6. I12302 7. (a) (b) (c) (d) 8. (a) (b) (c) Drive side: REMOVE AIR MIX SERVOMOTOR Remove the lower No. 1 panel. Remove the lower LH panel insert. Disconnect the connector. Remove the 3 screws and the servomotor. INSPECT AIR MIX DAMPER POSITION SENSOR CIRCUIT (See page DI-796 ) INSPECT AIR MIX CONTROL SERVOMOTOR CIRCUIT (See page DI-799 ) Passenger side: REMOVE AIR MIX SERVOMOTOR Remove the blower unit (See page AC-37 ). Disconnect the connector. Remove the 3 screws and the servomotor. INSPECT AIR MIX DAMPER POSITION SENSOR CIRCUIT (See page DI-787 ) INSPECT AIR MIX CONTROL SERVOMOTOR CIRCUIT (See page DI-799 ) Driver side: INSTALL AIR MIX SERVOMOTOR Install the servomotor with the 3 screws. Connect the connector. Install the lower LH panel insert. Install the lower No. 1 panel. Passenger side: INSTALL AIR MIX SERVOMOTOR Install the servomotor with the 3 screws. Connect the connector. Install the blower unit (See page AC-37 ). 2001 AVALON (RM808U) Author
: Date
: 1981 AC-60 AIR CONDITIONING - AIR OUTLET SERVOMOTOR AIR OUTLET SERVOMOTOR AC2GC-01 INSPECTION 1. (a) (b) REMOVE AIR OUTLET SERVOMOTOR Remove the instrument panel (See page BO-90 ). Disconnect the connector. (c) 2. Remove the 3 screws and servomotor. INSPECT AIR OUTLET DAMPER POSITION SENSOR CIRCUIT (See page DI-793 ) INSPECT AIR OUTLET DAMPER CONTROL SERVOMOTOR CIRCUIT (See page DI-808 ) INSTALL AIR OUTLET SERVOMOTOR Install the 3 screws with the 3 screws. Connect the connector. Install the instrument panel (See page BO-97 ). 3. I12303 4. (a) (b) (c) 2001 AVALON (RM808U) Author
: Date
: 1982 AC-89 AIR CONDITIONING - AIR REFINER FILTER AIR REFINER FILTER AC2GS-01 REPLACEMENT I12986 1. REMOVE GLOVE COMPARTMENT PARTS (See page BO-90 ) 2. (a) (b) (c) 3. (a) (b) (c) 4. REMOVE AIR REFINER FILTER Remove the filter cover. Pull out the filter. Remove the filter from the frame. INSTALL AIR REFINER FILTER Install the filter to the frame. Install the filter. Install the filter cover. INSTALL GLOVE COMPARTMENT PARTS (See page BO-97 ) 2001 AVALON (RM808U) Author
: Date
: 2011 AC-63 AIR CONDITIONING - AMBIENT TEMPERATURE SENSOR AMBIENT TEMPERATURE SENSOR AC2GF-01 INSPECTION 1. (a) (b) 2. I12306 3. (a) (b) REMOVE AMBIENT TEMPERATURE SENSOR Disconnect the connector. Remove the sensor. INSPECT AMBIENT TEMPERATURE SENSOR CIRCUIT (See page DI-766 ) INSTALL AMBIENT TEMPERATURE SENSOR Install the sensor. Connect the connector. 2001 AVALON (RM808U) Author
: Date
: 1985 AC-56 AIR CONDITIONING - BLOWER MOTOR BLOWER MOTOR AC2G8-01 INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS (See page BO-90 ) 2. (a) (b) REMOVE BLOWER MOTOR Disconnect the connector. Remove the 3 screws and blower motor. I12927 2 1 N16762 3. INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 1, then check that the motor operations smoothly. If operation is not as specified, replace the blower motor. 4. INSTALL BLOWER MOTOR (a) Install the blower motor with the 3 screws. (b) Connect the connector. 5. INSTALL GLOVE COMPARTMENT PARTS (See page BO-97 ) 2001 AVALON (RM808U) Author
: Date
: 1978 AC-57 AIR CONDITIONING - BLOWER RESISTOR (Manual A/C) BLOWER RESISTOR (Manual A/C) AC2G9-01 INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS (See page BO-90 ) 2. (a) (b) REMOVE BLOWER RESISTOR Disconnect the connector. Remove the 2 screws and blower resistor. I12966 3. INSPECT BLOWER RESISTOR RESISTANCE Measure resistance between terminals, as shown in the chart below. 1 2 4 3 I12963 Tester connection Condition Specified condition 1-3 Constant Approx. 0.42 Ω 1-4 Constant Approx. 1.42 Ω 2-4 Constant Approx. 2.24 Ω If resistance is not as specified, replace the blower resistor. 4. INSTALL BLOWER RESISTOR (a) Install the blower resistor with the 2 screws. (b) Connect the connector. 5. INSTALL GLOVE COMPARTMENT PARTS (See page BO-97 ) 2001 AVALON (RM808U) Author
: Date
: 1979 AC-35 AIR CONDITIONING - BLOWER UNIT BLOWER UNIT AC2G1-01 COMPONENTS Instrument Panel Blower Unit Security ECU ECM VSC Translate ECU Junction Connector I12959 2001 AVALON (RM808U) Author
: Date
: 1957 AC-36 AIR CONDITIONING - BLOWER UNIT Blower Unit Case Auto A/C models: Air Refiner Filter Air Inlet Servomotor Blower Motor Wire Harness Manual A/C: Blower Resister Auto A/C: Blower Motor Linear Controller I12954 2001 AVALON (RM808U) Author
: Date
: 1958 AC-38 AIR CONDITIONING - BLOWER UNIT AC2G2-01 DISASSEMBLY 1. (a) (b) (c) REMOVE AIR REFINER FILTER Release the 2 claws and remove the cover. Pull out the air refiner filter. Remove the filter from filter case. 2. REMOVE BLOWER MOTOR Remove the 3 screws and motor. I12927 3. REMOVE AIR INLET SERVOMOTOR Remove the 3 screws and servomotor. I12985 2001 AVALON (RM808U) Author
: Date
: 1960 AC-39 AIR CONDITIONING - BLOWER UNIT AC2G3-01 INSPECTION 2 1. To ”FRESH” 5 + - Manual A/C: INSPECT AIR INLET SERVOMOTOR Inspect the servomotor operation. (1) Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 2. (2) Check the motor arm rotates counterclockwise and arm stops on the ”FRESH” position. I12939 To ”RECIRC” (3) 1 5 + I12938 Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 1. (4) Check the motor arm rotates counterclockwise and arm stops on the ”RECIRC” position. If operations are not as specified, replace the servomotor. 2. Auto A/C: INSPECT AIR INLET DAMPER POSITION SENSOR CIRCUIT (See page DI-790 ) 3. Auto A/C: INSPECT AIR INLET CONTROL SERVOMOTOR CIRCUIT (See page DI-802 ) 2001 AVALON (RM808U) Author
: Date
: 1961 AC-41 AIR CONDITIONING - BLOWER UNIT AC0YW-02 INSTALLATION Installation is in the reverse order of removal (See page AC-37 ). 2001 AVALON (RM808U) Author
: Date
: 1963 AC-40 AIR CONDITIONING - BLOWER UNIT AC0YV-02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC-38 ). 2001 AVALON (RM808U) Author
: Date
: 1962 AC-37 AIR CONDITIONING - BLOWER UNIT AC0YT-03 REMOVAL 1. 2. 3. 4. REMOVE REMOVE REMOVE REMOVE INSTRUMENT PANEL (See page BO-90 ) SECURITY ECU TRANSLATE ECU ECM 5. (a) (b) (c) REMOVE BLOWER UNIT Remove the 2 connector bracket set screws. Disconnect the connectors. Remove the bolt, nut, 2 screws and blower unit. I12962 2001 AVALON (RM808U) Author
: Date
: 1959 AC-58 AIR CONDITIONING - BLOWER MOTOR LINEAR CONTROLLER (Auto A/C) BLOWER MOTOR LINEAR CONTROLLER (Auto A/C) AC2GA-01 INSPECTION 1. REMOVE GLOVE COMPARTMENT PARTS (See page BO-90 ) 2. (a) (b) REMOVE BLOWER MOTOR LINEAR CONTROLLER Disconnect the connector. Remove the 2 screws and controller. I12967 3. 4 3 2 INSPECT BLOWER MOTOR LINEAR CONTROLLER CIRCUIT Connect the connector to the controller and inspect the wire harness side connector from the back side, as shown in the chart. Test conditions:
Turn ignition switch to ON
Operate blower motor 1 I03539 Tester connection Condition Specified conditions 1 - Ground Constant Continuity 2 - Ground Constant Battery positive voltage 2 - Ground Turn ignition switch to LOCK or ACC No voltage If the circuit is as specified, try to replace the controller with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. 4. INSTALL BLOWER MOTOR LINEAR CONTROLLER (a) Install the blower motor linear controller with the 2 screws. (b) Connect the connector. 5. INSTALL GLOVE COMPARTMENT PARTS (See page BO-97 ) 2001 AVALON (RM808U) Author
: Date
: 1980 AC-43 AIR CONDITIONING - COMPRESSOR AND MAGNETIC CLUTCH AC1N0-02 COMPONENTS Generator 56 (570, 41) Discharge Hose 18 (185, 13) 10 (100, 7) Suction Hose 10 (100, 7) Drive Belt 25 (250, 18) Compressor 25 (250, 18) 25 (250, 18) Drive Belt Adjusting Bar Bracket 25 (250, 18) Rotor Stator Pressure Plate Shim 13.2 (135, 9) Compressor N·m (kgf·cm, ft·lbf) : Specified torque
Non reusable part
Snap Ring I12928 2001 AVALON (RM808U) Author
: Date
: 1965 AC-46 AIR CONDITIONING - COMPRESSOR AND MAGNETIC CLUTCH AC1N2-04 DISASSEMBLY 1. (a) REMOVE PRESSURE PLATE Using SST and a socket wrench, remove the shaft bolt. SST 07112-76060 Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf) (b) IInstall SST on the pressure plate. SST 07112-66040 (c) Using SST and socket wrench, remove the pressure plate. SST 07112-76060, 07112-66040 (d) Remove the shims from the pressure plate. 2. (a) REMOVE ROTOR Using SST, remove the snap ring. SST 95994-10020 SST AC0943 SST AC0944 SST AC0945 Shim Pressure Plate AC0946 SST AC0947 2001 AVALON (RM808U) Author
: Date
: 1968 AC-47 AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH NOTICE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that beveled side faces up. Snap Ring R-Shape - Rotor Compressor N20013 (b) Using a plastic hammer, tap the rotor off the shaft. NOTICE: Be careful not to damage the pulley when tapping on the rotor. AC1743 3. (a) REMOVE STATOR Disconnect the stator lead wire from the compressor housing. (b) Using SST, remove the snap ring. SST 95994-10020 AC1744 SST AC0950 NOTICE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that its beveled side faces up. R-Shape Snap Ring Stator Compressor N20012 2001 AVALON (RM808U) Author
: Date
: 1969 AC-48 AIR CONDITIONING (c) - COMPRESSOR AND MAGNETIC CLUTCH Remove the stator. Stator AC0951 2001 AVALON (RM808U) Author
: Date
: 1970 AC-50 AIR CONDITIONING - COMPRESSOR AND MAGNETIC CLUTCH AC1N4-02 INSTALLATION 1. (a) INSTALL COMPRESSOR Install the compressor with 3 nuts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (b) (A) (B) N20259 Install the generator drive belt adjusting bar bracket with 2 bolts and a nut. Torque: Bolt (A): 18 N·m (185 kgf·cm, 13 ft·lbf) Bolt (B): 25 N·m (250 kgf·cm, 18 ft·lbf) Nut: 25 N·m (250 kgf·cm, 18 ft·lbf) 2. INSTALL GENERATOR (a) Mount generator on the generator bracket with the pivot bolt and adjusting lock bolt. Do not tighten the bolts yet. (b) Connect the generator connector. (c) Connect the generator wire with the nut. 3. CONNECT DISCHARGE AND SUCTION HOSES Connect both hoses with the bolt and nut. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Hoses should be connected immediately after the caps have been removed. HINT: Lubricate 2 new O-ring with compressor oil and install them to the tube. 4. INSTALL AND CHECK DRIVE BELT (See page AC-19 , AC-17 ) 5. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY 6. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 7. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. 8. INSPECT A/C OPERATION 2001 AVALON (RM808U) Author
: Date
: 1972 AC-42 AIR CONDITIONING - COMPRESSOR AND MAGNETIC CLUTCH COMPRESSOR AND MAGNETIC CLUTCH AC2G4-01 ON-VEHICLE INSPECTION 1. INSPECT COMPRESSOR FOR METALLIC SOUND Check there is abnormal metallic sound from the compressor when the A/C switch is ON. If abnormal metallic sound is heard, replace the compressor assembly. 2. INSPECT REFRIGERANT PRESSURE (See page AC-3 ) 3. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly. 4. 1 2 I12297 INSPECT COMPRESSOR LOCK SENSOR RESISTANCE (a) Disconnect the connector. (b) Measure resistance between terminals 1 and 2. Standard resistance: 65 - 125 Ω at 20 °C (68 °F) If resistance is not as specified, replace the sensor. 5. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING 6. CHECK FOR SIGNS OF OIL ON PRESSURE PLATE OR ROTOR 7. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE (a) Start engine. (b) Check for abnormal noise from the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the magnetic clutch. 8. (a) (b) INSPECT MAGNETIC CLUTCH OPERATION Disconnect the connector. Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to the body ground. (c) Check that the magnetic clutch energized. If operation is not as specified, replace the magnetic clutch. 3 I12298 2001 AVALON (RM808U) Author
: Date
: 1964 AC-49 AIR CONDITIONING - COMPRESSOR AND MAGNETIC CLUTCH AC1N3-02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC-46 ). Dial Indicator N04963 AFTER REASSEMBLY, CHECK MAGNETIC CLUTCH CLEARANCE (a) Set the dial indicator to the pressure plate of the magnetic clutch. (b) Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. (c) Check the clearance between the pressure plate and rotor when connecting the negative (-) terminal to the battery. Standard clearance: 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) If the clearance is not within the standard, adjust the clearance using shims to obtain the standard. Shim thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) 2001 AVALON (RM808U) Author
: Date
: 1971 AC-44 AIR CONDITIONING - COMPRESSOR AND MAGNETIC CLUTCH AC1N1-02 REMOVAL 1. 2. 3. 4. 5. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES STOP ENGINE DISCONNECT NEGATIVE (- ) TERMINAL CABLE FROM BATTERY DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM REMOVE DRIVE BELT (See page AC-18 ) 6. DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 nuts and disconnect the both hoses. NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. I12935 7. (a) (b) (c) (d) REMOVE GENERATOR Disconnect the generator connector. Remove the nut, and disconnect the generator wire. Disconnect the wire harness from the clamp. Remove the pivot bolt, adjusting lock bolt and generator. 8. (a) (b) (c) REMOVE COMPRESSOR Disconnect the connector. Disconnect the wire harness clamp. Remove the 2 bolts, nut and drive belt adjusting bar bracket. P19978 N20259 2001 AVALON (RM808U) Author
: Date
: 1966 AC-45 AIR CONDITIONING (d) - COMPRESSOR AND MAGNETIC CLUTCH Remove the 3 bolts and compressor. I12947 2001 AVALON (RM808U) Author
: Date
: 1967 AC-70 AIR CONDITIONING - COOLING FAN RELAY COOLING FAN RELAY AC20V-02 No. 2 Cooling Fan Relay INSPECTION 1. REMOVE NO. 2 COOLING FAN RELAY FROM RELAY BLOCK NO. 8 2. REMOVE NO. 3 COOLING FAN RELAY FROM RELAY BLOCK NO. 8 3. INSPECT NO. 2 COOLING FAN RELAY (Marking: A.C FAN NO. 2) CONTINUITY I12944 No. 3 Cooling Fan Relay I12945 5 3 2 Condition Tester connection Specified condition Constant 1-2 3-4 Continuity Apply B+ between terminals 1 and 2. 3-5 Continuity If continuity is not as specified, replace the relay. 1 4 N23635 4. INSPECT NO. 3 COOLING FAN RELAY (Marking: A.C FAN NO. 3) CONTINUITY 2 Condition Tester connection Specified condition 3 5 Constant 1-2 Continuity 1 2 Apply B+ between terminals 1 and 2. 3-5 Continuity 3 5 If continuity is not as specified, replace the relay. 1 I05027 2001 AVALON (RM808U) Author
: Date
: 1992 AC-52 AIR CONDITIONING - CONDENSER AC28I-02 COMPONENTS Condenser Radiator Upper Support Discharge Hose Radiator Upper Support
O-ring 5.4 (55, 48 in.·lbf)
O-ring Liquid Tube 5.4 (55, 48 in.·lbf) Condenser Dryer I12949 I12950 Filter Cap 12.3 (125, 9) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Compressor oil ND-OIL 8 or equivalent I12965 2001 AVALON (RM808U) Author
: Date
: 1974 AC-55 AIR CONDITIONING - CONDENSER AC2G7-01 INSTALLATION Installation is in the reverse order of removal (See page AC-53 ). 2001 AVALON (RM808U) Author
: Date
: 1977 AC-51 AIR CONDITIONING - CONDENSER CONDENSER AC2G5-01 ON-VEHICLE INSPECTION 1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air. NOTICE: Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers. 2. INSPECT CONDENSER AND FITTING FOR LEAKAGE Using a gas leak detector, check for leakage. If there is leakage, check the tightening torque at the joints. 2001 AVALON (RM808U) Author
: Date
: 1973 AC-53 AIR CONDITIONING - CONDENSER AC2G6-01 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. REMOVE RADIATOR AND CONDENSER FANS (See page AC-46 ) 3. REMOVE 2 RADIATOR UPPER SUPPORTS I12299 I12300 4. DISCONNECT DISCHARGE HOSE AND LIQUID TUBE Remove the 2 bolts and disconnect the hose and tube. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O-rings with compressor oil and install them to the hose. 5. REMOVE CONDENSER (a) Remove the 2 condenser set bolts. (b) Push the radiator toward the engine. (c) Push the condenser toward the radiator and pull it upward. HINT: At the time of installation, please refer to the following item. If condenser is replaced, add compressor oil to the condenser. Add 40 cc (1.4 fl.oz.) Compressor oil: ND-OIL 8 or equivalent 2001 AVALON (RM808U) Author
: Date
: 1975 AC-54 AIR CONDITIONING - CONDENSER AC28K-02 REPLACEMENT REPLACE DRIER FROM MODULATOR (a) Using a hexagon wrench (10 mm, 0.39 in.), remove the cap from the modulator. (b) Remove the filter from the modulator. 10 mm (0.39 in.) Hexagon Wrench Modulator I10090 (c) Using pliers, remove the drier. I10092 (d) Insert a new drier into the modulator. NOTICE:
Do not remove the drier from a vinyl bag until inserting it into the modulator.
Install the drier with its 2 layered part faced upward to the modulator. 2 Layered Part I10093 (e) Insert the filter into the modulator. NOTICE: Install the filter with its protrusion faced downward to the modulator. Protrusion I10091 (f) Install the cap to the modulator. (1) Apply compressor oil to the O-rings and screw part of the cap. Compressor oil: ND-OIL 8 or equivalent (2) Using a hexagon wrench (10 mm, 0.39 in.), install the caps. Torque: 12.3 N·m (125 kgf·cm, 9 ft·lbf) I10094 2001 AVALON (RM808U) Author
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: 1976 AC-72 AIR CONDITIONING - CONDENSER FAN AC105-03 COMPONENTS Condenser Fan Connector Condenser Fan Upper Hose Fan Shroud Fan Motor Fan I12957 I12958 N·m (kgf·cm, in.·lbf) : Specified toque
Non reusable part I12968 2001 AVALON (RM808U) Author
: Date
: 1994 AC-71 AIR CONDITIONING - CONDENSER FAN CONDENSER FAN AC104-03 ON-VEHICLE INSPECTION 1. INSPECT CONDENSER FAN OPERATION Inspect the fan operation at these conditions, as shown in the chart. Test conditions:
Start engine
Blower speed control switch position ”HI”
Temperature control dial at ”COOL” position
Set on manifold gauge set
A/C switch ON Condition Fan operation (Fan speed) Engine coolant temperature 88 °C (190 °F) or below Rotate (Low speed) Engine coolant temperature 98 °C (208 °F) or above Rotate (High speed) Refrigerant pressure is less than 1,520 kPa (15.5 kgf/cm2, 220 psi) Rotate (Low speed) Refrigerant pressure is 1,520 kPa (15.5 kgf/cm2, 220 psi) or above Rotate (High speed) If operation is not as specified, proceed to the next inspection. 2 2. (a) (b) (c) 1 I12942 INSPECT CONDENSER FAN MOTOR OPERATION Disconnect the fan connector. Connect battery and ammeter. Check that the fan rotates smoothly, and then check the reading on the ammeter. Specified amperage: 9.2 - 11.0 A at 20 °C (68 °F) If operation is not as specified, replace the fan motor. If operation is as specified, check the pressure switch, cooling fan relays and water temp. switch. 2001 AVALON (RM808U) Author
: Date
: 1993 AC-19 AIR CONDITIONING - DRIVE BELT AC2FW-01 INSTALLATION Pivot Bolt Adjusting Lock Bolt P00763 INSTALL DRIVE BELT (a) Install the drive belt. (b) Apply drive belt tension by adjusting bolt. Drive belt tension: New belt: 165 ± 22 lbf Used belt: 110 ± 22 lbf (c) Tighten the adjusting lock bolt and pivot bolt. Torque: Pivot bolt: 56 N·m (570 kgf·cm, 41 ft·lbf) Adjusting lock bolt: 18 N·m (185 kgf·cm, 13 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1941 AC-17 AIR CONDITIONING - DRIVE BELT DRIVE BELT AC0YF-03 ON-VEHICLE INSPECTION 1. INSPECT DRIVE BELT’S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. Correct Wrong CH0086 Generator Crankshaft Pulley DENSO Compressor I14032 Borroughs 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt: 165 ± 22 lbf Used belt: 88 ± 22 lbf HINT:
”New belt” refers to a belt which has been used less than 5 minutes on the running engine.
”Used belt” refer to a belt which has been on a running engine for 5 minutes or more.
After installing the drive belt, check that it fits properly in the ribbed grooves. N01881 2001 AVALON (RM808U) Author
: Date
: 1939 AC-18 AIR CONDITIONING - DRIVE BELT AC0YG-03 REMOVAL Pivot Bolt REMOVE DRIVE BELT (a) Loosen the pivot bolt and adjusting lock nut. (b) Loosen the drive belt tension by adjusting bolt and remove the drive belt. Adjusting Lock Bolt P00763 2001 AVALON (RM808U) Author
: Date
: 1940 AC-64 AIR CONDITIONING - EVAPORATOR TEMPERATURE SENSOR EVAPORATOR TEMPERATURE SENSOR AC2GG-01 INSPECTION 1. (a) REMOVE EVAPORATOR TEMPERATURE SENSOR Remove the blower unit (See page AC-37 ). (b) Remove evaporator temperature sensor. (1) Disconnect the connector. (2) Pull out the sensor. I12917 2. INSPECT EVAPORATOR TEMPERATURE SENSOR Inspect evaporator temperature sensor resistance. (1) Place the sensor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. Thermometer Ice Ohmmeter 10 cm (3.94 in.) Sensor (Ω) 5,000 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1,000 500 0 AC0175 0 5 10 15 20 25 (°C) 32 41 50 59 68 77 (°F) (2) Compare the 2 readings on the chart. If resistance value is not as specified, replace the sensor. 3. INSTALL EVAPORATOR TEMPERATURE SENSOR (a) Install the evaporator temperature sensor. (1) Install the sensor. (2) Connect the connector. (b) Install the blower unit. (See page AC-41 ) Z04352 2001 AVALON (RM808U) Author
: Date
: 1986 AC-81 AIR CONDITIONING - HEATER CONTROL ASSEMBLY (Manual A/C) AC2GO-01 COMPONENTS Instrument Panel Register Radio Bracket Bucket seat type: Flash Receptacle Bench seat type: Instrument Lower Cover Bracket Heater Control Assembly Bulb Heater Control Cover Air Mix Damper Control Cable (Color: Black) Bulb Air Conditioning Panel Heater Control Housing Air Mix Damper Control Cable (Color: Blue) Heater Control Name Sheet I12961 I12955 Knobs I12970 2001 AVALON (RM808U) Author
: Date
: 2003 AC-83 AIR CONDITIONING - HEATER CONTROL ASSEMBLY (Manual A/C) AC2GQ-01 INSPECTION 1. INSPECT ILLUMINATION OPERATION Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 9 then check that the illuminations lights up. If operation is not as specified, check the faulty bulb. : Bulb 1 9 I12971 2. INSPECT BULB Apply the tester as shown in the illustration to the test for continuity. If continuity exists, replace the heater control. If no continuity exists, replace the bulb. I07872 3. (a) INSPECT A/C INDICATOR OPERATION Connect the positive (+) lead from the battery to terminal 10 and the negative (-) lead to terminal 11. (b) Push the A/C button in and then check that the indicator lights up. If operation is not as specified, replace the switch. 11 10 I12972 4. (a) INSPECT DIMMING OPERATION Connect the positive (+) lead from the battery to terminal 10 and the negative (-) lead to terminal 11 while press the switch. (b) Connect the positive (+) lead from the battery to terminal 1 and then check that the indicator dims. If operation is not as specified, replace the switch. 1 11 10 I12973 2001 AVALON (RM808U) Author
: Date
: 2005 AC-84 AIR CONDITIONING 5. - HEATER CONTROL ASSEMBLY (Manual A/C) INSPECT A/C SWITCH CONTINUITY Condition / Circuit Tester connection Specified condition OFF 5-6 No continuity ON 5-6 Continuity If operation is not as specified, replace the switch circuit board. I12974 6. (a) INSPECT RECIRC INDICATOR OPERATION Connect the positive (+) lead from the battery to terminal 10 and the negative (-) lead to terminal 8. (b) Push the REC button in and then check that the indicator lights up. If operation is not as specified, replace the switch circuit board. 8 10 I12975 7. (a) INSPECT DIMMING OPERATION Connect the positive (+) lead from the battery to terminal 10 and the negative (-) lead to terminal 8 while press the switch. (b) Connect the positive (+) lead from the battery to terminal 4 and then check that the indicator dims. If operation is not as specified, replace the switch circuit board. 1 8 10 I12976 8. INSPECT RECIRC SWITCH CONTINUITY Condition / Circuit Tester connection Specified condition OFF 18 - 8 No continuity ON 18 - 8 Continuity If operation is not as specified, replace the switch circuit board. I12977 9. (a) INSPECT FRESH INDICATOR OPERATION Connect the positive (+) lead from the battery to terminal 10 and the negative (-) lead to terminal 8. (b) Push the FRS button in and then check that the indicator lights up. If operation is not as specified, replace the switch circuit board. 7 10 I12978 2001 AVALON (RM808U) Author
: Date
: 2006 AC-85 AIR CONDITIONING - HEATER CONTROL ASSEMBLY (Manual A/C) 10. (a) INSPECT DIMMING OPERATION Connect the positive (+) lead from the battery to terminal 10 and the negative (-) lead to terminal 8 while press the switch. (b) Connect the positive (+) lead from the battery to terminal 1 and then check that the indicator dims. If operation is not as specified, replace the switch circuit board. 1 8 10 I12979 11. INSPECT FRESH SWITCH CONTINUITY Condition / Circuit Tester connection Specified condition OFF 17 - 8 No continuity ON 17 - 8 Continuity If operation is not as specified, replace the switch circuit board. I12977 12. INSPECT REAR DEFOGGER INDICATOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 10, 4 and negative (-) lead to terminal 8. (b) Push the RDEF button in and then check that the indicator lights up. If operation is not as specified, replace the switch circuit board. 8 4 10 I12980 13. (a) 8 4 1 10 INSPECT DIMMING OPERATION Connect the positive (+) lead from the battery to terminal 10, 4 and negative (-) lead to terminal 8 while press the switch. (b) Connect the positive (+) lead from the battery to terminal 1 and then check that the indicator dims. If operation is not as specified, replace the switch circuit board. I12981 14. INSPECT REAR DEFOGGER SWITCH CONTINUITY Condition / Circuit Tester connection Specified condition OFF 4-8 No continuity ON 4-8 Continuity If operation is not as specified, replace the switch circuit board. I12982 2001 AVALON (RM808U) Author
: Date
: 2007 AC-86 AIR CONDITIONING 15. LO M1 M2 HI - HEATER CONTROL ASSEMBLY (Manual A/C) INSPECT BLOWER SPEED CONTROL SWITCH CONTINUITY Condition / Circuit Tester connection Specified condition OFF - No continuity LO 1-8 Continuity M1 1-6-8 Continuity M2 1-5-8 Continuity HI 1-4-8 Continuity I12937 If operation is not as specified, replace the switch. 16. I12983 INSPECT MODE CONTROL SWITCH CONTINUITY Condition / Circuit Tester connection Specified condition FACE 12 - 8 Continuity B/L 13 - 8 Continuity FOOT 14 - 8 Continuity FOOT/DEF. 15 - 8 Continuity DEF. 16 - 8 Continuity If operation is not as specified, replace the switch. 2001 AVALON (RM808U) Author
: Date
: 2008 AC-87 AIR CONDITIONING - HEATER CONTROL ASSEMBLY (Manual A/C) AC2GR-01 INSTALLATION 1. (a) (b) INSTALL HEATER CONTROL ASSEMBLY Install the heater control assembly and stereo opening cover assembly to 2 brackets. Install the 8 bolts and 4 screws. I12923 (c) (d) (e) (f) I12922 Connect the connectors. Install the heater control assembly with the 4 bolts. Pass the through the air mix control cable (Driver side) as shown the illustration. Driver side cable should be set between driver side brace and A/C unit. Pass the throught the air mix control cable (Passenger side) as shown the illustration. Passenger side cable should be set outerside passenger side side brace. Air Mix Control Cable Air Mix Control Cable I12924 2. (a) CONNECT HEATER CONTROL CABLES Set the air mix control knobs to ”MAX. COOL” position. 2001 AVALON (RM808U) Author
: Date
: 2009 AC-88 AIR CONDITIONING - HEATER CONTROL ASSEMBLY (Manual A/C) (b) To ”Cool” Pull I12925 Pull Adjust air mix control cables. Set the cable connectors to lever pin and clamp the cable outers with keeping the knobs to ”MAX. COOL” position (Both driver side and passenger side). NOTICE:
Don’t bend the cable on setting the cable.
Don’t move the air mix knob before finishing on clamping the cable outer. 3. INSTALL CENTER CLUSTER FINISH PANEL (See page BO-97 ) To ”Cool” I12926 2001 AVALON (RM808U) Author
: Date
: 2010 AC-80 AIR CONDITIONING - HEATER CONTROL ASSEMBLY (Manual A/C) HEATER CONTROL ASSEMBLY (Manual A/C) AC2GN-01 ON-VEHICLE INSPECTION I12920 INSPECT HEATER CONTROL DIALS OPERATION Turn the control dials left and right then check that click sound can be heard and recoil is felt. If click sound can not be heard or recoil is felt, adjust the control cable or check control cable and heater control assembly. 2001 AVALON (RM808U) Author
: Date
: 2002 AC-82 AIR CONDITIONING - HEATER CONTROL ASSEMBLY (Manual A/C) AC2GP-01 REMOVAL 1. REMOVE CENTER CLUSTER FINISH PANEL (See page BO-90 ) 2. DISCONNECT HEATER CONTROL CABLES NOTICE: When the air mix damper control cable is disconnected, should not bend the cable. Air Mix Control Cable Air Mix Control Cable I12921 3. (a) REMOVE HEATER CONTROL ASSEMBLY Remove the 4 bolts and pull out the heater control assembly with stereo opening cover assembly, then disconnect the connectors. (b) (c) Remove the 8 bolts, 4 screws and 2 brackets. Separate the heater control assembly and stereo opening cover assembly. I12922 I12923 2001 AVALON (RM808U) Author
: Date
: 2004 AC-68 AIR CONDITIONING Heater Main Relay - HEATER MAIN RELAY HEATER MAIN RELAY AC20T-02 INSPECTION 1. REMOVE HEATER MAIN RELAY FROM NO. 2 J/B 2. INSPECT HEATER MAIN RELAY (Marking: HTR) CONTINUITY I12918 3 4 5 5 4 1 1 3 2 Condition Tester connection Specified condition Constant 2-4 3-5 Continuity Apply B+ between terminals 3 and 5. 1-2 Continuity If continuity is not as specified, replace the relay. 2 Z19533 2001 AVALON (RM808U) Author
: Date
: 1990 AC-69 AIR CONDITIONING Magnetic Clutch Relay - MAGNETIC CLUTCH RELAY MAGNETIC CLUTCH RELAY AC20U-03 INSPECTION 1. REMOVE MAGNETIC CLUTCH RELAY FROM NO. 2 J/B 2. INSPECT MAGNETIC CLUTCH RELAY (Marking: MG CLT) CONTINUITY I12919 2 1 3 5 3 1 2 Condition Tester connection Specified condition Constant 1-2 Continuity Apply B+ between terminals 1 and 2. 3-5 Continuity If continuity is not as specified, replace the relay. 5 Z18060 2001 AVALON (RM808U) Author
: Date
: 1991 AC-21 AIR CONDITIONING - MANIFOLD GAUGE SET AC0YJ-02 SET OFF 1. 2. N06553 CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick disconnect adapter upward to unlock the adapter and remove it from the service valve. 3. INSTALL CAPS TO SERVICE VALVES ON REFRIGERANT LINE 2001 AVALON (RM808U) Author
: Date
: 1943 AC-20 AIR CONDITIONING - MANIFOLD GAUGE SET MANIFOLD GAUGE SET AC0YI-02 SET ON 1. CONNECT CHARGE HOSE TO MANIFOLD GAUGE SET Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses. 2. CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand. 3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 4. REMOVE CAPS FROM SERVICE VALVE ON REFRIGERANT LINE High Pressure Charging Hose Low Pressure Charging Hose I12288 5. CONNECT QUICK DISCONNECT ADAPTER TO SERVICE VALVES HINT: Push the quick disconnect adapter onto the service valve, slide, then slide the sleeve of the quick disconnect adapter downward to lock it. Sleeve N04392 2001 AVALON (RM808U) Author
: Date
: 1942 AC-67 AIR CONDITIONING - PRESSURE SWITCH AC102-02 INSTALLATION Installation is in the reverse order of removal (See page AC-66 ). 2001 AVALON (RM808U) Author
: Date
: 1989 AC-65 AIR CONDITIONING - PRESSURE SWITCH PRESSURE SWITCH 1 AC100-03 4 ON-VEHICLE INSPECTION 3 1. 2. 2 3. SET ON MANIFOLD GAUGE SET (See page AC-20 ) DISCONNECT CONNECTOR FROM PRESSURE SWITCH RUN ENGINE AT APPROX. 1,500 RPM I12940 4. Magnetic clutch control Low pressure side High pressure side ON (Continuity) 3,140 kpa 196 kpa (2.0 kgf/cm2, 28 psi) (32.0 kgf/cm2, 455 psi) OFF (No Continuity) OFF (No Continuity) Magnetic clutch control: INSPECT PRESSURE SWITCH OPERATION (a) Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative (-) lead to terminal 1. (b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Z13470 5. Cooling fan control ON (Continuity) 1,520 kpa (15.5 kgf/cm2, 220 psi) OFF (No Continuity) 1,226 kpa (12.5 kgf/cm2, 178 psi) Z13471 Cooling fan control: INSPECT PRESSURE SWITCH OPERATION (a) Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 3. (b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 6. STOP ENGINE AND SET OFF MANIFOLD GAUGE SET 7. CONNECT CONNECTOR TO PRESSURE SWITCH 2001 AVALON (RM808U) Author
: Date
: 1987 AC-66 AIR CONDITIONING - PRESSURE SWITCH AC101-03 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) I12941 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) HINT:
Lock the switch mounted on the tube with an open end wrench, being careful not to deform the tube and remove the switch.
At the time of installation, please refer to the following item. Lubricate a new O-ring with the compressor oil and install them to the switch. 2001 AVALON (RM808U) Author
: Date
: 1988 AC-67 AIR CONDITIONING - PRESSURE SWITCH AC102-02 INSTALLATION Installation is in the reverse order of removal (See page AC-66 ). 2001 AVALON (RM808U) Author
: Date
: 1989 AC-65 AIR CONDITIONING - PRESSURE SWITCH PRESSURE SWITCH 1 AC100-03 4 ON-VEHICLE INSPECTION 3 1. 2. 2 3. SET ON MANIFOLD GAUGE SET (See page AC-20 ) DISCONNECT CONNECTOR FROM PRESSURE SWITCH RUN ENGINE AT APPROX. 1,500 RPM I12940 4. Magnetic clutch control Low pressure side High pressure side ON (Continuity) 3,140 kpa 196 kpa (2.0 kgf/cm2, 28 psi) (32.0 kgf/cm2, 455 psi) OFF (No Continuity) OFF (No Continuity) Magnetic clutch control: INSPECT PRESSURE SWITCH OPERATION (a) Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative (-) lead to terminal 1. (b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Z13470 5. Cooling fan control ON (Continuity) 1,520 kpa (15.5 kgf/cm2, 220 psi) OFF (No Continuity) 1,226 kpa (12.5 kgf/cm2, 178 psi) Z13471 Cooling fan control: INSPECT PRESSURE SWITCH OPERATION (a) Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 3. (b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 6. STOP ENGINE AND SET OFF MANIFOLD GAUGE SET 7. CONNECT CONNECTOR TO PRESSURE SWITCH 2001 AVALON (RM808U) Author
: Date
: 1987 AC-66 AIR CONDITIONING - PRESSURE SWITCH AC101-03 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) I12941 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) HINT:
Lock the switch mounted on the tube with an open end wrench, being careful not to deform the tube and remove the switch.
At the time of installation, please refer to the following item. Lubricate a new O-ring with the compressor oil and install them to the switch. 2001 AVALON (RM808U) Author
: Date
: 1988 AC-23 AIR CONDITIONING - REFRIGERANT LINE AC0YL-02 LOCATION Liquid Tube 10 (100, 7) Suction Hose 10 (100, 7) 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) Discharge Hose N·m (kgf·cm, ft·lbf) : Specified torque I12948 2001 AVALON (RM808U) Author
: Date
: 1945 AC-22 AIR CONDITIONING - REFRIGERANT LINE REFRIGERANT LINE AC0YK-01 ON-VEHICLE INSPECTION 1. INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. 2001 AVALON (RM808U) Author
: Date
: 1944 AC-24 AIR CONDITIONING - REFRIGERANT LINE AC0YM-02 REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TORQUE NOTICE: Connections should not be torqued tighter than the specified torqued. Part tightened N·m kgf·cm ft·lbf Condenser x Discharge hose 5.4 55 48 in.·lbf Condenser x Liquid tube 5.4 55 48 in.·lbf Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Expansion valve x Evaporator 5.4 55 48 in.·lbf Suction line (Block joint) 10 100 7 Liquid line (Block joint) 10 100 7 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 ± 50g (21.16 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. 6. INSPECT A/C OPERATION 2001 AVALON (RM808U) Author
: Date
: 1946 AC-62 AIR CONDITIONING - ROOM TEMPERATURE SENSOR ROOM TEMPERATURE SENSOR AC2GE-01 INSPECTION 1. (a) REMOVE ROOM TEMPERATURE SENSOR Remove the lower No. 1 panel (See page BO-90 ). (b) (c) 2. Disconnect the connector. Remove the sensor from the aspirator hose. INSPECT ROOM TEMPERATURE SENSOR CIRCUIT (See page DI-763 ) INSTALL ROOM TEMPERATURE SENSOR Install the sensor to the aspirator hose. Connect the connector. Install the lower No. 1 panel (See page BO-97 ). 3. (a) (b) (c) I12305 2001 AVALON (RM808U) Author
: Date
: 1984 AC-61 AIR CONDITIONING - SOLAR SENSOR SOLAR SENSOR AC2GD-01 INSPECTION 1. I12304 REMOVE SOLAR SENSOR Using a screwdriver, pull out the sensor, then disconnect the connector. HINT: Tape the screwdriver tip before use. 2. INSPECT SOLAR SENSOR CIRCUIT (See page DI-784 , DI-775 ) 3. INSTALL SOLAR SENSOR Install the solar sensor, then connect the connector. 2001 AVALON (RM808U) Author
: Date
: 1983 AC-15 AIR CONDITIONING - TROUBLESHOOTING (Manual A/C) TROUBLESHOOTING (Manual A/C) AC2FV-01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order If necessary , replace these parts. Symptom Suspect Area See page No blower operation 2. 3. 4. 5. 6. 7. HTR Fuse Heater main relay Blower motor Blower resistor Blower speed control switch Wire harness AC-68 AC-56 AC-57 AC-83 - No blower control 1. 2. 3. 4. Blower motor Blower resistor Blower speed control switch Wire harness AC-56 AC-57 AC-83 - No air temperature control 1. Engine coolant volume 2. Heater control assembly AC-80 No compressor operation 1. Refrigerant volume 2. A.C Fuse 3. Magnetic clutch 4. Compressor lock sensor 5. Compressor 6. Pressure switch 7. Heater main relay 8. Blower speed control switch 9. A/C switch 10.A/C amplifier 11.Evaporator temp. sensor 12.Wire harness AC-3 AC-42 AC-42 AC-42 AC-65 AC-68 AC-83 AC-83 AC-77 AC-64 - No cool air comes out 1. Refrigerant volume 2. Refrigerant pressure 3. Drive belt 4. Magnetic clutch 5. Compressor lock sensor 6. Pressure switch 7. Evaporator temp. sensor 8. A/C switch 9. A/C amplifier 10.Heater control assembly 11.Wire harness AC-3 AC-3 AC-17 AC-42 AC-42 AC-65 AC-64 AC-83 AC-77 AC-80 - No engine idle-up when A/C switch ON 1. A/C amplifier 2. Idle control system 3. Wire harness AC-77 DI-102 - No air inlet control 1. Air inlet servomotor 2. Heater control assembly 3. Wire harness AC-39 AC-80 - No mode control 1. Air outlet servomotor 2. Heater control assembly 3. Wire harness AC-60 AC-80 - 2001 AVALON (RM808U) Author
: Date
: 1937 AC-16 AIR CONDITIONING - TROUBLESHOOTING (Manual A/C) Blinking of A/C indicator 1. 2. 3. 4. Compressor Drive belt Compressor lock sensor A/C amplifier Brightness does not change when light control switch is turned 1. Headlight and taillight system 2. Heater control assembly AC-42 AC-17 AC-42 AC-77 BE-19 AC-80 2001 AVALON (RM808U) Author
: Date
: 1938 AX-2 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE SYSTEM AX03M-04 OPERATION Planetary Gear Unit O/D Direct Clutch (C0) 1st & Reverse Brake (B3) O/D Brake (B0) O/D One-Way Clutch (F0) One-W ay Clutch No.2 (F2) Counter Drive Gear O/D Planetary Gear Shift Lever Position Gear Position P Parking R Reverse N Neutral 2nd Brake (B2) Forward Clutch (C1) One-W ay Clutch No.1 (F1) C1 Direct Clutch (C2) Input Shaft Rear Planetary Gear Intermediate Shaft C0 2nd Coast Brake (B1) C2 Front Planetary Gear B0 B1 B2 B3 F0 F1 F2 1st D 2nd 3rd O/D 1st 2 2nd *3rd L 1st *2nd *Down-shift only - no up-shift : Operating D01018 2001 AVALON (RM808U) Author
: Date
: 1292 AX-1 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM AX03L-02 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. 2001 AVALON (RM808U) Author
: Date
: 1291 AX-33 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT AX03X-05 COMPONENTS Clip Engine Hood 26 (265, 19) Air Cleaner Assembly Cap Nut V-bank Fastener 13 (130, 9) V-bank Cover Shift Control Cable Clamp RH Drive Shaft Cruise Control Actuator Starter
Snap Ring 39 (400, 29)
41 (420, 30) 32 (330, 24) 48 (490, 35) Hold-Down Clamp 66 (670, 48) 20 (200, 15) Torque Converter Clutch x5 Battery Insulator 41 (420, 30) Hole Cover Exhaust Manifold Bracket Shift Control Cable Clip Battery Automatic Transaxle Clip Battery Tray 20 (200, 14)
Snap Ring 15 (150, 11) N·m (kgf·cm, ft·lbf) : Specified
Non-reusable part Plug for Line Pressure Test LH Drive Shaft 7.5 (80, 69 in.·lbf) D07233 2001 AVALON (RM808U) Author
: Date
: 1323 AX-34 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE UNIT 19 (195, 14) RH Rear Lower Brace RH Fender Apron Seal Rear Side Engine Mounting Insulator Stabilizer Bar 36 (370, 27) Stabilizer Bar Link 32 (330, 24) 66 (670, 48) 10 (100, 7) 39 (400, 29) PS Reservoir Pipe 181 (1,850, 134) 181 (1,850, 134) LH Fender Apron Seal 80 (820, 59) LH Rear Lower Brace Front Side Engine Mounting Insulator Tie Rod End 294 (3,000, 217) 80 (820, 59) RH Front Lower Brace 49 (500, 36) 48 (490, 35) 181 (1,850, 134) 127 (1,300, 94) LH Front Lower Brace Grommet 36 (370, 27)
Cotter Pin
Cotter Pin Lock Cap
Gasket 80 (820, 59) Exhaust Front Pipe Support Bracket RH Fender Liner 21 (210, 15)
Gasket
Gasket Front Exhaust Pipe
62 (630, 46) Exhaust Front Pipe Support Stay Spring
43 (440, 32)
62 (630, 46) 33 (330, 24) Engine Under Cover Center Engine Under Cover LH Fender Liner N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part D07770 2001 AVALON (RM808U) Author
: Date
: 1324 AX-42 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE UNIT AX03Z-05 INSTALLATION 1. AT3412 CHECK TORQUE CONVERTER CLUTCH INSTALLATION Using a scale and a straight edge, measure the distance from the installed surface to the transaxle housing. Correct distance: 13.7 mm (0.539 in.) or more 2. TRANSAXLE INSTALLATION Installation is in the reverse order of removal (See page AX-35 ). HINT: After installation, check and inspect the following items.
Fill ATF and check fluid level (See page DI-160 ).
Check front wheel alignment (See page SA-4 ).
Do the road test (See page DI-160 ).
Adjust the hood (See page BO-6 ). NOTICE: w/ VSC: After installation, perform the steering angle sensor zero point calibration (See page DI-252 ). 2001 AVALON (RM808U) Author
: Date
: 1332 AX-35 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE UNIT AX0KA-01 REMOVAL 1. 2. 3. 4. (a) (b) (c) 5 mm Hexagon Wrench REMOVE ENGINE HOOD Torque: 26 N·m (265 kgf·cm, 19 ft·lbf) REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY REMOVE V-BANK COVER Using a 5 mm hexagon wrench, remove the 3 cap nuts. Turn the V-bank cover fastener counterclockwise and loosen it. Remove the V-bank cover. A07441 HINT: At the time of installation, please refer to the following item. When installing the V-bank cover fastener, remove the fastener once, then position and push in it. V-bank Cover Fastener D04381 5. REMOVE THROTTLE CABLE FROM THROTTLE BODY Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) 6. (a) (b) REMOVE CRUISE CONTROL ACTUATOR Disconnect the connector. Remove the 3 bolts and disconnect cruise control actuator with the bracket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) D07234 Q09982 2001 AVALON (RM808U) Author
: Date
: 1325 AX-36 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE UNIT 7. 8. D07235 DISCONNECT GROUND CABLE SEPARATE WIRE HARNESS FROM AUTOMATIC TRANSAXLE Remove the bolt and separate the wire harness. 9. DISCONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR 10. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 11. DISCONNECT SOLENOID CONNECTOR 12. (a) (b) DISCONNECT SHIFT CONTROL CABLE Remove the nut and disconnect the shift control cable from the control shaft lever. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Remove the clip and disconnect the shift control cable from the bracket. Q00075 13. REMOVE 2 ENGINE MOUNTING ABSORBER BOLTS Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 14. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS Torque: 44 N·m (440 kgf·cm, 32 ft·lbf) 15. REMOVE STARTER AND SHIFT CONTROL CABLE CLAMP Disconnect the connector. Remove the nut and disconnect the terminal. Remove the 2 bolts, starter and shift control cable clamp. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Q10028 Q06478 (a) (b) (c) Q10286 2001 AVALON (RM808U) Author
: Date
: 1326 AX-37 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE UNIT 16. REMOVE EXHAUST MANIFOLD BRACKET MOUNTING BOLT Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) 17. REMOVE 5 TRANSAXLE-TO-ENGINE BOLTS AND DISCONNECT GROUND TERMINAL Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) RAISE AND SUPPORT VEHICLE SECURELY REMOVE LH AND RH FRONT WHEELS Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Q06530 18. 19. 20. Q10038 HINT: At the time of installation, please refer to the following item. Replace the used gasket with a new gasket. 21. DRAIN DIFFERENTIAL FLUID 22. REMOVE LH AND RH FRONT DRIVE SHAFTS (See page SA-16 ) 23. (a) REMOVE ENGINE UNDER COVER Remove the 6 screws and turn over the front side of the LH and RH fender liners. (b) Remove the 2 screws and turn over the rear side of LH and RH fender liners. Remove the engine under cover. D07216 (c) Q10037 2001 AVALON (RM808U) Author
: Date
: 1327 AX-38 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE UNIT (d) 24. Remove the 5 bolts and center engine under cover. REMOVE EXHAUST FRONT PIPE (See page EM-1 10) 25. REMOVE FRONT SIDE ENGINE MOUNTING INSULATOR BOLT Torque: 44 N·m (440 kgf·cm, 32 ft·lbf) D04375 Q00235 26. DISCONNECT OIL COOLER HOSE Loosen the 2 clip and disconnect the 2 oil cooler hoses. Q10027 27. (a) (b) REMOVE REAR SIDE ENGINE MOUNTING NUT Remove the 2 grommets. Remove the 4 nuts. Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) 28. (a) (b) REMOVE LEFT SIDE TRANSAXLE MOUNTING NUT Remove the 2 grommets. Remove the 2 nuts. Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) REMOVE FRONT STABILIZER BAR Remove the 4 bolts, LH and RH stabilizer bar brackets and bushings. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) Remove the front stabilizer bar (See page SA-41 ). Q10071 29. (a) Q10034 (b) 2001 AVALON (RM808U) Author
: Date
: 1328 AX-39 AUTOMATIC TRANSAXLE 30. 31. - AUTOMATIC TRANSAXLE UNIT TIE STEERING GEAR ASSEMBLY WITH CODE OR EQUIVALENT TO SUSPEND ASSEMBLY SECURELY, AS SHOWN REMOVE 2 STEERING GEAR ASSEMBLY MOUNTING BOLTS Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) D02910 32. Engine Hanger P19478 ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS (a) Install the No.2 engine hangers in the correct direction. Part No.: No.2 engine hanger: 12282-20020 Bolt: 91621-60822 Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (b) Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. 33. (a) REMOVE FRONT FRAME ASSEMBLY Remove the 2 bolts and PS reservoir pipe mounting brackets. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Q06479 2001 AVALON (RM808U) Author
: Date
: 1329 AX-40 AUTOMATIC TRANSAXLE (b) Front 34. - AUTOMATIC TRANSAXLE UNIT Remove the 6 bolts, 4 nuts, 4 lower brace and front frame assembly. Torque: 19 mm head bolt: 181 N·m (1,850 kgf·cm, 134 ft·lbf) 14 mm head bolt: 32 N·m (330 kgf·cm, 24 ft·lbf) Nut: 36 N·m (370 kgf·cm, 27 ft·lbf) SUPPORT TRANSAXLE WITH A JACK Q10172 Rear Q10064 35. (a) REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLT Remove the 2 bolts and hole cover. Q04659 (b) Turn the crankshaft to gain access to each bolt, remove the 6 bolts while holding the crankshaft pulley bolt with a wrench. Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) HINT: At the time of installation, please refer to the following item. First install black colored bolt and then the 5 other bolts. Q04660 36. REMOVE EXHAUST MANIFOLD PLATE Remove the bolt, nut and exhaust manifold plate. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) Q10036 2001 AVALON (RM808U) Author
: Date
: 1330 AX-41 AUTOMATIC TRANSAXLE - AUTOMATIC TRANSAXLE UNIT 37. REMOVE 3 LOWER TRANSAXLE- TO- ENGINE BOLTS Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) 38. REMOVE TRANSAXLE ASSEMBLY Separate the transaxle from the engine, and lower the transaxle. Left and lower Z14284 2001 AVALON (RM808U) Author
: Date
: 1331 AX-3 AUTOMATIC TRANSAXLE - DIRECT CLUTCH SPEED SENSOR DIRECT CLUTCH SPEED SENSOR AX03O-04 ON-VEHICLE REPAIR 1. 2. 3. (a) REMOVE AIR CLEANER ASSEMBLY DISCONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR REMOVE DIRECT CLUTCH SPEED SENSOR Remove the bolt and direct clutch speed sensor. Q05726 (b) 4. (a) O-Ring (b) 5. Q04733 6. Remove the O-ring from the direct clutch speed sensor. INSTALL DIRECT CLUTCH SPEED SENSOR Coat a new O-ring with ATF and install it to the direct clutch speed sensor. Install the direct clutch speed sensor with the bolt. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) CONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR INSTALL AIR CLEANER ASSEMBLY 2001 AVALON (RM808U) Author
: Date
: 1293 AX-14 AUTOMATIC TRANSAXLE - DIFFERENTIAL OIL SEAL DIFFERENTIAL OIL SEAL AX03S-05 ON-VEHICLE REPAIR SST 1. REMOVE FRONT DRIVE SHAFT (See page SA-16 ) 2. REMOVE SIDE GEAR SHAFT OIL SEAL Using SST, pull out the oil seal. SST 09308-00010 Q00394 3. (a) SST (b) INSTALL LEFT SIDE GEAR SHAFT OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09223-15020, 09350-32014 (09351-32130) Oil seal depth: 0 ± 0.5 mm (0 ± 0.02 in.) Coat the lip of the oil seal with MP grease. Q06348 4. (a) (b) 5. SST 6. Q00238 INSTALL RIGHT SIDE GEAR SHAFT OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09316-60010 (09316-00010) Oil seal depth: 0 ± 0.5 mm (0 ± 0.02 in.) Coat the lip of the oil seal with MP grease. INSTALL FRONT DRIVE SHAFT (See page SA-24 ) CHECK TRANSAXLE FLUID LEVEL (See page DI-160 ) 2001 AVALON (RM808U) Author
: Date
: 1304 AX-20 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY FLOOR SHIFT ASSEMBLY AX0KB-01 COMPONENTS Except Taiwan Spec.: Radio Assembly with Heater Control & Accessory Assembly RH Cowl Side Trim RH Scuff Plate Lower Instrument Panel Sub-assembly No. 2 Instrument Panel Under Cover Sub-assembly Lower No. 4 Instrument Panel Sub-assembly Hood Lock Release Lever RH Cowl Side Trim Taiwan Spec.: Radio Tuner Opening Covers with Heater Console & Accessory Assembly Taiwan Spec.: Center Instrument Cluster Finish Panel Sub-assembly Front Ash Receptacle Assembly Upper Console Panel Sub-assembly Front Console Box Assembly Upper Rear Console Panel Sub-assembly Console Box Plate RH Scuff Plate Clip Shift Control Cable 12 (120,9) Rear Console Box Assembly N·m (kgf·cm, ft·lbf) : Specified torque Floor Shift Lever Assembly D07772 2001 AVALON (RM808U) Author
: Date
: 1310 AX-21 AUTOMATIC TRANSAXLE Cover - FLOOR SHIFT ASSEMBLY Control Position Indicator Plate Shift Lever Knob Compression Spring Shift Lever Knob Sleeve Shift Lever Knob Button Slide Cover Lower Position Indicator Housing
O/D Main Switch Cover Detent Rod Manual Detent Spring Shift Lock Release Button Cushion Spring Shift Lever Knob Cover Compression Spring Grooved Pin Shift Lock Control Unit O/D Main Switch Collar Shift Lever Plate Shift Lever Sub-assembly Cap Bulb Spring Nut Indicator Light Wire Control Shaft 
Non-reusable part Apply MP grease Precoated part D08001 2001 AVALON (RM808U) Author
: Date
: 1311 AX-24 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY AX0KD-01 DISASSEMBLY 1. (a) REMOVE O/D MAIN SWITCH TERMINAL Remove the connector from the shift lever plate. (b) (c) Remove the secondary locking device. Release the looking lug of the terminals 2 and 4, and pull the terminals out from the rear. (d) Separate the O/D main switch wire harness from the 2 clamps. D07989 2 3 4 2 1 D07988 D07990 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (a) Side the shift lever knob cover. (b) Remove the 2 screws and shift lever knob sub-assembly. NOTICE: Pay attention not to apply unnatural load onto O/D main switch wire harness. D07221 3. (a) (b) DISASSEMBLE SHIFT LEVER KNOB SUB-ASSEMBL Y Using a small screwdriver, remove the O/D main switch cover. Using a small screwdriver, remove the O/D main switch from the shift lever knob. D07991 2001 AVALON (RM808U) Author
: Date
: 1314 AX-25 AUTOMATIC TRANSAXLE (c) (d) - FLOOR SHIFT ASSEMBLY Insert a small screwdriver into the position in the illustration and disengage the claw. Remove the shift lever knob button and compression spring. D07992 4. (a) (b) REMOVE INDICATOR LIGHT Remove the indicator light from the lower position indicator housing. Remove the cap and bulb from the indicator light wire. D07220 5. REMOVE LOWER POSITION INDICATOR HOUSING Remove the 4 screws and lower position indicator housing. D07222 6. (a) (b) (c) DISASSEMBLE LOWER POSITION INDICATOR HOUSING Remove the control position indicator plate. Remove the shift lock release button and spring. Remove the slide cover. D07239 7. REMOVE SHIFT LOCK CONTROL UNIT Remove the 2 screws and shift lock control unit assembly. D07225 2001 AVALON (RM808U) Author
: Date
: 1315 AX-26 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY 8. REMOVE MANUAL DETENT SPRING Remove the screw and manual detent spring. D07224 9. REMOVE SHIFT LEVER KNOB SLEEVE D07223 10. REMOVE GROOVED PIN Secure the room for the pin to be released by using the vice and etc. as shown in the illustration, and hit the grooved pin with a hammer and pull the grooved pin out. NOTICE:
Hit and pull the pin out gradually.
Do not damage the shift lever sub-assembly. 11. REMOVE DETENT ROD, COMPRESSION SPRING D07999 12. (a) (b) (c) REMOVE SHIFT LEVER SUB-ASSEMBLY Using a screwdriver, pry and push up the spring nut. Using nippers, cut the spring nut off it. Remove the control shaft and shift lever sub-assembly. D07993 2001 AVALON (RM808U) Author
: Date
: 1316 AX-27 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY 13. REMOVE CUSHION Remove the 2 screws and 2 cushion. D07994 14. REMOVE COLLAR Using a screwdriver and hammer, remove the 4 collars. D07995 2001 AVALON (RM808U) Author
: Date
: 1317 AX-32 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY AX0KF-01 INSTALLATION With the brake pedal depressed, shift while holding the shift lever knob button in. (The ignition switch must be in ON position.) Shift while holding the shift lever knob button in. Shift normally F00693 Installation is in the reverse order of removal (See page AX-22 ). HINT: After installation, inspect shift lever operation.
When shifting it to each position, make sure that the shifting lever moves smoothly, can be moderately operated and the position indicator displays correctly. Positions which can be operated without pressing the shift lever knob button R → N → D, L → 2 → D → N Positions which can be operated only with pressing the shift lever knob button 2 → L, N → R → P Positions which can be operated only with pressing the shift lever knob button, ignition switch ON and brake pedal depressed P→R
When starting the engine, make sure that the vehicle moves forward when shifting from N to D position, and moves rearward when shifting to R position. 2001 AVALON (RM808U) Author
: Date
: 1322 AX-28 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY AX0KE-01 REASSEMBLY 1. INSTALL 4 COLLARS 2. INSTALL CUSHION Install the 2 cushions with the 2 screws. D07994 3. (a) (b) (c) INSTALL SHIFT LEVER SUB-ASSEMBLY Install the shift lever sub-assembly with the control shaft. Support the control shaft, as shown in the illustration. Install a new spring nut to the control shaft by knocking them lightly via the 10-mm seated nut. 4. (a) INSTALL GROOVED PIN Apply MP grease on the compression spring, detent rod and shift lever sub-assembly. Place the shift lever plate. D07996 Apply MP Grease (b) D07997 (c) Insert the grooved pin in the detent rod pin hole. NOTICE:
Assemble the grooved pin to ensure that it fits into the guide hole of the shift lever sub-assembly in parallel.
Take care not to insert the pin in the wrong direction of the detent rod. D07998 2001 AVALON (RM808U) Author
: Date
: 1318 AX-29 AUTOMATIC TRANSAXLE (d) - FLOOR SHIFT ASSEMBLY Meet the grooved pin with the notch of the guide hole. D07999 (e) Press the pin with a hammer. A: 10.0 - 10.4 mm (0.39 - 0.41 in.) NOTICE: When pressing in the grooved pin, if doing it at the place other than the notch, the shift lever sub-assembly might be damaged. 5. CHECK DETENT ROD OPERATION Shift Lever Sub-assembly A Detent Rod Grooved Pin A00452 F01188 6. INSTALL SHIFT LEVER KNOB SLEEVE D07223 7. INSTALL MANUAL DETENT SPRING Install the manual detent spring with the screw. D07224 8. INSTALL SHIFT LOCK CONTROL UNIT Install the shift lock unit assembly with the 2 screws. D07225 2001 AVALON (RM808U) Author
: Date
: 1319 AX-30 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY NOTICE: Install the grooved pin into the groove of the shift lock unit as shown in the illustration. D08000 9. (a) (b) (c) ASSEMBLE LOWER POSITION INDICATOR HOUSING Install the slide cover. Install the spring and shift lock release bottom. Install the control position indicator plate. D07239 10. INSTALL LOWER POSITION INDICATOR HOUSING Install the lower position indicator housing with the 4 screws. D07222 11. (a) (b) 12. (a) (b) D07220 INSTALL INDICATOR LIGHT Install the bulb and cap to the indicator light wire. Install the indicator light to the lower position indicator housing. ASSEMBLE SHIFT LEVER KNOB SUB-ASSEMBLY Install the spring and shift lever knob to the shift lever knob. Install the O/D main switch and O/D main switch cover to the shift lever knob. 13. INSTALL SHIFT LEVER KNOB AND SHIFT LEVER KNOB COVER (a) Pass through the wire harness of the O/D main switch as shown in the illustration and set it. (b) Install the shift lever knob and shift lever knob cover to the shift lever sub-assembly. NOTICE: When operating the shift lever sub-assembly, check that excessive force is not applied to the wire harness of the O/D main switch. 2001 AVALON (RM808U) Author
: Date
: 1320 AX-31 AUTOMATIC TRANSAXLE (c) (d) 14. (a) (b) - FLOOR SHIFT ASSEMBLY Install the 2 shift lever sub-assembly set screws. Torque: 2.2 N·m (22 kgf·cm, 19 in.·lbf) Raise the shift lever knob cover. CONNECT O/D MAIN SWITCH TERMINAL Connect the terminals of the O/D main switch. Connect the O/D main switch connector to the shift lever plate. 2001 AVALON (RM808U) Author
: Date
: 1321 AX-22 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY AX0KC-01 REMOVAL 1. REMOVE UPPER REAR CONSOLE PANEL SUB-ASSEMBLY (See page BO-90 ) 2. REMOVE FRONT ASH RECEPTACLE ASSEMBLY (See page BO-90 ) 3. REMOVE UPPER CONSOLE PANEL SUB- ASSEMBLY (See page BO-90 ) 4. REMOVE CONSOLE BOX PLATE (See page BO-90 ) 5. REMOVE REAR CONSOLE BOX ASSEMBLY (See page BO-90 ) 6. REMOVE LH AND RH SCUFF PLATES (See page BO-90 ) 7. REMOVE LH AND RH COWL SIDE TRIMS (See page BO-90 ) 8. REMOVE LOWER NO.4 INSTRUMENT PANEL SUBASSEMBLY (See page BO-90 ) 9. REMOVE NO.2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBL Y (See page BO-90 ) 10. REMOVE LOWER INSTRUMENT PANEL SUB- ASSEMBLY (See page BO-90 ) 11. Taiwan Spec.: REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See page BO-90 ) 12. Taiwan Spec.: REMOVE RADIO TUNER OPENING COVERS WITH HEATER CONSOLE & ACCESSORY ASSEMBLY (See page BO-90 ) 13. Except Taiwan spec.: REMOVE RADIO ASSEMBLY WITH HEATER CONSOLE & ACCESSORY ASSEMBLY (See page BO-90 ) 14. REMOVE FRONT CONSOLE BOX ASSEMBLY (See page BO-90 ) 15. w/ Rear Heater: REMOVE REAR CONSOLE NO.1 BOX ASSEMBLY CONSOLE BOX DUCT Remove the clip and duct. 16. (a) (b) REMOVE FLOOR SHIFT LEVER ASSEMBLY Remove the clip and disconnect the shift cable from the floor shift assembly. Disconnect the wire harness from the wire harness clamp. D07218 2001 AVALON (RM808U) Author
: Date
: 1312 AX-23 AUTOMATIC TRANSAXLE (c) (d) - FLOOR SHIFT ASSEMBLY Remove the 2 bolts from the brace. Remove the 4 bolts and floor shift assembly. Torque: 12 N·m (120kgf·cm, 9 ft·lbf) D07219 2001 AVALON (RM808U) Author
: Date
: 1313 AX-20 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY FLOOR SHIFT ASSEMBLY AX0KB-01 COMPONENTS Except Taiwan Spec.: Radio Assembly with Heater Control & Accessory Assembly RH Cowl Side Trim RH Scuff Plate Lower Instrument Panel Sub-assembly No. 2 Instrument Panel Under Cover Sub-assembly Lower No. 4 Instrument Panel Sub-assembly Hood Lock Release Lever RH Cowl Side Trim Taiwan Spec.: Radio Tuner Opening Covers with Heater Console & Accessory Assembly Taiwan Spec.: Center Instrument Cluster Finish Panel Sub-assembly Front Ash Receptacle Assembly Upper Console Panel Sub-assembly Front Console Box Assembly Upper Rear Console Panel Sub-assembly Console Box Plate RH Scuff Plate Clip Shift Control Cable 12 (120,9) Rear Console Box Assembly N·m (kgf·cm, ft·lbf) : Specified torque Floor Shift Lever Assembly D07772 2001 AVALON (RM808U) Author
: Date
: 1310 AX-21 AUTOMATIC TRANSAXLE Cover - FLOOR SHIFT ASSEMBLY Control Position Indicator Plate Shift Lever Knob Compression Spring Shift Lever Knob Sleeve Shift Lever Knob Button Slide Cover Lower Position Indicator Housing
O/D Main Switch Cover Detent Rod Manual Detent Spring Shift Lock Release Button Cushion Spring Shift Lever Knob Cover Compression Spring Grooved Pin Shift Lock Control Unit O/D Main Switch Collar Shift Lever Plate Shift Lever Sub-assembly Cap Bulb Spring Nut Indicator Light Wire Control Shaft 
Non-reusable part Apply MP grease Precoated part D08001 2001 AVALON (RM808U) Author
: Date
: 1311 AX-24 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY AX0KD-01 DISASSEMBLY 1. (a) REMOVE O/D MAIN SWITCH TERMINAL Remove the connector from the shift lever plate. (b) (c) Remove the secondary locking device. Release the looking lug of the terminals 2 and 4, and pull the terminals out from the rear. (d) Separate the O/D main switch wire harness from the 2 clamps. D07989 2 3 4 2 1 D07988 D07990 2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (a) Side the shift lever knob cover. (b) Remove the 2 screws and shift lever knob sub-assembly. NOTICE: Pay attention not to apply unnatural load onto O/D main switch wire harness. D07221 3. (a) (b) DISASSEMBLE SHIFT LEVER KNOB SUB-ASSEMBL Y Using a small screwdriver, remove the O/D main switch cover. Using a small screwdriver, remove the O/D main switch from the shift lever knob. D07991 2001 AVALON (RM808U) Author
: Date
: 1314 AX-25 AUTOMATIC TRANSAXLE (c) (d) - FLOOR SHIFT ASSEMBLY Insert a small screwdriver into the position in the illustration and disengage the claw. Remove the shift lever knob button and compression spring. D07992 4. (a) (b) REMOVE INDICATOR LIGHT Remove the indicator light from the lower position indicator housing. Remove the cap and bulb from the indicator light wire. D07220 5. REMOVE LOWER POSITION INDICATOR HOUSING Remove the 4 screws and lower position indicator housing. D07222 6. (a) (b) (c) DISASSEMBLE LOWER POSITION INDICATOR HOUSING Remove the control position indicator plate. Remove the shift lock release button and spring. Remove the slide cover. D07239 7. REMOVE SHIFT LOCK CONTROL UNIT Remove the 2 screws and shift lock control unit assembly. D07225 2001 AVALON (RM808U) Author
: Date
: 1315 AX-26 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY 8. REMOVE MANUAL DETENT SPRING Remove the screw and manual detent spring. D07224 9. REMOVE SHIFT LEVER KNOB SLEEVE D07223 10. REMOVE GROOVED PIN Secure the room for the pin to be released by using the vice and etc. as shown in the illustration, and hit the grooved pin with a hammer and pull the grooved pin out. NOTICE:
Hit and pull the pin out gradually.
Do not damage the shift lever sub-assembly. 11. REMOVE DETENT ROD, COMPRESSION SPRING D07999 12. (a) (b) (c) REMOVE SHIFT LEVER SUB-ASSEMBLY Using a screwdriver, pry and push up the spring nut. Using nippers, cut the spring nut off it. Remove the control shaft and shift lever sub-assembly. D07993 2001 AVALON (RM808U) Author
: Date
: 1316 AX-27 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY 13. REMOVE CUSHION Remove the 2 screws and 2 cushion. D07994 14. REMOVE COLLAR Using a screwdriver and hammer, remove the 4 collars. D07995 2001 AVALON (RM808U) Author
: Date
: 1317 AX-32 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY AX0KF-01 INSTALLATION With the brake pedal depressed, shift while holding the shift lever knob button in. (The ignition switch must be in ON position.) Shift while holding the shift lever knob button in. Shift normally F00693 Installation is in the reverse order of removal (See page AX-22 ). HINT: After installation, inspect shift lever operation.
When shifting it to each position, make sure that the shifting lever moves smoothly, can be moderately operated and the position indicator displays correctly. Positions which can be operated without pressing the shift lever knob button R → N → D, L → 2 → D → N Positions which can be operated only with pressing the shift lever knob button 2 → L, N → R → P Positions which can be operated only with pressing the shift lever knob button, ignition switch ON and brake pedal depressed P→R
When starting the engine, make sure that the vehicle moves forward when shifting from N to D position, and moves rearward when shifting to R position. 2001 AVALON (RM808U) Author
: Date
: 1322 AX-28 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY AX0KE-01 REASSEMBLY 1. INSTALL 4 COLLARS 2. INSTALL CUSHION Install the 2 cushions with the 2 screws. D07994 3. (a) (b) (c) INSTALL SHIFT LEVER SUB-ASSEMBLY Install the shift lever sub-assembly with the control shaft. Support the control shaft, as shown in the illustration. Install a new spring nut to the control shaft by knocking them lightly via the 10-mm seated nut. 4. (a) INSTALL GROOVED PIN Apply MP grease on the compression spring, detent rod and shift lever sub-assembly. Place the shift lever plate. D07996 Apply MP Grease (b) D07997 (c) Insert the grooved pin in the detent rod pin hole. NOTICE:
Assemble the grooved pin to ensure that it fits into the guide hole of the shift lever sub-assembly in parallel.
Take care not to insert the pin in the wrong direction of the detent rod. D07998 2001 AVALON (RM808U) Author
: Date
: 1318 AX-29 AUTOMATIC TRANSAXLE (d) - FLOOR SHIFT ASSEMBLY Meet the grooved pin with the notch of the guide hole. D07999 (e) Press the pin with a hammer. A: 10.0 - 10.4 mm (0.39 - 0.41 in.) NOTICE: When pressing in the grooved pin, if doing it at the place other than the notch, the shift lever sub-assembly might be damaged. 5. CHECK DETENT ROD OPERATION Shift Lever Sub-assembly A Detent Rod Grooved Pin A00452 F01188 6. INSTALL SHIFT LEVER KNOB SLEEVE D07223 7. INSTALL MANUAL DETENT SPRING Install the manual detent spring with the screw. D07224 8. INSTALL SHIFT LOCK CONTROL UNIT Install the shift lock unit assembly with the 2 screws. D07225 2001 AVALON (RM808U) Author
: Date
: 1319 AX-30 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY NOTICE: Install the grooved pin into the groove of the shift lock unit as shown in the illustration. D08000 9. (a) (b) (c) ASSEMBLE LOWER POSITION INDICATOR HOUSING Install the slide cover. Install the spring and shift lock release bottom. Install the control position indicator plate. D07239 10. INSTALL LOWER POSITION INDICATOR HOUSING Install the lower position indicator housing with the 4 screws. D07222 11. (a) (b) 12. (a) (b) D07220 INSTALL INDICATOR LIGHT Install the bulb and cap to the indicator light wire. Install the indicator light to the lower position indicator housing. ASSEMBLE SHIFT LEVER KNOB SUB-ASSEMBLY Install the spring and shift lever knob to the shift lever knob. Install the O/D main switch and O/D main switch cover to the shift lever knob. 13. INSTALL SHIFT LEVER KNOB AND SHIFT LEVER KNOB COVER (a) Pass through the wire harness of the O/D main switch as shown in the illustration and set it. (b) Install the shift lever knob and shift lever knob cover to the shift lever sub-assembly. NOTICE: When operating the shift lever sub-assembly, check that excessive force is not applied to the wire harness of the O/D main switch. 2001 AVALON (RM808U) Author
: Date
: 1320 AX-31 AUTOMATIC TRANSAXLE (c) (d) 14. (a) (b) - FLOOR SHIFT ASSEMBLY Install the 2 shift lever sub-assembly set screws. Torque: 2.2 N·m (22 kgf·cm, 19 in.·lbf) Raise the shift lever knob cover. CONNECT O/D MAIN SWITCH TERMINAL Connect the terminals of the O/D main switch. Connect the O/D main switch connector to the shift lever plate. 2001 AVALON (RM808U) Author
: Date
: 1321 AX-22 AUTOMATIC TRANSAXLE - FLOOR SHIFT ASSEMBLY AX0KC-01 REMOVAL 1. REMOVE UPPER REAR CONSOLE PANEL SUB-ASSEMBLY (See page BO-90 ) 2. REMOVE FRONT ASH RECEPTACLE ASSEMBLY (See page BO-90 ) 3. REMOVE UPPER CONSOLE PANEL SUB- ASSEMBLY (See page BO-90 ) 4. REMOVE CONSOLE BOX PLATE (See page BO-90 ) 5. REMOVE REAR CONSOLE BOX ASSEMBLY (See page BO-90 ) 6. REMOVE LH AND RH SCUFF PLATES (See page BO-90 ) 7. REMOVE LH AND RH COWL SIDE TRIMS (See page BO-90 ) 8. REMOVE LOWER NO.4 INSTRUMENT PANEL SUBASSEMBLY (See page BO-90 ) 9. REMOVE NO.2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBL Y (See page BO-90 ) 10. REMOVE LOWER INSTRUMENT PANEL SUB- ASSEMBLY (See page BO-90 ) 11. Taiwan Spec.: REMOVE CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See page BO-90 ) 12. Taiwan Spec.: REMOVE RADIO TUNER OPENING COVERS WITH HEATER CONSOLE & ACCESSORY ASSEMBLY (See page BO-90 ) 13. Except Taiwan spec.: REMOVE RADIO ASSEMBLY WITH HEATER CONSOLE & ACCESSORY ASSEMBLY (See page BO-90 ) 14. REMOVE FRONT CONSOLE BOX ASSEMBLY (See page BO-90 ) 15. w/ Rear Heater: REMOVE REAR CONSOLE NO.1 BOX ASSEMBLY CONSOLE BOX DUCT Remove the clip and duct. 16. (a) (b) REMOVE FLOOR SHIFT LEVER ASSEMBLY Remove the clip and disconnect the shift cable from the floor shift assembly. Disconnect the wire harness from the wire harness clamp. D07218 2001 AVALON (RM808U) Author
: Date
: 1312 AX-23 AUTOMATIC TRANSAXLE (c) (d) - FLOOR SHIFT ASSEMBLY Remove the 2 bolts from the brace. Remove the 4 bolts and floor shift assembly. Torque: 12 N·m (120kgf·cm, 9 ft·lbf) D07219 2001 AVALON (RM808U) Author
: Date
: 1313 AX-4 AUTOMATIC TRANSAXLE - PARK/NEUTRAL POSITION (PNP) SWITCH PARK/NEUTRAL POSITION (PNP) SWITCH AX0CJ-02 ON-VEHICLE REPAIR 1. 2. REMOVE ENGINE UNDER COVER DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. (a) (b) REMOVE PARK/NEUTRAL POSITION SWITCH Remove the clip from the shift control cable. Remove the nut and disconnect the control cable. (c) (d) (e) (f) Remove the nut, washer and transaxle control shaft lever. Using a screwdriver, pry off the lock plate. Remove the nut and lock plate. Remove the 2 bolts and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Install the park/neutral position switch with the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Install a new lock plate and nut. Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf) Bend the claws on the lock plate to stake the nut. Q00229 Q06496 Q05727 (a) (b) (c) Q04617 (d) (e) Install the transaxle control shaft lever and washer. Install and torque the nut. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Q04687 2001 AVALON (RM808U) Author
: Date
: 1294 AX-5 AUTOMATIC TRANSAXLE - PARK/NEUTRAL POSITION (PNP) SWITCH (f) Q06496 Install the control cable and nut. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) (g) Install the clip to the shift control cable. 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. CHECK PARK/NEUTRAL POSITION SWITCH OPERATION Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as started above, carry out the adjustment procedure (See page DI-160 ). 7. TEST DRIVE VEHICLE 8. INSTALL ENGINE UNDER COVER 2001 AVALON (RM808U) Author
: Date
: 1295 AX-18 AUTOMATIC TRANSAXLE - SHIFT LOCK SYSTEM (Column Shift) AX05E-03 A IG ACC STP E B SLS- KLS+ INSPECTION C SLS+ 1. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the shift lock control unit assembly connector. P P2 D02453 D02452 D02451 P1 D02455 Terminal No. (Symbols) 1 (ACC) - 5 (E) Measuring Condition Voltage (V) Ignition switch ACC 10 - 14 Ignition switch ON 10 - 14 6 (STP) - 5 (E) Depressing brake pedal 10 - 14 4 (KLS+) - 5 (E) 4. Ignition switch ACC and P position 5. Ignition switch ACC and except P position 6. Ignition switch ACC and except P position (After approx. 1 second) 0 7.5 - 11 6-9 1. Ignition switch ACC and P position osition 2. De Depress ress brake pedal edal 3. Except P position 0 8.5 -13.5 13.5 0 4 (P1) - 1 (P) 1. Ignition switch ON, P position osition and de depress ress brake pedal edal 2. Shift except P position under condition above 0 9 - 13.5 3 (P2) - 1 (P) 1. Ignition switch ACC and P position osition 2. Shift except P position under condition above 9 - 13.5 0 3 (IG) - 5 (E) 2 (SLS+) - 1 (SLS- ) 2. (a) (b) INSPECT SHIFT LOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. Standard resistance: 29 - 35 Ω If resistance value is not as specified, replace the solenoid. Q06585 (c) Supply battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. Q06584 2001 AVALON (RM808U) Author
: Date
: 1308 AX-19 AUTOMATIC TRANSAXLE - SHIFT LOCK SYSTEM (Column Shift) 3. (a) (b) INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure the resistance between terminals. Standard resistance: 12.5 -16.5 Ω If resistance value is not as specified, replace the solenoid. AT8748 (c) Supply battery positive voltage between terminals. If the solenoid does not operate, replace the solenoid. 1 2 D02459 4. INSPECT SHIFT LOCK CONTROL SWITCH Inspect that continuity between at each terminal. P P1 P2 D07236 Shift position Tester connection Specified value P position (Release button is not pushed) 3 (P1) - 1 (P) Continuity P position (Release button is pushed) 3 (P1) - 1 (P) 4 (P2) - 1 (P) Continuity R, N, D, 2, L position 4 (P2) - 1 (P) Continuity If continuity is not specified, replace the switch. 2001 AVALON (RM808U) Author
: Date
: 1309 AX-17 AUTOMATIC TRANSAXLE - SHIFT LOCK SYSTEM (Column Shift) SHIFT LOCK SYSTEM (Column Shift) AX03T-04 LOCATION Shift Lock Control Switch Shift Lock Solenoid Key Interlock Solenoid Shift Lock Control ECU Stop Light Switch D07231 2001 AVALON (RM808U) Author
: Date
: 1307 AX-16 AUTOMATIC TRANSAXLE - SHIFT LOCK SYSTEM (Floor Shift) AX0CT-02 INSPECTION 5 (IG) 1 (ACC) 4 (KLS+) 3 (E) 2 (STP) Wire harness side: Q09455 Terminal (Symbol) 1 (ACC) - 3 (E) 1. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the shift lock control unit assembly connector. Measuring Condition Voltage (V) Ignition switch ACC 10 - 14 Ignition switch ON 10 - 14 2 (STP) - 3 (E) Depressing brake pedal 10 - 14 4 (KLS+) - 3 (E) (1) Ignition switch ACC and P position (2) Ignition switch ACC and except P position (3) Ignition switch ACC and except P position (After approx. 1 second) 0 7.5 - 11 6 - 9.5 5 (IG) - 3 (E) 2. (a) (b) INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. Standard resistance: 14.5 ± 1.5 Ω If resistance value is not as specified, replace the solenoid. 1 (KLS+) 2 (E) Q09456 (c) Apply battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. If the solenoid does not operated, replace the solenoid. 1 (KLS+) 2 (E) (-) (+) Q09457 2001 AVALON (RM808U) Author
: Date
: 1306 AX-15 AUTOMATIC TRANSAXLE - SHIFT LOCK SYSTEM (Floor Shift) SHIFT LOCK SYSTEM (Floor Shift) AX0CS-02 LOCATION Key Interlock Solenoid Stop Light Switch Shift Lock Control Unit Assembly D07232 2001 AVALON (RM808U) Author
: Date
: 1305 AX-43 AUTOMATIC TRANSAXLE - TORQUE CONVERTER CLUTCH AND DRIVE PLATE TORQUE CONVERTER CLUTCH AND DRIVE PLATE SST AX040-04 INSPECTION 1. (a) INSPECT ONE-WAY CLUTCH Install SST into the inner race of the one-way clutch. SST 09350-32014 (09351-32010) (b) Install SST so that it fits in the notch of the converter clutch hub and outer race of the one-way clutch. SST 09350-32014 (09351-32020) AT0952 SST AT0953 (c) With the torque converter clutch standing on its side, the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise. If necessary, clean the converter and retest the clutch. Replace the converter if the clutch still fails the test. Hold Lock Turn Free AT3306 2. AT2821 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR (a) Set up a dial indicator, and measure the drive plate runout. (b) Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within the specification or ring gear is damaged, replace the drive plate. Torque: 83 N·m (850 kgf·cm, 61 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1333 AX-44 AUTOMATIC TRANSAXLE - TORQUE CONVERTER CLUTCH AND DRIVE PLATE 3. AT4184 MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT (a) Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator and measure the torque converter clutch sleeve runout. Maximum runout: 0.30 mm (0.0118 in.) If the runout is not within the specification, try to correct by reorienting the installation of the converter clutch. HINT: Mark the position of the converter clutch to ensure the correct installation. (b) Remove the torque converter clutch. 2001 AVALON (RM808U) Author
: Date
: 1334 AX-12 AUTOMATIC TRANSAXLE - THROTTLE CABLE THROTTLE CABLE AX03R-05 ON-VEHICLE REPAIR 1. 2. (a) (b) REMOVE BATTERY REMOVE CRUISE CONTROL ACTUATOR Remove the 3 bolts and cruise control actuator. Disconnect the connector. Q09982 3. DISCONNECT THROTTLE CABLE FROM ENGINE Disconnect the cable from the throttle linkage. 4. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX-4 ) 5. REMOVE VALVE BODY (See page AX-6 ) D07234 6. (a) (b) REMOVE THROTTLE CABLE Remove the bolt and retaining plate. Pull out the cable from the transaxle case. Q00270 200 mm (7.87 in.) 0.8 - 1.5 mm (0.031-0.059 in.) Q05731 7. INSTALL THROTTLE CABLE If the throttle cable is new, do the following operations (a) - (b). (a) Bend the cable so there is a radius of about 200 mm (7.87 in.). (b) Pull the inner cable lightly until slight resistance is felt, and hold it there. (c) Stake the stopper, 0.8-1.5 mm (0.031-0.059 in.) from the end of outer cable. (d) Install a new O-ring to the throttle calbe. (e) (f) 8. Make sure to push it in all the way. Install the retaining plate and bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) INSTALL VALVE BODY (See page AX-6 ) Q00270 2001 AVALON (RM808U) Author
: Date
: 1302 AX-13 AUTOMATIC TRANSAXLE 9. 10. 11. - THROTTLE CABLE CONNECT THROTTLE CABLE TO ENGINE Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) ADJUST THROTTLE CABLE (See page DI-160 ) INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX-4 ) D07234 12. (a) (b) 13. 14. INSTALL CRUISE CONTROL ACTUATOR Install the cruise control actuator with the 3 bolts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Connect the connector. INSTALL BATTERY TEST DRIVE VEHICLE Q09982 2001 AVALON (RM808U) Author
: Date
: 1303 AX-6 AUTOMATIC TRANSAXLE - VALVE BODY ASSEMBLY VALVE BODY ASSEMBLY AX05D-03 ON-VEHICLE REPAIR 1. CLEAN TRANSAXLE EXTERIOR To help prevent contamination, clean the exterior of the transaxle. 2. DRAIN ATF Using a hexagon wrench, remove the drain plug and drain the fluid into the suitable container. 3. REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove oil pan bolts, and carefully remove the pan assembly. Discard the gasket. AT3785 4. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look at the chips and particles in the pan and magnet carefully to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bushing wear AT0103 5. REMOVE OIL STRAINER AND APPLY PIPE BRACKET (a) Remove the 3 bolts and oil strainer. NOTICE: Be careful as oil will come out of the strainer when it is removed. (b) Remove the 3 bolts and apply pipe bracket. D01019 Connector 6. REMOVE OIL PIPE Pry up both pipe ends with a large screwdriver and remove the 5 pipes. 7. DISCONNECT 3 SOLENOID CONNECTORS Q05728 2001 AVALON (RM808U) Author
: Date
: 1296 AX-7 AUTOMATIC TRANSAXLE 8. (a) (b) (c) - VALVE BODY ASSEMBLY REMOVE DETENT SPRING AND OIL PIPE Remove the 2 bolts and detent spring. Remove the bolt. Pry up the pipe with a screwdriver and remove the pipe. D01020 9. REMOVE MANUAL VALVE BODY Remove the 5 bolts and manual valve body. D01021 10. REMOVE CONNECTOR CLAMP AND PIPE RETAINER Remove the 2 bolts, connector clamp and pipe retainer. D01059 11. REMOVE B3 APPLY PIPE Pry up the pipe with a screwdriver and remove the pipe. D01058 12. (a) REMOVE VALVE BODY Remove the 9 bolts. D01023 2001 AVALON (RM808U) Author
: Date
: 1297 AX-8 AUTOMATIC TRANSAXLE (b) 13. - VALVE BODY ASSEMBLY Disconnect the throttle cable from the cam and remove the valve body. REMOVE 2ND BRAKE APPLY GASKET OR0038 14. (a) REMOVE SHIFT SOLENOID VALVE Remove the 3 bolts, shift solenoid valve No.1 and No.2 with the retainer. NOTICE: When removing solenoid, do not use a screwdriver, etc. to pry up the solenoid. (b) Remove the O-rings from the shift solenoid valve No.1 and No.2. Q05643 (c) (d) Remove the bolt and shift solenoid valve SL. Remove the 2 O-rings from the shift solenoid valve SL. (e) Remove the bolt and shift solenoid valve SLN. 15. (a) INSTALL SOLENOID VALVE Coat 2 new O-rings with ATF and install it to the shift solenoid valve SL. Install the shift solenoid valve SL with the bolt. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) Q05657 Q05402 (b) Q05657 2001 AVALON (RM808U) Author
: Date
: 1298 AX-9 AUTOMATIC TRANSAXLE (c) (d) - VALVE BODY ASSEMBLY Install the shift solenoid valve SLN with the bolt. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) Coat 2 new O-rings with ATF and install them to the shift solenoid valve No.1 and No.2. Q05402 (e) 16. Install the shift solenoid valve No.1 and No.2 with the 3 bolts. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) PLACE NEW 2ND BRAKE APPLY GASKET Q05643 17. (a) INSTALL VALVE BODY TO TRANSAXLE CASE While holding the cam down with your hand, slip the cable end into the slot. NOTICE: Be careful not to entangle the solenoid wire. OR0038 D (b) D A C C B C D01023 Install the valve body with the 9 bolts. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) HINT: Temporarily install the 9 bolts first, then torque them. Bolt length: Bolt A: 30 mm (1.181 in.) Bolt B: 43 mm (1.693 in.) Bolt C: 48 mm (1.890 in.) Bolt D: 52 mm (2.047 in.) 18. INSTALL B3 APPLY PIPE Using a plastic hammer, install the pipe into the position indicated in the illustration. NOTICE: Be careful not to bend or damage the pipe. D01058 2001 AVALON (RM808U) Author
: Date
: 1299 AX-10 AUTOMATIC TRANSAXLE B A - VALVE BODY ASSEMBLY 19. INSTALL CONNECTOR CLAMP AND PIPE RETAINER Install the connector clamp and pipe retainer with the 2 bolts. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) Bolt length: Bolt A: 48 mm (1.890 in.) Bolt B: 39 mm (1.535 in.) D01059 20. (a) B B A D01021 30 (1.18) B A mm (in.) Z19257 Connector INSTALL MANUAL VALVE BODY Aligning the valve body with the pin on the manual shaft lever. (b) Lower the manual valve body into place. (c) Temporarily the 5 bolts first. Then, tighten them with a torque wrench. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 37 mm (1.457 in.) 21. INSTALL DETENT SPRING AND OIL PIPE (a) Place the detent springs on the manual valve body and temporarily install the 2 bolts first. Then, tighten them with a torque wrench. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) Bolt length: Bolt A: 14 mm (0.551 in.) Bolt B: 37 mm (1.457 in.) (b) Check that the manual valve lever is touching the center of the detent spring tip roller. (c) Using a plastic hammer, install the pipe into the position. NOTICE: Be careful not to bend or damage the pipe. (d) Install the bolt. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 22. CONNECT 3 SOLENOID CONNECTORS 23. INSTALL OIL PIPE Using a plastic hammer, install the pipes into the positions. NOTICE: Be careful not to bend or damage the pipes. Q05728 2001 AVALON (RM808U) Author
: Date
: 1300 AX-1 1 AUTOMATIC TRANSAXLE A - VALVE BODY ASSEMBLY 24. INSTALL OIL STRAINER AND APPLY PIPE BRACKET Install the oil strainer and apply pipe bracket with the 6 bolts. Torque: Bolt A: 10 N·m (100 kgf·cm, 7 ft·lbf) Bolt B: 11 N·m (110 kgf·cm, 8 ft·lbf) Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 53 mm (2.087 in.) A B B Z19256 25. INSTALL MAGNET IN PLACE Install the 3 magnets in the indentations of the oil pan, as shown in the illustration. NOTICE: Make sure that the magnet does not interfere with the oil pipes. AT3741 26. (a) (b) AT3785 INSTALL OIL PAN AND GASKET Install the oil pan and a new gasket. Install the 17 bolts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) 27. INSTALL DRAIN PLUG Install a new gasket and drain plug. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) 28. FILL ATF AND CHECK FLUID LEVEL (See page DI-160 ) 2001 AVALON (RM808U) Author
: Date
: 1301 BE-126 BODY ELECTRICAL - AUDIO SYSTEM AUDIO SYSTEM BE214-01 DESCRIPTION OUTLINE OF AVC-LAN (a) What is AVC-LAN? AVC-LAN is the abbreviation, which stands for Audio Visual Communication-Local Area Network. This is a unified standard co-developed by 6 audio manufactures associated with Toyota Motor Corporation. The Unified standard covers signals, such as audio signal, visual signal, signal for switch indication and communication signal. Radio Receiver Assembly Power Amplifier CD Auto Changer I10058 (b) (c) Objectives Recently the car audio system has been rapidly developed and functions have been changed drastically. The conventional system has been switched to the multi-media type such as a navigation system. At the same time the level of customers needs to audio system has been upgraded. This lies behind this standardization. The concrete objectives are explained below. (1) When products by different manufactures were combined together, there used to be a case that malfunction occurred such as sound did not come out. This problem has been resolved by standardization of signals. (2) Various types of after market products have been able to add or replace freely. (3) Because of the above (2), each manufacture has become able to concentrate on developing products in their strongest field. This has enabled many types of products provided inexpensively. (4) Conventionally, a new product developed by a manufacture could not be used due to a lack of compatibility with other manufactures products. Because of this new standard, users can enjoy compatible products provided for them timely. The above descriptions are the objectives to introduce AVC-LAN. By this standardization, development of new products will no longer cause systematic errors. Thus, this is very effective standard for a product in the future. HINT:



When +B short or GND short is detected in AVC-LAN circuit, communication stops. Accordingly the audio system does not function normally. When audio system is not equipped with a navigation system, audio head unit is the master unit. (When audio system is equipped with a navigation system, radio receiver is the master unit.) The car audio system using AVC-LAN circuit has a diagnosis function. Each product has its own specified numbers called physical address. Numbers are also allotted to each function in one product, which are called logical address. 2001 AVALON (RM808U) Author
: Date
: 1730 BE-161 BODY ELECTRICAL - AUDIO SYSTEM BE16M-03 INSPECTION 1. INSPECT POWER AMPLIFIER CIRCUIT Connect the connector from power amplifier and inspect the connector on the wire harness side. Power amplifier side Connector ”A” Connector ”B” 6 5 4 3 2 1 14 1312 11 10 9 8 7 I14592 e 16 2 A Tester connection Condition Specified condition A1 - Ground (FR+) Audio sounding 5-7V A2 - Ground (FL+) Audio sounding 5-7V A3 - Ground (RR+) Audio sounding 5-7V A4 - Ground (Rl+) Audio sounding 5-7V A5 - Ground (WFl+) Audio sounding 5-7V A7 - Ground (+B) Constant Battery positive voltage A8 - Ground (FR-) Audio sounding 5-7V A9 - Ground (FL-) Audio sounding 5-7V A10 - Ground (RR-) Audio sounding 5-7V A11 - Ground (RL-) Audio sounding 5-7V A13 - Ground (GND) Constant Continuity A14 - Ground (WFL-) Audio sounding 5-7V B1 - Ground (AMP+) Radio power switch ON Battery positive voltage B2 - Ground (ACC) Ignition switch ON Battery positive voltage B4 - Ground (BEEP) Audio sounding - B5 - Ground (FLIN) Audio sounding 5-7V B6 - Ground (FRIN) Audio sounding 5-7V 2001 AVALON (RM808U) Author
: Date
: 1765 BE-162 BODY ELECTRICAL - AUDIO SYSTEM B11 - Ground (SGND) Constant Continuity B12 - Ground (MUTE) Audio sounding 1 V or below B13 - Ground (RLIN) Audio sounding 5-7V B14 - Ground (RRIN) Audio sounding 5-7V If the circuit is not as specified, inspect the circuits connected to other parts. 2001 AVALON (RM808U) Author
: Date
: 1766 BE-163 BODY ELECTRICAL - AUDIO SYSTEM 2. INSPECT RADIO RECEIVER ASSEMBLY CIRCUIT Connect the connectors from the radio receiver assembly, and inspect the connector on the wire harness side. Radio Receiver Side Connector ”A” Connector ”B” Connector ”C” I14591 Tester connection Condition Specified condition A1 - Ground (FR+) Audio sounding 5-7V A2 - Ground (FL+) Audio sounding 5-7V A3 - Ground (ACC, +B) Ignition switch ACC Battery positive voltage A4 - Ground (BU +B) Constant Battery positive voltage A5 - Ground (FR-) Audio sounding 5-7V A6 - Ground (FL-) Audio sounding 5-7V A7 - Ground (GND) Constant Continuity A8 - Ground (ANT +B) Radio power switch ON Battery positive voltage A10 - Ground (ILL+) Headlight dimmer switch ON Battery positive voltage B1 - Ground (RR+) Audio sounding 5-7V B2 - Ground (RL+) Audio sounding 5-7V B3 - Ground (RR-) Audio sounding 5-7V B4 - Ground (RL-) Audio sounding 5-7V C1 - Ground (+B) Constant Battery positive voltage C2 - Ground (ILL+) Hesdlight dimmer switch ON Battery positive voltage C3 - Ground (AMP+) Rasio switch ON Battery positive voltage C7 - Ground (MUTE) Audio sounding 1V or below 2001 AVALON (RM808U) Author
: Date
: 1767 BE-164 BODY ELECTRICAL - AUDIO SYSTEM C8 - Ground (FR+) Audio sounding 5-7V C9 - Ground (FL+) Audio sounding 5-7V C10 - Ground (SLD) Constant Continuity C11 - Ground (ACC) Ignition switch ON Battery positive voltage C13 - Ground (ANT+B) Radio power switch ON 10 - 14V C16 - Ground (S-GND) Constant Continuity C17 - Ground (BEEP) Audio sounding - C18 - Ground (RR) Audio sounding 5-7V C19 - Ground (RL) Audio sounding 5-7V C20 - Ground (GND) Constant Continuity If the circuit is not as specified, inspect the circuits connected to other parts. 3. INSPECT GLASS IMPRINTED ANTENNA Use same procedure as for ”INSPECT DEFOGGER WIRES” on page BE-67 . 4. REPAIR GLASS IMPRINTED ANTENNA Use same procedure as for ”REPAIR DEFOGGER WIRES” on page BE-67 . 2001 AVALON (RM808U) Author
: Date
: 1768 BE-160 BODY ELECTRICAL - AUDIO SYSTEM BE0AZ-07 LOCATION Twetter Radio Receiver Assembly Driver Side Junction Block
RADIO Fuse Rear Speaker Front Speaker Glass Printed Antenna Power Amplifier (Premium System Only) Sub Woofer (Premium System Only) I12536 2001 AVALON (RM808U) Author
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: 1764 BE-127 BODY ELECTRICAL - AUDIO SYSTEM BE215-01 TROUBLESHOOTING 1. (a) Europe models: DIAGNOSIS FUNCTION Diagnosis start-up For shifting diagnosis mode, turn ignition switch ON and push the ”DISC” switch 3 times while pressing ”ch1” and ”ch6” switches. HINT: To exist from the diagnosis mode, push the ”DISC” switch for 1.7 sec. or turn ignition switch to ACC or OFF. ”DISC” Switch ”TUNE UP” Switch ”TUNE DOWN” Switch ”1ch” Switch ”2ch” Switch (b) ”3ch” Switch ”4ch” Switch ”5ch” Switch ”6ch” Switch I12856 Service check mode (1) After the diagnosis start-up, the system enters service check mode. (2) Error codes over tuner and connected equipment are displayed on the screen of tuner. Results for each check are displayed as follows:  good: No DTC is detected for both ”System Check Confirmation” and ”Diagnosis Memory Response”.  nCon: The Component does not respond to the ”Diagnosis On Instruction” command. Applicable to only the system where connected components are limited to be used.  ECHn: Application of new version has been confirmed by the ”Diagnosis On Check”, and there is one or more DTC which indicates ”Replacement” in the ”System Check Result Response” or ”Diagnosis Memory Response”.  CHEC: Application of new version has been confirmed by the ”Diagnosis On Check”, and there is no DTC which indicates ”Replacement” in the ”System Check Result Response” or ”Diagnosis Memory Response”, but one or more DTC which indicated ”Check” is identified. 2001 AVALON (RM808U) Author
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: 1731 BE-128 BODY ELECTRICAL   - AUDIO SYSTEM Old: Application of old version is confirmed by the ”Diagnosis On Check”, and DTC is identified in the ”System Check Result Response” or ”Diagnosis Memory Response”. nrES: No response is identified to the ”System Check Start Instruction” and ”Request for System Check Result” commands. HINT:   Check the present and past condition of components by performing the System Check and collecting stored DTC memories. Check results shall be displayed as one of six following indications: ”good”, ”ECHn”, ”CHEC”,”nCon”, ”Old” or ”nrES”. 2001 AVALON (RM808U) Author
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: 1732 BE-129 BODY ELECTRICAL (c) - AUDIO SYSTEM Display Screen for Service Check. Example: Connection parts ( physical address): Radio receiver (P190), CD Auto Changer (P240), MD chnger (P3A0) Turn ignition switch ON. Push the ”DISC” switch 3 times while pressing ”ch1” and ”ch6” swithes. Normal Mode  3 beeps HINT: To exit from diagnosis mode, press the ”DISC” switch for 1.7 sec. or turn ignition switch to OFF P240 Service Check Mode TUNE DOWN TUNE UP ch2 Result (Replaceing) ECHn ch3 TUNE UP TUNE DOWN Physical Address P190 TUNE DOWN TUNE UP ch2 Result (Check) CHEC ch3 ”CHEC” Detail Display Mode (Refer to (g)) TUNE UP TUNE DOWN P3A0 Physical Address TUNE DOWN TUNE UP ch2 Result (Old) ”ECHn” Detail Display Mode (Refer to (f)) Old ch3 ”Old” Detail Display Mode (Refer to (h)) ch5 (1.7 sec.)  A long beep (3 sec.) : Indicates a switch operation CLr After 3 sec. Memory Clear Mode  After the memory is cleared, only the physical address is displayed cyclically.  When re-checking (ch1 switch is pressed) in that condition, the result is also displayed as shown above. 2001 AVALON (RM808U) Author
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: 1733 BE-130 BODY ELECTRICAL (d) - AUDIO SYSTEM ”ECHn” Detail Display Mode Screen P240 Service Check Mode TUNE UP TUNE DOWN TUNE UP CLr ECHn TUNE DOWN ch5 (Along) ch2 ch3 ”ECHn” Detail Display Mode Physical Address of Component P240 TUNE UP TUNE DOWN SyS TUNE UP TUNE DOWN 1L Logical Address ** TUNE UP TUNE DOWN 1d 45 DTC (Refer to diagnostic trouble code chart) Details for 1st Component TUNE UP TUNE DOWN COdE TUNE UP TUNE DOWN 2L Detail code is displayed cyclically. ** TUNE UP TUNE DOWN 2d E4 TUNE DOWN *** TUNE DOWN (*2): There are some diagnostic codes witch might not be displayed. In this case, ”- -” displayed. Auxiliary Code (*1) Details for 2nd Component TUNE UP 2n ** TUNE DOWN Connection Check Code (*2) TUNE UP 2c TUNE DOWN DTC (Refer to diagnostic trouble code chart) TUNE UP 2P (*1): There are some diagnostic codes witch might not be displayed. In this case, ”- - -” displayed. Logical Address ** Number of Occurrence (*2) TUNE UP Continued if more than one DTC is identified. TUNE DOWN TUNE UP : Indicates a switch operation 2001 AVALON (RM808U) Author
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: 1734 BE-131 BODY ELECTRICAL (e) - AUDIO SYSTEM ”CHEC” Detail Display Mode Screen P190 Service Check Mode TUNE UP TUNE DOWN TUNE UP CHEC CLr TUNE DOWN ch3 ”CHEC” Detail Display Mode ch5 (Along) ch2 P190 Physical Address of Component TUNE DOWN TUNE UP COde TUNE UP TUNE DOWN 1L Logical Address ** TUNE DOWN TUNE UP 1d E4 TUNE DOWN TUNE UP 1P *** Auxiliary Code (*1) ** Connection Check Code (*2) TUNE DOWN TUNE UP TUNE DOWN 1c ** TUNE DOWN ** 2d 43 TUNE DOWN : Indicates a switch operation DTC (Refer to diagnostic trouble code chart) TUNE UP 2P *** Details for 2nd Component Auxiliary Code (*1) TUNE UP TUNE DOWN 2n ** TUNE DOWN Connection Check Code (*2) TUNE UP 2c TUNE DOWN Logical Address TUNE UP TUNE DOWN (*2): There are some diagnostic codes witch might not be displayed. In this case, ”- -” displayed. Number of Occurrence (*2) TUNE UP 2L (*1): There are some diagnostic codes witch might not be displayed. In this case, ”- - -” displayed. Details for 1st Component TUNE UP 1n Detail code is displayed cyclically. DTC (Refer to diagnostic trouble code chart) ** Number of Occurrence (*2) TUNE UP Continued if more than one DTC is identified. TUNE DOWN TUNE UP 2001 AVALON (RM808U) Author
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: 1735 BE-132 BODY ELECTRICAL (f) - AUDIO SYSTEM ”Old” Detail Display Mode Screen P3A0 Service Check Mode TUNE UP TUNE DOWN TUNE UP Old CLr TUNE DOWN ch3 ”CHEC” Detail Display Mode ch5 (Along) ch2 P190 Physical Address of Component TUNE DOWN TUNE UP COdE TUNE UP TUNE DOWN 1L Logical Address ** TUNE DOWN TUNE UP 1d d4 DTC (Refer to diagnostic trouble code chart) TUNE DOWN TUNE UP 1P *** Auxiliary Code (*1) ** Connection Check Code (*2) TUNE DOWN TUNE UP 1n TUNE UP TUNE DOWN 1c Detail code is displayed cyclically. - - TUNE DOWN Logical Address ** TUNE UP TUNE DOWN 2d 43 TUNE DOWN : Indicates a switch operation *** Details for 2nd Component Auxiliary Code (*1) TUNE UP TUNE DOWN 2n TUNE DOWN ** Connection Check Code (*2) TUNE UP 2c TUNE DOWN DTC (Refer to diagnostic trouble code chart) TUNE UP 2P (*2): There are some diagnostic codes witch might not be displayed. In this case, ”- -” displayed. Number of Occurrence (*2) TUNE UP 2L (*1): There are some diagnostic codes witch might not be displayed. In this case, ”- - -” displayed. Details for 1st Component - - Number of Occurrence (*2) TUNE UP Continued if more than one DTC is identified. TUNE DOWN TUNE UP 2001 AVALON (RM808U) Author
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: 1736 BE-133 BODY ELECTRICAL - AUDIO SYSTEM 2. Except Europe models: DIAGNOSIS FUNCTION Error codes over tuner and connected equipment are displayed on the screen of tuner. (a) Diagnosis start-up For shifting to diagnosis mode, push ”DISC” switch 3 times with pressing ”1” and ”6” of PRESET switch at the same time while the audio power is OFF and ACC is ON. To exit from diagnosis mode, press ”DISC” switch for 2 seconds or turn the ignition key OFF. (When ”1-190” is displayed, the mode is transferred to LAN check mode.) (b) LAN check When starting up the diagnosis mode, the mode turns to LAN check mode, the screen displays the code numbers (physical address) of tuner and connected equipment. Smaller codes are displayed in order, displayed code numbers are switched by operating TUNE ”UP” or ”DOWN” switch. In LAN check mode, by pressing ”5” of PRESET switch for more than 2 secs., diagnosis memory of each equipment can be deleted, when deletion is completed, the mode returns to LAN check mode. ”4ch” Switch ”6ch” Switch ”5ch” Switch ”TUNE UP” Switch ”TUNE DOWN” Switch ”1ch” Switch ”2ch” Switch ”3ch” Switch ”DISC” Switch I19691 Code No. (physical address) List Code No. (physical address) (c) Equipment name 190 Radio receiver assembly (Audio head unit) 240 CD changer (in Luggage room) 360 CD changer (in center console and glove compartment box) 440 Power amplifier System check  When pressing ”1” of PRESET switch in LAN check mode, the mode turns to the system check mode, the system performs self diagnosis of connected equipment and displays the results.(”SYS” (showing the system is under detection) is displayed.)  Perform the operation shown in the following illustration, then read the result of the inspection. 2001 AVALON (RM808U) Author
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: 1737 BE-134 BODY ELECTRICAL - AUDIO SYSTEM HINT:       It sometimes takes approx. 40 secs. till the system inspection is completed. The chart below is an example of when diagnosis code ”21” appears on the physical address (190) equipment. (ROM error occurs on the radio receiver.) The smaller code numbers (physical address) are displayed in order (code No., diagnosis code, support code of diagnosis code (object equipment)). When no error is detected in the system, ”00” is displayed. When an error code is detected, up to 6 codes per one system are displayed. Pressing TUNE ”UP” or ”DOWN” switches the display. In the system check mode, when pressing ”6” of PRESET switch the mode returns to LAN check mode. H: This shows the equipment has a diagnosis code. 190: Physical address Pressing TURN ”DOWN” Pressing TURN ”UP” 1: This is the number allotted to the diagnosis code that occurred. 21: DTC No. 1: This is the number allotted to the diagnosis code that occurred. : NO DTC No. .. . .. . Last Code No. (d) Diagnosis memory (1) In LAN check mode, when pressing ”2” of PRESET switch the mode turns to the diagnosis memory mode. (”CODE” is displayed.) The results of self diagnosis performed over tuner and connected equipment are memorized and displayed. (2) Perform the operation shown in the following illustration, then read the result of the inspection. HINT:     The smaller code numbers (physical address) are displayed in order (code No. , periodic communication number when error occurs, diagnosis code, and support code of diagnosis code (object equipment)). When no error is detected in the system, ”00” is displayed. When an error code is detected, up to 6 codes per one system are displayed. Pressing TUNE ”UP” or ”DOWN” switches the display. Each diagnosis code is same as code in the system check mode. When pressing ”6” of PRESET switch, the mode returns to LAN check mode. The following illustration below is an example of when diagnosis code ”D1” appears on the code (190) and (240 or 360) equipment. (Communication error occurs between the radio receiver and CD changer.) 2001 AVALON (RM808U) Author
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: 1738 BE-135 BODY ELECTRICAL - AUDIO SYSTEM 06: Periodic communication number of when occurring in the diagnosis memory code. Pressing TURN ”UP” Pressing TURN ”DOWN” H: This shows the equipment has a diagnosis code. 190: Physical address 1: This is the number allotted to the diagnosis code that occurred. 21: Periodic communication number of when occurring in the diagnosis memory code. 1: This is the number allotted to the diagnosis code that occurred. d1: DTC No. .. . .. . 1: This is the number allotted to the diagnosis code that occurred. 360: Physical address (Equipment that is communicating code) Last Code No. (e) Diagnosis memory clear (1) After error is fixed, start up the diagnosis mode. (2) Continue pressing preset switch ”5” for 2 secs. (CLr is displayed.) (3) Press the preset switch ”2” and transfer to the diagnosis memory mode and check that the normal code (00) is output. 2001 AVALON (RM808U) Author
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: 1739 BE-136 BODY ELECTRICAL 3. - AUDIO SYSTEM Europe models: DIAGNOSIS CODE LIST Terms Meaning Physical address Logical address Three-digit code (shown in hexadecimal) which is given to each component comprising the AVC-LAN. Corresponding to the function, individual symbols are specified. Two-digit code (shown in hexadecimal) which is given to each function comprising the inner system of the AVC-LAN. (a) Physical address 190: Radio receiver assembly HINT:  *1: Even if no failure is detected, it may be stored depending on the battery condition or voltage for starting an engine.  *2: It is stored when 180 sec. has passed after the power supply connector is pulled out after engine start.  *3: It may be stored when the engine key is turned 1 min. again after engine start.  *4: It may be stored when the engine key is turned again after engine start.  *5: When 210 sec. has passed after pulling out the power supply connector of the master component with the ignition switch in ACC or ON, this code is stored. (1) Logical address: 01 (Communication control) DTC Diagnosis item Diagnosis content Countermeasure and inspected parts D6 *1 Absence of Master Component in which this code is recorded has been disconnected from system with ignition in ACC or ON. Or, when this code was recorded, multi-display assembly was disconnected.  Check harness for power supply system of multi-display.  Check harness for communication system of multi-display.  Check harness for power supply system of radio and player.  Check harness for communication system of radio and player. D8 *2 No Response to Connection Check Component shown by auxiliary code is or had been disconnected from system after engine is start. D9  Check harness for power supply system of component shown by auxiliary code.  Check harness for communication system of component shown by auxiliary code. D9 *1 Last Mode Error Component operated (sounds and/or images were provided) before engine stop is or has been disconnected with ignition switch in ACC or ON.  Check harness for power supply system of component shown by auxiliary code.  Check harness for communication system of component shown by auxiliary code. DA No Response to ON/OFF Instruction No response is identified when changing mode (audio and visual mode change). Detected when sound and picture does not change by button operation.  Check harness for power supply system of component shown by auxiliary code.  Check harness for communication system of component shown by auxiliary code.  If error occurs again, replace component shown by auxiliary code. DB *1 Mode Status Error Dual alarm is detected.  Check harness for power supply of component shown by auxiliary code.  Check harness for communication system of component shown by auxiliary code. DC *3 Transmission Error Transmission to component shown by auxiliary code has been failed. (Detecting this DTC does not necessarily mean actual failure.) If same auxiliary code is recorded in order component, check harness for power supply and communication system of all components shown by code. 2001 AVALON (RM808U) Author
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: 1740 BE-137 BODY ELECTRICAL - AUDIO SYSTEM DD *4 Master Reset (Momentary Interruption) After engine is started, multi-display assembly was disconnected from system.  Check harness for power supply system of multi-display.  Check harness for communication system of multi-display.  Check harness for power supply system of radio and player.  Check harness for communication system of radio and player.  If this error occurs frequently, replace multi-display assembly. DE *4 Slave Reset (Momentary Interruption) After engine is started, slave component was disconnected from system.  Check harness for power supply of component shown by auxiliary code.  Check harness for communication system of component shown by auxiliary code. DF *5 Master Error Due to defective condition of component with a display, master function is switched to audio equipment. Error occurs in communication between sub-master (audio) and master component.  Check harness for power supply of multidisplay assembly.  Check harness for communication system of multi-display assembly.  Check harness for communication system between multi-display assembly and submaster component. E0 *1 Registration Completion Instruction Error ”Registration Completion Instruction” command from master cannot be received. Since this DTC is provided for engineering purpose, it may be detected when no actual failure exists. E1 *1 Audio processor ON error While source equipment is operating, AMP output is stopped.  Check harness for power supply of multidisplay assembly.  Check harness for communication system of multi-display assembly. E2 ON/OFF Instruction Parameter Error Error occurs in ON/OFF controlling command from multi-display assembly. Replace multi-display assembly. E3 *1 Registration Request Transmission Registration Request command is output from slave component. Receiving Connection Check Instruction, Registration Request command is output from sub-master component. Since this DTC is provided for engineering purpose, it may be detected when no actual failure exists. E4 *1 Multiple Frame Abort Multiple frame transmission is aborted. Since this DTC is provided for engineering purpose, it may be detected when no actual failure exists. (2) Logical address: 61 (Cassette switch) DTC Diagnosis item Diagnosis content Countermeasure and inspected parts 40 Mechanical of Media Error Malfunction due to mechanical failure is identified. Or cassette tape is cut or entangled.  Inspect cassette tape.  Replace radio and player. (b) Physical address: 440 Stereo component amplifier HINT:  *1: Even if no failure is detected, it may be stored depending on the battery condition or voltage for starting an engine.  *2: It may be stored when the engine key is turned 1 min. again after engine start.  *3: It may be stored when the engine key is turned again after engine start.  *4: When 210 sec. has passed after pulling out the power supply connector of the master component with the ignition switch in ACC or ON, this code is stored. 2001 AVALON (RM808U) Author
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: 1741 BE-138 BODY ELECTRICAL - AUDIO SYSTEM Logical address: 01 (Communication control) DTC Diagnosis item Diagnosis content Countermeasure and inspected parts D6 *1 Absence of Master Component in which this code is recorded has been disconnected from system with ignition in ACC or ON. Or, when this code was recorded, multi-display assembly was disconnected.  Check harness for power supply of radio and player.  Check harness for communication system of radio and player.  Check harness for power supply of stereo component amplifier.  Check harness for communication system of stereo component amplifier. D4 Communication Check Error Component in which this code is recorded is or was disconnected from system after engine start. Or, when recording this code, multi-display assembly was disconnected.  Check harness for power supply of radio and player.  Check harness for communication system of radio and player.  Check harness for power supply of stereo component amplifier.  Check harness for communication system of stereo component amplifier. D1 *2 Transmission Error Transmission to component shown by auxiliary code has been failed. (Detecting this DTC does not necessarily mean actual failure.) If same auxiliary code is recorded in order component, check harness for power supply and communication system of all components shown by code. (c) Physical address: 240 CD Auto Changer HINT:  *1: Even if no failure is detected, it may be stored depending on the battery condition or voltage for starting an engine.  *2: It may be stored when the engine key is turned 1 min. again after engine start.  *3: It may be stored when the engine key is turned again after engine start.  *4: It may be stored when the engine key is turned again after engine start.  *5: When 210 sec. has passed after pulling out the power supply connector of the master component with the ignition switch in ACC or ON, this code is stored. (1) Logical address: 01 (Communication control) DTC Diagnosis item Diagnosis content Countermeasure and inspected parts DI Transmission Error Transmission to component shown by auxiliary code has been failed. (This code does not necessarily mean actual failure.) If same auxiliary code is recorded in other component(s), check harness for power supply and communication system of components shown sub code. Component in which this code is recorded is or was disconnected from system after engine start. Or, when recording this code, multi-display assembly was disconnected.  Check harness for power supply of multidisplay.  Check harness for communication system of multi-display.  Check harness for power supply of CD auto changer.  Check harness for communication system of CD auto changer. D4 *5 Connection check Error (2) Logical address: 63 (CD Auto Changer) DTC Diagnosis item Diagnosis content Countermeasure and inspected parts 60 CD Error Error is detected in CD auto changer. Replace CD auto changer 61 EJECT Error Magazine cannot be ejected. Replace CD auto changer 62 No Disc Readout Disc cannot be read. Inspect CD 2001 AVALON (RM808U) Author
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: 1742 BE-139 BODY ELECTRICAL 4.   Readout cannot be done because temperature around player’s pick-up (reading part) is too high. With IG switch OFF, leave vehicle in cool shaded place for a while and re-check. After deleting the DTC memory, if same code detected, replace CD auto changer. CD Changer Excess Current Excess current is applied CD auto changer. Replace CD auto changer Except Europe models: DIAGNOSIS CODE LIST If there is ”O” in the column of system check, an error can be detected when the mode is switched to the system check mode. If there is ”O” in the column of diagnosis mode, each unit is monitoring whether or not it has failure. In case of detectng failure, it memorizes DTC. Parts DTC Name Head Unit (190) Diagnosis item Diagnosis content System Check Countermeasure and inspected parts Diagnosis memory 50 Cassette error There is an error in cassette Radio receiver check. deck. X  D1 Transmitter error Communication with the equipment that is communicating has failed successively. Radio receiver check. Wire harness and connecter check.   Periodic D2 communication no response Error in periodic communication.  Wire harness and connector X  FF Diagnosis no response Result of diagnosis is not issued from start to finish. Radio receiver check.  X 60 CD error Error codes other than 61-69 are detected. CD changer check. X  61 EJECT error CD is not ejected. CD changer check. Magazine check. X  62 DISC inside out/flaw CD is inserted inside out or it has a flaw. High temperature of CD changer is detected. Excessive current to CD changer is detected. CD check. X  X  X  X  X    X  63 Pickup temperature detection 64 Excessive current detection CD (240) (360) AUDIO SYSTEM CD Auto Changer Temp. Too High 63 64 - 67 Tray insertion/ discharging error 68 Elevator error D1 Transmitter error D4 An error occurs in insertion and discharging operation of CD changer tray. An error occurs in elevator of CD changer elevator. Communication with the equipment that is communicating has failed successively. Periodic communication Connection confirmation has not come from the error equipment that is communicating CD changer check. CD changer check. Magazine check. CD changer check.  Radio receiver check.  Wire harness check. 2001 AVALON (RM808U) Author
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: 1743 BE-140 BODY ELECTRICAL Parts DTC Name Diagnosis item D1 Transmitter error AMP (440) D4 Periodic communication error - AUDIO SYSTEM Diagnosis content Communication with the equipment that is communicating has failed successively. Connection confirmation has not come from the equipment that is communicating Countermeasure System Diagnosis and inspected parts Check memory Stereo component amplifier check.    Radio receiver check.  Wire harness check. X  2001 AVALON (RM808U) Author
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: 1744 BE-141 BODY ELECTRICAL - AUDIO SYSTEM 5. PROBLEM SYSMPTOMS TABLE NOTICE: When replacing the internal mechanism (computer part) of the audio system, be careful that no part of your body or clothing comes in contact with the terminals of the leads from the IC, etc. of the replacement part (spare part). HINT: This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during system operation and was prepared on the assumption of system component troubles (except for the wires and connectors, etc.). Always inspect the trouble taking the following items into consideration.  Open or short circuit of the wire harness  Connector or terminal connection fault Problem Radio Tape Player CD Auto Chenger Power Amplifier Noise Flow chart No. Radio not operating when power switch turned to ’ON’. 1 Display indicates when power switch turned to ’ON’, but no sound (including ’noise’) is produced. 2 Noise present, but AM - FM not operating. 3 Any speaker does not work. 4 Any AM or FM does not work. 5 Few preset turning bands. 5 Reception poor. 6 Sound quality poor. 7 Preset memory disappears. 8 Cassette tape cannot be inserted. 9 Cassette tape inserted, but no power. 10 Power coming in, but tape player not operating. 11 Any speaker does not work. 12 Sound quality poor. 13 Tape jammed, malfunction with tape speed or auto-reverse. 14 Cassette tape will not eject. 15 CD magazine cannot be inserted. 16 CD magazine inserted, but no power. 17 Power coming in, but CD player not operating. 18 Sound jumps. 19 Sound quality poor (Volume faint). 20 Any speaker does not work. 21 CD magazine will not be ejected. 22 No power coming in. 23 Power coming in, but power amplifier not operating. 24 Any speaker does not work. 25 Noise occurs 26 Noise produced by vibration or shock while driving. 27 Noise produced when engine starts. 28 The term ”AM” includes LW,MW and SW, and the term ”FW” includes UKW. 2001 AVALON (RM808U) Author
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: 1745 BE-142 BODY ELECTRICAL 1 Radio - AUDIO SYSTEM RADIO NOT OPERATING WHEN POWER SWITCH TURNED TO ”ON” Is tape player operating normally? No Radio assembly faulty. Yes Check if RAD-No.2 fuse is OK? OK Replace fuse. NG Is power supplied to ACC terminal of power amplifier? Yes ACC wire harness faulty. No Check if RAD-No.1 fuse is OK? OK Replace fuse. NG + B wire harness faulty. Is power supplied to +B terminal of power amplifier? Yes Check if GND (wire harness side) of power amplifier grounded normally? No NG GND faulty. OK Is power supplied to ACC terminal of radio assembly? Yes Power amplifier or ACC wire harness faulty. No Is power supplied to +B terminal of radio assembly? Yes Power amplifier or +B wire harness faulty. No GND faulty. Check if GND (wire harness side) to radio assembly is OK? OK NG Radio assembly faulty. 2001 AVALON (RM808U) Author
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: 1746 BE-143 BODY ELECTRICAL 2 - AUDIO SYSTEM DISPLAY INDICATES WHEN POWER SWITCH TURNED TO ”ON”, BUT NO SOUND (INCLUDING ”NOISE”) IS PRODUCED Radio Is tape player operating normally? No Yes Replace fuse. Check if RAD-No.2 fuse is OK? OK NG Is power supplied to ACC terminal of power amplifier? Yes ACC wire harness faulty. No Replace fuse. Check if RAD-No.1 fuse is OK? OK NG Is power supplied to +B terminal of power amplifier? Yes + B wire harness faulty. No GND faulty. Check if GND (wire harness side) of power amplifier grounded normally? OK Is power supplied to ACC terminal of radio receiver? Yes NG Power amplifier faulty. No Is power supplied to +B terminal of radio receiver? Yes Check if GND (wire harness side) of power amplifier grounded normally? Radio assembly faulty. Power amplifier faulty. No GND faulty. NG OK Does continuity exist in speaker wire harness? Yes Speaker wire harness faulty. No Temporarily install another speaker. Functions OK? No Speaker faulty. Yes Hiss noise from speaker? Yes No Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. 2001 AVALON (RM808U) Author
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: 1747 BE-144 BODY ELECTRICAL 3 Radio - AUDIO SYSTEM NOISE PRESENT, BUT AM-FM NOT OPERATING Go to No.25 If radio side faulty. Radio faulty. 4 Radio ANY SPEAKER DOSE NOT WORK Is tape player operating normally? No Radio assembly faulty. Yes Is hiss noise produced by non-functioning speaker? No Yes Does continuity exist in speaker wire harness? Yes Speaker wire harness faulty. No Temporarily install another speaker? Functions OK? No Radio assembly faulty. Recheck system after repair. Speaker faulty. Yes Power amplifier faulty. Recheck system after repair. 2001 AVALON (RM808U) Author
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: 1748 BE-145 BODY ELECTRICAL 5 Radio - AUDIO SYSTEM ANY AM OR FM DOES NOR WORK FEW PRESET TUNING BANDS Problem with radio wave signals or location? No Poor signals, poor location. Yes Radio assembly faulty. Is power for the antenna being output from the radio assembly? No Are both AM and FM defective? Yes Yes No Go to No.16 Is tape player operating normally? No Temporarily install another speaker. Functions OK? No Hiss noise from speaker? Yes Radio assembly faulty. Yes Yes No Speaker faulty. Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. 2001 AVALON (RM808U) Author
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: 1749 BE-146 BODY ELECTRICAL 6 - AUDIO SYSTEM POOR RECEPTION Radio Is the condition bad in comparison with other vehicles? Yes An electric wave environment is bad. No Are there any additional installation parts? (Sun shade film, telephone antenna, etc.) Yes Does the condition get better if removing them? No Yes Influence of additional installation parts. Check if there is any scratch and breaking of a wire on the glass antenna and the defogger pattern. (visual check. tester) (See page BE-126 ) Yes Repair. (See Pub. No. RM588E on page BE-125) No Take a measure for contact. Is the contact of the plug jack of the radio OK? Yes Does the condition get better by using the outer antenna (such as pillar antenna)? No Check the radio. No Yes Is the contact of the antenna terminal on the glass surface and the defogger terminal? Take a measure for contact. No Yes Replace the antenna cord. Is the continuity of the antenna cord OK? Yes Check the grounding of the antenna, antenna cord, choke coil, and noise filter. (See page BE-126 ) No NG Grounding failure. OK Does the condition get better by replacing the choke coil? Replace the choke coil. Yes No Does the condition get better by replacing the antenna cord? Yes Replace the antenna cord. No Exchange the glass. 2001 AVALON (RM808U) Author
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: 1750 BE-147 BODY ELECTRICAL 7 Radio - AUDIO SYSTEM SOUND QUALITY POOR Is sound quality always bad? No Yes Is sound quality bad in certain areas only? Poor signals, poor location. Yes No Is tape player operating normally? Yes No Radio assembly faulty. Radio assembly or power amplifier faulty. Is tape player operating normally? No Radio assembly faulty. Yes Is speaker properly installed? Install properly. No Yes Temporarily install another speaker. Functions OK? No Radio assembly or power amplifier faulty. Recheck system after repair. 8 Radio Speaker faulty. Yes PRESET MEMORY DISAPPEARS Radio assembly faulty. Can cassette tape be inserted in tape player? No Yes Check if RADIO No.1 fuse is OK? OK Replace fuse. NG Is power supplied to +B terminal of power amplifier? Yes No Check if GND (wire harness side) of power amplifier grounded normally? OK Is power supplied to +B terminal of radio assembly? Yes Check if GND (wire harness side) of radio assembly grounded normally? +B wire harness faulty. GND faulty. NG No NG Power amplifier faulty. Power amplifier faulty. OK Radio assembly faulty. 2001 AVALON (RM808U) Author
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: 1751 BE-148 BODY ELECTRICAL 9 Tape Player - AUDIO SYSTEM CASSETTE TAPE CANNOT BE INSERTED Is there a foreign object inside tape player? Remove foreign object. Yes No Is auto search button radio operating normally? Radio assembly faulty. Yes No Check if RADIO No.1 fuse is OK? Replace fuse. NG OK Is power supplied to +B terminal of power amplifier? +B wire harness faulty. No Yes GND faulty. Check if GND (wire harness side) of power amplifier grounded normally? NG OK Power amplifier faulty. Is power supplied to +B terminal of radio assembly? No Yes Check if GND (wire harness side) of radio assembly grounded normally? Power amplifier faulty. NG OK Radio assembly faulty. 10 Tape Player CASSETTE TAPE INSERTED, BUT NO POWER Is radio operating normal? No Radio assembly faulty. Yes Check if RAD No.2 fuse is OK? OK Replace fuse. NG ACC wire harness faulty. Is power supplied to ACC terminal of power amplifier? Yes No Replace fuse. Check if RADIO No.1 fuse is OK? OK NG Is power supplied to +B terminal of radio assembly? Yes Is power supplied to ACC terminal of radio assembly? Yes +B wire harness faulty. No Power amplifier faulty. No Radio assembly faulty. 2001 AVALON (RM808U) Author
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: 1752 BE-149 BODY ELECTRICAL 11 Tape Player - AUDIO SYSTEM POWER COMING IN, BUT TAPE PLAYER NOT OPERATING Function OK if different cassette tape inserted? Cassette tape faulty. Yes No Radio assembly faulty. Is radio operating normally? Yes No Does continuity exist in speaker wire harness? Yes Temporarily install another speaker. Function OK? No Yes Speaker wire harness faulty. Speaker faulty. No Hiss noise from speaker? No Yes Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. 12 Tape Player ANY SPEAKER DOES NOT WORK Is radio operating normally? No Yes Is hiss noise produced by non-functioning speaker. No Yes Temporarily install another speaker. Function OK? Radio assembly faulty. Recheck system after repair. Speaker wire harness faulty. Does continuity exist in speaker wire harness? Yes Radio assembly faulty. No Yes Speaker faulty. No Radio assembly or power amplifier faulty. 2001 AVALON (RM808U) Author
: Date
: 1753 BE-150 BODY ELECTRICAL 13 Tape Player - AUDIO SYSTEM SOUND QUALITY POOR (VOLUME FAINT) Cassette tape faulty. Function OK if different cassette tape inserted? Yes No Head dirty. Operates normally after cleaning the heads? Yes No Is radio operating normally? Radio assembly faulty. Yes No Install properly. Is speaker properly installed? Yes No Temporarily install another speaker. Function OK? Speaker faulty. Yes No Radio assembly faulty. 14 Tape Player TAPE JAMMED MALFUNCTION WITH TAPE SPEED OR AUTO-REVERSE Function OK if different tape (less than 120 mins.) is inserted? No Cassette tape faulty. Yes Is there a foreign object inside tape player? No Operates normally after cleaning the heads? No Remove foreign object. Yes Yes Head dirty. Radio assembly faulty. 2001 AVALON (RM808U) Author
: Date
: 1754 BE-151 BODY ELECTRICAL 15 Tape Player - AUDIO SYSTEM CASSETTE TAPE WILL NOT BE EJECTED Cassette tape jammed. Is tape player operating normally? No Yes Is auto search button of radio operating normally? Radio assembly faulty. Yes No Check if RADIO No.1 fuse is OK? Replace fuse. NG OK +B wire harness faulty. Is power supplied to +B terminal of power amplifier? No Yes Power amplifier faulty. Is power supplied to +B terminal of radio receiver? No Yes Radio assembly faulty. 16 CD Auto Chenger CD MAGAZINE CANNOT BE INSERTED Is CD magazine already inserted? Eject CD magazine. Yes No Is auto search button of radio operating normally? Yes Is power supplied to +B terminal of CD auto chenger? No Radio assembly faulty. No Yes Check if GND (wire harness side) of CD player grounded normally? NG OK CD auto chenger faulty. Check if RADIO No.1 fuse is OK? OK Replace fuse. NG +B wire harness faulty. Is power supplied to +B terminal of power amplifier? Yes No Check if GND (wire harness side) of radio assembly grounded normally? NG OK Radio assembly faulty. 2001 AVALON (RM808U) Author
: Date
: 1755 BE-152 BODY ELECTRICAL 17 CD Auto Chenger - AUDIO SYSTEM CD MAGAZINE INSERTED, BUT NO POWER Yes Is radio operating normally? No Is power supplied to ACC terminal of CD auto chenger? No Radio assembly faulty. Yes CD auto chenger faulty. Check if RADIO No.2 fuse is OK? Replace fuse. NG OK ACC wire harness faulty. Is power supplied to ACC terminal of power amplifier? No Yes Power amplifier faulty. Is power supplied to ACC terminal of radio assembly? No Yes Radio assembly faulty. 18 CD Auto Chenger POWER COMING IN, BUT CD AUTO CHENGER NOT OPERATING Is CD inserted with correct side up? Insert correctly. No Yes Function OK if different CD magazine inserted? Yes No Is radio operating normally? Yes No CD magazine faulty. Is temperature inside cabin hot? Yes No Has sudden temperature change occurred inside cabin? Yes No Protective circuit in operation. Formation of condensation due to temp. changes. CD auto chenger faulty. Dose continuity exist in speaker wire harness? Yes Temporarily install another speaker. Functions OK? Speaker wire harness faulty. No Speaker faulty. Yes No Hiss noise from speaker? Yes No Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. 2001 AVALON (RM808U) Author
: Date
: 1756 BE-153 BODY ELECTRICAL 19 CD Auto Chenger - AUDIO SYSTEM SOUND JUMPS Jumping caused by vibration. Does sound jump only during strong vibration? Yes No Install properly. Is CD auto chenger properly installed? No Yes Functions OK if another CD is played? No CD faulty. Yes Has sudden temperature change occurred inside cabin? Yes No Formation of condensation due to temp. changes. CD auto chenger faulty. 20 CD Auto Chenger SOUND QUALITY POOR (VOLUME FAINT) Function OK if another CD is played? No CD faulty. Yes CD auto chenger faulty. Is radio operating normally? No Yes Is speaker property installed? Yes Temporarily install another speaker. Functions OK? Install properly. No Speaker faulty. Yes No Radio assembly or CD auto chenger or power amplifier faulty. 2001 AVALON (RM808U) Author
: Date
: 1757 BE-154 BODY ELECTRICAL 21 CD Auto Chenger - AUDIO SYSTEM ANY SPEAKER DOES NOT WORK Is radio operating normally? CD auto chenger faulty. Yes No Is hiss noise produced by non-functioning speaker? Radio assembly faulty. Recheck system after repair. Yes No Does continuity exist in speaker wire harness? Speaker wire harness faulty. No Yes Speaker faulty. Temporarily install another speaker. Function OK? Yes No Power amplifier faulty. Recheck system after repair. 22 CD Auto Chenger CD MAGAZINE WILL NOT BE EJECTED Is auto search button of radio operating normally? Yes No Is power supplied to +B terminal No of CD auto chenger? Radio assembly faulty. Yes CD auto chenger faulty. Check if RADIO No.1 fuse is OK? OK Replace fuse. NG Is power supplied to +B terminal of power amplifier? Yes +B wire harness faulty. No Is power supplied to +B terminal of radio receiver? Yes No Power amplifier faulty. Radio assembly faulty. 2001 AVALON (RM808U) Author
: Date
: 1758 BE-155 BODY ELECTRICAL 23 Power Amplifier - AUDIO SYSTEM NO POWER COMING IN Is tape player operating normally? No Radio assembly faulty. Yes Check if RAD-No.2 fuse is OK? OK Replace fuse. NG ACC wire harness faulty. Is power supplied to ACC terminal of power amplifier? Yes No Check if RAD-No.1 fuse is OK? OK Replace fuse. NG Is power supplied to +B terminal of power amplifier? Yes Check if GND (wire harness side) of power amplifier grounded normally? + B wire harness faulty. No NG GND faulty. OK Is power supplied to ACC terminal of radio assembly? Yes Power amplifier or wire harness faulty. No Power amplifier or wire harness faulty. Is power supplied to +B terminal of radio assembly? Yes Check if GND (wire harness side) of radio assembly grounded normally? No GND faulty. NG OK Radio assembly faulty. 2001 AVALON (RM808U) Author
: Date
: 1759 BE-156 BODY ELECTRICAL 24 Power Amplifier - AUDIO SYSTEM POWER COMIMG IN, BUT WOOFER (POWER) AMPLIFIER NOT OPERATING Is tape player operating normally? No Yes Replace fuse. Check if RAD-No.2 fuse is OK? OK NG Is power supplied to ACC terminal of power amplifier? Yes ACC wire harness faulty. No Replace fuse. Check if RAD-No.1 fuse is OK? OK NG Is power supplied to +B terminal of power amplifier? Yes Check if GND (wire harness side) of power amplifier grounded normally? Radio assembly faulty. + B wire harness faulty. No GND faulty. NG OK Is power supplied to ACC terminal of radio assembly? Yes Power amplifier faulty. No Is power supplied to +B terminal of radio assembly? Yes Check if GND (wire harness side) of radio assembly grounded normally? Power amplifier faulty. No GND faulty. NG OK Is there continuity in speaker wire harness? Yes No Temporarily install another speaker. Functions OK? No Speaker faulty. Yes Hiss noise from speaker? Yes Speaker wire harness faulty. No Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. 2001 AVALON (RM808U) Author
: Date
: 1760 BE-157 BODY ELECTRICAL 25 Power Amplifier - AUDIO SYSTEM ANY SPEAKER DOES NOT WORK Is radio operating normally? No CD player faulty. Yes Is hiss noise produced by non-functioning speaker? No Yes Does continuity exist in speaker wire harness? Yes Temporarily install another speaker. Function OK? Radio assembly faulty. Recheck system after repair. Speaker wire harness faulty. No Speaker faulty. Yes No Power amplifier faulty. Recheck system after repair. 2001 AVALON (RM808U) Author
: Date
: 1761 BE-158 BODY ELECTRICAL 26 Noise - AUDIO SYSTEM NOISE OCCURS (It occurs in the cassette and CD.) Does the noise occur only in the radio? Refer to No.27. No Yes An electric environment. Does the noise occur in a particular place? No Is there any additional installation part around the glass imprinted antenna? (Sun shade film, telephone antenna etc.) Yes Does the noise stop by removing it? Yes Influence of the film or the noise radiation of the additional installation part. No Does the noise occur even pulling out the antenna cord from the radio? Check the radio. Yes No Does the noise occur even after pulling out the antenna terminal on the glass surface? Yes Noise mixing into the antenna cable. No Isn’t there any adhesive (Butyl rubber) stuck on the bases of the antenna terminal, defogger terminal and bus bar? Yes Failure of glass installation. Must plane the butyl rubber. Yes Interfering noise from the defogger line and choke coil. No Does the noise occur even after pulling out the defogger terminal? No Check the grounding of the antenna, antenna cord, coke coil, and noise filter. (See page BE-126 ) Grounding failure. NG OK Does the condition get better by replacing the choke coil? Replace the choke coil. Yes No Does the condition get better by replacing the antenna cord. Replace the antenna cord. Yes No Noise rediates directly to the antenna from the generation source. 2001 AVALON (RM808U) Author
: Date
: 1762 BE-159 BODY ELECTRICAL 27 Noise - AUDIO SYSTEM NOISE PRODUCED BY VIBRATION OR SHOCK WHILE DRIVING Install properly. Is speaker properly installed? No Yes Is speaker properly installed? No Yes Each system faulty. With vehicles stationary lightly tap each system. Is noise produced? Yes No Noise is produced from static eletricity accumulating in the vehicle body. 28 Noise NOISE PRODUCED WHEN ENGINE STARTS Whistling noise which becomes high-pitched when accelerator strongly depressed, disappears shortly after engine stops. Generator noise. Yes No Whining noise occurs when A/C is operating. No Scratching noise occurs during sudden acceleration, driving on rough roads or when ignition switch is turned ON. Yes Yes A/C noise. Fuel gauge noise. No Clicking sound is heard when horn button is pressed, then released. Whirring/grating sound is heard when pushed continuously. Horn noise. Yes No Murmuring sound stops when engine stops. No Tick-tack noise occurs in co-ordination with blinking offlasher. Yes Ignition noise. Turn signal noise. Yes No Noise occurs during window washer operation. No Yes Scratching noise occurs while engine is running, and continues a while even after engine stops. Yes Washer noise. Engine coolant temp. gauge noise. No Wiper noise. Scraping noise in line with wiper beat. No Yes Other type of noise 2001 AVALON (RM808U) Author
: Date
: 1763 BE-1 BODY ELECTRICAL - BODY ELECTRICAL SYSTEM BODY ELECTRICAL SYSTEM BE04P-05 PRECAUTION HINT: Take care to observe the following precautions when performing inspections or removal and replacement of body electrical related parts. 1. HEADLIGHT SYSTEM Halogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or dropped. Hold a bulb only by its plastic or metal case. Don’t touch the glass part of a bulb with bare hands. 2. SRS (SUPPLEMENTAL RESTRAINT SYSTEM) The AVALON is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 3. AUDIO SYSTEM
If the negative (-) terminal cable is disconnected from the battery, the preset AM, FM 1 and FM 2 stations stored in memory are erased, so make sure to note the stations and reset them after the negative (-) terminal cable is reconnected to the battery.
If the negative (-) terminal cable is disconnected from the battery, the radio, tape player and CD player will not operate as well as audio anti - theft system. Be sure to input the correct ID number so that the radio, tape player and CD player can be operated again. 4. MOBILE COMMUNICATION SYSTEM If the vehicle is equipped with a mobile communication system, refer to precautions in the IN section. 2001 AVALON (RM808U) Author
: Date
: 1605 BE-34 BODY ELECTRICAL - BACK-UP LIGHT SYSTEM BE0I5-03 INSPECTION INSPECT BACK-UP LIGHT RELAY CONTINUITY 2 5 3 3 5 1 2 Condition Tester connection Specified condition Constant 1-2 Continuity Apply B+ between terminals 1 and 2. 3-5 Continuity If continuity is not as specified, replace the relay. 1 I05027 2001 AVALON (RM808U) Author
: Date
: 1638 BE-33 BODY ELECTRICAL - BACK-UP LIGHT SYSTEM BACK-UP LIGHT SYSTEM BE0I4-04 LOCATION Ignition Switch Back-Up Light Relay Driver Side Junction Block
ECU-ACC Fuse Back-Up Light I12528 2001 AVALON (RM808U) Author
: Date
: 1637 BE-165 BODY ELECTRICAL - CLOCK CLOCK BE1EJ-01 TROUBLESHOOTING HINT: Troubleshoot the clock according to the table below. Problem No. Clock will not operate BE-53 Clock loses or gains time BE-53 2001 AVALON (RM808U) Author
: Date
: 1769 BE-43 BODY ELECTRICAL - COMBINATION METER BE1DO-01 CIRCUIT Combination Meter: Connector ”A” Connector ”G” Connector ”B” Connector ”F” Multi Information Display: Connector ”E” Connector ”D” Connector ”C” I12772 2001 AVALON (RM808U) Author
: Date
: 1647 BE-44 BODY ELECTRICAL - COMBINATION METER Combination meter: Hi-beam indicator A11 A12 A14 A20 B2 F B3 B4 B5 E B6 B8 B9 T B11 B12 B13 S E2 PROM Fuel level warning A15 B14 B10 O/D off indicator A7 Security indicator A22 A9 Right turn indicator Left turn indicator A10 A1 A2 A3 A4 A5 A6 P R N D 2 L A16 Multi Information Display No. 1 2 3 4 5 6 7 8 9 10 A 11 12 13 Wire Connector Side Park/Neutral position switch (P position) Park/Neutral position switch (R position) Park/Neutral position switch (N position) Park/Neutral position switch (D position) Park/Neutral position switch (2 position) Park/Neutral position switch (L position) O/D main switch Turn signal switch (Right) Turn signal switch (Left) HEAD-LP Fuse Headlight dimmer switch - 14 ECU-B Fuse 15 ECU-IG Fuse 16 F (PANEL) Fuse 17 18 19 Rheostat Light Control Volume 20 Ground 21 Ground 22 Theft Deterrent ECU 1 2 3 4 5 6 7 8 B 9 10 11 12 13 14 15 16 17 18 Multi-information Multi-information Multi-information Multi-information Multi-information Multi-information Multi-information Multi-information Multi-information Multi-information Multi-information Multi-information - display display display display display meter meter meter meter meter display display display display display display display meter meter meter meter meter meter meter A21 Illumination F : Fuel receiver gauge A19 E : Engine coolant temperature gauge T : Tachometer S : Speedometer I12781 2001 AVALON (RM808U) Author
: Date
: 1648 BE-45 BODY ELECTRICAL - COMBINATION METER Multi information display: Combination meter D2 → D14 D10 C22 CPU C15 C9 C19 C8 E1 DRIVER ODO, TRIP Compass Sensor E2 E6 E7 LCD E5 DRIVER E3 C6 C5 C2 C16 C17 W/D *1 C3 C10 C1 C12 C13 Back Light Circuit Power Supply E9 C16 E11 E2 PROM E8 C4 *2 E1 C21 I12544 2001 AVALON (RM808U) Author
: Date
: 1649 BE-46 BODY ELECTRICAL - COMBINATION METER E2 *2 E7 *2 C4 ECU C7 ODO/TRIP MODE RESET/AD SELECT Speed control Unit ON/OFF C11 *1 C18 G3 G5 G13 G11 Open door indicator G2 SRS warning G6 SRS cut off indicator (Passenger) Discharge warning Washer level warning F6 Passenger seat belt warning VSC warning G10 F10 CRUISE main indicator F3 ABS warning F5 VSC cut off warning G7 TRAC warning F9 Brake warning G4 Rear light indicator G14 Mulfunction indicator F4 G12 F1 Low oil pressure warning *1: Hi-Grade *2: Lo-Grade G8 F7 Driver seat belt warning F2 I12543 2001 AVALON (RM808U) Author
: Date
: 1650 BE-47 BODY ELECTRICAL No. C D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Wire Connector Side ECU-IG No. 2 Fuse Injector *1 F (Panel) Fuse Outside temperature sensor Starter Relay ECM *1 ABS ECU Fuel sender gauge Fuel sender gauge Light control volume Ground RAD No. 1 Fuse ECU-ACC Fuse Engine coolant temperature sendoer gauge EFI Heater control ECU *1 Speed control unit Fuel sender gauge Sender ground Ground Combination meter Combination meter Combination meter Combination meter Combination meter Combination meter Combination meter Combination meter Combination meter Combination meter Combination meter Combination meter - - COMBINATION METER No. E 1 1 2 2 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Wire Connector Side Compass sensor *1 Low oil pressure warning switch *2 Compass sensor *1 Compressor lock sensor *2 A/C magnet switch Compass sensor *1 Compass sensor *1 Evaporator temperature sensor *2 Compass sensor *1 A/C switch *2 A/C indicator *2 ECM - *1: Hi Grade *2: Lo Grade 2001 AVALON (RM808U) Author
: Date
: 1651 BE-48 BODY ELECTRICAL No. 1 2 3 4 5 F 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 G 12 13 14 15 16 - COMBINATION METER Wire Connector Side Washer fluid level warning switch Body ECU Brake fluid level warning switch GAUGE Fuse ABS ECU Lo oil pressure warning switch ECM TRAC VSC ECU Driver’s door courtesy switch DOME Fuse Cruise ECU AIR BAG WRN Fuse Airbag ECU ABS&BA&DRAC&VSC ECU Body ECU Ignition switch Generator L terminal Light failure Sensor - 2001 AVALON (RM808U) Author
: Date
: 1652 BE-49 BODY ELECTRICAL - COMBINATION METER BE1DQ-01 COMPONENTS Multi Information Display: Circuit Plate Meter Case Multi Information Display No. 2 Multi Information Display Meter Plate Cold Cathode Tube Meter Glass I12773 2001 AVALON (RM808U) Author
: Date
: 1653 BE-50 BODY ELECTRICAL - COMBINATION METER Combination Meter: Meter Case Circuit Plate Meter Case Meter Plate Charactor Plate Meter Glass I13323 2001 AVALON (RM808U) Author
: Date
: 1654 BE-51 BODY ELECTRICAL - COMBINATION METER BE1DR-01 DISASSEMBLY 1. (a) (b) COMBINATION METER COVER: Remove the 6 screws. Remove the combination meter cover. (c) (d) Remove the screw. Remove the combination meter circuit plate. (e) Remove combination meter glass and hood. 2. (a) (b) MULTI INFORMATION DISPLAY: Remove the circuit plate. Disconnect the connector. (c) Remove the multi information display glass and plate. I13331 I13332 : 7 Clips I13333 I12778 I12774 2001 AVALON (RM808U) Author
: Date
: 1655 BE-52 BODY ELECTRICAL - COMBINATION METER (d) (e) Remove the 2 screws. Disconnect the cold cathode tube with plate. (f) (g) Remove the 6 screws. Remove the multi information display. (h) (i) Remove the 2 screws. Remove the No. 2 multi information display. I12775 I12776 I12777 2001 AVALON (RM808U) Author
: Date
: 1656 BE-53 BODY ELECTRICAL - COMBINATION METER BE1DS-01 INSPECTION 1. INSPECT COMBINATION METER CIRCUIT Disconnect connector ”A” and ”B” from the combination meter and inspect the connectors on the wire harness side as shown in the table. Connector ”A” Connector ”B” I12783 Tester connection Condition Specified condition A11 - Ground Headlight Dimmer switch HI Battery positive voltage A14 - Ground Constant Battery positive voltage A15 - Ground Ignition switch ON Battery positive voltage A16 - Ground Light control switch TAIL or HEAD Battery positive voltage O/D main switch ON Continuity O/D main switch OFF No continuity Ignition switch ON and rheostat light control volume OFF 4.5 5.5 V Ignition switch ON and rheostat light control volume ON No voltage A20 - Ground Constant Continuity A21 - Ground Constant Continuity A7 - Ground G d A19 - Ground G d If circuit is not as specified, wiring diagram and inspect the circuits connected to other parts. 2001 AVALON (RM808U) Author
: Date
: 1657 BE-54 BODY ELECTRICAL - COMBINATION METER 2. INSPECT MULTI INFORMATION DISPLAY CIRCUIT Disconnect connector ”C”, ”D”, ”E”, ”F”, ”G” from the multi information display and inspect the connectors on the wire harness side as shown in the table. Connector ”G” Connector ”E” Connector ”F” Connector ”C” Connector ”D” I12782 Tester connection Condition Specified condition Ignition switch OFF or ACC No voltage Ignition switch ON Battery positive voltage C3 - Ground Light control switch TAIL or HEAD Battery positive voltage C4 - C21 Outside temperature a + 25 °C (77 °F) Resistance 1.6 - 1.8 kΩ Engine running Battery positive voltage Engine stopped No voltage Ignition switch ON and fuel sender gauge flat UP 0.3 - 0.6 V C8 - C9 Ignition switch ON and fuel sender gauge float DOWN 4.9 - 6.9 V C9 - C19 Constant Continuity C10 - Ground Ignition switch ON and rheostat ON No voltage C10 - Ground Ignition switch ON and rheostat OFF 4.5 - 5.5 V C11 - Ground Constant Continuity C12 - Ground Constant Battery positive voltage Ignition switch ACC or ON Battery positive voltage Ignition switch OFF No voltage F1 - Ground Window washer level warning switch ON Continuity F4 - Ground Ignition switch OFF or ACC No voltage F4 - Ground Ignition switch ON Battery positive voltage G2 - Ground Door courtesy switch ON Continuity G3 - Ground Constant Battery positive voltage G5 - Ground Constant Battery positive voltage C1 - Ground G d C5 - Ground G d C13 - Ground G d 2001 AVALON (RM808U) Author
: Date
: 1658 BE-55 BODY ELECTRICAL G11 - Ground G d G12 - Ground - COMBINATION METER Ignition switch ON Battery positive voltage Ignition switch OFF or ACC No voltage Engine running Battery positive voltage If circuit is not as specified, wiring diagram and inspect the circuits connected to other parts. 3. INSPECT BETWEEN COMBINATION METER AND MULTI INFORMATION DISPLAY CIRCUIT Disconnect connector ”B”, ”D” from the multi information display and combination meter inspect the connectors on the wire harness side as shown in the table. Connector ”D” Tester connection Specified condition B2 - D2 Continuity B3 - D3 Continuity B4 - D4 Continuity B5 - D5 Continuity B6 - D6 Continuity B8 - D8 Continuity B9 - D9 Continuity B10 - D10 Continuity B11 - D11 Continuity B12 - D12 Continuity B13 - D13 Continuity B14 - D14 Continuity Connector ”B” I12784 If circuit is not as specified, wiring diagram and inspect the circuits connected to other parts. 4. INSPECT SPEEDOMETER ON-VEHICLE Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indication error. USA (mph) Standard indication CANADA TAIWAN (km/h) Allowable range Standard indication Allowable range 20 18 - 24 20 17 - 24 40 38 - 44 40 38 - 46 60 58 - 66 60 57.5 - 67 80 78 - 88 80 77 - 88 100 98 - 110 100 96 - 109 120 118 - 132 120 115 - 130 140 134 - 151.5 160 153 - 173 If error is excessive, replace the speedometer. 2001 AVALON (RM808U) Author
: Date
: 1659 BE-56 BODY ELECTRICAL 5. (a) 3 (b) 1 (c) (d) 2 N02332 - COMBINATION METER INSPECT VEHICLE SPEED SENSOR OPERATION Connect the positive (+) lead from battery to terminal 1 and negative (-) lead to terminal 2. Connect the positive (+) lead from tester to terminal 3 and the negative (-) lead to terminal 2. Rotate the shaft. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. 6. INSPECT SPEEDOMETER RESISTANCE Measure the resistance between terminals with fixing pointer to the stopper. B A Tester connection Resistance (Ω) A-B 250 C-D 250 If resistance value is not as the specified, replace the meter. D C I13320 7. INSPECT TACHOMETER/ON-VEHICLE (a) Connect a tune-up test tachometer, and start the engine. NOTICE:
Reversing the connection of the tachometer will damage the transistors and diodes inside.
When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks. (b) Compare the tester and tachometer indications. DC 13.5 V 25 °C at (77°F) Standard indication Allowable range 700 630 - 770 1,000 900 - 1,100 2,000 1,850 - 2,150 3,000 2,800 - 3,200 4,000 3,800 - 4,200 5,000 4,800 - 5,200 6,000 5,750 - 6,250 7,000 6,700 - 7,300 2001 AVALON (RM808U) Author
: Date
: 1660 BE-57 BODY ELECTRICAL - COMBINATION METER 8. INSPECT TACHOMETER RESISTANCE Measure the resistance between terminals with fixing pointer to the stopper. B A Tester connection Resistance (Ω) A-B 250 C-D 250 If resistance value is not as specified, replace the meter. D C I13321 Fuel Receiver Gauge Ignition Switch 9. (a) (b) INSPECT FUEL RECEIVER GAUGE OPERATION Disconnect the connector from the main sender gauge. Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY. (c) Connect terminals 2 and 3 on the wire harness side connector through a 3.4 W test bulb. Turn the ignition switch ON, check that the bulb lights up and receiver gauge needle moves toward the full side. Battery I13324 Ignition Switch Fuel Receiver Gauge Test Bulb (3.4 W) (d) Wire Harness Side Battery Z15787 HINT: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize. If operation is not as specified, inspect the receiver gauge resistance. 10. INSPECT FUEL RECEIVER GAUGE RESISTANCE Measure the resistance between terminals with fixing pointer to the stopper. B A D Tester connection Resistance (Ω) A-B 250 C-D 250 If resistance value is not as specified, replace the receiver gauge. C I13319 3 11. INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 3 and 2 for each float position. 2 F 1/2 E I13325 Float position mm (in.) Resistance (Ω) F: Approx. 91.1 (1.36) ± 3 (0.12) Approx. 2.0 ± 1.0 1/2: Approx. 34.2 (2.06) ± 3 (0.12) Approx. 26.1 ± 3.0 E: Approx. 30.8 (5.31) ± 3 (0.12) Approx. 48.7 ± 1.0 If resistance value is not as specified, replace the sender gauge. 2001 AVALON (RM808U) Author
: Date
: 1661 BE-58 BODY ELECTRICAL - COMBINATION METER 12. (a) (b) INSPECT FUEL LEVEL WARNING LIGHT Disconnect the connector from the sender gauge. Connect terminals 1 and 3 on the wire harness side connector. (c) Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. Warning Light Ignition Switch Battery 3 2 1 5 4 Z05730 Engine Coolant Temperature Gauge 13. (a) (b) Ignition Switch Sender Gauge Battery INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON, check that the receiver gauge needle indicates COOL. Z14203 (c) Engine Coolant Temperature Gauge Ignition Switch Test Bulb (3.4 W) Battery Wire Harness Side 1 Z15788 Ground terminal on the wire harness side connector through a 3.4 W test bulb. (d) Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves toward the hot side. If operation is as specified, replace the sender gauge. Then recheck the system. If operation is not as specified, measure the receiver gauge resistance. 14. B D INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals with fixing pointer to the stopper. A C I13322 Tester connection Resistance (Ω) A-B 250 C-D 250 If resistance value is not as specified, replace the receiver gauge. 2001 AVALON (RM808U) Author
: Date
: 1662 BE-59 BODY ELECTRICAL - COMBINATION METER 15. 35.63 ± 0.1 Ω Slide rheostat 35.63 ± 0.1 Ω INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the wire harness as shown in the illustration, and adjust the ammeter pointer to indicate ”0” using the slide rheostat, then read the rheostat indication. Temperature °C (°F) Resistance (Ω) 50 (122.0) 160 - 240 120 (248.0) 17.1 - 21.2 If resistance value is not as specified, replace the engine coolant sender gauge. I07709 16. (a) INSPECT LOW OIL PRESSURE WARNING LIGHT Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. (b) Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. Warning Light Ignition Switch Wire Harness Battery Z15789 17. (a) (b) N06640 INSPECT LOW OIL PRESSURE WARNING SWITCH OPERATION Check that continuity exists between the terminal and ground with the engine stopped. Check that no continuity exists between the terminal and ground with the engine running. HINT: Oil pressure should be over 29 kPa (0.35 kgf/cm2, 4.3 psi) If operation is not as specified, replace the switch. 18. (a) Warning Light Ignition Switch Battery BE1217 INSPECT BRAKE WARNING LIGHT Disconnect the connector from the brake fluid warning switch. (b) Release the parking brake pedal. (c) Connect the terminals on the wire harness side of the level warning switch connector. (d) Start the engine, check that the warning light lights up. If the warning light does not light up, test the bulb or wire harness. 2001 AVALON (RM808U) Author
: Date
: 1663 BE-60 BODY ELECTRICAL - COMBINATION METER 19. OFF ON 2 1 N02346 INSPECT BRAKE FLUID LEVEL WARNING SWITCH OPERATION (a) Remove the reservoir tank cap and strainer. (b) Disconnect the connector. (c) Check that no continuity exists between the terminals with the switch OFF (float up). (d) Use a siphon, etc. to take fluid out of the reservoir tank. (e) Check that continuity exists between the terminals with the switch ON (float down). (f) Pour the fluid back in the reservoir tank. If operation is not as specified, replace the switch. 20. INSPECT PARKING BRAKE WARNING SWITCH CONTINUITY (a) Check that continuity exists between terminal and switch body with the switch ON (switch pin released). (b) Check that no continuity exists between terminal and switch body with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch or inspect ground point. 1 Z11183 21. (a) INSPECT REAR LIGHTS WARNING LIGHT Disconnect the connector from the light failure sensor and ground terminal 4 on the wire harness side connector. (b) Start the engine, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. Warning Light Ignition Switch Wire Harness Side Battery 1 2 3 4 5 6 7 8 9 10 11 12 Z15790 2001 AVALON (RM808U) Author
: Date
: 1664 BE-61 BODY ELECTRICAL - COMBINATION METER 22. INSPECT LIGHT FAILURE SENSOR CIRCUIT Disconnect the connector from the sensor and inspect the connector on the wire harness side, as shown. Wire harness side: 1 2 3 4 5 6 7 8 9 10 11 12 Z07425 Tester connection Condition Specified condition 1 - Ground Constant Continuity* 2 - Ground Constant Continuity* 9 - Ground Constant Continuity* 10 - Ground Constant Continuity* 11 - Ground Constant Continuity 12 - Ground Constant Continuity* 3 - Ground Light control switch OFF No voltage 3 - Ground Light control switch TAIL or HEAD Battery positive voltage 4, 8 - Ground Ignition switch LOCK or ACC No voltage 4, 8 - Ground Ignition switch ON Battery positive voltage 7 - Ground Stop light switch OFF No voltage 7 - Ground Stop light switch ON Battery positive voltage *: There is resistance because this circuit is grounded through the bulb. If the circuit is as specified, replace the sensor. If the circuit is not as specified, inspect the circuits connected to other parts. 23. INSPECT OPEN DOOR WARNING LIGHT Disconnect the connector from the door courtesy switch, and ground terminal 1 on the wire harness side connector and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 24. INSPECT DOOR COURTESY SWITCH (See page BE-31 ) Warning Light Ignition Switch Battery 1 Z05732 25. (a) INSPECT SEAT BELT WARNING LIGHT Disconnect the connector from the terminals buckle switch and ground terminal on the wire harness side connector as shown in the illustration. (b) Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, check the bulb circuit. Warning Light Ignition Switch Battery 2 1 I14605 2001 AVALON (RM808U) Author
: Date
: 1665 BE-62 BODY ELECTRICAL OFF ON 26. (a) (b) - COMBINATION METER INSPECT BUCKLE SWITCH CONTINUITY Check that continuity exists between the terminals on the switch side connector with the switch ON (belt unfastened). Check that no continuity exists between the terminals on the switch side connector with the switch OFF (belt fastened). Z14380 27. (a) (b) INSPECT WASHER LEVEL WARNING LIGHT Disconnect the connectors from the level warning switch. Connect terminals on the wire harness side connector of the level warning switch connector. (c) Turn the ignition switch ON, check that the warning light come on. If the warning light does not light up, test the bulb. Warning Light Ignition Switch Battery BE1217 Ohmmeter OFF ON 28. (a) INSPECT WASHER LEVEL WARING SWITCH Check that no continuity exists between terminals with the switch OFF (float up). (b) Check that continuity exists between terminals with the switch ON (float down). If operation is not as specified, replace the switch. N20217 29. INSPECT WASHER FLUID LEVEL WARNING SWITCH CIRCUIT Disconnect the switch connector and inspect the connector on wire harness side. Wire harness side: Tester connection 12 2 - Ground Condition Constant Specified condition Continuity If the warning light does not light up, test the bulb or inspect wire harness. Z10258 2001 AVALON (RM808U) Author
: Date
: 1666 BE-63 BODY ELECTRICAL - COMBINATION METER 30. (a) 2 INSPECT LIGHT CONTROL RHEOSTAT OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative lead (-) to terminal 3. (b) Connect the positive (+) lead from the voltmeter to terminal 2 and the negative lead (-) to terminal 3. (c) Turn the rheostat knob and check that the voltage changes. If operation is not as specified, replace switch. 270° 3 1 N08958 31. Passenger ’s seat only: INSPECT SEAT BELT WARNING OCCUPANT DETECTION SENSOR CONTINUITY Check that continuity exists between the terminals 1 and 2 when pressing the sensing part (electric resistance <100Ω). If continuity is not as specified, replace the sensor. 21 Press I14604 2001 AVALON (RM808U) Author
: Date
: 1667 BE-41 BODY ELECTRICAL - COMBINATION METER COMBINATION METER BE0IE-03 LOCATION Brake Master Cylinder
Brake Fluid Level Warning Switch Engine Room Junction Block
SRS WRN Fuse Washer Tank
Washer Fluid Level Warning Switch Multi Information Display Combination Meter
Meter Circuit Light Control Rheostat Ignition Switch Parking Brake Switch Driver Side Junction Block
GAUGE No.1 Fuse
PANEL Fuse
ECU-B No.1, 2 Fuss
ECU-IG No.2 Fuse
RAD No.1 Fuse
DOME Fuse
ECU ACC Fuse I12531 2001 AVALON (RM808U) Author
: Date
: 1645 BE-42 BODY ELECTRICAL - COMBINATION METER Occupant Detection Sensor Door Courtesy Switch Fuel Sender Gauge Seat Belt Buckle Switch Light Failure Sensor Engine Coolant Temperature Sender Gauge Low Oil Pressure Warning Switch Park/Neutral Position Switch I12532 2001 AVALON (RM808U) Author
: Date
: 1646 BE-64 BODY ELECTRICAL - COMPASS COMPASS BE216-01 ADJUSTMENT Calendar LIGHT Button MODE Button RESET/ADJ Button I21290 1. MULTI INFORMATION DISPLAY ILLUMINATION Turn the ignition switch to the ON position and illuminate the all parts of the display by pushing the ”LIGHT” button. I21291 2. (a) (b) PERFORM CIRCLING CALIBRATION Push the ”MODE” button several times until ”COMPASS”appears and blinks on the calendar display. Then push the ”RESET/ADJ” button. ”CALIBRATE” appears and blinks together with the compass display. I21283 (c) (d) (e) Drive the vehicle in a circle until the blinking stops. If there is not enough space to drive in a circle, drive around the block until the blinking stops. When the compass and the calendar display return to normal mode, calibration is complete I21284 2001 AVALON (RM808U) Author
: Date
: 1668 BE-65 BODY ELECTRICAL - COMPASS NOTICE:
Do not perform circling calibration of the compass in a place where the earth’s magnetic field is subject to interference by artificial magnetic fields (underground parking, under a steel tower, between buildings, roof parking, near a crossing, near a large vehicle, etc.).
During calibration, do not operate electric systems (moonroof, power windows, etc.) as they may interfere with the calibration.
If you want to cancel the calibration before it is complete, push the ”MODE” button again. HINT: A compass could be magnetized during by vessels of freight cars. Before delivery, therefore, make sure to perform calibration and ensure that calibration can be done. If cannot be done (cannot complete in spite of driving round several times), it may be caused by magnetization. Demagnetize the vehicle using a demagnetizer and preform calibration again. 3. (a) (b) (c) PERFORM DEVIATION CALIBRATION Stop the vehicle and push the ”MODE” button several times until ”ZONE XX” appears on the calender display. Then push the ”RESET/ADJ” button, referring to the following map to select the number of the zone where the vehicle is. After calibration, push the ”MODE” button several times until the calendar display returns to the normal mode. I21285 Hawaii, A. Samoa: 7 Guam, Saipan: 9 Puerto Rico: 11 Taiwan (R.O.C): 9 I21286 2001 AVALON (RM808U) Author
: Date
: 1669 BE-67 BODY ELECTRICAL - DEFOGGER SYSTEM BE0IG-03 18 INSPECTION 17 1. 40 (a) 34 (b) A/C control panel assembly: INSPECT DEFOGGER SWITCH OPERATION Connect the positive (+) lead from the battery to terminal 17, 18 and negative (-) lead to terminal 40. Connect the positive (+) lead from the battery to terminal 24 through a 1.4 W test bulb. I12825 34 18 (c) Turn the defogger switch ON and check that the test bulb and indicator light turn ON, then turn OFF after about 15 minutes. If operation is not as specified, proceed to the next inspection. 17 40 W/ Mirror Heater: ON W/O Mirror Heater: ON I12826 2. 3 1 4 2 1 3 4 2 INSPECT DEFOGGER RELAY CONTINUITY Condition Tester connection Specified condition Constant 3-4 Continuity Apply B+ between terminals 3 and 4. 1-2 Continuity If continuity is not as specified, replace the relay. I05741 3. 3 (a) 6 I13308 (b) HINT: It will take a short time for the mirror to become warm. If the mirror does not become warm, replace the mirror assembly. 4. 5 (a) 10 I13307 W/ Mirror defogger: INSPECT MIRROR DEFOGGER OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 6. Check that the mirror becomes warm. W/ Mirror defogger and driving position memory: INSPECT MIRROR DEFOGGER OPERATION Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead to terminal 10. Check that the mirror becomes warm. (b) HINT: It will take a short time for the mirror to become warm. If the mirror does not become warm, replace the mirror assembly. 2001 AVALON (RM808U) Author
: Date
: 1671 BE-68 BODY ELECTRICAL Tester Probe Heat Wire Tin Foil - DEFOGGER SYSTEM 5. INSPECT DEFOGGER WIRE NOTICE: When cleaning the glass, use a soft, dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger, as shown. BE4029 (a) (b) (c) At Center BE0123 Serveral 0 Volt Volts Broken Wire v BE0124 (b) Broken Wire Masking Tape Voltage Criteria Approx. 5 V Okay (No break in wire) Approx. 10 V or 0 V Broken wire HINT: If there is approximately 10 V, the wire is broken between the center of the wire and the positive (+) end. If there is no voltage, the wire is broken between the center of the wire and ground. (d) Place the voltmeter positive (+) lead against the defogger positive (+) terminal. (e) Place the voltmeter negative (-) lead with the foil strip against the heat wire at the positive (+) terminal end and slide it toward the negative (-) terminal end. (f) The point where the voltmeter deflects from zero to several V is the place where the heat wire is broken. HINT: If the heat wire is not broken, the voltmeter indicates 0 V at the positive (+) end of the heat wire but gradually increases to about 12 V as the meter probe is moved to the other end. 6. (a) Repair Point Turn the ignition switch ON. Turn the defogger switch ON. Inspect the voltage at the center of each heat wire, as shown. (c) IF NECESSARY, REPAIR DEFOGGER WIRE Clean the broken wire tips with a grease, wax and silicone remover. Place the masking tape along both sides of the wire to be repaired. Thoroughly mix the repair agent (Dupont paste No. 4817). BE0150 2001 AVALON (RM808U) Author
: Date
: 1672 BE-69 BODY ELECTRICAL (d) (e) (f) - DEFOGGER SYSTEM Using a fine tip brush, apply a small amount to the wire. After a few minutes, remove the masking tape. Do not repair the defogger wire for at least 24 hours. BE0151 2001 AVALON (RM808U) Author
: Date
: 1673 BE-66 BODY ELECTRICAL - DEFOGGER SYSTEM DEFOGGER SYSTEM BE0IF-03 LOCATION Heater Control Assembly
Defogger Switch Ignition Switch Driver Side Junction Block
Defogger Relay
DEF Fuse
MIR HTR Fuse Mirror Defogger Defogger Wire I12533 2001 AVALON (RM808U) Author
: Date
: 1670 BE-120 BODY ELECTRICAL - ELECTRO CHROMIC MIRROR SYSTEM BE1ED-01 INSPECTION INSPECT ELECTRO CHROMIC INNER MIRROR OPERATION (a) Connect the positive (+) lead the battery to terminal 1 and the negative (-) lead to terminal2. (b) Shine an electric light on the mirror, and check that there is battery positive voltage and mirror surface becomes ”bright” to ”dark”. If operation is not as specified, replace the inner mirror. 2 1 I12835 2001 AVALON (RM808U) Author
: Date
: 1724 BE-1 19 BODY ELECTRICAL - ELECTRO CHROMIC MIRROR SYSTEM BE1EE-01 ELECTRO CHROMIC MIRROR SYSTEM LOCATION Driver Side Junction Block
ECU-IG No.1,2 Fuse Ignition Switch Electro Chromic Inner Mirror I12839 2001 AVALON (RM808U) Author
: Date
: 1723 BE-181 BODY ELECTRICAL - ENGINE IMMOBILISER SYSTEM BE0B4-04 INSPECTION INSPECTION TRANSPONDER KEY COIL CONTINUITY Check that continuity exists between terminal 1 and 2. If continuity is not as specified, replace the coil. I03099 2001 AVALON (RM808U) Author
: Date
: 1785 BE-180 BODY ELECTRICAL - ENGINE IMMOBILISER SYSTEM BE0B3-11 LOCATION Engine Room Junction Block
EFI No. 2 Fuse ECM Driver Side Junction Block
IGN Relay Ignition Switch Assembly
Transponder Key Amplifier
Transponder Key Coil
Key Unlock Warning Switch I12540 Author
: 1784 2001 AVALON (RM808U) Date
: BE-172 BODY ELECTRICAL - ENGINE IMMOBILISER SYSTEM ENGINE IMMOBILISER SYSTEM BE0B2-14 REGISTRATION PROCEDURE 1. KEY REGISTRATION IN AUTOMATIC REGISTRATION MODE (a) Registration of a new transponder key. HINT:
This must be done when you have installed a new ECM.
The new ECM is in the automatic key code registration mode. The already fixed number of key codes for this ECM can be registered. On this type of vehicle, up to 4 key codes can be registered.
In the automatic registration mode, the last key registered becomes sub-key. START Security indicator blinks until the first key is inserted. The indicator lights up after the key registration. Insert the key in the key cylinder. Security Indicator ON Under registration Security OFF Indicator Registration completion Remove the key. Yes Security Indicator ON (After the last key (sub-key) has been registered, the indicator goes off.) Will you register the next key? No END 2001 AVALON (RM808U) Author
: Date
: 1776 BE-173 BODY ELECTRICAL - ENGINE IMMOBILISER SYSTEM HINT:


When a key is not inserted in the key cylinder in the automatic registration mode, the security indicator always lights on. When the immobiliser system operations normally and the key is pull out, the security indicator blinks. When key code registration could not be performed in the automatic registration mode, code 2-1 is output from the security indicator and when inserting the already registered key, code 2-2 is output. Blinks 1.8 Sec. 0.2 Sec. (b) Code 2-1 0.25 Sec. Code2-2 0.25 Sec. 1 Sec. 0.25 Sec. 0.5 Sec. 1 Sec. 0.25 Sec.0.5 Sec. Automatic registration mode completion If completing the mode forcibly when more than 1 key code have been registered in the automatic registration mode, perform the following procedures. After 1 more key code have been registered with master key, perform step (1) or (2) without pulling the key out or inserting the already registered key. (1) Depress and release brake pedal 5 times or more within 15 secs. (2) With the hand-held tester, require automatic registration mode completion. 2001 AVALON (RM808U) Author
: Date
: 1777 BE-174 BODY ELECTRICAL - ENGINE IMMOBILISER SYSTEM 2. REGISTRATION OF ADDITIONAL MASTER KEY There are 2 ways for registration of additional master key, one is depressing brake pedal and acceleration pedal and the other is using hand-held tester. HINT:
It is possible to register up to 7 master key codes including the already registered key code.
When any operation time described below is over, registration mode completes.
When the next procedure is performed while the timer is working, the timer completes counting time, then next timer starts. (1) Depressing brake pedal and acceleration pedal: Insert already registered master key in the key cylinder Depress and release the acceleration pedal 5 times. Depress and release the brake pedal 6 times, and remove the master key. Within 15 secs. Within 20 secs. Within 10 secs. Insert key to be registered in key cylinder. Depress and release the acceleration pedal 1 time. (Security indicator blinks) Within 10 secs. Within 10 secs. After 60 secs. additional master key is registered. (Security indicator is OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10 secs. and the brake pedal is depressed or after indicator is off 10 secs. pass. 2001 AVALON (RM808U) Author
: Date
: 1778 BE-175 BODY ELECTRICAL (2) - ENGINE IMMOBILISER SYSTEM Using hand-held tester: Insert already registered master key in the key cylinder and turn the ignition switch ON. Listing hand-held tester select master key registration. Within 20 secs. Remove the master key. Within 10 secs. Insert key to be registered in key cylinder. (Security indicator blinks) After 60 secs., additional master key is registered. (Security indicator OFF) The registration mode completes when pulling out the key within 10 secs. and the brake pedal is depressed or after indicator is off 10 secs. pass. HINT: Please follow the screen of the hand-held tester for more detailed procedure. 2001 AVALON (RM808U) Author
: Date
: 1779 BE-176 BODY ELECTRICAL - ENGINE IMMOBILISER SYSTEM 3. REGISTRATION OF ADDITIONAL SUB-KEY There are 2 ways for registration of additional sub-key, one is depressing brake pedal and acceleration pedal and the other is using hand-held tester. HINT:
It is possible top register up to 3 sub-key codes including the already registered key code.
When any operation time described below is over, registration mode completes.
When the next procedure is performed while the timer is working, the timer completes counting time, then next timer starts. (1) Depressing brake pedal and acceleration pedal: Insert already registered master key in the key cylinder Depress and release the acceleration pedal 4 times. Depress and release the brake pedal 5 times, and remove the master key. Within 15 secs. Within 20 secs. Within 10 secs. Insert key to be registered in key cylinder. Within 10 secs. Depress and release the acceleration pedal 1 time. (Security indicator blinks) Within 10 secs. After 60 secs. additional sub-key is registered. (Security indicator is OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10 secs. and the brake pedal is depressed or after indicator is off 10 secs. pass. 2001 AVALON (RM808U) Author
: Date
: 1780 BE-177 BODY ELECTRICAL (2) - ENGINE IMMOBILISER SYSTEM Using hand-held tester: Insert already registered master key in the key cylinder and turn the ignition switch ON. Listing TOYOTA hand-held tester select sub-key registration. Within 20 secs. Remove the master key. Within 10 secs. Insert key to be registered in key cylinder. (Security indicator blinks) After 60 secs., additional sub-key is registered. (Security indicator OFF) The registration mode completes when pulling out the key within 10 secs. and the brake pedal is depressed or after indicator is off 10 secs. pass. HINT: Please follow the screen of the hand-held tester for more detailed procedure. 2001 AVALON (RM808U) Author
: Date
: 1781 BE-178 BODY ELECTRICAL - ENGINE IMMOBILISER SYSTEM 4. ERASURE OF TRANSPONDER KEY CODE There are 2 ways for erasure of transponder key code, one is depressing brake pedal and acceleration pedal and the other is using hand-held tester. NOTICE: All other master and sub-key codes are deleted leaving the master key code to use the operation. When using the key which was used before deleting, it is necessary to register the code again. HINT:
When any operation time described below is over, registration mode completes.
When the next procedure is performed while the timer is working, the timer completes counting time, then next timer starts. (1) Depressing brake pedal and acceleration pedal: 1. Insert master key in the key cylinder. Within 15 sec. 2. Depress and release the acceleration pedal 6 times. Within 20 sec. 3. Depress and release the brake pedal 7 times. Within 10 sec. 4. Remove the master key. 5. Leave the vehicle more than 20 sec. without any operation. END (Key code erased) HINT: If the key cannot be pulled out within 30 sec. from the first brake depression in the step 3, the key code deletion is canceled. 2001 AVALON (RM808U) Author
: Date
: 1782 BE-179 BODY ELECTRICAL (2) - ENGINE IMMOBILISER SYSTEM Using hand-held tester: 1. Insert already registered master key in the key cylinder and turn the ignition switch ON. 2. Require key code deletion from hand-held tester. (Security indicator blinks) Within 10 secs. 3. Remove the master key. END (Key code erased) HINT:
When the key cannot be pulled out in the step 3, key code deletion is canceled. (Security indicator is OFF)
Please follow the screen of the hand-held tester for more detailed procedure. 2001 AVALON (RM808U) Author
: Date
: 1783 BE-27 BODY ELECTRICAL - FOG LIGHT SYSTEM BE052-07 ADJUSTMENT ADJUST FOG LIGHT AIM A-bolt: Vertical Direction A I12791 2001 AVALON (RM808U) Author
: Date
: 1631 BE-26 BODY ELECTRICAL - FOG LIGHT SYSTEM BE0HZ-04 INSPECTION 1. ON INSPECT FOG LIGHT SWITCH CONTINUITY Switch position Tester connection OFF - ON 10 - 11 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. OFF 8 7 6 5 4 3 2 1 17 16 15 141312 11 10 9 I12795 2. 2 5 3 5 3 1 2 INSPECT FOG LIGHT RELAY CONTINUITY Condition Tester connection Specified condition Constant 1-2 Continuity Apply B+ between terminals 1 and 2. 3-5 No continuity If continuity is not as specified, replace the relay. 1 I05027 2001 AVALON (RM808U) Author
: Date
: 1630 BE-25 BODY ELECTRICAL - FOG LIGHT SYSTEM FOG LIGHT SYSTEM BE050-07 LOCATION Fog Light Combination Switch
Fog Light Switch Driver Side Junction Block
Fog Light Relay
FOG Fuse I12525 2001 AVALON (RM808U) Author
: Date
: 1629 BE-170 BODY ELECTRICAL - GARAGE DOOR OPENER SYSTEM BE0G5-04 INSPECTION 1. INSPECT GARAGE DOOR OPENER SWITCH Press the switch and check that each LED (red) lights up. Even if only one switch is found not to light up, replace it. I12836 2. I12837 INSPECT GARAGE DOOR OPENER REGISTRATION AND TRANSMITTING HINT: Use the home link tester made by KENT MORE for this test. As it is necessary to record the code of the hand held transmitter, customer’s code will be erased. When the inspection completes, please register the customer’s again. (a) Check that the code of hand held transmitter for inspection can be recorded. (See page If the code can not be registered, replace garage door opener. (b) Press the switch which an inspection code has been registered for and check that LED (green) of the home link tester lights up. If the LED (green) does not light up, replace the garage door opener. I12838 2001 AVALON (RM808U) Author
: Date
: 1774 BE-171 BODY ELECTRICAL - GARAGE DOOR OPENER SYSTEM 3. INSPECT GARAGE DOOR OPENER SWITCH CIRCUIT Disconnect the connector from the switch and inspect the connector on the wire harness side, as shown. Wire Harness Side I04194 Tester connection Condition Specified condition 1 - Ground Constant Continuity 2 - Ground Constant Battery positive voltage If the circuit is not as specified, inspect the power source or wire harness. 2001 AVALON (RM808U) Author
: Date
: 1775 BE-169 BODY ELECTRICAL - GARAGE DOOR OPENER SYSTEM BE0D3-03 LOCATION Enjine Room Junction Block
ECU-B Fuse Garage Door Opener I12840 2001 AVALON (RM808U) Author
: Date
: 1773 BE-166 BODY ELECTRICAL - GARAGE DOOR OPENER SYSTEM GARAGE DOOR OPENER SYSTEM BE0D2-03 REGISTRATION PROCEDURE 1. NEW CODE REGISTRATION NOTICE:
If pressing the switch of the original transmitter to register the code, the system might operate.
When registering the transmitter codes such as for garage or gate, check that there is nobody around those places then register. (a) Press the switch for the item to be registered for 20 seconds HINT: When transferring to registration mode, LED (red) blinks in 1 Hz cycle. (b) In the condition of (a), bring the original transmitter to within 1-inch area around the garage door opener and press the switch. (code transmitting). HINT: When code registration completes correctly, LED (red) blinks in 5.6 Hz cycle. I12837 2001 AVALON (RM808U) Author
: Date
: 1770 BE-167 BODY ELECTRICAL - GARAGE DOOR OPENER SYSTEM New code registration timing chart. PRESSED GARAGE DOOR OPENER SWITCH RELEASE ENTER LEARN MODE 20 sec EXIT LED OPERATION ON OFF LED flashes at a rate of 1 Hz ORIGINAL TRANSMITTER LED flashes at a rate of 5.6 Hz ON OFF I03487 If a code can not be registered, observe the following conditions. HINT:
If the battery of original transmitter is consumed.
Press the switch of the transmitter repeatedly in registration mode, as some transmitters stop transmitting for 1 to 2 seconds.
This system is not applicable to the garage door opener which had been made before 1982.
If any signal from the transmitter is not received, the registration mode continues for 75 sec. 2. CODE DELETION (a) Press the switches at both ends of garage door opener simultaneously for 20 seconds. HINT: When transferring to deletion mode, LED (red) blinks in 6 Hz cycle. (b) When releasing the switch within 10 seconds after transferring to deletion mode, all the registered codes will be erased. HINT: Press the switch until blinking in 5.6 Hz cycle stops, so that the default code for check is set. 2001 AVALON (RM808U) Author
: Date
: 1771 BE-168 BODY ELECTRICAL - GARAGE DOOR OPENER SYSTEM Code deletion timing chart GARAGE DOOR OPENER SWITCH (Switch at both end) PRESSED RELEASE CLEAR/DEFAULT MODE LED OPERATION Enter erase mode to erase all 3 channels ON 20 SEC 10 SEC LOAD DEFAULT OFF ON OFF LED flashes at a rate of 5.6 HZ I03488 2001 AVALON (RM808U) Author
: Date
: 1772 BE-23 BODY ELECTRICAL - HEADLIGHT AND TAILLIGHT SYSTEM BE1DK-07 ADJUSTMENT 1. ADJUST HEADLIGHT AIMING For Adjustment in Vertical Direction For Adjustment in Vertical Direction I12789 Author
: Date
: 1627 BE-24 BODY ELECTRICAL 2. (a) (b) - HEADLIGHT AND TAILLIGHT SYSTEM ADJUST HEADLIGHT AIM ONLY Place the vehicle in the following conditions.
The area around the headlight is not deformed.
The vehicle is parked on a level surface.
Tire inflation pressure is the specified value.
A driver is in the driver’s seat and the vehicle is in a state ready for driving (with a tank full).
The vehicle has been bounced several times. Check the headlight aiming. (1) Prepare a thick white paper. (2) Stand the paper perpendicular to the ground at the position 9.84 ft away from the headlights. (3) Ensure that the center line of the vehicle and the paper face forms a 90-degree angle as shown in the illustration. (4) Draw a horizontal line (H line) on the paper, showing where the headlights should strike. (5) Draw a vertical line (V line) to where the center line of the vehicle is to be. (6) Draw 2 vertical lines (by connecting the low and high beam center marks) to where the both headlights should strike (V RH and V LH lines). (7) Draw a horizontal line (by connecting the both low beam center marks) to where the headlights should strike (H RH and H LH lines). HINT: The H RH and H LH line is 0.4° below the horizontal line (H line) of the light axis. (8) Start the engine. (9) Turn the headlights ON. (10) Check that the headlights properly strike the position shown in the illustration. (11) If not, adjust the lights in the vertical direction. Low Beam: 20.9 mm (0.823 in.) 4 H 6 5 V LH Line V Line 6 V RH Line 0.4 ° H 4 Hight Bearm 20.9 mm (0.823 in.) Low Bearm 7 7 20.9 mm (0.823 in.) 3 m (9.84 ft) High Beam: V RH Line 1,342mm (52.8 in.) 1,342mm (52.8 in.) 90 ° 6 V LH Line 5 V Line 6 V RH Line 4 H 1,342mm (52.8 in.) V LH Line 20.9 mm (0.823 in.) O: step No. 20.9 mm (0.823 in.) I18944 HINT: As shown in the illustration, adjust each aim of the RH and LH lights. (c) When adjusting it in the vertical direction: Using adjusting bolt, adjust the headlight aim to within the specified range. Author
: Date
: 1628 BE-18 BODY ELECTRICAL - HEADLIGHT AND TAILLIGHT SYSTEM BE0HW-03 COMPONENTS Combination Switch
Wiper and Washer Switch Switch Body Combination Switch
Light Control Switch
Headlight Dimmer Switch Spiral Cable I12793 2001 AVALON (RM808U) Author
: Date
: 1622 BE-19 BODY ELECTRICAL - HEADLIGHT AND TAILLIGHT SYSTEM BE1DJ-01 INSPECTION AUTO HI 1. LO OFF TAIL Flash INSPECT LIGHT CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition OFF - TAIL 14 - 16 Continuity HEAD 13 - 14 - 16 Continuity AUTO 12 - 13 - 14 - 16 Continuity No continuity If continuity is not as specified, replace the switch. 2. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY 8 7 6 5 4 3 2 1 17 16 1514 1312 11 10 9 Switch position Tester connection Flash 7 - 8 - 16 Continuity Specified condition Low beam 16 - 17 Continuity High beam 7 - 16 Continuity If continuity is not as specified, replace the switch. I12794 3. 3 4 INSPECT HEADLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition 2 1 Constant 3-4 Continuity 3 4 Apply B+ between terminals 3 and 4. 1-2 Continuity If continuity is not as specified, replace the relay. 1 2 I05741 4. 2 3 5 3 1 5 2 INSPECT TAILLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition Constant 1-2 Continuity Apply B+ between terminals 1 and 2. 3-5 Continuity If continuity is not as specified, replace the relay. 1 I05027 5. 4 2 3 2 1 3 4 INSPECT D.R.L. NO.2 RELAY CIRCUIT Condition Tester connection Specified condition Constant 3-4 Continuity Apply B+ between terminals 3 and 4. 1-2 Continuity If continuity is not as specified, replace the relay. 1 I05741 2001 AVALON (RM808U) Author
: Date
: 1623 BE-20 BODY ELECTRICAL 6. 2 3 1 4 - HEADLIGHT AND TAILLIGHT SYSTEM INSPECT D.R.L. NO.3 RELAY CIRCUIT Condition Tester connection Constant 1 - 2, 3 - 4 Apply B+ between terminals 1 and 2. 3-5 Specified condition Continuity No continuity If continuity is not as specified, replace the relay. 1 5 I12785 7. 4 2 3 1 2 1 3 4 INSPECT D.R.L. NO.4 RELAY CIRCUIT Condition Tester connection Specified condition Constant 3-4 Continuity Apply B+ between terminals 3 and 4. 1-2 Continuity If continuity is not as specified, replace the relay. I05741 8. (a) (b) (c) (d) AUTO ON: INSPECT AUTOMATIC LIGHT CONTROL Turn the ignition switch ON. Turn the light control switch to AUTO. Gradually cover the top of the sensor. Check the accessory lights and the headlights should turn ON. I12786 9. (a) (b) 10. (a) (b) I12787 (c) 11. (a) (b) AUTO OFF: INSPECT AUTOMATIC LIGHT CONTROL Gradually expose the sensor. Check the headlights and the accessory lights should turn OFF. INSPECT LIGHTS-OFF CONDITION Turn the ignition switch ON. Lights auto ON: Gradually cover the top of the sensor. Check that the lights go off under the following conditions. (1) Light control switch is OFF. (2) The area surrounding the sensor gets bright. (3) The driver’s door is opened with the ignition switch OFF. INSPECT LIGHTS-ON CONDITION Open the driver’s door while the ignition switch is OFF. Turn the light control switch to AUTO leaving the door open and cover the top of the sensor, make sure that the lights go on when the ignition switch is turned ON. 2001 AVALON (RM808U) Author
: Date
: 1624 BE-21 BODY ELECTRICAL 12. (a) (b) Counter Clockwise Clockwise - HEADLIGHT AND TAILLIGHT SYSTEM ADJUST AUTOMATIC LIGHT CONTROL SENSOR Adjustment of the light control is performed by turning the sensitivity knob on the sensor. This will be determined at what light condition the automatic control will take place.
If response is too quick, turn the knob counterclockwise.
If response is too slow, turn the knob clockwise. N12536 13. From Back Side 4 3 1 2 I01255 Connector connected: INSPECT AUTOMATIC LIGHT CONTROL SENSOR CIRCUIT Connect the wire harness side connector to the sensor and inspect wire harness side connector from the back side, as shown. HINT:
Ignition switch ON.
Light control switch AUTO.
Vehicle’s surroundings are bright. Tester connection Condition Specified condition 3 - Ground Constant Continuity 1 - Ground Ignition switch LOCK or ACC No voltage 1 - Ground Ignition switch ON 9.5 V or more Vehicle is under the direct sun light. (Sensor is not covered) Taillight and Headlight are ON. If circuit is as specified, try replacing the sensor with a new one. If the circuit is not as specified, inspect the circuit connected to other parts. 2001 AVALON (RM808U) Author
: Date
: 1625 BE-22 BODY ELECTRICAL - HEADLIGHT AND TAILLIGHT SYSTEM 14. Connector disconnected: INSPECT AUTOMATIC LIGHT CONTROL SENSOR CIRCUIT Disconnect the connector from the sensor and inspect the connector on the wire harness side, as shown in the table. Wire Harness Side 1234 I01254 Tester connection Condition Specified condition 3 - Ground Constant Continuity 1 - Ground Ignition switch LOCK or ACC No voltage 1 - Ground Ignition switch ON Battery positive voltage 4 - Ground Ignition switch LOCK or ACC No voltage 4 - Ground Ignition switch ON 5.2 - 9.0 V If circuit is as specified, perform the inspection on the following page. If the circuit is not as specified, inspect the circuit connected to other parts. 2001 AVALON (RM808U) Author
: Date
: 1626 BE-17 BODY ELECTRICAL - HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM BE0HV-04 LOCATION Relay Block No.7
D.R.L. No.2, No.3 and No.4 Relay
HEAD LH UPR Fuse (w/ DRL)
HEAD RH UPR Fuse (w/ DRL) Engine Room Junction Block
H-LP LH Fuse (w/o DRL)
H-LP LH-LWR Fuse (w/ DRL)
H-LP RH Fuse (w/o DRL)
H-LP RH-LWR Fuse (w/ DRL)
DRL Fuse
Headlight Control Relay Headlight Automatic Light Control Sensor Driver Side Junction Block
Taillight Control Relay
BODY ECU
TAIL Fuse
TAIL Relay Combination Switch
Light Control Switch
Dimmer Switch Ignition Switch DRL: Daytime Running Light Taillight I12524 2001 AVALON (RM808U) Author
: Date
: 1621 BE-31 BODY ELECTRICAL - INTERIOR LIGHT SYSTEM BE1DL-01 INSPECTION w/ Sliding roof: 1. w/o Sliding roof: I13328 INSPECT FRONT PERSONAL LIGHT CONTINUITY Switch position Tester connection Specified condition OFF 1-3 No continuity - 2-3 No continuity ON 1-3 Continuity If continuity is not as specified, replace the light assembly or bulb. 2. INSPECT REAR INTERIOR LIGHT CONTINUITY Switch position Tester connection Specified condition OFF 1-2 No continuity ON 1-2 Continuity If continuity is not as specified, replace a bulb or rear personal light. ON N12373 3. (a) ON Ohmmeter OFF INSPECT DOOR COURTESY SWITCH CONTINUITY Check that continuity exists between terminal and the switch body with the switch ON (switch pin released: opened door). (b) Check that no continuity exists between terminal and the switch body withe the swtich OFF (switch pin pushed in: closed doors). If operation is not as specified, replace the switch. N20159 4. INSPECT VANITY LIGHT CONTINUITY Switch position Tester connection Specified condition OFF 1-2 No continuity ON 1-2 Continuity If continuity is not as specified, replace bulb or vanity light. ON OFF I13329 5. INSPECT LUGGAGE COMPARTMENT LIGHT CONTINUITY Switch position Tester connection OFF - ON 1-2 Specified condition No continuity Continuity If continuity is not as specified, replace the light. Z07389 2001 AVALON (RM808U) Author
: Date
: 1635 BE-32 BODY ELECTRICAL 6. ON - INTERIOR LIGHT SYSTEM INSPECT LUGGAGE COMPARTMENT DOOR COURTESY SWITCH CONTINUITY Condition Tester connection OFF - ON 1 - Switch body Specified condition No continuity Continuity If operation is not as specified, replace the switch. OFF Z05876 7. (a) (b) INSPECT INTERIOR LIGHT ASSEMBLY CONTINUITY Disconnect the connector from room light assembly. Turn the room light switch ON, check that there is continuity between terminal 1 and body ground. 1 I14261 (c) 2 1 Turn the room light switch DOOR, check that there is continuity between terminal 1 and 2. If operation is not as specified, replace the switch. 8. INSPECT ILLMINATION ENTRY SYSTEM (See Page BE-2 ) N01732 2001 AVALON (RM808U) Author
: Date
: 1636 BE-30 BODY ELECTRICAL - INTERIOR LIGHT SYSTEM INTERIOR LIGHT SYSTEM BE0I2-03 LOCATION Driver Side Junction Block
DOME Fuse
Body ECU Front Personal Light Rear Interior Light Assembly Interior Light Assembly Vanity Light Door Courtesy Switch Door Courtesy Light Door Courtesy Switch Luggage Compartment Light Door Courtesy Light I12527 2001 AVALON (RM808U) Author
: Date
: 1634 BE-16 BODY ELECTRICAL - IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE1DI-01 INSPECTION 1. ACC LOCK ON 4 8 3 7 2 6 1 5 INSPECT IGNITION SWITCH CONTINUITY Switch position Tester connection LOCK - ACC 2-3 Continuity ON 2-3-4 6-7 Continuity START 1-2-4 6-7-8 Continuity START I01256 Specified condition No continuity If continuity is not as specified, replace the switch. 2. OFF 21 ON INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY Condition Tester connection Switch OFF (Key removed) - Switch ON (Key set) 1-2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. N20125 3. 3 4 2 4 1 1 3 INSPECT IG1 RELAY CONTINUITY Condition Tester connection Specified condition Constant 3-4 Continuity Apply B+ between terninal 3 and 4 1-2 Continuity If continuity is not as specified, replace the switch. 2 I05741 2001 AVALON (RM808U) Author
: Date
: 1620 BODY ELECTRICAL - IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE-15 IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE0HT-04 LOCATION Ignition Switch
Key Unlock Warning Switch Driver Side Junction Block
ECU ACC Fuse
ECU I/G No.2 Fuse
IG1 Relay
BODY ECU I12523 2001 AVALON (RM808U) Author
: Date
: 1619 BE-125 BODY ELECTRICAL - LUGGAGE COMPARTMENT DOOR OPENER SYSTEM BE1EH-01 INSPECTION Not turned 1. Unlock INSPECT LUGGAGE COMPARTMENT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection Not turned - UNLOCK 1-2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. I03433 2. 1 2 INSPECT LUGGAGE COMPARTMENT DOOR OPENER MAIN SWITCH CONTINUITY Switch position Tester connection OFF - ON 1-2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. I13485 3. INSPECT LUGGAGE COMPARTMENT DOOR OPENER CANCEL SWITCH CONTINUITY Switch position Tester connection OFF - ON 1-2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. I13334 4. INSPECT LUGGAGE COMPARTMENT DOOR OPENER MOTOR OPERATION Connect positive (+) lead to the terminal 1 and negative (-) lead to the opener motor body, and check that the motor operateds. If operation is not as specified, replace the lock. 1 I04020 2001 AVALON (RM808U) Author
: Date
: 1729 BE-124 BODY ELECTRICAL - LUGGAGE COMPARTMENT DOOR OPENER SYSTEM LUGGAGE COMPARTMENT DOOR OPENER SYSTEM BE1EG-01 LOCATION Luggage Compartment Main Switch Luggage Compartment Cancel Switch Driver Side Junction Block
OPENER Fuse Luggage Compartment Door Unlock Motor I13482 2001 AVALON (RM808U) Author
: Date
: 1728 BE-88 BODY ELECTRICAL - POWER DOOR LOCK CONTROL SYSTEM BE212-01 ADJUSTMENT ENABLING/DISABLING AUTO DOOR LOCK FUNCTION (a) To disable auto door lock: (1) Enter the vehicle and shut all doors. (2) Insert the key into the ignition cylinder and turn it to the ON position (not ACC). (3) Open the driver’s door and keep it open. (4) Turn the key to the LOCK position and remove it from the ignition cylinder. (5) Insert the key into the ignition cylinder and remove it. Repeat this operation three more times. (End this step with the key out of the ignition cylinder.) (6) Push the ”UNLOCK” button on the driver’s door master switch 5 times within 10 seconds. Wait at least 10 seconds and shut the driver’s door. (7) Verify auto lock operation has been disabled by starting the engine, putting the vehicle into a gear and releasing the brake pedal. (b) To enable auto door lock: Follow the same sequence as above, except step 6. In step 6, push the ”LOCK” button on the driver’s door master switch 5 times within 10 seconds. Wait at least 10 seconds and shut the driver’s door. Author
: Date
: 1692 BE-82 BODY ELECTRICAL - POWER DOOR LOCK CONTROL SYSTEM BE1DY-02 INSPECTION 1. 65 4 321 LOCK UNLOCK I12841 Driver’s door: INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection LOCK 3-5 OFF - UNLOCK 3-6 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. 2. Passenger ’s Door: INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY 65 4 321 LOCK Switch position Tester connection LOCK 2-4 OFF - UNLOCK 1-4 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. UNLOCK I12842 3. UNLOCK 65 4 321 I12843 UNLOCK 65 4 321 I07301 Tester connection - ON (Door Lock set to UNLOCK) 3-4 Specified condition No continuity Continuity Passenger ’s Door: INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Switch position Tester connection OFF (Door Lock set to LOCK) - ON (Door Lock set to UNLOCK) 3-4 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. 5. LOCK Switch position OFF (Door Lock set to LOCK) If continuity is not as specified, replace the switch. 4. I12844 Driver’s Door: INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Rear LH Door: INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Switch position Tester connection OFF (Door Lock set to LOCK) - ON (Door Lock set to UNLOCK) 1-2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. 2001 AVALON (RM808U) Author
: Date
: 1686 BE-83 BODY ELECTRICAL 6. LOCK I07302 - POWER DOOR LOCK CONTROL SYSTEM Rear RH Door: INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Switch position Tester connection OFF (Door Lock set to LOCK) - ON (Door Lock set to UNLOCK) 3-4 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. 7. Driver’s Door: INSPECT DOOR LOCK MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the door lock link moves to UNLOCK position. (b) Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. UNLOCK LOCK LOCK UNLOCK 2 2 1 1 I12845 8. UNLOCK LOCK UNLOCK 6 5 Passenger ’s door: INSPECT DOOR LOCK MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead to terminal 6, and check that the door lock link moves to UNLOCK position. (b) Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. LOCK 6 5 I12846 2001 AVALON (RM808U) Author
: Date
: 1687 BE-84 BODY ELECTRICAL - POWER DOOR LOCK CONTROL SYSTEM 9. Rear LH Door: INSPECT DOOR LOCK MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the door lock link moves to UNLOCK position. (b) Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. LOCK UNLOCK LOCK UNLOCK 2 1 1 2 I07299 10. Rear RH door: INSPECT DOOR LOCK MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 5, and check that the door lock link moves to UNLOCK position. (b) Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. LOCK UNLOCK LOCK UNLOCK 4 3 4 3 I07300 11. UNLOCK 1 (a) 2 (b) LOCK I12847 Using an ammeter: INSPECT DRIVER’S DOOR PTC THERMISTOR OPERATION Connect the negative (-) lead from the battery to terminal 2. Connect the positive (+) lead from the ammeter to terminal 1 and the negative (-) lead to battery positive (+) terminal, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. 2001 AVALON (RM808U) Author
: Date
: 1688 BE-85 BODY ELECTRICAL - POWER DOOR LOCK CONTROL SYSTEM (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. UNLOCK 2 1 LOCK I12848 12. UNLOCK (a) 6 5 (b) I12849 Using an ammeter: INSPECT PASSENGER’S DOOR PTC THERMISTOR OPERATION Connect the negative (-) lead from the battery to terminal 6. Connect the negative (-) lead from the ammeter to terminal 5 and the positive (+) lead to battery positive (+) terminal, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 5, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. 5 6 LOCK I12854 13. UNLOCK (a) 2 1 (b) I07307 Using an ammeter: INSPECT REAR LH DOOR PTC THERMISTOR OPERATION Connect the negative (-) lead from the battery to terminal 2. Connect the negative (-) lead from the ammeter to terminal 1 and the positive (+) lead to battery positive (+) terminal, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. LOCK 2 1 I07308 2001 AVALON (RM808U) Author
: Date
: 1689 BE-86 BODY ELECTRICAL 14. (a) UNLOCK 4 3 (b) - POWER DOOR LOCK CONTROL SYSTEM Using an ammeter: INSPECT REAR RH PTC THERMISTOR OPERATION Connect the negative (-) lead from the battery to terminal 4. Connect the negative (-) lead from the ammeter to terminal 3 and the positive (+) lead to battery positive (+) terminal, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. I07309 (c) (d) LOCK 3 4 Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 3, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. I07310 15. 1 UNLOCK (a) 2 (b) I12850 Using an ammeter with a current-measuring probe: INSPECT DRIVER’S DOOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. Attach a current-measuring probe to either the positive (+) lead or the negative (-) lead, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. (c) (d) UNLOCK 2 1 Disconnect the leads from terminals. Approximately 60 seconds later, reverse the polarity, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. LOCK I12851 16. UNLOCK 6 (a) 5 (b) I12852 Using an ammeter with a current-measuring probe: INSPECT PASSENGER’S DOOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead to terminal 6. Attach a current-measuring probe to either the positive (+) lead or the negative (-) lead, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. 2001 AVALON (RM808U) Author
: Date
: 1690 BE-87 BODY ELECTRICAL - POWER DOOR LOCK CONTROL SYSTEM (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, reverse the polarity, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. 6 5 LOCK I12853 17. UNLOCK 2 1 (a) (b) I07317 Using an ammeter with a current-measuring probe: INSPECT REAR LH DOOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. Attach a current-measuring probe to either the positive (+) lead or the negative (-) lead, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, reverse the polarity, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. LOCK 2 1 I07308 18. 4 3 UNLOCK (a) (b) I07319 Using an ammeter with a current-measuring probe: INSPECT REAR RH DOOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 4. Attach a current-measuring probe to either the positive (+) lead or the negative (-) lead, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. (c) (d) LOCK 4 3 Disconnect the leads from terminals. Approximately 60 seconds later, reverse the polarity, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. I07310 2001 AVALON (RM808U) Author
: Date
: 1691 BE-81 BODY ELECTRICAL - POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM BE0IJ-03 LOCATION Ignition Switch Power Window Master Switch
Door Lock Control Switch
Driver Door ECU Front Door Lock Assembly
Door Lock Motor
Door Unlock Detection Motor
Door Key Lock and Unlock Switch Driver Side Junction Block
Door No.1 Fuse
Body ECU Rear Door Lock Assembly
Door Lock Motor
Door Unlock Detection Switch I12855 2001 AVALON (RM808U) Author
: Date
: 1685 BE-1 14 BODY ELECTRICAL - POWER MIRROR CONTROL SYSTEM BE1E8-01 INSPECTION Left/Right Adjustment Switch 1. 10 Mirror Switch 2. 1 I04167 W/O Memory: INSPECT LEFT SIDE MIRROR SWITCH CONTINUITY Switch position Tester connection Specified condition OFF - UP 3 - 4, 7 - 8 Continuity DOWN 3 - 8, 4 - 7 Continuity LEFT 4 - 9, 7 - 8 Continuity RIGHT 4 - 7, 8 - 9 Continuity No continuity INSPECT RIGHT SIDE MIRROR SWITCH CONTINUITY Switch position Tester connection OFF - Specified condition No continuity UP 2 - 4, 7 - 8 Continuity DOWN 2 - 8, 4 - 7 Continuity LEFT 4 - 10, 7 - 8 Continuity RIGHT 4 - 7, 8 - 10 Continuity If continuity is not as specified, replace the switch. If continuity is as specified. inspect the switch circuit. 3. W/ Memory: INSPECT LEFT SIDE MIRROR SWITCH CONTINUITY Switch position Tester connection Resistance (Ω) LEFE 8-9 100 RIGHT 8-9 0 Illumination 5-6 Continuity If continuity as specified, replace the switch. 4. w/ Memory: INSPECT MIRROR SWITCH RESISTANCE HINT:
Set the Left/Right abjustment switch to either position on the left or right.
Measure resistance between terminals 7 and 9 at each switch position, as shown in the chart. Switch Position Resistance (Ω) UP Approx. 100 RIGHT 250 DOWN 470 LEFT 800 If resistance as specified, replace the switch. 2001 AVALON (RM808U) Author
: Date
: 1718 BE-1 15 BODY ELECTRICAL - POWER MIRROR CONTROL SYSTEM 5. INSPECT MIRROR SWITCH CIRCUIT Disconnect the connector from the switch and inspect the connector on the wire harness side. Wire Harness Side 1 2 3 4 5 6 7 8 9 10 h-10-1-c N21376 Tester connection Condition Specified condition 8 - Ground Constant Continuity 4 - Ground Ignition switch position LOCK No voltage 4 - Ground Ignition switch position ACC or ON Battery voltage If the circuit is not as specified, inspect the circuits connected to other parts. 6. INSPECT MIRROR SWITCH INDICATOR LIGHT OPERATION Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead to terminal 6, and check that the indicator light does not light up, replace the switch. 6 5 N13659 7. (a) 1 2 w/o Mirror defogger and driving position memory: INSPECT MIRROR MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the mirror turns to the left side. I13295 (b) 1 Reverse the polarity, and check that the mirror turns to the right side. 2 I13296 2001 AVALON (RM808U) Author
: Date
: 1719 BE-1 16 BODY ELECTRICAL (c) 2 - POWER MIRROR CONTROL SYSTEM Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, and check that the mirror turns upward. 1 I13297 (d) 2 Reverse the polarity, and check that the mirror turns downward. If operation is not as specified, replace the mirror assembly. 1 I13298 8. 2 1 (a) w/ Mirror Defogger: INSPECT MIRROR MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the mirror turns to the left side. I13299 (b) 1 Reverse the polarity, and check that the mirror turns downward. If operation is not as specified, replace the mirror assembly. 2 I13300 (c) 2 Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 2, and check that the mirror turns upward. 4 I13301 2001 AVALON (RM808U) Author
: Date
: 1720 BE-1 17 BODY ELECTRICAL - POWER MIRROR CONTROL SYSTEM (d) Reverse the polarity, and check that the mirror turns downward. If operation is not as specified, replace the mirror assembly. 2 4 I13302 9. 2 1 (a) 7 w/ Driving position memory: INSPECT MIRROR POSITION MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the mirror turns to the left side. I13303 (b) 2 1 Reverse the polarity, and check that the mirror turns downward. If operation is not as specified, replace the mirror assembly. I13304 (c) 2 1 Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, and check that the mirror turns upward. I13305 (d) 1 2 Reverse the polarity, and check that the mirror turns downward. If operation is not as specified, replace the mirror assembly. I13306 2001 AVALON (RM808U) Author
: Date
: 1721 BE-1 18 BODY ELECTRICAL 10. 2 3 6 9 7 I13309 2 3 - POWER MIRROR CONTROL SYSTEM w/ Driving position memory: INSPECT MIRROR POSITION SENSORS OPERATION HINT: Strip off the vinyl tape of the connector and remove terminals 2, 3, 6, 7 and 9 from the connector housing. (a) Connect a series of three 1.5 V dry cell batteries. (b) Connect the positive (+) lead from the dry cell batteries to terminal 7 and the negative (-) lead to terminal 6. (c) Connect the positive (+) lead from the voltmeter to terminal 9 and the negative (-) lead to terminal 6. (d) Apply Battery voltage to terminals 2 and 3, then check that the voltage gradually changes according to the table below while the mirror moves between the uppermost position and lowermost position. Mirror position Lowermost Mirror position Uppermost Voltage 2.8 - 5.0 Changes gradually 0 - 1.8 6 9 7 I13310 If voltage value is not as specified, replace the motor assembly. (e) (f) 1 2 (g) 6 8 7 I13311 1 2 Disconnect the 4 leads of the battery and voltmeter. Connect the positive (+) lead from the voltmeter to terminal 8 and negative (-) lead to terminal 6. Apply Battery voltage to terminals 2 and 1, then inspect that the voltage gradually changes according to the table below while the mirror moves between the left-most position and right-most position. Mirror position Left-most Voltage LEFT 2.8 - 5.0 Voltage RIGHT 0 - 1.8 Mirror position Right-most Changes 0 - 1.8 gradually Changes gradually 2.8 -5.0 If voltage value is not as specified, replace the motor assembly. 6 8 7 I13312 11. SW2 SW1 SET Switch INSPECT DRIVING POSITION MEMORY AND RETURN SWITCH CONTINUITY Switch position Tester connection Specified condition SET switch ON 3-4 Continuity Return SW1 ON 2-3 Continuity Return SW2 ON 1-3 Continuity If continuity is not as specified, replace the switch. I07530 2001 AVALON (RM808U) Author
: Date
: 1722 BE-1 13 BODY ELECTRICAL - POWER MIRROR CONTROL SYSTEM BE1E5-01 POWER MIRROR CONTROL SYSTEM LOCATION Master Switch Driver Side Junction Block
ECU ACC Fuse Mirror Assembly
Mirror Motor I12539 2001 AVALON (RM808U) Author
: Date
: 1717 BE-14 BODY ELECTRICAL - POWER OUTLET BE1DH-01 INSPECTION INSPECT POWER OUTLET MAIN SWITCH CONTINUITY 3 2 4 5 6 1 Switch position Tester connection ON 2-3-6 OFF - illmination 1-5 Specified condition continuity No Continuity Continuity If continuity is not as specified, replace the switch. I13486 2001 AVALON (RM808U) Author
: Date
: 1618 BE-13 BODY ELECTRICAL - POWER OUTLET BE1DG-01 POWER OUTLET LOCATION Floor shift vehicle: Power Point Relay Power Outlet Main Switch Driver Side Junction Block
PWR - OUTLET Fuse (No.1,2) Ignition Switch Power Outlet Socket Column shift vehicle: Ignition Switch Power Point Relay Driver Side Junction Block
PWR - OUTLET Fuse (No.1,2) Power Outlet Main Switch Power Outlet Socket I13484 2001 AVALON (RM808U) Author
: Date
: 1617 BE-9 BODY ELECTRICAL - POWER SOURCE POWER SOURCE BE1DF-01 LOCATION Engine Room Junction Block Relay Block No.7 Relay Block No.8 Instrument Panel Junction Block I12522 2001 AVALON (RM808U) Author
: Date
: 1613 BE-10 BODY ELECTRICAL - POWER SOURCE Engine Room Junction Block: 2 1 4 5 6 3 7 9 10 11 8 A 12 13 14 15 16 B 19 20 C 28 30 E F D 27 29 23 24 17 18 21 22 Fuses: 1. MAIN Fuse - 40 A 2. RDI Fuse - 30 A 3. CDS Fuse - 30 A 4. HAZ Fuse - 15 A 5. SRS WRN Fuse - 5 A 6. DCC 1 Fuse - 30 A 7. ALT-S Fuse - 5 A 8. AM2 Fuse - 10 A 9. HORN Fuse - 10 A 10. DOOR NO. 2 Fuse - 15 A 11. A/F Fuse - 25 A 12. IG2 Fuse - 15 A 13. EFI NO. 1 Fuse - 15 A 14. ABS NO. 2 Fuse - 25 A 15. ABS NO. 3 Fuse - 25 A 16. EFI NO. 2 Fuse - 7.5 A 17. ALT Fuse - 120 A 18. ABS Fuse - 60 A 19. DRL Fuse - 7.5 A 20. ABS NO. 4 Fuse - 5 A 21. HTR Fuse - 50 A 22. AM1 Fuse - 40 A G 25 26 H Relays: LH Fuse - 15 A *2 RH Fuse - 15 A *2 23. H-LP 24. H-LP 25. H-LP LH LWR Fuse - 15 A *1 26. H-LP RH LWR Fuse - 15 A *1 27. SPARE Fuse - 10 A 28. SPARE Fuse - 15 A 29. SPARE Fuse - 25 A 30. SPARE Fuse - 30 A A. MG/CLT Relay B. A/F Relay C. HORN Relay D. EFI Relay E. IG2 Relay F. ST Relay G. HEAD Relay H. HTR Relay *1: w/ Daytime Running Light *2: w/o Daytime Running Light I12519 2001 AVALON (RM808U) Author
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: 1614 BE-1 1 BODY ELECTRICAL Driver Side Junction Block: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 G 32 B F C POWER SOURCE Fuses: 1. ECU-IG NO. 1 Fuse - 5 A 2. ECU-B NO. 2 Fuse - 7.5 A 3.TAIL Fuse - 10 A 4. SEAT HTR Fuse - 20 A 5. FR P/W Fuse - 20 A 6.GAUGE NO. 1 Fuse - 10 A 7. HTR Fuse - 10 A 8. FOG Fuse - 15 A 9. TURN Fuse - 7.5 A 10. A/C Fuse - 10 A 11. RADIO Fuse - 15 A 12. PANEL Fuse - 5 A 13.FL P/W Fuse - 25 A 14.PWR OUTLET NO. 1 Fuse - 15 A 15. ECU-ACC Fuse - 5 A 16. SRS ACC Fuse - 10 A 17. MIR HTR Fuse - 10 A 18. PWR OUTLET NO. 2 Fuse - 15 A 19. GAUGE NO. 2 Fuse - 10 A 20. OBDII Fuse - 7.5 A 21.STOP Fuse - 15 A 22.DOME Fuse - 7.5 A 23. OPNER Fuse - 5 A 24.RL P/W Fuse - 20 A 25.RR P/W Fuse - 20 A 26. WIP Fuse - 25 A 27.ECU-IG NO. 2 Fuse - 10 A 28.CIG Fuse - 15 A 29.DOOR NO. 1 Fuse - 25 A 30. SUN ROOF Fuse - 30 A 31. DEF Fuse - 40 A 32.PWR SEAT Fuse - 30 A Relays: A. FOG Relay B. DEF Relay C. IG1 Relay D. TAIL Relay E. PWR Relay E A - D F. N/F-1 G.N/F-2 I12518 2001 AVALON (RM808U) Author
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: 1615 BE-12 BODY ELECTRICAL - POWER SOURCE Relay Block No. 7: (w/ Day time running light) Fuses: A B 1 2 C 1.HEAD LH UPR Fuse - 10 A *1 2. HEAD RH UPR Fuse - 10 A *1 Relays: A. DRL NO. 3 Relay *1 B. DRL NO. 4 Relay *1 C. DRL NO. 2 Relay *1 Relay Block No. 8: A B Relays: A. FAN NO. 3 Relay B. ABS-MTR Relay C. FAN NO. 2 Relay D. ABS-SOL Relay E. FAN NO. 1 Relay C D E *1: w/ Daytime Running Light System I12520 2001 AVALON (RM808U) Author
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: 1616 BODY ELECTRICAL - POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) BE-105 BE0GL-04 INSPECTION Reclining Forward Front Front Vertical Up Rear Back 1. INSPECT DRIVER’S POWER SEAT SWITCH CONTINUITY Slide switch: Switch position Tester connection FRONT 1-9 4-6 Continuity OFF 4-6 4-9 Continuity BACK 1-6 4-9 Continuity Lifter Up Specified condition Front vertical switch: Down Down I04159 Switch position Tester connection Specified condition UP 1 - 10 4-5 Continuity OFF 4-5 4 - 10 Continuity DOWN 1-5 4 - 10 Continuity Lifter switch: Switch position Tester connection UP 1-7 4-8 Specified condition Continuity OFF 4-7 4-8 Continuity DOWN 1-8 4-7 Continuity Reclining switch: Switch position Tester connection Specified condition FORWARD 1-3 2-4 Continuity OFF 2-4 3-4 Continuity REAR 1-2 3-4 Continuity If continuity is not as specified, replace the switch. 2001 AVALON (RM808U) Author
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: 1709 BE-106 BODY ELECTRICAL 2. (a) Wire Harness Side (b) - POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) INSPECT DRIVER’S POWER SEAT SWITCH CIRCUIT Disconnect the switch connector and connect the seat wire harness to the floor wire harness. Inspect the connector on the wire harness side. I05472 Tester connection Condition Specified condition 4 - Ground Constant Continuity 1 - Ground Constant Battery positive voltage If circuit is not as specified, inspect the circuits connected to other parts. 3. INSPECT PASSENGER’S POWER SEAT SWITCH CONTINUITY Slide switch: Reclining Forward Rear Back Lifter Up Switch position Tester connection FRONT 1-9 4-6 Continuity OFF 4-6 4-9 Continuity BACK 1-6 4-9 Continuity Front Front Vertical Up Specified condition Front vertical switch: Down Down I04160 Switch position Tester connection Specified condition UP 1-5 4 - 10 Continuity OFF 4-5 4 - 10 Continuity DOWN 1 - 10 4-5 Continuity Lifter switch: Switch position Tester connection Specified condition UP 1-8 4-7 Continuity OFF 4-7 4-8 Continuity DOWN 1-7 4-8 Continuity 2001 AVALON (RM808U) Author
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: 1710 BODY ELECTRICAL - POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) BE-107 Reclining switch: Switch position Tester connection FORWARD 1-3 2-4 Specified condition Continuity OFF 2-4 3-4 Continuity REAR 1-2 3-4 Continuity If continuity is not as specified, replace the switch. 4. Wire Harness Side (a) (b) INSPECT PASSENGER’S POWER SEAT SWITCH CIRCUIT Disconnect the switch connector and connect the seat wire harness to the floor wire harness. Inspect the connector on the wire harness side. I05472 Tester connection Condition 4 - Ground Constant 1 - Ground Constant Specified condition Continuity Battery positive voltage If circuit is not as specified, inspect the circuits connected to other parts. 5. FORWARD INSPECT DRIVER’S LUMBAR SUPPORT SWITCH CONTINUITY Switch position Tester connection FORWARD 1-4 2-3 Continuity OFF 1-3 2-3 Continuity RELEASE 1-3 2-4 Continuity RELEASE I04161 Specified condition If continuity is not as specified, replace the switch. 2001 AVALON (RM808U) Author
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: 1711 BE-108 BODY ELECTRICAL 6. Wire Harness Side (a) (b) - POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) INSPECT DRIVER’S LUMBAR SUPPORT SWITCH CIRCUIT Disconnect the switch connector and connect the seat wire harness to the floor wire harness. Inspect the connector on the wire harness side. I04162 Tester connection Condition Specified condition 3 - Ground Constant Continuity 4 - Ground Constant Battery positive voltage If circuit is not as specified, inspect the circuits connected to other parts. 7. FORWARD INSPECT PASSENGER’S LUMBAR SUPPORT SWITCH CONTINUITY Switch position Tester connection FORWARD 1-4 2-3 Continuity OFF 1-3 2-3 Continuity RELEASE 1-3 2-4 Continuity RELEASE I04161 Specified condition If continuity is not as specified, replace the switch. 8. INSPECT PASSENGER’S LUMBAR SUPPORT SWITCH CIRCUIT (a) Disconnect the switch connector and connect the seat wire harness to the floor wire harness. (b) Inspect the connector on the wire harness side. Wire Harness Side I04162 Tester connection Condition Specified condition 2 - Ground Constant Continuity 1 - Ground Constant Battery positive voltage If circuit is not as specified, inspect the circuits connected to other parts. 2001 AVALON (RM808U) Author
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: 1712 BODY ELECTRICAL (a) POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) BE-109 9. (a) INSPECT SLIDE MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 - 2 1 1 N21865 10. 1 2 (a) (b) N21866 2 INSPECT SLIDE MOTOR PTC THERMISTOR OPERATION ( ): Passenger side Connect the positive (+) lead from the battery to terminal 1 (2), the positive (+) lead from the ammeter to terminal 2 (1) and the negative (-) lead to the battery negative (-) terminal, then move the seat cushion to the front position. Continue to apply voltage, check that current changes to less than 1 ampere within 4 to 90 seconds. (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 (1) and the negative (-) lead to terminal 1 (2), check that the seat cushion begins to move backwards. If operation is not as specified, replace the seat adjuster. 1 N21867 (a) 11. (a) INSPECT FRONT VERTICAL MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 1 1 2 N21865 2 12. 1 (a) N22086 (b) INSPECT FRONT VERTICAL MOTOR PTC THERMISTOR OPERATION ( ): Passenger side Connect the positive (+) lead from the battery to terminal 1 (2), the positive (+) lead from the ammeter to terminal 2 (1) and the negative (-) lead to the battery negative (-) terminal, then move the seat cushion to the highest position. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. 2001 AVALON (RM808U) Author
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: 1713 BE-1 10 BODY ELECTRICAL 1 2 - POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) (c) (d) Disconnect the leads from the terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 (1) and the negative (-) lead to terminal 1 (2), check that the seat cushion begins to descend. If operation is not as specified, replace the seat adjuster. N22087 (a) 13. (a) INSPECT REAR VERTICAL MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 2 1 1 N21865 2 14. 1 (a) (b) N22088 2 INSPECT REAR VERTICAL MOTOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 (1), the positive (+) lead from the ammeter to terminal 1 (2) and the negative (-) lead to the battery negative (-) terminal, then move the seat cushion to the highest position. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. (c) (d) Disconnect the leads from the terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 (2) and the negative (-) lead to terminal 2 (1), check that the seat cushion begins to descend. If operation is not as specified, replace the seat adjuster. 1 N22089 (a) 15. (a) INSPECT RECLINING MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 1 2 1 N21865 2001 AVALON (RM808U) Author
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: 1714 BODY ELECTRICAL 2 16. 1 (a) (b) - POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) BE-1 11 INSPECT RECLINING MOTOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 2, the positive (+) lead from the ammeter to terminal 1 and the negative (-) lead to the battery negative (-) terminal, then recline the seat back to the most forward position. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. N21868 2 (c) (d) Disconnect the leads from the terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the seat back begins to fall backward. If operation is not as specified, replace the seat adjuster. 1 N21869 17. (a) 1 INSPECT LUMBAR SUPPORT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, check that the lumbar support moves to release side. 2 I13315 (b) 1 Reverse the polarity, check that the lumbar support moves forward. If operation is not as specified, replace the seat adjuster. 2 I13316 1 18. (a) 2 INSPECT LUMBAR SUPPORT MOTOR CIRCUIT BREAKER OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1 on the lumbar support motor connector and move the lumbar support to front end position. I13317 2001 AVALON (RM808U) Author
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: 1715 BE-1 12 BODY ELECTRICAL 1 2 - POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) (b) Continue to apply voltage, check that a circuit breaker operation noise can be heard within 4 to 60 seconds. (c) Reverse the polarity, check that the lumbar support begins to move release side with in spproximately 60 seconds. If operation is not as specified, replace the motor. I13318 2001 AVALON (RM808U) Author
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: 1716 BE-104 BODY ELECTRICAL - POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) POWER SEAT CONTROL SYSTEM (w/o Driving Position Memory) BE0IR-03 LOCATION Front Vertical Motor Instrument Panel Junction Block
PWR Seat Fuse
ECU-B Fuse Reclining Motor Power Seat Switch Reclining Motor Rear Vertical Motor Power Seat Switch Rear Vertical Motor Slide Motor Front Vertical Motor I12538 2001 AVALON (RM808U) Author
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: 1708 BE-80 BODY ELECTRICAL - POWER WINDOW CONTROL SYSTEM BE0HG-33 ADJUSTMENT HOW TO RESET POWER WINDOW MOTOR (LIMIT SWITCH) NOTICE: If the jam protection function is not functioning properly, perform the following procedures. HINT: It is necessary to reset the power window motor (in initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed. (a) Remove the power window motor. HINT: Place matchmarks on the power window motor and window regulator gear. (b) Connect the power window motor and power window switch to the wire harness of the vehicle. (c) Turn the ignition switch ON. (d) Press the power window UP switch until the motor completes 6 to 10 rotations (4 seconds of rotation or more). (e) Assemble the power window motor and regulator. HINT:
Install the motor when the regulator arm is below the middle point.
Align the matchmarks on the power window motor and window regulator gear when installing the power window motor. (f) Assemble the power window regulator and door glass. HINT: Never rotate the motor downward until the completion of the window glass installation. (g) Connect the power window switch to the wire harness and turn the ignition switch ON. (h) Repeat UP and DOWN operation several times manually. (i) Check AUTO UP → AUTO DOWN automatic operation is normal. NOTICE:
The jam protection function does not operate immediately after performing reset.
If the jam protection function is triggered and the window lowers after the window has been fully closed by AUTO UP operation (step i), reset the power window motor again. (j) Check the power window function. Author
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: 1684 BE-73 BODY ELECTRICAL - POWER WINDOW CONTROL SYSTEM BE1DW-01 INSPECTION 1. (a) (b) (c) (d) 1 (e) 14 I12857 Using an ammeter: INSPECT ONE TOUCH POWER WINDOW SYSTEM/ CURRENT OF CIRCUIT Disconnect the connector from the master switch. Connect the positive (+) lead from the ammeter to terminal 1 on the wire harness side connector and the negative (-) lead to negative (-) terminal of the battery. Connect the positive (+) lead from the battery to terminal 14 on the wire harness side connector. As the window goes down, check that the current flow is approximately 7 A. Check that the current increases up to approximately 14.5 A or more when the window stops going down. HINT: The PTC opens some 4 - 90 seconds after the window stops going down, so that check must be made before the PTC operates. If the operation is as specified, replace the driver door ECU. 2. (a) (b) (c) (d) (e) Using an ammeter with a current-measuring probe: INSPECT ONE TOUCH POWER WINDOW SYSTEM/ CURRENT OF CIRCUIT Remove the driver door ECU with connectors connected. Attach a current-measuring probe to terminal 25 of the wire harness. Turn the ignition switch ON and set the power window switch in the down position. As the window goes down, check that the current flow is approximately 7 A. Check that the current increases up to approximately 14.5 A or more when the window stops going down. HINT: The PTC opens some 4 - 90 seconds after the window stops going down, so that check must be made before the PTC operates. If operation is as specified, replace the driver door ECU. 25 I12858 3. 2 1 6 5 4 3 INSPECT REAR POWER WINDOW SWITCH CONTINUITY Switch position Tester connection Specified condition UP 5 - 4, 2 - 6 Continuity OFF 4 - 6, 2 - 6 No continuity DOWN 2 - 5, 4 - 6 Continuity If continuity is not as specified, replace the switch. I14262 2001 AVALON (RM808U) Author
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: 1677 BE-74 BODY ELECTRICAL 4. 1 2 3 5 5 1 2 - POWER WINDOW CONTROL SYSTEM INSPECT POWER MAIN RELAY CONTINUITY Condition Tester connection Constant 1-2 Continuity Specified condition Apply B+ between terminals 1 and 2. 3-5 Continuity If continuity is not as specified, replace the relay. 3 I01200 5. (a) 2 1 Driver’s Door: INSPECT POWER WINDOW MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the motor turns clockwise. I12547 (b) 2 Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the motor. NOTICE: Since the jam protection may not work properly be sure to conduct procedures described in ”HOW TO RESET POWER MOTOR (RESET AND PULSE SWITCH)” after this inspection. 1 I12548 6. (a) 2 Front Passenger’s Door: INSPECT POWER WINDOW MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, and check that the motor turns clockwise. 1 I12549 (b) Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the motor. 2 1 I12550 2001 AVALON (RM808U) Author
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: 1678 BE-75 BODY ELECTRICAL 7. (a) 1 - POWER WINDOW CONTROL SYSTEM Rear Left Side Door: INSPECT POWER WINDOW MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, and check that the motor turns clockwise. 2 I12553 (b) Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the motor. 1 2 I12554 8. (a) 2 Rear Right Side Door: INSPECT POWER WINDOW MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the motor turns clockwise. 1 I12551 (b) Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the motor. 2 1 I12552 2 1 9. (a) (b) (c) I12555 Driver’s door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION Disconnect the connector from the power window motor. Connect the positive (+) lead from the ammeter to terminal 2 on the wire harness side connector and the negative (-) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 1 on the wire harness side connector, and raise the window to the fully position. 2001 AVALON (RM808U) Author
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: 1679 BE-76 BODY ELECTRICAL (d) 2 - POWER WINDOW CONTROL SYSTEM Continue to apply voltage, and check that the current changes to less than 1 A with 4 to 90 seconds. (e) (f) Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 1, and check that the window begins to descended. If operation is not as specified, replace the motor. 1 I12556 2 1 I12557 2 1 10. Front Passenger’s door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION (a) Disconnect the connector from the power window motor. (b) Connect the positive (+) lead from the ammeter to terminal 1 on the wire harness side connector and the negative (-) lead to negative terminal of the battery. (c) Connect the positive (+) lead from the battery to terminal 2 on the wire harness side connector, and raise the window to the fully position. (d) Continue to apply voltage and check that the current changes to less than 1 A within 4 to 90 seconds. (e) Disconnect the leads from the terminals. (f) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the window begins to descend. If operation is not as specified, replace the motor. I12558 11. 2 1 (a) (b) (c) I12561 Rear LH door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION Disconnect the connector from the power window motor. Connect the positive (+) lead from the ammeter to terminal 2 on the wire harness side connector and the negative (-) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 2 on the wire harness side connector, and raise the window to the fully position. 2001 AVALON (RM808U) Author
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: 1680 BE-77 BODY ELECTRICAL - POWER WINDOW CONTROL SYSTEM (d) Continue to apply voltage and check that the current changes to less than 1 A within 4 to 90 seconds. (e) Disconnect the leads from the terminals. (f) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the window begins to descend. If operation is not as specified, replace the motor. 1 2 I12560 1 2 I12559 2 1 I12764 12. Rear RH Door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION (a) Disconnect the connector from the power window motor. (b) Connect the positive (+) lead from the ammeter to terminal 2 on the wire harness side connector and the negative (-) lead to negative terminal of the battery. (c) Connect the positive (+) lead from the battery to terminal 1 on the wire harness side connector, and raise the window to the fully position. (d) Continue to apply voltage and check that the current changes to less than 1 A within 4 to 90 seconds. (e) Disconnect the leads from the terminals. (f) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, and check that the window begins to descend. If operation is not as specified, replace the motor. 13. INSPECT JAM PROTECTION FUNCTION NOTICE: Never, ever be caught any part of your body when checking. HINT: In case of performing resetting of the limit switch, do checking after repeating up and down of the glass with automatic operation. (a) Confirmation of AUTO up operation: Confirm that the window will be fully close with AUTO up operation. (b) Checking of the operation of the jam protection function: (1) Move up the window with AUTO up operation and check that the window will go down when it touches the handle of the hammer stetted. (2) Confirm that the window will then stop going down about 200 mm . HINT: In case of removing the glass, glass guide, regulator and etc. be sure to perform checking of the jam protection function. 2001 AVALON (RM808U) Author
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: 1681 BE-78 BODY ELECTRICAL 1 2 14. 4 (a) 5 (b) (c) I12760 1 2 4 5 - POWER WINDOW CONTROL SYSTEM Driver’s Door (Window Up): INSPECT JAM PROTECTION LIMIT SWITCH OPERATION Connect the negative (-) lead from the ohmmeter to terminal 5 and the positive (+) lead to terminal 4. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. Check that the continuity exists when the window goes up. (d) Check that the no continuity exists when the window is in the fully closed position. If operation is not as specified, replace the motor. NOTICE: If connecting the wire harness wrongly, the sensor might be damaged so caution is necessary. I12761 1 2 15. 4 (a) 5 (b) (c) I12762 1 2 4 5 Driver’s Door (Window Down): INSPECT JAM PROTECTION LIMIT SWITCH OPERATION Connect the negative (-) lead from the ohmmeter to terminal 5 and the positive (+) lead to terminal 4. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1. Check that the continuity exists when the window goes down. (d) Check that the no continuity exists when the window is in the fully opened position. If operation is not as specified, replace the motor. NOTICE: If connecting the wire harness wrongly, the sensor might be damaged so caution is necessary. I12763 16. 1 2 3 (a) 5 (b) I12768 (c) Driver’s Door: INSPECT JAM PROTECTION PULSE SWITCH OPERATION Connect the positive (+) lead from the TOYOTA electrical tester to terminal 3 and the negative (-) lead to terminal 5. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2. Check that pulse is generated during the motor running. 2001 AVALON (RM808U) Author
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: 1682 BE-79 BODY ELECTRICAL 2 1 3 5 I12769 - POWER WINDOW CONTROL SYSTEM (d) Reverse the polarity and check that pulse is generated. If operation is not as specified, replace the motor. NOTICE: If connecting the wire harness wrongly, the sensor might be damaged so caution is necessary. 17. INSPECT JAM PROTECTION FUNCTION NOTICE: Never, ever be caught any part of your body when checking. HINT: In case of performing resetting of the limit switch, do checking after repeating up and down of the glass with automatic operation. (a) Confirmation of AUTO up operation: Confirm that the window will be fully close with AUTO up operation. (b) Checking of the operation of the jam protection function: (1) Move up the window with AUTO up operation and check that the window will go down when it touches the handle of the hammer stetted. (2) Confirm that the window will then stop going down about 200 mm. HINT: In case of removing the glass, glass guide, regulator and etc. be sure to perform checking of the jam protection function. If the jam protection is not function properly, adjust power window motor reset switch and pulse switch. 2001 AVALON (RM808U) Author
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: 1683 BE-72 BODY ELECTRICAL - POWER WINDOW CONTROL SYSTEM BE0IH-03 LOCATION Power Window Switch (Passenger Door ECU) Ignition Switch Driver Side Junction Block
FL P/W, FR P/W, RL P/W, RR P/W Fuse
Power Main Relay
Body ECU Power Window Master Switch (Driver Door ECU) Front Power Window Motor Rear Power Window Switch Rear Power Window Motor I12534 2001 AVALON (RM808U) Author
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: 1676 BE-70 BODY ELECTRICAL - POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM BE02C-11 TROUBLESHOOTING 1 The window moves down during the up operation. Sliding resistance check: Yes Disassemble the door and replace or repair the component. Yes Normal. (After checking the operation repeatedly, perform the function check.) No Check or repair door glass run and window guide frame. With ignition switch ON, when performing the auto-up operation, if the factor which increases the sliding resistance of window glass near the inverse position is recognized. No Power window motor reset: Reset the limit switch. Check operation power window control is normal. No Remove power window regulator assembly. Sliding resistance check: When raising the assembled window glass by hand if the glass slides smoothly without being caught. Yes Unit check: If power window regulator and motor operate smoothly. Replace the driver door control ECU with the normal one removed from another seat. Power window motor reset: *1 Install power window regulator and reset the limit switch. Check operation power window control is normal. Yes Driver door control ECU faulty. No Power window motor faulty. HINT: When difference of descending time comparing to the opposite window is recognized, there seems to be an error on sliding components (door glass run and window regulator.) 2001 AVALON (RM808U) Author
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: 1674 BE-71 BODY ELECTRICAL 2 - POWER WINDOW CONTROL SYSTEM The DOWN function does not work though some other objects are caught in the power window glass. Is the system in the jam protection function operating No condition?
The AUTO UP operation works with the ignition switch ON. (One-touch operation) Normal (Perform function check) Yes Is the power window outside the jam protection function operating area? < Out of the operating area > Area around the fully closed position Yes No Reset the limit switch. *2 Does the power window operate normally? Yes Normal (After performing operation check repeatedly, conduct the function check.) No Master switch defective. 2001 AVALON (RM808U) Author
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: 1675 BE-122 BODY ELECTRICAL - SEAT HEATER SYSTEM BE1EF-02 12 INSPECTION 25 1. 24 2 (a) 1 (b) A/C control panel assembly: INSPECT DRIVERS SEAT HEATER SWITCH OPERATION Connect the positive (+) lead from the battery to terminal 1, 2 and negative (-) lead to terminal 24, 25. Connect the positive (+) lead from the battery to terminal 12 through a 1.4 W test bulb. I12827 (c) 12 Turn the drivers seat heater switch ON and check that the test bulb and indicator light turn ON. If operation is not as specified, proceed to the next inspection. 25 24 2 1 ON I12828 2. 13 26 (a) 24 2 1 (b) A/C control panel assembly: INSPECT PASSENGER SEAT HEATER SWITCH OPERATION Connect the positive (+) lead from the battery to terminal 1, 2 and negative (-) lead to terminal 24, 26. Connect the positive (+) lead from the battery to terminal 13 through a 1.4 W test bulb. I12829 (c) 13 Turn the passenger seat heater switch ON and check that the test bulb and indicator light turn ON. If operation is not as specified, proceed to the next inspection. 26 24 2 1 ON I12830 2001 AVALON (RM808U) Author
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: 1726 BE-123 BODY ELECTRICAL Connector ”A” - SEAT HEATER SYSTEM 3. (a) Connector ”B” I21287 INSPECT SEAT CUSHION HEATER CONTINUITY Disconnect the seat back heater from the seat cushion heater. (b) Heat the 2 thermostats with a light and check that there is no continuity above 50 °C (122 °F) between terminals A1 and B2, A2 and B1. (c) Cool the 2 thermostats below 40 °C (104 °F) between terminals A1 and B2, A2 and B1. If continuity is not as specified, replace the seat heater. 4. INSPECT SEAT BACK CONTINUITY Check that there is continuity between terminals 1 and 2. If continuity is not as specified, replace the seat back pad. I21288 5. 1 2 1 5 5 3 3 INSPECT IGNITION MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1-2 Continuity Apply B+ between terminals 1 and 2. 3-5 Continuity If continuity is not as specified, replace the relay. 2 Z14186 2001 AVALON (RM808U) Author
: Date
: 1727 BE-121 BODY ELECTRICAL - SEAT HEATER SYSTEM SEAT HEATER SYSTEM BE0IV-05 LOCATION Heater Control Panel
Seat Heater Switch Instrument Panel Junction Block
SEAT HTR Fuse
Ignition Main Relay Ignition Switch Seat Heater
Seat Cushion Seat Heater
Seat Back I13483 2001 AVALON (RM808U) Author
: Date
: 1725 BE-36 BODY ELECTRICAL - STOP LIGHT SYSTEM BE1DM-01 INSPECTION w/o Cruise Control: Free 1. Pushed in 2 1 w/ Cruise Control: Free Pushed in 2 w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY Switch position Tester connection Specified condition Switch pin free 1-2 Continuity Switch pin pushed in 1-2 No continuity If continuity is not as specified, replace the switch. 2. w/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY 1 Switch position Tester connection Specified condition Switch pin free 1-2 Continuity Switch pin pushed in 1-2 No continuity Switch pin free 3-4 No continuity Switch pin pushed in 3-4 Continuity If continuity is not as specified, replace the switch. 4 3 N18026 3. INSPECT HI- MOUNTED STOP LIGHT ASSEMBLY CONTINUITY Using the ohmmeter,check that continuity exists between terminal 1 and terminal 2. If continuity is not as specified,replace the light assembly or bulb. I13416 2001 AVALON (RM808U) Author
: Date
: 1640 BE-35 BODY ELECTRICAL - STOP LIGHT SYSTEM STOP LIGHT SYSTEM BE0I6-05 LOCATION Stop Light Switch Driver Side Junction Block
STOP Fuse HI-Mounted Stop Light Light Failure Sensor Stop Light I12529 2001 AVALON (RM808U) Author
: Date
: 1639 BE-103 BODY ELECTRICAL - SLIDING ROOF SYSTEM BE1E2-01 INSPECTION Wire Harness Side: 1. I04045 INSPECT SLIDING ROOF CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition Slide Open 2-3 Continuity Tilt Up 1-2 Continuity If continuity is not as specified, replace the switch. 2. INSPECT SLIDING ROOF CONTROL ASSEMBLY CIRCUIT Disconnect the connector from the assembly and inspect the connector on the wire harness side, as shown in the chart. Tester connection Condition Specified condition Driver’s door courtesy switch ”ON” (Door opened) Continuity Driver’s door courtesy switch ”OFF” (Door closed) No continuity Passenger’s door courtesy switch ”ON” (Door opened) Continuity Passenger’s door courtesy switch ”OFF” (Door closed) No continuity 5 - Ground (+B) Constant Battery positive voltage 7 - Ground (E) Constant Continuity Ignition switch LOCK or ACC No voltage Ignition switch ON Battery positive voltage 9 - Ground (DOWN) Sliding roof control switch OPEN / DOWN Continuity 9 - Ground (DOWN) Sliding roof control switch CLOSE / UP No continuity Sliding roof control switch CLOSE / UP Continuity Sliding roof control switch OPEN / DOWN No continuity 3 - Ground (DCTY) 4 - Ground (PCTY) 8 - Ground (IG) 10 - Ground (UP) *: Exceptions: During 60 second period after ignition switch ON → OFF (ACC) or until driver of passenger door in opened after ignition switch ON → OFF (ACC). If circuit is as specified, replace the assembly. 2001 AVALON (RM808U) Author
: Date
: 1707 BE-102 BODY ELECTRICAL - SLIDING ROOF SYSTEM BE0IP-06 LOCATION Sliding Roof Assembly
Sliding Roof Switch
Sliding Roof Control ECU Door Courtesy Switch Instrument Panel Junction Block
Sun Roof Fuse
GAUGE No,1 Fuse Ignition Switch I12542 2001 AVALON (RM808U) Author
: Date
: 1706 BE-101 BODY ELECTRICAL - SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM BE0O9-02 TROUBLESHOOTING Sliding Roof reverses during close (down) operation. Start Perform forced operation.* Mechanical check Replace sliding roof motor with ECU. *: Holding the CLOSE/UP (OPEN/DOWN) switch pressed inhibits the jam protection function at approx. 10 sec. after starting the reverse operation. If the switch remains pressed any longer, the sliding door starts close operation and it stops when detecting the fully closed position. CLOSE/UP (OPEN/DOWN) SWITCH ON OFF Close (Down) Reverse Stop Roof Operation Forced Operation Stop Close (Down) Approx. 10 sec. Close Position HINT: At approx. 10 sec. after starting the reverse operation, it is switched to the forced close (down) operation. 2001 AVALON (RM808U) Author
: Date
: 1705 BE-2 BODY ELECTRICAL - TROUBLESHOOTING BE04Q-06 TROUBLESHOOTING PROBLEM SYMPTOMS TABLE POWER OUTLET Symptom Electric power source cannot be taken out of the power outlet Suspect Area See page 11.PWR OUTLET No. 1, 2 Fuse 12.Wire Harness - IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH: This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before checking the body control system. HEADLIGHT AND TAILLIGHT SYSTEM: This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before checking the body control system. FOG LIGHT SYSTEM: Symptom Suspect Area See page Fog light does not light with light control SW HEAD. (Headlight is normal) 1. 2. 3. 4. FOG Fuse Fog Light Relay Fog Light Switch Wire Harness BE-26 BE-26 - Fog light does not light with light control SW HEAD. (Headlight does not light) 1. Other Parts*1 2. Wire Harness - Only one light does not light. 1. Bulb 2. Wire Harness - *1: Inspect Headlight System. TURN SIGNAL AND HAZARD WARNING SYSTEM: Symptom Suspect Area See page ”Hazard” and ”Turn” do not light up. 1. Hazard Warning Switch 2. Turn Signal Flasher 3. Wire Harness BE-29 BE-29 - The flashing frequency is abnormal. 1. Bulb 2. Turn Signal Switch 3. Wire Harness BE-29 - Hazard warning light does not light up. (Turn is normal.) 1. HAZ Fuse 2. Wire Harness Hazard warning light does not light up in one direction. 1. Hazard Warning Switch 2. Wire Harness BE-29 - *1Turn signal does not light up. 1. 2. 3. 4. Ignition Switch TURN Fuse Turn Signal Switch Wire Harness BE-16 BE-29 - *2Turn signal does not light up. 1. TURN Fuse 2. Turn Signal Switch 3. Wire Harness BE-29 - Turn signal does not light up in one direction. 1. Turn Signal Switch 2. Wire Harness BE-29 - Only one bulb does not light up. 1. Bulb 2. Wire Harness - - *1: Combination Meter, Wiper and Washer do not operate. *2: Combination Meter, Wiper and Washer are normal. 2001 AVALON (RM808U) Author
: Date
: 1606 BE-3 BODY ELECTRICAL - TROUBLESHOOTING INTERIOR LIGHT SYSTEM: This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before checking the body control system. BACK-UP LIGHT SYSTEM: Symptom Suspect Area See page Back-Up Light does not light up. 1. 2. 3. 4. 5. 6. GAUGE Fuse Ignition Switch Park/Neutral Position Switch Back-up Light Relay (Column Shift) Bulb Wire Harness BE-16 DI-199 BE-34 - Back-Up Light remains always ON. 1. Park/Neutral Position Switch 2. Back-up Light Relay (Column Shift) 3. Wire Harness DI-199 BE-34 - Only one light does not light up. 1. Bulb 2. Wire Harness - STOP LIGHT SYSTEM: Symptom Suspect Area See page Stop light does not light up. 1. 2. 3. 4. 5. STOP Fuse GAUGE Fuse Stop Light Switch Light Failure Sensor Wire Harness BE-36 BE-53 - Only one light always lights up. 1. Wire Harness - Only one light does not light. 1. Bulb 2. Wire Harness - WIPER AND WASHER SYSTEM: Symptom Suspect Area See page Wiper and washers do not operate. 1. 2. 3. 4. 5. IG 1 Relay WIPER Fuse Wiper Switch Wiper Motor Wire Harness BE-38 BE-38 - Wipers do not operate in LO or HI. 1. Wiper Switch 2. Wiper Motor 3. Wire Harness BE-38 BE-38 - Wipers do not operate in INT. 1. 2. 3. 4. BE-38 BE-38 - Washer motor does not operate. 1. Washer Switch 2. Washer Motor 3. Wire Harness BE-38 BE-38 - Wipers do not operate when washer switch in ON. 1. Washer Motor 2. Wire Harness BE-38 - Washer fluid does not operate. 1. Washer Hose and Nozzle
In wiper switch HI position, the wiper blade is in contact with the body.
When the wiper switch is OFF, the wiper blade does not retract or the retract position is wrong. 1. *1Wiper Switch 2. Wire Harness Wiper Fuse Wiper Switch Wiper Motor Wire Harness BE-38 - *1: Inspect wiper arm and blade set position 2001 AVALON (RM808U) Author
: Date
: 1607 BE-4 BODY ELECTRICAL - TROUBLESHOOTING COMBINATION METER (Meter, Gauges and Illumination): Symptom Suspect Area See page Tachometer, Fuel Gauge and Engine Coolant Temperature Gauge do not operate. 1. 2. 3. 4. 5. ECU-B Fuse ECU-IG No. 2 Fuse Meter Circuit Plate Wire Harness Multi Display BE-43 - Speedometer does not operate. 1. 2. 3. 4. Vehicle Speed Sensor (ABS - ECU) Meter Circuit Plate Wire Harness Multi Display BE-53 BE-43 - Tachometer does not operate. 1. 2. 3. 4. EFI - ECU Meter Circuit Plate Wire Harness Multi Display BE-43 - Fuel Gauge does not operate or abnormal operation. 1. 2. 3. 4. Fuel Receiver Gauge Fuel Sender Gauge Meter Circuit Plate Wire Harness BE-53 BE-53 BE-43 - Engine Coolant Temperature Gauge does not operate or abnormal operation. 1. 2. 3. 4. Engine Coolant Temperature Receiver Gauge Engine Coolant Temperature Sender Gauge Meter Circuit Plate Wire Harness BE-53 BE-53 BE-43 - All illumination lights do not light up. 1. 2. 3. 4. Bulb PANEL Fuse Light Control Rheostat Wire Harness BE-53 - Brightness does not change even when rheostat turned. 1. Bulb 2. Rheostat 3. Wire Harness - Only one illumination light does not light up. 1. Bulb 2. Wire Harness - COMBINATION METER (Warning Lights): Symptom Suspect Area See page Warning lights do not light up. (Except Discharge, Open Door and SRS) 1. 2. 3. 4. Bulb GAUGE No. 1 Fuse Meter Circuit Plate Wire Harness BE-53 - Low Oil Pressure warning light does not light up. 1. 2. 3. 4. 5. Multi Display Bulb Low Oil Pressure Warning Switch Meter Circuit Plate Wire Harness BE-53 BE-43 - Fuel Level warning light does not light up. 1. 2. 3. 4. 5. Multi Display Bulb Fuel Sender Gause Meter Circuit Plate Wire Harness BE-53 BE-43 - ABS warning light does not light up. 1. Bulb 2. ABS ECU 3. Wire Harness DI-210 - 2001 AVALON (RM808U) Author
: Date
: 1608 BE-5 BODY ELECTRICAL - TROUBLESHOOTING Seat Belt warning light does not light up. 1. 2. 3. 4. Bulb Body Control System Meter Circuit Plate Wire Harness DI-615 BE-53 - Discharge warning light does not light up. 1. 2. 3. 4. 5. AM2 - Fuse Bulb Meter Circuit Plate Wire Harness Generator BE-53 CH-9 Light Failure warning light does not light up. 1. 2. 3. 4. 5. Bulb Light Failure Sensor Bulb Check Relay Wire Harness Taillight System BE-53 BE-53 BE-2 Brake warning light does not light up. 1. 2. 3. 4. 5. 6. Bulb Parking Brake Switch Brake Fluid Level Warning Switch Bulb Check Relay Meter Circuit Plate Wire Harness BE-53 BE-53 BE-53 BE-43 - SRS Warning light does not light up. 1. 2. 3. 4. 5. AM2 - Fuse Bulb Airbag Sensor Assembly Meter Circuit Plate Wire Harness RS-62 RS-67 BE-43 Open Door warning light does not light up. 1. 2. 3. 4. 5. 6. DOME Fuse Bulb Door Courtesy Switch Body Control System Meter Circuit Plate Wire Harness BE-31 DI-615 BE-43 - Washer Level warning light does not light up. 1. 2. 3. 4. Bulb Washer Fluid Level Warning Switch Meter Circuit Plate Wire Harness BE-53 BE-43 - COMBINATION METER (Indicator Lights): Symptom Suspect Area See page O/D OFF indicator light does not light up. 1. 2. 3. 4. 5. Bulb O/D OFF Switch ECM Meter Circuit Plate Wire Harness DI-203 DI-1 BE-43 - Cruise Control indicator light does not light up. 1. 2. 3. 4. Bulb Cruise Control ECU Meter Circuit Plate Wire Harness DI-549 BE-43 - High beam indicator light does not light up. 1. 2. 3. 4. Bulb and Taillight Headlight System Meter Circuit Plate Wire Harness BE-2 BE-43 - Turn indicator light does not light up. 1. 2. 3. 4. Bulb Turn Signal and Hazard Warning System Meter Circuit Plate Wire Harness BE-2 BE-43 - 2001 AVALON (RM808U) Author
: Date
: 1609 BE-6 BODY ELECTRICAL - TROUBLESHOOTING Shift indicator lights do not light up. 1. 2. 3. 4. Bulb Park/Neutral Position Switch Meter Circuit Plate Wire Harness DI-199 BE-43 - Only one shift indicator does not light up. 1. Bulb 2. Meter Circuit Plate BE-43 Malfunction indicator light does not light up. 1. 2. 3. 4. Bulb ECM Meter Circuit Plate Wire Harness DI-1 BE-43 - SLIP indicator light does not light up. 1. 2. 3. 4. Bulb ABS & TRAC ECU Meter Circuit Plate Wire Harness DI-250 BE-43 - TRAC OFF indicator light does not light up. 1. 2. 3. 4. Bulb ABS & TRAC ECU Meter Circuit Plate Wire Harness DI-250 BE-43 - Security indicator light does not light up. 1. 2. 3. 4. LED Theft Deterrent ECU Meter Circuit Plate Wire Harness DI-517 BE-43 - Indicator lights do not light up. (Except Turn, Hi-beam and security) 1. GAUGE Fuse 2. Wire Harness - DEFOGGER SYSTEM: Symptom Suspect Area See page All defogger systems do not operate. 1. 2. 3. 4. 5. SEAT HEATER Fuse DEF Fuse Defogger Relay Defogger Switch Wire Harness BE-67 DI-1 - Rear window defogger does not operate. 1. Defogger Wire 2. Choke Coil 3. Wire Harness BE-67 - Mirror defogger does not operate. 1. MIR/HTR Fuse 2. Mirror Defogger 3. Wire Harness BE-67 - POWER WINDOW CONTROL SYSTEM: This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before checking the body control system. POWER DOOR LOCK CONTROL SYSTEM: This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before checking the body control system. 2001 AVALON (RM808U) Author
: Date
: 1610 BE-7 BODY ELECTRICAL - TROUBLESHOOTING WIRELESS DOOR LOCK CONTROL SYSTEM This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before checking the body control system. Some functions of wireless door lock control system do not operate. HINT:  Troubleshooting of the wireless door lock control system is based on the premise that the door lock control system is operating normally. Accordingly, before troubleshooting the wireless door lock control system, first make certain that the door lock control system is operating normally.  If the trouble still reappears even though there are no abnormalities in any of the other circuits, then check and replace the Wireless Door Lock Control Receiver as the last step. SLIDING ROOF SYSTEM: Symptom Suspect Area See page Sliding roof system does not operate. (Door Lock does not operate) 1. SUN ROOF Fuse 2. GAUGE Fuse 3. Wire Harness - Sliding roof system does not operate. (Door Lock is normal) 1. 2. 3. 4. Sliding Roof Control Switch Sliding Roof Motor and Limit Switch Sliding Roof Control Relay Wire Harness BE-103 BE-103 BE-103 - Sliding roof system operates abnormally. 1. 2. 3. 4. Sliding Roof Control Switch Sliding Roof Motor and Limit Switch Sliding Roof Control Relay Wire Harness BE-103 BE-103 BE-103 - Sliding roof system stops operation half way. (Stones of foreign material trapped in motor assembly) 1. Sliding Roof Control Relay and Switch 2. Sliding Roof Motor and Limit Switch 3. Wire Harness BE-103 BE-103 - ”Key-of f Sliding Roof” operation does not operate. 1. 2. 3. 4. 5. BE-16 BE-16 - DOOR Fuse GAUGE Fuse Ignition Switch Body ECU Wire Harness POWER SEAT CONTROL SYSTEM (w/o Driving position memory driver’s seat): Symptom Suspect Area See page Power seat does not operate. (Door lock system does not operate) 1. DOOR Fuse 2. Wire Harness - Power seat does not operate. (Door lock system is normal) 1. Power Seat Swtich (D,P) 2. Wire Harness BE-105 - ”Slide operation” does not operate. 1. Power Seat Switch (D, P) 2. Slide Motor (D, P) 3. Wire Harness BE-16 BE-105 - ”Front vertical Operation” does not operate. 1. Power Seat Switch (D, P) 2. Front Vertical Motor (D, P) 3. Wire Harness BE-105 BE-105 - ”Rear vertical” does not operate. 1. Power Seat Switch 2. Rear Vertical Motor 3. Wire Harness BE-105 BE-105 - ”Reclining Operation” does not operate. 1. Power Seat Switch (D, P) 2. Reclining Motor (D, P) 3. Wire Harness BE-105 BE-105 - (D): Driver’s Seat (P): Passenger’s Seat 2001 AVALON (RM808U) Author
: Date
: 1611 BE-8 BODY ELECTRICAL - TROUBLESHOOTING POWER MIRROR CONTROL SYSTEM: This system uses the multiplex communication system, so check diagnosis system of the multiplex communication system before checking the body control system. ELECTRO CHROMIC MIRROR SYSTEM Symptom Electro Chromic Inner Mirror does not operate. Suspect Area See page 1. ECU-IG Fuse 2. Elector Chromic Inner Mirror 3. Wire Harness BE-120 SEAT HEATER SYSTEM: Symptom Suspect Area See page Seat heaters do not operate. (Driver’s and Passenger’s) 1. SEAT HEATER Fuse 2. Ignition Main Relay 3. Wire Harness BE-122 - Driver’s seat heater does not operate. 1. Seat Heater Switch (Driver’s) 2. Seat Heater 3. Wire Harness BE-122 BE-122 - Passenger’s seat heater does not operate. 1. Seat Heater Switch (Passenger’s) 2. Seat Heater 3. Wire Harness BE-122 BE-122 - Seat Heater temperature is too hot. 1. Seat Heater BE-122 GARAGE DOOR OPENER SYSTEM Symptom Suspect Area See page The equipment of which code has been registered does not operate. 1. Garage Door Opener 2. Wire Harness 3. * BE-170 LED does not light up. (Even though either switch is pressed.) 1. Garage Door Opener 2. Wire Harness BE-170 LED does not light up. (Only one switch is pressed.) 1. Garage Door Opener BE-170 * As the GARAGE DOOR OPENER on the vehicle side seems to be normal, check the OPENER on the equipment side, of which code has been registered. 2001 AVALON (RM808U) Author
: Date
: 1612 BE-29 BODY ELECTRICAL - TURN SIGNAL AND HAZARD WARNING SYSTEM BE0I1-04 INSPECTION Right Turn 1. INSPECT TURN SIGNAL SWITCH CONTINUITY Switch position Tester connection Left turn 1-2 Neutral - Right turn 2-3 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. Left Turn 8 7 6 5 4 3 2 1 17 16 15 141312 11 10 9 I12796 2. INSPECT HAZARD WARNING SWITCH CONTINUITY Condition Tester connection Specified condition OFF 5-7 Continuity ON 5 - 6, 1-2-3-4 Continuity Illumination circuit 8-9 Continuity If continuity is not as specified, replace the switch. I12792 3. (a) 3 2 (b) 1 INSPECT TURN SIGNAL FLASHER OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 3. Connect the 2 turn signal light bulbs parallel to each other to terminals 1 and 3, check that the bulbs flash. HINT:
BE1843

The turn signal lights should flash 60 or 120 times per minute. If one of the front or rear turn signal lights has an open circuit, the number of flashers will be more than 140 per minute. If operation is not as specified, replace the flasher. 2001 AVALON (RM808U) Author
: Date
: 1633 BE-28 BODY ELECTRICAL - TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL AND HAZARD WARNING SYSTEM BE0I0-04 LOCATION Engine Room Junction Block
HAZ Fuse Hazard Warning Switch Turn Signal Light Combination Switch
Turn Signal Switch Flasher Relay Driver Side Junction Block
TURN Fuse Turn Signal Light I12526 2001 AVALON (RM808U) Author
: Date
: 1632 BE-38 BODY ELECTRICAL - WIPER AND WASHER SYSTEM BE1DN-01 INSPECTION Washer ON 1. INSPECT WIPER AND WASHER SWITCH CONTINUITY Switch position Tester connection OFF 7 - 16 Continuity MIST (w/ Mist wiper) 3 - 11 Continuity INT (w/ Intermittent wiper) 7 - 16 Continuity LO 7 - 17 Continuity HI 8 - 17 Continuity Washer ON 2 - 11 Continuity OFF INT LO Specified condition If continuity is not as specified, replace the switch. HI 9 8 7 65 4 3 21 1817161514131211 10 I12797 7 2. (a) (b) (c) 2 (d) 16 INSPECT WIPER INTERMITTENT OPERATION Turn the wiper switch to INT position. Turn the intermittent time control switch to FAST position. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage. I01313 (e) 7 17 2 After connecting terminal 16 to terminal 17, connect to terminal 2 to terminal 17, check the voltage rises from 0 volts to battery positive voltage with in the times, as shown in the table. INT time control switch position Voltage Approx. 1 - 3 sec. 16 I01314 FAST Battery positive voltage 0 Volt Approx. 10 - 15 sec. SLOW Battery positive voltage 0 Volt If operation is not as specified, replace the wiper and washer switch. 2001 AVALON (RM808U) Author
: Date
: 1642 BE-39 BODY ELECTRICAL 7 3. (a) 2 (b) (c) - WIPER AND WASHER SYSTEM INSPECT WASHER LINKED OPERATION Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2. Push in the washer switch, and check that the voltage changes as shown in the table. 16 I01313 Washer Switch ON OFF Less than 1 sec. Approx. 3 sec. Battery positive voltage 0 Volt If operation is not as specified, replace the wiper and washer switch. 4. 5 4 Low speed: INSPECT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead from the battery to the motor body or terminal 4, and check that the motor operates at low speed. If operation is not as specified, replace the motor. I13330 5. 3 4 High speed: INSPECT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead from the battery to the motor body or terminal 4, and check that the motor operates at high speed. If operation is not as specified, replace the motor. I12831 2001 AVALON (RM808U) Author
: Date
: 1643 BE-40 BODY ELECTRICAL 6. 3 (a) 4 - WIPER AND WASHER SYSTEM Stopping at stop position: INSPECT WIPER MOTOR OPERATION Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 3. I12832 (b) (c) 2 5 1 4 Connect terminals 1 and 5. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead from the battery to the motor body or terminal 4, and check that the motor stops running at the stop position after the motor operates again. If operation is not as specified, replace the motor. I12833 7. INSPECT WASHER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, check that the motor operates. NOTICE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. 2 1 N13907 2001 AVALON (RM808U) Author
: Date
: 1644 BE-37 BODY ELECTRICAL - WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM BE0IA-03 LOCATION Wiper Motor Washer Tank
Washer Motor Combination Switch
Wiper and Washer Switch Driver Side Junction Block
WIP Fuse
IG1 Relay Ignition Switch I12530 2001 AVALON (RM808U) Author
: Date
: 1641 BE-91 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM BE2MA-01 INSPECTION 1. INSPECT WIRELESS DOOR LOCK DIAGNOSIS MODE (a) Start up diagnosis mode. HINT: Follow the method below. (1) Insert the ignition key into the ignition key cylinder. (2) Remove the ignition key from the ignition key cylinder. (3) Insert the key into the ignition switch. (4) Turn the ignition switch ON once within 5 sec. (5) Repeat turning the ignition switch OFF → ON 9 times within 30 sec. (6) Enter the diagnosis mode, and make sure that the buzzer sounds. Within. 5 sec. Within. 30 sec. Key Plate Inserted Key Plate Not Inserted 1 ON 2 3 9 10 OFF Once Nine times I20790 (b) Finishing the Diagnosis Mode. During the Diagnosis mode, turn the ignition switch OFF → ON to go back to the normal mode. At this time make sure that the buzzer sounds. 2001 AVALON (RM808U) Author
: Date
: 1695 BE-92 BODY ELECTRICAL (1) LOCK switch ON OFF 0.13 sec. 0.5 sec. (2) UNLOCK switch ON OFF 0.13 sec. 0.25 sec. 0.5 sec. (3) Luggage door switch ON OFF 0.5 sec. 0.5 sec. (4) Disagreement of recognition code or rolling code. ON OFF While receiving I20456 Dry cell battery (1.5 V x 2) Push I06938 - WIRELESS DOOR LOCK CONTROL SYSTEM (c) Diagnosis Mode Check. HINT: Check how the buzzer sounds when pressing each transmitter switch. (1) LOCK switch (2) UNLOCK switch (3) Luggage door switch (4) Disagreement of recognition code or rolling code. HINT: If (4) is detected in the Diagnosis Check, conduct the recognition code registration. (5) No response from the buzzer. HINT: Conduct the following checks.
Check the wireless door lock transmitter.
Check the wireless door lock receiver. 2. INSPECT WIRELESS DOOR LOCK TRANSMITTER OPERATION HINT: Refer to ”Wireless door lock control receiver and transmitter replacement”. (a) Using a screwdriver, remove the cover. (b) Remove the battery (lithium battery). (c) Install a new or normal battery (lithium battery). HINT: When a new or normal battery can not be obtained, connect 2 new 1.5 V batteries in series, connect the battery (+) to the battery receptacle side terminal and battery (-) to the bottom terminal, then apply 3 V voltage to the transmitter. (d) In the location where is approx. 1 M away from driver’s outside handle in the right direction, face the key plate of the transmitter to the vehicle, and check the transmitter operation when pressing transmission switch on the side of the transmitter body. Standard:
Remote control of vehicle door lock can be operated.
LED lights up more than once. HINT:
The minimum operation distance differs according to operator, the way of holding, and location.
As weak wave is used, operation distance might be shortened when noise is detected in strong wave or used frequency. 2001 AVALON (RM808U) Author
: Date
: 1696 BE-93 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM (e) Install the battery (lithium battery). 3. CHECK BATTERY CAPACITY HINT:
Make sure to use the TOYOTA electrical tester.
With the battery unloaded, judge can not be made whether the battery is available or not on the test.
When the transmitter is faulty, the energy amount left in the battery might not be checked correctly.
On the lithium battery used for the transmitter, the voltage more than 2.5 V with the battery unloaded is shown on the tester until the energy is completely consumed. Accordingly when inspecting the energy amount left in the battery, it is necessary to measure the voltage when the battery is loaded. (1.2 kΩ). (-) terminal (a) (b) (c) Remove the cover using a (-) driver. Remove the battery (lithium battery) from the transmitter. Connect the lead to the (-) terminal of the transmitter and install the battery. (d) Connect the (+) tester to the (+) battery (lithium battery), and (-) tester to the lead respectively. Press one of the transmitting switches on the transmitter for approx. 1 second. Press the transmitting switch on the transmitter again to check the voltage. Standard: 2.1 V or more I06939 (e) (f) (+) terminal I02935 2001 AVALON (RM808U) Author
: Date
: 1697 BE-94 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM HINT:


(g) (h) 4. N13470 2 When the temperature of the battery is low, the judge can not be made correctly. When the outcome of the test is less than 2.1 V, conduct the test again after leaving the battery in the place at 18 °C for more than 30 minutes. By auto power off function, the voltage becomes no load voltage (more than 2.5 V) condition 0.8 seconds after the switch was pressed. Make sure to read the voltage before of it. High voltage might be shown 1 to 2 times after leaving the battery, judge should be made with the voltage shown at the 3rd time or later. Disconnect the lead. Set the battery (lithium battery) in the transmitter. INSPECT WIRELESS DOOR LOCK CONTROL CANCEL SWITCH Switch position Tester connection OFF - ON 1-2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. If continuity is as specified, inspect the switch circuit. 5. INSPECT WIRELESS DOOR LOCK CONTROL CANCEL SWITCH CIRCUIT (See page DI-653 ) 6. INSPECT WIRELESS DOOR LOCK BUZZER OPERATION Connect the positive (+) lead from the ohmmeter to terminal 1 and the negative (-) lead to terminal 2, and buzzer sounds. If operation is not as specified, replace the buzzer. 7. INSPECT WIRELESS DOOR LOCK BUZZER CIRCUIT (See page DI-653 ) 1 I11597 2001 AVALON (RM808U) Author
: Date
: 1698 BE-95 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM 8. Connector disconnected: INSPECT WIRELESS DOOR LOCK CONTROL RECEIVER CIRCUIT Disconnect the connector from the receiver and inspect the connector on the wire harness side, as shown. Wire Harness Side I04152 Tester connection Condition Specified condition 1 - Ground Constant Continuity 7 - Ground Constant Battery positive voltage If the circuit is not as specified, inspect the circuit connected to other parts. 9. Connector connected: INSPECT WIRELESS DOOR LOCK CONTROL RECEIVER CIRCUIT Connect the wire harness side connector to the receiver and inspect the wire harness side connector from the back side, as shown. From Back Side I04153 Tester connection Condition Specified condition 3 - Ground Ignition switch position OFF Key removed Transmitter OFF → ON 4.5 - 5.5 V → below 1 V 4 - Ground Ignition switch position OFF Key removed Transmitter OFF 10 - 14 V If circuit is as specified, replace the receiver. If the circuit is not as specified, inspect the circuit connected to other parts. 2001 AVALON (RM808U) Author
: Date
: 1699 BE-89 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM BE1DZ-02 WIRELESS DOOR LOCK CONTROL SYSTEM LOCATION Engine Room Junction Block
Door No.2 Fuse Transmitter Front Door Lock Assembly Driver Side Junction Block
Door No.1 Fuse
Body ECU Wireless Door Lock Control Receiver Rear Door Lock Assembly I20800 2001 AVALON (RM808U) Author
: Date
: 1693 BE-90 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM BE217-01 PRE-CHECK 1. (a) (b) 2. (a) (b) CHARACTERS OF WIRELESS DOOR LOCK The operation distance changes according to how customers hold the transmitter or where it is used. Because of using the very weak radio wave, if there is a strong wave or noise on the frequency being used, the operation distance may become shorter. WIRELESS DOOR LOCK BASIC FUNCTION Stand on the driver’s side. Stay 1 m away from the vehicle. Turn the transmitter toward the vehicle and press any one of the transmission switched for 1 sec. 2001 AVALON (RM808U) Author
: Date
: 1694 BE-96 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM BE2M9-01 REPLACEMENT I06940 1. REPLACE TRANSMITTER (LITHIUM) BATTERY NOTICE: Special caution should be taken for handling each component as they are precision electronic components. (a) Using a screwdriver, remove the cover. NOTICE: Do not pry out the cover forcibly. HINT: Push the cover with a finger as shown in the illustration, so that there becomes clearance, then pry out the cover from that clearance. (b) Remove the transmitter. (c) Remove the battery (lithium battery). NOTICE:  Do not push the terminals with a finger.  If prying up the battery (lithium battery) forcibly to remove, the terminals are deformed. (d) Install a battery (lithium battery) as shown in the illustration. NOTICE: Face the battery upward. Take care not to deform the terminals. (e) Assemble the transmitter to the key plate and the cover. I06941 2001 AVALON (RM808U) Author
: Date
: 1700 BE-97 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM 2. REPLACE DOOR CONTROL RECEIVER AND TRANSMITTER NOTICE: When replacing the door control receiver and transmitter, registration of recognition code is necessary because they are provided as a single components. (a) Select the operation mode to perform from the following operation modes.  Add mode  Rewrite mode  Prohibition mode  Confirmation mode HINT:  The add mode is used to retain codes already registered while you register new recognition codes. This mode is used when adding a transmitter. However, if the number of registered codes exceeds 4 codes, previously registered codes are correspondingly erased in order, starting from the first registered code.  The rewrite mode is used to erase all previously registered codes and register only new recognition codes.  The prohibition mode is used to erase all registered codes and cancels the wireless door lock function. Use this mode when the transmitter is lost.  The confirmation mode is for confirming few many recognition codes ar already registered before you register additional recognition codes. (b) Follow the chart on the following page to register the transmitter recognition code at the wireless door lock control receiver. HINT:  When procedure is out of the specified, the operation returns to normal operation.  Maximum 4 recognition codes can be registered. 2001 AVALON (RM808U) Author
: Date
: 1701 BE-98 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM Start registration of recognition code The vehicle should be in the following conditions.
The key is not inserted in the ignition key cylinder.
Driver’s door is OPEN. (Other doors are CLOSED)
Driver’s door is UNLOCKED. (Other doors are CLOSED) Insert the key into the ignition key cylinder, then pull it out. Press the door lock control switch (for manual operation) 5 times to LOCK/UNLOCK at approx. 1 sec. interval. 1st time 2nd time 3rd time 4th time Within 40 secs. LOCK 5th time Approx. Approx. 1 sec. 1 sec. OFF UNLOCK Close the driver’s door, then open it. Again press the door lock control switch (for manual operation) 5 times to LOCK/UNLOCK at approx. 1 sec. interval. 1st time 2nd time 3rd time 4th time 5th time LOCK Within 40 secs. Approx. Approx. 1 sec. 1 sec. OFF UNLOCK Insert the key into the ignition key cylinder. 2001 AVALON (RM808U) Author
: Date
: 1702 BE-99 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM Turn the ignition switch from ON to LOCK at approx. 1 sec. interval 1 to 5 times to select the mode. Confirmation mode Add mode ON - LOCK change occurs 1 time ON - LOCK change occurs 3 times Approx. Approx. 1 sec. 1 sec. Approx. 1 sec. ON ON LOCK LOCK Prohibition mode Rewrite mode ON - LOCK change occurs 2 times ON - LOCK change occurs 5 times Approx. Approx. 1 sec. 1 sec. Approx. Approx. 1 sec. 1 sec. ON ON LOCK LOCK Pull out the key plate from the ignition key cylinder. When add mode or rewrite mode is selected. MPX body ECU automatically performs the LOCK-UNLOCK operation once or twice at 1 sec, interval to inform the operator that either the add mode or rewrite mode has been selected. LOCK-UNLOCK occurs once Within Indicates that add mode has been selected. 3 secs. 1 sec. LOCK UNLOCK When prohibition mode is selected. MPX body ECU automatically performs the LOCK-UNLOCK operation 1 to 4 times at 2 sec. interval to inform the operator of the number of the registered codes. HINT: When the number of the registered code is 0, the operation is automatically performed 5 times. Example: When the operation is performed twice, it directs that 2 type of recognition code have been registered. LOCK-UNLOCK occurs twice 1st time 2nd time Indicates that rewrite mode has been selected. 1 sec. 1 sec. LOCK When confirmation mode is selected. 2 secs. 2 secs. LOCK UNLOCK UNLOCK Registration of recognition code (Confirmation mode and probation mode) is completed. 2001 AVALON (RM808U) Author
: Date
: 1703 BE-100 BODY ELECTRICAL - WIRELESS DOOR LOCK CONTROL SYSTEM When prohibition mode is selected. Within 40 secs. MPX body performs operates LOCK-UNLOCK operation 5 times at a 1 sec. interval to inform the operator that prohibition mode has been selected. Approx. Approx. 1 sec. 1 sec. ON LOCK Press the lock and unlock switches on the transmitter simultaneously within 1.5 sec. Within 3 secs. Press again either of switches on the transmitter. MPX body ECU automatically performs LOCK-UNLOCK operation once or twice at a 1 sec. interval to inform the operator that it has received the signal from the transmitter. Within 3 secs. LOCK-UNLOCK occurs once Registration of recognition code is completed LOCK-UNLOCK occurs twice Registration of recognition code has not been completed.
Recognition code received first time and second time did not match. If they are not performed, the mode returns to the normal mode, then start with ”Start registration of recognition code”. Proceed to finish registration Proceed to continue registration Within 40 secs. If even one of the following conditions is satisfied, registration of recognition codes in completed.
40 secs. elapses since the MPX body ECU response.
The driver’s door is closed.
The key plate is inserted in the ignition key cylinder.
4 types recognition codes are registration at one time. Registration of recognition codes (add mode or rewrite mode) is completed. 2001 AVALON (RM808U) Author
: Date
: 1704 BO-43 BODY - BODY OUTSIDE MOULDING BODY OUTSIDE MOULDING BO0Y6-03 COMPONENTS Rear Door Outside Moulding Front Door Outside Moulding H12136 2001 AVALON (RM808U) Author
: Date
: 1828 BO-45 BODY - BODY OUTSIDE MOULDING BO0Y8-03 INSTALLATION 1. (a) CLEAN BODY MOUNTING SURFACE Using a heat light, heat the body mounting surface to 40 - 60 °C (104 - 140 °F). NOTICE: Do not heat the body excessively. (b) Remove the adhesive tape from the body. (c) Wipe off stains with cleaner. 2. CLEAN MOULDING If reusing moulding: (a) Using a heat light, heat the moulding to 20 - 30 °C (68 86 °F). NOTICE: Do not heat the moulding excessively. (b) Remove the adhesive tape from the moulding. (c) Wipe off stains with cleaner. (d) Apply a new adhesive tape to the moulding as shown in the illustration. Adhesive Tape Adhesive Tape Adhesive Tape Adhesive Tape H12138 3. (a) INSTALL MOULDING Using a heat light, heat the body and moulding. Body: 40 - 60 °C (104 - 140 °F) Moulding: 20 - 30 °C (68 - 86 °F) NOTICE: Do not heat the moulding excessively. (b) Lift the moulding release sheet from the face of moulding. NOTICE: When the moulding release sheet is removed, make sure that no dirt or dust can get onto the coated area. 2001 AVALON (RM808U) Author
: Date
: 1830 BO-46 BODY - BODY OUTSIDE MOULDING (c) Align the bosess with their corresponding holes in the body, and press firmly on the moulding. NOTICE: Do not apply excessive force onto the moulding, but steady pressure with your thumbs. BO5229 2001 AVALON (RM808U) Author
: Date
: 1831 BO-44 BODY - BODY OUTSIDE MOULDING BO0Y7-03 REMOVAL 1. HEAT MOULDING Using a heat light, heat the moulding to 40 - 60 °C (104 - 140 °F). NOTICE: Do not heat moulding excessively. 2. REMOVE OUTSIDE MOULDING (a) Tie both piano wire ends to wooden blocks or similar objects. (b) Cut the adhesive tape by pulling the piano wire as shown. NOTICE:
If reusing the moulding, take care not to damage the moulding.
Do not damage the body. (c) Remove the moulding. Protective Tape H00792 2001 AVALON (RM808U) Author
: Date
: 1829 BO-69 BODY - BACK WINDOW GLASS BACK WINDOW GLASS BO2PK-01 COMPONENTS w/ Rear personal light: Rear Personal Light RH Roof Side Inner Garnish
No. 1 Stopper
No. 2 Stopper Roof Headlining
No. 1 Stopper
No. 2 Stopper
Back Window Moulding Back Window Glass Rear Door Opening Trim w/o Speaker: High-mounted Stop Light w/ Speaker: High-mounted Stop Light LH Roof Side Inner Garnish Package Tray Trim Upper Back Silencer Rear Seatback Rear Seat Outer Belt RH Rear Seat Cushion 41 (420, 30) Rear Seat Inner with Center Belt 18 (185, 13) 18 (185, 13) Rear Seat Inner Belt 41 (420, 30) 41 (420, 30) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Rear Seat Outer Belt LH H12166 2001 AVALON (RM808U) Author
: Date
: 1854 BO-73 BODY - BACK WINDOW GLASS BO2PM-01 INSTALLATION Adhesive BO4420 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (a) Using a knife, cut away any rough areas on the body. HINT: Leave of the adhesive on the body as much as possible. (b) Clean the cut surface of the adhesive with a shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. (a) (b) CLEAN REMOVED GLASS Remove the damaged No. 2 stoppers. Using a scraper, remove the adhesive sticking to the glass. (c) Clean the glass with cleaner. NOTICE:
Be careful not to damage the glass.
Do not touch the glass face after cleaning it. BO5231 3. (a) (b) H10503 REPLACE NO. 1 STOPPERS Remove the damaged stoppers. Cut off the old adhesive around the stopper installation area. NOTICE: Be careful not to damage the body. (c) Clean the installation area. (d) Attach new stoppers to the body so that the notches on the body will align with the stoppers as shown in the illustration. HINT: Make sure that the stoppers are installed facing the correct direction. 4. INSTALL NEW NO. 2 STOPPERS Attach new stoppers to the glass so that the ceramic notches on the glass will align with the stoppers as shown in the illustration. A: 12 mm (0.47 in.) A Stopper H12165 2001 AVALON (RM808U) Author
: Date
: 1858 BO-74 BODY - BACK WINDOW GLASS 5. INSTALL NEW BACK WINDOW OUTSIDE MOULDING Install new back window outside moulding to the back window glass as shown in the illustration. HINT:
Install the back window outside moulding from the center of the glass at the lower side of the vehicle.
When installing the back window outside moulding, do not stretch it. Connected Portion H07649 6. (a) (b) (c) (d) POSITION GLASS Place the glass in the correct position. Check that all contacting parts of the glass rim are set perfectly even. Place reference marks on the glass and body. Remove the glass. H10504 7. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim. NOTICE: Do not touch the glass face after cleaning it. BO4421 8. Primer M Primer M Adhesive H02865 COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat Primer M to the exposed part of body on the vehicle side. NOTICE:
Allow 3 minutes or more dry the primer coated surface.
Do not coat Primer M to the adhesive.
Do not keep any of the opened Primer M for later use. 2001 AVALON (RM808U) Author
: Date
: 1859 BO-75 BODY - BACK WINDOW GLASS 9. a a b b b b a-a COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration. (b) When the primer is applied by mistake to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTICE:
Allow 3 minutes or more dry the primer coated surface.
Do not keep any of the opened Primer G for later use. b-b Primer G H10507 10. (a) a b a b HINT: After cutting off the tip, use all adhesive within the time described in the table below. b b a-a b-b A B APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent Temperature Tackfree time 35 °C (95 °F) 15 minutes 20 °C (68 °F) 100 minutes 5 °C (41 °F) 8 hours (b) (c) Load the cartridge into the sealer gun. Coat the glass with adhesive as shown in the illustration. A: 13.5 mm (0.531 in.) B: 8.0 mm (0.315 in.) 11. (a) INSTALL GLASS Position the glass so that the reference marks are lined up, and press in gently along the rim. A B Adhesive H07651 H10505 2001 AVALON (RM808U) Author
: Date
: 1860 BO-76 BODY - BACK WINDOW GLASS HINT: Confirm that the moulding is attached to the body panel as shown in the illustration. (b) Hold the back window glass in place securely with a protective tape or equivalent until the adhesive hardens. NOTICE: Take care not to drive the vehicle during the time described in the table below. H08966 Temperature Minimum time prior to driving the vehicle 35 °C (95 °F) 1.5 hours 20 °C (68 °F) 5 hours 5 °C (41 °F) 24 hours 12. INSPECT FOR LEAK AND REPAIR NOTICE: Conduct a leak test after hardening time has elapsed. 13. CONNECT DEFOGGER WIRE CONNECTOR 14. INSTALL ROOF HEADLINING 15. w/ Rear personal light: INSTALL REAR PERSONAL LIGHT 16. INSTALL UPPER BACK SILENCER 17. INSTALL PACKAGE TRAY TRIM 18. INSTALL HIGH-MOUNTED STOP LIGHT 19. INSTALL ROOF SIDE INNER GARNISH 20. INSTALL REAR SEAT (See page BO-123 ) 2001 AVALON (RM808U) Author
: Date
: 1861 BO-70 BODY - BACK WINDOW GLASS BO2PL-01 REMOVAL 1. REMOVE REAR SEAT (See page BO-120 ) 2. REMOVE ROOF SIDE INNER GARNISH (a) Using a screwdriver, remove the roof side inner garnish. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. :7 Clips H12128 3. REMOVE HIGH-MOUNTED STOP LIGHT Remove the high-mounted stop light as shown in the illustration, then disconnect the connector. w/o Speaker: w/ Speaker: 2 Clips H03125 H12122 H12806 4. REMOVE PACKAGE TRAY TRIM (a) Using a screwdriver, remove the 3 rear seat belt bezel. HINT: Tape the screwdriver tip before use. H07599 2001 AVALON (RM808U) Author
: Date
: 1855 BO-71 BODY - BACK WINDOW GLASS (b) 5. Remove the package tray trim as shown in the illustration. REMOVE UPPER BLACK SILENCER 6. w/ Rear personal light: REMOVE REAR PERSONAL LIGHT Using a screwdriver, remove the rear personal light, then disconnect the connector. 2 Clips H12124 Claw (a) HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. Claw H12161 7. REMOVE ROOF HEADLINING Disengage the 3 clips and remove the rear side of roof headlining. 8. DISCONNECT DEFOGGER WIRE CONNECTOR 3 Clips H12162 9. REMOVE BACK WINDOW MOULDING (a) Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. (b) Remove the remaining moulding. H08965 Protective Tape H10479 10. (a) REMOVE BACK WINDOW GLASS Insert a piano wire between body and glass and let it pass through. Tie both wire ends to wooden blocks or similar objects. (b) HINT: Apply protective tape to the outer surface to keep the surface from being scratched. NOTICE: When separating the glass, take care not to damage the paint and exterior. 2001 AVALON (RM808U) Author
: Date
: 1856 BO-72 BODY Protective Tape - BACK WINDOW GLASS (c) Cut the adhesive by pulling the piano wire around it. HINT: Cut the adhesive areas as shown in the illustration, leaving the adhesive where the stoppers are. H10480 (d) Let the piano wire pass as shown in the illustration, cut off the adhesive sticking to the stoppers. NOTICE: Do not damage the glass stoppers. H07610 (e) Disengage the stoppers, then remove the glass. NOTICE: Leave of the adhesive on the body as much as possible when cutting off the glass. H10413 2001 AVALON (RM808U) Author
: Date
: 1857 BO-1 BODY - CLIP CLIP BO0XH-02 REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the operation, always replace it with a new clip. Shape (Example) Removal/Installation Pliers Clip Remover Screwdriver Scraper V00005 2001 AVALON (RM808U) Author
: Date
: 1786 BO-2 BODY Shape (Example) - CLIP Removal/Installation Removal Removal Installation Installation V00012 2001 AVALON (RM808U) Author
: Date
: 1787 BO-4 BODY - FRONT BUMPER FRONT BUMPER BO0XJ-04 COMPONENTS Oil Cooler 11 (115, 8) Front Bumper Upper Reinforcement 5.4 (55, 48 in.·lbf) 11 (115, 8) RH Side Support RH No. 2 Extension Insert LH Side Support 11 (115, 8) Front Bumper Reinforcement LH No. 2 Extension Insert 13 (130, 9) 13 (130, 9) Front Bumper Energy Absorber 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) Front Bumper Cover w/o Fog light: RH Hole Cover 8.3 (85, 74 in.·lbf) w/o Fog light: LH Hole Cover w/ Fog light: RH Fog Light Assembly N·m (kgf·cm, ft·lbf) : Specified torque w/ Fog light: LH Fog Light Assembly H12099 2001 AVALON (RM808U) Author
: Date
: 1789 BO-14 BODY - FRONT DOOR BO2OQ-01 ADJUSTMENT SST 1. ADJUST DOOR IN FORWARD/REARWARD AND VERTICAL DIRECTIONS Using SST, loosen the body side hinge bolts to adjust. SST 09812-00010 Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) N01363 2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. HINT: Substitute the bolt with washer for the centering bolt. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) N01364 3. (a) (b) (c) ADJUST DOOR LOCK STRIKER Check that the door fit and door lock linkages are adjusted correctly. Loosen the striker mounting screws. Torque: 23 N·m (230 kgf·cm, 17 ft·lbf) Using a plastic hammer, tap the striker to adjust it. BO2556 2001 AVALON (RM808U) Author
: Date
: 1799 BO-8 BODY - FRONT DOOR FRONT DOOR BO2OO-01 COMPONENTS Outside Rear View Mirror Front Door Weatherstrip Door Lock Striker Door Glass Run Rear Lower Frame Lower Frame Bracket Garnish 23 (230, 17) 7.8 (80, 69 in.·lbf) 25 (260, 19) Door Hinge Door Glass 7.8 (80, 69 in.·lbf) Outside Handle Key Cylinder 5.4 (55, 48 in.·lbf) 25 (260, 19) Door Check Front Lower Frame 25 (260, 19) 5.4 (55, 48 in.·lbf) Door Speaker Board Front Door Outside Lower Moulding Door Lock Protector Door Lock Door Hinge Service Hole Cover Inside Handle 4.9 (50, 43 in.·lbf) 5.4 (55, 48 in.·lbf) Upper Armrest Base Panel Inside Handle Bezel Cover Front Door Belt Moulding Front Door Inner Weatherstrip x10 Door Trim 5.4 (55, 48 in.·lbf) Window Regulator Guide Assembly Power Window Switch x8 Front Door Armrest x4 Courtesy Light 5.4 (55, 48 in.·lbf) Window Regulator Motor N·m (kgf·cm, ft·lbf) : Specified torque
Precoated part No. 2 Service Hole Cover Front Door Trim Pocket H12112 2001 AVALON (RM808U) Author
: Date
: 1793 BO-9 BODY - FRONT DOOR BO2OP-01 DISASSEMBLY 1. REMOVE INSIDE HANDLE BEZEL (a) Using a screwdriver, remove the cover. HINT: Tape the screwdriver tip before use. (b) (c) Remove the screw. Using a screwdriver, remove the inside handle bezel as shown in the illustration. HINT: Tape the screwdriver tip before use. 2. REMOVE COURTESY LIGHT H04751 3. (a) H12102 REMOVE UPPER ARMREST BASE PANEL WITH POWER WINDOW SWITCH Using a screwdriver, remove the upper armrest base panel with power window switch. HINT: Tape the screwdriver tip before use. (b) Disconnect the connector. (c) Remove the 3 screws and power window switch from the upper armrest base panel. 4. REMOVE DOOR TRIM (a) Using a screwdriver, remove the 2 caps. HINT: Tape the screwdriver tip before use. (b) Remove the 6 screws and clip. (c) Pull the trim upward to remove it. H12103 (d) x10 x8 (e) (f) Using a screwdriver, remove the front door inner weatherstrip from the front door trim. Remove the 10 screws and front door armrest from the front door trim. Remove the 8 screws and front door trim pocket from the front door trim. H12137 2001 AVALON (RM808U) Author
: Date
: 1794 BO-10 BODY Clip H12104 - FRONT DOOR 5. REMOVE LOWER FRAME BRACKET GARNISH Using a screwdriver, remove the lower frame bracket as shown in the illustration. HINT: Tape the screwdriver tip before use. 6. REMOVE OUTSIDE REAR VIEW MIRROR Torque: 7.8 N·m (80 kgf·cm, 69 ft·lbf) 7. REMOVE DOOR SPEAKER BOARD 8. REMOVE INSIDE HANDLE (a) Remove the screw. (b) Slide the inside handle backward to remove it. (c) Disconnect the 2 cables from the inside handle as shown in the illustration. H06127 H12105 9. REMOVE SERVICE HOLE COVER (a) Using a clip remover, remove the grommets. (b) Remove the service hole cover. NOTICE: Do not tear the cover. HINT: At the time of reassembly, please refer to the following item. Bring out the 2 control cables and wire harness through the service hole cover. 10. (a) (b) (c) (d) REMOVE FRONT DOOR WEATHERSTRIP Using a clip remover, remove the clip. Remove the screw from the door check. Using a clip remover, remove the front door weatherstrip. Reinstall the screw to the door check. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) H12106 2001 AVALON (RM808U) Author
: Date
: 1795 BO-1 1 BODY 11. (a) (b) - FRONT DOOR REMOVE FRONT DOOR BELT MOULDING Apply protective tape to the outer surface as shown in the illustration, to keep the surface from being scratched. Using a moulding remover, remove the front door belt moulding. Protective Tape H12107 12. (a) H12108 REMOVE FRONT DOOR OUTSIDE LOWER MOULDING Using a drill of less than ø3.2 mm (0.126 in.), drill out the 3 rivet heads. HINT: Gently and vertically put the drill to the rivets, and cut the rivet flanges. CAUTION: Take care as the cut rivets are hot. NOTICE: Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself. (b) Using a clip remover, remove the clip. (c) Remove the front door outside lower moulding. (d) Using a vacuum cleaner, remove the drilled rivets and accociated metallic dust from the inside of door panel. HINT: At the time of reassembly, please refer to the following item. Using an air riveter with nose piece No. 1 or a hand riveter with nose piece No. 1 to install new 3 rivets to the front door outside lower moulding. NOTICE:
At the time of reassembly, please refer to the following items.
Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent. H02440 2001 AVALON (RM808U) Author
: Date
: 1796 BO-12 BODY
- FRONT DOOR Do not tilt the riveter disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly. H02441
H02442 H12109 Install the rivet while attaching materials, as they are not tightened firmly. 13. REMOVE NO. 2 SERVICE HOLE COVER Remove the window regulator connector clamp, 3 screws and No. 2 service hole cover. 14. REMOVE DOOR GLASS (a) Open the door glass until the bolts appear in the service hole. (b) Remove the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: Be careful not to drop the door glass. (c) Pull the door glass upward to remove it. 15. REMOVE DOOR GLASS RUN 16. REMOVE WINDOW REGULATOR ASSEMBLY (a) Disconnect the connector, then remove the bolt, 3 nuts and window regulator assembly. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) HINT: Remove the window regulator assembly through the service hole. (b) Using a torx driver, remove the 3 torx screws and window regulator motor from the window regulator guide assembly. HINT: At the time of reassembly, please refer to the following items.
Apply MP grease to the glass guide and rollers of window regulator assembly.
After installing the window regulator assembly, window regulator assembly need to be re-initialized. Refer to BE-80 . 17. REMOVE FRONT LOWER FRAME 18. REMOVE REAR LOWER FRAME 2001 AVALON (RM808U) Author
: Date
: 1797 BO-13 BODY 19. (a) (b) (c) - FRONT DOOR REMOVE DOOR LOCK Disconnect the 2 control links from the outside handle and door lock cylinder. Disconnect the connector. Remove the 3 torx screws, bolt and door lock. Torque: Bolt: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Screw: 4.9 N·m (50 kgf·cm, 43 in.·lbf) HINT: Remove the door lock through the service hole. HINT: At the time of reassembly, please refer to the following item. Apply adhesive to 3 screws. Part No. 08833-00070, THREE BOND 1324 or equivalent (d) Remove the 2 screws and door lock protector from the door lock. H12110 HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the sliding and rotating parts of the door lock. 20. REMOVE OUTSIDE HANDLE (a) Remove the 2 bolts and outside handle with key cylinder. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (b) Remove the bolt and key cylinder from the outside handle. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 2001 AVALON (RM808U) Author
: Date
: 1798 BO-15 BODY - FRONT DOOR BO2OR-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO-9 ). 2001 AVALON (RM808U) Author
: Date
: 1800 BO-1 11 BODY - FRONT SEAT (Manual Adjuster Type) FRONT SEAT (Manual Adjuster Type) BO2Q7-01 COMPONENTS Headrest Seatback Board Headrest Support Seatback Pad Seatback Cover Seat Cushion Cover Seatback Frame
Hog Ring Seat Cushion Pad
Hog Ring Seat Cushion Frame Front Seat Inner Belt 43 (440, 32) Seat Cushion Inner Cover Seat Cushion Shield Reclining Connecting Pipe 41 (420, 30) Seat Cushion Inside Cover Inner Track 37 (375, 27) 37 (375, 27) Outer Track 43 (440, 32) 37 (375, 27) Front Seat Cushion Shield Seat Track Cover 37 (375, 27) Spring Ring Reclining Adjuster Release Handle Seat Track Handle N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part w/ Vertical adjster: Vertical Adjuster Knob H12218 2001 AVALON (RM808U) Author
: Date
: 1896 BO-1 13 BODY - FRONT SEAT (Manual Adjuster Type) BO2Q9-01 DISASSEMBLY CAUTION:
When storing the seatback frame with the side airbag assembly, do not face down the airbag deployment side.
Never disassemble the side airbag assembly. 1. REMOVE HEADREST Seat Cushion Seatback Board A H12693 2. REMOVE SEATBACK BOARD Remove the seatback board. HINT: Insert your hand between the upper part of the seatback board and seat cushion, and press ”A” of the clips to remove the clips from the frame wire. 3. w/ Vertical adjuster: REMOVE VERTICAL ADJUSTER KNOB Using a screwdriver, remove the snap ring and vertical adjuster knob. HINT: Tape the screwdriver tip before use. 4. REMOVE RECLINING ADJUSTER RELEASE HANDLE 5. REMOVE FRONT SEAT CUSHION SHIELD Remove the screw and front seat cushion shield as shown in the illustration. H12212 6. REMOVE FRONT SEAT CUSHION INNER SHIELD Remove the 2 screws and front seat cushion inner shield as shown in the illustration. H12213 2001 AVALON (RM808U) Author
: Date
: 1898 BO-1 14 BODY 7. (a) - FRONT SEAT (Manual Adjuster Type) (b) 8. (a) (b) REMOVE FRONT SEAT INNER BELT Remove the front seat inner belt wire harness from the front seat cushion frame. Remove the bolt, washer and front seat inner belt. REMOVE SEATBACK COVER Remove the headrest supports. Remove the hog rings. (c) (d) (e) Disengage the hook as shown in the illustration. Remove the seatback cover with pad. Remove the seatback cover from the seatback pad. H12214 H12207 9. (a) H12215 REMOVE SEAT CUSHION COVER Remove the hog rings and side airbag assembly wire harness. (b) Remove the 4 bolts and seat cushion assembly. (c) Remove the seat cushion cover with pad from the seat cushion frame. (d) Remove the seat cushion cover from the seat cushion pad. 10. REMOVE SEATBACK FRAME 11. REMOVE RECLINING CONNECTING PIPE 12. REMOVE SEAT CUSHION INSIDE COVER (a) Remove the screws and seat cushion inside cover. (b) Employ the same manner described above to the other side. 13. REMOVE SEAT TRACK HANDLE Using a screwdriver, remove the seat track handle. HINT: Tape the screwdriver tip before use. H12216 14. (a) (b) w/ Vertical adjuster: DISASSEMBLE OUTER TRACK AND INNER TRACK Using a screwdriver, remove the E-ring. Disassemble the outer track and inner track. H12217 2001 AVALON (RM808U) Author
: Date
: 1899 BO-1 15 BODY - FRONT SEAT (Manual Adjuster Type) BO2QA-01 INSPECTION INSPECT RECLINING LOCK POSITION AND SLIDING LOCK POSITION SLIPPING OFF (a) When reclining the seat, inspect that the outer and inner recliners are released at the same time. HINT: When the reclining lock position slips off, disassemble the seat to adjust the position. (b) When sliding the seat, inspect that the outer and inner tracks are locked at the same time. HINT: When sliding lock positions slip off, loosen the bolts to adjust the position. 2001 AVALON (RM808U) Author
: Date
: 1900 BO-1 18 BODY - FRONT SEAT (Manual Adjuster Type) BO2QC-01 INSTALLATION INSTALL FRONT SEAT (a) Slide the front seat to the frontmost position. NOTICE: Make sure that the seat adjuster locks. (b) Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted frontmost positions will slip off. (c) Connect the airbag connector. (d) Tighten the bolts on the rear side temporarily, tighten them completely starting from the bolt on the inner side. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (e) Slide the seat to the rearmost position to install the bolts on the front side. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1903 BO-1 16 BODY - FRONT SEAT (Manual Adjuster Type) BO2QB-01 REASSEMBLY 1. 2. w/ Vertical adjuster: ASSEMBLE OUTER TRACK AND INNER TRACK INSTALL SEAT TRACK HANDLE 3. (a) (b) INSTALL SEAT CUSHION INSIDE COVER Install the seat cushion inside cover with the screw. Employ the same manner described above to the other side. 4. (a) (b) (c) INSTALL RECLINING CONNECTING PIPE Adjust the reclining lock positions of the seat adjusters. Slide the seat adjusters to the most front position. Place the adjusters on a spacer to adjust the seat rails in parallel and install the connecting pipe. H12216 H11197 HINT: When installing the connecting pipe while raising up the adjusters, the lock positions adjusted in 4-(a) may become detached. When this happens, a lock error will occur. 5. INSTALL SEATBACK FRAME Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 6. INSTALL SEAT CUSHION ASSEMBLY (a) Install the seat cushion cover to the seat cushion pad. (b) Install the seat cushion cover with pad to the seat cushion frame. (c) Install the seat cushion assembly to the seat adjuster with 4 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) (d) 7. (a) (b) (c) (d) (e) Install the side airbag assembly wire harness and new hog rings. INSTALL SEATBACK ASSEMBLY Install the seatback cover to the seatback pad. Install the seatback cover with pad to the seatback frame. Engage the hook as shown in the illustration. Install new hog rings. Install the headrest support. H12215 2001 AVALON (RM808U) Author
: Date
: 1901 BO-1 17 BODY 8. (a) (b) - FRONT SEAT (Manual Adjuster Type) INSTALL FRONT SEAT INNER BELT Install the front seat inner belt with bolt and washer. Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) Install the front seat inner belt wire harness to the seat cushion frame. H12214 9. INSTALL FRONT SEAT CUSHION INNER SHIELD Install the front seat cushion inner shield with the 2 screws as shown in the illustration. H12213 10. INSTALL FRONT SEAT CUSHION SHIELD Install the front cushion shield with the screw as shown in the illustration. 11. INSTALL RECLINING ADJUSTER RELEASE HANDLE 12. w/ Vertical adjuster: INSTALL VERTICAL ADJUSTER KNOB 13. INSTALL SEATBACK BOARD 14. INSTALL HEADREST H12212 2001 AVALON (RM808U) Author
: Date
: 1902 BO-1 12 BODY - FRONT SEAT (Manual Adjuster Type) BO2Q8-01 REMOVAL REMOVE FRONT SEAT (a) Using a screwdriver, remove the seat track covers. HINT: Tape the screwdriver tip before use. (b) Remove the 4 bolts. (c) Disconnect the connectors. NOTICE: When disconnecting the side airbag connector take care not to damage the airbag wire harness. (d) Remove the front seat. NOTICE: Be careful not to damage the body. 2001 AVALON (RM808U) Author
: Date
: 1897 BO-103 BODY - FRONT SEAT (Power Adjuster Type) FRONT SEAT (Power Adjuster Type) BO2Q2-01 COMPONENTS Headrest Separate type: Headrest Support
Hog Ring Seatback Cover Seatback Board Seatback Pad
Hog Ring Seatback Frame Seat Cushion Pad Seat Cushion Cover w/ Lumbar support: Lumbar Support Assembly w/ Power seat control: Power Seat Position Control Computer Seat Cushion Frame Seat Wire 18 (185, 13) 43 (440, 32) Seat Cushion Inner Shield 37 (375, 27) 41 (420, 30) Reclining Adjuster Inside Cover Seat Track Cover Front Seat Inner Belt 37 (375, 27) Power Seat Switch Seat Track Cover Sliding Motor w/ Lumbar support: Lumbar Support Switch Front Power Adjuster Shield Seat Cushion Shield Slide Motor 37 (375, 27) w/ 4 way-vertical: Front Vertical Motor N·m (kgf·cm, ft·lbf) : Specified torque Power Seat Switch Knob Rear Vertical Motor w/ Power seat control: Seat Memory Switch
Non-reusable part H12211 2001 AVALON (RM808U) Author
: Date
: 1888 BO-104 BODY - FRONT SEAT (Power Adjuster Type) Headrest Bench type:
Hog Ring Center Armrest Seatback Board Headrest Support 41 (420, 30)
Hog Ring Seatback Frame Seatback Pad Seatback Cover Seat Cushion Pad Seat Cushion Cover Seat Wire 18 (185, 13) Seat Cushion Frame 18 (185, 13) 18 (185, 13) 43 (440, 32) Seat Cushion Inner Shield w/ Power seat control: Power Seat Position Control Computer 37 (375, 27) 41 (420, 30) Front Seat Inner Belt Seat Track Cover Reclining Adjuster Inside Cover Seat Track Cover 37 (375, 27) 43 (440, 32) Seat Track Cover Reclining Motor Power Seat Switch Front Power Adjuster Shield Rear Vertical Motor Slide Motor Seat Cushion Shield 37 (375, 27) w/ 4 way-vertical: Front Vertical Motor 41 (420, 30) Power Seat Switch Knob N·m (kgf·cm, ft·lbf) : Specified torque w/ Power seat control: Seat Memory Switch
Non-reusable part H12210 2001 AVALON (RM808U) Author
: Date
: 1889 BO-106 BODY - FRONT SEAT (Power Adjuster Type) BO2Q4-01 DISASSEMBLY CAUTION:
When storing the seatback frame with the side airbag assembly, do not face down the airbag deployment side.
Never disassemble the side airbag assembly. 1. Bench type: Driver’s seat REMOVE CENTER ARMREST 2. REMOVE HEADREST 3. REMOVE SEATBACK BOARD Remove the seatback board. HINT: Insert your hand between the upper part of the seatback board and seat cushion, and press ”A” of the clips to remove the clips from the frame wire. A H12693 4. (a) H12203 REMOVE SEAT CUSHION SHIELD Using a screwdriver, remove the power seat switch knobs. HINT: Tape the screwdriver tip before use. (b) Remove the 5 screws. (c) Remove the seat cushion shield as shown in the illustration, then disconnect the connectors. (d) w/ Lumbar support: Remove the 2 screws and lumbar support switch from the seat cushion shield. (e) w/ Power seat control: Remove the 2 screws and seat memory switch from the seat cushion shield. 5. REMOVE SEAT CUSHION LOWER SHIELD Remove the screw and seat cushion lower shield as shown in the illustration. H12204 2001 AVALON (RM808U) Author
: Date
: 1891 BO-107 BODY 6. (a) (b) Bench type: 7. 8. (a) (b) - FRONT SEAT (Power Adjuster Type) REMOVE FRONT SEAT INNER BELT Disconnect the connector. Remove the connector, then remove the nut, washer and front seat inner belt. Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) REMOVE SEAT CUSHION INNER SHIELD REMOVE SEATBACK COVER Remove the headrest supports. Remove the hog rings. Separate type: H12205 H12206 H12660 (c) (d) (e) 9. 10. H12207 11. (a) (b) (c) (d) (e) 12. 13. Disengage the hook as shown in the illustration. Remove the seatback cover with pad. Remove the seatback cover from the seatback pad. REMOVE FRONT POWER ADJUSTER SHIELD Bench type: REMOVE FRONT SEAT CENTER BELT Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) REMOVE SEAT CUSHION COVER Remove the seat wire clamp from the seat cushion assembly. Separate type: Remove the 4 bolts and seat cushion assembly. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Bench type: Remove the 5 bolts and seat cushion assembly. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Remove the seat cushion cover with pad from the seat cushion frame. Remove the seat cushion cover from the seat cushion pad. REMOVE POWER SEAT SWITCH REMOVE SEAT WIRE 2001 AVALON (RM808U) Author
: Date
: 1892 BO-108 BODY LH side: Side Airbag Wire Harness RH side: - FRONT SEAT (Power Adjuster Type) 14. REMOVE RECLINING ADJUSTER INSIDE COVERS Remove the 4 screws and reclining adjuster inside covers. 15. REMOVE SEATBACK FRAME Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) 16. w/ Lumbar support: REMOVE LUMBAR SUPPORT ASSEMBLY Lumber Support Wire Harness H12208 17. (a) (b) 18. 19. 20. REMOVE SLIDE MOTOR Remove the 2 screws, then disconnect the drive cable. Remove the slide motor from the power seat adjuster. w/ 4 way-vertical: REMOVE FRONT VERTICAL MOTOR REMOVE REAR VERTICAL MOTOR REMOVE RECLINING MOTOR H12209 2001 AVALON (RM808U) Author
: Date
: 1893 BO-1 10 BODY - FRONT SEAT (Power Adjuster Type) BO2Q6-01 INSTALLATION Installation is in the reverse order of removal (See page BO-105 ). 2001 AVALON (RM808U) Author
: Date
: 1895 BO-109 BODY - FRONT SEAT (Power Adjuster Type) BO2Q5-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO-106 ). 2001 AVALON (RM808U) Author
: Date
: 1894 BO-105 BODY - FRONT SEAT (Power Adjuster Type) BO2Q3-01 REMOVAL REMOVE FRONT SEAT (a) Using a screwdriver, remove the seat track covers. HINT: Tape the screwdriver tip before use. (b) Remove the 4 bolts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (c) Disconnect the connectors. NOTICE: When disconnecting the side airbag connector take care not to damage the airbag wire harness. (d) Remove the front seat. NOTICE: Be careful not to damage the body. 2001 AVALON (RM808U) Author
: Date
: 1890 BO-41 BODY - FRONT WIPER AND WASHER BO2P5-01 ADJUSTMENT 2 - 2.5 mm (0.079 - 0.098 in.) 0.7 - 0.75 mm (0.028 - 0.030 in.) ADJUST WASHER NOZZLE Using a tool like the one shown in the illustration, change the direction of the nozzle hole to adjust the point where washer fluid hits the windshield. BE3367 2001 AVALON (RM808U) Author
: Date
: 1826 BO-38 BODY - FRONT WIPER AND WASHER FRONT WIPER AND WASHER BO2P2-01 COMPONENTS Wiper Arm 24 (248, 18) Hood To Cowl Top Seal Cowl Top Ventilator Louver Front Wiper Motor Hood Insulator 7.0 (71, 62 in.·lbf) x9 Front Wiper Link Window Washer Nozzle 7.5 (76, 66 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque H12135 2001 AVALON (RM808U) Author
: Date
: 1823 BO-40 BODY - FRONT WIPER AND WASHER BO2P4-01 2 Jet nozzle: INSPECTION B B A C D E B B 3 Jet nozzle: V W B I F G J B H K L O M N U S R H12132 H12133 P Q T H12807 INSPECT FRONT WASHER NOZZLE While operating the washer, check that both the point where the washer fluid from the upper nozzles hits the windshield, and the upsurge area are within the range indicated by the hatched line. A: 360 mm (14.17 in.) B: 150 mm (5.91 in.) C: 370 mm (14.57 in.) D: 190 mm (7.48 in.) E: 200 mm (7.87 in.) F: 220 mm (8.66 in.) G: 430 mm (16.93 in.) H: 265 mm (10.43 in.) I: 165 mm (6.50 in.) J: 35 mm (1.38 in.) K: 215 mm (8.46 in.) L: 180 mm (7.09 in.) M: 175 mm (6.89 in.) N: 265 mm (10.43 in.) O: 195 mm (7.68 in.) P: 40 mm (1.57 in.) Q: 230 mm (9.06 in.) R: 90 mm (3.54 in.) S: 270 mm (10.63 in.) T: 545 mm (21.46 in.) U: 505 mm (19.88 in.) V: 130 mm (5.12 in.) W: 350 mm (13.78 in.) 2001 AVALON (RM808U) Author
: Date
: 1825 BO-42 BODY - FRONT WIPER AND WASHER BO2P6-01 INSTALLATION 1. 2. 3. (a) (b) 4. (a) INSTALL WINDOW WASHER NOZZLES INSTALL HOOD INSULATOR INSTALL WIPER MOTOR Install the wiper motor to the wiper link with the 3 bolts. Torque: 7.5 kgf·cm (76 kgf·cm, 66 in.·lbf) Connect teh wiper link to the wiper motor. INSTALL FRONT WIPER MOTOR & LINK ASSEMBLY Place the front wiper motor & link assembly into the cowl panel. HINT: Snow clutch should be in the normal condition. If snow clutch position is changed into the winter condition, rechange it into the normal condition. (b) 3 2 4 (c) 1 H12130 5. 6. 7. (a) (b) (c) C (d) A B (e) B Set the front wiper motor & link assembly aligning the installation holes and tighten the bolts in the order shown in the illustration. Torque: 7.0 kgf·cm (71 kgf·cm, 62 in.·lbf) Install the wire harness clamp, then connect the connector. INSTALL COWL TOP VENTILATOR LOUVER INSTALL HOOD TO COWL TOP SEAL INSTALL WIPER ARMS Operate the wiper motor once and turn the wiper switch OFF. Install the wiper arms and tighten nuts by hand. Adjust the installation position of the wiper arms to the position as shown in the illustration. A: 52 mm (2.05 in.) B: 30 ± 10 mm (1.18 ± 0.39 in.) C: 21.3 mm (0.839 in.) Torque the 2 nuts. Torque: 24 kgf·cm (248 kgf·cm, 18 ft·lbf) Install the 2 wiper arm head caps. H12134 2001 AVALON (RM808U) Author
: Date
: 1827 BO-39 BODY - FRONT WIPER AND WASHER BO2P3-01 REMOVAL 1. REMOVE WIPER ARMS 2. REMOVE HOOD TO COWL TOP SEAL NOTICE: Do not strongly pull off the hood to cowl top seal as it may tear. 3. (a) (b) REMOVE COWL TOP VENTILATOR LOUVER Using a clip remover, remove the 2 clips. Remove the cowl top ventilator louver as shown in the illustration. 4. (a) (b) 5. (a) REMOVE FRONT WIPER MOTOR & LINK ASSEMBLY Disconnect the connector, then remove the wire harness. Remove the 4 bolts and front wiper motor & link assembly. REMOVE WIPER MOTOR Using a screwdriver, disconnect the wiper link from the wiper motor. H12129 H12130 HINT: Tape the screwdriver tip before use. (b) Remove the 3 bolts and motor from the wiper link assembly. 6. REMOVE WINDOW WASHER NOZZLE (a) Remove the 9 clips and hood insulator. (b) Using a screwdriver, remove the window washer nozzle. HINT: Tape the screwdriver tip before use. (c) Employ the same manner described above to the other side. H12131 2001 AVALON (RM808U) Author
: Date
: 1824 BO-6 BODY - HOOD HOOD BO0XL-03 ADJUSTMENT Centering Bolt Bolt with Washer HINT: Since the centering bolt is used as a hood hinge and lock set bolt, the hood and lock cannot be adjusted with it on. Substitute the bolt with washer for the centering bolts. BO5235 1. ADJUST HOOD IN FORWARD/REARWARD AND LEFT/RIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge bolts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) H10149 2. ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTION Adjust the hood by turning the cushions. N01360 3. ADJUST HOOD LOCK Adjust the lock by loosening the 2 bolts and nut. Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf) H10148 2001 AVALON (RM808U) Author
: Date
: 1791 BO-7 BODY - HOOD SUPPORT HOOD SUPPORT BO0XM-03 REPLACEMENT 1. REMOVE SUPPORT FROM HOOD Remove the bolt and support from the hood. HINT: While supporting the hood by hand, remove the support. 2. REMOVE SUPPORT FROM BODY Remove the bolt and support. 150 mm (5.91 in.) H12101 3. IF NECESSARY, REPLACE HOOD SUPPORT NOTICE: Handling the hood support
Do not disassemble the support because the cylinder is filled with pressurized gas.
If the support is to be replaced, drill a 2.0 - 3.0 mm (0.079 - 0.118 in.) hole in the area shown in the illustration to completely discharge the high-pressure gas before disposing of it.
When drilling, chips may fly out so work carefully.
The gas is colorless, odorless and non-toxic.
When working, handle the support carefully. Never score or scratch the exposed part of the piston rod, and allow any paint or oil to get on it.
Do not turn the piston rod and cylinder with the support fully extended. 4. INSTALL HOOD SUPPORT (a) Install the bolt and hood support to the body. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) (b) Install the bolts and hood support to the hood. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1792 BO-87 BODY - INSTRUMENT PANEL INSTRUMENT PANEL BO2PU-02 COMPONENTS K K Instrument Panel Reinforcement A A Front Pillar Garnish No. 2 Instrument Panel to Cowl Brace K K K Upper Cluster Finish Panel K No. 1 Heater to Register Duct N Front Pillar Garnish K K Instrument Panel Safety Pad K K Speaker Opening Cover Assembly B Glove Compartment Door Finish Plate 20 (204, 15) Instrument Panel K to Cowl Brace K B Multi Information Display H H L Lower Cluster Finish Panel H H C C C C No. 1 Lower Panel I E Steering Column Cover H Column shift: Lower Cover I I I E I Radio Assembly with Heater Control Assembly End Finish Panel LH Register No. 2 Heater to Register Duct No. 1 Register Floor shift: Cup Holder LH Lower Insert Cluster Finish Panel H Combination Meter Speaker Opening Cover Assembly Lower Panel TAIWAN: Center Cluster Finish Panel No. 2 Under Cover Floor shift: Front Ash Receptacle Column shift: Front Ash Receptacle J J J J G Lower Finish G G Panel G H G Hood Lock G G Release Lever G Column shift: Finish Panel Floor shift: Front Console Box TAIWAN: Opening Covers with Heater Control Assembly Console Box Hole Cover Floor shift: Upper Console Panel H Floor shift: Console Box Plate G G 50 (510, 37) Combination Switch Steering Wheel Floor shift: Under Rear Console Panel Steering Wheel Pad D D D Floor shift: Rear Console Box N·m (kgf·cm, ft·lbf) : Specified torque H12194 2001 AVALON (RM808U) Author
: Date
: 1872 BO-88 BODY - INSTRUMENT PANEL Instrument Panel Wire Harness No. 1 Defroster Nozzle Garnish J J Defroster Nozzle No. 2 Side defroster Nozzle Duct J No. 5 Heater to Register Duct No. 4 Heater to Register Duct J J J J No. 1 Side Defroster Nozzle Duct No. 2 Meter Hood Set Bracket J J J No. 3 Meter Hood Set Bracket J J J No. 4 Meter Hood Set Bracket J J J No. 1 Instrument Panel Pin J No. 1 Meter Hood Set Bracket J Side Defroster Nozzle No. 1 Instrument Panel Pin M M M M M M Side Defroster Nozzle No. 3 Register J J Instrument Panel Safety Pad Front Passenger Airbag Assembly N N J J J J F No. 1 Instrument Panel Center Bracket No. 1 Instrument Panel Safety Pad H12195 2001 AVALON (RM808U) Author
: Date
: 1873 BO-89 BODY - INSTRUMENT PANEL HINT: Screw shapes and sizes are indicated in the table below. The codes (”A” - ”N”) correspond to those indicated on the previous page. mm (in.) Shape Size Shape Size Shape Size ø=8 (0.31) ø=6 (0.24) ø=6 (0.24) L = 20 (0.79) L = 20 (0.79) L = 20 (0.79) ø=6 (0.24) L = 16 (0.63) ø=6 (0.24) L = 18 (0.71) ø=6 (0.24) L = 16 (0.63) ø = 5.22 (0.2055) ø = 5.22 (0.2055) ø=5 (0.20) L = 20 (0.79) L = 16 (0.63) L = 16 (0.63) ø=8 (0.31) ø=6 (0.24) ø=5 (0.20) L = 14 (0.55) ø=6 (0.24) ø=6 (0.24) H12196 2001 AVALON (RM808U) Author
: Date
: 1874 BO-95 BODY - INSTRUMENT PANEL BO2PW-01 DISASSEMBLY 3 Clips H12191 H11898 1. REMOVE NO. 1 INSTRUMENT PANEL (a) Remove the 3 screws. (b) Using a screwdriver, remove the No.1 instrument panel. HINT: Tape the screwdriver tip before use. 2. REMOVE SIDE DEFROSTER NOZZLES 3. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH 4. REMOVE NO. 1 INSTRUMENT PANEL PINS 5. REMOVE NO. 1 SIDE DEFROSTER NOZZLE DUCT 6. REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT 7. REMOVE DEFROSTER NOZZLE 8. REMOVE NO. 5 HEATER TO REGISTER DUCT 9. REMOVE NO. 4 HEATER TO REGISTER DUCT 10. REMOVE METER HOOD SET BRACKETS 11. REMOVE CENTER BRACKET 12. REMOVE INSTRUMENT PANEL WIRE HARNESS 13. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY Remove the 6 nuts and front passenger airbag assembly as shown in the illustration. CAUTION:
Do not store the front passenger airbag assembly with the airbag deployment side facing down.
Never disassemble the front passenger airbag assembly. NOTICE: When removing the front passenger airbag assembly, take care not to damage the wire harness. 14. REMOVE NO. 1 INSTRUMENT PANEL SAFETY PAD 15. REMOVE NO. 3 REGISTER 2001 AVALON (RM808U) Author
: Date
: 1880 BO-97 BODY - INSTRUMENT PANEL BO2PY-01 INSTALLATION Installation is in the reverse order of removal (See page BO-90 ). 2001 AVALON (RM808U) Author
: Date
: 1882 BO-96 BODY - INSTRUMENT PANEL BO2PX-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO-95 ). 2001 AVALON (RM808U) Author
: Date
: 1881 BO-90 BODY - INSTRUMENT PANEL BO2PV-01 REMOVAL 1. 2. 3. 4. 5. REMOVE FRONT SEATS (See page BO-105 or BO-1 12) REMOVE FRONT DOOR WEATHERSTRIPS REMOVE FRONT PILLAR GARNISHES REMOVE STEERING WHEEL PAD (See page SR-12 ) REMOVE COLUMN COVERS 6. REMOVE LOWER FINISH PANEL Using a screwdriver, remove the lower finish panel. HINT: Tape the screwdriver tip before use. 2 Clips H12176 7. REMOVE NO. 1 LOWER PANEL (a) Remove the 2 screws and hood lock release lever. (b) Using a screwdriver, remove the No. 1 lower panel. HINT: Tape the screwdriver tip before use. 8. REMOVE LH LOWER INSERT 9. REMOVE NO. 2 HEATER TO REGISTER DUCT Remove the 2 clips and heater to register duct. 4 Clips H12177 10. REMOVE NO. 1 REGISTER Using a screwdriver, remove the No. 1 register, then disconnect the connectors. HINT: Tape the screwdriver tip before use. 11. REMOVE STEERING COLUMN (See page SR-12 ) 12. REMOVE NO. 2 UNDER COVER 4 Clips H12178 13. (a) DISCONNECT AIRBAG CONNECTOR Using a screwdriver, pry out the glove compartment door finish plate inside the lower panel. HINT: Tape the screwdriver tip before use. (b) Remove the connector from the the glove compartment door finish plate. (c) Disconnect the airbag connector. H12181 2001 AVALON (RM808U) Author
: Date
: 1875 BO-91 BODY - INSTRUMENT PANEL NOTICE: When disconnecting the airbag connector, take care not to damage the airbag wire harness. 14. (a) (b) 2 Clips REMOVE LOWER PANEL Remove the 5 screws. Using a screwdriver, remove the lower panel, then disconnect the connector. HINT: Tape the screwdriver tip before use. H12179 15. REMOVE LH REGISTER Using a screwdriver, remove the LH register, then disconnect the connector. HINT: Tape the screwdriver tip before use. 3 Clips H12180 16. 2 ClipsH12182 6 Clips Floor shift: REMOVE UPPER REAR CONSOLE PANEL Using a screwdriver, remove the upper rear console panel. HINT: Tape the screwdriver tip before use. 17. Floor shift: REMOVE FRONT ASH RECEPTACLE HINT: Do not pull the front ash receptacle door when removing the front ash receptacle. 18. Floor shift: REMOVE UPPER CONSOLE PANEL (a) Remove the 2 screws. (b) Using a screwdriver, remove the upper console panel. HINT: Tape the screwdriver tip before use. H12183 2001 AVALON (RM808U) Author
: Date
: 1876 BO-92 BODY 19. 20. (a) (b) - INSTRUMENT PANEL Floor shift: REMOVE CUP HOLDER Floor shift: REMOVE REAR CONSOLE BOX Remove the console box plate. Remove the 2 screws, 3 bolts and rear console box, then disconnect the connector. 21. H12700 Floor shift: REMOVE CONSOLE BOX HOLE COVER Using a screwdriver, remove the console box hole cover. HINT: Tape the screwdriver tip before use. 22. Floor shift: REMOVE RADIO ASSEMBLY WITH HEATER CONTROL ASSEMBLY (a) Except TAIWAN: Remove the 4 bolts and radio assembly with heater control assembly, then disconnect the connectors. (b) TAIWAN: Using a screwdriver, remove the center cluster finish panel. HINT: Tape the screwdriver tip before use. (c) TAIWAN: Remove the 4 bolts and opening covers with heater control assembly, then disconnect the connectors. 4 Clips H12184 23. Floor shift: REMOVE FRONT CONSOLE BOX Remove the 6 screws. Using a screwdriver, remove the front console box. (a) (b) HINT: Tape the screwdriver tip before use. 2 Clips H12185 2001 AVALON (RM808U) Author
: Date
: 1877 BO-93 BODY - INSTRUMENT PANEL 24. Column shift: REMOVE LOWER COVER Using a screwdriver, remove the lower cover. HINT: Tape the screwdriver tip before use. 2 Clips H12186 25. (a) (b) 4 Clips H12187 2 Clips Column shift: REMOVE FINISH PANEL Remove the 4 screws and 2 clips. Using a screwdriver, remove the finish panel, then disconnect the connector. HINT: Tape the screwdriver tip before use. (c) Remove the 4 screws and front ash receptacle. 26. Column shift: REMOVE RADIO ASSEMBLY WITH HEATER CONTROL ASSEMBLY Remove the 4 bolts and radio assembly with heater control assembly. 27. (a) REMOVE SPEAKER OPENING COVER ASSEMBLY Using a screwdriver, remove the speaker opening cover assembly, then disconnect the connector. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. H12188 28. REMOVE UPPER CLUSTER FINISH PANEL Using a screwdriver, remove the upper cluster finish panel. HINT: Tape the screwdriver tip before use. H12189 2001 AVALON (RM808U) Author
: Date
: 1878 BO-94 BODY - INSTRUMENT PANEL 29. REMOVE LOWER CLUSTER FINISH PANEL Using a screwdriver, remove the lower cluster finish panel. HINT: Tape the screwdriver tip before use. 7 Clips H12190 30. REMOVE CLUSTER FINISH PANEL (a) Remove the 2 screws. (b) Using a screwdriver, remove the cluster finish panel. HINT: Tape the screwdriver tip before use. 31. REMOVE END FINISH PANEL 32. REMOVE MULTI INFORMATION DISPLAY 33. REMOVE COMBINATION METER 2 Clips H12192 34. (a) H12193 (b) (c) (d) (e) 35. 36. 37. 38. REMOVE INSTRUMENT PANEL SAFETY PAD Remove the 2 bolts from the passenger airbag assembly. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) Remove the 6 bolts and nut. Disconnect the connectors. Remove the bolts and ground terminals. Remove the instrument panel safety pad. REMOVE INSTRUMENT PANEL TO COWL BRACE REMOVE NO. 2 INSTRUMENT PANEL TO COWL BRACE REMOVE NO. 1 HEATER TO REGISTER DUCT REMOVE INSTRUMENT PANEL REINFORCEMENT 2001 AVALON (RM808U) Author
: Date
: 1879 BO-87 BODY - INSTRUMENT PANEL INSTRUMENT PANEL BO2PU-02 COMPONENTS K K Instrument Panel Reinforcement A A Front Pillar Garnish No. 2 Instrument Panel to Cowl Brace K K K Upper Cluster Finish Panel K No. 1 Heater to Register Duct N Front Pillar Garnish K K Instrument Panel Safety Pad K K Speaker Opening Cover Assembly B Glove Compartment Door Finish Plate 20 (204, 15) Instrument Panel K to Cowl Brace K B Multi Information Display H H L Lower Cluster Finish Panel H H C C C C No. 1 Lower Panel I E Steering Column Cover H Column shift: Lower Cover I I I E I Radio Assembly with Heater Control Assembly End Finish Panel LH Register No. 2 Heater to Register Duct No. 1 Register Floor shift: Cup Holder LH Lower Insert Cluster Finish Panel H Combination Meter Speaker Opening Cover Assembly Lower Panel TAIWAN: Center Cluster Finish Panel No. 2 Under Cover Floor shift: Front Ash Receptacle Column shift: Front Ash Receptacle J J J J G Lower Finish G G Panel G H G Hood Lock G G Release Lever G Column shift: Finish Panel Floor shift: Front Console Box TAIWAN: Opening Covers with Heater Control Assembly Console Box Hole Cover Floor shift: Upper Console Panel H Floor shift: Console Box Plate G G 50 (510, 37) Combination Switch Steering Wheel Floor shift: Under Rear Console Panel Steering Wheel Pad D D D Floor shift: Rear Console Box N·m (kgf·cm, ft·lbf) : Specified torque H12194 2001 AVALON (RM808U) Author
: Date
: 1872 BO-88 BODY - INSTRUMENT PANEL Instrument Panel Wire Harness No. 1 Defroster Nozzle Garnish J J Defroster Nozzle No. 2 Side defroster Nozzle Duct J No. 5 Heater to Register Duct No. 4 Heater to Register Duct J J J J No. 1 Side Defroster Nozzle Duct No. 2 Meter Hood Set Bracket J J J No. 3 Meter Hood Set Bracket J J J No. 4 Meter Hood Set Bracket J J J No. 1 Instrument Panel Pin J No. 1 Meter Hood Set Bracket J Side Defroster Nozzle No. 1 Instrument Panel Pin M M M M M M Side Defroster Nozzle No. 3 Register J J Instrument Panel Safety Pad Front Passenger Airbag Assembly N N J J J J F No. 1 Instrument Panel Center Bracket No. 1 Instrument Panel Safety Pad H12195 2001 AVALON (RM808U) Author
: Date
: 1873 BO-89 BODY - INSTRUMENT PANEL HINT: Screw shapes and sizes are indicated in the table below. The codes (”A” - ”N”) correspond to those indicated on the previous page. mm (in.) Shape Size Shape Size Shape Size ø=8 (0.31) ø=6 (0.24) ø=6 (0.24) L = 20 (0.79) L = 20 (0.79) L = 20 (0.79) ø=6 (0.24) L = 16 (0.63) ø=6 (0.24) L = 18 (0.71) ø=6 (0.24) L = 16 (0.63) ø = 5.22 (0.2055) ø = 5.22 (0.2055) ø=5 (0.20) L = 20 (0.79) L = 16 (0.63) L = 16 (0.63) ø=8 (0.31) ø=6 (0.24) ø=5 (0.20) L = 14 (0.55) ø=6 (0.24) ø=6 (0.24) H12196 2001 AVALON (RM808U) Author
: Date
: 1874 BO-95 BODY - INSTRUMENT PANEL BO2PW-01 DISASSEMBLY 3 Clips H12191 H11898 1. REMOVE NO. 1 INSTRUMENT PANEL (a) Remove the 3 screws. (b) Using a screwdriver, remove the No.1 instrument panel. HINT: Tape the screwdriver tip before use. 2. REMOVE SIDE DEFROSTER NOZZLES 3. REMOVE NO. 1 DEFROSTER NOZZLE GARNISH 4. REMOVE NO. 1 INSTRUMENT PANEL PINS 5. REMOVE NO. 1 SIDE DEFROSTER NOZZLE DUCT 6. REMOVE NO. 2 SIDE DEFROSTER NOZZLE DUCT 7. REMOVE DEFROSTER NOZZLE 8. REMOVE NO. 5 HEATER TO REGISTER DUCT 9. REMOVE NO. 4 HEATER TO REGISTER DUCT 10. REMOVE METER HOOD SET BRACKETS 11. REMOVE CENTER BRACKET 12. REMOVE INSTRUMENT PANEL WIRE HARNESS 13. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY Remove the 6 nuts and front passenger airbag assembly as shown in the illustration. CAUTION:
Do not store the front passenger airbag assembly with the airbag deployment side facing down.
Never disassemble the front passenger airbag assembly. NOTICE: When removing the front passenger airbag assembly, take care not to damage the wire harness. 14. REMOVE NO. 1 INSTRUMENT PANEL SAFETY PAD 15. REMOVE NO. 3 REGISTER 2001 AVALON (RM808U) Author
: Date
: 1880 BO-97 BODY - INSTRUMENT PANEL BO2PY-01 INSTALLATION Installation is in the reverse order of removal (See page BO-90 ). 2001 AVALON (RM808U) Author
: Date
: 1882 BO-96 BODY - INSTRUMENT PANEL BO2PX-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO-95 ). 2001 AVALON (RM808U) Author
: Date
: 1881 BO-90 BODY - INSTRUMENT PANEL BO2PV-01 REMOVAL 1. 2. 3. 4. 5. REMOVE FRONT SEATS (See page BO-105 or BO-1 12) REMOVE FRONT DOOR WEATHERSTRIPS REMOVE FRONT PILLAR GARNISHES REMOVE STEERING WHEEL PAD (See page SR-12 ) REMOVE COLUMN COVERS 6. REMOVE LOWER FINISH PANEL Using a screwdriver, remove the lower finish panel. HINT: Tape the screwdriver tip before use. 2 Clips H12176 7. REMOVE NO. 1 LOWER PANEL (a) Remove the 2 screws and hood lock release lever. (b) Using a screwdriver, remove the No. 1 lower panel. HINT: Tape the screwdriver tip before use. 8. REMOVE LH LOWER INSERT 9. REMOVE NO. 2 HEATER TO REGISTER DUCT Remove the 2 clips and heater to register duct. 4 Clips H12177 10. REMOVE NO. 1 REGISTER Using a screwdriver, remove the No. 1 register, then disconnect the connectors. HINT: Tape the screwdriver tip before use. 11. REMOVE STEERING COLUMN (See page SR-12 ) 12. REMOVE NO. 2 UNDER COVER 4 Clips H12178 13. (a) DISCONNECT AIRBAG CONNECTOR Using a screwdriver, pry out the glove compartment door finish plate inside the lower panel. HINT: Tape the screwdriver tip before use. (b) Remove the connector from the the glove compartment door finish plate. (c) Disconnect the airbag connector. H12181 2001 AVALON (RM808U) Author
: Date
: 1875 BO-91 BODY - INSTRUMENT PANEL NOTICE: When disconnecting the airbag connector, take care not to damage the airbag wire harness. 14. (a) (b) 2 Clips REMOVE LOWER PANEL Remove the 5 screws. Using a screwdriver, remove the lower panel, then disconnect the connector. HINT: Tape the screwdriver tip before use. H12179 15. REMOVE LH REGISTER Using a screwdriver, remove the LH register, then disconnect the connector. HINT: Tape the screwdriver tip before use. 3 Clips H12180 16. 2 ClipsH12182 6 Clips Floor shift: REMOVE UPPER REAR CONSOLE PANEL Using a screwdriver, remove the upper rear console panel. HINT: Tape the screwdriver tip before use. 17. Floor shift: REMOVE FRONT ASH RECEPTACLE HINT: Do not pull the front ash receptacle door when removing the front ash receptacle. 18. Floor shift: REMOVE UPPER CONSOLE PANEL (a) Remove the 2 screws. (b) Using a screwdriver, remove the upper console panel. HINT: Tape the screwdriver tip before use. H12183 2001 AVALON (RM808U) Author
: Date
: 1876 BO-92 BODY 19. 20. (a) (b) - INSTRUMENT PANEL Floor shift: REMOVE CUP HOLDER Floor shift: REMOVE REAR CONSOLE BOX Remove the console box plate. Remove the 2 screws, 3 bolts and rear console box, then disconnect the connector. 21. H12700 Floor shift: REMOVE CONSOLE BOX HOLE COVER Using a screwdriver, remove the console box hole cover. HINT: Tape the screwdriver tip before use. 22. Floor shift: REMOVE RADIO ASSEMBLY WITH HEATER CONTROL ASSEMBLY (a) Except TAIWAN: Remove the 4 bolts and radio assembly with heater control assembly, then disconnect the connectors. (b) TAIWAN: Using a screwdriver, remove the center cluster finish panel. HINT: Tape the screwdriver tip before use. (c) TAIWAN: Remove the 4 bolts and opening covers with heater control assembly, then disconnect the connectors. 4 Clips H12184 23. Floor shift: REMOVE FRONT CONSOLE BOX Remove the 6 screws. Using a screwdriver, remove the front console box. (a) (b) HINT: Tape the screwdriver tip before use. 2 Clips H12185 2001 AVALON (RM808U) Author
: Date
: 1877 BO-93 BODY - INSTRUMENT PANEL 24. Column shift: REMOVE LOWER COVER Using a screwdriver, remove the lower cover. HINT: Tape the screwdriver tip before use. 2 Clips H12186 25. (a) (b) 4 Clips H12187 2 Clips Column shift: REMOVE FINISH PANEL Remove the 4 screws and 2 clips. Using a screwdriver, remove the finish panel, then disconnect the connector. HINT: Tape the screwdriver tip before use. (c) Remove the 4 screws and front ash receptacle. 26. Column shift: REMOVE RADIO ASSEMBLY WITH HEATER CONTROL ASSEMBLY Remove the 4 bolts and radio assembly with heater control assembly. 27. (a) REMOVE SPEAKER OPENING COVER ASSEMBLY Using a screwdriver, remove the speaker opening cover assembly, then disconnect the connector. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. H12188 28. REMOVE UPPER CLUSTER FINISH PANEL Using a screwdriver, remove the upper cluster finish panel. HINT: Tape the screwdriver tip before use. H12189 2001 AVALON (RM808U) Author
: Date
: 1878 BO-94 BODY - INSTRUMENT PANEL 29. REMOVE LOWER CLUSTER FINISH PANEL Using a screwdriver, remove the lower cluster finish panel. HINT: Tape the screwdriver tip before use. 7 Clips H12190 30. REMOVE CLUSTER FINISH PANEL (a) Remove the 2 screws. (b) Using a screwdriver, remove the cluster finish panel. HINT: Tape the screwdriver tip before use. 31. REMOVE END FINISH PANEL 32. REMOVE MULTI INFORMATION DISPLAY 33. REMOVE COMBINATION METER 2 Clips H12192 34. (a) H12193 (b) (c) (d) (e) 35. 36. 37. 38. REMOVE INSTRUMENT PANEL SAFETY PAD Remove the 2 bolts from the passenger airbag assembly. Torque: 20 N·m (204 kgf·cm, 15 ft·lbf) Remove the 6 bolts and nut. Disconnect the connectors. Remove the bolts and ground terminals. Remove the instrument panel safety pad. REMOVE INSTRUMENT PANEL TO COWL BRACE REMOVE NO. 2 INSTRUMENT PANEL TO COWL BRACE REMOVE NO. 1 HEATER TO REGISTER DUCT REMOVE INSTRUMENT PANEL REINFORCEMENT 2001 AVALON (RM808U) Author
: Date
: 1879 BO-35 BODY - LUGGAGE COMPARTMENT DOOR AND HINGE BO2OZ-01 ADJUSTMENT 1. (a) ADJUST LUGGAGE COMPARTMENT DOOR Using a clip remover, remove the 15 clips and luggage compartment door cover. (b) 2. (a) For forward/rearward and left/right adjustment loosen the bolts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) For vertical adjustment of the front end of the door, increase or decrease the number of washers between the hinge and the door. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) ADJUST DOOR LOCK STRIKER Remove the LH and RH rear floor finish side plates. (b) Remove the rear floor finish plate. (c) Loosen the bolts to adjust. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (c) H10388 2 Clips Clip H12121 N01422 2001 AVALON (RM808U) Author
: Date
: 1820 BO-30 BODY - LUGGAGE COMPARTMENT DOOR AND HINGE LUGGAGE COMPARTMENT DOOR AND HINGE BO2OW-02 COMPONENTS Luggage Compartment Door Rear Seatback No. 1 Upper Back Panel Hole Cover Rear Seat Cushion Luggage Compartment Weatherstrip Room Partition Reinforcement Upper Back Silencer 7.8 (80, 69 in.·lbf) w/o Speaker: High-mounted Stop Light w/ Speaker: High-mounted Stop Light Rear Seat Belt Bezel Pin Rear Seat Belt Bezel Luggage Compartment Door Hinge Arm CRS Tether Anchor Bracket Cover Torsion Bar Torsion Bar Clamp 7.8 (80, 69 in.·lbf) RH Roof Side Inner Garnish 41 (420, 30) LH Roof Side Inner Garnish Package Tray Trim 41 (420, 30) RH Inner Luggage Compartment Trim Cover Front LH Luggage Compartment Trim Cover Door Inside Handle Bezel LH Inner Luggage Compartment Trim Cover Luggage Compartment Door Cover Luggage Compartment Side Cover Luggage Compartment Floor Mat No. 1 Luggage Compartment Trim Hook RH Rear Floor Finish Side Plate Luggage Compartment Side Tray Front Luggage Compartment Trim Cover Spare Wheel Cover Clamp Rear Floor Finish Plate Luggage Compartment Door Lock Cylinder Rear Combination Light x4 5.4 (55, 48 in.·lbf) No. 1 Luggage Compartment Trim Hook x3 Spare Wheel Cover Luggage Compartment Outside Garnish Backup Light LH Rear Floor Finish Side Plate Luggage Door Lock Opener Assembly Rear Combination Light x4 x3 License Plate Light Backup Light Luggage Compartment Door Lock 5.4 (55, 48 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque Luggage Compartment Door Striker H15908 2001 AVALON (RM808U) Author
: Date
: 1815 BO-34 BODY - LUGGAGE COMPARTMENT DOOR AND HINGE BO2OY-02 DISASSEMBLY 1. (a) (b) (c) (d) H12125 REMOVE LUGGAGE COMPARTMENT DOOR LOCK Disconnect the control links from the luggage compartment door lock cylinder and door lock opener assembly. w/ Power door opener: Disconnect the connector. Remove the 2 bolts and door lock. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Remove the door lock cover from the door lock. HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the sliding and rotating parts of the door lock. 2. REMOVE LUGGAGE COMPARTMENT DOOR LOCK OPENER ASSEMBLY Remove the bolt and luggage compartment door lock opener assembly. 3. REMOVE LUGGAGE COMPARTMENT DOOR LOCK CYLINDER 4. REMOVE LUGGAGE COMPARTMENT DOOR OUTSIDE GARNISH (a) Remove the nut. (b) Remove the luggage compartment door outside garnish by compressing clips from the inside to disengage them. 5. REMOVE BACKUP LIGHTS 3 Clips H12126 6. REMOVE LICENSE PLATE LIGHTS (a) Disconnect the connectors. (b) Using a screwdriver, remove the license plate lights. HINT: Tape the screwdriver tip before use. H12127 2001 AVALON (RM808U) Author
: Date
: 1819 BO-37 BODY - LUGGAGE COMPARTMENT DOOR AND HINGE BO2P1-01 INSTALLATION Installation is in the reverse order of removal (See page BO-31 ). 2001 AVALON (RM808U) Author
: Date
: 1822 BO-36 BODY - LUGGAGE COMPARTMENT DOOR AND HINGE BO2P0-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO-34 ). 2001 AVALON (RM808U) Author
: Date
: 1821 BO-31 BODY - LUGGAGE COMPARTMENT DOOR AND HINGE BO41D-01 REMOVAL H15909 1. REMOVE DOOR INSIDE HANDLE BEZEL Using a screwdriver, remove the door inside handle bezel as shown in the illustration. HINT: Tape the screwdriver tip before use. 2. REMOVE LUGGAGE COMPARTMENT DOOR COVER Using a clip remover, remove the 15 clips and luggage compartment door cover. 3. REMOVE LUGGAGE COMPARTMENT DOOR (a) Disconnect the connectors. (b) Disconnect the clamps of wire harness. (c) Remove the 4 bolts and luggage compartment door. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) 4. REMOVE REAR SEAT (See page BO-1 19) 5. REMOVE NO. 1 UPPER BACK PANEL HOLE COVER 6. REMOVE ROOM PARTITION REINFORCEMENT (a) Remove the 6 nuts. (b) Remove the 2 bolts and room partition reinforcement. 7. REMOVE FRONT LH LUGGAGE COMPARTMENT TRIM COVER 8. REMOVE FRONT UPPER LUGGAGE COMPARTMENT TRIM COVER 9. REMOVE LUGGAGE COMPARTMENT FLOOR MAT 10. REMOVE LH AND RH REAR FLOOR FINISH SIDE PLATES (a) Remove the 2 screws and No. 1 luggage compartment trim hooks. (b) Remove the 4 clips and rear floor finish side plates. 11. REMOVE LUGGAGE COMPARTMENT SIDE TRAY 12. (a) (b) 13. 14. 2 Clips Clip H12121 15. 16. REMOVE REAR FLOOR FINISH PLATE Using a clip remover, remove the 2 clips. Remove the rear floor finish plate. REMOVE LH AND RH INNER LUGGAGE COMPARTMENT TRIM COVERS REMOVE FRONT LUGGAGE COMPARTMENT TRIM COVER REMOVE SPARE WHEEL COVER AND CLAMP REMOVE REAR COMBINATION LIGHTS 2001 AVALON (RM808U) Author
: Date
: 1816 BO-32 BODY - LUGGAGE COMPARTMENT DOOR AND HINGE 17. REMOVE ROOF SIDE INNER GARNISH (a) Using a screwdriver, remove the roof side inner garnish. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. :7 Clips H12128 18. REMOVE HIGH-MOUNTED STOP LIGHT Remove the high-mounted stop light as shown in the illustration, then disconnect the connector. w/o Speaker: w/ Speaker: 2 Clips H03125 H12122 H12806 19. REMOVE PACKAGE TRAY TRIM (a) Using a screwdriver, remove the 3 rear seat belt bezel. HINT: Tape the screwdriver tip before use. H07599 (b) 20. 21. (a) Remove the package tray trim as shown in the illustration. REMOVE UPPER BACK SILENCER REMOVE TORSION BAR Disconnect the torsion bars from the torsion bar clamp, then remove the torsion bar clamp. 2 Clips H12124 2001 AVALON (RM808U) Author
: Date
: 1817 BO-33 BODY - LUGGAGE COMPARTMENT DOOR AND HINGE (b) Install SST to the torsion bar on the hinge side. SST 09804-24010 (c) Push down on SST, and pull the luggage compartment door hinge from the torsion bar. (d) Slowly lift SST, and remove the torsion bar from the torsion bar bracket with SST. (e) (f) Disconnect the torsion bar from the bracket. Employ the same manner described above to the other side. BO4010 BO4011 BO4012 HINT: Check the color of marks on the torsion bar when replacing or installing the torsion bar. BO4013 22. 23. Side Color RH Yellow LH None REMOVE LUGGAGE COMPARTMENT DOOR HINGE ARMS AND PINS REMOVE LUGGAGE COMPARTMENT DOOR WEATHERSTRIP 2001 AVALON (RM808U) Author
: Date
: 1818 BO-25 BODY - OUTSIDE REAR VIEW MIRROR OUTSIDE REAR VIEW MIRROR BO41E-01 COMPONENTS TAIWAN: Mirror Outside Rear View Mirror Outside Rear View Mirror Wire Retainer Mirror Gasket 7.8 (80, 69 in.·lbf) 7.8 (80, 69 in.·lbf) Lower Frame Bracket Garnish Inside Handle Bezel Upper Armrest Base Panel with Power Window Switch Door Trim Courtesy Light N·m (kgf·cm, ft·lbf) : Specified torque H17368 2001 AVALON (RM808U) Author
: Date
: 1810 BO-29 BODY - OUTSIDE REAR VIEW MIRROR BO41H-01 INSTALLATION Installation is in the reverse order of removal (See page BO-26 ). 2001 AVALON (RM808U) Author
: Date
: 1814 BO-26 BODY - OUTSIDE REAR VIEW MIRROR BO41F-01 REMOVAL 1. REMOVE INSIDE HANDLE BEZEL (a) Using a screwdriver, remove the cover. HINT: Tape the screwdriver tip before use. (b) (c) Remove the screw. Using a screwdriver, remove the inside handle bezel as shown in the illustration. HINT: Tape the screwdriver tip before use. 2. REMOVE COURTESY LIGHT H04751 3. (a) REMOVE UPPER ARMREST BASE PANEL WITH POWER WINDOW SWITCH Using a screwdriver, remove the upper armrest base panel with power window switch. HINT: Tape the screwdriver tip before use. (b) Disconnect the connector. H12102 4. REMOVE DOOR TRIM (a) Using a screwdriver, remove the 2 caps. HINT: Tape the screwdriver tip before use. (b) Remove the 6 screws and clip. (c) Pull the trim upward to remove it. H12103 Clip H12104 5. REMOVE LOWER FRAME BRACKET GARNISH Using a screwdriver, remove the lower frame bracket as shown in the illustration. HINT: Tape the screwdriver tip before use. 6. REMOVE OUTSIDE REAR VIEW MIRROR (a) Disconnect the connector. (b) Remove the 3 nuts and outside rear view mirror. Torque: 7.8 N·m (80 kgf·cm, 69 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1811 BO-27 BODY - OUTSIDE REAR VIEW MIRROR BO41G-01 REPLACEMENT 1. 2 3 2 1 H17369 Except TAIWAN: IF NECESSARY, REMOVE MIRROR (a) Press the inboard end of the mirror inward to access the back of the mirror. (b) Reach fingers behind mirror and unlatch both ends of the wire retainer. (c) Remove the mirror. (d) w/ Heated mirrors: Disconnect the heater wires. NOTICE: Be careful not to damage the wires on heated mirrors. Disconnect the wires from the back side of the heater. 2. Except TAIWAN: INSTALL MIRROR (a) w/ Heated mirrors: Connect the heater wires. (b) Completely install the wire retainer to the mirror. (c) Carefully align the 2 alignment tabs to the slots on the motor. (d) Press the mirror firmly into place to engage all 6 lugs of the wire retainer. (e) Press on glass with open palm and rock the mirror through its full range of motion to engage all 6 lugs only low forces will be required. NOTICE: Confirm that all 6 wire retainer lugs are completely engaged to the mirror housing by gently pulling on the mirror edges. (f) Confirm mirror operation through full range of motion. 3. (a) (b) TAIWAN: IF NECESSARY, REMOVE MIRROR Insert a shop rag between the mirror and the mirror body. Pull up the lower side of the shop rag to disconnect the mirror joint. H02947 2001 AVALON (RM808U) Author
: Date
: 1812 BO-28 BODY - OUTSIDE REAR VIEW MIRROR (c) Pull up the mirror and disconnect it. (d) w/ Heated mirrors: Disconnect the connector. 4. TAIWAN: INSTALL MIRROR w/ Heated mirrors: Connect the connector. Connect the claws (A) and set the mirror to the mirror body. Push the mirror to connect the claws (B) and set it. H02948 H02949 (a) Claw (B) (b) Claw (A) (c) H02941 2001 AVALON (RM808U) Author
: Date
: 1813 BO-25 BODY - OUTSIDE REAR VIEW MIRROR OUTSIDE REAR VIEW MIRROR BO41E-01 COMPONENTS TAIWAN: Mirror Outside Rear View Mirror Outside Rear View Mirror Wire Retainer Mirror Gasket 7.8 (80, 69 in.·lbf) 7.8 (80, 69 in.·lbf) Lower Frame Bracket Garnish Inside Handle Bezel Upper Armrest Base Panel with Power Window Switch Door Trim Courtesy Light N·m (kgf·cm, ft·lbf) : Specified torque H17368 2001 AVALON (RM808U) Author
: Date
: 1810 BO-29 BODY - OUTSIDE REAR VIEW MIRROR BO41H-01 INSTALLATION Installation is in the reverse order of removal (See page BO-26 ). 2001 AVALON (RM808U) Author
: Date
: 1814 BO-26 BODY - OUTSIDE REAR VIEW MIRROR BO41F-01 REMOVAL 1. REMOVE INSIDE HANDLE BEZEL (a) Using a screwdriver, remove the cover. HINT: Tape the screwdriver tip before use. (b) (c) Remove the screw. Using a screwdriver, remove the inside handle bezel as shown in the illustration. HINT: Tape the screwdriver tip before use. 2. REMOVE COURTESY LIGHT H04751 3. (a) REMOVE UPPER ARMREST BASE PANEL WITH POWER WINDOW SWITCH Using a screwdriver, remove the upper armrest base panel with power window switch. HINT: Tape the screwdriver tip before use. (b) Disconnect the connector. H12102 4. REMOVE DOOR TRIM (a) Using a screwdriver, remove the 2 caps. HINT: Tape the screwdriver tip before use. (b) Remove the 6 screws and clip. (c) Pull the trim upward to remove it. H12103 Clip H12104 5. REMOVE LOWER FRAME BRACKET GARNISH Using a screwdriver, remove the lower frame bracket as shown in the illustration. HINT: Tape the screwdriver tip before use. 6. REMOVE OUTSIDE REAR VIEW MIRROR (a) Disconnect the connector. (b) Remove the 3 nuts and outside rear view mirror. Torque: 7.8 N·m (80 kgf·cm, 69 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1811 BO-27 BODY - OUTSIDE REAR VIEW MIRROR BO41G-01 REPLACEMENT 1. 2 3 2 1 H17369 Except TAIWAN: IF NECESSARY, REMOVE MIRROR (a) Press the inboard end of the mirror inward to access the back of the mirror. (b) Reach fingers behind mirror and unlatch both ends of the wire retainer. (c) Remove the mirror. (d) w/ Heated mirrors: Disconnect the heater wires. NOTICE: Be careful not to damage the wires on heated mirrors. Disconnect the wires from the back side of the heater. 2. Except TAIWAN: INSTALL MIRROR (a) w/ Heated mirrors: Connect the heater wires. (b) Completely install the wire retainer to the mirror. (c) Carefully align the 2 alignment tabs to the slots on the motor. (d) Press the mirror firmly into place to engage all 6 lugs of the wire retainer. (e) Press on glass with open palm and rock the mirror through its full range of motion to engage all 6 lugs only low forces will be required. NOTICE: Confirm that all 6 wire retainer lugs are completely engaged to the mirror housing by gently pulling on the mirror edges. (f) Confirm mirror operation through full range of motion. 3. (a) (b) TAIWAN: IF NECESSARY, REMOVE MIRROR Insert a shop rag between the mirror and the mirror body. Pull up the lower side of the shop rag to disconnect the mirror joint. H02947 2001 AVALON (RM808U) Author
: Date
: 1812 BO-28 BODY - OUTSIDE REAR VIEW MIRROR (c) Pull up the mirror and disconnect it. (d) w/ Heated mirrors: Disconnect the connector. 4. TAIWAN: INSTALL MIRROR w/ Heated mirrors: Connect the connector. Connect the claws (A) and set the mirror to the mirror body. Push the mirror to connect the claws (B) and set it. H02948 H02949 (a) Claw (B) (b) Claw (A) (c) H02941 2001 AVALON (RM808U) Author
: Date
: 1813 BO-64 BODY - QUARTER WINDOW GLASS QUARTER WINDOW GLASS BO2PH-01 COMPONENTS RH Rear Seat Inner with Center Belt Rear Seatback LH Rear Seat Inner with Center Belt 18 (185, 13) Roof Side Inner Garnish 41 (420, 30) 18 (185, 13) Rear Seat Cushion Rear Door Opening Trim
Quarter WIndow Glass
Non-reusable part H12701 2001 AVALON (RM808U) Author
: Date
: 1849 BO-67 BODY - QUARTER WINDOW GLASS BO2PJ-01 INSTALLATION Adhesive BO4420 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (a) Using a knife, cut away any rough areas on the body. HINT: Leave of the adhesive on the body as much as possible. (b) Clean the cut surface of the adhesive with a shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. CLEAN REMOVED GLASS (a) Using a scraper, remove the adhesive sticking to the glass. (b) Clean the glass with cleaner. NOTICE: Do not touch the glass after cleaning it. 3. Primer M Primer M Adhesive H02865 COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat Primer M to the exposed part of body on the vehicle side. NOTICE:
Allow 3 minutes or more to dry the primer coated surface.
Do not coat Primer M to the adhesive.
Do not keep any of the opened Primer M for later use. 4. b a COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the edge of the glass and contact surface with Primer G. (b) When the primer is applied by mistake to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTICE:
Allow 3 minutes or more to dry the primer coated surface.
Do not keep any of the opened Primer G for later use. b a c c a-a b-b Primer G c - c Primer G H12159 2001 AVALON (RM808U) Author
: Date
: 1852 BO-68 BODY 5. (a) a - QUARTER WINDOW GLASS APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table below. ab b c Temperature Tackfree time c 35 °C (95 °F) 15 minutes 20 °C (68 °F) 100 minutes 5 °C (41 °F) 8 hours a-a b-b B B A c - c B A H12160 (b) (c) Load the cartridge into the sealer gun. Coat the glass with adhesive as shown in the illustration. A: 8.0 mm (0.315 in.) B: 13.5 mm (0.531 in.) 6. INSTALL QUARTER WINDOW GLASS (a) Install the glass to the body. (b) Hold the glass in place securely with a protective tape or equivalent until the adhesive hardens. NOTICE: Take care not to drive the vehicle during the time described in the table below. Temperature Minimum time prior to driving the vehicle 35 °C (95 °F) 1.5 hours 20 °C (68 °F) 5 hours 5 °C (41 °F) 24 hours 7. INSPECT FOR LEAKS AND REPAIR NOTICE: Conduct a leak test after hardening time has elapsed. 8. INSTALL ROOF SIDE INNER GARNISH 9. INSTALL REAR DOOR OPENING TRIM 10. INSTALL REAR SEAT (See page BO-123 ) 2001 AVALON (RM808U) Author
: Date
: 1853 BO-65 BODY - QUARTER WINDOW GLASS BO2PI-01 REMOVAL 1. 2. REMOVE REAR SEAT (See page BO-120 ) REMOVE REAR DOOR OPENING TRIM 3. REMOVE ROOF SIDE INNER GARNISH Using a screwdriver, remove the roof side inner garnish. HINT: Tape the screwdriver tip before use. :7 Clips H12128 Protective Tape H12156 4. (a) REMOVE QUARTER WINDOW GLASS Insert a piano wire between body and glass and let it pass through. Tie both wire ends to wooden blocks or similar objects. (b) HINT: Apply protective tape to the outer surface to keep the surface from being scratched. NOTICE: When separating the glass, take care not to damage the paint and exterior. (c) Cut the adhesive by pulling the piano wire around it. HINT: Cut the adhesive areas as shown in the illustration, leaving the adhesive where the clips are. H12157 2001 AVALON (RM808U) Author
: Date
: 1850 BO-66 BODY Protective Tape H12158 - QUARTER WINDOW GLASS (d) Let the piano wire pass as shown in the illustration, cut off the left adhesive around the clips. NOTICE:
Do not damage the glass retainer.
When separating the glass, take care not to damage the paint and interior and exterior ornaments. (e) Remove the glass. NOTICE: Leave of the adhesive on the body as much as possible when cutting off the glass. 2001 AVALON (RM808U) Author
: Date
: 1851 BO-50 BODY - ROOF DRIP SIDE FINISH CENTER MOULDING ROOF DRIP SIDE FINISH CENTER MOULDING BO2PA-01 COMPONENTS Roof Drip Side Finish Center Moulding H12140 2001 AVALON (RM808U) Author
: Date
: 1835 BO-52 BODY - ROOF DRIP SIDE FINISH CENTER MOULDING BO2PC-01 INSTALLATION 1. (a) CLEAN CONTACT SURFACE OF BODY Using a heat light, heat the moulding surface to 40 - 60 °C (104 - 140 °F). NOTICE: Do not heat the body excessively. (b) Using a knife, cut away any rough areas on the body. NOTICE: Be careful not to damage the body. (c) Wipe off stains with cleaner. 2. If reusing the moulding: CLEAN MOULDING (a) Using a heat light, heat the moulding surface to 20 - 30 °C (68 - 86 °F). NOTICE: Do not heat the moulding excessively. (b) Using a knife, cut the remaining adhesive from the moulding. NOTICE: Be careful not to damage the moulding. (c) Wipe off stains with cleaner. 3. Primer M A Primer M H10545 COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat the contact surface on the body with Primer M as shown in the illustration. Front and rear end: A: 60 mm (2.36 in.) NOTICE:
Allow 3 minutes or more to dry the primer cared surface.
Do not coat the adhesive.
Do not keep any of the opened Primer M for later use. 2001 AVALON (RM808U) Author
: Date
: 1837 BO-53 BODY 4. (a) Adhesive - ROOF DRIP SIDE FINISH CENTER MOULDING APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table below. A 10.0 mm (0.394 in.) (b) (c) Adhesive 7.0 mm (0.276 in.) Primer M H10546 Temperature Tackfree time 35 °C (95 °F) 15 minutes 20 °C (68 °F) 100 minutes 5 °C (41 °F) 8 hours Load the cartridge into the sealer gun. Apply adhesive to the hatched area in the illustration for both front and rear of the vehicle. Front end: A: 35 mm (1.38 in.) Rear end: A: 35 mm (1.38 in.) HINT: When removing the moulding, apply adhesive well to the part where the body sealer is removed. 5. INSTALL MOULDING Push the moulding to the body. NOTICE:
Make sure that the body and moulding are heated to a proper temperature.
Do not depress the adhesive coated parts excessively but just hold them down with your thumb.
Scrape off any overflowing adhesive with a plastic spatula and clean the surface with a dry rag.
Take care not to drive the vehicle during the time described in the table below. Temperature Minimum time prior to driving the vehicle 35 °C (95 °F) 1.5 hours 20 °C (68 °F) 5 hours 5 °C (41 °F) 24 hours 2001 AVALON (RM808U) Author
: Date
: 1838 BO-51 BODY - ROOF DRIP SIDE FINISH CENTER MOULDING BO2PB-01 REMOVAL 1. (a) REMOVE ENDS OF MOULDING Apply protective tape to the outer surface as shown in the illustration to keep the surface from being scratched. (b) Using a heat light heat the moulding to 20 - 30 °C (68 86 °F). NOTICE: Do not heat the moulding excessively. (c) Using a scraper, pull off the roof drip side finish moulding from the front end and rear end. HINT: Tape the scraper tip before use. N18625 2. (a) REMOVE MOULDING AND ADHESIVE Pull off the moulding by cutting the adhesive with a knife at the front and rear ends. (b) Remove the moulding. NOTICE: Do not damage the body with the knife. 3. REMOVE ROOF DRIP SIDE FINISH MOULDING CLIP N18626 2001 AVALON (RM808U) Author
: Date
: 1836 BO-47 BODY - ROOF DRIP SIDE FINISH MOULDING ROOF DRIP SIDE FINISH MOULDING BO2P7-01 COMPONENTS Roof Drip Side Finish Moulding H12139 2001 AVALON (RM808U) Author
: Date
: 1832 BO-49 BODY - ROOF DRIP SIDE FINISH MOULDING BO2P9-01 INSTALLATION INSTALL ROOF DRIP SIDE FINISH MOULDING Using a air riveter with nose piece No. 1 or hand riveter with nose piece No. 1, install the 10 rivets to the roof drip side finish moulding. NOTICE:
Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent. H02440
Do not tilt the riveter and disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.
Install the rivet while attaching materials, as they are not tightened firmly. H02441 H02442 2001 AVALON (RM808U) Author
: Date
: 1834 BO-48 BODY - ROOF DRIP SIDE FINISH MOULDING BO2P8-01 REMOVAL REMOVE ROOF DRIP SIDE FINISH MOULDING (a) Using a drill of less than 3.0 mm (0.118 in.), drill out the 10 rivet heads. HINT: Gently and vertically put the drill to the rivet, and cut the rivet flanges. CAUTION: Take care as the cut rivet is hot. NOTICE: Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill. (b) Remove the roof drip side finish moulding. 2001 AVALON (RM808U) Author
: Date
: 1833 BO-5 BODY - REAR BUMPER REAR BUMPER BO0XK-03 COMPONENTS RH Inner Luggage Compartment Trim Cover LH Inner Luggage Compartment Trim Cover Side Tray Luggage Compartment Floor Mat No. 1 Luggage Compartment Trim Hook RH FLoor Finish Side Plate Quarter Vent Rear Floor Finish Plate LH Floor Finish Side Plate 33 (340, 25) Rear Bumper Arm Mounting Bracket Rear Bumper Reinforcement 33 (340, 25) Rear Bumper Energy Absorber 33 (340, 25) 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) 33 (340, 25) 5.4 (55, 48 in.·lbf) Center Bar Reinforcement Rear Bumper Cover N·m (kgf·cm, ft·lbf) : Specified torque H12100 2001 AVALON (RM808U) Author
: Date
: 1790 BO-22 BODY - REAR DOOR BO2OU-01 ADJUSTMENT 1. (a) (b) (c) (d) (e) (f) (g) (h) N12124 (i) (j) ADJUST DOOR IN FORWARD/REARWARD AND VERTICAL DIRECTIONS Remove the front door scuff plate. Remove the center pillar lower garnish. Remove the front seat belt floor anchor. Remove the front seat belt retractor. (See page BO-128 ) Remove the side airbag sensor assembly. (See page RS-78 ) Loosen the body side hinge nuts to adjust. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) Reinstall the side airbag sensor assembly. (See page RS-81 ) Torque: Reinstall the front seat belt retractor. (See page BO-137 ) Torque: Upper bolt: 7.5 N·m (76 kgf·cm, 66 in.·lbf) Lower bolt: 41 N·m (420 kgf·cm, 30 ft·lbf) Reinstall the front seat belt floor anchor. Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) Reinstall the center pillar lower garnish and front door scuff plate. 2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) N12125 2001 AVALON (RM808U) Author
: Date
: 1807 BO-23 BODY 3. (a) (b) (c) - REAR DOOR ADJUST DOOR LOCK STRIKER Check that the door fit and door lock linkages are adjusted correctly. Loosen the striker mounting screws to adjust. Torque: 23 N·m (230 kgf·cm, 17 ft·lbf) Using a plastic hammer, tap the striker to adjust it. BO2556 2001 AVALON (RM808U) Author
: Date
: 1808 BO-16 BODY - REAR DOOR REAR DOOR BO2OS-01 COMPONENTS Guide Piece Plate Door Lock Striker Rear Door Weatherstrip Rear Door Glass Run 25 (260, 19) 25 (260, 19) 23 (230, 17) Rear Door Window Guide 7.8 (80, 69 in.·lbf) Rear Guide Bracket Garnish Door Check Rear Door Glass Outside Handle 25 (260, 19) Door Hinge 5.4 (55, 48 in.·lbf) 25 (260, 19) 5.4 (55, 48 in.·lbf)
4.9 (50, 43 in.·lbf) Door Speaker Board Rear Door Outside Lower Moulding Door Lock Protector Inside Handle 5.4 (55, 48 in.·lbf) Service Hole Cover Door Lock Inside Handle Bezel Cover Rear Door Belt Moulding Upper Armrest Base Panel Rear Door Inner Weatherstrip Power Window Switch Door Trim x13 Window Regulator Guide Assembly Rear Door Armrest x7 5.4 (55, 48 in.·lbf) Window Regulator Motor N·m (kgf·cm, ft·lbf) : Specified torque Rear Door Trim Pocket
Precoated Part H12120 2001 AVALON (RM808U) Author
: Date
: 1801 BO-17 BODY - REAR DOOR BO2OT-01 DISASSEMBLY 1. REMOVE INSIDE HANDLE BEZEL (a) Using a screwdriver, remove the cover. HINT: Tape the screwdriver tip before use. (b) (c) Remove the screw. Using a screwdriver, remove the inside handle bezel as shown in the illustration. HINT: Tape the screwdriver tip before use. H04751 2. (a) H12111 REMOVE UPPER ARMREST BASE PANEL WITH POWER WINDOW SWITCH Using a screwdriver, remove the upper armrest base panel with power window switch. HINT: Tape the screwdriver tip before use. (b) Disconnect the connector. (c) Remove the power window switch from the upper armrest base panel. 3. REMOVE REAR GUIDE BRACKET GARNISH Using a screwdriver, remove the rear guide bracket garnish. HINT: Tape the screwdriver tip before use. Clip H12113 4. (a) (b) REMOVE DOOR TRIM Remove the 3 screws and 2 clips. Pull the trim upward to remove it. H12114 2001 AVALON (RM808U) Author
: Date
: 1802 BO-18 BODY (c) x13 x7 (d) (e) 5. (a) (b) - REAR DOOR Using a screwdriver, remove the rear door inner weatherstrip. Remove the 13 screws and rear door armrest. Remove the 7 screws and rear door trim pocket. REMOVE INSIDE HANDLE Remove the screw. Slide the inside handle backward to remove it. H12163 (c) 6. Disconnect the 2 cables from the inside handle as shown in the illustration. REMOVE DOOR SPEAKER BOARD H06127 7. (a) (b) H12115 REMOVE SERVICE HOLE COVER Disconnect the 2 control cables from the link clamp. Using a clip remover, remove the grommets and link clamp. (c) Remove the service hole cover. NOTICE: Do not tear the cover. HINT: At the time of reassembly, please refer to the following item. Bring out the 2 control cables and wire harness through the service hole cover. 8. REMOVE REAR DOOR WEATHERSTRIP (a) Remove the screw from the door check. (b) Using a clip remover, remove the rear door weatherstrip. (c) Reinstall the screw to the door check. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) 9. (a) (b) REMOVE REAR DOOR BELT MOULDING Apply protective tape to the outer surface as shown in the illustration, to keep the surface from being scratched. Using a moulding remover, remove the rear door belt moulding. Protective Tape H12116 2001 AVALON (RM808U) Author
: Date
: 1803 BO-19 BODY 10. (a) H12117 - REAR DOOR REMOVE REAR DOOR OUTSIDE LOWER MOULDING Using a drill of less than ø3.2 mm (0.126 in.), drill out the 2 rivet heads. HINT: Gently and vertically put the drill to the rivet, and cut the rivet flanges. CAUTION: Take care as the cut rivet is hot. NOTICE: Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill. (b) Using a clip remover, remove the clip. (c) Remove the rear door outside lower moulding. (d) Using a vacuum cleaner, remove the drilled rivets and their dust from the inside of door panel. HINT: At the time of reassembly, please refer to the following item. Using an air riveter with nose piece No. 1 or hand riveter with nose piece No. 1, install the 3 rivets to the front door outside lower moulding. NOTICE:
At the time of reassembly, please refer to the following items.
Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent. H02440
Do not tilt the riveter and disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.
Install the rivet while attaching materials, as they are not tightened firmly. REMOVE DOOR GLASS RUN REMOVE REAR DOOR WINDOW GUIDE WITH GUIDE PIECE PLATE Remove the bolt, nut, 3 screws and rear door window guide with guide piece plate. Remove the guide piece plate from the rear door window guide. H02441 11. 12. (a) (b) H02442 2001 AVALON (RM808U) Author
: Date
: 1804 BO-20 BODY - REAR DOOR 13. (a) REMOVE REAR DOOR GLASS Open the door glass until the bolts appear in the service hole. (b) Remove the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: Be careful not to drop the door glass. (c) Pull the door glass upward to remove it. 14. REMOVE WINDOW REGULATOR ASSEMBLY (a) Disconnect the connector, then remove the 4 nuts and window regulator assembly. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) HINT: Remove the window regulator assembly through the service hole. (b) Using a torx driver, remove the 3 torx screws and window regulator motor from the window regulator guide assembly. HINT:


H12118 15. (a) (b) (c) At the time of reassembly, please refer to the following items. Apply MP grease to the glass guide and rollers of window regulator assembly. After installing the window regulator assembly, window regulator assembly need to be re-initialized. Refer to BE-80 . REMOVE DOOR LOCK Disconnect the control link from the outside handle. Disconnect the connector. Remove the 3 torx screws and door lock. Torque: Bolt: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Screw: 4.9 N·m (50 kgf·cm, 43 in.·lbf) HINT: Remove the door lock through the service hole. HINT: At the time of reassembly, please refer to the following item. Apply adhesive to 3 screws. Part No. 08833-00070, THREE BOND 1324 or equivalent (d) Remove the 2 screws and door lock protector from the door lock. 2001 AVALON (RM808U) Author
: Date
: 1805 BO-21 BODY - REAR DOOR HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the sliding and rotating parts of the door lock. 16. REMOVE OUTSIDE HANDLE Remove the 2 bolts and outside handle. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) H12119 2001 AVALON (RM808U) Author
: Date
: 1806 BO-24 BODY - REAR DOOR BO2OV-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO-17 ). 2001 AVALON (RM808U) Author
: Date
: 1809 BO-1 19 BODY - REAR SEAT REAR SEAT BO2QD-01 COMPONENTS Headrest Center Armrest Bracket Shoulder Belt Guide Center Armrest Hinge 5.9 (60, 52 in.·lbf) Headrest Support Headrest Support
Hog Ring Center Armrest Seatback Cover 18 (185, 13) 41 (420, 30) Seat Cushion Cover 18 (185, 13) Seatback Pad with Frame Seat Cushion Pad with Frame
Hog Ring N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part H12219 2001 AVALON (RM808U) Author
: Date
: 1904 BO-121 BODY - REAR SEAT BO2QF-01 DISASSEMBLY H03147 1. REMOVE HEADRESTS 2. REMOVE CENTER ARMREST Remove the 2 nuts and center armrest. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) 3. REMOVE SHOULDER BELT GUIDES Remove the 4 screws and 2 shoulder belt guides. 4. REMOVE HEADREST SUPPORTS 5. REMOVE SEATBACK COVER Remove the hog rings and seatback cover from the seatback pad with frame. 6. REMOVE SEAT CUSHION COVER Remove the hog rings and seat cushion cover from the seat cushion pad. 2001 AVALON (RM808U) Author
: Date
: 1906 BO-123 BODY - REAR SEAT BO2QH-01 INSTALLATION Installation is in the reverse order of removal (See page BO-123 ). 2001 AVALON (RM808U) Author
: Date
: 1908 BO-122 BODY - REAR SEAT BO2QG-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO-121 ). 2001 AVALON (RM808U) Author
: Date
: 1907 BO-120 BODY - REAR SEAT BO2QE-01 REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY Remove the rear seat cushion. H13186 2. (a) (b) REMOVE REAR SEATBACK ASSEMBLY Remove the 4 bolts. Torque: Center: 41 N·m (420 kgf·cm, 30 ft·lbf) LH, RH Side: 18 N·m (185 kgf·cm, 13 ft·lbf) Raise the seatback assembly upward to remove the seatback assembly. H12220 2001 AVALON (RM808U) Author
: Date
: 1905 BO-98 BODY - ROOF HEADLINING ROOF HEADLINING BO2PZ-01 COMPONENTS w/ Rear personal light: Rear Personal Light Roof Headlining w/ Sliding roof: Assist Grip Roof Console Box Sliding Roof Opening Trim Roof Headlining Assist Grip Map Light Lens Sun Visor Room Light Lens Cover Center Pillar Garnish Holder Front Pillar Garnish Cover Roof Side Inner Garnish Front Seat Outer Belt Floor Anchor 41 (420, 30) Lap Belt Outer Anchor Cover Rear Door Opening Trim Front Door Opening Trim Rear Seatback Front Door Scuff Inside Plate 18 (185, 13) 41 (420, 30) 41 (420, 30) RH Rear Seat Inner with Center Belt 18 (185, 13) LH Rear Seat Inner with Center Belt Inside Rear Door Scuff Plate Lower Center Pillar Garnish Rear Seat Cushion N·m (kgf·cm, ft·lbf) : Specified torque H12201 2001 AVALON (RM808U) Author
: Date
: 1883 BO-102 BODY - ROOF HEADLINING BO2Q1-01 INSTALLATION Installation is in the reverse order of removal (See page BO-99 ). 2001 AVALON (RM808U) Author
: Date
: 1887 BO-99 BODY - ROOF HEADLINING BO2Q0-01 REMOVAL 1. REMOVE REAR SEAT (See page BO-120 ) 2. (a) (b) REMOVE INSIDE REAR DOOR SCUFF PLATE Remove the clip. Remove the inside rear door scuff plate as shown in the illustration. Employ the same manner described above to the other side. REMOVE REAR DOOR OPENING TRIMS (c) 3. H12197 : 7 Clips H12128 4. REMOVE ROOF SIDE INNER GARNISH (a) Using a screwdriver, remove the roof side inner garnish. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. 5. REMOVE ASSIST GRIPS (a) Using a screwdriver, remove the cover. HINT: Tape the screwdriver tip before use. (b) Loosen bolts until assist grip detaches from the vehicle. (c) Repeat at 4 positions. 6. Claw (a) w/ Rear personal light: REMOVE REAR PERSONAL LIGHT Using a screwdriver, remove the rear personal light, then disconnect the connector. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. Claw H12161 2001 AVALON (RM808U) Author
: Date
: 1884 BO-100 BODY 7. (a) (b) 8. - ROOF HEADLINING REMOVE FRONT DOOR SCUFF INSIDE PLATE Remove the front door scuff inside plate. Employ the same manner described above to the other side. REMOVE FRONT DOOR OPENING TRIMS H12175 9. (a) (b) REMOVE LOWER CENTER PILLAR GARNISH Using a screwdriver, remove the lap belt outer anchor cover. Remove the front seat outer belt floor anchor. Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) H12198 (c) :5 Clips (d) Remove the lower center pillar garnish as shown in the illustration. Employ the same manner described above to the other side. H12199 10. REMOVE CENTER PILLAR GARNISH (a) Remove the 2 clips. (b) Using a screwdriver, remove the center pillar garnish. HINT: Tape the screwdriver tip before use. (c) Employ the same manner described above to the other side. Clip H12200 11. (a) (b) 2 Clips REMOVE FRONT PILLAR GARNISH Remove the front pillar garnish. Employ the same manner described above to the other side. H12145 2001 AVALON (RM808U) Author
: Date
: 1885 BO-101 BODY H12144 - ROOF HEADLINING 12. REMOVE ROOF CONSOLE BOX (a) Using a screwdriver, remove the map light lens. HINT: Tape the screwdriver tip before use. (b) Remove the 3 screws and roof console box, then disconnect the connector. 13. REMOVE ROOM LIGHT (a) Using a screwdriver, remove the room light lens. HINT: Tape the screwdriver tip before use. (b) Remove the 4 screws and room light, then disconnect the connector. 14. w/ Sliding roof: REMOVE SLIDING OPENING TRIM 15. REMOVE SUN VISORS AND HOLDERS (a) Using a screwdriver, pry the bracket cover off from the rear. (b) Remove the 2 screws from the visor bracket and a screw from the holder. (c) Remove the visor assembly from the holder and disconnect the connector. (d) Pull off the holder. 16. REMOVE ROOF HEADLINING Disengage the 3 clips and remove the roof headlining. 3 Clips H12162 2001 AVALON (RM808U) Author
: Date
: 1886 BO-54 BODY - ROCKER PANEL MOULDING ROCKER PANEL MOULDING BO2PD-01 COMPONENTS Rocker Panel Moulding H12142 2001 AVALON (RM808U) Author
: Date
: 1839 BO-131 BODY - SEAT BELT PRETENSIONER BO2QM-01 DISPOSAL HINT: When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with seat belt pretensioner) always first activate the seat belt pretensioner in accordance with the procedure described below. If any abnormality occurs in the seat belt pretensioner operation, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a front seat outer belt (with seat belt pretensioner) activated in a collision, follow the same procedure given in step 1-(e) in ”DISPOSAL”. SST AB0152 CAUTION:
Never dispose of the front seat outer belt which has an inactivated pretensioner.
The seat belt pretensioner produces a sizeable exploding sound when it activates, so perform the operation out-of-door and where it will not create a nuisance to nearby residents.
When activating the seat belt pretensioner, always use the specified SST. (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082-00700, 09082-00740
When activating a front seat outer belt (with seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat outer belt.
Use gloves and safety glasses when handling a front seat outer belt with activated pretensioner.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat outer belt with the activated pretensioner. 2001 AVALON (RM808U) Author
: Date
: 1916 BO-132 BODY 1. Battery - SEAT BELT PRETENSIONER SEAT BELT PRETENSIONER ACTIVATION WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to activate the seat belt pretensioner. SST AB0158 (a) Check the functioning of SST. CAUTION: When activating the seat belt pretensioner, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700, 09082-00740 SST AB0152 (1) Battery Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the seat belt pretensioner. SST AB0158 (2) SST H01580 Press the SST activation switch, and check the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. (b) Disconnect the pretensioner connector. (1) Remove the front door scuff inside plate. (2) Remove lower center pillar garnish. (3) (c) Disconnect the pretensioner connector as shown in the illustration. Install the SST. (1) Buckle the front seat belt and check that there is no looseness and slack in the front seat inner belt and front seat outer belt. H11075 2001 AVALON (RM808U) Author
: Date
: 1917 BO-133 BODY - SEAT BELT PRETENSIONER (2) SST Connect the 2 SST, then connect them to the seat belt pretensioner. SST 09082-00700, 09082-00740 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST Battery H11079 (3) Battery SST 10 m (33 ft) or more R13455 Move the SST to at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (4) NOTICE: Take care not to damage the SST wire harness. (5) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-) terminal. (d) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up. (e) Dispose of the front seat outer belt (with seat belt pretensioner). CAUTION:
The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation.
Use gloves and safety glasses when handling a front seat outer belt with the activated seat belt pretensioner.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat outer belt with the activated seat belt pretensioner. HINT: When scrapping a vehicle, activate the seat belt pretensioner and scrap the vehicle with the activated front seat outer belt still installed. 2. ACTIVATION WHEN DISPOSING OF FRONT SEAT OUTER BELT ONLY NOTICE:
When disposing of the front seat outer belt (with seat belt pretensioner) only, never use the customer’s vehicle to activate the seat belt pretensioner. 2001 AVALON (RM808U) Author
: Date
: 1918 BO-134 BODY
- SEAT BELT PRETENSIONER Be sure to follow the procedure given on the next page when activating the seat belt pretensioner. HINT: Have a battery ready as the power source when activating the seat belt pretensioner. (a) Remove the front seat outer belt (See page BO-128 ). HINT: Cut the belt near the seat belt retractor. (b) Check the functioning of SST (See step 1-(a)). SST 09082-00700, 09082-00740 Battery SST AB0158 (c) SST Install the SST. (1) Connect the 2 SST, then connect them to the seat belt pretensioner. SST 09082-00700, 09082-00740 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST Battery H11079 (2) SST SST H11080 Place the front seat outer belt on the ground and cover it with the disc wheel with tire. NOTICE: Place the front seat outer belt as shown in the illustration. (3) Move the SST at least 10 m (33 ft) away from the disc wheel. NOTICE: Take care not to damage the SST wire harness. (d) Activate the seat belt pretensioner. (1) Connect the SST red clip to the battery positive (+) terminal and black clip to the battery negative (-) terminal. (2) Check that no one is within 10 m (33 ft) area around the disc wheel. (3) Press the SST activation switch and activate the seat belt pretensioner. 2001 AVALON (RM808U) Author
: Date
: 1919 BO-135 BODY - SEAT BELT PRETENSIONER HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up. Battery SST 10 m (33 ft) or more R05181 (e) H11081 Dispose of the front seat outer belt (with seat belt pretensioner). CAUTION:
The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation.
Use gloves and safety glasses when handling a front seat outer belt with the activated seat belt pretensioner.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat outer belt with the activated seat belt pretensioner. (1) Remove the disc wheel and SST. (2) Place the front seat outer belt in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts. 2001 AVALON (RM808U) Author
: Date
: 1920 BO-130 BODY - SEAT BELT PRETENSIONER BO2QL-01 INSPECTION 1. (a) PRETENSIONER IS NOT ACTIVATED Perform a diagnostic system check (See page DI-349 ). (b) Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle.
Check for cuts and cracks in, or marked discoloration on the front quarter trim or center pillar lower garnish.
Check for cuts and cracks in wire harness, and for chipping in connectors. H03712
Check for deformation of the quarter panel or center pillar.
Check for cuts and minute cracks in wire harness or marked discoloration on the front seat outer belt. H12223 CAUTION: For removal and installation of the front seat outer belt, see page BO-128 and BO-137 . Be sure to follow the correct procedure. 2. PRETENSIONER IS ACTIVATED (a) Perform a diagnostic system check (See page DI-349 ). H11078 (b) Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle.
Check for deformation of the quarter panel or center pillar.
Check for damage on the connector and wire harness. H12223 2001 AVALON (RM808U) Author
: Date
: 1915 BO-137 BODY - SEAT BELT PRETENSIONER BO2QO-01 INSTALLATION NOTICE:
Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts.
Make sure that the front seat outer belt is installed in the specified torque.
If the front seat outer belt has been dropped, or there are cracks, dents or any identified other defects in the case or connector, replace the front seat outer belt with a new one.
When installing the front seat outer belt, take care that the wiring does not interfere with other parts and is not pinched between other parts. 1. INSTALL RETRACTOR OF FRONT SEAT OUTER BELT (a) Install the retractor of front seat outer belt with the 2 bolts. Torque: Upper bolt: 7.5 N·m (76 kgf·cm, 66 in.·lbf) Lower bolt: 41 N·m (420 kgf·cm, 30 ft·lbf) (b) 2. 3. 4. 5. H11075 6. Connect the pretensioner connector as shown in the illustration. INSTALL FRONT SEAT OUTER BELT SHOULDER ANCHOR Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) INSTALL CENTER PILLAR GARNISH INSTALL LOWER CENTER PILLAR GARNISH INSTALL FRONT SEAT OUTER BELT FLOOR ANCHOR Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) INSTALL FRONT DOOR SCUFF INSIDE PLATE 2001 AVALON (RM808U) Author
: Date
: 1922 BO-128 BODY - SEAT BELT PRETENSIONER SEAT BELT PRETENSIONER BO2QK-01 REMOVAL NOTICE:
If the wiring connector of the seat belt pretensioner is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded.
Never use SRS parts from another vehicle. When replace parts, replace them with new parts. 1. REMOVE FRONT DOOR SCUFF INSIDE PLATE Remove the front door scuff inside plate. H12175 2. (a) (b) REMOVE LOWER CENTER PILLAR GARNISH Using a screwdriver, remove the lap belt outer anchor cover. Remove the front seat outer belt floor anchor. H12198 (c) :5 Clips Remove the lower center pillar garnish as shown in the illustration. H12199 Clip H12200 3. REMOVE CENTER PILLAR GARNISH (a) Remove the 2 clips. (b) Using a screwdriver, remove the center pillar garnish. HINT: Tape the screwdriver tip before use. 4. REMOVE FRONT SEAT OUTER BELT SHOULDER ANCHOR 5. REMOVE RETRACTOR OF FRONT SEAT OUTER BELT 2001 AVALON (RM808U) Author
: Date
: 1913 BO-129 BODY - SEAT BELT PRETENSIONER CAUTION: Never disassemble the front seat outer belt. NOTICE: When removing the retractor of front seat outer belt, take care not to pull the seat belt pretensioner wire harness. (a) Disconnect the pretensioner connector as shown in the illustration. CAUTION: When removing the seat belt pretensioner, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and negative (-) terminal cable is disconnected from the battery. (b) Remove the 2 bolts and retractor of front seat outer belt. H11075 2001 AVALON (RM808U) Author
: Date
: 1914 BO-136 BODY - SEAT BELT PRETENSIONER BO2QN-01 REPLACEMENT REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner.
If the seat belt pretensioner has been activated.
If the seat belt pretensioner has been found to be faulty in troubleshooting.
If the front seat outer belt has been found to be faulty during checking item 1-(b) or 2-(b) (See page BO-130 ).
If the front seat outer belt has been dropped. CAUTION: For removal and installation of the seat belt pretensioner, see page BO-128 and BO-137 . Be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1921 BO-124 BODY - SEAT BELT SEAT BELT BO2QI-01 COMPONENTS 41 (420, 30) Front Seat Adjustable Anchor Center Pillar Garnish 41 (420, 30) Lower Center Pillar Garnish 7.5 (76, 66 in.·lbf) Front Door Scuff Inside Plate Front Seat Outer Belt Lap Belt Outer Anchor Cover 41 (420, 30) Front Seat Inner Belt Front Seat Manual seat: Front Seat Inner Belt 41 (420, 30) 41 (420, 30) Bench type: Front Seat Inner Belt 41 (420, 30) Front Seat Inner Belt 41 (420, 30) Front Seat Center Belt 41 (420, 30) N·m (kgf·cm, ft·lbf) : Specified torque H12221 2001 AVALON (RM808U) Author
: Date
: 1909 BO-125 BODY - SEAT BELT w/o Speaker: High-mounted Stop Light w/ Speaker: High-mounted Stop Light Roof Side Inner Garnish Package Tray Trim Rear Seat Outer Belt 41 (420, 30) 41 (420, 30) Seat Belt Retractor Cover 41 (420, 30) Rear Seat Outer Belt 41 (420, 30) RH Rear Seat Inner with Center Belt 18 (185, 13) 41 (420, 30) 41 (420, 30) LH Rear Inner with Center Belt Rear Seatback Assembly Roof Side Inner Garnish 18 (185, 13) Rear Seat Cushion Assembly N·m (kgf·cm, ft·lbf) : Specified torque H12222 2001 AVALON (RM808U) Author
: Date
: 1910 BO-126 BODY - SEAT BELT BO2QJ-01 INSPECTION CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts or sill-bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. RUNNING TEST (IN SAFE AREA) (a) Fasten the front seat belts. (b) BO0632 HINT: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper operation before installation. 2. Driver’s seat belt (ELR): STATIC TEST (a) Make sure that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Tilt the retractor slowly. (d) 15° 45° If a 3. BO0633 Drive the car at 10 mph (16 km/h) and slam on the brakes. Check that the belt locks and cannot be extended at this time. (a) (b) (c) (d) If a Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out over 45 degrees of tilt. problem is found, replace the assembly. Except driver’s seat belt (ALR/ELR): STATIC TEST Make sure that the belt locks when pulled out quickly. Remove the locking retractor assembly. Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again Make sure that the belt cannot be extended further. problem is found, replace the assembly. 2001 AVALON (RM808U) Author
: Date
: 1911 BO-127 BODY (e) (f) - SEAT BELT Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted. Tilt the retractor slowly. Full Belt Length Minus 200 mm (7.87 in.) N10070 (g) Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. 15° 45° BO0633 2001 AVALON (RM808U) Author
: Date
: 1912 BO-84 BODY - SLIDING ROOF BO2PR-01 ADJUSTMENT ADJUST SLIDING ROOF GLASS IN CLEARANCE (a) When the front or rear/left or right alignment is not correct, remove the drive gear and sliding roof glass, then adjust the drive cable. BO3396 NOTICE: Remove the drive gear with the sliding roof fully closed. (b) Adjust by sliding the cable forward or rearward or rearward to align the 2 marks as shown. (c) Install the driving ear and sliding roof glass. H12171 2001 AVALON (RM808U) Author
: Date
: 1869 BO-78 BODY - SLIDING ROOF BO2PO-01 COMPONENTS Sliding Roof Glass Window Deflector Panel 4.0 (41, 35 in.·lbf) Drive Cable Side Garnish Guide Cashing Rear Roof Drip Channel Drain Hose Guide Block Sliding Roof Housing Drive Gear Sunshade Trim Map Light Bracket Sliding Roof Panel Stopper 5.4 (55, 48 in.·lbf) Rear Frame Sliding Roof Bracket 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) Sliding Roof Bracket 5.4 (55, 48 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque H12167 2001 AVALON (RM808U) Author
: Date
: 1863 BO-81 BODY - SLIDING ROOF BO2PQ-01 DISASSEMBLY 1. (a) (b) 2. REMOVE SLIDING ROOF PANEL STOPPER Remove the screw and stopper. Employ the same manner described above to the other side. REMOVE SUNSHADE TRIM N21523 3. REMOVE REAR ROOF DRIP CHANNEL Remove the 2 screws and rear roof drip channel as shown in the illustration. H10166 4. REMOVE REAR FRAME Remove the 4 screws and rear frame. N21424 5. (a) (b) (c) REMOVE DRIVE CABLE Remove the screws and guide rail stopper. Remove the screw from the sliding roof housing. Slightly lift the sliding roof housing, and slide the drive cable rearward to then remove it. H12170 HINT:

At the time of reassembly, please refer to the following items. Adjust the drive cable to a closed and tilted down position. 2001 AVALON (RM808U) Author
: Date
: 1866 BO-82 BODY

(d) 6. - SLIDING ROOF Slide the cable forward or backward to align the 2 marks as shown in the illustration. Slide the cable to the forefront with your hand. Employ the same manner described above to the other side. REMOVE WINDOW DEFLECTOR PANEL H12171 7. (a) (b) (c) REMOVE SLIDING ROOF HOUSING Remove the 2 screws from the sliding roof housing. Remove the 4 screws from the guide block. Employ the same manner described above to the other side. (d) Disconnect the sliding roof housing from the drive rail, and slide the sliding roof housing forward. Remove the 2 guide blocks. H12172 (e) H12173 (f) Remove the sliding roof housing as shown in the illustration. H12174 2001 AVALON (RM808U) Author
: Date
: 1867 BO-83 BODY - SLIDING ROOF 8. REMOVE CABLE GUIDE CASING Remove the 2 screws and cable guide casing. H11049 2001 AVALON (RM808U) Author
: Date
: 1868 BO-86 BODY - SLIDING ROOF BO2PT-01 INSTALLATION Installation is in the reverse order of removal (See page BO-79 ). 2001 AVALON (RM808U) Author
: Date
: 1871 BO-77 BODY - SLIDING ROOF SLIDING ROOF BO2PN-01 ON-VEHICLE INSPECTION N10192 INSPECT SLIDING ROOF GLASS ALIGNMENT (a) Start the engine and check the operation time of the sliding roof. Operation time: Approx. 6 secs. (b) Check for abnormal noise or binding during operation. (c) With the sliding roof fully closed, check for water leakage. (d) Check for a difference in level between the sliding roof weatherstrip and roof panel. Except rear corners: 0 ± 1.5 mm (0 ± 0.059 in.) Rear corners: 0 + 1.5 mm (0 + 0.059 in.) 0 - 1.0 mm (0 - 0.039 in.) 2001 AVALON (RM808U) Author
: Date
: 1862 BO-85 BODY - SLIDING ROOF BO2PS-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO-81 ). 2001 AVALON (RM808U) Author
: Date
: 1870 BO-79 BODY - SLIDING ROOF BO2PP-01 REMOVAL 1. H12168 REMOVE ROOF HEADLINING (See page BO-99 ) 2. REMOVE SIDE GARNISH (a) Using a screwdriver, remove the garnish. HINT: Tape the screwdriver tip before use. (b) Employ the same manner described above to the other side. 3. REMOVE SLIDING ROOF GLASS ASSEMBLY (a) Using a torx wrench, remove the 4 nuts. Torque: 4.0 N·m (41 kgf·cm, 35 in.·lbf) (b) Pull the glass upward to remove it. 4. REMOVE DRIVE GEAR NOTICE: Remove the drive gear with the sliding roof fully closed. (a) Disconnect the connector. (b) Remove the 2 bolts an drive gear. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (c) Remove the 2 screws and map light bracket from the drive gear. 2001 AVALON (RM808U) Author
: Date
: 1864 BO-80 BODY 5. (a) (b) (c) - SLIDING ROOF REMOVE SLIDING ROOF HOUSING Disconnect the 4 drain hoses from the housing. Remove the 8 bolts and 4 brackets. Torque: 5.4 (55 kgf·cm, 48 in.·lbf) Remove the 6 nuts, then remove the sliding roof housing. Torque: 5.4 (55 kgf·cm, 48 in.·lbf) H12169 2001 AVALON (RM808U) Author
: Date
: 1865 BO-3 BODY - SRS AIRBAG SRS AIRBAG BO0XI-03 PRECAUTION The AVALON is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag and side airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 2001 AVALON (RM808U) Author
: Date
: 1788 BO-3 BODY - SRS AIRBAG SRS AIRBAG BO0XI-03 PRECAUTION The AVALON is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag and side airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 2001 AVALON (RM808U) Author
: Date
: 1788 BO-55 BODY - WINDSHIELD WINDSHIELD BO2PE-01 COMPONENTS Assist Grip Roof Headlining Sun Visor Inner Rear View Mirror Cover Front Pillar Garnish w/ Sliding roof: Sliding Roof Opening Trim Holder Inner Rear View Mirror Roof Console Box
No. 2 Stopper
No. 1 Stopper Front Door Opening Trim Sun Visor
Dam Lens
No. 1 Stopper Holder Front Pillar Garnish Front Door Opening Trim
No. 2 Stopper
Retainer
Windshield Upper Moulding
Dam Windshield Glass 24 (248, 18) Wiper Arm Cowl Top Ventilator Louver 24 (248, 18) Hood To Cowl Top Seal N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part H12155 2001 AVALON (RM808U) Author
: Date
: 1840 BO-59 BODY - WINDSHIELD BO2PG-01 INSTALLATION Adhesive BO4420 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (a) Using a knife, cut away any rough areas on the body. HINT: Leave of the adhesive on the body as much as possible. (b) Clean the cut surface of the adhesive with a piece of shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. (a) (b) CLEAN REMOVED GLASS Remove the damaged No. 2 stoppers and dams. Using a scraper, remove the adhesive sticking to the glass. (c) Clean the glass with cleaner. NOTICE:
Be careful not to damage the glass.
Do not touch the glass face after cleaning it. BO5231 3. (a) (b) H10503 REPLACE NO. 1 STOPPERS Remove the damaged stoppers. Cut off the old adhesive around the stopper installation area. NOTICE: Be careful not to damage the body. (c) Clean the installation area. (d) Attach new stoppers to the body so that the notches on the body will align with the stoppers as shown in the illustration. HINT: Make sure that the stoppers are installed facing in the correct direction. 4. INSTALL NEW NO. 2 STOPPERS Attach new stoppers to the glass so that the ceramic notches on the glass will align with the stoppers as shown in the illustration. HINT: Make sure that the stoppers are installed facing the correct direction. A: 7.2 ± 0.5 mm (0.283 ± 0.020 in.) A H12148 2001 AVALON (RM808U) Author
: Date
: 1844 BO-60 BODY - WINDSHIELD 5. INSTALL NEW RETAINERS Attach new retainers to the glass with the ceramic notch on the glass aligned with the retainers as shown in the illustration. H12149 6. INSTALL NEW DAMS Attach new dams to the glass as shown in the illustration. Dam H12150 7. (a) (b) (c) (d) POSITION GLASS Place the glass in the correct position. Check that all contacting parts of the glass rim are set perfectly even. Place reference marks on the glass and body. Remove the glass. H04300 8. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black-colored area around the entire glass rim. NOTICE: Do not touch the glass face after cleaning it. BO4421 2001 AVALON (RM808U) Author
: Date
: 1845 BO-61 BODY - WINDSHIELD 9. Primer M Primer M Adhesive H02865 COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat Primer M to the exposed part of body on the vehicle side. NOTICE:
Allow 3 minutes or more to dry the primer coated surface.
Do not coat Primer M to the adhesive.
Do not keep any of the opened Primer M for later use. 10. COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G as shown in the illustration. (b) When the primer is applied by mistake to the area other than the specified, wipe it off with a clean shop rag before the primer dries. NOTICE:
Allow 3 minutes or more to dry the primer coated surface.
Do not keep any of the opened Primer G for later use. a a b b c c a-a b-b c - c Primer G H12151 11. (a) a a b APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850-00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table below. b a-a Temperature Tackfree time c 35 °C (95 °F) 15 minutes c 20 °C (68 °F) 100 minutes 5 °C (41 °F) 8 hours b-b B c - c (b) (c) A A B Load the cartridge into the sealer gun. Coat the glass with adhesive as shown in the illustration. A: 13.5 mm (0.531 in.) B: 8.0 mm (0.315 in.) A B Adhesive H12152 2001 AVALON (RM808U) Author
: Date
: 1846 BO-62 BODY 12. (a) - WINDSHIELD INSTALL WINDSHIELD GLASS AND MOULDING Install the glass, aligning the reference marks using a suction rubber. HINT: Check to see that the stoppers are attached to the body correctly. (b) Lightly press the glass front surface for close contact. BO2821 (c) Correct insufficient or protruded adhesive agent using a spatula. HINT: Apply adhesive agent up to the windshield glass edge. H00679 (d) w/o Rain gutter: H12153 w/ Rain gutter: a a b a-a b Install a new windshield moulding to the windshield glass before the adhesive agent hardens. HINT: Install the moulding, aligning the center of moulding with the center of body. (e) Remove any excessive adhesive agent before it hardens. (f) Hold the glass and moulding in place securely with a protective tape or equivalent until the adhesive hardens. NOTICE: Take care not to drive the vehicle during the time described in the table below. Temperature Minimum time prior to driving the vehicle 35 °C (95 °F) 1.5 hours 20 °C (68 °F) 5 hours 5 °C (41 °F) 24 hours 13. INSPECT FOR LEAK AND REPAIR NOTICE: Conduct a leak test after the hardening time has elapsed. 14. w/ Sliding roof: INSTALL SLIDING ROOF OPENING TRIM 15. INSTALL ASSIST GRIP 16. INSTALL COWL TOP VENTILATOR LOUVER 17. INSTALL HOOD TO COWL TOP SEAL 18. INSTALL WIPER ARMS (a) Operate the wiper motor once and turn the wiper switch OFF. (b) Install the wiper arms and tighten nuts by hand. b-b H12154 2001 AVALON (RM808U) Author
: Date
: 1847 BO-63 BODY (c) C A (d) B B H12134 (e) 19. 20. 21. 22. 23. - WINDSHIELD Adjust the installation position of the wiper arms to the position as shown in the illustration. A: 52 mm (2.05 in.) B: 30 ± 10 mm (1.18 ± 0.39 in.) C: 21.3 mm (0.839 in.) Torque the 2 nuts. Torque: 24 N·m (248 kgf·cm, 18 ft·lbf) Install the 2 wiper arm head caps. INSTALL FRONT PILLAR GARNISH INSTALL FRONT DOOR OPENING TRIMS INSTALL ROOF CONSOLE BOX INSTALL SUN VISORS AND HOLDERS INSTALL INNER REAR VIEW MIRROR 2001 AVALON (RM808U) Author
: Date
: 1848 BO-56 BODY - WINDSHIELD BO2PF-01 REMOVAL 1. (a) REMOVE INNER REAR VIEW MIRROR w/ Electrochromic rear view mirror: Using a screwdriver, remove the inner rear view mirror cover. HINT: Tape the screwdriver tip before use. (b) w/ Electrochromic rear view mirror: Disconnect the connector. (c) 2. Remove the inner rear view mirror as shown in the illustration. REMOVE SUN VISORS AND HOLDERS H12143 3. REMOVE ROOF CONSOLE BOX (a) Using a screwdriver, remove the map light lens. HINT: Tape the screwdriver tip before use. (b) Remove the 3 screws and roof console box, then disconnect the connector. 4. REMOVE FRONT DOOR OPENING TRIMS H12144 5. (a) (b) 6. 7. 2 Clips REMOVE FRONT PILLAR GARNISH Remove the front pillar garnish. Employ the same manner described above to the other side. REMOVE WIPER ARMS REMOVE HOOD TO COWL TOP SEAL H12145 8. (a) (b) 9. 10. REMOVE COWL TOP VENTILATOR LOUVER Using a clip remover, remove the 2 clips. Remove the cowl top ventilator louver as shown in the illustration. REMOVE ASSIST GRIP w/ Sliding roof: REMOVE SLIDING ROOF OPENING TRIM H12129 2001 AVALON (RM808U) Author
: Date
: 1841 BO-57 BODY w/ Rain gutter: a a b a-a b - WINDSHIELD 11. REMOVE WINDSHIELD UPPER MOULDING (a) Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. (b) Remove the remaining moulding. b- -b H12146 w/o Rain gutter: H12147 12. (a) REMOVE WINDSHIELD GLASS Insert a piano wire between body and glass and let it pass through. Tie both wire ends to wooden blocks or similar objects. (b) HINT: Apply protective tape to the outer surface to keep the surface from being scratched. BO5232 NOTICE: When separating the glass, take care not to damage the paint and interior and exterior ornaments. To prevent the safety pad from being scratched when removing the windshield, place a plastic sheet between the piano wire and safety pad. (c) Cut the adhesive by pulling the piano wire around it. (d) Remove the glass. BO1689 2001 AVALON (RM808U) Author
: Date
: 1842 BO-58 BODY - WINDSHIELD NOTICE: Leave of the adhesive on the body as much as possible when cutting off the glass. 2001 AVALON (RM808U) Author
: Date
: 1843 BR-47 BRAKE - ABS ACTUATOR ABS ACTUATOR BR0LL-05 COMPONENTS 15 (155, 11) 13 (130, 9) Holder ABS Actuator Holder 15 (155, 11) Cushion Cushion 19 (195, 14) Actuator Bracket Air Cleaner Assembly 19 (195, 14) N·m (kgf·cm, ft·lbf) : Specified torque F09731
3.0 (31, 27 in.·lbf) ECU Spring Plate Actuator N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part W03328 2001 AVALON (RM808U) Author
: Date
: 1446 BR-49 BRAKE - ABS ACTUATOR BR0LN-03 DISASSEMBLY 1. 2. (a) W03326 DISCONNECT CONNECTOR REMOVE ECU Using a T20 torx wrench, loosen the 6 screws. Torque: 3.0 N·m (31 kgf·cm, 27 in.·lbf) NOTICE: At the time of reassembly, tighten the screws according to the order shown on the left. (b) Remove the ECU and spring plate from the actuator. NOTICE: Protect the actuator in order to prevent sealing surface from getting dirty and causing damage on the valve body. If the dirt and the like are stuck to the sealing surface, use plastic tools or soft objects to remove the dirt. Do not use chemical solvents. 2001 AVALON (RM808U) Author
: Date
: 1448 BR-51 BRAKE - ABS ACTUATOR BR0LP-04 INSTALLATION Installation is in the reverse order of removal (See page BR-48 ). HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks. 2001 AVALON (RM808U) Author
: Date
: 1450 BR-50 BRAKE - ABS ACTUATOR BR0LO-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR-49 ). 2001 AVALON (RM808U) Author
: Date
: 1449 BR-48 BRAKE - ABS ACTUATOR BR154-01 REMOVAL 2 1. REMOVE AIR CLEANER ASSEMBLY 2. DISCONNECT CONNECTOR Pull out the release bar, and disconnect the connector. 1 F09732 3. DISCONNECT BRAKE LINES Using SST, disconnect the 6 brake lines from the ABS actuator. SST 09023-00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) F09733 4. REMOVE ABS ACTUATOR ASSEMBLY Remove the 3 bolts and ABS actuator assembly. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) 5. REMOVE ABS ACTUATOR (a) Remove the 2 nuts and ABS actuator. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (b) Remove the 2 holders and 3 cushions from the ABS actuator. F09734 2001 AVALON (RM808U) Author
: Date
: 1447 BR-53 BRAKE - ABS & VSC ACTUATOR BR156-01 COMPONENTS 15 (155, 11) 15 (155, 11) Air Cleaner Assembly ABS & VSC Actuator Assembly 19 (195, 14) 19 (195, 14) Holder 13 (130, 9) ABS & VSC Actuator Holder 13 (130, 9) Cushion Cushion Actuator Bracket N·m (kgf·cm, ft·lbf) : Specified torque F09735 2001 AVALON (RM808U) Author
: Date
: 1452 BR-55 BRAKE - ABS & VSC ACTUATOR BR158-01 INSTALLATION Installation is in the reverse order of removal (See page BR-54 ). HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks. 2001 AVALON (RM808U) Author
: Date
: 1454 BR-52 BRAKE TOYOTA Hand-held Tester - ABS & VSC ACTUATOR ABS & VSC ACTUATOR BR155-01 ON-VEHICLE INSPECTION 1. (a) (b) (c) DLC3 D07259 CONNECT TOYOTA HAND-HELD TESTER: Connect the TOYOTA hand-held tester to the DLC3. Start the engine and run it at idle. Select the ACTIVE TEST mode on the TOYOTA handheld tester. Please refer to the TOYOTA hand-held tester operator’s manual for further details. 2. INSPECT ACTUATOR MOTOR OPERATION (a) With the motor relay ON, check the actuator motor operation noise. (b) Turn the motor relay OFF. (c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be depressed. (d) With the motor relay ON, check that the pedal does not pulsate. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (e) Turn the motor relay OFF and release the brake pedal. 3. INSPECT RIGHT FRONT WHEEL OPERATION NOTICE: Never turn ON the solenoid which is not described below. (a) With the brake pedal depressed, perform the following operations. (b) Turn the SFRH and SFRR solenoid ON simultaneously, and check that the pedal cannot be depressed. NOTICE: Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (c) Turn the SFRH and SFRR solenoid OFF simultaneously, and check that the pedal can be depressed. (d) Turn the motor relay ON, and check that the pedal returns. NOTICE: Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously, set the interval of more than 20 seconds. (e) Turn the motor relay OFF and release the brake pedal. 4. INSPECT OTHER WHEEL OPERATION As in the same procedure, check the solenoids of other wheels. HINT: Left front wheel: SFLH, SFLR Right rear wheel: SRRH, SRRR Left rear wheel: SRLH, SRLR 5. CLEAR DTC (See page DI-252 ) 2001 AVALON (RM808U) Author
: Date
: 1451 BR-54 BRAKE - ABS & VSC ACTUATOR BR157-01 REMOVAL 1. 2. REMOVE AIR CLEANER ASSEMBLY DISCONNECT ABS & VSC ACTUATOR CONNECTOR 3. DISCONNECT BRAKE LINES Using SST, disconnect the 6 brake lines from the ABS & VSC actuator. SST 09023-00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) F09736 F09737 4. REMOVE ABS & VSC ACTUATOR ASSEMBLY Remove the 3 bolts and ABS & VSC actuator assembly. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) 5. REMOVE ABS & VSC ACTUATOR (a) Remove the 2 nuts and ABS & VSC actuator from the bracket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (b) Remove the 2 holders and 3 cushions from the ABS & VSC actuator. 2001 AVALON (RM808U) Author
: Date
: 1453 BR-22 BRAKE - BRAKE BOOSTER ASSEMBLY BR0KX-04 COMPONENTS Air Cleaner with Air Cleaner Hose Return Spring Pin Vacuum Hose Wave Washer Master Cylinder 15 (155, 11) Clip Clevise 2-way Level Warning Switch Connetor 13 (130, 9)
Gasket Brake Booster Assembly 13 (130, 9) w/ VSC: 15 (155, 11) 12 (260, 19) 19 (195, 14) 13 (130, 9) 19 (195, 14) Precharge Pump Assembly Lower LH Instrument Panel Insert Lower No. 1 Instrument Panel No. 2 Heater to Register Duct N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part F09719 2001 AVALON (RM808U) Author
: Date
: 1421 BR-24 BRAKE - BRAKE BOOSTER ASSEMBLY BR152-01 INSTALLATION 1. (a) (b) (c) (d) (e) Master Cylinder INSTALL BRAKE BOOSTER Install the booster and a new gasket. Install the clevis to the operating rod. Install and torque the booster installation nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. Install the pedal return spring. 2. (a) ADJUST LENGTH OF BOOSTER PUSH ROD Set the SST on the master cylinder, and lower the pin until its tip slightly touches the piston. SST 09737-0001 1 (b) Turn the SST upside down, and set it on the booster. SST 09737-0001 1 Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 in.) SST F05420 SST (c) F05422 (d) 3. SST F05421 4. 5. 6. 7. 8. 9. 10. Using SST, adjust the booster push rod length until the push rod lightly touches the pin head. SST 09737-00020 w/ VSC: INSTALL PRECHARGE PUMP ASSEMBLY (See page BR-58 ) INSTALL MASTER CYLINDER (See page BR-20 ) CONNECT VACUUM HOSE TO BRAKE BOOSTER FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR-4 ) CHECK FOR LEAKS CHECK AND ADJUST BRAKE PEDAL (See page BR-6 ) INSTALL NO. 2 HEATER TO REGISTER DUCT, LOWER LH INSTRUMENT PANEL INSERT AND LOWER NO. 1 INSTRUMENT PANEL (See page BO-87 ) DO OPERATIONAL CHECK (See page BR-21 ) 2001 AVALON (RM808U) Author
: Date
: 1423 BR-21 BRAKE - BRAKE BOOSTER ASSEMBLY BRAKE BOOSTER ASSEMBLY BR0KW-04 ON-VEHICLE INSPECTION 1. (a) (b) BR2237 1st 2nd 2. (a) NO GOOD GOOD OPERATING CHECK Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. 3rd BR2238 AIR TIGHTNESS CHECK Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. (b) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reverse travel after holding the pedal for 30 seconds, the booster is air tight. 2001 AVALON (RM808U) Author
: Date
: 1420 BR-23 BRAKE - BRAKE BOOSTER ASSEMBLY BR0KY-05 REMOVAL 1. 2. 3. 4. 5. 6. (a) (b) (c) (d) REMOVE AIR CLEANER COVER WITH AIR CLEANER HOSE REMOVE MASTER CYLINDER (See page BR-15 ) w/ VSC: REMOVE PRECHARGE PUMP ASSEMBLY (See page BR-57 ) DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOWER LH INSTRUMENT PANEL INSERT AND NO. 2 HEATER TO REGISTER DUCT (See page BO-87 ) REMOVE BRAKE BOOSTER ASSEMBLY Remove the pedal return spring. Remove the clip and clevis pin. Remove the 4 nuts and clevis. Pull out the brake booster and gasket. F06431 2001 AVALON (RM808U) Author
: Date
: 1422 BR-13 BRAKE - BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER BR0KQ-04 COMPONENTS Air Cleaner Cover with Air Cleaner Hose w/ VSC: 3-way Master Cylinder Level Warning Switch Connetor 15 (155, 11) 2-way 13 (130, 9) 13 (130, 9) Brake Booster 15 (155, 11) N·m (kgf·cm, ft·lbf) : Specified torque F09712 2001 AVALON (RM808U) Author
: Date
: 1412 BR-14 BRAKE - BRAKE MASTER CYLINDER w/o VSC: Cap Strainer Reservoir Set Screw Reservoir 1.7 (17.5, 15.2 in.·lbf) Snap Ring
O-Ring Grommet Grommet No. 1 Piston and Spring Cylinder Body No. 2 Piston and Spring
Gasket Stopper Bolt 10 (100, 7) w/ VSC: Cap Strainer Reservoir Set Screw Reservoir 1.7 (17.5, 15.2 in.·lbf) Snap Ring
O-Ring Straight Pin Grommet Grommet No. 1 Piston and Spring No. 2 Piston and Spring N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Lithium soap base giycol grease Cylinder Body F09748 2001 AVALON (RM808U) Author
: Date
: 1413 BR-16 BRAKE - BRAKE MASTER CYLINDER BR0KS-03 DISASSEMBLY 1. (a) (b) 2. 3. REMOVE RESERVOIR Remove the set screw and pull out the reservoir. Torque: 1.7 N·m (17.5 kgf·cm, 15.2 in.·lbf) Remove the cap and strainer from the reservoir. REMOVE 2 GROMMETS w/o VSC: PLACE CYLINDER IN VISE 4. w/o VSC: REMOVE PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket. HINT: Tape the screwdriver tip before use. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Soft Jows F09715 5. (a) Soft Jows F09716 w/o VSC: REMOVE 2 PISTONS AND SPRINGS Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. (b) Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle. NOTICE:
If pulled out and install at an angle, there is a possibility that the cylinder bore could be damaged.
At the time of reassembly, be careful not to damage the rubber lips on the pistons. (c) Place a rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against the block edges until the No. 2 piston drops out of the cylinder. HINT: Make sure that the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 in.). A R12236 2001 AVALON (RM808U) Author
: Date
: 1415 BR-17 BRAKE 6. (a) F09717 - BRAKE MASTER CYLINDER w/ VSC: REMOVE 2 PISTONS AND SPRINGS Push in the piston with a screwdriver, and remove the straight pin by turning over the cylinder body. HINT: Tape the screwdriver tip before use. (b) Remove the 2 piston and springs by hand, pulling straight out, not at an angle. NOTICE:
If pulled out and installed at an angle, there is a possibly that the cylinder bore could be damaged.
At the time of reassembly, be careful not to damage the rubber lips on the pistons. HINT: Insert the No. 2 piston with the groove positioning horizontally. F09718 2001 AVALON (RM808U) Author
: Date
: 1416 BR-18 BRAKE - BRAKE MASTER CYLINDER BR0KT-01 INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT CYLINDER BORE FOR RUST OR SCORING 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. 2001 AVALON (RM808U) Author
: Date
: 1417 BR-20 BRAKE - BRAKE MASTER CYLINDER BR0KV-05 INSTALLATION Installation is in the reverse order of removal (See page BR-15 ). HINT:
Before installation, adjust length of brake booster push rod (See page BR-24 ).
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ), and check for leaks.
Check and adjust brake pedal (See page BR-6 ). 2001 AVALON (RM808U) Author
: Date
: 1419 BR-19 BRAKE - BRAKE MASTER CYLINDER BR0KU-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See-page BR-16 ). NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page BR-13 ). 2001 AVALON (RM808U) Author
: Date
: 1418 BR-15 BRAKE - BRAKE MASTER CYLINDER BR0KR-02 REMOVAL 1. REMOVE AIR CLEANER COVER WITH AIR CLEANER HOSE 2. TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 3. DISCONNECT LEVEL WARNING SWITCH CONNECTOR 4. w/ VSC: DISCONNECT RESERVOIR HOSE 5. (a) (b) SST F09713 DISCONNECT BRAKE LINES w/o VSC: Using SST, disconnect the 4 brake lines from the master cylinder and 2-way. SST 09023-00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) w/ VSC: Using SST, disconnect the 5 brake lines from the master cylinder and 3-way. SST 09023-00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) 6. REMOVE MASTER CYLINDER Remove the 2 mounting nuts, and pull out the 2 or 3-way, master cylinder and gasket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) F09714 2001 AVALON (RM808U) Author
: Date
: 1414 BR-4 BRAKE - BRAKE FLUID BRAKE FLUID BR14Z-01 BLEEDING HINT: If any work is done on the brake system or if air in the brake lines is suspected, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 F09707 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. SST 09023-00100 (b) Slowly depress the brake pedal and hold it. F09708 (c) (d) Block off the outlet plugs with your fingers, and release the brake pedal. Repeat (b) and (c) 3 or 4 times. F09709 3. CONNECT VINYL TUBE TO BRAKE CALIPER BLEEDER PLUG Insert other end of the tube in a half-full container of brake fluid. NOTICE: Bleed air of the rear brake first. If front brake is bled first, rear brake air cannot be bled. 4. BLEED BRAKE LINE (a) Slowly depress the brake pedal several times. R00699 2001 AVALON (RM808U) Author
: Date
: 1403 BR-5 BRAKE (b) (c) 5. - BRAKE FLUID While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. Repeat this procedure until there are no more air bubbles in the fluid. Bleeder plug tightening torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) REPEAT PROCEDURE FOR EACH WHEEL 6. SST F10182 1 (-) 2 (+) F07901 w/ VSC: BLEED PRECHARGE PUMP CAUTION: When repairing the brake master cylinder or precharge pump, bleed the precharge pump of the air. (a) Install the SST to the reservoir. SST 09992-00242, 09992-00350 (b) Using SST, apply pressure to the reservoir. Pressure: 98.1 kpa (1.0 kgf/cm2, 14.2 psi) (c) Disconnect the precharge pump connector. (d) Connect ML+ (2) terminal to the battery positive (+) and ML- (1) terminal to the battery negative (-), and activate the precharge pump about 20 seconds. (e) Remove the SST from the reservoir. (f) Connect the vinyl tube to the front brake caliper RH, and loosen the bleeder plug. (g) Activate the precharge pump again until there are no more air bubbles in the fluid. Bleeder plug tightening torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) (h) Connect the precharge pump connector. 7. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 2001 AVALON (RM808U) Author
: Date
: 1404 BR-8 BRAKE - BRAKE PEDAL BR150-01 COMPONENTS Lower No. 1 Instrument Panel Brake Pedal Assembly 13 (130, 9) Lower LH Panel Insert 13 (130, 9) Stop Light Switch Brake Pedal Bracket 5.0 (51, 44 in.·lbf) Cruise Control ECU
Bushing Collar Cushion Plate
Bushing Clevis Pin 39 (400, 29) Clip Wave Washer Return Spring N·m (kgf·cm, ft·lbf) Pedal Pad : Specified torque
Non-reusable part Lithium soap base glycol grease Brake Pedal F09720 2001 AVALON (RM808U) Author
: Date
: 1407 BR-6 BRAKE - BRAKE PEDAL BRAKE PEDAL Stop Light Switch BR0KI-04 ON-VEHICLE INSPECTION 1. Push Rod Pedal Height R00954 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. (a) Pedal Freeplay R00935 CHECK PEDAL FREEPLAY 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 resistance 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 clearance 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. 2001 AVALON (RM808U) Author
: Date
: 1405 BR-7 BRAKE Pedal Reserve Distance - BRAKE PEDAL 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 system. R00934 2001 AVALON (RM808U) Author
: Date
: 1406 BR-1 BRAKE - BRAKE SYSTEM BRAKE SYSTEM BR0MH-01 PRECAUTION


Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent. It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 2001 AVALON (RM808U) Author
: Date
: 1400 BR-28 BRAKE - FRONT BRAKE CALIPER FRONT BRAKE CALIPER BR0L2-04 COMPONENTS Caliper 107 (1,090, 79) Torque Plate 29 (300, 22) 34 (350, 25) Disc Bleeder Plug 8.3 (85, 74 in.·lbf) 29 (300, 22)
Gasket Sliding Pin
Sliding Bushing Piston
Dust Boot Set Ring Piston Seal Boot Sliding Pin Pad Support Plate
Dust Boot Anti-squeal Shim Pad Wear Indicator Plate Inner Pad Inner Anti-squeal Shim Outer Pad Inner Anti-squeal Shim Anti-squeal Shim N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Lithium soap base glycol grease Disc brake grease F06986 2001 AVALON (RM808U) Author
: Date
: 1427 BR-30 BRAKE - FRONT BRAKE CALIPER BR0L4-04 DISASSEMBLY 1. REMOVE SET RING AND CYLINDER BOOT Using a screwdriver, remove the set ring and cylinder boot from the caliper. R00121 2. (a) REMOVE PISTON Place a piece of cloth or similar, between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. R00122 3. REMOVE PISTON SEAL Using a screwdriver, remove the piston seals from the cylinder. R00123 R02877 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. NOTICE: At the time of reassembly, insert the sliding pin with sliding bushing into the top side. (b) Using a screwdriver and hammer, tap out the 2 dust boots. HINT: At the time of reaseembly, use a 24 mm socket wrench and tap in 2 new dust boots into the torque plate. NOTICE: At the time of reassembly, confirm that the metal plate portion of the dust boot fits snugly in the torque plate. 2001 AVALON (RM808U) Author
: Date
: 1429 BR-31 BRAKE - FRONT BRAKE CALIPER BR0L5-04 INSPECTION 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the minimum thickness or less, or if the pad has severe, uneven wear. F06988 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) Replace the disc if the disc’s thickness is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. F06395 F06396 3. MEASURE DISC RUNOUT Using a dial indicator, measure the disc runout 10 mm (0.39 in.) from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) If the disc’s runout is at the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See page SA-9 ). If the bearing play and axle hub runout are not abnormal, adjusting the disc runout or grind it on a ”On-Car” brake lathe. 4. (a) (b) F06397 (c) (d) (e) (f) IF NECESSARY, ADJUST DISC RUNOUT Remove the mounting bolts and torque plate from the knuckle. Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the hub nuts. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) Remeasure the disc runout. Make a note of the runout and the disc’s position on the hub. Repeat (b) until the disc has been installed on the 3 remaining hub positions. If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 in.), install the disc in that position. If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. Install the torque plate and torque the mounting bolts. Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1430 BR-33 BRAKE - FRONT BRAKE CALIPER BR0L7-04 INSTALLATION Installation is in the reverse order of removal (See page BR-29 ). HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks. 2001 AVALON (RM808U) Author
: Date
: 1432 BR-32 BRAKE - FRONT BRAKE CALIPER BR0L6-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR-30 ). NOTICE: Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR-28 ). 2001 AVALON (RM808U) Author
: Date
: 1431 BR-29 BRAKE - FRONT BRAKE CALIPER BR0L3-04 REMOVAL R02840 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. DISCONNECT FLEXIBLE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. (b) Use a container to catch the brake fluid as it drains out. 3. REMOVE CALIPER (a) Remove the 2 installation bolts. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) (b) Remove the caliper from the torque plate. 4. REMOVE 2 BRAKE PADS WITH ANTI- SQUEAL SHIMS 5. REMOVE 2 PAD SUPPORT PLATES 2001 AVALON (RM808U) Author
: Date
: 1428 BR-25 BRAKE - FRONT BRAKE PAD FRONT BRAKE PAD BR0L0-04 COMPONENTS 34 (350, 25) Anti-squeal Shim Inner Anti-squeal Shim Pad Wear Indicator Plate Outer Pad Pad Support Plate Inner Pad N·m (kgf·cm, ft·lbf) : Specified torque Disc brake grease F06983 2001 AVALON (RM808U) Author
: Date
: 1424 BR-26 BRAKE - FRONT BRAKE PAD BR0L1-04 REPLACEMENT F06984 F06985 1. REMOVE FRONT WHEEL 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace the pads if it is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Remove the bolt and flexible hose from the shock absorber bracket. (b) Remove the bottom side installation bolt. (c) Lift up the caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the caliper. 4. REMOVE 2 BRAKE PADS WITH 4 ANTI- SQUEAL SHIMS 5. REMOVE PAD WEAR INDICATOR PLATE 6. REMOVE 2 PAD SUPPORT PLATES NOTICE: The support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 7. CHECK DISC THICKNESS AND RUNOUT (See page BR-31 ) 8. INSTALL 2 PAD SUPPORT PLATES 9. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti-squeal shims and wear indicator plates must be replaced together with the pads. (a) Install a pad wear indicator plate on the inner pad. (b) Apply disc brake grease to both sides of the inner antisqueal shims (See page BR-25 ). (c) Install the 2 anti-squeal shims on each pad. (d) Install inner pad with the pad wear indicator plate facing upward. (e) Install outer pad. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 2001 AVALON (RM808U) Author
: Date
: 1425 BR-27 BRAKE 10. (a) (b) R02981 - FRONT BRAKE PAD INSTALL CALIPER Draw out a small amount of brake fluid from the reservoir. Press in the piston with a hammer handle or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. (c) Install the caliper. (d) Hold the sliding pin and torque the installation bolt. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) (e) Install the flexible hose and bolt to the shock absorber bracket. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) 11. INSTALL FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 12. DEPRESS BRAKE PEDAL SEVERAL TIMES 13. CHECK THAT FLUID LEVEL IS AT MAX LINE 2001 AVALON (RM808U) Author
: Date
: 1426 BR-59 BRAKE - FRONT SPEED SENSOR FRONT SPEED SENSOR BR0LU-02 COMPONENTS Sensor Rotor 8.0 (82, 71 in.·lbf) 5.4 (55, 48 in.·lbf) Front Speed Sensor N·m (kgf·cm, ft·lbf) : Specified torque F09738 2001 AVALON (RM808U) Author
: Date
: 1458 BR-61 BRAKE - FRONT SPEED SENSOR BR0LW-03 INSTALLATION Installation is in the reverse order of removal (See page BR-60 ). AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI-252 or DI-212 ) 2001 AVALON (RM808U) Author
: Date
: 1460 BR-60 BRAKE - FRONT SPEED SENSOR BR0LV-03 REMOVAL 1. (a) (b) DISCONNECT SPEED SENSOR CONNECTOR Remove the fender liner. Disconnect the speed sensor connector. 2. (a) REMOVE SPEED SENSOR Remove the 2 clamp bolts holding the sensor harness to the body and shock absorber. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Remove the bolt and speed sensor from the steering knuckle. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) R00327 (b) F09739 2001 AVALON (RM808U) Author
: Date
: 1459 BR-43 BRAKE - PARKING BRAKE PARKING BRAKE BR0LG-03 COMPONENTS Adjuster Guide Plate Spring Shoe Strut Shoe Return Spring 47 (475, 34) Pin Shim
C-washer Parking Brake Lever 47 (475, 34) Cap Pin Shoe Hold-down Spring Adjuster Rear Disc Brake Assembly Front Shoe Rear Shoe Tension Spring Cap Plug N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part High temperature grease Disc F09730 2001 AVALON (RM808U) Author
: Date
: 1442 BR-44 BRAKE - PARKING BRAKE BR0LH-03 DISASSEMBLY 1. 2. (a) (b) W04053 REMOVE REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) REMOVE REAR DISC BRAKE ASSEMBLY Remove the 2 mounting bolts and remove the disc brake assembly. Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) Suspend the disc brake securely. Ensure that the hose is not stretched. 3. REMOVE DISC Release the parking brake pedal, and remove the disc. HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. R00309 4. REMOVE SHOE RETURN SPRINGS Using needle-nose pliers, remove the 2 shoe return springs. 5. REMOVE FRONT SHOE, ADJUSTER AND TENSION SPRING (a) Disconnect the tension spring from the front shoe. (b) Slide out the front shoe and remove the shoe adjuster. (c) Remove the shoe strut with the spring. (d) Remove the shoe hold-down spring, 2 caps and pin. BR3948 6. (a) (b) (c) REMOVE REAR SHOE Slide out the rear shoe and remove the tension spring. Remove the shoe hold-down spring, 2 caps and pin. Using needle-nose pliers, disconnect the parking brake cable from the parking brake shoe lever. R00310 2001 AVALON (RM808U) Author
: Date
: 1443 BR-45 BRAKE - PARKING BRAKE BR0LI-03 INSPECTION R00311 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. 2. MEASURE BRAKE SHOE LINING THICKNESS Using a ruler, measure the thickness of the shoe lining. Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is at the minimum thickness or less, or if there is severe, uneven wear, replace the brake shoe. 3. MEASURE DISC INSIDE DIAMETER Using a brake drum gauge or equivalent, measure the inside diameter of the disc. Standard inside diameter: 170 mm (6.69 in.) Maximum inside diameter: 171 mm (6.73 in.) Replace the disc if the inside diameter is at the maximum value or more. Replace the disc or grind it with a lathe if the disc is scored or worn unevenly. F06409 4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the disc and the brake shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly. BR0828 5. MEASURE CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.0138 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Shim Clearance R00343 6. (a) (b) (c) Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) - IF NECESSARY, REPLACE SHIM Using a screwdriver, remove the C-washer and shim. Install the correct size shim with a new C-washer. Remeasure the clearance. R00313 2001 AVALON (RM808U) Author
: Date
: 1444 BR-46 BRAKE - PARKING BRAKE BR0LJ-03 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR-44 ). NOTICE: Apply high temperature grease to the parts indicated by the arrows (See page BR-43 ). 1. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Temporarily install the hub nuts. (b) Remove the hole plug. (c) Contract (d) (e) 2. (a) (b) Expand BR0823 (c) (d) 3. Turn the adjuster and expand the shoes until the disc locks. Return the adjuster 8 notches. Install the hole plug. SETTLING PARKING BRAKE SHOES AND DISC Depress the parking brake pedal with 147 N (15 kgf, 33 lbf). Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road. Drive the vehicle for about 400 meters (0.25 mile) in this condition. Repeat this procedure 2 or 3 times. RECHECK AND ADJUST PARKING BRAKE PEDAL TRAVEL (See page BR-9 ) 2001 AVALON (RM808U) Author
: Date
: 1445 BR-10 BRAKE - PARKING BRAKE PEDAL BR0KK-03 COMPONENTS No. 2 Heater to Register Duct Lower LH Panel Insert Lower No. 1 Instrument Panel 61 (620, 45) Parking Brake Pedal Assembly Parking Brake Switch Clip 61 (620, 45) Cushion Pedal Pad 61 (620, 45) Parking Brake Cable N·m (kgf·cm, ft·lbf) : Specified torque F09711 2001 AVALON (RM808U) Author
: Date
: 1409 BR-12 BRAKE - PARKING BRAKE PEDAL BR0KM-03 INSTALLATION Installation is in the reverse order of removal (See page BR-1 1). AFTER INSTALLATION, ADJUST PARKING BRAKE PEDAL TRAVEL (See page BR-6 ) 2001 AVALON (RM808U) Author
: Date
: 1411 BR-9 BRAKE - PARKING BRAKE PEDAL PARKING BRAKE PEDAL BR0KJ-02 ON-VEHICLE INSPECTION R00254 2. Adjusting Hexagon Lock Nut 1. CHECK PARKING BRAKE PEDAL TRAVEL Slowly depress the parking brake pedal all the way, and count the number of clicks. Parking brake pedal travel at 294 N (30 kgf, 66 lbf): 3 - 6 clicks If incorrect, adjust the parking brake. No. 4 Cable F09710 IF NECESSARY, ADJUST PARKING BRAKE PEDAL TRAVEL HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment, see step 1 on page BR-46 . (a) Floor shift: Remove the console box. (b) Column shift: Remove the hole cover. (c) Confirm that the parking brake pedal is released. (d) Hold the screw end of No. 4 cable not to rotate. (e) Loosen the lock nut. (f) Red Paint W03176 Hold the parking brake cable and turn the adjusting hexagon until the pedal travel is correct. NOTICE: To prevent the parking brake cable from twisting, always keep the red-painted surface up. (g) Holding the adjusting hexagon, tighten the lock nut. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (h) Floor shift: Install the console box. (i) Column shift: Install the hole cover. 2001 AVALON (RM808U) Author
: Date
: 1408 BR-1 1 BRAKE - PARKING BRAKE PEDAL BR151-01 REMOVAL 1. 2. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOWER LH PANEL INSERT AND NO. 2 HEATER TO REGISTER DUCT (See page BO-87 ) RELEASE PARKING BRAKE PEDAL 3. (a) (b) REMOVE PARKING BRAKE PEDAL ASSEMBLY Disconnect the parking brake switch connector. Remove the clip, and disconnect the parking brake cable. (c) Remove the 3 nuts and parking brake pedal assembly. Torque: 61 N·m (620 kgf·cm, 45 ft·lbf) Remove the parking brake switch and cushion from the parking brake pedal assembly. F09746 (d) F09747 2001 AVALON (RM808U) Author
: Date
: 1410 BR-56 BRAKE - PRECHARGE PUMP PRECHARGE PUMP BR159-01 COMPONENTS Air Cleaner Cover With Air Cleaner Hose Level Warning Switch Connector Master Cylinder 19 (195, 14) 3-way 15 (155, 11) 13 (130, 9) Precharge Pump Assembly 19 (195, 14) 15 (155, 11) Master Cylinder Pressrue Sensor 81 (830, 60) Spacer
O-Ring Precharge Pump 20 (200, 15) Cushion Holder Precharge Pump Bracket Collar Cushion Washer 8.0 (82, 71in.·lbf) N·m (kgf·cm, ft·lbf) 13 (130, 9) : Specified torque
Non-reusable part F09741 2001 AVALON (RM808U) Author
: Date
: 1455 BR-58 BRAKE - PRECHARGE PUMP BR15B-01 INSTALLATION Installation is in the reverse order of removal (See page BR-57 ). HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks. 2001 AVALON (RM808U) Author
: Date
: 1457 BR-57 BRAKE - PRECHARGE PUMP BR15A-01 REMOVAL 1. 2. 3. REMOVE AIR CLEANER CASE WITH AIR CLEANER HOSE REMOVE MASTER CYLINDER (See page BR-15 ) DISCONNECT PRECHARGE PUMP CONNECTOR 4. (a) REMOVE PRECHARGE PUMP ASSEMBLY Remove the 3 bolts and precharge pump assembly. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (b) Using SST, disconnect the 2 brake lines from the precharge pump. SST 09751-3601 1 Torque: 10 mm nut: 15 N·m (155 kgf·cm, 11 ft·lbf) 12 mm nut: 20 N·m (200 kgf·cm, 15 ft·lbf) 5. (a) REMOVE PRECHARGE PUMP Remove the 2 nuts, 2 bolts and precharge pump from the pump bracket. Torque: Nut: 13 N·m (130 kgf·cm, 9 ft·lbf) Bolt: 8.0 N·m (82 kgf·cm, 71 in.·lbf) Remove the 2 holders, 2 collars, 2 washers and 4 cushions. F09742 SST F09743 (b) F09744 6. (a) (b) REMOVE MASTER CYLINDER PRESSURE SENSOR Place the precharge pump in a vise with a cloth shown in the illustration on the left. Using 30 mm deeper socket wrench, and remove the master cylinder pressure sensor, O-ring and spacer. Torque: 81 N·m (830 kgf·cm, 60 ft·lbf) F09745 2001 AVALON (RM808U) Author
: Date
: 1456 BR-37 BRAKE - REAR BRAKE CALIPER REAR BRAKE CALIPER BR0LA-03 COMPONENTS Disc
Gasket 34 (350, 25) 29 (300, 22) Plug Bleeder Plug Flexble Hose 8.3 (85, 74 in.·lbf)
Gasket Brake Caliper 34 (350, 25) 47 (475, 34) Inner Anti-squeal Shim Anti-squeal Shim Pad Support Plate
Dust Boot Piston Seal
Sliding Bushing Piston 47 (475, 34) Boot Inner Pad Pad Support Plate Outer Pad Set Ring Torque Plate Anti-squeal Shim N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Lithium soap bass glycol grease Disc brake grease Inner Anti-squeal Shim F09724 2001 AVALON (RM808U) Author
: Date
: 1436 BR-39 BRAKE - REAR BRAKE CALIPER BR153-01 DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RING AND CYLINDER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot from the cylinder. F09726 2. (a) REMOVE PISTON Place a piece of cloth or similar, between the piston and caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. F09727 3. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the cylinder. 4. REMOVE 2 DUST BOOTS F09728 2001 AVALON (RM808U) Author
: Date
: 1438 BR-40 BRAKE - REAR BRAKE CALIPER BR0LD-03 INSPECTION 1. MEASURE PAD LINING THICKNESS (See page BR-31 ) Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) 2. MEASURE DISC THICKNESS (See step 2 on page BR-31 ) Standard thickness: 12.0 mm (0.472 in.) Minimum thickness: 10.5 mm (0.413 in.) 3. MEASURE DISC RUNOUT (See step 3 on page BR-31 ) Maximum disc runout: 0.15 mm (0.0059 in.) If the disc’s runout is at the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See page SA-45 ). If the bearing play and axle hub runout are not abnormal, adjusting the disc runout or grind it on a ”On-Car” brake lathe. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the 2 bolts and torque plate. (b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the hub nuts. Torque: 103 N·m (1050 kgf·cm, 76 ft·lbf) Remeasure the disc runout. Make a note of the runout and the disc’s position on the hub. (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.15 mm (0.0059 in.), install the disc in that position. (e) If the minimum runout recorded in (b) and (c) is greater than 0.15 mm (0.0059 in.), replace the disc and repeat step 3. (f) Install the torque plate and torque the mounting bolts. Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) F09729 2001 AVALON (RM808U) Author
: Date
: 1439 BR-42 BRAKE - REAR BRAKE CALIPER BR0LF-03 INSTALLATION Installation is in the reverse order of removal (See page BR-38 ). HINT:
After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for fluid leaks. 2001 AVALON (RM808U) Author
: Date
: 1441 BR-41 BRAKE - REAR BRAKE CALIPER BR0LE-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR-39 ). NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR-37 ). 2001 AVALON (RM808U) Author
: Date
: 1440 BR-38 BRAKE - REAR BRAKE CALIPER BR0LB-02 REMOVAL F09725 1. REMOVE REAR WHEEL Remove the wheel and temporarily fasten the disc with hub nuts. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. DISCONNECT FLEXIBLE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) HINT: At the time of installation, insert the flexible hose lock securely in the lock hole in the caliper. (b) Use a container to catch the brake fluid as it drains out. 3. REMOVE CALIPER (a) Remove the 2 installation bolts. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) NOTICE: At the time of installation, insert the sliding pin with sliding bushing into the bottom side. (b) Remove the caliper from the torque plate. 4. REMOVE 2 BRAKE PADS WITH ANTI- SQUEAL SHIMS 5. REMOVE 4 PAD SUPPORT PLATES NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or disc. 2001 AVALON (RM808U) Author
: Date
: 1437 BR-34 BRAKE - REAR BRAKE PAD REAR BRAKE PAD BR0L8-03 COMPONENTS 34 (350, 35) Anti-squeal Shim Inner Anti-squeal Shim Pad Support Plate Outer Pad Inner Pad Pad Support Plate Inner Anti-squeal Shim Anti-squeal Shim N·m (kgf·cm, ft·lbf) : Specified torque Disc brake grease F09721 2001 AVALON (RM808U) Author
: Date
: 1433 BR-35 BRAKE - REAR BRAKE PAD BR0L9-03 REPLACEMENT 1. REMOVE REAR WHEEL 2. INSPECT PAD LINING THICKNESS Check the pad’s thickness through the caliper inspection hole and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 in.) F09722 F09723 3. LIFT UP CALIPER (a) Remove the bottom side installation bolt. (b) Lift up and suspend it securely. HINT: Do not disconnect the flexible hose from the caliper. 4. REMOVE 2 BRAKE PADS WITH 4 ANTI- SQUEAL SHIMS 5. REMOVE 4 PAD SUPPORT PLATES NOTICE: The support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 6. CHECK DISC THICKNESS AND RUNOUT (See page BR-40 ) 7. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. 8. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads. (a) Apply disc brake grease to both side of the inner anti-squeal shims (See page BR-37 ). (b) Install the 2 anti-squeal shims on each pad. (c) Install 2 pads with the pad wear indicator plates facing downward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 9. (a) (b) INSTALL CALIPER Draw out a small amount of brake fluid from the reservoir. Press in the piston with a hammer handle or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. R10387 2001 AVALON (RM808U) Author
: Date
: 1434 BR-36 BRAKE (c) (d) 10. 11. 12. - REAR BRAKE PAD Install the caliper. Install the installation bolt. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) INSTALL REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) DEPRESS BRAKE PEDAL SEVERAL TIMES CHECK THAT FLUID LEVEL IS AT MAX LINE F09723 2001 AVALON (RM808U) Author
: Date
: 1435 BR-62 BRAKE - REAR SPEED SENSOR REAR SPEED SENSOR BR0LX-03 COMPONENTS 5.4 (55 48 in.·lbf) Rear Speed Sensor 8.0 (82, 71 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque F09740 2001 AVALON (RM808U) Author
: Date
: 1461 BR-64 BRAKE - REAR SPEED SENSOR BR0LZ-04 INSTALLATION Installation is in the reverse order of removal (See page BR-63 ). AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI-252 or DI-212 ) 2001 AVALON (RM808U) Author
: Date
: 1463 BR-63 BRAKE - REAR SPEED SENSOR BR0LY-03 REMOVAL 1. (a) (b) DISCONNECT SPEED SENSOR CONNECTOR Remove the seat cushion and seatback. Disconnect the speed sensor connector, and pull out the sensor wire harness with the grommet. 2. (a) REMOVE SPEED SENSOR Remove the bolt and speed sensor from the axle carrier. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) Remove the 2 clamp bolts holding the sensor wire harness to the body and shock absorber. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) R00330 (b) R00331 2001 AVALON (RM808U) Author
: Date
: 1462 BR-2 BRAKE - TROUBLESHOOTING TROUBLESHOOTING BR0KG-05 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page 5. Fluid leaks for brake system Lower pedal or spongy pedal DI-249 DI-346 BR-4 BR-28 BR-37 BR-13 BR-24 6. Air in brake system 7. Piston seals (Worn or damaged) 8. Master cylinder (Faulty) 9. Booster push rod (Out of adjustment) 1. 2. 3. 4. 5. Brake drag Brake pedal freeplay (Minimal) Parking brake pedal travel (Out of adjustment) Parking brake wire (Sticking) Rear brake shoe clearance (Out of adjustment) Pad (Cracked or distorted) 6. Piston (Stuck) 7. Piston (Frozen) 8. Tension or return spring (Faulty) 9. Booster push rod (Out of adjustment) 10.Vacuum leaks for booster system 11.Master cylinder (Faulty) 1. Piston (Stuck) BR-28 BR-37 BR-25 BR-34 BR-28 BR-37 BR-28 BR-37 BR-25 BR-34 2. Pad (Oily) Brake pull 3. Piston (Frozen) 4. Disc (Scored) 5. Pad (Cracked or distorted) 1. Fluid leaks for brake system DI-249 DI-346 BR-4 BR-28 BR-37 BR-25 BR-34 BR-25 BR-34 BR-25 BR-34 BR-28 BR-37 BR-24 BR-22 2. Air in brake system 3. Piston (Stuck) 4. Pad (Cracked or distorted) Hard pedal but brake inefficient BR-6 BR-9 BR-46 BR-25 BR-34 BR-28 BR-37 BR-28 BR-37 BR-43 BR-24 BR-22 BR-13 5. Pad (Oily) 6. Pad (Glazed) 7. Disc (Scored) 8. Booster push rod (Out of adjustment) 9. Vacuum leaks for booster system 2001 AVALON (RM808U) Author
: Date
: 1401 BR-3 BRAKE - TROUBLESHOOTING Symptom Suspect Area See page 1. Pad (Cracked or distorted) BR-25 BR-34 BR-28 BR-37 BR-28 BR-37 BR-25 BR-34 BR-28 BR-37 BR-25 BR-34 BR-25 BR-34 BR-43 BR-25 BR-34 BR-43 2. Installation bolt (Loosen) 3. Disc (Scored) 4. Pad support plate (Loosen) Noise from brake 5. Sliding pin (Worn) 6. Pad (Dirty) 7. Pad (Glazed) 8. Tension or return spring (Faulty) 9. Anti-squeal shim (Damage) 10.Hold-down spring (Damage) 2001 AVALON (RM808U) Author
: Date
: 1402 CH-1 CHARGING - CHARGING SYSTEM CHARGING SYSTEM CH03U-03 ON-VEHICLE INSPECTION CAUTION:
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running. 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 water 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 battery. Except Maintenance-Free Battery Z11577 3. Maintenance-Free Battery Voltmeter Z11556 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 engine, 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 systems. (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. 2001 AVALON (RM808U) Author
: Date
: 1274 CH-2 CHARGING - CHARGING SYSTEM 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 corroded. (b) Check the fusible link and fuses for continuity. Maintenance-Free Battery Type A CLEAR EYE or GREE NEYE DARK EYE LIGHT YELLOW CHARGED DISCHARGED ADD WATER Type B Blue OK White Red Charging Insufficient Necessary Water Z18811 5. (a) INSPECT DRIVE BELT 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. P13121 DENSO Borroughs Z00038 (b) Using a belt tension gauge, measure the drive belt tension. Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Drive belt tension: New belt 175 ± 5 lbf Used belt 115 ± 20 lbf If the belt tension is not as specified, adjust it. HINT:


CORRECT WRONG
P13120 ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. ”Used belt” refers to a belt which has been used on a running 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. 2001 AVALON (RM808U) Author
: Date
: 1275 CH-3 CHARGING
- CHARGING SYSTEM After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 6. P19934 Ammeter Disconnect Wire from Terminal B Battery Voltmeter Generator Z03473 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 ”ON”. 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 discharge 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 ammeter to the charging circuit as follows:
Disconnect the wire from terminal B of the generator, 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 2001 AVALON (RM808U) Author
: Date
: 1276 CH-4 CHARGING - CHARGING SYSTEM If the voltmeter reading is more than standard voltage, replace the voltage regulator. Terminal F P20106 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 voltage, replace the voltage regulator.
If the voltmeter reading is less than standard voltage, 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 ”HI”. (b) Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than the standard amperage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. 2001 AVALON (RM808U) Author
: Date
: 1277 CH-5 CHARGING - GENERATOR GENERATOR CH03V-02 COMPONENTS Generator Wire Plate Washer Pivot Bolt Generator Connector Wire Clamp Adjusting Bolt Wire Clamp Generator Drive Belt Adjusting Lock Bolt B09070 Bearing Cover Retainer
Front Bearing Drive End Flame (Stator) Thrust Washer Bearing Cover
Rear Bearing Pulley Plate Terminal Rotor Terminal Insulator Seal Plate Cord Clip Rear End Cover Rectifire End Flame x4
Non-reusable part Brush Holder Cover x4 Brush Holder Voltage Regulator Rectifire Holder Robber Insulator B09071 2001 AVALON (RM808U) Author
: Date
: 1278 CH-7 CHARGING - GENERATOR CH03X-01 DISASSEMBLY 1. (a) REMOVE REAR END COVER Remove the nut and terminal insulator. (b) Remove the screw, 3 nuts, plate terminal and end cover. 2. (a) (b) REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR Remove the brush holder cover from the brush holder. Remove the 5 screws, brush holder and voltage regulator. 3. (a) (b) (c) REMOVE RECTIFIER HOLDER Remove the 4 screws and rectifier holder. Remove the 4 rubber insulators. Remove the seal plate. 4. (a) REMOVE PULLEY Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the rotor shaft. P20102 Plate Terminal P14233 P14234 P20103 Turn SST (A) (b) SST (B) P10835 2001 AVALON (RM808U) Author
: Date
: 1280 CH-8 CHARGING (c) (d) - GENERATOR Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). SST (B) Insert SST (C) P10834 (e) SST (C) SST (A) Turn Turn To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn. (f) Remove the generator from SST (C). P10827 (g) (h) Turn SST (B), and remove SST (A and B). Remove the pulley nut and pulley. 5. (a) (b) REMOVE RECTIFIER END FRAME Remove the wire clamp. Remove the 4 nuts and cord clip. (c) Using SST, remove the rectifier end frame. SST 09286-4601 1 Remove the thrust washer. REMOVE ROTOR FROM DRIVE END FRAME SST (A) SST (B) P10836 P19942 (d) 6. SST P01762 2001 AVALON (RM808U) Author
: Date
: 1281 CH-9 CHARGING - GENERATOR CH03Y-01 INSPECTION 1. (a) INSPECT ROTOR Inspect the rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.1 - 2.5 Ω at 20°C (68°F) If there is no continuity, replace the rotor. Ohmmeter Continuity CH0784 (b) Inspect the rotor for ground. Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. Ohmmeter No Continuity B02105 (c) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (d) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 - 14.4 mm (0.559-0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. CH0192 2. (a) INSPECT STATOR (DRIVE END FLAME) Inspect the stator for open circuit. Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. Continuity Ohmmeter P00484 (b) Inspect the stator for ground. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. Continuity Ohmmeter P00482 2001 AVALON (RM808U) Author
: Date
: 1282 CH-10 CHARGING - GENERATOR 3. INSPECT BRUSHES Using a vernier caliper, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes and brush holder assembly. Length P13535 4. (a) Ohmmeter Positive (+) Terminal Rectifire Terminal P00480 Negative (-) Terminal Ohmmeter P00481 INSPECT RECTIFIERS (RECTIFIRE HOLDER) Check the positive (+) rectifire. (1) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (a). (3) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. (b) Check the negative (-) rectifire. (1) Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (a). (3) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 5. INSPECT BEARING Check that bearing is not rough or worn. If necessary, replace the bearing (See page CH-1 1). 2001 AVALON (RM808U) Author
: Date
: 1283 CH-16 CHARGING - GENERATOR CH041-01 INSTALLATION Installation is in the reverse order of removal (See page CH-6 ). 2001 AVALON (RM808U) Author
: Date
: 1289 CH-13 CHARGING - GENERATOR CH040-02 REASSEMBLY Pulley 1. (a) (b) INSTALL ROTOR TO DRIVE END FRAME Place the rectifier end frame on the pulley. Install the rotor to the rectifier end frame. 2. (a) INSTALL RECTIFIER END FRAME Place the thrust washer on the rotor. (b) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. (c) NUT A: Install the cord clip and 4 nuts. Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf) NUT B: Install the cord clip and 4 nuts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Install the wire clamp. P01364 P00427 29 mm Socket Wrench P01763 A B (d) A A (e) P19942 3. (a) Turn SST (A) (b) (c) SST (B) INSTALL PULLEY Install the pulley to the rotor shaft by tightening the pulley nut by hand. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the pulley shaft. P10835 2001 AVALON (RM808U) Author
: Date
: 1286 CH-14 CHARGING - GENERATOR (d) (e) Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (f) (g) To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110.5 N·m (1,125 kgf·cm, 81 ft·lbf) Remove the generator from SST (C). (h) Turn SST (B), and remove SST (A and B). 4. (a) INSTALL RECTIFIER HOLDER Place the seal plate on the rectifier end frame. (b) Install the 4 rubber insulators on the lead wires. SST (A) SST (C) Insert P10834 SST (C) SST (A) Turn P10829 Turn SST (A) SST (B) P10836 P00428 P00645 2001 AVALON (RM808U) Author
: Date
: 1287 CH-15 CHARGING (c) - GENERATOR Install the rectifier holder with the 4 screws. Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) P20103 5. Upward INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER (a) Place the voltage regulator and brush holder on the rectifier end frame. NOTICE: Be careful of the holder installation direction. (b) Install the 5 screws. Torque: 2.0 N·m (20 kgf·cm, 18 in.·lbf) S05460 (c) Place the brush holder cover on the brush holder. 6. (a) INSTALL REAR END COVER Install the end cover and plate terminal with the 3 nuts and screw. Torque: Screw: 3.9 N·m (39 kgf·cm, 35 in.·lbf) Nut: 4.4 N·m (45 kgf·cm, 39 in.·lbf) (b) Install the terminal insulator with the nut. Torque: 4.1 N·m (41.5 kgf·cm, 36 in.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY P14235 Plate Terminal P14233 7. P20102 2001 AVALON (RM808U) Author
: Date
: 1288 CH-6 CHARGING - GENERATOR CH03W-02 REMOVAL 1. REMOVE DRIVE BELT Loosen the pivot bolt, adjusting lock bolt and adjusting bolt, and remove the drive belt. Torque: Lock bolt: 18 N·m (180 kgf·cm, 13 ft·lbf) Pivot bolt: 56 N·m (570 kgf·cm, 41 ft·lbf) P19938 2. (a) (b) (c) (d) REMOVE GENERATOR Disconnect the generator connector. Remove the nut, and disconnect the generator wire. Torque: 9.8 N·m (100 kgf·cm, 86 in.·lbf) Disconnect the wire harness from the clip. Remove the pivot bolt, plate washer, adjusting lock bolt and generator. P19978 2001 AVALON (RM808U) Author
: Date
: 1279 CH-1 1 CHARGING - GENERATOR CH03Z-02 REPLACEMENT 1. (a) REPLACE FRONT BEARING Remove the 4 screws and bearing retainer. (b) Using a socket wrench and press, press out the bearing. (c) Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00520) Install the bearing retainer with the 4 screws. Torque: 3.0 N·m (31 kgf·cm, 27 in.·lbf) P14225 Socket Wrench P00628 SST (d) P00479 2. (a) REPLACE REAR BEARING Using SST,remove the bearing cover (outside) and bearing. SST 09820-00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). SST N00581 (c) Place the bearing cover (inside) on the rotor. P13567 2001 AVALON (RM808U) Author
: Date
: 1284 CH-12 CHARGING - GENERATOR (d) Using SST and a press, press in a new bearing. SST 09820-00030 (e) Using SST, push in the bearing cover (outside). SST 09285-76010 SST N00578 SST P00074 2001 AVALON (RM808U) Author
: Date
: 1285 CH-17 CHARGING - IGNITION RELAY (No.1) IGNITION RELAY (No.1) Driver Side J/B SF0DX-05 INSPECTION Ignition Relay 1. REMOVE IGNITION RELAY (Marking: IG1) B09784 2. (a) INSPECT IGNITION RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. Ohmmeter No Continuity 1 2 3 4 Continuity B09785 (b) Inspect the relay operation. (1) Apply battery positive voltage across terminals 3 and 4. (2) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 3. REINSTALL IGNITION RELAY Ohmmeter Continuity 2 1 3 4 Battery B09786 2001 AVALON (RM808U) Author
: Date
: 1290 CO-31 COOLING - COOLING FAN RELAY COOLING FAN RELAY CO0WW-01 INSPECTION No.1 Cooling Fan Relay 1. 2. (a) REMOVE RELAY BOX COVER INSPECT NO.1 COOLING FAN RELAY Remove the No.1 cooling fan relay. (Marking: FAN NO.1) B09430 (b) Continuity Ohmmeter Ohmmeter 2 1 5 3 Inspect the No.1 cooling fan 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. No Continuity S04970 (c) 2 Ohmmeter 1 5 3 Inspect the No.1 cooling fan 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. (d) Reinstall the No.1 cooling fan relay. Battery Continuity S04969 3. (a) INSPECT NO.2 COOLING FAN RELAY Remove the No.2 cooling fan relay. (Marking: FAN NO.2) No.2 Cooling Fan Relay B09428 Ohmmeter (b) Continuity 4 Ohmmeter 2 1 5 Ohmmeter 3 Continuity No Continuity S04972 Inspect the No.2 cooling fan 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 continuity between terminals 3 and 4. If there is no continuity, replace the relay. (3) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 2001 AVALON (RM808U) Author
: Date
: 1224 CO-32 COOLING - COOLING FAN RELAY (c) 4 2 Ohmmeter 5 1 Battery Ohmmeter 3 No Continuity Continuity S04971 Inspect the No.2 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. (3) Check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (d) Reinstall the No.2 cooling fan relay. 4. INSPECT NO.3 COOLING FAN RELAY (a) Remove the No.3 cooling fan relay. (Marking: FAN NO.3) No.3 Cooling Fan Relay B09429 (b) Continuity Ohmmeter Ohmmeter 2 1 5 3 Inspect the No.3 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is mo continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04970 (c) 2 Ohmmeter 1 5 3 Battery Continuity Inspect the No.3 cooling fan 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. (d) Reinstall the No.3 cooling fan relay. 5. REINSTALL RELAY BOX COVER S04969 2001 AVALON (RM808U) Author
: Date
: 1225 CO-1 COOLING - COOLANT COOLANT CO02K-03 INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add ’’Toyota Long Life Coolant” or Equivalent up to the ”FULL” 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. 2001 AVALON (RM808U) Author
: Date
: 1194 CO-2 COOLING - COOLANT CO02L-03 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 radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Drain Plug Drain Plug B09030 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 cooling system.
Use ”Toyota Long life Coolant” or equivalent and mix it with plan water according to the manufacturer’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 ethylene-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 (preferably 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 ”FULL” line. 3. CHECK ENGINE COOLANT FOR LEAKS 4. CHECK ENGINE COOLANT SPECIFIC GRAVITY CORRECTLY 2001 AVALON (RM808U) Author
: Date
: 1195 CO-25 COOLING - ELECTRIC COOLING FAN CO0WV-01 COMPONENTS No.1 Fan Shroud Fan Fan Motor Cruise Control Actuator Nut No.1 Cooling Fan Connector Hold-Down Clamp Battery Insulator No.1 Cooling Fan No.3 Engine Room Relay Block Battery Battery Tray
Non-reusable part B09038 2001 AVALON (RM808U) Author
: Date
: 1218 CO-26 COOLING - ELECTRIC COOLING FAN No.2 Fan Shroud Fan No.1 ECT Switch Wire Nut Fan Motor No.1 ECT Switch Wire Connector No.2 Cooling Fan Connector No.2 Cooling Fan Upper Radiator Hose
Non-reusable part B09037 2001 AVALON (RM808U) Author
: Date
: 1219 CO-28 COOLING - ELECTRIC COOLING FAN CO09R-02 INSTALLATION Installation is in the reverse order of removal. (See page CO-27 ) 2001 AVALON (RM808U) Author
: Date
: 1221 CO-23 COOLING - ELECTRIC COOLING FAN ELECTRIC COOLING FAN CO0WU-01 ON-VEHICLE INSPECTION 1. B09054 CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83°C (181°F)) (a) Turn the ignition switch ON. (b) Check that the cooling fans stop. If not, check the cooling fan relays and ECT switches. (c) Disconnect the No.1 ECT switch wire connector. (d) Connect terminals on the No.1 ECT switch wire connector. B09056 (e) Check that the No.1 cooling fan rotates at high speed. If not, check the No.1 cooling fan relay and No.1 cooling fan. (f) Reconnect the No.1 ECT switch connector. (g) Disconnect the No.2 ECT switch connector. B09434 (h) Ground terminal on the No.2 ECT switch wire harness side connector. B09432 (i) Check that the No.1 and No.2 cooling fans rotate at low speed. If not, check the No.2 cooling fan relay, No.3 cooling fan relay and No.2 cooling fan. (j) Reconnect the No.2 ECT switch connector. B09435 2001 AVALON (RM808U) Author
: Date
: 1216 CO-24 COOLING 2. (a) (b) Ammeter (c) (d) Battery - ELECTRIC COOLING FAN INSPECT NO.1 COOLING FAN Disconnect the cooling fan connector. Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.5 - 11.5 A at 20°C (68°F) Reconnect the cooling fan connector. B09050 Ammeter 3. (a) (b) (c) (d) INSPECT NO.2 COOLING FAN Disconnect the cooling fan connector. Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.5 - 11.5 A at 20°C (68°F) Reconnect the cooling fan connector. BatteryB09053 2001 AVALON (RM808U) Author
: Date
: 1217 CO-27 COOLING - ELECTRIC COOLING FAN CO09O-02 REMOVAL No.1 B09051 REMOVE COOLING FANS (a) Remove the No.1 cooling fan. (1) Remove the batter and battery tray. (2) Disconnect the cruise control actuator. (3) Disconnect the No.3 engine room relay block from radiator. (4) Disconnect the cooling fan connector. (5) Disconnect the wire clamps from the fan shroud. (6) Remove the 2 bolts and cooling fan. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) (b) No.2 B09052 Remove the No.2 cooling fan. (1) Drain the engine coolant. (2) Disconnect the upper radiator hose from the radiator. (3) Disconnect the cooling fan and No.1 ECT switch wire connectors. (4) Disconnect the wire clamps from the fan shroud. (5) Disconnect the No.1 ECT switch connector. (6) Remove the 2 bolts and cooling fan. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) 2001 AVALON (RM808U) Author
: Date
: 1220 CO-29 COOLING - ENGINE COOLANT TEMPERATURE (ECT) SWITCH ENGINE COOLANT TEMPERATURE (ECT) SWITCH CO037-03 INSPECTION 1. DRAIN ENGINE COOLANT 2. (a) INSPECT NO.1 ECT SWITCH Remove the No.1 ECT switch. No.1 ECT Switch S04602 (b) Ohmmeter P01924 Inspect the No.1 ECT switch. (1) Using an ohmmeter, check that there is continuity between the terminals when the coolant temperature is above 98°C (208°F). If there is no continuity, replace the switch. (2) Check that there is no continuity, between the terminals when the coolant temperature is below 88°C (190°F). If there is continuity, replace the switch. (c) Reinstall the No.1 ECT switch. 3. INSPECT NO.2 ECT SWITCH (a) Remove the No.2 ECT switch. No.2 ECT Switch B04397 (b) Ohmmeter P06722 Inspect the No.2 ECT switch. (1) Using an ohmmeter, check that there is continuity between terminals when the coolant temperature is above 93°C (199°F). If there is no continuity, replace the switch. (2) Check that there is no continuity between the terminals when the coolant temperature is below 83°C (181°F). If there is continuity, replace the switch. (c) Reinstall the No.2 ECT switch. 2001 AVALON (RM808U) Author
: Date
: 1222 CO-30 COOLING 4. 5. - ENGINE COOLANT TEMPERATURE (ECT) SWITCH REFILL ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS 2001 AVALON (RM808U) Author
: Date
: 1223 CO-15 COOLING - RADIATOR CO02W-03 COMPONENTS No.2 Cooling Fan Radiator No.1 Cooling Fan No.1 ECT Switch
O-Ring No.2 Cooling Fan Connector No.1 ECT Switch Wire Connector No.1 Cooling Fan Connector Hold-Down Clamp No.3 Engine Room Relay Block Upper Radiator Support Radiator Assembly Lower Radiator Support
O-Ring Battery Insulator Battery Drain Plug Upper Radiator Hose Battery Tray Lower Radiator Hose Engine Under Cover A/T Oil Cooler Hose
Non-reusable part B09039 2001 AVALON (RM808U) Author
: Date
: 1208 CO-16 COOLING - RADIATOR Upper Tank
O-Ring Cushion Core
O-Ring Oil Cooler Inlet Pipe Nut Lower Tank Plate Washer
O-Ring
Non-reusable part B09036 2001 AVALON (RM808U) Author
: Date
: 1209 CO-18 COOLING - RADIATOR CO02Y-03 Part ”A” DISASSEMBLY 1. 2. Dimension ”B” SST Claw Stopper Bolt Overhaul Handle CO1205 Tank SST REMOVE CUSHION FROM RADIATOR ASSEMBLE SST SST 09230-01010 (a) Install the claw to the overhaul handle, inserting it in the hole in part ”A” as shown in the diagram. (b) While gripping the handle, adjust the stopper bolt so that dimension ”B” shown in the diagram is 0.2 - 0.5 mm (0.008 - 0.020 in.). NOTICE: If this adjustment is not done, the claw may be damaged. 3. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230-01010 Lock Plate Stopper Bolt B09048 4. (a) Tap (b) REMOVE TANKS AND O-RINGS Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft-faced hammer and remove the tank. Remove the O-ring. 5. (a) (b) (c) REMOVE OIL COOLER FROM LOWER TANK Remove the pipe. Remove the nuts and plate washers. Remove the oil cooler and O-rings. B09042 B09043 2001 AVALON (RM808U) Author
: Date
: 1211 CO-22 COOLING - RADIATOR CO030-01 INSTALLATION Installation is in the reverse order of removal (See page CO-17 ). 2001 AVALON (RM808U) Author
: Date
: 1215 CO-13 COOLING - RADIATOR RADIATOR CO09H-01 ON-VEHICLE CLEANING Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core) 2001 AVALON (RM808U) Author
: Date
: 1206 CO-14 COOLING - RADIATOR CO09I-02 ON-VEHICLE INSPECTION Radiator Cap Tester 30° or More Radiator Cap Z00570 1. REMOVE RADIATOR CAP 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 blow out under pressure. 2. INSPECT RADIATOR CAP NOTICE:
If the radiator cap has contaminations, always rinse it with water.
When performing steps (a) and (b) below, keep the radiator cap tester at an angle of over 30° above the horizontal.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. (a) Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed: 1 push/(3 seconds or more) NOTICE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the radiator cap. (b) Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTICE: This pump speed is for the first pump only (in order to close the vacuum valve). After this, the pump speed can be reduced. Standard opening pressure: 83 - 113 kPa (0.85 - 1.15 kgf/cm2, 12.1 - 16.4 psi) Minimum opening pressure: 69 kPa (0.7 kgf/cm2, 10.0 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. 3. (a) Radiator Cap Tester P13014 INSPECT COOLING SYSTEM FOR LEAKS Fill the radiator with coolant, and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 127 kPa (1.3 kgf/cm2, 18.5 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head. 4. REINSTALL RADIATOR CAP 2001 AVALON (RM808U) Author
: Date
: 1207 CO-19 COOLING - RADIATOR CO02Z-03 REASSEMBLY (1) (2) 1. (a) (6) (b) (c) (d) (5) (4) (3) S04435 (e) Lock Plate Lock Plate Core CO1267 2. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT:
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented, Therefore, repair or replace if necessary. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 3. (a)  Normal X Twisted O-Ring INSTALL OIL COOLER TO LOWER TANK Clean the O-ring contact surface of the lower tank and oil cooler. Install a new O-rings (1) to the oil cooler (2). Install the oil cooler with the O-rings to the lower tank (3). Install the plate washers (4), and nuts (5). Torque the nuts. Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) Install the pipe (6). Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf) INSTALL NEW O-RINGS AND TANKS After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. X Twisted CO0317 2001 AVALON (RM808U) Author
: Date
: 1212 CO-20 COOLING CORRECT - RADIATOR (b) (c) Install the tank without damaging the O-ring. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank. 4. ASSEMBLE SST SST 09230-01010, 09231-14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part ”A” as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension ”B” shown in the diagram. Dimension ”B”: 8.4 mm (0.34 in.) Tank WRONG Lock Plate Tap B09047 Part ”A” (a) (b) Dimension ”B” SST Punch Assembly Stopper Bolt Overhaul Handle 5. (a) 7 3 5 CO1206 1 2 6 8 4 Lock Plate SST Stopper Bolt CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. SST 09230-01010 Tank B09045 HINT: Rib
Bracket Do not stake the areas protruding around the pipes, brackets or tank ribs. B09044 2001 AVALON (RM808U) Author
: Date
: 1213 CO-21 COOLING
- RADIATOR The points shown in the rib sides and oil cooler near here cannot be staked with SST. Use pliers or similar object and be careful not to damage the core plates. B09041 (b) Check the lock plate height (H) after completing the caulking. Plate height (H): 7.4 - 7.8 mm (0.2959 - 0.3119 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. 6. INSTALL CUSHION H B09046 2001 AVALON (RM808U) Author
: Date
: 1214 CO-17 COOLING - RADIATOR CO0WT-01 REMOVAL HINT: At the time of installation, please refer to the following items.
Start the engine, and check for coolant and A/T fluid leaks.
Check the A/T fluid level (See page DI-160 ). 1. REMOVE BATTERY AND BATTERY TRAY 2. REMOVE ENGINE UNDER COVER 3. DRAIN ENGINE COOLANT 4. DISCONNECT NO.3 ENGINE ROOM RELAY BLOCK FROM RADIATOR 5. DISCONNECT NO.1 COOLING FAN CONNECTOR 6. DISCONNECT WIRE CLAMPS FROM NO.1 FAN SHROUD 7. DISCONNECT NO.2 COOLING FAN CONNECTOR 8. DISCONNECT NO.1 ECT SWITCH WIRE CONNECTOR 9. DISCONNECT WIRE CLAMPS FROM NO.2 FAN SHROUD 10. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 11. DISCONNECT LOWER RADIATOR HOSE FROM RADIATOR 12. DISCONNECT A/T OIL COOLER HOSES FROM RADIATOR 13. B09040 REMOVE RADIATOR AND COOLING FANS ASSEMBLY (a) Remove the 2 bolts and 2 upper supports. Torque: 12.8 N·m (130 kgf·cm, 9 ft·lbf) (b) Lift out the radiator, and remove the radiator and cooling fans assembly. (c) Remove the 2 lower supports. 14. REMOVE NO.1 ECT SWITCH 15. REMOVE NO.1 COOLING FAN FROM RADIATOR Remove the 2 bolts and cooling fan. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) 16. REMOVE NO.2 COOLING FAN FROM RADIATOR Remove the 2 bolts and cooling fan. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) 2001 AVALON (RM808U) Author
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: 1210 CO-9 COOLING - THERMOSTAT THERMOSTAT CO02Q-03 COMPONENTS V-Bank Cover Fastener V-Bank Cover Air Cleaner Hose w/ Resonator Vacuum Hose Heater Hose Thermostat No.2 ECT Switch Connector
Gasket Water Inlet 8 (80, 69 in.·lbf) Engine Wire Protector
O-Ring 19.5 (200, 14) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Water Inlet Pipe B09035 2001 AVALON (RM808U) Author
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: 1202 CO-1 1 COOLING - THERMOSTAT CO02S-03 INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. P13255 (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 - 84°C (176 - 183°F) If the valve opening temperature is not as specified, replace the thermostat. CO0601 (c) Check the valve lift. Valve lift: 10.0 mm (0.394 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat. 10 mm Z10579 2001 AVALON (RM808U) Author
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: 1204 CO-12 COOLING - THERMOSTAT CO02T-03 INSTALLATION 15° 15° Stud Bolt Jiggle Valve B04153 1. (a) PLACE THERMOSTAT IN WATER PUMP Install a new gasket on to the thermostat. (b) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 15° of either side of the prescribed position. 2. INSTALL WATER INLET Install the water inlet with the 3 nuts. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 3. 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 LH cylinder head. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) 4. INSTALL ENGINE WIRE PROTECTOR 5. CONNECT NO.2 ECT SWITCH CONNECTOR 6. CONNECT HEATER HOSES 7. REINSTALL AIR CLEANER HOSE WITH RESONATOR 8. INSTALL V-BANK COVER (a) Using 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts. (b) Press down the V-bank cover fastener. 9. FILL WITH ENGINE COOLANT 10. START ENGINE AND CHECK FOR LEAKS 11. RECHECK ENGINE COOLANT LEVEL 2001 AVALON (RM808U) Author
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: 1205 CO-10 COOLING - THERMOSTAT CO0SW-02 REMOVAL HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT 5 mm Hexagon Wrench A10518 2. 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. 3. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 4. REMOVE AIR CLEANER HOSE WITH RESONATOR 5. DISCONNECT HEATER HOSES 6. DISCONNECT NO.2 ECT SWITCH CONNECTOR 7. DISCONNECT ENGINE WIRE PROTECTOR FROM WATER INLET AND RH CYLINDER HEAD Remove the nut and disconnect the clamp, and disconnect the engine wire protector from the water inlet and cylinder head. B08906 8. (b) DISCONNECT WATER INLET PIPE FROM WATER INLET AND LH CYLINDER HEAD Remove the bolt, and disconnect the inlet pipe from the water inlet. Remove the O-ring from the inlet pipe. 9. (a) (b) REMOVE WATER INLET AND THERMOSTAT Remove the 3 nuts, water inlet and thermostat. Remove the gasket from the thermostat. (a) B06725 B04150 2001 AVALON (RM808U) Author
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: 1203 CO-3 COOLING - WATER PUMP WATER PUMP CO02M-03 COMPONENTS RH Fender Apron Seal 64 (650, 47) Generator Drive Belt Engine Moving Control Rod 32 (320, 23) No.2 RH Engine Mounting Bracket PS Pump Drive Belt Engine Coolant Reservoir Hose Ground Strap Connector N·m (kgf·cm, ft·lbf) : Specified torque A10834 2001 AVALON (RM808U) Author
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: 1196 CO-4 COOLING - WATER PUMP Timing Belt Gasket No.2 Timing Belt Cover RH Engine Mounting Bracket Timing Belt Guide 28 (290, 21) No.2 Generator Bracket No.1 Timing Belt Cover Gasket Crankshaft Pulley 215 (2,200, 159) Engine Wire Protector No.2 Idler Pulley RH Camshaft Timing Pulley 125 (1,300, 94) *88 (900, 65) 43 (400, 32) LH Camshaft Timing Pulley 125 (1,300, 94) Dust Boot Timing Belt Tensioner N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part *For use with SST 27 (280, 20) B06475 2001 AVALON (RM808U) Author
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: 1197 CO-5 COOLING - WATER PUMP Gasket No.3 Timing Belt Cover Collar Bushing x6 8.5 (65, 74 in.·lbf) Engine Wire
Gasket Water Pump 8 (80, 69 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B06476 2001 AVALON (RM808U) Author
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: 1198 CO-7 COOLING - WATER PUMP CO02O-03 INSPECTION P12487 1. INSPECT WATER PUMP (a) Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. (b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT TIMING BELT COMPONENTS (See page EM-19 ) 2001 AVALON (RM808U) Author
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: 1200 CO-8 COOLING - WATER PUMP CO02P-03 INSTALLATION P12942 1. INSTALL WATER PUMP Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) NOTICE: Do not get oil on the gasket. 2. INSTALL NO.3 TIMING BELT COVER (See page EM-59 ) 3. INSTALL NO.2 IDLER PULLEY (See page EM-21 ) 4. INSTALL CAMSHAFT TIMING PULLEYS (See page EM-21 ) 5. INSTALL TIMING BELT (See page EM-21 ) 6. FILL WITH ENGINE COOLANT 7. START ENGINE AND CHECK FOR LEAKS 8. RECHECK ENGINE COOLANT LEVEL 2001 AVALON (RM808U) Author
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: 1201 CO-6 COOLING - WATER PUMP CO0WS-01 REMOVAL 1. 2. 3. 4. 5. DRAIN ENGINE COOLANT REMOVE TIMING BELT (See page EM-15 ) REMOVE CAMSHAFT TIMING PULLEYS (See page EM-15 ) REMOVE NO.2 IDLER PULLEY (See page EM-31 ) REMOVE NO.3 TIMING BELT COVER (See page EM-15 ) 6. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. P12942 2001 AVALON (RM808U) Author
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: 1199 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-243 DI6NM-02 ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, the ABS warning light lights up and ABS control is prohibited at the same time. At this time, the ECU records a DTC in memory. Connecting terminals Tc and E1 of the DLC1 makes the ABS warning light blink and output the DTC. WIRING DIAGRAM R-L A21 Active Light Relay 1 Multi Display 15 4B 15 4H 15 IE1 7 J/B No. 4 R-L 5 M6 ABS ABS Actuator and ECU B B 20 A7 WA J/B No. 4 4 M6 4 4D 13 R-B 4F R-B Driver Side J/B 15 4A W IG1 Relay 1 1G 1 R-L 3 1B 14 ABS 4 GAUGE No. 1 10 1D 2 Ignition Switch 4 1C 3 D2 DLC2 Engine Room J/B 1 1 2H 2G W-B B-L 1 F8 1 FL Block B 4 W-R IG1 2 W-L AM1 Engine Room R/B No. 5 AM1 1 2 5 5 7 IF1 W-L 1 F6 B FL MAIN ALT F10 Battery IG F09799 2001 AVALON (RM808U) Author
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: 399 DI-244 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE Troubleshooting in accordance with the chart below for each trouble symptom. ABS warning light does not light up Go to step 1 ABS warning light remains on Go to step 2 1 Check ABS warning light. See combination meter troubleshooting on page BE-2 . NG Repair bulb or combination meter assembly. NG Replace active lamp relay. OK 2 Check active lamp relay. OK Check for open circuit in harness and connector between GAUGE fuse and active lamp relay, ECU-IG No. 2 fuse and active lamp relay, short circuit between active lamp relay and ABS ECU (See page IN-30 ). 3 Is DTC output? Check the DTC on page DI-212 . YES Repair circuit indicated by the code output. NO Check for short circuit in harness and connector and active lamp relay, ECU-IG No. 2 fuse and active lamp relay, short circuit between active lamp relay and ABS ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 400 DI-238 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6NK-01 DTC Always ON ABS ECU Malfunction CIRCUIT DESCRIPTION DTC No. Always ON DTC Detecting Condition Trouble Area Either of the following 1., 2. or 3. is detected: 1. The ECU connectors are OFF the ECU. 2. There is a malfunction in the ECU internal circuit. 3. There is a malfunction in ABS warning light circuit.
Charging system
ABS warning light circuit INSPECTION PROCEDURE 1 Check that the ECU connectors are securely connected to the ECU. NO Connect the connector to the ECU. YES Repair circuit indicated by the output code. YES 2 Is DTC output? Check DTC on page DI-212 . NO 3 Does ABS warning light go off? YES Check for open or short circuit in harness and connector between ECU-IG fuse and ECU (See page IN-30 ). NO 2001 AVALON (RM808U) Author
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: 394 DIAGNOSTICS 4 - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-239 Check battery positive voltage. PREPARATION: Start the engine. CHECK: Check the battery positive voltage. OK: Voltage: 10 - 16 V NG Check and repair the charging system (See page CH-1 ). OK 5 Check operation of the ABS warning light. PREPARATION: (a) Turn the ignition switch OFF. (b) Disconnect the connector from the ABS ECU. (c) Turn the ignition switch ON. CHECK: Check the ABS warning light goes on. OK Check and replace combination meter (See page BE-2 ). NG 6 Check for short circuit in harness and connector between active lamp relay and ABS ECU (See page IN-30 ). NG Repeir or replace harness or connector. OK Check and replace ABS ECU. 2001 AVALON (RM808U) Author
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: 395 DI-240 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6NL-02 BRAKE Warning Light Circuit CIRCUIT DESCRIPTION The BRAKE warning light lights up when the brake fluid is insufficient, parking brake is applied or the EBD is defective. WIRING DIAGRAM 14 3B 3B 5 ABS Actuator and ECU A21 Active Light Relay J/B No. 3 Y-G 5 3A 6 Y-G 15 B4 6 R-Y R-W 3 8 Multi Display PKB 7 IC1 Body ECU J/B No. 3 Y-G 15 Driver Side J/B 12 8 1H 1I J1 J/C B 1 1 F8 W-B Engine Room J/B 4 4 2F 2D 1 F10 W-B ED 4 M6 16 R-Y IE1 21 A7 EBDW R-B J/B No. 4 13 4 4D 4F 1 1 IG1 Relay GAUGE No. 1 2 1G 3 4 3 1B B-L 2 B P3 Parking Brake Switch PKB R-B 10 1D 4 1C Ignition Switch 4 2 W-L W-R Engine Room R/B No. 5 7 IF1 Engine Room J/B 1 1 1 AM1 2 B 2G 5 5 2H W-L R-W B1 Bake Fluid Level Warning Switch W-B 13 A7 Driver Side J/B 3B W 1 BRAKE R-W R-W 15 3H R-W 15 3A 3 M6 Y-B 5 IE1 Y-B FL Block 1 F6 B FL MAIN ALT W-B Battery IG F09801 2001 AVALON (RM808U) Author
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: 396 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-241 INSPECTION PROCEDURE 1 Check parking brake switch circuit (See page BE-53 ). NG Repair or replace parking brake switch circuit. OK 2 Check brake fluid level warning switch circuit (See page BE-53 ). NG Repair or replace brake fluid level warning switch circuit. Yes Repair circuit indicated by the output code. OK 3 Is DTC output for ABS ? No 4 Check BRAKE warning light. See combination meter troubleshooting on page BE-2 . NG Repair or replace combination meter. OK 2001 AVALON (RM808U) Author
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: 397 DI-242 5 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check active lamp relay. NG Replace active lamp relay. OK 6 Check for open or short circuit in harness and connector. NG Repair or replace harness or connector. OK Check and replace ABS ECU. 2001 AVALON (RM808U) Author
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: 398 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-249 DI6NP-01 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. F07888 2001 AVALON (RM808U) Author
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: 405 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-219 DI6NC-01 CIRCUIT INSPECTION DTC 11 ABS Solenoid Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. 11 DTC Detecting Condition Trouble Area When any of the following 1. through 3. is detected: 1. 3 or more solenoids are shown faulty in response and simultaneously solenoid supply voltage is detected faulty. 2. Solenoid relay will not be switched OFF. 3. Solenoid relay is frozen in spite of its high valve relay supply voltage.
ABS solenoid relay
ABS solenoid relay circuit WIRING DIAGRAM Engine Room R/B No. 5 ABS 5 5 2 1 B L L 19 A7 GND1 W-B 1 2H ABS Actuator and ECU 17 A7 +B 18 A7 BAT 10 2F Engine Room J/B FL Block 1 ALT 1 F6 F8 1 2G 4 2F W-B B-L 16 A7 GND2 B FL MAIN W-B Battery ED EE F09803 2001 AVALON (RM808U) Author
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: 375 DI-220 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE 1 Check voltage between terminals +B (A7 - 17, 18) and GND (A7 - 16, 19) of ABS actuator connector. PREPARATION: Disconnect the connector from the ABS actuator. CHECK: Measure the voltage between terminals A7 - 17, 18 and A7 16, 19 of ABS actuator harness side connector. OK: Voltage: 10 - 14 V LOCK A7 18 17 (-) 16 (+) 19 F00064 NG Check and replace fuses. Check and repair harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. 2001 AVALON (RM808U) Author
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: 376 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-221 DI6ND-01 DTC 13 ABS Motor Relay Circuit CIRCUIT DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. When the ABS is activated, the ECU switches the ABS motor relay ON and operates the ABS pump motor. DTC No. DTC Detecting Condition Trouble Area 13 When any of the following 1. through 3. is detected: 1. Pump motor voltage is not supplied within 0.06 sec. after actuation of the motor relay. 2. Pump motor voltage is high, and the motor relay will not actuate for 2.5 sec. or more. 3. Pump motor voltage remains low for longer 0.4 sec. or more and the pump repeats activating for 0.7 sec. 3 times maximally. After the last activation, the pump motor is deactivated gone dead because of short circuit.
ABS motor relay
ABS motor relay circuit WIRING DIAGRAM Engine Room R/B No. 5 ABS 5 5 2 1 B L L 18 A7 BAT 19 A7 GND1 W-B 1 2H ABS Actuator and ECU 17 A7 +B 10 2F Engine Room J/B FL Block 1 ALT 1 F6 F8 1 2G 4 2F W-B B-L 16 A7 GND2 B FL MAIN W-B Battery ED EE F09803 2001 AVALON (RM808U) Author
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: 377 DI-222 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE 1 Check voltage between terminals +B (A7 - 17, 18) and GND (A7 - 16, 19) of brake actuator connector. PREPARATION: Disconnect the connector from the brake actuator. CHECK: Measure the voltage between terminals A7 - 17, 18 and A7 16, 19 of brake actuator harness side connector. OK: Voltage: 10 - 14 V LOCK A7 19 17 18 (-) 16 (+) F00064 NG Check and replace fuses. Check and repair harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. 2001 AVALON (RM808U) Author
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: 378 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-223 DI6NE-01 DTC 21 - 24 ABS Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU, and controls the pressure acting on the wheel cylinders thus controlling the braking force. DTC No. DTC Detecting Condition Trouble Area 21, 22, 23, 24 Solenoid signal does not match the check result.
Brake actuator
Each solenoid circuit WIRING DIAGRAM Engine Room R/B No. 5 ABS 5 5 2 1 B L L 19 A7 GND1 W-B 1 2H ABS Actuator and ECU 17 A7 +B 18 A7 BAT 10 2F Engine Room J/B FL Block 1 ALT 1 F6 F8 1 2G 4 2F W-B B-L 16 A7 GND2 B FL MAIN W-B Battery ED EE F09803 2001 AVALON (RM808U) Author
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: 379 DI-224 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE 1 Check the DTC once more. PREPARATION: (a) Clear the DTC (See page DI-212 ). (b) Turn the ignition switch OFF. CHECK: Turn the ignition switch ON, and check if the same DTC is stored in the memory. NO No problem. YES Replace ABS ECU. 2001 AVALON (RM808U) Author
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: 380 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-225 DI6NF-02 DTC 31 - 36, 38, 39 Speed Sensor Circuit CIRCUIT DESCRIPTION Rotor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. Each of the front and rear rotors has 48 serrations. When the rotors rotate, a magnetic field emitted by a permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Speed Sensor S Magnet N Coil To ECU Low Speed High Speed +V BR3583 BR3582 -V F00010 DTC No. DTC Detecting Condition Trouble Area 31, 32, 33, 34 When any of the following 1. through 3. is detected: 1. Vehicle speed is more than 40 km/h (25 mph), and pulses are not input for 0.01 sec. 2. After the initial start or restart and when the vehicle speed has reached 12 km/h (7 mph), the wheel speed of 0 km/h (0 mph) is detected. 3. After the initial start or restart and when the vehicle speed has reached 18 km/h (11 mph), the front wheel speed of 0 km/h (0 mph) is detected.
Right front, left front, right rear, left rear speed sensor
Each speed sensor circuit
Sensor installation 35, 36, 38, 39 Detecting abnormality in the resistance value of each speed sensor.
Right front, left front, right rear, left rear speed sensor
Each speed sensor circuit HINT:



DTC DTC DTC DTC No. No. No. No. 31 32 33 34 and and and and 35 36 38 39 are for the right front speed sensor. are for the left front speed sensor. are for the right rear speed sensor. are for the left rear speed sensor. 2001 AVALON (RM808U) Author
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: 381 DI-226 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) WIRING DIAGRAM ABS Actuator and ECU A8 2 ABS Speed Sensor Front LH 1 6 A7 FL- B-W 5 A7 FR+ L 3 IE1 L 4 A7 FR- (Shielded) BR BR A BR J1 J/C A A A BR 11 ID1 BR BR 8 IE1 BR LG 22 ID1 LG 7 IE1 LG 9 A7 RL+ V 21 ID1 V 6 IE1 V 8 A7 RL- (Shielded) EE B-R 2 IE1 A A30 1 ABS Speed Sensor Rear RH 2 FL+ B-W (Shielded) A29 1 ABS Speed Sensor Rear LH 2 7 A7 (Shielded) 1 IE1 A9 2 ABS Speed Sensor Front RH 1 BR 10 IK1 (Shielded) 9 IE1 (Shielded) G 12 IK1 G 10 IE1 G 2 A7 RR+ Y 11 IK1 Y 11 IE1 Y 1 A7 (Shielded) (Shielded) RR- (Shielded) F09802 2001 AVALON (RM808U) Author
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: 382 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-227 INSPECTION PROCEDURE 1 Check speed sensor. 1 2 R14205 1 2 R14213 Front: PREPARATION: (a) Remove the front fender liner. (b) Disconnect the speed sensor connector. CHECK: Measure the resistance between terminals 1 and 2 of the speed sensor connector. OK: Resistance: 0.6 - 2.5 kΩ (1.6 ± 0.2 kΩ at 20 °C) CHECK: Measure the resistance between terminals 1 and 2 of the speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher Rear: PREPARATION: (a) Remove the seat cushion and seatback. (b) Disconnect the speed sensor connector. CHECK: Measure the resistance between terminals 1 and 2 of the speed sensor connector. OK: Resistance: 1.2 - 2.3 kΩ (1.6 ± 0.1 kΩ at 20 °C) CHECK: Measure the resistance between terminals 1 and 2 of the speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI-212 ). OK 2001 AVALON (RM808U) Author
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: 383 DI-228 DIAGNOSTICS 2 - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check for open and short circuit in harness and connector between each speed sensor and ABS ECU (See page IN-30 ). NG Repair or replace harness or connector. OK 3 Check speed sensor installation. CHECK: Check the speed sensor installation. OK: The installation bolt shall be tightened properly and there is no clearance is allowed between the sensor and front steering knuckle or rear axle carrier. OK NG BR3795 NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI-212 ). OK 4 Check speed sensor and sensor rotor serrations. Normal Signal Waveform GND 2 m/s / Division 1 V / Division REFERENCE: INSPECTION USING OSCILLOSCOPE PREPARATION: (a) Disconnect the connector from the brake actuator. (b) Connect the oscilloscope to the terminals FR+, FL+, RR+ or RL+ and GND of the ABS ECU harness side connector. CHECK: Drive the vehicle at about 30 km/h (19 mph), and check the signal waveform. W04200 OK Check and replace ABS ECU. NG 2001 AVALON (RM808U) Author
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: 384 DIAGNOSTICS 5 - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-229 Check sensor rotor and sensor tip. R00948 R00947 Front: PREPARATION: Remove the front drive shaft (See page SA-16 ). CHECK: Check the sensor rotor serrations. OK: No scratches, missing teeth or foreign objects. PREPARATION: Remove the front speed sensor (See page BR-60 ). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. Rear: PREPARATION: Remove the axle hub (See page SA-45 ). CHECK: Check the sensor rotor serrations. OK: No scratches, missing teeth or foreign objects. PREPARATION: Remove the rear speed sensor (See page BR-63 ). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. NG Replace sensor rotor or speed sensor. NOTICE: Check the speed sensor signal last (See page DI-212 ). OK Check and replace ABS ECU. 2001 AVALON (RM808U) Author
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: 385 DI-230 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6NG-01 DTC 37 Speed Sensor Rotor Faulty CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 37 When any of the following 1. through 3. is detected: 1. Occurrence of wheel speed difference between the front and rear wheels of either left or right side of the vehicle and the front left and right wheels. (Detection of mini tire size, spinning wheel or decelerating wheel.) 2. Continuous ABS control for 60 sec. or more. 3. Interference on 1 or more wheels for 20 sec. with the brake pedal depressed, or for 5 sec. when the brake pedal is not depressed.
Speed sensor
Sensor rotor INSPECTION PROCEDURE 1 Check sensor rotor (See page DI-225 ). NG Replace sensor rotor. OK 2 Check speed sensor (See page DI-225 ). NG Replace speed sensor. OK 3 Check for open or short circuit in harness and connector between speed sensor and ABS ECU (See page IN-30 ). NG Repair or replace harness and connector. OK Check and replace ABS ECU. 2001 AVALON (RM808U) Author
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: 386 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-231 DI6NH-01 DTC 41 Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the actuators. DTC No. DTC Detecting Condition Trouble Area At a vehicle speed of about 6 km/h (4 mph), low battery voltage is less than 9.4 V during non-operation of ABS control or less than 8.8 V during operation of ABS control, and high battery voltage is more than 17.4 V. 41
Battery
Charging system
Power source circuit WIRING DIAGRAM Driver Side J/B IG1 Relay ECU-IG No. 2 1 1G ABS Actuator and ECU 2 1H 1 3 4 1B B-L W W-B 15 A7 IG1 Y-R 2 Ignition Switch 4 3 1C Engine Room J/B 1 1 B 2G 2H 10 4 2F 2F 4 2 W-R IG1 AM1 Engine Room R/B No. 5 AM1 2 1 5 5 W-L 7 IF1 W-L W-B 19 A7 GND1 W-B 1 F8 1 F10 FL Block 1 F6 W-B ALT B ED IG Battery 16 A7 GND2 EE FL MAIN F09798 2001 AVALON (RM808U) Author
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: 387 DI-232 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE 1 Check ECU-IG No. 2 fuse. PREPARATION: Remove ECU-IG No. 2 fuse from driver side J/B. CHECK: Check continuity of ECU-IG No. 2 fuse. OK: Continuity Driver Side J/B ECU-IG No. 2 F07886 NG Check for short circuit in all the harness and components connected to ECU-IG No. 2 fuse (See attached wiring diagram). NG Check and repair the charging system (See page CH-1 ). OK 2 Check battery positive voltage. OK: Voltage: 10 - 14 V OK 2001 AVALON (RM808U) Author
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: 388 DIAGNOSTICS 3 - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-233 Check voltage between terminals IG1 (A7 - 15) and GND (A7 - 16, 19) of the brake actuator connector. ON A7 19 16 15 (-) (+) PREPARATION: Disconnect the connector from the brake actuator. CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals A7 - 15 and A7 - 16, 19 of the brake actuator harness side connector. OK: Voltage: 10 - 14 V F00067 OK Check and replace ABS ECU. NG 4 Check continuity between terminals GND (A7 - 16, 19) of brake actuator connector and body ground. LOCK A7 (-) 19 16 CHECK: Measure the resistance between terminal A7 - 16, 19 of brake actuator harness side connector and body ground. OK: Resistance: 1 Ω or less (+) F00068 NG Repair or replace harness or connector. OK Check for open circuit in harness and connector between terminal IG1 of brake actuator and ECU-IG fuse (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 389 DI-234 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6NI-02 DTC 58 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No. 58 DTC Detecting Condition Trouble Area Stop light switch circuit is open, and stop light switch voltage is in the level between 55 % and 75 % of the battery voltage.
Stop light switch
Stop light switch circuit WIRING DIAGRAM G-W Driver Side J/B J/B No. 4 J/B No. 3 3 3 3 5 16 16 G-W G-W 1D 1B 3C 4F 3F 4D ABS Actuator and ECU G-W 14 IE1 G-W 14 A7 STP 4 1E G-W R7 Rear Combination Light LH Stop 3 6 S4 Stop Light Switch 5 IK1 2 1 W R Driver Side J/B 1 11 STOP 1G 1D FL Block 1 ALT 1 F10 F6 G-R G-W 7 W-B R8 Rear Combination Light RH C Stop B 3 6 W-B G-R C B 2 B G-R J12 J/C B FL MAIN 1 Battery R-W J12 J/C H11 High Mounted Stop Light 1 C 2 W-B C W-B L5 Light Failure Sensor BM F09800 2001 AVALON (RM808U) Author
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: 390 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-235 INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that the stop light lights up when the brake pedal is depressed and turns off when the brake pedal is released. NG Repair stop light circuit (See page BE-36 ). OK 2 (-) Check voltage between terminal STP (A7 - 14) of brake actuator and body ground. PREPARATION: Disconnect the connector from the brake actuator. CHECK: Measure the voltage between terminal A7 - 14 of brake actuator harness side connector and body ground when the brake pedal is depressed. OK: Voltage: 8 - 14 V (+) A7 14 F00069 OK Check and replace ABS ECU. NG 3 Check for open circuit in harness and connector between terminal STP of brake actuator and stop light switch (See page IN-30 ). NG Repair or replace harness or connector. OK Proceed to next circuit inspection shown in problem symptoms table (See page DI-218 ). 2001 AVALON (RM808U) Author
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: 391 DI-236 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6NJ-01 DTC 62 ABS ECU Malfunction CIRCUIT DESCRIPTION DTC No. 62 DTC Detecting Condition Trouble Area ABS ECU continuously detects the proper operation of ABS. ABS ECU INSPECTION PROCEDURE 1 Is DTC output? Check the DTC on page DI-212 . YES Repair circuit indicated by the code output. YES Check for short circuit in harness and connector between DLC1 or DLC2 and ABS ECU (See page IN-30 ). YES Check open and short circuit of the harness and connector in the Tc circuit between ABS ECU and DLC2 or DLC1. NO 2 Is normal code displayed? NO 3 Is ABS warning light off? NO 2001 AVALON (RM808U) Author
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: 392 DIAGNOSTICS 4 - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-237 Check voltage between terminals IG1 (A7 - 15) and GND (A7 - 16, 19) of brake actuator connector. ON A7 15 19 (+) 16 (-) PREPARATION: Disconnect the connector from the brake actuator. CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals A7 - 15 and A7 - 16, 19 of brake actuator harness side connector. OK: Voltage: 10 - 14 V F00067 NG Check for open or short circuit in harness and connector between ECU-IG fuse and IG1 of brake actuator (See page IN-30 ). OK 5 Check connection of brake actuator connector. CHECK: Check the connection of the brake actuator connector and check the ABS warning light goes off. OK Repair or replace harness or connector. NG Check and replace ABS ECU. 2001 AVALON (RM808U) Author
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: 393 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-245 DI6NN-01 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminals Tc and E1 of the DLC1 causes the ECU to display the DTC by flashing the ABS warning light. WIRING DIAGRAM J/B No. 4 LG-R J/B No. 3 6 6 4A 4H 4 LG-R 4 3B 3G ABS Actuator and ECU Driver Side J/B LG-R 5 1I 7 1H 12 LG-R A7 Tc 13 3A II2 22 11 LG-R 4 Tc LG-R Tc E1 3 W-B DLC1 EB DLC2 F09805 INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1. CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals Tc and E1 of DLC1 or terminal Tc of DLC2 and body ground. OK: Voltage: 10 - 14 V DLC1 ON E1 DLC2 Tc Tc F10163 OK If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective. NG 2001 AVALON (RM808U) Author
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: 401 DI-246 2 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check for open and short circuit in harness and connector between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS ECU. 2001 AVALON (RM808U) Author
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: 402 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-247 DI6NO-01 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalily in the speed sensor signal which cannot be detected by the DTC check. Connecting terminals Ts and E1 of the DLC1 starts the check. WIRING DIAGRAM ABS Actuator and ECU DLC1 J/B No. 4 11 LG-B Ts 16 E1 II2 LG-B 12 4A 3 4B LG-B 13 IE1 11 LG-B A7 Ts W-B 3 EB F09804 2001 AVALON (RM808U) Author
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: 403 DI-248 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE 1 Check voltage between terminals Ts and E1 of DLC1. AB0119 S08096 CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals Ts and E1 of DLC1. OK: Voltage: 10 - 14 V Ts ON E1 DLC1 F00446 OK If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. NG 2 Check for open and short circuit in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS ECU. 2001 AVALON (RM808U) Author
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: 404 DIAGNOSTICS - DI-21 1 ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6N6-01 CUSTOMER PROBLEM ANALYSIS CHECK ABS Check Sheet Inspector’s : Name Registration No. Registration Date Customer’s Name / / Frame No. Date Vehicle Brought In / Date Problem First Occurred / Frequency Problem Occurs km miles Odometer Reading / Continuous / Intermittent ( times a day) ABS does not operate. ABS does not operate intermittently. Symptoms ABS Warning Light Abnormal Remains ON Does not Light Up BRAKE Warning Light Abnormal Remains ON Does not Light Up 1st Time Normal Code Malfunction Code (Code ) 2nd Time Normal Code Malfunction Code (Code ) DTC Check 2001 AVALON (RM808U) Author
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: 367 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-215 DI6N8-01 DIAGNOSTIC TROUBLE CODE CHART HINT:


Using SST 09843-18020, connect the terminals Tc and E1. If any abnormality is found when inspecting parts, inspect the ECU. If a malfunction code is displayed during the DTC check, check the circuit listed under the code. For details of each code, refer to the page under respective ”DTC No.” in the DTC chart. DTC No. (See Page) Detection Item Trouble Area 11 (DI-219 ) Open or short circuit in ABS solenoid relay circuit
ABS solenoid relay
ABS solenoid relay circuit 13 (DI-221 ) Open or short circuit in ABS pump motor circuit
ABS motor relay
ABS motor relay circuit 21 (DI-223 ) Open or short circuit in brake actuator
Brake actuator
SFRR or SFRH circuit 22 (DI-223 ) Open or short circuit in brake actuator
Brake actuator
SFLR or SFLH circuit 23 (DI-223 ) Open or short circuit in brake actuator
Brake actuator
SRRR or SRRH circuit 24 (DI-223 ) Open or short circuit in brake actuator
Brake actuator
SRLR or SRLH circuit 31* (DI-225 ) Right front wheel speed sensor signal malfunction 32* (DI-225 ) Left front wheel speed sensor signal malfunction 33* (DI-225 ) Right rear wheel speed sensor signal malfunction 34* (DI-225 ) Left rear wheel speed sensor signal malfunction 35* (DI-225 ) Open circuit in right front wheel speed sensor circuit 36* (DI-225 ) Open circuit in left front wheel speed sensor circuit 37 (DI-230 ) Speed sensor rotor has wrong number of teeth on one of the 4 wheels 38* (DI-225 ) Open circuit in right rear wheel speed sensor circuit 39* (DI-225 ) Open circuit in left rear wheel speed sensor circuit 41 (DI-231 ) Low and high battery positive voltage
Battery
Charging system
Power source circuit 58 (DI-234 ) Open circuit in stop light switch circuit
Stop light switch
Stop light switch circuit 62 (DI-236 ) Malfunction in ABS ECU ABS ECU Always ON (DI-238 ) Malfunction in ABS ECU
Charging system
ABS warning light circuit
Right front, left front, right rear and left rear speed sensor
Each E h speed d sensor circuit i it
Sensor installation
Right front, left front speed s eed sensor
Each speed sensor circuit
Speed sensor
Sensor rotor
Right rear, left rear sspeed eed sensor
Each speed sensor circuit *: As the DTC cannot only be erased by replacing parts, do either of the following operations. (1) Clear DTC (See page DI-212 ). (2) At a vehicle speed of 20 km/h (12 mph), drive the vehicle for 30 sec. or more. 2001 AVALON (RM808U) Author
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: 371 DI-210 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6N5-01 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. Vehicle Brought to Workshop 1 Customer Problem Analysis P. DI-21 1 2 Check and Clear DTC (Precheck) P. DI-212 Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. Symptom does not occur 3 Problem Symptom Confirmation 4 Symptom Simulation P. IN-20 7 Problem Symptoms Table P. DI-218 Symptom occurs 5 Normal code DTC Check P. DI-212 Malfunction code 6 DTC Chart P. DI-215 8 Circuit Inspection 9 Sensor Check P. DI-219 - DI-247 Check for Fluid Leakage P. DI-249 Identification of Problem 10 11 Repair Confirmation Test End Fail safe function: When a failure occurs in the ABS system, the ABS warning light is lit and the ABS operation is prohibited. In addition to this, when the failure which disables the EBD operation occurs, the brake warning light is lit as well and EBD operation is prohibited. 2001 AVALON (RM808U) Author
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: 366 DI-216 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6N9-01 PARTS LOCATION Active Lamp Relay Rear Speed Sensor ABS Warning Light BRAKE Warning Light Sensor Rotor DLC1 Front Speed Sensor Rear Speed Sensor Stop Light Switch Sensor Rotor DLC2 Front Speed Sensor Brake Actuator (w/ ECU, Relay) Sensor Rotor F07882 2001 AVALON (RM808U) Author
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: 372 DI-212 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6N7-01 PRE-CHECK 1. (a) (b) DIAGNOSIS SYSTEM Release the parking brake pedal. Check the indicator. When the ignition switch is turned ON, check that the ABS warning light and BRAKE warning light goes on for approx. 3 seconds. HINT: F07879

(c) E1 Tc When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light is lit. If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit or BRAKE warning light circuit (See page DI-243 , DI-240 ). Check the DTC. (1) Using SST, connect terminals Tc and E1 of DLC1. SST 09843-18020 (2) Turn the ignition switch ON and read the DTC from the ABS warning light on the combination meter. HINT:
If no codes appears, inspect the diagnostic circuit or ABS warning light circuit (See page DI-245 or DI-243 ).
As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. (3) Codes are explained in the code table on page DI-215 . (4) After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunction codes are identified at the same time, the lowest numbered DTC will be displayed 1st. DLC1 F02201 Normal Code 0.25 sec. 0.5 sec. 0.25 sec. ON OFF Code 11 and 21 0.5 sec. 1.5 sec. 4 sec. 0.5 sec. 2.5 sec. ON OFF Code 11 Code 21 F00103 2001 AVALON (RM808U) Author
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: 368 DIAGNOSTICS (d) BR3890 - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI-213 Clear the DTC. (1) Using SST, connect terminals Tc and E1 of DLC1. SST 09843-18020 (2) Turn the ignition switch ON. (3) Clear the DTC stored in ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) Check that the warning light shows the normal code. (5) Remove the SST from the terminals of DLC1. SST 09843-18020 HINT: Cancellation cannot be done by removing the battery cable or ECU-IG fuse. 2. (a) E1 Tc Ts SPEED SENSOR SIGNAL CHECK (TEST MODE) Check the sensor signal. (1) Using SST, connect terminals Ts and E1 of DLC1. SST 09843-18020 (2) Start the engine. DLC1 0.13 sec. F02201 0.12 sec. ON OFF BR3904 (3) Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page DI-243 ). (4) Drive vehicle straight forward. (5) Drive vehicle at a speed faster than 45 km/h (28 mph) for several seconds. HINT: If the brake is applied during the check, the check routine must be started again. (6) Stop the vehicle. (7) Using SST, connect terminals Tc and E1 of DLC1. SST 09843-18020 (8) Read the number of blinks of the ABS warning light. HINT:
See the list of DTC shown on the next page.
If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated).
If 2 or more malfunction codes are identified at the same time, the lowest numbered code will be displayed 1st. 2001 AVALON (RM808U) Author
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: 369 DI-214 DIAGNOSTICS 7 - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Malfunction Code (Example Code 72, 76) 7 2 6 ON OFF 1.5 sec. 0.5 sec. 0.5 sec. 0.5 sec. 2.5 sec. 4 sec. 0.5 sec. Repeat BR3893 (9) After completing the check, disconnect the SST from terminals Tc and E1 of DLC1, and turn the ignition switch OFF. SST 09843-18020 DTC of speed sensor check function: Code No. Diagnosis Trouble Area 71 Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Right front speed sensor rotor 72 Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Left front speed sensor rotor 73 Low output voltage of right rear speed sensor
Right rear speed sensor
Sensor installation
Right rear speed sensor rotor 74 Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Left rear speed sensor rotor 75 Abnormal change in output voltage of right front speed sensor
Right front speed sensor rotor 76 Abnormal change in output voltage of left front speed sensor
Left front speed sensor rotor 77 Abnormal change in output voltage of right rear speed sensor
Right rear speed sensor rotor 78 Abnormal change in output voltage of left rear speed sensor
Left rear speed sensor rotor 2001 AVALON (RM808U) Author
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: 370 DI-218 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6NB-01 PROBLEM SYMPTOMS TABLE If a normal code is displayed during DTC check but a problem still occurs, check the circuits corresponding to each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. NOTICE: When replacing ABS ECU, sensor or etc., turn the IG switch OFF. Symptom ABS does not operate ABS does not operate intermittently Suspect Area See page Only when 1. - 4. are all normal and the problem is still occurring, replace the ABS ECU. 5. Check the DTC reconfirming that the normal code is output. 6. Power source circuit 7. Speed sensor circuit 8. Check the hydraulic circuit for leakage. Only when 1. - 4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the DTC reconfirming that the normal code is output. 2. Speed sensor circuit 3. Stop light switch circuit 4. Check the hydraulic circuit for leakage. DI-212 DI-231 DI-225 DI-249 DI-212 DI-225 DI-234 DI-249 ABS warning light abnormal 1. ABS warning light circuit 2. ABS ECU DI-243 BRAKE warning light abnormal 1. BRAKE warning light circuit 2. ABS ECU DI-240 DTC check cannot be done Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS ECU. 1. ABS warning light circuit 2. Tc terminal circuit Speed sensor signal check cannot be done 1. Ts terminal circuit 2. ABS ECU DI-243 DI-245 DI-247 2001 AVALON (RM808U) Author
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: 374 DIAGNOSTICS - DI-217 ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI6NA-01 TERMINALS OF ECU A7 F10161 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) RR+ (A7 - 2) - RR- (A7 - 1) G↔Y IG switch ON Slowly turn right rear wheel AC generation FR+ (A7 - 5) - FR- (A7 - 4) B-W ↔ L IG switch ON Slowly turn right front wheel AC generation FL+ (A7 - 7) - FL- (A7 - 6) BR ↔ B-R IG switch ON Slowly turn left front wheel AC generation RL+ (A7 - 9) - RL- (A7 - 8) LG ↔ V IG switch ON Slowly turn left rear wheel AC generation Ts (A7 - 11) - GND (A7 - 16, 19) LG-B ↔ W-B IG switch ON 5.7 - 8.1 Tc (A7 - 12) - GND (A7 - 16, 19) LG-R ↔ W-B IG switch ON 5.7 - 8.1 STP (A7 - 14) - GND (A7 - 16, 19) G W ↔ W-B G-W WB Stop light switch pushed in Below 1.5 Stop light switch released 5 - 14 IG1(A7 - 15) - GND (A7 - 16, 19) Y-R ↔ W-B IG switch ON 10 - 14 +B (A7 - 17) - GND (A7 - 16, 19) L ↔ W-B Always 10 - 14 BAT (A7 - 18) - GND (A7 - 16, 19) L ↔ W-B Always 10 - 14 WA (A7 - 20) - GND (A7 - 16, 19) B ↔ W-B WB EBDW (A7 - 21) - GND (A7 16, 19) R Y ↔ W-B R-Y WB PN (A7 - 23) - GND (A7 - 16, 19) L W ↔ W-B L-W WB IG switch ON, ABS warning light ON Below 2.6 IG switch ON, ABS warning light OFF 10 - 14 IG switch ON, BRAKE warning light ON Below 2.6 IG switch ON, BRAKE warning light OFF 10 - 14 IG switch ON, Shift lever is Por N range 10 - 14 IG switch ON, Shift lever is not Por N range Below 2.0 2001 AVALON (RM808U) Author
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: 373 DI-325 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OI-03 ABS Warning Light Circuit WIRING DIAGRAM J/B No. 4 15 4B D2 DLC2 E1 ABS 14 R-L 15 4A 15 4H ABS J/B No. 4 GAUGE No. 1 10 1D W 1 1G 1 3 1B 4 ECU-IG No. 2 2 W-B B-L R-L M6 5 Driver Side J/B IG1 Relay R-B 4 4D 13 4F M6 4 Multi Display R-B J/B No. 3 13 1B Y-R 2 11 3C 3D 4 1C 1 2 Y-R 2 4 W-R IG1 AM1 W-L Ignition Switch IF1 Engine Room J/B Engine Room R/B No. 5 1 1 1 AM1 2 B 5 5 2G 2H W-L 3 1 F8 FL Block ABS & BA & TRAC & VSC ECU R-L 1 F6 B FL MAIN A21 4 Active W-B Light B Relay J4 7 J/C B W-B W-B ALT W 81 7 A20 WA B 1 F10 Battery IG F09823 2001 AVALON (RM808U) Author
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: 481 DI-326 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Troubleshoot in accordance with the chart below for each trouble symptom. ABS warning light does not light up * ABS warning light remains on Go to step 2 *: Start the inspection from step 1 in case of using a TOYOTA hand-held tester and start from step 2 in case of not using the TOYOTA hand-held tester. 1 Check operation of the ABS warning light. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check that ”ON” and ”OFF” of the ABS warning light can be shown on the combination meter on the TOYOTA hand-held tester. OK Check and replace ABS & BA & TRAC & VSC ECU. NG 2 Check ABS warning light. See combination meter troubleshooting on page BE-2 . NG Replace bulb or repair combination meter assembly. NG Replace active lamp relay. OK 3 Check active lamp relay. OK Repair or replace and check for open or short circuit in harness and connector. 2001 AVALON (RM808U) Author
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: 482 DI-322 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OH-03 DTC Always ON Malfunction in ECU VSC Warning Light Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area Either of the following 1. or 2. is detected: 1. There is a malfunction in the ECU internal circuit. 2. There is a malfunction in VSC warning light circuit. Always ON
Charging system
VSC warning light circuit HINT: TOYOTA hand-held tester may not be able to be used when ECU is defective. WIRING DIAGRAM ABS & BA & TRAC & VSC ECU Multi Display VSC 4 M6 10 M6 J/B No. 4 R-B 1 W 1G Ignition Switch 4 4 1C IG1 W-R 2 AM1 W-L 7 IF1 W-L Engine Room R/B No. 5 2 AM1 1 5 5 1 F10 FL Block 15 4C 4 4D 15 4F 13 4F P-B R-B Driver Side J/B IG1 Relay GAUGE No. 1 2 1 3 4 B 10 1D 3 1B W-B Engine Room J/B 1 1 2H 2G 1 F8 B-L ALT 1 F6 70 A20 VSCW P-B B FL MAIN Battery IG F09818 2001 AVALON (RM808U) Author
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: 478 DI-323 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check that the ECU connectors are securely connected to the ECU. NO Connect the connector to the ECU. YES Repair circuit indicated by the output code . YES 2 Is DTC output? Check DTC on page DI-252 . NO 3 Does VSC warning light go off? YES Check for open or short circuit in harness and connector between ECU-IG fuse and ECU (See page IN-30 ). NO 4 Check battery positive voltage. PREPARATION: Start the engine. CHECK: Check the battery positive voltage. OK: Voltage: 10 - 16 V NG Check and repair the charging system (See page CH-1 ). OK 2001 AVALON (RM808U) Author
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: 479 DI-324 DIAGNOSTICS 5 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check operation of the VSC warning light. In case of using the TOYOTA hand-held tester: PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check that ”ON” and ”OFF” of the VSC warning light can be shown on the combination meter by the TOYOTA hand-held tester. In case of not using the TOYOTA hand-held tester: PREPARATION: (a) Turn the ignition switch OFF. (b) Disconnect the connector from the ABS & BA & TRAC & VSC ECU. (c) Turn the ignition switch ON. CHECK: Check the VSC warning light goes off. NG Check and replace combination meter (See page BE-2 ). OK 6 Check for short circuit in harness and connector between combination meter and ABS & BA & TRAC & VSC ECU, combination meter and DLC1 (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
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: 480 DI-319 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OG-02 DTC Always ON Malfunction in ECU ABS Warning Light Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area Either of the following 1., 2. or 3. is detected: 1. The ECU connectors are OFF the ECU. 2. There is a malfunction in the ECU internal circuit. 3. There is a malfunction in ABS warning light circuit. Always ON
Charging system
ABS warning light circuit HINT: TOYOTA hand-held tester may not be able to be used when the ECU is defective. WIRING DIAGRAM J/B No. 4 15 4B D2 DLC2 14 E1 ABS R-L 15 4A 15 4H ABS J/B No. 4 GAUGE No. 1 10 1D W 1 1G 1 3 1B 4 13 1B 1 2G 1 F8 13 4F M6 4 Multi Display R-B Y-R 1 2 11 3C 3D 2 Y-R 4 1C 2 4 W-R IG1 AM1 W-L Ignition Switch Engine Room R/B No. 5 IF1 3 Engine Room J/B B-L R-B 4 4D J/B No. 3 ECU-IG No. 2 2 W-B R-L M6 5 Driver Side J/B IG1 Relay 1 2H FL Block ABS & BA & TRAC & VSC ECU R-L 1 F6 B 5 B 1 AM1 2 FL MAIN A21 4 Active W-B Light B Relay J4 7 J/C B 5 W-L W-B W-B ALT W 81 7 A20 WA B 1 F10 Battery IG F09823 2001 AVALON (RM808U) Author
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: 475 DI-320 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check that the ECU connectors are securely connected to the ECU. NO Connect the connector to the ECU. YES Repair circuit indicated by the output code . YES 2 Is DTC output? Check DTC on page DI-252 . NO 3 Does ABS warning light go off? YES Check for open or short circuit in harness and connector between ECU-IG fuse and ECU (See page IN-30 ). NO 4 Check battery positive voltage. PREPARATION: Start the engine. CHECK: Check the battery positive voltage. OK: Voltage: 10 - 16 V NG Check and repair the charging system (See page CH-1 ). OK 2001 AVALON (RM808U) Author
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: 476 DI-321 DIAGNOSTICS 5 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check operation of the ABS warning light. In case of using the TOYOTA hand-held tester: PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check that ”ON” and ”OFF” of the ABS warning light can be shown on the combination meter by the TOYOTA hand-held tester. In case of not using the TOYOTA hand-held tester: PREPARATION: (a) Turn the ignition switch OFF. (b) Disconnect the connector from the ABS & BA & TRAC & VSC ECU. (c) Turn the ignition switch ON. CHECK: Check the ABS warning light goes on. OK Check and replace combination meter (See page BE-2 ). NG 6 Check for short circuit in harness and connector between active lamp relay and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repeir or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
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: 477 DI-330 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OK-02 BRAKE Warning Light Circuit CIRCUIT DESCRIPTION
The BRAKE warning light lights up when the brake fluid is insufficient, when the parking brake is applied or when the EBD is defective. If the translate ECU detects trouble, it makes VSC warning light lights up while prohibiting VSC & TRAC control. At this time, the ECU records a DTC in memory. Connect terminals Tc and E1 of the DLC1 or DLC2 to make BRAKE warning light blink and output the DTC.
WIRING DIAGRAM 1 1G W 4 1C R-B Driver Side J/B IG1 Relay GAUGE No. 1 10 1 2 1D 3 J/B No. 4 4 R-B M6 3 1B 4 CUP W-R Ignition Switch W-B W-L 4 IG1 AM1 2 7 IF1 Engine Room R/B No. 5 5 1 AM1 2 BRAKE 13 4F 4 4D 7 M3 L-O 6 IL1 3 M6 7 IC1 Multi Display W-L Y-G 2 T5 PKB2 PKB 15 T5 LBL 25 T5 B Engine Room J/B 15 1 2H 3A 1 2G R-W B-L 1 F10 1 F8 1 15 11 R-W 3B T5 Driver Side J/B 12 1I 32 A20 EBDW BRL 14 Y-G 3A 5 3B 8 R-Y Active Light Relay 16 T5 J/B No. 3 5 A21 R-W 3 R-W R-W R-W IG ABS & BA & TRAC & VSC ECU 68 L-O A20 SP1 8 1H LVL2 Y-G L-B Translate ECU R-W (Shielded) BR 74 A20 PKB 40 A20 LBL 60 A20 FSS J1 J/C ALT FL Block P3 Parking B W-B Battery Brake FL MAIN Switch 1 F6 B 2 B W-B Engine Room J/B 4 4 2F 2D 1 B1 Brake Fluid Level Warning Switch W-B ED F09824 2001 AVALON (RM808U) Author
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: 486 DI-331 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check parking brake switch circuit (See page BE-53 ). NG Repair or replace parking brake switch circuit. OK 2 Check brake fluid level warning switch circuit (See page BE-53 ). NG Repair or replace brake fluid level warning switch circuit. YES Repair circuit indicated by the output code. OK 3 Is DTC output for ABS ? No 4 Check BRAKE warning light. See combination meter troubleshooting on page BE-2 . NG Repair or replace combination meter. OK 2001 AVALON (RM808U) Author
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: 487 DI-332 DIAGNOSTICS 5 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check active lamp relay. NG Replace active lamp relay. OK 6 Check for open or short circuit in harness and connector between combination meter and active lamp relay (See page IN-30 ). NG Repair or replace harness or connector. OK 7 Check for open or short circuit in harness and connector between active lamp relay and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
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: 488 DI-267 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NX-03 CIRCUIT INSPECTION DTC C0200 / 31 - C1331 / 36 Speed Sensor Circuit DTC C1332 / 38, C1333 / 39 Speed Sensor Circuit CIRCUIT DESCRIPTION Rotor The speed sensor detects a wheel speed and sends the appropriate signals to the ECU. These signals are used to control of the ABS and VSC system. Each of the front and rear rotors has 48 serrations. When the rotors rotate, a magnetic field emitted by a permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Speed Sensor S Magnet N Coil To ECU Low Speed High Speed +V BR3583 BR3582 -V F00010 DTC No. DTC Detecting Condition Trouble Area C0200 / 31 C0205 / 32 C0210 / 33 C0215 / 34 When any of the following 1. to 3. is detected : 1. Vehicle speed is more than 40 km/h (25 mph), pulses are not input for 0.01 sec. 2. After the initial start or restart and when the vehicle speed has reached 12 km/h (7 mph), the wheel speed of 0 km/h (0 mph) is detected. 3. After the initial start or restart and when the vehicle speed has reached 18 km/h (11 mph), the front wheel speed of 0 km/h (0 mph) is detected.
Right front, left front, right rear, left rear speed sensor
Each speed sensor circuit
Sensor installation C1330 / 35 C1331 / 36 C1332 / 38 C1333 / 39 Detecting abnormality in the resistance value of each speed sensor.
Right front, left front, right rear, left rear speed sensor
Each speed sensor circuit HINT:



DTC DTC DTC DTC No. No. No. No. C0200 C0205 C0210 C0215 / / / / 31 32 33 34 and and and and C1330 / 35 are for the right front speed sensor. C1331 / 36 are for the left front speed sensor. C1332 / 38 are for the right rear speed sensor. C1333 / 39 are for the left rear speed sensor. 2001 AVALON (RM808U) Author
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: 423 DI-268 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM WIRING DIAGRAM ABS & BA & TRAC & VSC ECU (Shielded) A9 Right Front Speed Sensor 16 A20 FR- B-W 17 A20 FR+ 1 2 (Shielded) A8 Left Front Speed Sensor L B-R 19 IE1 BR 18 IE1 1 2 BR (Shielded) B-R 10 A20 FL- BR 8 A20 FL+ 20 IE1 A BR-W 10 IK1 Y 12 A20 RR- G 12 IK1 G 11 A20 RR+ IG 11 ID1 (Shielded) BR-W V 21 ID1 V 14 A20 RL- LG 22 ID1 LG 13 A20 RL+ 2 1 A BR 11 IK1 (Shielded) A29 Left Rear Speed Sensor A Y 2 1 J4 J/C A BR A30 Right Rear Speed Sensor A (Shielded) (Shielded) F09825 2001 AVALON (RM808U) Author
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: 424 DI-269 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check speed sensor. 1 2 R14205 1 2 R14213 Front: PREPARATION: (a) Remove the front fender liner. (b) Disconnect the speed sensor connector. CHECK: Measure the resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 0.6 - 2.5 kΩ (1.6 ± 0.2 kΩ at 20 °C) CHECK: Measure the resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher Rear: PREPARATION: (a) Remove the seat cushion and seatback. (b) Disconnect the speed sensor connector. CHECK: Measure the resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 1.2 - 2.3 kΩ (1.6 ± 0.1 kΩ at 20 °C) CHECK: Measure the resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI-252 ). OK 2001 AVALON (RM808U) Author
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: 425 DI-270 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check for open and short circuit in harness and connector between each speed sensor and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness or connector. OK 3 Check speed sensor installation. CHECK: Check the speed sensor installation. OK: The installation bolt shall be tightened properly and no clearance is allowed between the sensor and front steering knuckle or rear axle carrier. OK NG BR3795 NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI-252 ). OK 2001 AVALON (RM808U) Author
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: 426 DI-271 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check speed sensor and sensor rotor serrations. Normal Signal Waveform GND 2 m/s / Division 1 V / Division W04200 REFERENCE: INSPECTION USING OSCILLOSCOPE PREPARATION: (a) Disconnect the connector from the ABS & BA & TRAC & VSC ECU. (b) Connect the oscilloscope to the terminals FR+, FL+, RR+ or RL+ and GND of the ECU harness side connector. CHECK: Drive the vehicle at about 30 km/h (19 mph), and check the signal waveform. OK Check and replace ABS & BA & TRAC & VSC ECU. NG 5 Check sensor rotor and sensor tip. R00948 Front: PREPARATION: Remove the front drive shaft (See page SA-16 ). CHECK: Check the sensor rotor serrations. OK: No scratches, missing teeth or foreign objects. PREPARATION: Remove the front speed sensor (See page BR-60 ). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. 2001 AVALON (RM808U) Author
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: 427 DI-272 DIAGNOSTICS R00947 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Rear: PREPARATION: Remove the axle hub (See page SA-45 ). CHECK: Check the sensor rotor serrations. OK: No scratches, missing teeth or foreign objects. PREPARATION: Remove the rear speed sensor (See page BR-63 ). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. NG Replace sensor rotor or speed sensor. NOTICE: Check the speed sensor signal last (See page DI-252 ). OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 428 DI-273 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NY-03 DTC C0226 / 21 - C1228 / 28 Brake Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force. DTC No. DTC Detecting Condition Trouble Area C0226 / 21 Open or short in SFRR or SFRH circuit.
Brake actuator
SFRR or SFRH circuit C0236 / 22 Open or short in SFLR or SFLH circuit.
Brake actuator
SFLR or SFLH circuit C0246 / 23 Open or short in SRRR or SRRH circuit.
Brake actuator
SRRR or SRRH circuit C0256 / 24 Open or short in SRLR or SRLH circuit.
Brake actuator
SRLR or SRLH circuit C1225 / 25 Open or short circuit for SMC1 circuit.
Brake actuator
SMC1 circuit C1226 / 26 Open or short circuit for SMC2 circuit.
Brake actuator
SMC2 circuit C1227 / 27 Open or short circuit for SRC1 circuit.
Brake actuator
SRC1 circuit C1228 / 28 Open or short circuit for SRC2 circuit.
Brake actuator
SRC2 circuit 2001 AVALON (RM808U) Author
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: 429 DI-274 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM WIRING DIAGRAM ABS & BA & TRAC & VSC ECU J/B No. 3 19 3H GR-R 6 3A GR-R 17 IE1 R 2 A20 R+ Engine Room J/B No. 3 21 IF3 GR-R 3 W 3 3 ABS Solenoid Relay 6 4 3 1 R 3 36 A20 SR 3 2 W-B W-L 2F 8 2F 10 ABS No. 2 ABS & BA & TRAC & VSC Actuator 2 Engine BS A5 Room 9 J/B SFRH A5 2F 4 2G 1 SFRR B-L SFLH F8 1 SFLR ALT FL Block SRRH SRRR F6 1 W-B B SRLH SRLR FL MAIN 11 A5 7 A5 8 A5 4 A5 5 A5 1 A5 3 A5 3 SMC1 A6 Battery ED 2 SMC2 A6 5 SRC1 A6 4 SRC2 A6 B-W W-G W-R G-O GR G-R Y-B L-Y G-Y V-W B-Y R-B 2 IE1 3 IE1 4 IE1 5 IE1 6 IE1 7 IE1 10 IE1 11 IE1 12 IE1 13 IE1 14 IE1 15 IE1 B-W W-G W-R G-O GR G-R Y-B L-Y G-Y V-W B-Y R-B 26 A20 55 A20 5 A20 3 A20 6 A20 4 A20 53 SFRH SFRR SFLH SFLR SRRH SRRR A20 SRLH 25 A20 SRLR 49 A20 SMC1 50 A20 SMC2 54 A20 SRC1 52 A20 SRC2 F09826 2001 AVALON (RM808U) Author
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: 430 DI-275 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check brake actuator solenoid. 12 11 10 (-) PREPARATION: Disconnect the connector from brake actuator. CHECK: Check continuity between terminals 10 and each of 1, 2, 3, 4, 5, 6, 7, 8, 9, 11, 12, 15 of brake actuator connector. OK: Continuity (+) 15 9 8 1 7 6 5 4 3 2 F07890 NG Replace brake actuator. OK 2 Check for open and short circuit in harness and connector between ABS & BA & TRAC & VSC ECU and brake actuator (See page IN-30 ). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. 2001 AVALON (RM808U) Author
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: 431 DI-276 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NZ-03 DTC C0273 / 13 ABS Motor Relay Circuit CIRCUIT DESCRIPTION The ABS motor relay supplies power to the brake actuator pump motor. While the ABS & BA & TRAC & VSC are activated, the ECU switches the motor relay ON and operates the brake actuator pump motor. DTC No. DTC Detecting Condition C0273 / 13 Trouble Area
ABS motor relay
ABS motor relay circuit Open or short circuit is detected. WIRING DIAGRAM ABS & BA & TRAC & VSC ECU 6 IE1 GR-L Engine RoomR/B No. 3 J/B No. 3 ABS Motor Relay 4 3 1 GR-R 19 3H 6 3A GR-R 2 A20 R+ O 27 A20 MT ABS & BA & TRAC& VSC Actuator 10 6 W-B L A5 A5 2 3 3 21 IF3 GR-R 3 3 7 A20 MR GR-L EE Engine Room R/B No. 5 ABS No. 4 5 5 2 1 ABS 1 2 5 5 L W FL Block B Battery FL MAIN 1 F6 ALT 1 F8 B-L O IF3 3 B Engine Room J/B 1 1 2H 2G F09816 2001 AVALON (RM808U) Author
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: 432 DI-277 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand-held tester and start from step 2 in case of not using the TOYOTA hand-held tester. 1 Check ABS motor relay operation. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check the operation sound of the ABS motor relay individually when operating it with the TOYOTA handheld tester. OK: The operation sound of the ABS motor relay should be heard. NG Go to step 3. OK 2 Check for short circuit in harness and connector between BM of motor relay and brake actuator and MT of ABS & BA & TRAC & VSC ECU (See page IN-30 ). OK Check and replace ABS & BA & TRAC & VSC ECU. NG 2001 AVALON (RM808U) Author
: Date
: 433 DI-278 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check voltage between terminal 1 of engine room R/B No. 8 (for ABS motor relay) and body ground. PREPARATION: Remove ABS motor relay from engine room R/B No. 8. CHECK: Measure the voltage between terminal 1 of engine room R/B No. 8 (for ABS motor relay) and body ground. OK: Voltage: 10 - 14 V Engine Room R/B No. 8 1 LOCK F07899 NG Check and repair harness or connector. OK 4 Check ABS motor relay. 2 1 4 3 CHECK: Check continuity between following terminals of motor relay. OK: Open Terminals 3 and 4 Continuity (Reference value 62 Ω) Terminals 1 and 2 Open 1 2 Continuity CHECK: (a) Apply battery positive voltage between terminals 3 and 4. (b) Check continuity between terminals. OK: 4 3 Terminals 1 and 2 Continuity Continuity 1 2 (-) 4 NG 3 Replace ABS motor relay. (+) F00044 OK 2001 AVALON (RM808U) Author
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: 434 DI-279 DIAGNOSTICS 5 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check continuity between terminal BM (2) of engine room R/B No. 8 (for ABS motor relay) and terminal MT (27) of ABS & BA & TRAC & VSC ECU. ABS Motor Relay Engine Room R/B No. 8 2 Brake Actuator PREPARATION: Disconnect the connector from the ABS & BA & TRAC & VSC ECU. CHECK: (a) Check continuity between terminal BM (2) of engine room R/B No. 8 and terminal GND (28) of ABS & BA & TRAC & VSC ECU. (b) Check continuity between terminal BM (2) of engine room R/B No. 8 and terminal MT (27) of ABS & BA & TRAC & VSC ECU. OK: Continuity ECU 27 13 F07900 NG Repair or replace harness or brake actuator. OK 6 Check for open and short circuit in harness and connector between ABS motor relay and ABS & BA & TRAC &VSC ECU (See page IN-30 ). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. 2001 AVALON (RM808U) Author
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: 435 DI-280 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O0-03 DTC C0278 / 11 ABS Solenoid Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. C0278 / 11 DTC Detecting Condition Detection of any conditions from 1. through 2.: 1. 3 or more solenoids are show faulty in response and simultaneously solenoid supply voltage is detected faulty. 2. Solenoid relay will not be switched OFF. Trouble Area
ABS solenoid relay
ABS solenoid relay circuit 2001 AVALON (RM808U) Author
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: 436 DI-281 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM WIRING DIAGRAM ABS & BA & TRAC & VSC ECU J/B No. 3 19 3H GR-R 6 3A GR-R 17 IE1 R 2 A20 R+ Engine Room J/B No. 3 21 IF3 GR-R 3 W 3 3 ABS Solenoid Relay 6 4 3 1 R 3 36 A20 SR 3 2 W-B W-L 2F 8 2F 10 ABS No. 2 ABS & BA & TRAC & VSC Actuator 2 Engine BS A5 Room 9 J/B SFRH A5 2F 4 2G 1 SFRR B-L SFLH F8 1 SFLR ALT FL Block SRRH SRRR F6 1 W-B B SRLH SRLR FL MAIN 11 A5 7 A5 8 A5 4 A5 5 A5 1 A5 3 A5 3 SMC1 A6 Battery ED 2 SMC2 A6 5 SRC1 A6 4 SRC2 A6 B-W W-G W-R G-O GR G-R Y-B L-Y G-Y V-W B-Y R-B 2 IE1 3 IE1 4 IE1 5 IE1 6 IE1 7 IE1 10 IE1 11 IE1 12 IE1 13 IE1 14 IE1 15 IE1 B-W W-G W-R G-O GR G-R Y-B L-Y G-Y V-W B-Y R-B 26 A20 55 A20 5 A20 3 A20 6 A20 4 A20 53 SFRH SFRR SFLH SFLR SRRH SRRR A20 SRLH 25 A20 SRLR 49 A20 SMC1 50 A20 SMC2 54 A20 SRC1 52 A20 SRC2 F09826 2001 AVALON (RM808U) Author
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: 437 DI-282 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals 1 and 2 of engine room R/B No. 8 (for ABS solenoid relay). LOCK 2 PREPARATION: Remove the ABS solenoid relay from engine room R/B No. 8. CHECK: Measure the voltage between terminals 1 and 2 of engine room R/B No. 8 (for ABS solenoid relay). OK: Voltage: 10 - 14 V 1 Engine R/B No. 8 F07891 NG Check and repair harness or connector. OK 2001 AVALON (RM808U) Author
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: 438 DI-283 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check ABS solenoid relay. 3 2 1 6 5 4 Open 3 2 1 6 5 4 CHECK: Check continuity between following terminals of ABS solenoid relay. OK: Terminals 4 and 6 Continuity (Reference value 80 Ω) Terminals 2 and 3 Continuity Terminals 1 and 3 Open Continuity Continuity Continuity CHECK: (a) Apply battery positive voltage between terminals 4 and 6. (b) Check continuity between following terminals of ABS solenoid relay. OK: 3 2 1 Open (-) 6 5 4 (+) Terminals 2 and 3 Open Terminals 1 and 3 Continuity F00042 NG Replace ABS solenoid relay. OK 2001 AVALON (RM808U) Author
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: 439 DI-284 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check continuity between terminal 3 of engine room R/B No. 8 (for ABS solenoid relay) and each solenoid terminal of ABS & BA & TRAC & VSC ECU. Engine Room R/B No. 8 ABS Solenoid Relay 3 Brake Actuator 55 54 53 4 3 52 PREPARATION: Disconnect the connector from the ABS & BA & TRAC & VSC ECU. CHECK: Check continuity between terminal 3 of engine room R/B No. 8 and each terminal, 3, 4, 5, 6, 25, 26, 49, 50, 52, 53, 54 and 55 of ECU harness side connector. OK: Continuity HINT: Resistance of each solenoid coil. SFLH (5), SRRH (6), SFRH (26), SMC1 (49), SMC2 (50), SRLH (53): 8 - 9.1 Ω SFLR (3), SRRR (4), SRLR (25), SRC2 (52), SRC1 (54), SFRR (55): 4.0 - 4.6 Ω ECU 49 26 25 50 6 5 F07892 NG Repair or replace harness or brake actuator. OK 4 Check for open and short circuit in harness and connector between ABS solenoid relay and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. 2001 AVALON (RM808U) Author
: Date
: 440 DI-285 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O1-03 DTC C0365 / 43 Deceleration Sensor Circuit CIRCUIT DESCRIPTION Deceleration sensor is combined with yaw rate sensor. DTC No. DTC Detecting Condition C0365 / 43 Detection of any of conditions from 1. through 4.: 1. The sensor signal is out of range, less than 0.25 V or more than 4.75 V. 2. Deceleration difference between sensor signal and reference value is large. 3. Offset value of sensor signal is higher than the standard value. 4. sensor signal change rapidly higher than the value at the normal condition. Trouble Area
Deceleration sensor
Deceleration sensor circuit WIRING DIAGRAM ABS & BA & TRAC & VSC ECU Deceleration Sensor (Shielded) 3 Y1 R 13 ID1 6 Y1 GNDA W 14 ID1 5 GL1 Y1 G IGA BR-W A 16 ID1 15 ID1 BR-W 34 A20 YIGA W 78 A20 YGNA G 18 A20 GL1 BR A BR BR IG (Shielded) R J4 J/C F09813 2001 AVALON (RM808U) Author
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: 441 DI-286 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand-held tester and start from step 2 in case of not using the TOYOTA hand-held tester. 1 Check output value of the deceleration sensor. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand-held tester. CHECK: Check that the deceleration value of the deceleration sensor displayed on the TOYOTA hand-held tester is changing when tilting the vehicle. OK: Deceleration value must be changing. OK Check and replace ABS & BA & TRAC & VSC ECU. NG 2 Check deceleration sensor (See page DI-252 ). NG Replace deceleration sensor. OK 3 Check for open or short circuit in harness and connector between deceleration sensor and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness and connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 442 DI-287 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O2-03 DTC C0371 / 55 Yaw Rate Sensor Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C0371 / 55 Detection of any of conditions from 1. through 4.: 1. The voltage of sensor signal is out of range. 2. The offset value of sensor signal is outside the plausible range. 3. Sensor signal change rapidly under normal driving. 4. Sensor is more or worse sensitivity than reference yaw rate during cornering.
Yaw rate sensor
Yaw rate sensor circuit WIRING DIAGRAM ABS & BA & TRAC & VSC ECU Yaw Rate Sensor YD (Shielded) 2 Y1 BR 1 GYW2 Y1 Y 4 YAW2 Y1 L J4 J/C A BR (Shielded) BR 1 ID1 2 ID1 12 ID1 BR-W 15 ID1 BR-W 75 A20 YD Y 76 A20 GYAW L 77 A20 YAW BR A BR IG F09813 2001 AVALON (RM808U) Author
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: 443 DI-288 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand-held tester and start from step 2 in case of not using the TOYOTA hand-held tester. 1 Check output value of the yaw rate sensor. F07893 PREPARATION: (a) Remove the 2 bolts and yaw rate sensor with connector still connected. (b) Connect the TOYOTA hand-held tester to the DLC3. (c) Turn the ignition switch ON and push the TOYOTA handheld tester main switch ON. (d) Select the DATALIST mode on the TOYOTA hand-held tester. CHECK: Check that the yaw rate value of the yaw rate sensor displayed on the TOYOTA hand-held tester is changing: Place the yaw rate sensor vertically to the ground and turn the sensor pivoted on its center. OK: Yaw rate value must be changing. OK Go to step 3. NG 2 Check whether continuity exists between terminal YD of yaw rate sensor and terminal YD of ABS & BA & TRAC & VSC ECU. NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 444 DI-289 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check yaw rate sensor. 4 3 CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals IGA (3) and GYW2 (1), YAW2 (4) and GYW2 (1) of the yaw rate sensor with connector still connected. OK: 2 1 1 F09478 NG Terminals 3 and 1 (IGA - GYW2) Approx. 12 V Terminals 4 and 1 (YAW2 - GYW2) Approx. 2.5 V Replace yaw rate sensor. OK 4 Check for open and short circuit in harness and connector between yaw rate sensor and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 445 DI-290 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O3-01 DTC C1202 / 44 Brake Fluid Level Warning Switch Circuit CIRCUIT DESCRIPTION The brake fluid level warning switch sends appropriate signals to the ECU when the brake fluid level is lowered. HINT: Depressing the parking brake pedal turns on the brake warning light, but this DTC No. C1202/44 is not output. DTC No. C1202 / 44 DTC Detecting Condition Trouble Area
Brake fluid level
Brake fluid level warning switch
Brake fluid level warning switch circuit Fluid level in the brake master cylinder reservoir tank remains low for 60 sec. or more. This means brake fluid warning switch likes on. WIRING DIAGRAM Driver Side J/B 8 12 1H 1I R-W 15 3A J/B No. 3 15 3B 11 T5 LVL2 R-W R-W Level Warning Switch 2 1 B W-B ED J1 J/B B W-B ABS & BA & TRAC & VSC ECU Translate ECU 25 LBL T5 16 BRL T5 Engine Room J/B 4 4 2D Driver Side J/B 10 GAUGE No. 1 1D W-B J/B No. 4 R-B R-W IC1 7 2F 4 4D 40 A20 LBL L-B 13 4F M6 Multi Display 3 R-W BRAKE 4 R-B F09814 2001 AVALON (RM808U) Author
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: 446 DI-291 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check brake fluid level. CHECK: Check the amount of fluid in the brake reservoir. NG Check for fluid leakage, repair brake line and add fluid. OK 2 Check brake fluid level warning switch (See page BE-53 ). NG Replace brake fluid level warning switch. OK 3 Check for open circuit in all the harness and components connected to brake fluid level warning light (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 447 DI-292 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O4-01 DTC C1208 / 54 Steering Angle Sensor Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1208 / 54 Detection of any of conditions 1. through 7: 1. When the condition that ECU terminal IG1 voltage is 9.8 v or more, and does not receive data from steering angle sensor continues for 0.1 sec. or more. 2. Sensor internal failure. 3. The offset value is out of range. 4. Sensor signal change higher. 5. Steering angle value difference between measured and reference is out of range. 6. Steering sensor is not centered. 7. Steering sensor signal is out of range.
Steering angle sensor
Steering angle sensor circuit WIRING DIAGRAM 4 VSC+ T5 W 17 VSC- T5 O 6 RSS T5 ABS & BA & TRAC & VSC ECU (Shielded) Translate ECU 59 A20 SS1 61 A20 SS2 BR BR C11 Steering Sensor 5 SS1 T5 L 18 SS2 T5 B-W 5 4 60 A20 FSS J/B No. 3 8 R-B 7 W-B 19 3A 6 3A 7 3B 7 3A 2 A20 R+ GR-R W-B A J5 J/C (Shielded) W-B A IG F09819 Author
: Date
: 448 DI-294 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand-held tester and start from step 2 in case of not using the TOYOTA hand-held tester. 1 Check output value of the steering angle sensor. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand-held tester. CHECK: Check that the steering wheel turning angle value of the steering angle sensor displayed on the TOYOTA hand-held tester is appropriate when turning the steering wheel. OK: Steering wheel turning angle value must be appropriate. OK Go to step 4. NG 2 Check the installation condition of steering angle sensor and adapter. NG Repair or replace steering angle sensor (See page SR-12 ). OK 3 Check for open and short circuit in harness and connector between steering angle sensor, translate ECU and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness or connector. OK Author
: Date
: 449 DI-294 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Calibrate the steering angle sensor (See page DI-252 ). NG Replace steering angle sensor. NO No problem. OK 5 Is DTC still output? Check DTC on page DI-252 . YES 6 Replace steering angle sensor. Is DTC still output? NOTICE: When replacing the steering angle sensor, perform the zero point calibration (See page DI-252 ). NO No problem. YES Replace skid control ECU. NOTICE: When replacing the skid control ECU, perform the zero point calibration (See page DI-252 ). Author
: Date
: 450 DI-295 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O5-01 DTC C1237 / 37 Wrong Number of Teeth at 1 of 4 Wheels CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1237 / 37 Detection of any of conditions from 1. through 4.: 1. When the ignition switch is ON, the speed difference between the rear right and rear left wheels is 5 km/h (3mph) or more (vehicle speed: 100 km/h (62 mph) or less). 2. When the ignition switch is ON, the slip difference between the reference wheel and any other wheels is 6 % or more (vehicle speed: 100 km/h (62 mph) or more). 3. Continuous ABS control for 60 sec. or more. 4. Interference on 1 or more wheels for 20 sec. with the brake pedal depressed, or for 5 sec. when the brake pedal is not depressed.
Tire size
Speed sensor rotor INSPECTION PROCEDURE 1 Check tire size. NG Replace tires so that all 4 tires are the same in size. OK 2 Check sensor rotor (See page DI-267 ). NG Replace speed sensor rotor. OK 3 Check speed sensor (See page DI-267 ). NG Replace speed sensor. OK 2001 AVALON (RM808U) Author
: Date
: 451 DI-296 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check for open and short circuit in harness and connector between front speed sensor, rear speed sensor and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness and connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 452 DI-297 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O6-03 DTC C1241 / 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the brake actuators. DTC No. DTC Detecting Condition C1241 / 41 At a vehicle speed of 6 km/h (4 mph) or more, the condition that low battery voltage is 9.8 V or less (during non-operation of ABS control) or 9.4 V or less (during operation of ABS control) and high battery voltage is more than 17.4 V, continues for 0.5 sec. or more. Trouble Area
Battery
Charging system
Power source circuit WIRING DIAGRAM Driver Side J/B IG1 Relay ECU-IG 1 2 No. 2 1 1G 4 1C 3 J/B No. 3 13 1B W-R 4 IG1 AM1 2 7 W-L IF1 W B-L F8 11 3F Y-R 18 4H 18 4A Engine Room R/B No. 5 2 AM1 1 5 5 Engine Room J/B 1 1 2G 2H B A 29 A20 GND2 W-B W-B J9 J/C 1 28 A J5 W-B A20 GND1 J/C FL Block ALT Y-R 1 A20 IG1 W-B W-B Ignition Switch F10 1 2 3C 3 1B 4 W-L Y-R ABS & BA & TRAC & VSC ECU J/B No. 4 B IJ A J4 J/C F6 1 W-B FL MAIN B W-B B W-B Battery IG F09821 2001 AVALON (RM808U) Author
: Date
: 453 DI-298 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check ECU-IG No. 2 fuse. PREPARATION: Remove the ECU-IG No. 2 fuse from the driver side J/B. CHECK: Check continuity of the ECU-IG No. 2 fuse. OK: Continuity Driver Side J/B ECU-IG No. 2 F07886 NG Check for short circuit in all the harness and components connected to ECU-IG No. 2 fuse (See attached wiring diagram). NG Check and repair the charging system (See page CH-1 ). OK 2 Check battery positive voltage. OK: Voltage: 10 - 14 V OK 2001 AVALON (RM808U) Author
: Date
: 454 DI-299 DIAGNOSTICS 3 28 29 (+) ABS WITH EBD & BA & TRAC & VSC SYSTEM Check voltage between terminals IG1 (1) and GND (28, 29) of ABS & BA & TRAC & VSC ECU. ON 1 - (-) F07895 PREPARATION: Disconnect the connector from the ABS & BA & TRAC & VSC ECU. CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals 1 and 28, 29 of ABS & BA & TRAC & VSC ECU harness side connector. OK: Voltage: 10 - 14 V OK Check and replace ABS & BA & TRAC & VSC ECU. NG 4 Check continuity between terminals GND (28, 29) of ABS & BA & TRAC & VSC ECU and body ground. CHECK: Measure the resistance between terminal 28, 29 of ABS & BA & TRAC & VSC ECU harness side connector and body ground. OK: Resistance: 1 Ω or less LOCK 28 29 (-) (+) F07896 NG Repair or replace harness or connector. OK Check for open circuit in harness and connector between ABS & BA & TRAC & VSC ECU and ECU-IG fuse (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 455 DI-300 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O7-02 DTC C1246 / 53 Master Cylinder Pressure Sensor Circuit CIRCUIT DESCRIPTION DTC No. C1246 / 53 DTC Detecting Condition Trouble Area When any of the following 1. through 3. is detected: 1. The voltage of sensor signal is out of range (less than 0.25 V, more than 4.75 V). 2. The sensor supply voltage is out of range (above 5.6 V, below 4.4 V). 3. The sensor signal offset value is out of range.
Master cylinder pressure sensor
Master cylinder pressure sensor circuit WIRING DIAGRAM M2 Master Cylinder Pressure Sensor VCM 3 P-L 8 IF3 P-L 65 A20 VCM 2 R-L 9 IF3 R-L 66 A20 PMC 1 BR-Y 2 IF3 BR-Y 67 A20 E2 PMC E2 ABS & BA & TRAC & VSC ECU F09812 2001 AVALON (RM808U) Author
: Date
: 456 DI-301 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1, in case of using the TOYOTA hand-held tester and start from step 2, in case of not using the TOYOTA hand-held tester. 1 Check output value of the master cylinder pressure sensor. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the DATALIST mode on the TOYOTA hand-held tester. CHECK: Check that the brake fluid pressure value of the master cylinder pressure sensor displayed on the TOYOTA hand-held tester is changing when depressing the brake pedal. OK: Brake fluid pressure value must be changing. OK Go to step 4. NG 2 Check master cylinder pressure sensor. E2 PMC F07902 PREPARATION: Install LSPV gauge to the front caliper bleeder plug portion, and bleed the air from LSPV gauge. SST 09709-29018 CHECK: Start the engine and depress the brake pedal, then check the relation between the fluid pressure and voltage of PMC and E2 terminals of the master cylinder pressure sensor with connector still connected. OK: Front brake caliper fluid pressure 0 kPa (0 Kgf/cm2, 0 psi) Voltage 0.44 - 0.76 V 5,883 kPa (60 kgf/cm2, 853 psi) 1.34 - 1.66 V 11,768 kPa (120 kgf/cm2, 1,706 psi) 2.24 - 2.56 V HINT: Voltage between terminals VCM and E2: 4.7 - 5.3 V NG Replace master cylinder pressure sensor. OK 2001 AVALON (RM808U) Author
: Date
: 457 DI-302 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check for open and short circuit in harness and connector between master cylinder pressure sensor and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness or connector. OK 4 Check whether or not the ECU terminal STP input voltage is changed when the stop light switch is turned on and off. NO Check the stop light switch circuit (See page BE-36 ). YES Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 458 DI-303 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O8-03 DTC C1249 / 58 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1249 / 58 After the ignition switch is turned ON, the condition that the STP terminal voltage of ECU is 55 % to 75 % of supplied voltage, continues for 1 sec. or more.
Stop light switch
Stop light switch circuit WIRING DIAGRAM ABS & BA & TRAC & VSC ECU G-W Driver Side J/B J/B No. 4 J/B No. 3 3 3 16 16 5 3 G-W G-W 1D 3C 4F 4D 1B 3F 1E 1 2 G-W R Driver Side J/B 1 11 STOP W 1G 1D 1 F10 FL Block ALT 1 F6 G-R 5 IK1 3 Stop 6 W-B R8 Rear Combination Light RH G-W 7 B B 3 G-R 2 B G-R B J12 J/C 1 FL MAIN Battery A20 STP R7 Rear Combination Light LH 4 S4 Stop Light Switch 48 G-W R-W Stop 6 C W-B J12 J/C H11 High Mounted Stop Light 1 C 2 W-B C L5 Light Failure Sensor W-B BM F09817 2001 AVALON (RM808U) Author
: Date
: 459 DI-304 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that the stop light lights up when the brake pedal is depressed and turns off when the brake pedal is released. NG Repair stop light circuit (See page BE-36 ). OK 2 Check voltage between terminal STP (48) of ABS & BA & TRAC & VSC ECU and body ground. 48 F07897 PREPARATION: Disconnect the connector from the ABS & BA & TRAC & VSC ECU. CHECK: Measure the voltage between terminal 48 of ABS & BA & TRAC & VSC ECU harness side connector and body ground when the brake pedal is depressed. OK: Voltage: 7.5 - 14 V OK Check and replace ABS & BA & TRAC & VSC ECU. NG 3 Check for open circuit in harness and connector between terminal STP of ABS & BA & TRAC & VSC ECU and stop light switch (See page IN-30 ). NG Repair or replace harness or connector. OK Proceed to next circuit inspection shown in problem symptoms table (See page DI-266 ). 2001 AVALON (RM808U) Author
: Date
: 460 DI-305 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6O9-01 DTC C1300 / 62 ABS & BA & TRAC & VSC ECU Malfunction CIRCUIT DESCRIPTION DTC No. C1300 / 62 DTC Detecting Condition Trouble Area ABS & BA & TRAC & VSC ECU internal malfunction is detected.
ABS & BA & TRAC & VSC ECU INSPECTION PROCEDURE 1 Check the DTC for the ABS and VSC (See page DI-252 ). *1 Repair ABS and VSC control system according to the code output. *2 Check if ECU is connected to malfunction indicator light. *1: Output NG code *2: Malfunction indicator light remains ON 2001 AVALON (RM808U) Author
: Date
: 461 DI-306 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OA-03 DTC Brake Actuator Pump Motor Failure C1350 / 51 CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1350 / 51 When any of the following 1. through 3. is detected. 1. No motor voltage supply after actuator of the motor relay. 2. A high level of motor voltage with no actuator of the motor relay. 3. The pump motor voltage is high level for a certain time after the motor relay has elapsed.
Brake actuator pump motor
Brake actuator pump motor circuit WIRING DIAGRAM ABS & BA & TRAC & VSC ECU 6 IE1 GR-L Engine RoomR/B No. 3 J/B No. 3 ABS Motor Relay 4 3 1 GR-R 19 3H 6 3A GR-R 2 A20 R+ O 27 A20 MT ABS & BA & TRAC& VSC Actuator 10 6 W-B L A5 A5 2 3 3 21 IF3 GR-R 3 3 7 A20 MR GR-L EE Engine Room R/B No. 5 ABS No. 4 5 5 2 1 ABS 1 2 5 5 L W FL Block B Battery FL MAIN 1 F6 ALT 1 F8 B-L O IF3 3 B Engine Room J/B 1 1 2H 2G F09816 2001 AVALON (RM808U) Author
: Date
: 462 DI-307 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check operation of brake actuator pump motor. 14 13 F07898 PREPARATION: Disconnect the connector from the brake actuator. CHECK: Connect positive
lead to terminal 14 and negative  lead to terminal 13 of the brake actuator connector, check that the pump motor is operated. OK: The running sound of the pump motor should be heard. OK Check for open circuit in harness and connector between ABS motor relay, brake actuator and ECU (See page IN-30 ). NG Replace brake actuator. 2001 AVALON (RM808U) Author
: Date
: 463 DI-308 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OB-02 DTC C1351 / 52 Precharge Pump Motor Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area C1351 / 52 When any of the following 1. or 2. is detected: 1. After the ignition switch is turned ON, an open or short circuit continues for 0.06 sec. or more. 2. The precharge pump motor voltage is out of range when precharge pump if off.
Precharge pump motor
Precharge pump motor circuit WIRING DIAGRAM Precharge Pump ML+ ML- ABS & BA & TRAC & VSC ECU Brake Actuator 2 ML+ 1 A6 W-R 8 IE1 W-R 22 A20 ML+ 1 ML- 6 A6 V 9 IE1 V 24 A20 ML- F09810 2001 AVALON (RM808U) Author
: Date
: 464 DI-309 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand-held tester and start from step 2 in case of not using TOYOTA hand-held tester. 1 Check precharge pump motor operation. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check the operation sound of the precharge pump motor when operating it with the TOYOTA hand-held tester. OK: The operation sound of the precharge pump motor should be heard. NG Go to step 3. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. 2 Check precharge pump motor operation. 1 (-) PREPARATION: Disconnect the connector from the precharge pump motor. CHECK: Connect ML+ (2) terminal to the battery positive (+) and ML- (1) terminal to the battery negative (-). OK: The operation sound of the pump motor should be heard. 2 (+) F07901 NG Check and replace precharge pump. OK 2001 AVALON (RM808U) Author
: Date
: 465 DI-310 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check for open and short circuit in harness and connector between precharge pump and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness and connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 466 DI-31 1 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OC-03 DTC 42 ECU Communication System Malfunction CIRCUIT DESCRIPTION The circuit is used to send TRAC & VSC control information from ABS & BA & TRAC & VSC ECU to the translate ECU (VSC+, VSC-), engine control information and steering angle information from translate ECU to ABS & BA & TRAC & VSC ECU DTC No. DTC Detecting Condition Trouble Area 42 IG1 voltage is 9.5 V or more, and the condition that data from ECU can not be received continues for 5 sec. or more.
VSC+ or VSC- circuit
Translate ECU
ABS & BA & TRAC & VSC ECU WIRING DIAGRAM ABS & BA & TRAC & VSC ECU Translate ECU 4 VSC+ T5 VSC- 17 T5 W 59 A20 SS1 O 61 A20 SS2 BR 60 A20 FSS (Shielded) F09809 2001 AVALON (RM808U) Author
: Date
: 467 DI-312 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check DTC of translate ECU. Check DTC on page DI-252 . *1 Repair circuit indicated by the output code. *2 2 Check transrate ECU communication. Normal Signal Waveform GND 1 V / Division REFERENCE: INSPECTION USING OSCILLOSCOPE PREPARATION: (a) Remove the translate ECU. (b) Connect the oscilloscope to the terminal VSC+ (4) and GND (14) of the translate ECU harness side connector. CHECK: Start the engine, and check the signal waveform. 2 m/s / Division F10171 OK Check and replace ABS & BA & TRAC & VSC ECU. NG 3 Check for open and short circuit in harness and connector between each of terminals VSC+ and VSC- of translate ECU and ABS & BA & TRAC & VSC ECU (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. *1: Output NG code *2: Output nomal code 2001 AVALON (RM808U) Author
: Date
: 468 DI-313 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OD-03 DTC 44 NEO Signal Circuit CIRCUIT DESCRIPTION The ABS & BA & TRAC & VSC ECU receives engine revolution speed signals (NEO signal) from the ECM. DTC No. 44 DTC Detecting Condition Trouble Area When either of the following 1. or 2. is detected: 1. The vehicle speed is 30 km/h (19 mph) or more, and open or short condition of the engine revolution signal under the normal communication condition with ECU continues for 10 secs. or more. 2. While cancel of cruise control is instructed from VSC ECU, open or short condition of the engine revolution signal continues for 0.24 sec. or more.
NEO circuit
ECM
Translate ECU WIRING DIAGRAM Translate ECU ECM 16 NEO E7 13 T5 NEO Y-B F09807 2001 AVALON (RM808U) Author
: Date
: 469 DI-314 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check for open and short circuit in harness and connector between terminal NEO of translate ECU and terminal NEO of ECM (See page IN-30 ). NG Repair or replace harness and connector. OK 2 Check voltage between terminal NEO (13) of translate ECU and body ground. PREPARATION: Remove the translate ECU with connectors still connected. CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminal 13 of the translate ECU and body ground under the engine conditions below. OK: ON NEO 13 F09477 Engine condition Voltage OFF (IG ON) 3 - 6 V or below 1 V ON (Idling) 3 - 6 V ↔ below 1 V (Pulse) (Reference) 3-6V Below 1 V F03007 NG Check and replace ECM. OK Check and replace transrate ECU. If the same code is still output after the DTC is deleted, check the contact condition of each connection. 2001 AVALON (RM808U) Author
: Date
: 470 DI-315 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OE-03 DTC 53 ECM Communication Circuit Malfunction CIRCUIT DESCRIPTION The circuit is used to send TRAC & VSC control information from the translate ECU to the ECM (TRC+, TRC-), and engine control information from the ECM to the translate ECU (ENG+, ENG-). DTC No. DTC Detecting Condition Trouble Area 53 When any of the following 1. through 3. is detected : 1. IG1 voltage is 8.5 V or more, and the condition that data can not be sent to ECM continues for 5 sec. or more. 2. IG1 voltage is 8.5 V or more, engine speed is 500 r.p.m or more, and the condition that data can not be received from ECM continues for 5 sec. or more. 3. The condition that data can not be transmitted between the translate ECU and ECM occurs at least once within 5 sec. continues 10 consecutive times.
TRC+ or TRC- circuit
ENG+ or ENG- circuit
ECM
Translate ECU WIRING DIAGRAM Translate ECU ECM 20 G-W 7 T5 TRC- 13 E8 TRC+ BR 20 T5 TRC+ 21 E8 GR 9 T5 ENG- V 22 T5 ENG+ TRC- ENG- E8 14 ENG+ E8 F09815 2001 AVALON (RM808U) Author
: Date
: 471 DI-316 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 Check translate ECU communication. Normal Signal Waveform GND 1 V / Division 2 m/s / Division REFERENCE: INSPECTION USING OSCILLOSCOPE PREPARATION: (a) Remove the translate ECU. (b) Connect the oscilloscope to each of the terminals ENG+ or TRC+ and GND of the translate ECU harness side connector. CHECK: Start the engine, and check the signal waveform. F10171 OK Check and replace translate ECU. NG 2 Check for open and short circuit in harness and connector between each of terminals ENG+, ENG-, TRC+ and TRC- of translate ECU and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM. 2001 AVALON (RM808U) Author
: Date
: 472 DI-346 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OQ-01 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. F07889 2001 AVALON (RM808U) Author
: Date
: 502 DI-318 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OF-04 DTC Non Code Translate ECU Malfunction CIRCUIT DESCRIPTION DTC No. Non Code DTC Detecting Condition Trouble Area Translate ECU internal malfunction is detected.
Tc terminal circuit
Brake warning light circuit
Translate ECU INSPECTION PROCEDURE 1 Check the BRAKE warning light circuit (See page DI-330 ). NG Repair or replace the BRAKE warning light circuit. OK 2 Check the Tc terminal circuit (See page DI-342 ). NG Repair or replace the Tc terminal circuit. OK Check and replace Translate ECU. 2001 AVALON (RM808U) Author
: Date
: 474 DI-317 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OF-03 DTC Normal Code Malfunction in ECM CIRCUIT DESCRIPTION If any trouble occurs in the ECM control system, the ECU prohibits ABS & VSC control. DTC No. DTC Detecting Condition Normal Code Conditions 1., 2,. 3, or 4,continue for 5 sec. or more: 1. Engine malfunction signal is sent from ECM. 2. Shift malfunction signal is sent from ECM 3. The shift position is other than P and N range input voltage is 8 V or more. 4. The shift position is PN or rev and D range input voltage is 8 V or more. Trouble Area
ECM circuit
ECM
Brake fluid level
Brake fluid level warning switch circuit
Steering angle sensor
ABS & BA & TRAC & VSC ECU INSPECTION PROCEDURE 1 Is DTC out put for ECM? Check DTC on page DI-3 . YES Repair engine control system according to the output code. NO 2 Check the DTC for the ABS and VSC (See page DI-252 ). *1 Repair ABS and VSC control system according to the code output. *2 Check and replace translate ECU. *1: Output NG code except for DTC of VSC system C1301/42 *2: Output NG code DTC of VSC system C1301/42 only 2001 AVALON (RM808U) Author
: Date
: 473 DI-333 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OL-03 SLIP Indicator Light Circuit CIRCUIT DESCRIPTION The SLIP indicator light blinks during TRAC & VSC operation. WIRING DIAGRAM Multi Display SLIP 9 4 J/B No. 4 R-B 10 1D 4 4D 13 4F R-B Driver Side J/B GAUGE IG1 Relay No. 1 2 1 3 1B 4 3 M6 1 2H 18 IL1 V 1 1G W Ignition Switch 4 W-L 7 W-R W-L 1C IF1 4 IG1 AM1 2 Engine Room J/B 1 2G M6 V ABS & BA & TRAC & VSC ECU 31 A20 IND B Engine Room R/B No. 5 AM1 1 2 5 5 B-L F8 1 F10 1 W-B FL Block IG Battery ALT F6 1 FL MAIN B F09822 2001 AVALON (RM808U) Author
: Date
: 489 DI-334 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1, in case of using the TOYOTA hand-held tester and start from step 2, in case of not using the TOYOTA hand-held tester. 1 Check operation of the SLIP indicator light. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check that ”ON” and ”OFF” of the SLIP indicator light can be shown on the combination meter with the TOYOTA hand-held tester. OK Go to step 4. NG 2 Check that the SLIP indicator light is ON for 3 seconds immediately after ignition switch is turned ON. OK Check and replace ABS & BA & TRAC & VSC ECU. NG 3 Check SLIP indicator light. See combination meter troubleshooting on page BE-2 . NG Repair or replace combination meter. Check and replace ABS & BA & TRAC & VSC ECU. OK 2001 AVALON (RM808U) Author
: Date
: 490 DI-335 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check for open and short circuit in harness and connector between ABS & BA TRAC & VSC ECU and SLIP indicator light (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 491 DI-342 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OO-01 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminals Tc and E1 of the DLC1 or the DLC2 causes the ECU to display DTC by blinking the ABS warning light, VSC warning light and BRAKE warning light. WIRING DIAGRAM D2 DLC2 J/B No. 3 E1 TC LG-R 4 13 3A 4 LG-R 3G D1 DLC1 3 E1 TC J/B No. 4 LG-R 11 22 II2 LG-R 6 4H ABS & BA & TRAC & VSC ECU 6 4A 19 4A LG-R 84 A20 TC Translate ECU W-B 21 TC T5 EB LG-R 19 4B F09806 INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1. ON E1 CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals Tc and E1 of or DLC1 or terminal Tc of DLC2 and body ground. OK: Voltage: 10 - 14 V DLC1 DLC2 Tc Tc F10163 OK If each warning light does not blink even after Tc and E1 are connected, the ECU may be defective. NG 2001 AVALON (RM808U) Author
: Date
: 498 DI-343 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check for open and short circuit in harness and connector between ABS & BA & TRAC & VSC ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 499 DI-344 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OP-03 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormality in the speed sensor signal which cannot be detected with the DTC check. Connecting terminals Ts and E1 of the DLC1 starts the check. WIRING DIAGRAM D3 DLC3 TS LG-B J/B No. 4 D1 DLC1 3 E1 TS ABS & BA & TRAC & VSC ECU 14 LG-B 16 11 II2 LG-B LG-B 3 4A 12 4A LG-B 42 A20 TS Translate ECU W-B 24 TS T5 EB LG-B 12 4B F09808 INSPECTION PROCEDURE 1 Check voltage between terminals Ts and E1 of DLC1. AB0119 S08096 CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals Ts and E1 of DLC1. OK: Voltage: 10 - 14 V Ts ON E1 DLC1 F00446 OK If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. NG 2001 AVALON (RM808U) Author
: Date
: 500 DI-345 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check for open and short circuit in harness and connector between ABS & BA & TRAC & VSC ECU and DLC1, DLC1 and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 501 DI-339 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6ON-03 VSC Buzzer Circuit CIRCUIT DESCRIPTION The VSC buzzer sounds during VSC operation. WIRING DIAGRAM Driver Side J/B IG1 Relay 1 W 1G W-R 4 1C 1 2 3 4 ECU-IG No. 2 3 1B Ignition Switch 4 2 W-L IG1 AM1 1 F8 B-L ALT 1 F6 FL MAIN 1 F10 FL Block 7 IF1 13 1B W-L V9 VSC Warning Buzzer 2 1 Buzzer Y-R L-W ABS & BA & TRAC & VSC ECU 86 A20 BZ W-B Engine Room R/B No. 5 2 AM1 1 5 5 Engine Room J/B 1 1 2G 2H B Battery IG B F09811 INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand-held tester and start from step 3 in case of not using the TOYOTA hand-held tester. 1 Check operation of the VSC buzzer. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check ”ON-OFF” function of the VSC buzzer with the TOYOTA hand-held tester. OK Check and replace ABS & BA & TRAC & VSC ECU. NG 2001 AVALON (RM808U) Author
: Date
: 495 DI-340 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check voltage between terminal 1 of VSC buzzer and body ground. PREPARATION: Disconnect the connector from VSC buzzer. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminal (1) of VSC buzzer and body ground. OK: Voltage: 10 - 14 V NG Repair or replace harness or connector from voltage supply to VSC buzzer. OK 3 Check VSC buzzer. 1 (+) (-) 2 PREPARATION: Disconnect the VSC buzzer connector. CHECK: Apply battery positive voltage to the terminals 1 and 2 of VSC buzzer connector, and check that the VSC buzzer sounds. F02192 NG Replace VSC buzzer. OK 2001 AVALON (RM808U) Author
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: 496 DI-341 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check for open and short circuit in harness and connector between ABS & BA & TRAC & VSC ECU and VSC buzzer (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 497 DI-336 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OM-03 VSC OFF Indicator Light, VSC OFF Switch Circuit CIRCUIT DESCRIPTION This is the TRAC & VSC control main switch. When the VSC OFF switch is pressed, TRAC & VSC control is deactivated and the VSC OFF indicator light lights up. By turning off the ignition switch, TRAC & VSC control is surely activated when the ignition switch turns ON next time. Also, the VSC OFF indicator light truns ”ON” when the ECU prohibit TRAC & VSC controls. WIRING DIAGRAM V8 VSC OFF Switch J/B No. 4 W-B 8 4F 21 4D 16 4H 13 4F 16 4A 4 4D 1 W-B ABS & BA & TRAC & VSC ECU 44 4 A20 CSW W-L Multi Display 4 M6 VSC OFF 7 M7 Y-R R-B B J6 J/C 1 1G B W Ignition Switch 2 AM1 W-L 7 IF1 W-L W-B Engine Room R/B No. 5 AM1 2 1 5 5 1 FL Block R-B Driver Side J/B GAUGE IG1 Relay No. 1 10 2 1 1D 3 4 3 1B ALT 1 F6 W-B Engine Room J/B B 1 2H 1 2G 1 F8 F10 II 4 4 1C IG1 W-R 69 A20 WT Y-R B-L B FL MAIN Battery IG F09820 2001 AVALON (RM808U) Author
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: 492 DI-337 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand-held tester and start from step 2 in case of not using the TOYOTA hand-held tester. 1 Check operation of the VSC OFF indicator light. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check that ”ON” and ”OFF” of the VSC OFF indicator light can be shown on the combination meter with the TOYOTA hand-held tester. NG Go to step 4. OK 2 Check VSC OFF switch. PREPARATION: (a) Remove the VSC OFF switch. (b) Disconnect the VSC OFF switch connector. CHECK: Measure the resistance between terminals 1 and 4 of the VSC OFF switch when the VSC OFF switch is ON and OFF. OK: 1 4 (+) (-) F00052 NG VSC OFF switch Resistance Pressed Continuity Released 1MΩ or higher Replace VSC OFF switch. OK 2001 AVALON (RM808U) Author
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: 493 DI-338 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check for open and short circuit in harness and connector between terminal CSW of ABS & BA & TRAC & VSC ECU and VSC OFF switch and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK 4 Check VSC OFF indicator light. See combination meter troubleshooting on page BE-2 . NG Repair or replace combination meter. OK 5 Check for open and short circuit in harness and connector between terminal WT of ABS & BA & TRAC & VSC ECU and VSC OFF indicator light (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
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: 494 DI-327 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6OJ-03 VSC Warning Light Circuit CIRCUIT DESCRIPTION If the ECU stores DTC to be necessary to shut down VSC operation, the VSC warning light lights on the combination meter. WIRING DIAGRAM ABS & BA & TRAC & VSC ECU Multi Display VSC 4 M6 10 M6 J/B No. 4 15 4F 13 4F P-B R-B 1 W 1G Ignition Switch 4 4 1C IG1 W-R 2 AM1 W-L 7 IF1 W-L Engine Room R/B No. 5 2 AM1 1 5 5 1 F10 FL Block 15 4C 4 4D R-B Driver Side J/B IG1 Relay GAUGE No. 1 2 1 3 4 B 10 1D 3 1B W-B Engine Room J/B 1 1 2H 2G 1 F8 B-L ALT 1 F6 70 A20 VSCW P-B B FL MAIN Battery IG F09818 2001 AVALON (RM808U) Author
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: 483 DI-328 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the TOYOTA hand-held tester and start from step 2 in case of not using the TOYOTA hand-held tester. 1 Check operation of the VSC warning light. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand-held tester. CHECK: Check that ”ON” and ”OFF” of the VSC warning light can be shown on the combination meter with the TOYOTA hand-held tester. OK Check and replace ABS & BA & TRAC & VSC ECU. YES Repair circuit indicated by the output code. NG 2 Is DTC output? NO 3 Check for open and short circuit in harness and connector between ABS & BA & TRAC & VSC ECU and VSC warning light (See page IN-30 ). NG Repair or replace harness or connector. OK 2001 AVALON (RM808U) Author
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: 484 DI-329 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Check VSC warning light. See the combination meter troubleshooting on page BE-2 . NG Repair or replace combination meter. OK Check and replace ABS & BA & TRAC & VSC ECU. 2001 AVALON (RM808U) Author
: Date
: 485 DI-251 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NR-01 CUSTOMER PROBLEM ANALYSIS CHECK ABS & BA & VSC Check Sheet Inspector’s : Name Registration No. Registration Data Customer’s Name / / Frame No. Date Vehicle Brought In / km miles Odometer Reading / Date Problem First Occurred / Frequency Problem Occurs Continuous / Intermittent ( times a day) ABS does not operate. ABS does not operate efficiently. TRAC does not operate. VSC does not operate. (Wheels spin when starting rapidly.) Symptoms Check Item BA does not operate. ABS Warning Light Abnormal Remains ON Does not Light Up VSC OFF Indicator Light Abnormal Remains ON Does not Light Up VSC Warning Light Abnormal Remains ON Does not Light Up SLIP Indicator Light Abnormal Remains ON Does not Light Up BRAKE Warning Light Abnormal Remains ON Does not Light Up Malfunction Indicator Light Normal Does not Light Up 1st Time Normal Code Malfunction Code (Code ) 2nd Time Normal Code Malfunction Code (Code ) DTC Check 2001 AVALON (RM808U) Author
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: 407 DI-258 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NT-03 DIAGNOSTIC TROUBLE CODE CHART NOTICE:
When removing the part, turn the ignition switch OFF.
When replacing the steering angle sensor or ECU, make sure to perform steering angle sensor zero point calibration. HINT:
Using SST 09843-18020, connect the terminals Tc and E1.
If any abnormality is not found when inspecting parts, inspect the ECU.
If a malfunction code is displayed during the DTC check, check the circuit corresponding the code. For details of each code, refer to the page under respective ”DTC No.” in the DTC chart. DTC chart of ABS system: DTC No. (See Page) Detection Item Trouble Area C0278 / 11 (DI-280 ) Open or short circuit in ABS solenoid relay circuit
ABS solenoid relay
ABS solenoid relay circuit C0273 / 13 (DI-276 ) Open or short circuit in ABS motor relay circuit
ABS motor relay
ABS motor relay circuit C0226 / 21 (DI-273 ) Open or short circuit in brake actuator
Brake actuator
SFRR or SFRH circuit C0236 / 22 (DI-273 ) Open or short circuit in brake actuator
Brake actuator
SFLR or SFLH circuit C0246 / 23 (DI-273 ) Open or short circuit in brake actuator
Brake actuator
SRRR or SRRH circuit C0256 / 24 (DI-273 ) Open or short circuit in brake actuator
Brake actuator
SRLR or SRLH circuit C0200 / 31* (DI-267 ) Right front wheel speed sensor signal malfunction C0205 / 32* (DI-267 ) Left front wheel speed sensor signal malfunction C0210 / 33* (DI-267 ) Right rear wheel speed sensor signal malfunction C0215 / 34* (DI-267 ) Left rear wheel speed sensor signal malfunction C1330 / 35* (DI-267 ) Open circuit in right front speed sensor circuit
Right front speed sensor
Right front speed sensor circuit C1331 / 36* (DI-267 ) Open circuit in left front speed sensor circuit
Left front speed sensor
Left front speed sensor circuit C1237 / 37 (DI-295 ) Front tires are different from rear in size.
Tire size
Speed sensor rotor C1332 / 38* (DI-267 ) Open circuit in right rear speed sensor circuit
Right rear speed sensor
Right rear speed sensor circuit C1333 / 39* (DI-267 ) Open circuit in left rear speed sensor circuit
Left rear speed sensor
Left rear speed sensor circuit C1241 / 41 (DI-297 ) Low battery positive voltage or abnormally high battery positive voltage
Battery
Charging system
Power source circuit C1249 / 58 (DI-303 ) Open circuit in stop light switch circuit
Stop light switch
Stop light switch circuit
Right front, left front, right rear and left rear speed sensor
Each E h speed d sensor circuit i it
Speed sensor rotor 2001 AVALON (RM808U) Author
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: 414 DI-259 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM C1300 / 62 (DI-305 ) Malfunction in ABS & BA & TRAC & VSC ECU ABS & BA & TRAC & VSC ECU Always ON (DI-319 ) Malfunction in ABS & BA & TRAC & VSC ECU Open circuit in ABS warning light circuit
Charging system
ABS warning light circuit *: As the DTC cannot be erased only by replacing parts, do either of the following operations. (1) Clear DTC (See page DI-252 ). (2) At a vehicle speed of 20 km/h (12 mph), drive the vehicle for 30 sec. or more. DTC chart of VSC system: DTC No. (See Page) Detection Item Trouble Area C1225 / 25 (DI-273 ) Open or short circuit in brake actuator solenoid circuit (SMC1 circuit)
Brake actuator
SMC1 circuit C1226 / 26 (DI-273 ) Open or short circuit in brake actuator solenoid circuit (SMC2 circuit)
Brake actuator
SMC2 circuit C1227 / 27 (DI-273 ) Open or short circuit in brake actuator solenoid circuit (SRC1 circuit)
Brake actuator
SRC1 circuit C1228 / 28 (DI-273 ) Open or short circuit in brake actuator solenoid circuit (SRC2 circuit)
Brake actuator
SRC2 circuit C1301 / 42* Malfunction in communication with the translate ECU
Brake fluid level warning switch circuit
Translate ECU
Translate ECU circuit
ECM
ECM circuit C0365 / 43 (DI-285 ) Malfunction in deceleration sensor (combined in yaw rate sensor)
Deceleration sensor
Deceleration sensor circuit C1202 / 44 (DI-290 ) Brake fluid level low Open circuit in brake fluid level warning switch circuit
Brake fluid level
Brake fluid level warning switch
Brake fluid level warning switch circuit C1350 / 51 (DI-306 ) Pump motor is locked Open circuit in pump motor ground
Brake actuator pump motor
Brake actuator pump motor circuit C1351 / 52 (DI-308 ) VSC pump motor is locked Open or short circuit in VSC pump motor circuit
Precharge pump motor
Precharge pump motor circuit C1246 / 53 (DI-300 ) Malfunction in master cylinder pressure sensor
Master cylinder pressure sensor
Master cylinder pressure sensor circuit C1208 / 54 (DI-292 ) Malfunction in steering angle sensor
Steering angle sensor
Steering angle sensor circuit C0371 / 55 (DI-287 ) Malfunction in yaw rate sensor circuit
Yaw rate sensor
Yaw rate sensor circuit Always ON (DI-322 ) Malfunction in ABS & BA & TRAC & VSC ECU Open circuit in VSC warning light circuit
Charging system
VSC warning light circuit *: Troubleshoot according to the DTC chart of the translate ECU. 2001 AVALON (RM808U) Author
: Date
: 415 DI-260 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DTC chart of translate ECU(output NG code DTC of VSC system C1301/42 only): DTC No. (See Page) Detection Item Trouble Area Malfunction in ECM control system
ECM circuit
ECM
Brake fluid level
Brake fluid level warning switch circuit
Steering angle sensor
ABS & BA & TRAC & VSC ECU 42 (DI-31 1) Malfunction in communication with the ABS & BA & TRAC & VSC ECU
VSC+ or VSC- circuit
Translate ECU
ABS & BA & TRAC & VSC ECU 44 (DI-313 ) Open or short circuit in NEO circuit
NEO circuit
ECM
Translate ECU 53 (DI-315 ) Malfunction in communication with the ECM
TRC+ or TRC- circuit
ENG+ or ENG- circuit
ECM
Translate ECU Non code (DI-318 ) Malfunction in translate ECU
Tc terminal circuit
BRAKE warning light circuit
Translate ECU Normal code* (DI-317 ) *: Translate ECU is normal. HINT: The BRAKE warning light does not turn on due to an error in VSC. If it is on, check that the parking brake pedal is released, the brake fluid level is normal and no malfunction is identified in the fluid level warning switch system. 2001 AVALON (RM808U) Author
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: 416 DI-250 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NQ-01 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. 1 Customer Problem Analysis P. DI-251 2 Check and Clear DTC (Precheck) P. DI-252 Symptom does not occur 3 Problem Symptom Confirmation 4 Symptom Simulation P. IN-20 7 Problem Symptoms Table P. DI-266 Symptom occurs 5 Normal code DTC Check P. DI-252 Malfunction code 6 DTC Chart P. DI-258 8 Circuit Inspection 9 Sensor Check P. DI-267 - DI-344 Check for Fluid Leakage P. DI-346 Identification of Problem 10 11 Repair Confirmation Test End Step 2, 5, 8, 9, 11: Diagnostic steps permitting the use of the TOYOTA hand-held tester or TOYOTA break-out-box. Fail safe function: When a failure occurs in the ABS & BA & TRAC & VSC system, the respective warning light (ABS, VSC) is lit and the operation of ABS & BA & TRAC & VSC is prohibited. In addition to this, when the failure which disables the EBD operation occurs, the brake warning light is lit as well and the EBD operation is prohibited. 2001 AVALON (RM808U) Author
: Date
: 406 DI-261 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NU-01 PARTS LOCATION ABS Motor Relay ABS Solenoid Relay Active Lamp Relay Rear Speed Sensor Sensor Rotor Front Speed Sensor DLC1 Engine Room R/B No. 8 Rear Speed Sensor Stop Light Switch Parking Brake Switch Master Cylinder Pressure Sensor Sensor Rotor Sensor Rotor Brake Actuator Front Speed Sensor Precharge Pump ABS Warning Light VSC Warning Light VSC OFF Indicator Light SLIP Indicator Light BRAKE Warning Light ABS & BA & TRAC & VSC ECU Steering Angle Sensor Translate ECU DLC2 DLC3 VSC OFF Switch Yaw Rate Sensor (Including Deceleration Sensor) F07883 2001 AVALON (RM808U) Author
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: 417 DI-252 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NS-01 PRE-CHECK 1. (a) F07880 DIAGNOSIS SYSTEM Check the warning lights. (1) Release the parking brake pedal. (2) When the ignition switch is turned ON, check that the ABS warning light, VSC warning light, VSC OFF indicator light, BRAKE warning light and SLIP indicator light goes on for approx. 3 seconds. HINT:

When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light is lit. If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit, VSC warning light circuit, VSC OFF indicator light circuit, BRAKE warning light circuit or SLIP indicator light circuit. Trouble Area ABS warning light circuit DI-325 VSC warning light circuit DI-327 VSC OFF indicator light circuit DI-336 BRAKE warning light circuit DI-330 SLIP indicator light circuit DI-333 (b) E1 See page DLC1 In case of not using TOYOTA hand-held tester: Check the DTC of ABS & BA & TRAC & VSC ECU. (1) Using SST, connect terminals Tc and E1 of DLC1. SST 09843-18020 (2) Turn the ignition switch ON. (3) Read the DTC from the ABS warning light and VSC warning light on the combination meter. HINT: Tc F02201
If no code appears, inspect the diagnostic circuit, ABS warning light circuit or VSC waning light circuit. Trouble Area See page Tc terminal circuit DI-342 ABS warning light circuit DI-325 VSC warning light circuit DI-327 2001 AVALON (RM808U) Author
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: 408 DI-253 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM
As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. (4) Codes are explained in the code table on page DI-258 . (5) After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunction codes are identified at the same time, the lowest numbered DTC will be displayed 1st. Normal Code 2 sec. 0.25 sec. 0.25 sec. ON OFF Code 11 and 21 0.5 sec. 1.5 sec. 4 sec. 0.5 sec. 2.5 sec. ON OFF Code 11 Code 21 R01346 (c) E1 Tc DLC1 F02201 In case of not using TOYOTA hand-held tester: Check the DTC of translate ECU. (1) Release the parking brake pedal. (2) Check the brake fluid level. (3) Using SST, connect terminals Tc and E1 of DLC1. SST 09843-18020 (4) Turn the ignition switch ON. (5) Read the DTC from the BRAKE warning light. HINT:
If no code appears, inspect the diagnostic circuit, and BRAKE warning light circuit. Trouble Area See page Tc terminal circuit DI-342 BRAKE warning light circuit DI-330


When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light is lit. If every sensor is normal, a normal code is output. (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated.) If 2 or more malfunction codes are identified at the same time, the lowest numbered code will be displayed 1st. 2001 AVALON (RM808U) Author
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: 409 DI-254 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM Malfunction Code (Example Code 42, 44) 42 44 0.5 sec. 2.5 sec. ON OFF 0.5 sec. 4 sec. Repeat 1.5 sec. TOYOTA Handheld Tester (d) DLC3 F07887 BR3890 TOYOTA Handheld Tester DLC3 F07887 In case of using TOYOTA hand-held tester: Check the DTC. (1) Hook up the TOYOTA hand- held tester to the DLC3. (2) Turn the ignition switch ON. (3) Read the DTC by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand-held tester operator’s manual for further details. (e) In case of not using TOYOTA hand-held tester: Clear the DTC. (1) Using SST, connect terminals Tc and E1 of DLC1. SST 09843-18020 (2) Turn the ignition switch ON. (3) Clear the DTC stored in ECU by depressing the brake pedal 8 times or more within 5 seconds. (4) Check that the warning light shows the normal code. (5) Remove the SST from the terminals of DLC1. SST 09843-18020 HINT: Cancellation cannot be done by removing the battery cable or ECU-IG fuse. (f) In case of using TOYOTA hand-held tester: Clear the DTC. (1) Hook up the TOYOTA hand- held tester to the DLC3. (2) Turn the ignition switch ON. (3) Operate the TOYOTA hand-held tester to erase the codes. HINT: Please refer to the TOYOTA hand-held tester operator’s manual for further details. 2001 AVALON (RM808U) Author
: Date
: 410 DI-255 DIAGNOSTICS 2. (a) E1 Ts DLC1 - SPEED SENSOR SIGNAL CHECK (TEST MODE) In case of not using TOYOTA hand-held tester: Check the sensor signal. (1) Turn the ignition switch OFF. (2) Using SST, connect terminals Ts and E1 of DLC1. SST 09843-18020 (3) Start the engine. Tc F02201 (4) 0.13 sec. ABS WITH EBD & BA & TRAC & VSC SYSTEM 0.13 sec. ON OFF BR3904 Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page DI-325 ). (5) Drive vehicle straight forward. Drive vehicle at a speed faster than 45 km/h (28 mph) for several seconds. HINT: The sensor check may not be completed if the front wheels are spun or the steering wheel is steered during this check. (6) Stop the vehicle. (7) Using SST, connect terminals Tc and E1 of DLC1. SST 09843-18020 (8) Read the number of blinks of the ABS warning light. HINT:
See the list of DTC shown on the next page.
If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated).
If 2 or more malfunction codes are identified at the same time, the lowest numbered code will be displayed 1st. Malfunction Code (Example Code 72, 76) 7 2 7 6 ON OFF 0.5 sec. 1.5 sec. 0.5 sec. 0.5 sec. 4 sec. 2.5 sec. 0.5 sec. Repeat BR3893 (9) After doing the check, disconnect the SST from terminals Ts and E1, Tc and E1 of DLC1, and turn the ignition switch OFF. SST 09843-18020 2001 AVALON (RM808U) Author
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: 411 DI-256 DIAGNOSTICS TOYOTA Handheld Tester (b) DLC3 F07887 - ABS WITH EBD & BA & TRAC & VSC SYSTEM In case of using TOYOTA hand-held tester: Check the sensor signal. (1) Hook up the TOYOTA hand- held tester to the DLC3. (2) Do step (3) - (6) on the previous page. (3) Read the DTC by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand-held tester operator’s manual for further details. DTC of speed sensor check function: Code No. Diagnosis Trouble Area C1271 / 71 Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Right front speed sensor rotor C1272 / 72 Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Left front speed sensor rotor C1273 / 73 Low output voltage of right rear speed sensor
Right rear speed sensor
Sensor installation
Right rear speed sensor rotor C1274 / 74 Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Left rear speed sensor rotor C1275 / 75 Abnormal change in output signal of right front speed sensor Right front speed sensor rotor C1276 / 76 Abnormal change in output signal of left front speed sensor Left front speed sensor rotor C1277 / 77 Abnormal change in output signal of right rear speed sensor Right rear speed sensor rotor C1278 / 78 Abnormal change in output signal of left rear speed sensor Left rear speed sensor rotor 3. E1 STEERING ANGLE SENSOR ZERO POINT CALIBRATION NOTICE: Make sure to perform steering angle sensor zero point calibration when:
Replacing the steering angle sensor or ECU.
Adjusting the front wheel alignment of the steering wheel center point in accordance with removal and installation or replacement of the suspension, axle or steering parts. (a) Using the SST, connect terminals Ts and E1 of DLC1 or Ts and CG of DLC3. SST DLC1: 09843-18020 DLC3: 09843-18040 (b) Turn the ignition switch to the ON position, without starting the engine. (c) Make sure the steering wheel off center angle is within 3 degrees of center before attempting calibration. DLC1 Ts CG DLC3 Ts F19119 2001 AVALON (RM808U) Author
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: 412 DI-257 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM HINT: If the off center angle is greater than 3 degrees from center, further adjustments to the tie rods may be necessary. (d) Shift the gear selector switch to the P range. (e) Press the VSC OFF switch and hold it while depressing the brake pedal 3 times within 2 seconds. (f) Continue to hold the VSC OFF switch until the VSC buzzer (repeated beeping) sounds. (g) Release the VSC OFF switch. The VSC buzzer will continue to sound for 3 seconds confirming the operation is complete. HINT: If the procedure is done correctly and VSC buzzer does not sound, there may be a malfunction of the steering angle sensor. 4. (a) (b) GND GL1 (c) IGA DECELERATION SENSOR CHECK Apply battery positive voltage. Connect IGA terminal to the battery positive (+) terminal, and GND terminal to the battery negative (-) terminal, and apply about 12 V between IGA and GND terminals. Check the output voltage of GL1 terminal. Symbols Condition Standard Value GL1 Horizontal About 2.5 V GL1 Lean right down About 2.3 V - 4V GL1 Lean left down 1 V - About 2.3 V HINT: Front Lean to Right


If the sensor is tilted too much, it may show the wrong value. If dropped, the sensor should be replaced with a new one. The sensor removed from the vehicle should not be placed upside down. Lean to Left F09479 2001 AVALON (RM808U) Author
: Date
: 413 DI-266 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NW-01 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. NOTICE: When replacing ABS & BA & TRAC & VSC ECU, sensor, etc., turn the IG switch OFF. Symptom Suspect Area See page ABS does not operate Only when 1. - 4. are all normal and the problem is still occurring, replace the ABS & BA & TRAC & VSC ECU. 4. Check the DTC, reconfirming that the normal code is output. 5. IG power source circuit 6. Speed sensor circuit 7. Check the brake actuator with a hand-held tester. If abnormal, check the hydraulic circuit for leakage (See page DI-346 ). ABS does not operate efficiently Only when 1. - 4. are all normal and the problem is still occurring, replace the ABS & BA & TRAC & VSC ECU. 1. Check the DTC, reconfirming that the normal code is output. 2. Speed sensor circuit 3. Stop light switch circuit 4. Check the brake actuator with a hand-held tester. If abnormal, check the hydraulic circuit for leakage (See page DI-346 ). ABS warning light abnormal 1. ABS warning light circuit 2. ABS & BA & TRAC & VSC ECU DTC check cannot be done Only when 1. - 4. are all normal and the problem is still occurring, replace the ABS & BA & TRAC & VSC ECU. 1. ABS warning light circuit 2. VSC warning light circuit 3. Tc terminal circuit Speed sensor signal check cannot be done 1. Ts terminal circuit 2. ABS & BA & TRAC & VSC ECU VSC does not operate Only when circuits inspected for each problem symptom are all normal and the problem is still occurring, replace the ABS & BA & TRAC & VSC ECU. 1. Check the DTC, reconfirming that the normal code is output. 2. IG power source circuit 3. Hydraulic circuit for leakage 4. Speed sensor circuit DI-252 DI-297 DI-267 BR-52 DI-252 DI-267 DI-303 BR-52 DI-325 DI-325 DI-327 DI-342 DI-344 DI-252 DI-297 DI-346 DI-267 BA does not operate Stop light switch circuit DI-303 SLIP indicator light abnormal SLIP indicator light circuit DI-333 BRAKE warning light abnormal 1. BRAKE warning light circuit 2. ABS & BA & TRAC & VSC ECU DI-330 VSC OFF indicator light abnormal Only when circuits inspected for each problem symptom are all normal and the problem is still occurring, replace the ABS & BA & TRAC & VSC ECU. 1. VSC OFF indicator light circuit 2. VSC OFF switch circuit DI-336 DI-336 2001 AVALON (RM808U) Author
: Date
: 422 DI-262 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DI6NV-03 TERMINALS OF ECU ABS & BA & TRAC & VSC ECU: A20 F07884 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) IG1 (A20 - 1) - GND (A20 28, 29) Y-R ↔ W-B IG switch ON 10 - 14 R+ (A20 - 2) - SR (A20 - 36) GR-R ↔ R IG switch ON, ABS warning light OFF 10 - 14 R+ (A20 - 2) - MR (A20 - 7) GR-R ↔ GR-L IG switch ON Below 1.0 SFLR (A20 - 3) - GND (A20 28, 29) G-O ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 SRRR (A20 - 4) - GND (A20 28, 29) G-R ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 SFLH (A20 - 5) - GND (A20 28, 29) W-R ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 SRRH (A20 - 6) - GND (A20 28, 29) GR ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 FL+ (A20 - 8) - FL- (A20 - 10) BR ↔ B-R IG switch ON, slowly turn left front wheel AC generation RR+ (A20 - 11) - RR- (A20 12) G↔Y IG switch ON, slowly turn right rear wheel AC generation RL+ (A20 - 13) - RL- (A20 14) LG ↔ V IG switch ON, slowly turn left rear wheel AC generation FR+ (A20 - 17) - FR- (A20 16) B-W ↔ L IG switch ON, slowly turn right front wheel AC generation GL1 (A20 - 18) - GND (A20 28, 29) G ↔ W-B IG switch ON 0.5 - 4.5 ML+ (A20 - 22) - ML- (A20 24) W-R ↔ V IG switch ON 10 - 14 SRLR (A20 - 25) - GND (A20 28, 29) L-Y ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 SFRH (A20 - 26) - GND (A20 - 28, 29) B-W ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 MT (A20 - 27) - GND (A20 28, 29) O ↔ W-B IG switch ON, ABS warning light OFF Below 1.5 IND (A20 - 31) - GND (A20 28, 29) V ↔ W-B WB IG switch ON, SLIP indicator light ON Below 2.0 EBDW (A20 - 32) - GND (A20 - 28, 29) R Y ↔ W-B R-Y WB LBL (A20 - 40) - GND (A20 28, 29) L-B ↔ W-B IG switch ON, SLIP indicator light OFF 10 - 14 IG switch ON, BRAKE warning light OFF Below 1.5 IG switch ON, BRAKE warning light ON 10 - 14 IG switch ON, fluid level switch ON Below 1.0 2001 AVALON (RM808U) Author
: Date
: 418 DI-263 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM Ts (A20 - 42) - GND (A20 - 28, 29) LG-B ↔ W-B CSW (A20 - 44) - GND (A20 28, 29) W L ↔ W-B W-L WB D/G (A20 - 46) - GND (A20 28, 29) W ↔ W-B STP (A20 - 48) - GND (A20 28, 29) G W ↔ W-B G-W WB SMC1 (A20 - 49) - GND (A20 - 28, 29) G-Y ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 SMC2 (A20 - 50) - GND (A20 - 28, 29) V-W ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 BAT (A20 - 51) - GND (A20 28, 29) W-L ↔ W-B IG switch OFF 10 - 14 SRC2 (A20 - 52) - GND (A20 28, 29) R-B ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 SRLH (A20 - 53) - GND (A20 28, 29) Y-B ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 SRC1 (A20 - 54) - GND (A20 28, 29) B-Y ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 SFRR (A20 - 55) - GND (A20 - 28, 29) W-G ↔ W-B IG switch ON, ABS warning light OFF 10 - 14 SS1 (A20 - 59) - GND (A20 28, 29) W ↔ W-B IG switch ON Pulse generation FSS (A20 - 60) - GND (A20 28, 29) BR ↔ W-B IG switch OFF Continuity SS2 (A20 - 61) - GND (A20 28, 29) O ↔ W-B IG switch ON Pulse generation VCM (A20 - 65) - GND (A20 28, 29) P-L ↔ W-B IG switch ON 4.5 - 5.5 PMC (A20 - 66) - GND (A20 28, 29) R-L ↔ W-B IG switch ON, brake pedal released 0.3 - 0.8 IG switch OFF Continuity E2 (A20 - 67) - GND (A20 28, 29) BR-Y ↔ W-B SP1 (A20 - 68) - GND (A20 28, 29) L-O ↔ W-B WT (A20 - 69) - GND (A20 28, 29) Y R ↔ W-B Y-R WB VSCW (A20 - 70) - GND (A20 - 28, 29) P B ↔ W-B P-B WB PKB (A20 - 74) - GND (A20 28, 29) Y G ↔ W-B Y-G WB YD (A20 - 75) - GND (A20 28, 29) BR ↔ W-B IG switch ON 10 - 14 IG switch ON, VSC OFF indicator ON Below 1.5 IG switch ON, VSC OFF indicator OFF 8 - 14 IG switch ON 10 - 14 Stop light switch ON (Brake pedal pushed) 8 - 14 Stop light switch OFF (Brake pedal released) Below 1.5 Vehicle driveing at about 20 km/h (12 mph) Pulse generation IG switch ON, VSC OFF indicator light ON Below 2.0 IG switch ON, VSC OFF indicator light OFF 10 - 14 IG switch ON, VSC warning light ON Below 2.0 IG switch ON, VSC warning light OFF 10 - 14 IG switch ON, parking brake switch ON Below 2.0 IG switch ON, parking brake switch OFF 10 - 14 IG switch ON, VSC warning light OFF 4.5 - 5.5 Continuity GYAW (A20 - 76) - GND (A20 - 28, 29) Y ↔ W-B IG switch OFF YAW (A20 - 77) - GND (A20 28, 29) L ↔ W-B IG switch ON, vehicle stationaly condition 2-3 2001 AVALON (RM808U) Author
: Date
: 419 DI-264 DIAGNOSTICS WA (A20 - 81) - GND (A20 28, 29) B ↔ W-B WB Tc (A20 - 84) - GND (A20 - 28, 29) LG-R ↔ W-B Bz (A20 - 86) - GND (A20 28, 29) L W ↔ W-B L-W WB - ABS WITH EBD & BA & TRAC & VSC SYSTEM IG switch ON, ABS warning light ON 10 - 14 IG switch ON, ABS warning light OFF Below 2.0 IG switch ON 10 - 14 Below 1.0 ↔ 10 - 14 IG switch ON, VSC buzzer sounds IG switch ON, VSC buzzer does not sound 10 - 14 2001 AVALON (RM808U) Author
: Date
: 420 DI-265 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM Translate ECU: T5 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 F07885 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) IG1(T5 - 1) - GND (T5 - 14) Y-R ↔ W-B PKB2 (T5 - 2) - GND (T5 14) Y G ↔ W-B Y-G WB VSC+ (T5 - 4) - VSC- (T5 17) W↔O Engine idling Pulse generation SS1 (T5 - 5) - SS2 (T5 - 18) L ↔ B-W Engine idling Pulse generation RSS (T5 - 6) - GND (T5 - 14) BR ↔ W-B IG switch ON 10 - 14 IG switch ON, paking brake switch ON Below 2.0 IG switch ON, paking brake switch OFF 10 - 14 IG switch OFF Continuity IG switch ON, shift lever is in P range 8 - 14 P (T5 - 10) - GND (T5 - 14) G W ↔ W-B G-W WB LVL2 (T5 - 11) - GND (T5 - 14) R-W ↔ W-B D (T5 - 12) - GND (T5 - 14) Y R ↔ W-B Y-R WB NEO (T5 - 13) - GND (T5 - 14) Y-B ↔ W-B Engine idling PKB (T5 - 15) - GND (T5 - 14) Y-G ↔ W-B IG switch OFF, parking brake switch ON Below 2.0 R W ↔ W-B R-W WB IG switch ON, BRAKE warning light ON Below 2.0 BRL (T5 - 16) - GND (T5 - 14) IG switch ON, BRAKE warning light OFF 10 - 14 IG switch ON, shift lever is in other than P range Below 1.5 IG switch ON, fluid level switch ON Below 1.5 IG switch ON, shift lever is in D range 8 - 14 IG switch ON, shift lever is in other than D range Below 1.5 Pulse generation TRC+ (T5 - 20) - TRC- (T5 7) BR ↔ W-B Engine idling Pulse generation Tc (T5 - 21) - GND (T5 - 14) LG-R ↔ W-B IG switch ON 10 - 14 ENG+ (T5 - 22) - ENG- (T5 9) V ↔ GR Engine idling Pulse generation Ts (T5 - 24) - GND (T5 - 14) LG-B ↔ W-B IG switch ON 10 - 14 LBL (T5 - 25) - GND (T5 - 14) L-B ↔ W-B IG switch ON, fluid level switch ON Below 1.0 CCS (T5 - 26) - GND (T5 - 14) Y-R ↔ W-B IG switch ON Below 2.0 2001 AVALON (RM808U) Author
: Date
: 421 DI-203 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02S-08 O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising overdrive may be prohibited temporarily under some condition. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are discontinued. WIRING DIAGRAM ECM Cruise Control ECU 14 OD C15 24 OD1 E7 GR D07905 2001 AVALON (RM808U) Author
: Date
: 359 DI-204 DIAGNOSTICS - AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Check voltage between terminal OD1 of ECM and body ground. PREPARATION: (a) Remove the glove compartment. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal OD1 of ECM and body ground. OK: Voltage: 10 - 14 V ON (-) (+) BE3840 D00835 OD1 D07206 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-175 ). NG 2 Check voltage between terminal OD of cruise control ECU harness side connector and body ground. PREPARATION: (a) Disconnect the cruise control ECU connector. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal OD of cruise control ECU harness side connector and body ground. OK: Voltage: 10 - 14 V ON O/D (-) (+) AB0119 N19917 I00742 OK Check and replace the cruise control ECU (See page IN-30 ). NG 2001 AVALON (RM808U) Author
: Date
: 360 DI-205 DIAGNOSTICS 3 - AUTOMATIC TRANSAXLE Check harness and connector between cruise control ECU and ECM (See page IN-30 ). NG Repair or replace the harness or connector. OK Check and replace the ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 361 DI-206 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI1KD-08 O/D Main Switch & O/D OFF Indictor Light Circuit CIRCUIT DESCRIPTION The O/D main switch is a momentary type switch. When pressing the O/D OFF main switch, the O/D OFF indicator light lights up and ECM prohibits shifting to O/D, and when pressing it again, the O/D OFF indicator light goes off and ECM allows shifting to O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. WIRING DIAGRAM C9 O/D OFF Indicator Light 15 7 G-O ECM J/B No. 3 16 16 3G 3A 9 E8 ODLP 12 E6 ODMS Driver Side J/B 2 2 3F Y-G G-O 13 1B Y-R 3C AM1 1 5 2 1 1G W 3 4 1C W-R 4 IG1 RELAY I15 Ignition Switch Engine Room R/B No. 5 B 1 ECU-IG No. 2 3 1B W-B IG 2 W-L 5 7 IF1 2 W-L 4 AM1 IG1 W 1 2H O/D Main Switch *1 4 J/B No. 4 Engine Room J/B 7 4B 1 2G 7 4A O3 W-B B-L 1*2 2*1 O3 3*2 8 II2 G-O G-O J9 J/ C W-B 1 F8 A 1 F10 1 F6 B FL MAIN Battery IJ ALT *1: Floor Shift *2: Column Shift D07910 2001 AVALON (RM808U) Author
: Date
: 362 DI-207 DIAGNOSTICS - AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Check operation of O/D main switch. PREPARATION: Turn the ignition switch ON. CHECK: (a) Check O/D OFF indicator light when O/D main switch is pushed in to ON. (b) Check O/D OFF indicator light when O/D main switch is pushed again. OK: (a) O/D OFF indicator light lights up. (b) O/D OFF indicator light goes off. OK Proceed to next inspection shown on symptoms problem tables (See page DI-175 ). NG 2 Check and replace the combination meter (See page BE-2 ). NG Replace the combination meter. OK 2001 AVALON (RM808U) Author
: Date
: 363 DI-208 DIAGNOSTICS 3 - AUTOMATIC TRANSAXLE Check O/D main switch. 2 4 Q07595 PREPARATION: Disconnect the O/D main switch connector. CHECK: (a) Floor shift: Check continuity between terminals 2 and 4 of O/D main switch connector. (b) Column shift: Check continuity between terminals 1 and 3 of O/D main switch connector. OK: O/D main switch condition Specified condition Press continuously O/D main switch Continuously Release O/D main switch No continuously NG Replace and repair O/D main switch. OK 4 Check voltage between terminal ODMS of ECM and body ground. ON PREPARATION: Turn the ignition switch ON. CHECK: Check voltage between terminal ODMS of ECM and body ground when O/D main switch is ON and OFF. OK: ODMS O/D main switch condition Specified condition Press continuously O/D main switch Below 1.0 V Release O/D main switch 10 - 14 V D06554 OK Check and replace the ECM (See page IN-30 ). NG 2001 AVALON (RM808U) Author
: Date
: 364 DI-209 DIAGNOSTICS 5 - AUTOMATIC TRANSAXLE Check voltage between terminal ODLP of ECM and body ground. ON ODLP PREPARATION: (a) Disconnect the connector of ECM. (b) Turn the ignition switch ON. CHECK: Check voltage between terminal ODLP of ECM and body ground. OK: Voltage: 7.5 - 14 V D06553 OK Check and replace the ECM (See page IN-30 ). NG Check and replace harness and connector between combination meter and ECM, O/D main switch and ECM, O/D main switch and body ground. (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 365 DI-178 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI4DO-02 CIRCUIT INSPECTION DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The speed sensor for ABS detects the wheel speed and sends the appropriate signals to the ABS ECU. The ECU converts these signals in to a 4-pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. 4-pulse 4-pulse From Speed Sensor ABS ECU ECM Combination Meter A00022 DTC No. P0500 DTC Detecting Condition Satisfying all of the following conditions, 2 sec. (Intake air temperature: -10 °C or more) or 8 sec. (Intake air temperature: less than -10 °C) elapsed. (c) After 2 sec. (the engine coolant temperature: 20 °C or more) or 30 sec. (the engine coolant temperature: less than 20 °C) with the park/neutral position switch set to P, N position. (d) No abnormality of the throttle position sensor is detected. (e) After 0.5 sec. or more with the ignition switch turned ON. (f) No vehicle speed is signal to ECM. (g) The engine rpm is equal to the speed sensor rpm or more when the throttle opening angle is as shown below. 1. The throttle opening angle is less than 13° and the engine rpm is 2,350 or more. 2. The throttle opening angle is less than 21° and the engine rpm is 2,680 or more. 3. The throttle opening angle is less than 30° and the engine rpm is 2,835 or more. 4. The throttle opening angle is less than 30° and the engine rpm is 3,145 or more. Trouble Area
Open or short in vehicle speed sensor circuit
ABS speed sensor
Combination meter
ECM
ABS ECU
Automatic transaxle (clutch, brake or gear etc.) Clutch or brake slips or gear is broken (2-trip detection logic) 2001 AVALON (RM808U) Author
: Date
: 334 DI-179 DIAGNOSTICS - AUTOMATIC TRANSAXLE WIRING DIAGRAM ECM Combination Meter J/B No. 3 18 M3 1 3F V-W 1 3C V-W 22 E7 SPD D07904 INSPECTION PROCEDURE 1 Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG Check speedometer circuit. OK 2 Check for short in harness and connector between terminal SPD of ECM and body ground. SPD PREPARATION: (a) Remove the glove compartment (See page BO-90 ). (b) Disconnect the connector from ECM. CHECK: Check continuity between terminal SPD of ECM and body ground. OK: No continuity A02373 NG Repair or replace harness or connector. 2001 AVALON (RM808U) Author
: Date
: 335 DI-180 DIAGNOSTICS - AUTOMATIC TRANSAXLE OK 3 Check voltage between terminal SPD of ECM connector and body ground. ON SPD (-) BE6653 D01908 PREPARATION: Turn the ignition switch ON. CHECK: Measure voltage between terminal SPD of ECM connector and body ground. OK: Voltage: 9 - 14 V (+) D07204 NG Check for open in harness and connector between J/B No. 3 and ECM (See page IN-30 ). OK 4 Check for open in harness and connector between J/B No. 3 and combination meter (See page IN-30 ). NG Repair or replace harness or connector. NG Replace ECM. OK 5 Check ECM (See page IN-30 ). OK Check and repair the transaxle (clutch, brake or gear etc.). 2001 AVALON (RM808U) Author
: Date
: 336 DI-181 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02K-08 DTC P0750, P0755 Shift Solenoid A/B Malfunction (Shift Solenoid Valve No.1/No.2) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor and direct clutch speed sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical trouble of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.). DTC No. DTC Detecting Condition Trouble Area During normal driving, the gear required by the ECM does not match the actual gear (2-trip detection logic) P0750 P0755
Shift solenoid valve No.1/No.2 is stuck open or closed
Valve body is blocked up or stuck
Automatic transaxle (clutch, brake or gear etc.) HINT: Check the shift solenoid valve No.1 when DTC P0750 is output and check the shift solenoid valve No.2 when DTC P0755 is output. INSPECTION PROCEDURE 1 Check shift solenoid valve No.1 or No.2 operation. PREPARATION: (a) Remove the oil pan. (b) Remove the shift solenoid valve No.1 or No.2. CHECK: (a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the solenoid valve does not leak air. (b) When battery positive voltage is supplied to the shift solenoid valve, check that the valve opens. OK: (a) Solenoid valve does not leak air. (b) Solenoid valve opens. (+) (-) (+) (-) Q30002 NG Replace the shift solenoid valve No.1 or No.2. OK 2001 AVALON (RM808U) Author
: Date
: 337 DI-182 DIAGNOSTICS 2 - AUTOMATIC TRANSAXLE Check the valve body (See page DI-175 ). NG Repair or replace the valve body. OK Repair the transaxle. 2001 AVALON (RM808U) Author
: Date
: 338 DI-183 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02L-08 DTC P0753, P0758 Shift Solenoid A/B Electrical Malfunction (Shift Solenoid Valve No.1/No.2) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ON and OFF of the shift solenoid valves No.1 and No.2 controlled by ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). Fail safe function: If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunctioning, hydraulic control cannot be performed electronically and must be done manually. Manual shifting as shown in the following table must be done (In the case of a short circuit, the ECM stops sending current to the short circuited solenoid). NORMAL Position D 2 L Solenoid valve No.1 No.2 Gear SHIFT SOLENOID NO.1 MALFUNCTIONING Solenoid valve Gear No.1 No.2 X 3rd ON SHIFT SOLENOID NO.2 MALFUNCTIONING Solenoid valve Gear No.1 No.2 X 1st ON BOTH SOLENOIDS MALFUNCTIONING Gear when shift selector is manually operated O/D ON OFF 2nd ON ON 1st X ON 3rd OFF X O/D O/D OFF ON 3rd X ON 3rd OFF X O/D O/D OFF OFF O/D X OFF O/D OFF X O/D O/D ON 3rd ON X 1st O/D ON OFF 2nd X ON ON 1st X ON 3rd OFF X O/D O/D OFF ON 3rd X ON 3rd OFF X O/D O/D ON OFF 1st X OFF 1st ON X 1st 1st ON ON 2nd X ON 2nd ON X 1st 1st X: Malfunctions HINT: Check the shift solenoid valve No.1 when DTC P0753 is output and check the shift solenoid valve No.2 when DTC P0758 is output. DTC No. DTC Detecting Condition P0753 P0758 The ECM checks for an open or short circuit in the shift solenoid valve No.1 and/or No.2 circuit when it changes. The ECM records DTC P0753 or P0758 if condition (a) or (b) is detected once, but it does not light up MIL. After ECM detects condition (a) or (b) continuously 8 times or more in a trip and the MIL lights up. (a) When the solenoid is energized, the solenoid resistance is 8 Ω or less and is counted. (b) When the solenoid is not energized, the solenoid resistance is 100 kΩ or more and is counted. Trouble Area
Open or short in shift solenoid valve No.1/No.2 circuit
Shift solenoid valve No.1/No.2
ECM 2001 AVALON (RM808U) Author
: Date
: 339 DI-184 DIAGNOSTICS - AUTOMATIC TRANSAXLE WIRING DIAGRAM ECM Transaxle Shift Solenoid Valve No.1 3 7 E4 P S1 J8 J/C 6 S2 Shift Solenoid Valve No.2 G-Y G-Y B B S1 1 E6 S2 B From Cruise Control ECU D07908 2001 AVALON (RM808U) Author
: Date
: 340 DI-185 DIAGNOSTICS - AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Measure resistance between terminal S1 or S2 of ECM and body ground. PREPARATION: (a) Remove the glove compartment (See page BO-90 ). (b) Disconnect the connector from ECM. CHECK: Measure resistance between terminal S1 or S2 of ECM and body ground. OK: Resistance: 11 - 15 Ω S1 S2 D06557 OK Check and replace the ECM (See page IN-30 ). NG 2 Measure resistance of harness and connector between ECM and automatic transaxle solenoid connector. S2 S1 S2 D06558 Q02283 S1 PREPARATION: Disconnect the solenoid connector from the automatic transaxle. CHECK: Measure resistance of the harness and connector between terminal S1 or S2 of ECM and terminal S1 or S2 of solenoid connector. OK: Resistance: 0 Ω NG Repair or replace the harness or connector. D07489 OK 2001 AVALON (RM808U) Author
: Date
: 341 DI-186 DIAGNOSTICS 3 - AUTOMATIC TRANSAXLE Check shift solenoid valve No.1 or No.2. PREPARATION: (a) Jack up the vehicle. (b) Remove the oil pan. (c) Disconnect the solenoid connector. (d) Remove the shift solenoid valve No.1 or No.2. CHECK: (a) Measure resistance between solenoid connector and body ground. (b) Connect the positive
lead to terminal of solenoid connector, negative  lead to solenoid body. OK: (a) Resistance: 11 - 15 Ω (b) The solenoid makes an operating noise. (+) (-) D04448 NG Replace the solenoid valve. OK Repair or replace the solenoid wire. 2001 AVALON (RM808U) Author
: Date
: 342 DI-187 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02M-08 DTC P0770 Shift Solenoid E Malfunction (Shift Solenoid Valve SL) SYSTEM DESCRIPTION Controlled Pressure Line Pressure Controlled Pressure Drain Q04874 The ECM uses the signals from the throttle position sensor, airflow meter and crankshaft position sensor to monitor the engagement condition of the lock-up clutch. Then the ECM compares the engagement condition of the lock-up clutch with the lock-up schedule in the ECM memory to detect mechanical trouble of the shift solenoid valve SL, valve body, torque converter clutch or automatic transaxle (clutch, brake or gear etc.). DTC No. DTC Detecting Condition Trouble Area P0770
Lock-up does not occur when driving in the lock-up range (normal driving at 80 km/h [50 mph]), or lock-up remains ON in the lock-up OFF range. (2-trip detection logic)
When lock-up is ON, clutch or brake slips or gear is broken.
Shift solenoid valve SL is stuck open or closed
Valve body blocked up or stuck
Lock-up clutch
Automatic transaxle (clutch, brake or gear etc.) INSPECTION PROCEDURE 1 Check solenoid valve SL operation. (+) (+) (-) (-) Q08040 D02461 PREPARATION: (a) Remove the oil pan. (b) Remove the shift solenoid valve SL. CHECK: (a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the solenoid valve does not leak air. (b) When battery positive voltage is supplied to the shift solenoid valve, check that the solenoid valve opens. OK: (a) Solenoid valve does not leak air. (b) Solenoid valve opens. NG Replace the solenoid valve SL. OK 2001 AVALON (RM808U) Author
: Date
: 343 DI-188 DIAGNOSTICS 2 - AUTOMATIC TRANSAXLE Check valve body (See page DI-175 ). NG Repair or replace the valve body. OK 3 Check the torque converter clutch (See page AX-43 ). NG Replace the torque converter clutch. OK Repair the transaxle (See page AX-33 ). 2001 AVALON (RM808U) Author
: Date
: 344 DI-189 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02N-08 DTC P0773 Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL) CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock-up relay valve, which then controls operation of the lock-up clutch. Fail safe function: If the ECM detects a malfunction, it turns the shift solenoid valve SL OFF. DTC No. DTC Detecting Condition Trouble Area P0773 Either (a) or (b) is detected for 1 time. (2-trip detection logic) (a) Solenoid resistance is 8 Ω or less short when solenoid is energized. (b) Solenoid resistance is 100 kΩ or more when solenoid is not energized.
Open or short in shift solenoid valve SL circuit
Shift solenoid valve SL
ECM WIRING DIAGRAM E1 Transaxle ECM Shift Solenoid Valve SL SL 2 15 E6 SL G-W D07906 2001 AVALON (RM808U) Author
: Date
: 345 DI-190 DIAGNOSTICS - AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Measure resistance between terminal SL of ECM and body ground. PREPARATION: (a) Remove the glove compartment (See page BO-90 ). (b) Disconnect the connector from ECM. CHECK: Measure resistance between terminal SL of ECM and body ground. OK: Resistance: 11 - 15 Ω at 20 °C (68 °F) SL D06559 OK Check and replace the ECM (See page IN-30 ). NG 2 Measure resistance of harness and connector between ECM and automatic transaxle solenoid connector. SL PREPARATION: Disconnect the solenoid connector from the transaxle. CHECK: Measure resistance of the harness and connector between terminal SL of ECM and terminal SL of solenoid connector. OK: Resistance: 0 Ω SL D06560 NG Repair or replace the harness or connector. OK 2001 AVALON (RM808U) Author
: Date
: 346 DI-191 DIAGNOSTICS 3 - AUTOMATIC TRANSAXLE Check shift solenoid valve SL. (+) (-) D04449 PREPARATION: (a) Jack up the vehicle. (b) Remove the oil pan. (c) Disconnect the shift solenoid valve SL connector. (d) Remove the shift solenoid valve SL. CHECK: (a) Measure resistance between terminal SL of shift solenoid valve and solenoid body. (b) Connect positive
lead to terminal of solenoid connector, negative  lead to solenoid body. OK: (a) Resistance: 11 - 15 Ω at 20 °C (68 °F) (b) The shift solenoid valve SL makes operation noise. NG Replace the shift solenoid valve SL. OK Replace or repair the solenoid wire, harness and connector between ECM and automatic transaxle solenoid connector. 2001 AVALON (RM808U) Author
: Date
: 347 DI-192 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02O-06 DTC P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. DTC No. P1520 DTC Detecting Condition No stop light switch signal to ECM during driving. (2-trip detection logic) Trouble Area
Open or short in stop light switch circuit
Stop light switch
ECM WIRING DIAGRAM See page DI-134 . INSPECTION PROCEDURE See page DI-134 . 2001 AVALON (RM808U) Author
: Date
: 348 DI-193 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02P-07 DTC P1705 NC2 Revolution Sensor Circuit Malfunction (Direct Clutch Speed Sensor) CIRCUIT DESCRIPTION This sensor detects the rotation speed of the direct clutch drum. By comparing the direct clutch speed signal with the vehicle speed sensor signal, the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure in response to various conditions, thus performing smooth gear shifting. NC2 Revolution Sensor Q04869 DTC No. DTC Detecting Condition The ECM detects conditions (a), (b), (c), (d), (e) and (f) continuity for 4 secs. or more. (2-trip detection logic) (a) Gear change not being performed (b) Gear position: 1st, 2nd 3rd or O/D (c) T/M input shaft rpm: 300 rpm or less (d) T/M output shaft rpm: 1,000 rpm or more (e) Park/neutral position switch: OFF (f) Shift solenoid valves No. 1, No. 2, SL and vehicle speed sensor are in normal operation. P1705 Trouble Area
Open or short in direct clutch speed sensor circuit
Direct clutch speed sensor
ECM WIRING DIAGRAM ECM R 24 E4 NC2+ G 23 E4 NC2- 2 O1 Direct Clutch Speed Sensor 1 D07907 2001 AVALON (RM808U) Author
: Date
: 349 DI-194 DIAGNOSTICS - AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Check resistance between terminals NC2+ and NC2- of ECM. PREPARATION: (a) Remove the glove compartment. (b) Disconnect the connector from ECM. CHECK: Check resistance between terminals NC2+ and NC2- of ECM. OK: Resistance: 560 - 680 Ω at 20 °C (68 °F) NC2- NC2+ D06556 OK Check and replace the ECM (See page IN-30 ). NG 2 Check direct clutch speed sensor. Magnet PREPARATION: Remove the Direct clutch speed sensor from transaxle. CHECK: (a) Measure resistance between terminals 1 and 2 of speed sensor. (b) Check voltage between terminals 1 and 2 of the speed sensor when a magnet is put close to the front end of the speed sensor then taken away quickly. OK: (a) Resistance: 560 - 680 Ω at 20 °C (68 °F) (b) Voltage is generated intermittently. HINT: The voltage generated is extremely low. Q08218 NG Replace the direct clutch speed sensor. OK Check and repair the harness and connector between ECM and direct clutch speed sensor (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 350 DI-195 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02Q-07 DTC P1765 Linear Solenoid for Accumulator Pressure Control Circuit Malfunction (Shift Solenoid Valve SLN) CIRCUIT DESCRIPTION The shift solenoid valve SLN controls the hydraulic pressure acting on the accumulator control valve when gears are shifted and performs smooth gear shifting. The ECM determines optimum operating pressure according to the signals from the throttle position sensor, vehicle speed sensor and direct clutch speed sensor and controls the volume of current flow to the solenoid valve. The amount of current to the solenoid is controlled by the (*) duty ratio of ECM output signals, causing a momentary change to the hydraulic pressure acting on the clutches during gear shifting. When the duty ratio is high, the hydraulic pressure acting on the clutches is low. Accumulator Control Pressure High 0 Electric Current (A) 1 AT5608 (*) Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then D00060 DTC No. DTC Detecting Condition After the engine is warmed up, the current flows to the shift solenoid valve SLN for 1 sec or more under condition (a) or (b): (a) Engine speed: 500 rpm or more (b) Park/neutral position switch: ON (P or N position) P1765 Trouble Area
Open or short in shift solenoid valve SLN circuit
Shift solenoid valve SLN
ECM Reference Waveform between terminals SLN+ and SLN- when engine is idling. Waveform between terminals SLN+ and SLN- during shift change. 5 V / Div. 5 V / Div. GND GND 1 msec. / Div. 1 msec. / Div. D00062 2001 AVALON (RM808U) Author
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: 351 DI-196 DIAGNOSTICS - AUTOMATIC TRANSAXLE WIRING DIAGRAM ECM E1 Transaxle 1 P-L 4 Y 20 E4 SLN+ Shift Solenoid Valve SLN 19 E4 SLN- D07911 2001 AVALON (RM808U) Author
: Date
: 352 DI-197 DIAGNOSTICS - AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Check shift solenoid valve SLN. 2 2 (-) 1 1 Check solenoid resistance and operation: PREPARATION: Disconnect the shift solenoid valve SLN connector. CHECK: (a) Measure resistance between terminals 1 and 2 of solenoid connector. (b) Connect positive
lead with an 8 - 10 W bulb to terminal 1 of solenoid connector and negative  lead to terminal 2, then check the movement of the valve. OK: (a) Resistance: 5.1 - 5.5 Ω (b) When battery positive voltage is supplied. Valve moves in direction shown in illustration. (on the left) When battery positive voltage is cut off. Valve moves in direction shown in illustration. (on the right) (+) D04720 (+) 1 2 Check solenoid operation: PREPARATION: Connect positive
lead of the variable power supply to terminal 1 of solenoid connector and negative  lead to terminal 2. CHECK: (a) Check the movement of the valve when the voltage is gradually increased. (A current greater than 1A should not be supplied.) (b) Check the movement of the valve when the voltage is cut off. OK: (a) As the voltage is increased, the valve should move direction. slowly in the direction. (b) The valve should return in the (-) D00051 NG Replace the shift solenoid valve SLN. OK 2001 AVALON (RM808U) Author
: Date
: 353 DI-198 DIAGNOSTICS 2 - AUTOMATIC TRANSAXLE Check harness and connector between battery and shift solenoid valve SLN, shift solenoid valve SLN and ECM (See page IN-30 ). NG Repair or replace the harness or connector. OK Check and replace the ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 354 DI-199 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI6K8-01 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. DTC No. P1780 DTC Detection Condition When driving under conditions (a) and (b) for 30 seconds or more, the park/neutral position switch is ON (N position). (2-trip detection logic) (a) Vehicle speed: 70 km/h (44 mph) or more (b) Engine speed: 1,500 - 2,500 rpm Trouble Area
Short in park/neutral position switch circuit
Park/neutral position switch
ECM 2001 AVALON (RM808U) Author
: Date
: 355 DI-200 DIAGNOSTICS - AUTOMATIC TRANSAXLE WIRING DIAGRAM J5 J/C W-B A J/B No. 3 7 7 W-B 3A 3G 21 A C9 Combination Meter R P1 Park/Neutral Position switch W-B 2 RL R-B 8 2L G-Y 3 LL Y 4 2 L ECM 2 5 6 R-B G-Y Y 18 3F 16 3F 17 3G 18 R-B 3C 16 G-Y 3C 1 II1 2 II2 1 II2 17 3B Y 18 R-B 3D 16 G-Y 3D 18 R-B II2 7 G-Y II2 8 E6 14 E6 17 3A 6 II2 13 E6 L 20 E7 NSW Y Y R 2 J/B No. 3 R-L J/B No. 3 20 7 3C 3C 20 3D 15 3C *2 15 GR 3D *2 GR FUSIBLE LINK BLOCK IG R-L 3 *2 J/B No. 4 2 11 1 4D 4C GR *2 1 GAUGE No. 2 1C 2 3 1B 4 W-B 10 1C IG1 RELAY 1 F10 *2 R-L 2 ACC 3 1 1G W-R 2 4 IG1 AM1 4 1C 3 W-L W B 2 2G 1 F6 B I15 Ignition Switch AM2 8 7 ST2 Driver Side J/B W-G Engine Room R/B No. 5 B AM1 5 5 1 1 F7 B-W 1 Engine Room J/B 1 1 1 B-L F8 2G 2H ALT D6 DIODE ECU-ACC 8 1D R-L W-B R-L *1 20 II1 FL MAIN AM2 7 2C W-L 7 IF1 2 4 IF1 W-R W-R *1: Floor Shift *2: Column Shift Battery D07909 2001 AVALON (RM808U) Author
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: 356 DI-201 DIAGNOSTICS - AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Read PNP, REVERSE, 2ND and LOW signals. When using TOYOTA hand-held tester: PREPARATION: (a) Remove the DLC3 cover. (b) Connect a TOYOTA hand-held tester to the DLC3. (c) Turn the ignition switch ON and TOYOTA hand-held tester main switch ON. CHECK: Shift lever into the P, R, N, 2 and L positions, and read the PNP, REVERSE, 2ND and LOW signals on the TOYOTA hand-held tester. OK: R NSW 2 L D06555 Shift position Signal 2 2ND OFF → ON L LOW OFF → ON R REVERSE OFF → ON P, N NSW OFF → ON When not using TOYOTA hand-held tester: PREPARATION: (a) Remove the glove compartment. (b) Turn the ignition switch ON. CHECK: Measure voltage between each of terminals NSW, 2, L and R of ECM and body ground when the shift lever is shifted to the following positions. OK: Position P, N NSW-Body ground 0V R-Body ground 2-Body ground L-Body ground 0V 0V 0V R 9 - 14 V* 9 - 14 V* 0V 0V D 9 - 14 V 0V 0V 0V 2 9 - 14 V 0V 9 - 14 V 0V L 9 - 14 V 0V 0V 9 - 14 V HINT: *: The voltage will drop slightly due to lighting up of the back up light. OK Check and replace the ECM (See page IN-30 ). NG 2001 AVALON (RM808U) Author
: Date
: 357 DI-202 DIAGNOSTICS 2 - AUTOMATIC TRANSAXLE Check park/neutral position switch. PREPARATION: (a) Jack up the vehicle. (b) Remove the park/neutral position switch (See page AX-4 ). CHECK: Check continuity between each terminal shown below when the shift lever is moved to each position. Shift Position Q07657 Terminal No. to continuity P 2-7 5-6 R 2-8 - N 2-9 5-6 D 2 - 10 - 2 2-3 - L 2-4 - OK: There is continuity. NG Replace the park/neutral position switch. OK Repair or replace harness and connector between battery and park/neutral position switch, park/ neutral position switch and ECM (See page IN-30 ). NG Repair or replace the harness and connector. OK Check and replace the ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 358 DI-159 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02D-02 CUSTOMER PROBLEM ANALYSIS CHECK Transaxle Control System Check Sheet Inspector’s Name : Registration No. Customer’s Name Registration Year / / Frame No. Date Vehicle Brought In / Date Problem Occurred Frequency prob lem occurs / / Continuous Vehicle does not move ( No up-shift No down-shift km mile Odometer Reading ( ( / Intermittent ( Any position 1st → 2nd O/D →3rd times a day) Particular position ) 2nd → 3rd 3rd → 2nd 3rd → O/D) 2nd → 1st) Lock-up malfunction Symptoms Shift point too high or too low Harsh engagement ( N→D Lock-up Any drive position) Slip or shudder No kick-down Others Check Item Malfunction Indicator Lamp Normal Remains ON 1st Time Normal code Malfunction code (Code ) 2nd Time Normal code Malfunction code (Code ) DTC Check 2001 AVALON (RM808U) Author
: Date
: 315 DI-172 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02F-06 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the page given. *:
...MIL lights up DTC No. (See Page) Detection Item Trouble Area MIL * Memory P0500 (DI-178 ) Vehicle Speed Sensor Malfunction (Vehicle Speed Sensor)  Open or short in vehicle speed sensor circuit  Vehicle speed sensor  Combination meter  ECM  Automatic transaxle (clutch, brake or gear etc.)
 P0750 (DI-181 ) Shift Solenoid A Malfunction (Shift Solenoid Valve No.1)  Shift solenoid valve No.1 is stuck open or closed  Valve body is blocked up or stuck  Automatic transaxle (clutch, brake or gear etc.)
 P0753 (DI-183 ) Shift Solenoid A Electrical Malfunction (Shift Solenoid Valve No.1)  Open or short in shift solenoid valve No.1 circuit  Shift solenoid valve No.1  ECM
 P0755 (DI-181 ) Shift Solenoid B Malfunction (Shift Solenoid Valve No.2)  Shift solenoid valve No.2 is stuck open or closed  Valve body is blocked up or stuck  Automatic transaxle (clutch, brake or gear etc.)
 P0758 (DI-183 ) Shift Solenoid B Electrical Malfunction (Shift Solenoid Valve No.2)  Open or short in shift solenoid valve No.2 circuit  Shift solenoid valve No.2  ECM
 P0770 (DI-187 ) Shift Solenoid E Malfunction (Shift Solenoid Valve SL)  Shift solenoid valve SL is stuck open or closed  Valve body is blocked up or stuck  Lock-up clutch  Automatic transaxle (clutch, brake or gear etc.)
 P0773 (DI-189 ) Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL)  Open or short in shift solenoid valve SL circuit  Shift solenoid valve SL  ECM
 P1520 (DI-192 ) Stop Light Switch Signal Malfunction  Open or short in stop light switch circuit  Stop light switch  ECM
 P1705 (DI-193 ) NC2 Revolution Sensor Circuit Malfunction (Direct Clutch Speed Sensor)  Open or short in direct clutch speed sensor circuit  Direct clutch speed sensor  ECM
 P1765 (DI-195 ) Linear Solenoid for Accumulator Pressure Control Circuit Malfunction (Shift Solenoid Valve SLN)  Open or short in shift solenoid valve SLN circuit  Shift solenoid valve SLN  ECM
 P1780 (DI-199 ) Park/Neutral Position Switch Malfunction  Short in park/neutral position switch circuit  Park/neutral position switch  ECM
 2001 AVALON (RM808U) Author
: Date
: 328 DI-158 DIAGNOSTICS - AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE DI02C-06 HOW TO PROCEED WITH TROUBLESHOOTING Items inside are titles of pages in this manual, with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Vehicle Brought to Workshop 1 Customer Problem Analysis P. DI-159 2 Connect an OBD II scan tool or TOYOTA hand-held tester to DLC3. If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the scan tool / TOYOTA hand-held tester, inspect DLC3 P. DI-160 3 Check DTC and Freeze Frame Data (Pre-check) Record or Print DTC and Freeze Frame Data P. DI-160 4 Clear DTC and Freeze Frame Data P. DI-160 5 Visual Inspection 6 Setting the Check Mode Diagnosis P. DI-160 Symptom does not occur 8 7 Problem Symptom Confirmation Symptom Simulation P. DI-160 Symptom occurs 9 DTC Check P. DI-160 10 DTC Chart P. DI-172 11 OK Code OK 12 Mechanical System Test NG P. DI-160 OK NG Manual Shifting Test P. DI-160 Matrix Chart of Problem Symptoms - P. DI-175 13 Chapter 1 (Electronic) P. DI-175 NG 14 NG Basic Inspection P. DI-160 OK OK Chapter 2 (On-V ehicle) P. DI-175 OK Chapter 3 (Off-V ehicle) P. DI-175 NG NG
O/D Cancel Signal Check
O/D Main Switch & O/D OFF Indicator Light Check 15 Circuit Inspection P. DI-203 to DI-206 Identification of Problem 16 Repair 17 Confirmation Test Parts Inspection End 2001 AVALON (RM808U) Author
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: 314 DI-173 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02G-06 PARTS LOCATION Floor Shift: O/D Main Switch Column Shift: O/D Main Switch ECM Direct Clutch Speed Sensor DLC3 Stop Light Switch Cruise Control ECU Shift Solenoid Valve SL Shift Solenoid Valve SLN Park/Neutral Position Switch Shift Solenoid Valve D07229 2001 AVALON (RM808U) Author
: Date
: 329 DI-160 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02E-08 PRE-CHECK 1. (a) DIAGNOSIS SYSTEM Description
When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect to the vehicle an OBD II scan tool complying with SAE J1987 or TOYOTA handheld tester, and read off various data output from the vehicle’s ECM.
OBD II regulations require that the vehicle’s onboard computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components which affect vehicle emissions. In addition to the MIL lighting up when a malfunction is detected, the applicable DTCs prescribed by SAE J2012 are recorded in the ECM memory (See page DI-14 ). If the malfunction only occurs in 3-trip, the MIL goes off but the DTCs remain recorded in the ECM memory.
To check the DTCs, connect an OBD II scan tool or TOYOTA hand-held tester to DLC3 on the vehicle. The OBD II scan tool or TOYOTA hand-held tester also enables you to erase the DTCs and check freeze frame data and various forms of engine data (For instruction book). DTCs include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while Manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits (See DTC chart on page ). FI0534 TOYOTA hand-held tester
DLC3 F07887 2001 AVALON (RM808U) Author
: Date
: 316 DI-161 DIAGNOSTICS -

(b) AUTOMATIC TRANSAXLE The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most DTCs use 2-trip detection logic(*) to prevent erroneous detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up and for a malfunction that is only detected once or momentarily (TOYOTA hand-held tester) (See page DI-160 ). *2-trip detection logic: When a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same malfunction is detected again during the 2nd test drive, this 2nd detection causes the MIL to light up. Inspect the DLC3. The vehicle’s ECM uses ISO 9141-2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. N09214 Tester connection Condition Specified condition 7 (Bus
Line) - 5 (Signal ground) During communication 4 (Chassis Ground) - Body Always 1 Ω or less 5 (Signal Ground) - Body Always 1 Ω or less 16 (B+) - Body Always 9 - 14 V Pulse generation HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of OBD II scan tool or TOYOTA hand-held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 2001 AVALON (RM808U) Author
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: 317 DI-162 DIAGNOSTICS 2. (a) FI0534 TOYOTA hand-held tester HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE-2 ). (2) When the engine is started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE: TOYOTA hand-held tester only: When the diagnostic system is switched from normal mode to check mode, it erases all DTCs and freeze frame data recorded in normal mode. So before switching modes, always check the DTCs and freeze frame data, and note them down. (1) Prepare an OBD II scan tool (complying with SAE J1978) or TOYOTA hand-held tester. (2) (4) F07887 AUTOMATIC TRANSAXLE INSPECT DIAGNOSIS (NORMAL MODE) Check the MIL. (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. (3) DLC3 - Connect the OBD II scan tool or TOYOTA handheld tester to DLC3 at the lower of the instrument panel. Turn the ignition switch ON and turn the OBD II scan tool or TOYOTA hand-held tester switch ON. Use the OBD II scan tool or TOYOTA hand-held tester to check the DTCs and freeze frame data and note them down (For operating instructions, see the OBD II scan tool’s instruction book). See page DI-172 to confirm the details of the DTCs. (5) NOTICE: When simulating symptoms with an OBD II scan tool (excluding TOYOTA hand-held tester) to check the DTCs, use normal mode. For codes on the DTCs chart subject to ”2-trip detection logic”, turn the ignition switch OFF after the symptoms have been simulated the 1st time. Then repeat the simulation process again. When the program has DTCs they are recorded in the ECM. 2001 AVALON (RM808U) Author
: Date
: 318 DI-163 DIAGNOSTICS - AUTOMATIC TRANSAXLE 3. INSPECT DIAGNOSIS (CHECK MODE) HINT: TOYOTA hand- held tester only: Compared to the normal mode, the check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in Normal mode can also be detected in Check mode. (a) Check the DTC. (1) Check the initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transaxle in P position
Air conditioning switched OFF (2) Turn the ignition switch OFF (3) Prepare a TOYOTA hand-held tester TOYOTA hand-held tester (4) (5) DLC3 F07887 (6) 0.13 sec. Connect the TOYOTA hand-held tester to DLC3 at the lower of the instrument panel. Turn the ignition switch ON and switch the TOYOTA hand-held tester ON. (7) 0.13 sec. ON (8) OFF BR3904 Switch the TOYOTA hand-held tester from Normal mode to Check mode (Check that the MIL flashes). Start the engine (MIL goes out after the engine starts). Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTCs, etc.. (9) After simulating the malfunction conditions, use the TOYOTA hand-held tester diagnosis selector to check the DTCs and freeze frame data, etc. HINT: Take care not to turn the ignition switch OFF, as turning it off switches the diagnosis system from Check mode to Normal mode, so all DTCs, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. 2001 AVALON (RM808U) Author
: Date
: 319 DI-164 DIAGNOSTICS (b) - AUTOMATIC TRANSAXLE Clearance the DTC. The following operation will erase the DTC and freeze frame data. Operating an OBD II scan tool (complying with SAE J1978) or TOYOTA hand-held tester to erase the codes (See the OBD II scan tool’s instruction book for operating instructions.). 4. ROAD TEST NOTICE: Perform the test at normal operating ATF temperature 50 - 80 °C (122 - 176 °F). (a) D position test Shift into the D position and fully depress the accelerator pedal and check the following points: (1) Check up-shift operation. Check to see that 1 → 2, 2 → 3 and 3 → O/D up-shift takes place,and that the shift points conform the automatic shift schedule (See page SS-24 ). HINT:
O/D Gear Up-shift Prohibition Control (1. Coolant temp. is 60 °C (140 °F) or less. 2. If there is a 10 km/h (6 mph) difference between the set cruise control speed and vehicle speed.)
O/D Gear Lock-up Prohibition Control (1. Brake pedal is depressed. 2. Coolant temp. is 60 °C (140 °F) or less.) (2) Check for shift shock and slip. Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up-shifts. (3) Check for abnormal noises and vibration. Run at the D position lock-up or O/D gear and check for abnormal noises and vibration. HINT: The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be due to loss of balance in the differential torque converter clutch, etc. (4) Check kick-down operation. While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick-down vehicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick-downs conform to those indicated in the automatic shift schedule (See page SS-24 ). (5) Check abnormal shock and slip at kick-down. (6) Check the lock-up mechanism.
Drive in D position, O/D gear, at a steady speed (lock-up ON) of about 60 km/h (37 mph).
Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. If there is a big jump in engine speed, there is no lock-up. (b) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points: (1) Check up-shift operation. Check to see that the 1 → 2 up-shift takes place and that the shift point conforms to the automatic shift schedule (See page SS-24 ). HINT: There is no O/D up-shift and lock-up in the 2 position. (2) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. 2001 AVALON (RM808U) Author
: Date
: 320 DI-165 DIAGNOSTICS - AUTOMATIC TRANSAXLE (c) L position test Shift into the 2 position and fully depress the accelerator pedal and check the following points: (1) Check no up-shift. While running in the L position, check that there is no up-shift to 2nd gear. (2) Check engine braking. While running in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (d) R position test Shift into the R position and fully depress the accelerator pedal and check for slipping. CAUTION: Before conducting this test ensure that the test area is free from people and obstruction. (e) P position test Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check to see that the parking lock pawl holds the vehicle in place. 5. BASIC INSPECTION (a) Check the fluid level. HINT:
Drive the vehicle so that the engine and transaxle are at normal operating temperature. Fluid temp.: 70 - 80 °C (158 - 176 °F)
Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. (1) Column Shift: (2) Park the vehicle on a level surface and set the parking brake. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. Floor Shift: D07227 D07228 D07756 2001 AVALON (RM808U) Author
: Date
: 321 DI-166 DIAGNOSTICS - AUTOMATIC TRANSAXLE (3) (4) (5) OK if hot Add if hot AT3417 Pull out the dipstick and wipe it clean. Push it back fully into the pipe. Pull it out and check that the fluid level is in the HOT range. If the level is not within the range, add new fluid. Fluid type: ATF D-II or DEXRON®III (DEXRON®II) NOTICE:
Do not overfill.
After filling ATF, check the oil level securely then drive a vehicle. (b) Check the fluid condition. If the fluid smells burnt or is black, replace it. (c) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. AT4657 (3) With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF D-II or DEXRON®III (DEXRON®II) Capacity: 4.75 liters (5.0 US qts, 4.2 Imp. qts) (4) Start the engine and shift the shift lever into all positions from P to L position and then shift into P position. AT8562 (5) OK if hot (6) Add if hot With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. Check the fluid level at the normal operating temperature, 70 - 80 °C (158 - 176 °F), and add as necessary. NOTICE: Do not overfill. AT3417 2001 AVALON (RM808U) Author
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: 322 DI-167 DIAGNOSTICS - AUTOMATIC TRANSAXLE (d) Check the fluid leaks. Check for leaks in the transaxle. If there are leaks, it is necessary to repair or replace O-rings, gasket, oil seals, plugs or other parts. (e) Inspect and adjust the throttle cable. (1) Check that the accelerator pedal is fully released. (2) Check that the inner cable is not slack. (3) Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 - 1 mm (0 - 0.04 in.) If the distance is not the standard, adjust the cable by adjusting nuts. 0 - 1 mm (0 - 0.04 in.) AT4252 (f) Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator is aligned with the correct position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. (1) Loosen the nut on the shift lever. Q00199 (2) (3) N R P D02450 Push the control shaft fully downward. Return the control shaft lever 2 notches to N position. (4) Set the shift lever to N position. (5) While holding the shift lever lightly toward the R position side, tighten the shift lever nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (6) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. 2001 AVALON (RM808U) Author
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: 323 DI-168 DIAGNOSTICS - AUTOMATIC TRANSAXLE (g) Neutral Basic Line Bolt Groove Bolt Q04700 Inspect and adjust the park/neutral position. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If it is not as stated above, carry out the following adjustment procedures. (1) Loosen the park/neutral position switch bolt and set the shift lever to the N position. (2) Align the groove and neutral basic line. (3) Hold in position and tighten the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) For continuity inspection of the park/neutral position switch, see page DI-199 . (h) Check the idle speed. Idle speed: 700 ± 50 rpm (In N position and air conditioner OFF) 6. (a) MECHANICAL SYSTEM TESTS Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions. NOTICE:
Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176 °F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an OBD II scan tool or TOYOTA hand-held tester to DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressing firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. Quickly read the stall speed at this time. Stall speed: 2,325 − 2,775 rpm (7) Do the same test in R position. Stall speed: 2,325 − 2,775 rpm Evaluation: Problem Possible cause (a) Stall speed low in D and R positions
Engine output may be insufficient
Stator one-way clutch is operating properly HINT: If more than 600 rpm below the specified value, the torque converter clutch could be faulty. (b) Stall speed high in D position
Line pressure too low
Forward clutch slipping
No.2 one-way clutch not operating properly
O/D clutch slipping 2001 AVALON (RM808U) Author
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: 324 DI-169 DIAGNOSTICS - AUTOMATIC TRANSAXLE (c) Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st & reverse brake slipping
O/D clutch slipping (d) Stall speed high in D and R positions
Line pressure too low
Improper fluid level
O/D one-way clutch not operating properly (b) Measure the time lag. When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the conditions of the O/D direct clutch, forward clutch, and 1st & reverse brake. NOTICE:
Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176 °F).
Be sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value. (1) Connect an OBD II scan tool or TOYOTA hand-held tester to DLC3. (2) Fully apply the parking brake. (3) Start the engine and check idle speed. Idle speed: 700 ± 50 rpm (In N position and air conditioner OFF) (4) Shift the shift lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D Less than 1.2 seconds In the same manner, measure the time lag for N → R. Time lag: N → R Less than 1.5 seconds Evaluation (If N → D time or N → R time lag is longer than the specified): Problem Possible cause N → D time lag is longer
Line pressure too low
Forward clutch worn
O/D one-way clutch not operating N → R time lag is longer
Line pressure too low
Direct clutch worn
1st & reverse brake worn
O/D one-way clutch not operating properly 2001 AVALON (RM808U) Author
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: 325 DI-170 DIAGNOSTICS - AUTOMATIC TRANSAXLE 7. HYDRAULIC TEST Measure the line pressure. NOTICE:
Do the test at normal operation fluid temperature 50 - 80 °C (122 - 176 °F).
The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Be careful to prevent SST’s hose from interfering with the exhaust pipe. (1) Warm up the ATF. (2) Remove the test plug on the transaxle case front left side and connect SST (See page AX-33 for the location to connect SST). SST 09992-00095 (09992-00231, 09992-00271) (3) Fully apply the parking brake and chock the 4 wheels. (4) Connect an OBD II scan tool or TOYOTA hand-held tester to DLC3. (5) Start the engine and check idling speed. (6) Keep your left foot pressing firmly on the brake pedal and shift into D position. (7) Measure the line pressure when the engine is idling. (8) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (9) In the same manner, do the test in R position. Specified line pressure: Condition D position kPa (kgf/cm2, psi) R position kPa (kgf/cm2, psi) Idling 401 - 461 (4.1 - 4.7, 58 - 66) 804 - 882 (8.2 - 9.0, 117 - 128) Stall 1,138 - 1,236 (11.6 - 12.6, 165 - 179) 1,716 - 1,854 (17.5 - 18.9, 249 - 269) If the measured pressure is not up to the specified value, recheck the throttle cable adjustment and retest. Evaluation: Problem Possible cause If the measured values at all positions are higher
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective If the measured values at all positions are lower
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective If pressure is low in the D position only
D position circuit fluid leakage
Forward clutch defective If pressure is low in the R position only
R position circuit fluid leakage
Direct clutch defective
1st & reverse brake defective 2001 AVALON (RM808U) Author
: Date
: 326 DI-171 DIAGNOSTICS Q00224 - AUTOMATIC TRANSAXLE 8. MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble is within the electrical circuit or is a mechanical problem in the transaxle. (a) Disconnect the solenoid wire. (b) Inspect the manual driving operation. Check that the shift and gear positions correspond with the table below. While driving, shift through the L, 2 and D positions. Check that the gear change corresponds to the shift position. Shift Position Gear Position D O/D 2 O/D L 1st R Reverse P Pawl Lock HINT: If the L, 2 and D position gear positions are difficult to positions are difficult to distinguish, do the above read test. If any abnormality is found in the above test, the problem is in the transaxle itself. (c) Connect the solenoid wire. (d) Cancel out the DTC (See page DI-160 ). 2001 AVALON (RM808U) Author
: Date
: 327 DI-175 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI02I-07 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Electronic circuit matrix chart Chapter 2: On-vehicle repair matrix chart Chapter 3: Off-vehicle repair matrix chart If the instruction ”Proceed to next circuit inspection shown in matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check. If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check and replace the ECM. Chapter 1: Electronic circuit matrix chart Symptom Suspect Area See page No up-shift (A particular gear, from 1st to 3rd gear, is not upshifted) ECM IN-30 No up-shift (3rd → O/D) 1. O/D main switch & O/D OFF indicator light circuit 2. O/D cancel signal circuit 3. ECM DI-206 DI-203 IN-30 No down-shift (O/D → 3rd) ECM IN-30 No down-shift (A particular gear, from 3rd to 1st gear, is not down-shifted) ECM IN-30 No lock-up or No lock-up off ECM IN-30 Shift point too high or too low ECM IN-30 Up-shift to 2nd while in L position ECM IN-30 Up-shift to 3rd while in 2 position ECM IN-30 Up-shift to O/D from 3rd while O/D main switch is OFF 1. O/D main switch & O/D OFF indicator light circuit 2. ECM DI-206 IN-30 Up-shift to O/D from 3rd while engine is cold ECM IN-30 Harsh engagement (N → D) ECM IN-30 Harsh engagement (Any driving position) ECM IN-30 Poor acceleration ECM IN-30 Engine stalls when starting off or stopping ECM IN-30 No kick-down ECM IN-30 2001 AVALON (RM808U) Author
: Date
: 331 DI-176 DIAGNOSTICS - AUTOMATIC TRANSAXLE Chapter 2: On-vehicle repair (
: A541E automatic transaxle repair manual Pub. No. RM741U) Symptom Suspect Area See page


- Vehicle does not move in any forward position and reverse position 1. 2. 3. 4. Manual valve Throttle valve Primary regulator valve Off-vehicle repair matrix chart Vehicle does not move in R position Off-vehicle repair matrix chart - No up-shift (1st → 2nd) 1. 1-2 shift valve 2. Off-vehicle repair matrix chart
- No up-shift (2nd → 3rd) 1. 2-3 shift valve 2. Off-vehicle repair matrix chart
- No up-shift (3rd → O/D) 1. 3-4 shift valve 2. Off-vehicle repair matrix chart
- No down-shift (O/D → 3rd) 3-4 shift valve
No down-shift (3rd → 2nd) 2-3 shift valve
No down-shift (2nd → 1st) 1-2 shift valve
No lock-up or No lock-up off 1. Lock-up relay valve 2. Off-vehicle repair matrix chart
- Harsh engagement (N → D) 1. C1 accumulator 2. Off-vehicle repair matrix chart
- Harsh engagement (N → R) 1. C2 accumulator 2. No.1 accumulator control valve 3. Off-vehicle repair matrix chart

- Harsh engagement (N → L) Low coast modulator valve
Harsh engagement (Lock-up) 1. Lock-up relay valve 2. Off-vehicle repair matrix chart
- Harsh engagement (1st → 2nd → 3rd → O/D) 1. Throttle modulator valve 2. Cut back valve 3. Throttle valve


Harsh engagement (2nd → 3rd) C2 accumulator
Harsh engagement (3rd → O/D) B0 accumulator
Harsh engagement (O/D → 3rd) 1. C0 accumulator 2. B0 accumulator

Slip or shudder (Forward and reverse) 1. Throttle valve 2. Oil strainer 3. Off-vehicle repair matrix chart

- No engine braking (1st: L position) 1. Low coast modulator valve 2. Off-vehicle repair matrix chart
- No engine braking (2nd: 2 position) 1. 2nd coast modulator valve 2. Off-vehicle repair matrix chart
- No kick-down 1. 1-2 shift valve 2. 2-3 shift valve 3. 3-4 shift valve


2001 AVALON (RM808U) Author
: Date
: 332 DI-177 DIAGNOSTICS - AUTOMATIC TRANSAXLE Chapter 3: Off-vehicle repair (
: A541E automatic transaxle repair manual Pub. No. RM741U) Symptom Suspect Area See page Vehicle does not move in any forward position and reverse position 1. 2. 3. 4. 5. 6. Front and rear planetary gear O/D planetary gear O/D one-way clutch (F0) O/D direct clutch (C0) Forward clutch (C1) O/D brake (B0)





Vehicle does not move in R position 1. 2. 3. 4. Front and rear planetary gear unit Direct clutch (C2) O/D direct clutch (C0) 1st & reverse brake (B3)



No up-shift (1st → 2nd) 1. No. 1 one-way clutch (F1) 2. 2nd brake (B2)

No up-shift (2nd → 3rd) Direct clutch (C2)
No up-shift (3rd → O/D) O/D brake (B0)
No lock-up or No lock-up off Torque converter clutch - Harsh engagement (N → D) 1. Forward clutch (C1) 2. O/D one-way clutch (F0) 3. No. 2 one-way clutch (F2)


Harsh engagement (N → R) 1. Direct clutch (C2) 2. 1st & reverse brake (B3)

Harsh engagement (Lock-up) Torque converter clutch - Slip or shudder (Forward position: After warm-up) 1. 2. 3. 4. Torque converter clutch O/D direct clutch (C0) Forward clutch (C1) O/D one-way clutch (F0)



Slip or shudder (R position) 1. Direct clutch (C2) 2. 1st & reverse brake (B3) 3. O/D direct clutch (C0)


Slip or shudder (1st) No. 2 one-way clutch (F2)
Slip or shudder (2nd) 1. No. 1 one-way clutch (F1) 2. 2nd brake (B2)

Slip or shudder (3rd) Direct clutch (C2)
Slip or shudder (O/D) O/D brake (B0)
No engine braking (1st ∼ 3rd: D position) 2nd brake (B2)
No engine braking (1st: L position) 1st & reverse brake (B3)
No engine braking (2nd: 2 position) 2nd coast brake (B1)
Poor acceleration (All position) 1. Torque converter clutch 2. O/D planetary gear
Poor acceleration (O/D) 1. O/D direct clutch (C0) 2. O/D planetary gear

Large shift shock or engine stalls when starting off or stopping Torque converter clutch - - 2001 AVALON (RM808U) Author
: Date
: 333 DI-174 DIAGNOSTICS - AUTOMATIC TRANSAXLE DI6K7-01 TERMINALS OF ECM ECM Terminals E4 E5 E6 E7 E8 D01054 Symbols (Terminals No.) S1 (E4 (E4-7) 7) ↔ E1 (E5 (E5-17) 17) S2 (E6 (E6-1) 1) ↔ E1 (E5 (E5-17) 17) SL (E6-15) (E6 15) ↔ E1 (E5-17) (E5 17) Wiring Color P ↔ BR G-Y G Y ↔ BR G W ↔ BR G-W Condition STD Voltage (V) IG ON 10 - 14 1st or 2nd gear 10 - 14 3rd or O/D gear Below 1 IG ON Below 1 2nd or 3rd gear 10 - 14 1st or O/D gear Below 1 IG ON Below 1 Vehicle driving under lock-up position 10 - 14 Pulse signal is output Below 1 ↔ 4 - 5 NC2+ (E4-24) ↔ NC2- (E4-23) R↔G SLN+ (E4-20) ↔ SLN- (E4-19) P-L ↔ Y IG ON 10 - 14 OD1 (E7-24) ↔ E1 (E5-17) GR ↔ BR IG ON 5-6 ODLP (E8-9) (E8 9) ↔ E1 (E5-17) (E5 17) G O ↔ BR G-O L (E6-13) (E6 13) ↔ E1 (E5-17) (E5 17) Y ↔ BR 2 (E6-14) (E6 14) ↔ E1 (E5-17) (E5 17) G Y ↔ BR G-Y R (E6-8) (E6 8) ↔ E1 (E5-17) (E5 17) R B ↔ BR R-B NSW (E7-20) (E7 20) ↔ E1 (E5-17) (E5 17) B W ↔ BR B-W ODMS (E6-12) (E6 12) ↔ E1 (E5-17) (E5 17) G O ↔ BR G-O SPD (E7-22) ↔ E1 (E5-17) V-W ↔ BR Engine is running (Except 2nd gear) Except O/D gear 10 - 14 O/D gear Below 1 IG ON and Shift lever L position 10 - 14 IG ON and Shift lever other than L position Below 1 IG ON and Shift lever 2 position 10 - 14 IG ON and Shift lever other than 2 position Below 1 IG ON and Shift lever R position 10 - 14 IG ON and Shift lever other than R position Below 1 IG ON and Shift lever P or N position 10 - 14 IG ON and Shift lever other than P or N position Below 1 IG ON 10 - 14 IG ON and Press continuously O/D main switch Below 1.5 IG ON and vehicle stationary Below 1.5 Pulse signal is output Below 1.5 ↔ 4 - 5 IG ON and one front wheel is turned slowly 2001 AVALON (RM808U) Author
: Date
: 330 DI-658 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LY-01 Driver buckle switch circuit WIRING DIAGRAM B8 Buckle Switch LH 2 1 Body ECU R-W *3 W-B 6 BC1 *1 R-W 9 ID1 *2 R-W 16 B4 DBKL *4 W-B R-W J14 J/C C C W-B 11 BC1 W-B J11 J/C A A BK *1: w/ Sliding Roof *2: w/o Power Seat *3: w/o Driving Position Memory *4: w/ Driving Position Memory I13657 2001 AVALON (RM808U) Author
: Date
: 814 DI-659 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check driver buckle switch. (See page BE-53 ) NG Replace the driver buckle switch. OK 2 Check wireharness and connector between driver buckle switch and body ground (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
: Date
: 815 DI-666 DIAGNOSTICS - BODY CONTROL SYSTEM DI6M2-01 Diagnosis Circuit CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that DTC output is required. WIRING DIAGRAM Body ECU D2 DLC2 J/B No. 3 Tc 13 3A 4 LG-R 4 3A LG-R 18 B4 Tc 3G 4 LG-R D1 DLC1 J/B No. 4 Tc 11 LG-R 22 II2 LG-R 6 4A 6 4H I13660 2001 AVALON (RM808U) Author
: Date
: 822 DI-667 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC3. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals SIL(7) and CG(4) of DLC3. OK: Voltage: 10 - 14 V ON DLC3 AB0119 N09214 I11292 OK Proceed to next circuit inspection shown in problem symptom table (See page DI-622 ). NG 2 Check harness and connector between body control ECU and DLC3, DLC3 and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace Body Control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 823 DI-639 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LP-01 Door courtesy switch circuit CIRCUIT DESCRIPTION The door courtesy switch goes on when the door is opened and goes off when door is closed. WIRING DIAGRAM D11 Door Courtesy Switch Front LH 1 Body ECU J/B No. 3 17 3D 17 3E R-L R-L 5 B4 DCTY D12 Door Courtesy Switch Front RH 1 J/B No. 4 17 4F 17 4E O O 3 B5 PCTY D13 Door Courtesy Switch Rear LH 2 1 IA1 R-W J/B No. 4 R-W D14 Door Courtesy Switch Rear RH 1 5 4F 14 4F R-W 16 B5 RCTY 4E 5 R-W I13649 2001 AVALON (RM808U) Author
: Date
: 795 DI-640 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of door courtesy light. CHECK: Check that door courtesy light comes on when door opened, and goes off when door is closed. OK: Must be operated normally. OK Proceed to next circuit inspection shown on problem symptom table (See page DI-622 ). NG 2 Check courtesy switch (See page BE-31 ). NG Replace the courtesy switch. OK 3 Check wireharness and connector between courtesy light and body ECU, courtesy switch and body door ECU (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
: Date
: 796 DI-643 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LR-01 Rear door unlock detection switch circuit CIRCUIT DESCRIPTION The door unlock detection switch is built in the door lock motor assembly. This switch is ON when the door lock knob is in the unlock position and OFF when the lock knob is in the lock position. The ECU detects the door lock knob conditions is this circuit. It is used as one of the operating conditions for the key confinement prevention function. WIRING DIAGRAM D15 Door Unlock Detection Switch Rear LH 4 3 L-O W-B Body ECU J/B No. 3 9 BA1 L-O 6 3E 6 3F L-O 5 B5 LSR 3F 19 BA1 8 W-B A J11 J/C A 9 BB1 10 IM2 L-O L-O D16 L-O Door Unlock Detection Switch Rear RH 8 2 1 BB1 W-B W-B BM BK I13651 2001 AVALON (RM808U) Author
: Date
: 799 DI-644 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check door unlock detection switch. (See page BE-82 ) NG Replace the door lock motor. OK 2 Check wireharness and connector between door unlock detection switch and body ECU. (See page IN-30 ) NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table. (See page DI-622 ) 2001 AVALON (RM808U) Author
: Date
: 800 DI-641 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LQ-01 Door lock motor circuit WIRING DIAGRAM D16 Door Lock Motor Rear RH 3 L-B 5 BB1 4 L-R L-B J2 J/C 12 IM2 Body ECU A L-R A A A L-R 2 B5 ACT+ D15 Door Lock Motor Rear LH 5 BA1 2 1 L-B L-R L-R 13 IA1 L-R A 10 BB1 BA1 10 L-R L-B L-B 11 IM2 IA1 5 C L-B C L-B 10 IN1 L-R D18 Door Lock Motor Front RH 5 6 L-R L-B 11 IN1 C 15 B5 ACT- C L-B J3 J/C 3 IB2 2 L-R 1 L-B 9 IB2 L-W 1 B5 ACTD D17 Door Lock Motor Front LH I14523 2001 AVALON (RM808U) Author
: Date
: 797 DI-642 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check door lock motor. (See page BE-82 ) NG Replace the door lock motor. OK 2 Check wireharness and connector between door lock motor and body ECU. (See page IN-30 ) NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table. (See page DI-622 ) 2001 AVALON (RM808U) Author
: Date
: 798 DI-668 DIAGNOSTICS - BODY CONTROL SYSTEM DI6M3-01 Daytime running light No.2, 3 and 4 relay circuit WIRING DIAGRAM Engine Room R/B No. 2 DRL No. 2 Relay 4 3 2 R R R 1 2 R-B 10 B4 DRL R-B R-B 2 R 2 2 HEAD RH-UPR HEAD LH-UPR 2 1 1 2 2 H1 Headlight High LH 9 1 2 IF1 IF1 L G H2 Headlight High RH 9 1 2 IC1 R-W G G 2 L 10 EA1 L R-W Engine Room R/B No. 2 G G W-R 5 EA1 W-B DRL No. 4 Relay 2 EA1 W-R 8 EA1 Engine Room R/B No. 7 8 IF1 R 2 2 6 EA1 R-B Body ECU W-R 2 2 2 1 2 4 3 DRL No. 3 Relay 1 2 2 3 5 10 IF3 4 Engine Room J/B 2E 4 1 2E MAIN 2 2 1 2G 2 W-B 2 W-B 2 2 W-B 5 B B 11 EA1 W-B Engine Room R/B No. 5 R-B FL MAIN R-W 2 R-L Battery EA1 9 1 FL Block1 F6 F7 R-B 2 DRL 1 5 5 5 R 5 R-L HEAD Relay 3 4 2 1 5 EA to Headlight Low LH and RH to Body ECU I14524 2001 AVALON (RM808U) Author
: Date
: 824 DI-669 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check D.R.L relay No.2,3 and 4. NG Replace the D.R.L relay No.2, 3 and4. OK 2 Check wire harness and connector between D.R.L relay and Body ECU, battery and D.R.L relay (See page IN-30 ). NG Repair or replace wire harness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
: Date
: 825 DI-635 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LN-01 Headlight relay circuit CIRCUIT DESCRIPTION Head light relay will be ”ON” by operating the headlight switch. The transistor which activates the taillight relay has two sorts: one activates directly by the headlight switch for fail safe and the other activates by CPU. the one that activates by CPU has two systems and prevents the headlight from turning off at the time of one system trouble in the automatic operation circuit. WIRING DIAGRAM Body ECU Engine Room R/B No. 5 Headlight Relay 4 3 5 Driver Side J/B 5 R-B R 2 5 1 5 4 1J HRLY 8 R-B Engine Room R/B No. 5 5 Engine Room J/B R-B 1 2E 2 2G 2 MAIN 1 1 HEAD RH LWR B B 1 F6 FL Block FL MAIN Battery 2 1 F7 HEAD LH LWR 2 5 5 3 IF1 R-B G-W G-W H4 Headlight 1 Low RH W-B *1 EB: Canada *1 EA: Except Canada 2 1 H3 Headlight Low LH 1 W-B ED 2 I13647 2001 AVALON (RM808U) Author
: Date
: 791 DI-636 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check headlight relay (See page BE-19 ). NG Replace the headlight relay. OK 2 Check wireharness and connector between headlight relay and Body ECU, battery and headlight relay (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
: Date
: 792 DI-672 DIAGNOSTICS - BODY CONTROL SYSTEM DI6M4-01 Horn circuit CIRCUIT DESCRIPTION The horn is connected to the body ECU and activated by the body ECU during warning of the theft deterrent system. WIRING DIAGRAM Engine Room J/B Body ECU Driver Side J/B HORN RELAY 1 2 2 2G HORN 5 3 2C 1 1J G-B 3 2F 3 10 11 1C G-W B G-B FL Block 1 1 F7 F6 6 G-W B Battery FL MAIN HORN 1 H5 Horn LH H6 Horn RH C12 Horn Switch (in Combination Switch) I13640 2001 AVALON (RM808U) Author
: Date
: 828 DI-673 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check horn. PREPARATION: Connect positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2 of theft deterrent horn connector. OK: Theft deterrent horn blows. 1 (+) 2 (-) N14682 NG Replace the horn. OK 2 Check wireharness and connector between horn relay and body ECU, battery and horn relay. (See page IN-30 ) NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table. (See page DI-622 ) 2001 AVALON (RM808U) Author
: Date
: 829 DI-655 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LX-01 Illumination circuit CIRCUIT DESCRIPTION Receiving the courtesy signal from either of the door ECU, the Body ECU will make the interior light, ignition light, and foot light come on. 2001 AVALON (RM808U) Author
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: 811 DI-656 DIAGNOSTICS - BODY CONTROL SYSTEM WIRING DIAGRAM V11 Vanity Light RH J/B No.4 10 4C 1 4C 1 4F 1 4D P-L 1 2 P-L W-B P-L P-L V10 Vanity Light RH Driver Side J/B DOME 7 1D W-B P-L Engine Room J/B DCC 2 2G B 1 F7 IG1 5 1 2C P-L 13 4F R-B 2 2 I14 Ignition Key Cylinder Light Driver Side J/B IG1 RELAY 10 GAUGE No. 1 2 1 1D 1 1G 4 1C 3 1B 4 3 M7 ON 1 8 G-R IG1 OFF G-R DOOR G-R G-R Driver Side J/B Open Door 10 M7 W 4 FL Block 1 F10 7 IF1 AM1 2 IG1 W-L W-L Engine Room R/B No.5 IG 5 ALT B 1 2H 3 1C 5 ILL 25 B5 AJAR R G-W 23 B5 DBEW 11 B5 PBEW G-R Passenger Seat Belt 1 FL MAIN F6 B 1 F8 Engine Room J/B 2 AM1 1 5 2 M7 4 Driver Seat Belt 2 M6 M6 W-B G-R IG1 11 G-R Multi Display R-B I15 Ignition Switch 2 I17 Interior Light P-L B J/B No.4 3 W-B OFF DOOR 1 1 4 4D ON 3 1 F6 FL MAIN BL P9 Personal Light W-L FL Block Battery 1 2 9 1J P-L W-R Body ECU B-L Battery 1 2G I13641 2001 AVALON (RM808U) Author
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: 812 DI-657 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check illumination light (Interior light system)(See page BE-31 ). NG Replace the failure light. OK 2 Check wireharness and connector between each illumination light and Body ECU, battery and each illumination light (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
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: 813 DI-637 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LO-01 Key unlock warning switch circuit CIRCUIT DESCRIPTION The key unlock warning switch goes on when the ignition key is inserted in the key cylinder and goes off when the ignition key is removed. The ECU operates the key confinement prevention function while the key unlock warning switch is on. WIRING DIAGRAM Body ECU J/B No. 3 22 3D 9 3D U1 Key Unlock Warning Switch 1 W-B 2 R-Y J/B No. 4 2 4B 11 4A R-Y 17 B4 KSW W-B IG I13648 2001 AVALON (RM808U) Author
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: 793 DI-638 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check key unlock warning switch (See page BE-16 ). NG Replace the key unlock warning switch. OK 2 Check wireharness and connector between key unlock warning switch and Body ECU (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
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: 794 DI-631 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LL-01 Light control switch circuit WIRING DIAGRAM Body ECU 13 B4 HU B-R 2 B4 HF B-W 3 B4 HEAD R-Y 14 B4 TAIL P G-O 7 OFF 8 13 14 4 B4 AUTO 12 C13 TAIL Combination Switch
Light Control Switch
Dimmer Switch HEAD AUTO LOW HIGH FLASH 16 W-B IG I13645 2001 AVALON (RM808U) Author
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: 787 DI-632 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check headlight control switch (See page BE-19 ). NG Replace the headlight control switch. OK 2 Check wireharness and connector between headlight control switch and Body ECU (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
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: 788 DI-649 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LU-01 Luggage opener motor circuit WIRING DIAGRAM Body ECU L9 Luggage Compartment Light Switch 1 R-W J/B No. 4 12 4E 2 L L7 Luggage Compartment Door Unlock Motor 12 4C 4 IK1 R L 6 B4 LGC 25 B4 TR+ I13654 2001 AVALON (RM808U) Author
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: 805 DI-650 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check luggage opener motor. (See page BE-82 ) NG Replace the luggage opener motor. OK 2 Check wireharness and connector between luggage opener motor and body ECU. (See page IN-30 ) NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table. (See page DI-622 ) 2001 AVALON (RM808U) Author
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: 806 DI-647 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LT-01 Luggage opener switch circuit WIRING DIAGRAM L1 Luggage Compartment Door Opener Main Switch 2 1 L-B L2 Luggage Compartment Door Opener Switch 2 1 L Body ECU 18 B5 TKL W-B J/B No. 4 7 4H 7 4B W-B A J9 J/C IJ I13653 2001 AVALON (RM808U) Author
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: 803 DI-648 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check luggage opener switch and main switch (See page BE-82 ). NG Replace the luggage opener switch and main switch. OK 2 Check wireharness and connector between luggage opener switch and Body ECU (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
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: 804 DI-670 DIAGNOSTICS - BODY CONTROL SYSTEM DI29Y-05 Parking brake switch circuit WIRING DIAGRAM Body ECU P3 Parking Brake Switch 1 J/B No. 3 Y-G 5 3B 5 3A Y-G 15 B4 PKB I13643 2001 AVALON (RM808U) Author
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: 826 DI-671 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check parking brake switch (See page BE-53 ). NG Replace the parking brake switch. OK 2 Check wireharness and connector between parking brake switch and body ECU. (See page IN-30 ) NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table. (See page DI-622 ) 2001 AVALON (RM808U) Author
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: 827 DI-660 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LZ-01 Passenger buckle switch and seat belt warning occupant detection sensor CIRCUIT DESCRIPTION This circuit detects the conditions of the passenger buckle switch and the seat belt warning occupant detection sensor, and makes the passenger seat belt warning flash. WIRING DIAGRAM B9 Buckle Switch RH *2 2 Body ECU 1 W-B G 6 BD1 6 IM2 *1 G *1 G S11 *1 11 BD1 *1 *1 2 Seat Belt Warning Occupant Detection Sensor 1 W-R W-B 8 BD1 W-B *2 R-W W-R 4 B5 SEAT W-R W-B W-B 2 IM2 *1 *2 *2 *1 G *2 W-B *2 17 B5 PBKL *1: w/ Sliding Roof *2: w/o Power Seat A J10 J/C BN I13658 2001 AVALON (RM808U) Author
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: 816 DI-661 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check passenger buckle switch. (See page BE-53 ) NG Replace the passenger buckle switch. OK 2 Check seat belt warning occupant Detection sensor. (See page BE-53 ) NG Replace the seat belt warning occupant Detection sensor. OK 3 Check wireharness and connector between seat belt warning occupant Detection sensor and body ECU, passenger buckle switch and seat belt warning occupant Detection sensor, passenger buckle switch and body ground. NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table. (See page DI-622 ) 2001 AVALON (RM808U) Author
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: 817 DI-664 DIAGNOSTICS - BODY CONTROL SYSTEM DI6M1-01 Park/Neutral Position Switch Circuit CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever p position and sends signals to the Body ECU. WIRING DIAGRAM P1 Park/Neutral Position Switch 2 PL 7 G-W R-L *2 20 II1 Body ECU J/B No. 3 3 II2 18 3A G-W D6 Diode A/T Indicator Light *2 2 3 R-Y R-L R-L *1 18 3H G-W J/B No. 3 20 3D 20 3C 7 3C Driver Side J/B 1 1G W 4 1C W-R IG1 RELAY 1 2 3 4 IG1 R-L GAUGE No. 2 1 1C 3 1B 4 I15 Ignition Switch 1 B4 P J/B No. 5 AM1 2 W-L 7 IF1 W-L 5 2 AM1 1 5 W-B B FL Block 1 F10 1 F6 B 1 F8 B-L Engine Room J/B 1 1 2H 2G ALT FL MAIN Battery IG *1: FLOOR SHIFT *2: COLUMN SHIFT I13659 2001 AVALON (RM808U) Author
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: 820 DI-665 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check A/T shift operation. CHECK: Check that the A/T shift operates normally. NG Proceed to AT troubleshooting. (See page DI-158 ) OK 2 Check harness and connector between Body ECU and park/neutral position switch (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace Body ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 821 DI-627 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LK-01 CIRCUIT INSPECTION Power source circuit CIRCUIT DESCRIPTION This circuit provides power to operate the Body ECU. 2001 AVALON (RM808U) Author
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: 783 DI-628 DIAGNOSTICS - BODY CONTROL SYSTEM WIRING DIAGRAM Engine Room J/B DCC 2 2G 1 2C W-L DOOR No. 2 12 2C L-R 5 3C W-G B FL Block 1 F6 1 F10 W 1 F8 ALT Engine Room J/B B-L Engine Room R/B No. 5 AM1 1 2 5 5 W-L W-L DOOR No. 1 1 IG1 RELAY 3 1B 1 2 4 3 W-B ECU-IG No. 2 2 J4 J/C B B W-B W-B Battery ACC BDR1 SIG 4 1C Ignition Switch FL MAIN 3 BDR2 R-G R-G IG1 4 W-R ECU-ACC 1 1G 3 ACC 2 AM1 7 10 1C B 7 IF1 ECU-B 5 1J L-R W B W-G 24 B4 B 9 1J W-L 1 2G 1 2H 14 3D Driver Side J/B 9 1B 1 F7 Body ECU J/B No. 3 W-B IG 11 B4 GND2 14 B5 GND1 IF I13637 2001 AVALON (RM808U) Author
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: 784 DI-629 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check ECU-ACC, DOOR No. 1, DOOR No. 2, ECU-IG No. 2, ECU-B No. 1 and ECU-B No. 2 fuse. CHECK: Check continuity of ECU-ACC, DOOR No. 1, DOOR No. 2, ECU-IG No. 2, ECU-B No. 1 and ECU-B No. 2 fuse. OK: Continuity NG Replace the failure fuse. OK 2 Check voltage between terminals ACC, B, BDR 1, BDR 2, SIG and GND or GND2 of Body ECU connector. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals ACC, SIG, BDR 1, and GND, GND2. OK: Voltage: 10 - 14V PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the Body ECU connector. CHECK: Measure voltage between terminals B, BDR 2, BSUB and GND, GND2. OK: Voltage: 10 - 14V OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). NG 2001 AVALON (RM808U) Author
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: 785 DI-630 DIAGNOSTICS 3 - BODY CONTROL SYSTEM Check wireharness and connector between Body ECU and body ground (See page IN-30 ). NG Repair or replace wireharness or connector. OK Check and repair wireharness and connector between Body ECU and battery (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 786 DI-645 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LS-01 Rear power window switch circuit CIRCUIT DESCRIPTION Power window switch circuit can be checked using DTC check. (Refer to DI-738 ) WIRING DIAGRAM P10 J11 J/C Body ECU Power WIndow Control Switch Rear LH 12 3 BA1 E W-B P14 1 2 2 D R A W-B BK G Power Window 5 Motor LH DOWN UP U B 1 Y-R 6 G-Y 4 P Driver Side J/B 3 BA1 2 BA1 Y-R G-Y L-Y 18 ID1 17 ID1 1 F6 ALT 6 IB2 B P11 Power WIndow Control Switch Rear RH FL MAIN 12 BB1 3 E W-B B 4 LG P15 2 Battery BM G-Y 10 1A RR P/W 1 1L LG P-B FL Block W-B 22 B4 RLU RL P/W 12 1L 2 1 F10 Y-R 1 IA1 1G 1 W 8 B4 RLD P PWR RELAY 3 5 1 1 BA1 2 1 R D 1 DOWN R-B Power WIndow Motor RH G 5 U UP 7 D19 WLSW P-B 2 BB1 1 BB1 3 6 BB1 G-B L-W R-B G-B Driver Door ECU 1 IM2 4 IM2 3 IM2 R-B G-B 22 B5 RRD 10 B5 RRU I13652 2001 AVALON (RM808U) Author
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: 801 DI-646 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check the power window switch. (See page BE-73 ) NG Replace the power window switch. OK 2 Check wireharness and connector between power window switch and Body ECU. (See page IN-30 ) NG Repair or replace wireharness or connector. OK 3 Check wireharness and connector between power window switch and power window master switch. (See page IN-30 ) NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table. (See page DI-622 ) 2001 AVALON (RM808U) Author
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: 802 DI-662 DIAGNOSTICS - BODY CONTROL SYSTEM DI6M0-01 Stop light switch circuit CIRCUIT DESCRIPTION The Body ECU is detecting the condition of the stop light switch. WIRING DIAGRAM Body ECU S4 Stop Light Switch Engine Room J/B STOP 11 1 1G 1D 1 2 R G-W 3 1D 11 STOP Engine Room J/B W 1 F10 ALT 1 F6 FL MAIN B Battery I13638 2001 AVALON (RM808U) Author
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: 818 DI-663 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check stop light switch. (See page BE-36 ) NG Replace the stop light switch. OK 2 Check wireharness and connector between stop light switch and Body ECU, battery and stop light switch (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
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: 819 DI-633 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LM-01 Taillight relay circuit CIRCUIT DESCRIPTION Taillight relay will be ”ON” by operating the taillight switch. The transistor which activates the tail light relay has two sorts: one activates by the tail light switch for fail safe and the other activates by CPU. WIRING DIAGRAM Body ECU Driver Side J/B TAIL RELAY FL Block 1 F6 ALT 1 F10 W 1 1G 5 3 1 2 9 TRLY B FL MAIN to Taillight Battery I13646 2001 AVALON (RM808U) Author
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: 789 DI-634 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check taillight relay (See page BE-19 ). NG Replace the taillight relay. OK 2 Check wireharness and connector between taillight relay and Body ECU, battery and taillight relay (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
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: 790 DI-653 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LW-01 Wireless door lock buzzer circuit WIRING DIAGRAM Body ECU W6 Wireless Door Lock Buzzer 1 W-B Buzzer 2 P-L 20 B4 BZ A J9 J/C IJ I13656 2001 AVALON (RM808U) Author
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: 809 DI-654 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check wireless door lock buzzer. (See page BE-91 ) NG Replace the wireless door lock buzzer. OK 2 Check wireharness and connector between wireless door lock buzzer and Body ECU, Body ECU and wireless door lock buzzer (See page IN-30 ). NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). 2001 AVALON (RM808U) Author
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: 810 DI-651 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LV-01 Wireless door lock tuner circuit CIRCUIT DESCRIPTION The signal from the transmitter will be input to the body ECU through RDA line. RDA line is diagnosed by the Body ECU, so check DTC also in case of the failure of the wireless function. WIRING DIAGRAM D8 Wireless Door Control Receiver J/B No. 4 W-B 8 4F 8 4E 1 RDA 2 E L-W W-B Body ECU 9 IK2 L-W 21 B4 RDA J/B No. 4 1 4D 1 4E 5 P-L PRG 3 +B G-R 20 IK2 G-R 7 B4 PRG P-L Driver Side J/B DOME 7 1D 9 1J B Engine Room J/B J6 J/C 2 2G B DCC W-L FL MAIN 1 2C W-B B II FL Block 1 1 F7 F6 Battery B I13655 2001 AVALON (RM808U) Author
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: 807 DI-652 DIAGNOSTICS - BODY CONTROL SYSTEM INSPECTION PROCEDURE 1 Check that DTC 42 is not output. NG Check the RDA line. OK 2 Check wireharness. PREPARATION: Disconnect connectors of wireless door lock tuner and Body ECU. CHECK: Check continuity between terminals PRG of wireless door lock tuner and PRG of Body ECU. OK: Continuity NG Repair or replace wireharness. OK 3 Check the wireless door lock tuner. CHECK: Replace the wireless door lock tuner and check if it recovers normally. OK: Must be recovered normally. NG Proceed to next circuit inspection shown on problem symptoms table (See page DI-622 ). OK Failure of the original wireless door lock tuner. 2001 AVALON (RM808U) Author
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: 808 DI-616 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LG-01 CUSTOMER PROBLEM ANALYSIS CHECK BODY CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Brought in / / Date Problem First Occurred Frequency Problem Occurs Weather Conditions When Problem Occurred km Mile Odometer Reading / Constant Once only / Sometimes ( Weather Fine Cloudy Various/ Others Rainy Outdoor Temperature Hot Warm Cool Cold (Approx. °F ( °C)) times per day, month) Snowy Key Unlock Warning System Headlight and Taillight System (Light Auto Turn-of f system Daytime Running Light System) Combination Meter Luggage Compartment Door Opener System Automatic Light Control System Malfunction System Illuminated Entry System Theft Deterrent System Seat Belt Warning Power Window Control System Power Door Lock Control System Auto Lock/Unlock System Wireless Door Lock Control System Others (Buzzer etc.) 2001 AVALON (RM808U) Author
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: 772 DI-615 DIAGNOSTICS - BODY CONTROL SYSTEM BODY CONTROL SYSTEM DI6LF-01 HOW TO PROCEED WITH TROUBLESHOOTING HINT: This ECU is connected to the multiplex communication system. Therefore, be sure to check that there is no troubles in the multiplex communication system before performing the trouble shooting. Vehicle Brought to Workshop Titles inside are titles of pages in this manual, with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. 1 Customer Problem Analysis P.DI-616 Symptom does not occur 2 Problem Symptom Confirmation 3 Symptom Simulation P. IN-20 Symptom occur 4 Multiplex communication system inspection * P. DI-718 *: Confirm that there is no trouble by basic inspection and DTC check 5 Problem Symptoms Table P. DI-622 6 Circuit Inspection P. DI-627 - DI-666 Identification of Problem 7 Repair 8 Confirmation Test End Step 6, 8 : Diagnostic steps permitting the use of the hand-held tester . 2001 AVALON (RM808U) Author
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: 771 DI-617 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LH-01 PARTS LOCATION Engine Room Junction Block
Headlight Control Relay Ignition Switch
Key Unlock Warning Switch Light Control Switch Luggage Compartment Door Opener Switch DLC3 Instrument Panel Junction Block
Body ECU
DOME Fuse I11666 2001 AVALON (RM808U) Author
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: 773 DI-618 DIAGNOSTICS - BODY CONTROL SYSTEM Park/Neutral Position Switch Front Personal Light Vanity Light Wireless Door Lock Buzzer Rear Power Window Switch Room Light Rear Power Seat Switch Door Lock Assembly
Door Lock Motor
Door Unlock Detection Switch Door Courtesy Switch Luggage Compartment Door Opener Motor and Courtesy Switch Door Courtesy Switch Door Courtesy Light Door Lock Assembly
Door Lock Motor
Door Unlock Detection Switch Passenger Seat Belt Occupant Detection Sensor Buckle Switch Door Courtesy Light Wireless Door Lock Receiver I13586 2001 AVALON (RM808U) Author
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: 774 DI-622 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LJ-01 PROBLEM SYMPTOMS TABLE IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH: Symptom Suspect Area See page Ignition switch is not set to each position. 1. Ignition switch 2. Power source circuit BE-16 DI-627 Key unlock warning system does not operate. (The buzzer does not sound when the driver’s door is opened with the ignition OFF and key inserted) 1. 2. 3. 4. 5. 6. 7. DI-627 DI-637 DI-639 DI-676 DI-718 IN-30 IN-30 Key unlock warning system does not operate. (The buzzer sounds when the ignition key is ACC or ON) 1. Ignition switch 2. Power source circuit 3. Wire harness Power source circuit Key unlock warning switch circuit Door courtesy switch circuit Driver door ECU Multiplex communication circuit Body ECU Wire harness BE-16 DI-627 IN-30 HEADLIGHT AND TAILLIGHT SYSTEM (USA): Symptom Suspect Area See page Only one side headlight does not light. 1. HEAD-(LH, RH) fuse 2. Headlight bulb 3. Wire harness BE-9 IN-30 Headlight does not light. 1. 2. 3. 4. 5. HEAD-(LH, RH) fuse Headlight control relay circuit Light control switch circuit Headlight bulb Wire harness BE-9 DI-635 DI-631 IN-30 ”Lo-Beam” does not light. 1. 2. 3. 4. Headlight bulb Headlight dimmer switch Light control switch circuit Wire harness DI-631 DI-631 IN-30 ”Hi-Beam” does not light. 1. 2. 3. 4. Headlight bulb Headlight dimmer switch Light control switch circuit Wire harness DI-631 DI-631 IN-30 ”Flash” does not light. 1. Headlight dimmer switch 2. Wire harness DI-631 IN-30 Only one side taillight does not light. 1. Taillight bulb 2. Wire harness IN-30 Taillight does not light. 1. 2. 3. 4. 5. BE-9 DI-633 DI-631 IN-30 IN-30 Rear Combination light does not light. 1. Bulb 2. Light failure sensor 3. Wire harness TAIL fuse Taillight control relay circuit Light control switch circuit Body ECU Wire harness BE-53 IN-30 2001 AVALON (RM808U) Author
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: 778 DI-623 DIAGNOSTICS - BODY CONTROL SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM (CANADA): Symptom Suspect Area See page Only one side headlight does not light. 1. Headlight bulb 2. HEAD LWR (LH, RH) fuse 3. Wire harness BE-9 IN-30 Headlight does not light. 1. 2. 3. 4. Headlight bulb Headlight control relay circuit Light control switch circuit Wire harness DI-635 DI-631 IN-30 ”Lo-Beam” does not light. 1. 2. 3. 4. 5. Headlight bulb HEAD LWR (LH, RH) fuse Headlight control relay circuit Headlight dimmer switch Wire harness BE-9 DI-635 DI-631 IN-30 ”Hi-Beam” does not light. 1. 2. 3. 4. 5. 6. Headlight bulb HEAD UPR (LH, RH) fuse DRL fuse D.R.L. relay No.2, 3 and 4 relay circuit Headlight dimmer switch Wire harness BE-9 BE-9 DI-668 DI-631 IN-30 ”Flash” does not light. 1. 2. 3. 4. 5. 6. Headlight bulb HEAD UPR (LH, RH) fuse DRL fuse (R/B No.7) D.R.L. relay No.2, 3 and 4 relay circuit Headlight dimmer switch Wire harness BE-9 BE-9 DI-668 DI-631 IN-30 Headlight does not light with engine running and light control SW OFF. 1. 2. 3. 4. 5. 6. DOME fuse GAUGE fuse DRL fuse Parking brake switch circuit Generator Wire harness BE-9 BE-9 BE-9 DI-670 CH-9 IN-30 Only one side taillight does not light. 1. Bulb 2. Wire harness IN-30 Taillight does not light. 1. 2. 3. 4. 5. BE-9 DI-633 DI-631 IN-30 IN-30 Rear Combination light does not light. 1. Taillight bulb 2. Light failure sensor 3. Wire harness TAIL fuse Taillight control relay circuit Light control switch circuit Body ECU Wire harness BE-53 IN-30 AUTO TURN OFF SYSTEM: Symptom ”Auto turn-off system” does not operate. Suspect Area 1. 2. 3. 4. See page Drivers door courtesy switch circuit Driver door ECU Multiplex communication circuit Body ECU DI-639 DI-676 DI-718 IN-30 2001 AVALON (RM808U) Author
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: 779 DI-624 DIAGNOSTICS - BODY CONTROL SYSTEM INTERIOR LIGHT SYSTEM: Symptom Suspect Area See page Only one light does not light up. 1. Bulb 2. Wire harness IN-30 Room light does not light up (All). 1. DOME fuse 2. Body ECU 3. Wire harness BE-9 IN-30 IN-30 Room light does not light up (Room light only). 1. Bulb 2. Room light assembly 3. Wire harness BE-31 IN-30 1. Illumination circuit 2. Door courtesy switch circuit 3. Door unlock detection switch circuit 4. Body ECU 5. Wire harness DI-655 DI-639 DI-643 DI-686 DI-708 IN-30 IN-30 Front personal light does not light up. 1. 2. 3. 4. Bulb Front personal light Body ECU Wire harness BE-31 IN-30 IN-30 Rear personal light does not light up. 1. Bulb 2. Rear personal light BE-31 Vanity light does not light up. 1. Bulb 2. Vanity light 3. Wire harness BE-31 IN-30 Luggage room light does not light up. 1. 2. 3. 4. 5. Bulb Luggage compartment light Luggage compartment door courtesy switch circuit Body ECU Wire harness BE-31 BE-31 IN-30 IN-30 Seat Belt warning light does not light up. 1. 2. 3. 4. 5. Warning light bulb Buckle switch circuit Body ECU Meter circuit plate Wire harness BE-43 BE-53 IN-30 BE-43 IN-30 Open Door warning light does not light up. 1. 2. 3. 4. 5. 6. DOME fuse Warning light bulb Door courtesy switch circuit Illumination circuit Meter circuit plate Wire harness BE-9 BE-43 DI-639 DI-655 BE-43 IN-30 ”Illuminated Entry System” does not operate. COMBINATION METER: Symptom Suspect Area See page 2001 AVALON (RM808U) Author
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: 780 DI-625 DIAGNOSTICS - BODY CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM: Symptom Suspect Area See page All power window system does not operate. 1. Power main relay 2. Driver door control system 3. Passenger door control system BE-73 DI-676 DI-677 Driver door window system dose not operate. 1. 2. 3. 4. Driver door control ECU Door lock motor circuit (Driver) Body ECU Wire harness DI-692 DI-692 DI-641 - Passenger door window system dose not operate. 1. 2. 3. 4. Passenger door control ECU Door lock motor circuit (Passenger) Body ECU Wire harness DI-714 DI-714 DI-641 - Rear power window control system does not operate. (Both left and right) 1. Body ECU 2. Wire harness IN-30 IN-30 Rear power window control system does not operate. (Only one side) 1. Rear power window switch circuit 2. Body ECU 3. Wire harness DI-645 IN-30 IN-30 POWER DOOR LOCK CONTROL SYSTEM: Symptom Suspect Area See page ”Door lock system” does not operate at all. 1. 2. 3. 4. 5. GAUGE Fuse DOOR Fuse Driver door control ECU Body ECU Wire Harness DI-676 IN-30 - Door lock system does not operate by manual switch. 1. Driver door control ECU 2. Body ECU 3. Wire Harness DI-676 IN-30 - Door lock system does not operate by door key. 1. 2. 3. 4. Door Key Lock and Unlock Switch circuit Body ECU Wire Harness Door Lock Link Disconnected DI-637 IN-30 - Fault in 2-Operation unlock function of Driver’s side door key lock and unlock switch. 1. Door Key Lock and Unlock Switch circuit 2. Body ECU 3. Wire Harness DI-637 IN-30 - Only one door lock does not operate. 1. Door Lock Motor circuit 2. Wire Harness DI-641 - Key confinement prevention function does not operate. 1. Key unlock warning switch circuit 2. Driver door control system 3. Passenger door control system DI-637 DI-676 DI-677 Auto lock/unlock system does not operate. 1. Door lock motor circuit 2. Driver door control system 3. Passenger door control system DI-641 DI-676 DI-677 LUGGAGE COMPARTMENT DOOR OPENER SYSTEM: Symptom Luggage compartment door opener system does not operate. Suspect Area See page 1. Luggage door switch circuit 2. Luggage door motor circuit 3. Body ECU DI-647 DI-649 IN-30 2001 AVALON (RM808U) Author
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: 781 DI-626 DIAGNOSTICS - BODY CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM: Symptom Suspect Area See page 1. Wireless door lock control receiver circuit 2. Key unlock warning switch circuit 3. Body ECU DI-651 DI-637 IN-30 1. Door key lock and unlock switch circuit 3. Body ECU DI-688 DI-710 DI-686 DI-708 IN-30 Automatic lock function operates even if any door is opened within 30 seconds after all doors are unlocked by wireless door lock control system. 1. Door courtesy switch circuit 2. Body ECU DI-639 IN-30 Wireless door lock operates, but the buzzer does not sound. 1. Wireless door lock buzzer circuit 2. Wireless door lock receiver circuit 3. Body ECU DI-653 DI-651 IN-30 Buzzer sound, but wireless door lock function does not operate. 1. Wireless door lock receiver circuit 2. Body ECU DI-651 IN-30 Luggage compartment door opener wireless function. 1. Luggage compartment door opener motor circuit 2. Body ECU DI-649 IN-30 All functions of wireless door lock control system do not operate. Lock or unlock function does not operate. 2. Door unlock detection switch circuit POWER MIRROR CONTROL SYSTEM: Symptom Suspect Area See page Mirror does not operate. 1. 2. 3. 4. 5. CIG/RAD fuse Mirror switch circuit Mirror motor Body ECU Wire harness BE-9 DI-515 BE-1 14 IN-30 IN-30 Mirror operates abnormally. 1. 2. 3. 4. Mirror switch circuit Mirror motor Body ECU Wire harness DI-515 BE-1 14 IN-30 IN-30 HORN SYSTEM: Symptom Suspect Area See page Horn system does not operate. 1. HORN fuse 2. Horn circuit 3. Wire harness BE-9 DI-672 IN-30 Horns blow all the time. 1. Horn circuit 2. Wire harness DI-672 IN-30 One horn operates but the other horn does not operate. 1. Horn circuit 2. Wire harness DI-672 IN-30 Horns operate abnormally. 1. Horn circuit 2. Wire harness DI-672 IN-30 2001 AVALON (RM808U) Author
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: 782 DI-619 DIAGNOSTICS - BODY CONTROL SYSTEM DI6LI-01 TERMINALS OF ECU B4 B5 I11362 I11578 I11577 Terminal No. (Symbols) I13264 Wring Color 1 ↔ B5-14 (BDR1 ↔ GND1) - ↔ W-B 2 ↔ B5-14 B5 14 (SIG ↔ GND1) - ↔ W-B WB 3 ↔ B5-14 B5 14 (ACC ↔ GND1) - ↔ W-B WB 5 ↔ B5-14 B5 14 (ILL ↔ GND1) - ↔ W-B WB 7 ↔ B5-14 (BDR2 ↔ GND1) - ↔ W-B 8 ↔ B5-14 B5 14 (HEAD ↔ GND1) - ↔ W-B WB 9 ↔ B5-14 B5 14 (TRLY ↔ GND1) - ↔ W-B WB 10 ↔ B5 B5-14 14 (HORN ↔ GND1) - ↔ W-B WB 11 ↔ B5 B5-14 14 (STOP ↔ GND1) - ↔ W-B WB B4 1 ↔ B5 B4-1 B5-14 14 (P ↔ GND1) G W ↔ W-B G-W WB B4 2 ↔ B5 B4-2 B5-14 14 (HF ↔ GND1) B W ↔ W-B B-W WB B4 3 ↔ B5 B4-3 B5-14 14 (HEAD ↔ GND1) R Y ↔ W-B R-Y WB B4 4 ↔ B5 B4-4 B5-14 14 (AUTO ↔ GND1) G O ↔ W-B G-O WB B4 5 ↔ B5 B4-5 B5-14 14 (DCTY ↔ GND1) R L ↔ W-B R-L WB B4 6 ↔ B5 B4-6 B5-14 14 (LGC ↔ GND1) R ↔ W-B WB Condition STD Voltage (V) Constant 10 - 14 V Ignition switch OFF or ACC Below 1 V Ignition switch ON 10 - 14 V Ignition switch OFF Below 1 V Ignition switch ACC or ON 10 - 14 V Each door are opened Below 1 V All door are closed 10 - 14 V Constant 10 - 14 V Ignition switch ON and light control switch HEAD Below 2 V Ignition switch ON and light control switch OFF 10 - 14 V Ignition switch ON and light control switch TAIL Below 2 V Ignition switch ON and light control switch OFF 10 - 14 V Horn switch position is ON Below 1 V Horn switch position is OFF 10 - 14 V Brake pedal is pushed 10 - 14 V Brake pedal is released Below 1 V Park/neutral position switch is except P position 10 - 14 V Park/neutral position switch is P position Below 1 V Headlight control switch position is FLASH Below 1 V Headlight control switch position is except FLASH 10 - 14 V Light control switch HEAD Below 2 V Light control switch OFF or TAIL 10 - 14 V Light control switch AUTO Below 2 V Light control switch OFF, TAIL or HEAD 10 - 14 V Driver door closed 10 - 14 V Driver door opened Below 1 V Luggage compartment door is opened Below 1 V Luggage compartment door is closed 10 - 14 V 2001 AVALON (RM808U) Author
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: 775 DI-620 DIAGNOSTICS - BODY CONTROL SYSTEM B4 7 ↔ B5 B4-7 B5-14 14 (PRG ↔ GND1) G R ↔ W-B G-R WB Wi l Wireless d door llock k receiver i communication i ti circuit i it B4 8 ↔ B5 B4-8 B5-14 14 (RLD ↔ GND1) Y R ↔ W-B Y-R WB R Rear left l ft side id power window i d DOWN operation ti B4-9 ↔ B5-14 (MPX2 ↔ GND1) G-W ↔ W-B Multiplex communication circuit B4 10 ↔ B5 B4-10 B5-14 14 (DRL ↔ GND1) R B ↔ W-B R-B WB B4-1 1 ↔ Body ground (GND2 ↔ Body ground) W-B B4-13 B4 13 ↔ B5-14 B5 14 (HU ↔ GND1) B-R ↔ W-B B4 14 ↔ B5 B4-14 B5-14 14 (TAIL ↔ GND1) P ↔ W-B WB B14 15 ↔ B5 B14-15 B5-14 14 (PKB ↔ GND1) Y G ↔ W-B Y-G WB B4 16 ↔ B5 B4-16 B5-14 14 (DBKL ↔ GND1) R W ↔ W-B R-W WB B4 17 ↔ B5 B4-17 B5-14 14 (KSW ↔ GND1) R Y ↔ W-B R-Y WB B4 18 ↔ B5 B4-18 B5-14 14 (TC ↔ GND1) LG R ↔ W-B LG-R WB B4 19 ↔ B5 B4-19 B5-14 14 (GSW ↔ GND1) L ↔ W-B WB B4 20 ↔ B5 B4-20 B5-14 14 (BZ ↔ GND1) P L ↔ W-B P-L WB B4 21 ↔ B5 B4-21 B5-14 14 (RDA ↔ GND1) L W ↔ W-B L-W WB B4-22 ↔ B5-14 (RLU ↔ GND1) G-Y ↔ W-B B4-23 ↔ B5-14 (MPX1 ↔ GND1) V ↔ W-B B4-24 ↔ B5-14 (B ↔ GND1) W-G ↔ W-B B4 25 ↔ B5 B4-25 B5-14 14 (TR+ ↔ GND1) L ↔ W-B WB B5-1 ↔ B5-14 (ACTD ↔ GND1) L-W ↔ W-B B5-2 ↔ B5-15 (ACT+ ↔ ACT-) L-R ↔ L B5 3 ↔ B5 B5-3 B5-14 14 (PCTY ↔ GND1) O ↔ W-B WB B5 4 ↔ B5 B5-4 B5-14 14 (SEAT ↔ GND1) W R ↔ W-B W-R WB B5 5 ↔ B5 B5-5 B5-14 14 (LSW ↔ GND1) L O ↔ W-B L-O WB - B l Below 1V - Daytime running light system is operating Below 1 V Constant 10 - 14 V Constant Below 1 V Headlight control switch position is HI beam or FLASH Below 1 V Headlight control switch position is except HI beam or FLASH 10 - 14 V Light control switch TAIL or HEAD Below 2 V Light control switch OFF 10 - 14 V Parking brake is used Below 1 V Parking brake is not used 10 - 14 V With seat belt ON Below 1 V No seat belt ON 10 - 14 V Key is inserted Below 1 V Key is not inserted 10 - 14 V DLC3 communication i ti circuit i it - Normal condition 2 - 3.5 V When wire harness is open 4-6V Buzzer sound 10 - 14 V Buzzer does not sound Below 1 V Wireless door lock control system is operated Below 1 V Wireless door lock control system is not operated 10 - 14 V Rear left side power window UP operation Below 1 V Multiplex communication circuit - Constant 10 - 14 V Luggage compartment door opener switch is operated Below 1 V Luggage compartment door opener switch is not operated 10 - 14 V Driver door lock is operating 10 - 14 V Door lock is operating 10 - 14 V Driver door closed 10 - 14 V Driver door opened Below 1 V Passenger seat switch OFF 10 - 14 V Passenger seat switch ON Below 1 V Rear door locked Below 2 V Rear door unlocked 10 - 14 V 2001 AVALON (RM808U) Author
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: 776 DI-621 DIAGNOSTICS - BODY CONTROL SYSTEM B5 6 ↔ B5 B5-6 B5-14 14 (ALTL ↔ GND1) R L ↔ W-B R-L WB B5-7 ↔ B5-14 (CLTE ↔ GND1) Y-B ↔ W-B Automatic light control sensor communication circuit - B5-8 ↔ B5-14 (CLTS ↔ GND1) LG ↔ W-B Automatic light control sensor communication circuit - B5-9 ↔ B5-14 (MPX3 ↔ GND1) R-Y ↔ W-B Multiplex communication circuit - B5-10 ↔ B5-14 (RRU ↔ GND1) G-B ↔ W-B Rear right side power window UP operation Below 1 V B5 1 1 ↔ B5 B5-1 B5-14 14 (PBEW ↔ GND1) G R ↔ W-B G-R WB Passenger seat belt unfastened Below 1 V Passenger seat belt fastened 10 - 14 V Ignition switch ON 10 - 14 V Engine running Below 1 V B5-13 ↔ Body ground (CLTC ↔ Body ground) W-B ↔ Body ground Constant Below 1 V B5-14 ↔ Body ground (GND1 ↔ Body ground) W-B ↔ - Constant Below 1 V Rear door closed 10 - 14 V Rear door opened Below 1 V Passenger seat belt unfastened Below 1 V Passenger seat belt fastened 10 - 14 V Luggage compartment door opener switch is operated Below 1 V Luggage compartment door opener switch is not operated 10 - 14 V B5 16 ↔ B5 B5-16 B5-14 14 (RCTY ↔ GND1) R W ↔ W-B R-W WB B5 17 ↔ B5 B5-17 B5-14 14 (PBKL ↔ GND1) G ↔ W-B WB B5 18 ↔ B5 B5-18 B5-14 14 (TKU ↔ GND1) L B ↔ W-B L-B WB B5-20 ↔ B5-14 (CLTB ↔ GND1) L ↔ W-B B5-21 ↔ B5-14 (MPX4 ↔ GND1) Automatic light control sensor communication circuit - G-B ↔ W-B Multiplex communication circuit - B5-22 ↔ B5-14 (RRD ↔ GND1) R-B ↔ W-B Rear right side power window DOWN operation Below 1 V B5 23 ↔ B5 B5-23 B5-14 14 (DBEW ↔ GND1) G W ↔ W-B G-W WB Passenger seat belt unfastened Below 1 V Passenger seat belt fastened 10 - 14 V B5 25 ↔ B5 B5-25 B5-14 14 (AJAR- ↔ GND1) R ↔ W-B WB Each door closed 10 - 14 V Each door opened Below 1 V 2001 AVALON (RM808U) Author
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: 777 DI-561 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08M-14 CIRCUIT INSPECTION DTC 11, 15 Actuator Motor Circuit CIRCUIT DESCRIPTION The actuator motor is operated by signals from the ECU. Acceleration and deceleration signals are transmitted according to changes in the Duty Ratio (See below). Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity. A A Duty Ratio = A+B DTC No. ON x 100 (%) OFF B 1 cycle Detection Item Trouble Area 11 Short in actuator motor circuit.
Actuator motor
Harness or connector between cruise control ECU and actuator motor
Cruise control ECU 15 Open in actuator motor circuit.
Actuator motor WIRING DIAGRAM C15 Cruise Control ECU C4 Cruise Control Actuator MO 1 P MC 2 R-B 15 II1 15 P 14 II1 7 R MO MC I13618 2001 AVALON (RM808U) Author
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: 717 DI-562 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check resistance between terminals MO and MC of actuator motor. 2 1 I00004 I00151 PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Measure resistance between terminals 1 and 2. HINT: If control plate is in fully opened or fully closed positions, resistance can not be measured. OK: Resistance: more than 4.2 Ω NG Replace cruise control actuator. OK 2 Check for open and short in harness and connectors between cruise control ECU and actuator motor (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 718 DI-563 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08N-15 DTC 12 Actuator Magnetic Clutch Circuit CIRCUIT DESCRIPTION This circuit turns on the magnetic clutch inside the actuator during cruise control operation according to the signal from the ECU. If a malfunction occurs in the actuator or speed sensor, etc. during cruise control operation, the rotor shaft between the motor and control plate is released. When the brake pedal is depressed, the stop light switch turns on, supplying electrical power to the stop light. Power supply to the magnetic clutch is mechanically cut and the magnetic clutch is turned OFF. When driving downhill, if the vehicle speed exceeds the set speed by 15 km/h (9 mph), the ECU turns the safety magnet clutch OFF. If the vehicle speed later drops to within 10 km/h (6 mph), cruise control at the set speed is resumed. DTC No. 12 Detection Item Trouble Area
STOP Fuse
Stop light switch
Actuator magnetic clutch
Harness or connector between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground
Cruise control ECU Short in actuator magnetic clutch circuit. Open (0.8 sec.) in actuator magnetic clutch circuit. WIRING DIAGRAM C15 C4 Cruise Control ECU S4 Cruise Control Actuator 4 GND L 3 P-B W-B 9 II1 13 II1 Stop Light Switch 4 P-B 8 3 L G-B W-B A J9 J/C IJ I13617 2001 AVALON (RM808U) Author
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: 719 DI-564 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check STOP fuse. PREPARATION: (a) Turn ignition switch OFF. (b) Remove the STOP fuse from instrument panel junction block. CHECK: Check fuse continuity. OK: There is continuity. STOP Fuse I14465 NG Replace STOP fuse. OK 2 Check stop light switch. 2 4 1 PREPARATION: Disconnect the stop light switch connector. CHECK: Check continuity between terminals. 3 I00133 NG Switch position Continuity Switch pin free (Brake pedal depressed) 1-2 Switch pin pushed in (Brake pedal released) 3-4 Replace stop light switch. OK 2001 AVALON (RM808U) Author
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: 720 DI-565 DIAGNOSTICS 3 - CRUISE CONTROL SYSTEM Check resistance between terminals L and GND of actuator magnetic clutch. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Measure resistance between terminals 3 and 4. OK: Resistance: 34.65 - 42.35 Ω. 4 3 I00311 NG Replace cruise control actuator. OK 4 Check for open and short in harness and connectors between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 721 DI-566 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08O-14 DTC 14 Actuator Mechanical Malfunction CIRCUIT DESCRIPTION The circuit detects the rotation position of the actuator control plate and sends a signal to the ECU. DTC No. 14 Detection Item Trouble Area Cruise control actuator mechanical malfunction.
Actuator lock: (motor, arm)
Actuator motor
Cruise control ECU WIRING DIAGRAM See page DI-563 . INSPECTION PROCEDURE 1 Check cruise control actuator arm locking operation 4 (+) (-) 3 I00055 PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: (a) Connect the positive (+) lead from the battery to the terminal 3 of actuator and the negative (-) lead to terminal 4. NOTICE: Do not connect the high tension cables to the wrong battery terminal. The cruise control actuator will be damaged. (b) Move the control plate by hand. OK: Control plate doesn’t move. NG Replace cruise control actuator. OK 2001 AVALON (RM808U) Author
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: 722 DI-567 DIAGNOSTICS 2 - CRUISE CONTROL SYSTEM Check cruise control actuator operation. Fully open side 1 4 (+) (-) 3 Fully Closed side 2 PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Connect the positive (+) lead from the battery to terminals 1 and 3 of actuator, connect the negative (-) lead to terminals 2 and 4 of actuator. OK: Control arm moves to fully open side Control plate 1 (+) (-) 4 3 2 Control plate CHECK: Connect the positive (+) lead from the battery to terminals 2 and 3 of actuator, connect the negative (-) lead to terminals 1 and 4 of actuator. OK: Control arm moves to fully colsed side I03209 NG Replace cruise control actuator. OK 3 Check harness and connector between cruise control ECU and cruise control actuator (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 723 DI-568 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08P-18 DTC 21 Open in Vehicle Speed Sensor Circuit CIRCUIT DESCRIPTION The signal from the vehicle speed sensor circuit is sent to cruise control ECU as vehicle speed signal. The rotor shaft is driven by the gear of the transmission. For each rotation of the shaft, the vehicle speed sensor sends a 4-pulse signal through the combination meter to the cruise control ECU (See the following installation). This signal is converted inside the combination meter and sent as a 4-pulse signal to the cruise control ECU. The ECU calculates the vehicle speed from this pulse frequency. 4 pulses/ 4 pulses/ 1 rotation 1 rotation of rotor shaft of rotor shaft Vehicle Speed Sensor Combination Meter ECU DTC No. Detection Item I00292 Trouble Area Speed signal is not input to the cruise control ECU while cruise control is set. 21 Cruise Control ECU
Combination meter
Harness or connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor
Vehicle speed sensor
Cruise control ECU WIRING DIAGRAM C15 Cruise Control ECU Combination Meter BR 22 M3 18 M3 V-W 10 3C 1 3F 12 SPD V-W J/B No. 3 IJ1 11 BR to ABS ECU 7 M3 1 M3 to ECU-IG Fuse Y-R EB I13616 2001 AVALON (RM808U) Author
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: 724 DI-569 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Input signal check. Indicator Light Blinking Pattern Input Signal Drive at about 40 km/h (25 mph) or below Light Drive at about 40 km/h (25 mph) or higher Light ON OFF ON OFF CHECK: (a) See input signal check on page DI-551 . (b) Check indicator light operation when driving with vehicle speed above 40 km/h (25 mph), and with vehicle speed below 40 km/h (25 mph). OK: Vehicle speed above 40 km/h (25 mph): Indicator light blinks Vehicle speed below 40 km/h (25 mph): Indicator light stays on OK Check and replace cruise control ECU (See page IN-30 ). NG 2 Check speedometer circuit (See Combination meter troubleshooting on page BE-2 ). NG Repair or replace harness, connector or combination meter assembly. OK 3 Check harness and connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor (See page IN-30 ). NG Repair or replace harness or connector. OK 2001 AVALON (RM808U) Author
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: 725 DI-570 DIAGNOSTICS 4 - CRUISE CONTROL SYSTEM Check vehicle speed sensor (See page BE-53 ). NG Replace vehicle speed sensor. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 726 DI-571 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08Q-13 DTC 23 Vehicle Speed Signal Abnormal CIRCUIT DESCRIPTION See page DI-568 . DTC No. 23 Detection Item Trouble Area
Vehicle speed sensor
Cruise control ECU Vehicle speed sensor pulse is abnormal. WIRING DIAGRAM See page DI-568 . INSPECTION PROCEDURE 1 Check vehicle speed sensor (See page BE-53 ). NG Replace vehicle speed sensor. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 727 DI-572 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08R-16 DTC 32 Control Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION This circuit carries the SET/COAST, RESUME/ACCEL and CANCEL signals (each voltage) to the ECU. DTC No. 32 Detection Item Trouble Area
Cruise control switch
Harness or connector between cruise control ECU and cruise control switch, cruise control switch and body ground
Cruise control ECU Short in control switch circuit. WIRING DIAGRAM C15 Cruise Control ECU C12 Cruise Control Switch CANCEL 4 W-B 3A 20 COAST/ RES/ SET ACC A 1 W-L CAN MAIN J/B No. 3 3A 3 10 5 W CCS 7 W-B J5 J/C A W-B IG I13615 2001 AVALON (RM808U) Author
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: 728 DI-573 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Input signal check. Indicator Light Blinking Pattern Input Signal SET/COAST switch 2 Pulses ON OFF RESUME/ACCEL switch OFF ON CANCEL switch 3 Pulses ON SW OFF OFF SW ON PREPARATION: See input signal check on page DI-551 . CHECK: Check the indicator light operation when each of the SET/ COAST, RESUME/ACCEL and CANCEL is turned on. OK: SET/COAST, RESUME/ACCEL switch The signals shown in the table on the left should be output when each switch is ON. The signal should disappear when the switch is turned OFF. CANCEL switch The indicator light goes off when the cancel switch is turned ON. OK Wait and see. NG 2 Check voltage between terminals CCS of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals 18 of ECU connector and body ground, when each of the SET/COAST, RESUME/ACCEL and CANCEL is turned ON. ON CCS (-) (+) AB0119 I00168 I00171 NG Switch position Resistance (V) Neutral 10 - 16 V MAIN Below 1V REST/ACC 4.7 - 7.7 V SET/COAST 2.6 - 4.2 V Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ) OK 2001 AVALON (RM808U) Author
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: 729 DI-574 DIAGNOSTICS 3 - CRUISE CONTROL SYSTEM Check control switch. 3 PREPARATION: (a) Remove steering wheel center pad. (b) Disconnect the control switch connector. CHECK: Measure resistance between terminals 2 and 3 of control switch connector when control switch is operated. 2 I11618 NG Switch position Resistance (Ω) Neutral ∞ (No continuity) MAIN 0 Ω (Continuity) RES/ACC 240 SET/COAST 630 Replace control switch. OK 4 Check harness and connector between cruise control ECU and cruise control switch, cruise control switch and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Wait and see. OK 5 Input signal check (See step 1). NG Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 730 DI-575 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI6L6-01 DTC 51 Idle Signal Circuit CIRCUIT DESCRIPTION When the idle switch is turned ON, a signal is sent to the ECU. The ECU uses this signal to correct the discrepancy between the throttle valve position and the actuator position sensor value to enable accurate cruise control at the set speed. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine. DTC No. 51 Detection Item Trouble Area
Harness or connector between ECM and throttle position sensor
Throttle position sensor
Harness or connector between cruise control ECU and ECM
Cruise control ECU Short in idle signal circuit. WIRING DIAGRAM C15 Cruise Control ECU ECM 25 IDLO E7 13 Y IDL I13614 2001 AVALON (RM808U) Author
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: 731 DI-576 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal IDL of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Disconnect the ECM connector. (c) Turn ignition switch ON. CHECK: Measure voltage between terminal IDL of ECU connector and body ground when the throttle valve is fully closed and fully opened. OK: ON IDL (-) (+) AB0119 I00167 I00172 OK Throttle valve position Voltage Fully opened 10 - 14 V Fully closed Below 2 V Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ). NG 2 Check harness and connector between ECM and throttle position sensor (See page IN-30 ). NG Repair or replace harness or connector. OK 3 Check throttle position sensor circuit (See page DI-38 ). NG Replace throttle position sensor. OK 2001 AVALON (RM808U) Author
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: 732 DI-577 DIAGNOSTICS 4 - CRUISE CONTROL SYSTEM Check throttle position sensor. NG Replace throttle position sensor. OK 5 Check for open and short in harness and connector between cruise control ECU and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 733 DI-596 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI6L9-01 Actuator Control Cable INSPECTION PROCEDURE 1 Actuator control cable inspection OK: (a) Check that the actuator and control cable throttle link are properly installed and that the cable and link are connected correctly. (b) Check that the actuator and bell crank operate smoothly. (c) Check that the cable is not loose or too tight. OK: Freeplay: less than 10 mm HINT:
If the control cable is very loose, the vehicle’s loss of speed going uphill will be large.
If the control cable is too tight, the idle RPM will become high. 2001 AVALON (RM808U) Author
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: 752 DI-590 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI6L8-01 Cancel Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION When the cruise control cancel switch is turned ON, the cruise control does not operate. WIRING DIAGRAM See page DI-572 . INSPECTION PROCEDURE 1 Check voltage between terminal CAN of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal CAN of cruise control ECU connector when main switch is held ON and OFF. OK: ON CAN (-) (+) Main switch Voltage OFF 10 - 14 V ON Below 0.5 V AB0119 I00145 I00177 OK Proceed to next circuit inspection shown on problem symptom table (See page DI-560 ). NG 2001 AVALON (RM808U) Author
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: 746 DI-591 DIAGNOSTICS 2 - CRUISE CONTROL SYSTEM Check cancel switch continuity. 4 PREPARATION: (a) Remove steering wheel center pad (See page SR-12 ). (b) Disconnect the control switch connector. CHECK: Check continuity between terminals 3 and 4 of control switch connector when cancel switch is held ON and OFF. OK: 3 Switch position Tester connection Specified condition OFF 3-4 No continuity Hold ON 3-4 Continuity N16045 NG Replace control switch. OK 3 Check harness and connector between cruise control ECU and cancel switch (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 747 DI-592 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI090-28 CRUISE MAIN Indicator Light Circuit CIRCUIT DESCRIPTION When the cruise control main switch is turned ON, CRUISE MAIN indicator light lights up. WIRING DIAGRAM Cruise Control Indicator Light (in Multi Display) 4 4 M6 M7 GR-R J/B No. 4 4 4D 13 4F R-B R-B C15 Cruise Control ECU J/B No. 4 17 4H 17 4A 4 GR-R PI Driver Side J/B IG1 RERAY GAUGE NO. 1 1 2 10 1D 3 1B 4 1 1G W 4 1C 3 W-R I15 Ignition Switch Engine Room R/B No. 5 W-B AM1 1 5 2 7 5 W-L 2 W-L IF1 AM1 IG1 4 B Engine Room J/B 1 2H 1 2G F10 1 B-L 1 F8 FL Block 1 ALT F6 B FL MAIN IG Battery I13610 2001 AVALON (RM808U) Author
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: 748 DI-593 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals PI and GND of cruise control ECU connector. PREPARATION: Tun ignition switch ON. CHECK: Measure voltage between terminals PI and GND of cruise control ECU connector when main switch is ON and OFF. OK: ON PI (-) Switch position Voltage OFF 10 - 16 V ON Below 1.2 V (+) AB0119 I00144 I00178 OK Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ). NG 2 Check combination meter (See page BE-2 ). NG Replace combination meter. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 749 DI-594 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI091-15 Diagnosis Circuit CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that outputs DTC. WIRING DIAGRAM C15 D2 Cruise Control ECU DLC2 A/D J/B No. 4 17 4B 10 GR-R 17 4 4A GR-R PI J/B No. 3 Tc 13 13 3A 4 LG-R 3B 5 TC LG-R 3G 4 D1 DLC1 LG-R J/B No. 4 11 Tc LG-R 22 II2 LG-R 6 4A 6 4H I13609 2001 AVALON (RM808U) Author
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: 750 DI-595 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC2. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals Tc and E1 of DLC2. OK: Voltage: 10 - 14 V ON AB0119 I00169 TC E1 I00179 OK Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ). NG 2 Check harness and connector between cruise control ECU and DLC2, DLC2 and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 751 DI-587 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08X-15 ECU Power Source Circuit CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc, when terminal GND and the cruise control ECU case are grounded. WIRING DIAGRAM C15 J/B No. 3 Driver Side J/B IG1 RELAY 1 1G ECU-IG NO. 2 2 1 4 1C 3 4 Engine Room J/B W 1 2G 1 2H 4 5 B B IG1 AM1 2 W-R W-L Engine Room R/B No. 5 1 9 Y-R Ignition Switch I15 3 1B 2 3D 2 3C Y-R 13 1B Cruise Control ECU AM1 2 5 W-L 7 IF1 B-L J/B No. 3 B-L W-B 1 F10 7 3A FL Block 1 F6 W-B ALT 1 F8 20 3B 16 GND W-B A J5 J/C B FL MAIN A W-B Battery W-B IG I13611 2001 AVALON (RM808U) Author
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: 743 DI-588 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check ECU-IG fuse. PREPARATION: Remove the ECU-IG fuse from instrument panel junction block. CHECK: Check continuity of ECU-IG fuse. OK: Continuity ECU-IG Fuse I14465 NG Check for short in all the harness and components connected to ECU-IG fuse. OK 2 Check voltage between terminals B and GND of cruise control ECU connector. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals B and GND of ECU connector. OK: 10 - 14 V ON GND B (-) (+) AB0119 I00147 I00176 OK Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ). NG 2001 AVALON (RM808U) Author
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: 744 DI-589 DIAGNOSTICS 3 - CRUISE CONTROL SYSTEM Check resistance between terminal GND of cruise control ECU connector and body ground. CHECK: Measure resistance between terminal GND of ECU connector and body ground. OK: Resistance: Below 1 Ω GND I00140 NG Repair or replace harness or connector. OK Check and repair harness and connector between cruise control ECU and battery (See page DI-560 ). 2001 AVALON (RM808U) Author
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: 745 DI-581 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08U-13 Electronically Controlled Transmission Communication Circuit CIRCUIT DESCRIPTION When driving uphill under the cruise control, in order to reduce shifting due to ON-OFF overdrive operation and to provide smooth driving, when down shifting in the electronically controlled transmission occurs, a signal to prevent upshift until the end of the uphill slope is sent from the cruise control ECU to the electronically controlled transmission. Terminal ECT of the cruise control ECU detects the shift change signal (output to electronically controlled transmission No. 2 solenoid) from the ECM. If the vehicle speeds down, also when terminal ECT of the cruise control ECU receives down shifting signal, it sends a signal from terminal OD to ECM to cut overdrive until the end of the uphill slope, and the gear shifts are reduced and gear shift points in the electronically controlled transmission are changed. WIRING DIAGRAM C15 Cruise Control ECU ECM 24 OD1 E7 1 S2 E6 14 GR J8 J/C B B G-Y G-Y 21 II2 6 G-Y OD ECT B G-Y E1 ECT No.2 Solenoid 6 S2 I13613 2001 AVALON (RM808U) Author
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: 737 DI-582 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of overdrive. PREPARATION: Test drive after engine warms up. CHECK: Check that overdrive ON ↔ OFF occurs by operation of OD switch ON-OFF. NG Check and repair electronically controlled transmission (See page DI-158 ). OK 2 Check voltage between terminal OD of harness side connector of cruise control ECU and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. (c) Disconnect the ECU connector. CHECK: Measure voltage between terminal OD of harness side connector of ECU and body ground. OK: Voltage: 10 - 14 V ON O/D (-) (+) AB0119 I00143 I00174 NG Go to step 5. OK 2001 AVALON (RM808U) Author
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: 738 DI-583 DIAGNOSTICS 3 - CRUISE CONTROL SYSTEM Check voltage between terminal ECT of cruise control ECU connector and body ground (On test drive). (-) (+) ECT PREPARATION: (a) Connect the ECU connector. (b) Test drive after engine warms up. CHECK: Check voltage between terminal ECT of ECU connector and body ground when OD switch is ON and OFF. OK: I00141 OK OD switch position Voltage ON 8 - 14 V OFF Below 0.5 V Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ). NG 4 Check harness and connector between terminal ECT of cruise control ECU and electronically controlled transmission solenoid (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU. 5 Check harness and connector between terminal OD of cruise control ECU and terminal OD1 of ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 739 DI-584 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08V-15 Park/Neutral Position Switch Circuit CIRCUIT DESCRIPTION When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM P1 A/T Indicator Light 2 J/B No. 4 4 II1 DL 10 Y-R D6 Diode R-L 20 II1 *4 R-Y 6 4C Y-R 19 4C Y-R J/B No. 3 3 R-L 2 C15 Cruise Control ECU 20 3D 20 3C *3 R-L *2 T5 Translate ECU CCS 7 3C 3 Y-R 26 *1 D R-L Driver Side J/B IG1 Relay 1 1G 4 1C 2 W W-R GAUGE NO. 2 1 2 1 1C 3 4 3 1B I15 Ignition Switch 4 IG1 W-B Engine Room R/B No. 5 AM1 2 W-L 7 IF1 AM1 W-L 2 5 1 5 B 1 F6 FL Block ALT F10 1 FL MAIN B Engine Room J/B 1 F8 B-L 1 2G 1 2H IG Battery *1: w/ Traction Control *2: w/o Tranction Control *3: Floor Shift *4: Column Shift I17550 2001 AVALON (RM808U) Author
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: 740 DI-585 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check starter operation. CHECK: Check that the starter operates normally and that the engine starts. NG Proceed to engine troubleshooting. OK 2 Input signal check. Input Signal Indicator Light Blinking Pattern Turn PNP switch ON SW ON Light OFF (Shift to posiSW OFF tions except D ) OFF PREPARATION: See input signal check on page DI-551 . CHECK: Check the indicator light when shifting into positions except D. OK: The indicator light goes off when shifting into positions except D. OK Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ). NG 2001 AVALON (RM808U) Author
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: 741 DI-586 DIAGNOSTICS 3 - CRUISE CONTROL SYSTEM Check voltage between terminal D of cruise control ECU connector and body ground. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminal D of ECU connector and body ground when shifting into D position and other positions. OK: ON D (-) Shift Position Voltage D position 10 - 14 V Other positions Below 1 V (+) AB0119 I00139 I00175 OK Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ). NG 4 Check harness and connector between cruise control ECU and park/neutral position switch (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 742 DI-578 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08T-17 Stop Light Switch Circuit CIRCUIT DESCRIPTION When the brake pedal is depressed, the stop light switch sends a signal to the ECU. When the ECU receives this signal, it cancels the cruise control. A fail-safe function is provided so that the cancel functions normally, even if there is a malfunction in the stop light signal circuit. The cancel conditions are: Battery positive voltage at terminal STPWhen the brake is ON, battery positive voltage normally is applied through the STOP fuse and stop light switch to terminal STP- of the ECU, and the ECU turns the cruise control OFF. If the harness connected to terminal STP- has an open circuit, terminal STP- will have battery positive voltage and the cruise control will be turned OFF. Also, when the brake is ON, the magnetic clutch circuit is cut mechanically by the stop light switch, turning the cruise control OFF. (See page DI-563 for operation of the magnetic clutch) WIRING DIAGRAM Driver Side J/B 5 1B 3 1D G-W 3 3C G-W 3 3D 11 1D 2 R STOP 1 1G W FL Block FL MAIN G-W 2 C15 STP Driver Side J/B S4 Stop Light Switch 1 Cruise Control ECU J/B No. 3 1 F6 B 1 ALT F10 C4 Cruise Control Actuator S4 Stop Light Switch 13 II1 3 4 P-B W-B Battery 9 II1 8 3 C15 L G-B 4 P-B J9 J/C A W-B IJ I13608 2001 AVALON (RM808U) Author
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: 734 DI-579 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that stop light comes ON when brake pedal is depressed, and turns OFF when brake pedal is released. NG Check stop light system (See page BE-2 ). OK 2 Input signal check. Indicator Light Blinking Pattern Input Signal Stop Light switch ON OFF Light ON SW OFF SW ON CHECK: (a) See input signal check on DI-551 . (b) Check the indicator light when the brake pedal is depressed. OK: The indicator light goes OFF when the brake pedal is depressed. OK Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ). NG 2001 AVALON (RM808U) Author
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: 735 DI-580 DIAGNOSTICS 3 - CRUISE CONTROL SYSTEM Check voltage between terminal STP- of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal STP- of cruise control ECU connector and body ground, when the brake pedal is depressed and released. OK: ON STP- (-) (+) OK AB0119 I00142 Depressed 10 - 14 V Released Below 1 V Proceed to next circuit inspection shown in problem symptom table (See page DI-560 ). I00173 NG 4 Check for open in harness and connectors between terminal STP- of cruise control ECU and stop light switch (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 736 DI-550 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08G-10 CUSTOMER PROBLEM ANALYSIS CHECK CRUISE CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Brought in / / Date of Problem Occurrence Condition of How Often does Problem Occurrence Problem Occurs / Continuous Symptoms / Intermittent ( Vehicle Speed when Problem Occurred Auto cancel occurs km Mile Odometer Reading Times a day) km Mile
Driving condition  City driving  Freeway  Up hill  Down hill
After cancel occurred, did the driver activate cruise control again?  Yes  No  Cancel does not occur  With brake ON  Except D position shift  At 40 km/h (25 mph) or less  When control SW turns to CANCEL position  Cruise control malfunction  Slip to acceleration side  Slip to deceleration side  Hunting occurs  O/D cut off does not occur  O/D does not return  Switch malfunction  SET  Cruise MAIN indicator light  Remains ON  Does not light up 1st Time  Normal Code  Malfunction Code (Code ) 2nd Time  Normal Code  Malfunction Code (Code ) DTC Check  ACCEL  COAST  RESUME  CANCEL  Blinking 2001 AVALON (RM808U) Author
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: 706 DI-556 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI0EJ-09 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the appropriate page. DTC No. (See Page) Circuit Inspection Trouble Area Actuator Motor Circuit
Actuator motor
Harness or connector between cruise control ECU and actuator motor
Cruise control ECU 12 (DI-563 ) Actuator Magnetic Clutch Circuit
STOP Fuse
Stop light switch
Actuator magnetic clutch
Harness or connector between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground
Cruise control ECU 14 (DI-566 ) Actuator Mechanical Malfunction
Actuator motor (actuator lock: motor, arm)
Cruise control ECU 21 (DI-568 ) Open in Vehicle Speed Sensor Circuit
Combination meter
Harness or connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor
Vehicle speed sensor
Cruise control ECU 23 (DI-571 ) Vehicle Speed Signal Abnormal
Vehicle speed sensor
Cruise control ECU Control Switch Circuit
Cruise control switch
Harness or connector between cruise control ECU and cruise control switch, cruise control switch and body ground
Cruise control ECU 41 Cruise control ECU
Cruise control ECU 42 Source voltage drop
Power source Idle Signal Circuit
Throttle position sensor
Harness or connector between ECM and throttle position sensor
Harness or connector between cruise control ECU and ECM
Cruise control ECU 11, 15 (DI-561 ) 32 (DI-572 ) 51 (DI-575 ) 2001 AVALON (RM808U) Author
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: 712 DI-549 DIAGNOSTICS - CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM DI08F-13 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Vehicle Brought to Workshop 1 Items inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Customer Problem Analysis P. DI-550 2 Check and Clear DTC (Precheck) P. DI-551 Symptom does not occur 3 4 Problem Symptom Confirmation Symptom Simulation P. IN-20 Symptom occurs 5 Normal code DTC Check P. DI-556 Malfunction code 6 7 DTC Chart Problem Symptom Table P. DI-560 P. DI-556 9 8 Circuit Inspection Input Signal Check Parts Inspection P. DI-561 - DI-594 Identification of Problem Repair NG 10 Confirmation Test OK Step 2, 5: Diagnostic steps permitting the use of the hand-held tester or breakout-box. End 2001 AVALON (RM808U) Author
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: 705 DI-557 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08J-10 PARTS LOCATION Cruise Control ECU ECM Cruise Control Actuator Cruise Control Switch Instrument Panel Junction Block
ECU-IG No. 1 Fuse
ECU-IG No. 2 Fuse
STOP Fuse Ignition Switch Vehicle Speed Sensor Park/Neutral Position Switch I12541 2001 AVALON (RM808U) Author
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: 713 DI-551 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI6L5-01 PRE-CHECK 1. (a) I11635 HINT: If the indicator check result is not normal, proceed to troubleshooting (See page BE-43 ) for the combination meter section. (b) Check the DTC. HINT: If a malfunction occurs in the No. 1 vehicle speed sensor or actuator, etc. during cruise control driving, the ECU actuates AUTO CANCEL of the cruise control and turns on and off the CRUISE MAIN indicator light to inform the driver of a malfunction. At the same time, the malfunction is stored in memory as a DTC. Indicator Light 0.5 sec. 1.5 sec. DIAGNOSIS SYSTEM Check the indicator. (1) Turn the ignition switch ON. (2) Check that the CRUISE MAIN indicator light comes ON when the cruise control main switch is turned ON, and that the indicator light goes OFF when the main switch is turned OFF. ON OFF BE4034 (c) DLC2 Tc Output of DTC using diagnosis check wire. (1) Turn the ignition switch ON. (2) Using SST, connect terminals Tc and E1 of DLC2. SST 09843-18020 (3) Read the DTC on the CRUISE MAIN indicator light. E1 I00169 2001 AVALON (RM808U) Author
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: 707 DI-552 DIAGNOSTICS - CRUISE CONTROL SYSTEM HINT: Normal Code
0.25 sec. 0.25 sec.
If the DTC is not output, inspect the diagnosis circuit (See page DI-594 ). As an example, the blinking patterns for codes; normal, 11 and 21 are shown in the illustration. ON OFF Malfunction codes 11 and 21 0.5 sec. 4 sec. 0.5 sec. 1.5 sec. 2.5 sec. 1.5 sec. ON OFF Code 11 BE4032 BE4033 Code 21 I00021 Hand-held Tester DLC3 F07887 DLC2 (c) (d) Tc E1 I00169 I13679 I14212 2. (a) (b) USING HAND-HELD TESTER Hook up the hand-held tester to the DLC3. Monitor the ECU data by following the prompts on the tester screen. HINT: Hand-held tester has a ”Snapshot” function which records the monitored data. Please refer to the hand-held tester operator’s manual for further details. 3. DTC CLEARANCE (ERASE MODE) HINT: During in the erase mode, diag detection does not work. (a) Drive at about 15 km/h or below. (b) Using SST, connect terminals Tc and E1 of DLC2. SST 09843-18020 (c) Push the cruise control switch to CANCEL. (d) On the above metioned condition, turn on the cruise control main switch 5 times within 3 seconds. 4. (a) PROBLEM SYMPTOM CHECK (ROAD TEST) Inspect the SET switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Press the control switch to the SET/COAST. (4) After releasing the switch, check that the vehicle cruises at the desired speed. I13679 2001 AVALON (RM808U) Author
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: 708 DI-553 DIAGNOSTICS CRUISE CONTROL SYSTEM (b) Inspect the ACCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed increases while the control switch is pushed to RES/ACC, and that the vehicle cruises at the set speed when the switch is released. (4) Momentarily raise the control switch push to the RES/ACC position and then immediately release it. Check that the vehicle speed increases by approx. 1.5 km/h (Tap-up function). (c) Inspect the COAST switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed decreases while the control switch is turned to SET/COAST, and the vehicle cruises at the set speed when the switch is released. (4) Momentarily push the control switch down to SET/ COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap-down function). I13679 I13679 - 2001 AVALON (RM808U) Author
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: 709 DI-554 DIAGNOSTICS CRUISE CONTROL SYSTEM (d) Inspect the CANCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the following operations, check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Shift to except D position
Push the main switch OFF
Push the cruise control switch to CANCEL (e) Inspect the RESUME switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the following operations check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Shift to except D position
Push the main switch OFF
Push the cruise control switch to CANCEL (4) After the control switch is pushed to RES/ACC at the driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed prior to the cancellation. I13679 I13679 - 2001 AVALON (RM808U) Author
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: 710 DI-555 DIAGNOSTICS (a) (a) (b) I13679 No. - 5. INPUT SIGNAL CHECK HINT: (1) For check No.1 ∼ No.3: Turn ignition switch ON. (2) For check No.4:
Jack up the vehicle.
Start the engine.
Shift to D position. (a) Push the control switch to SET/COAST or RES/ACC position and hold it down or up. (b) Push the main switch ON. (c) Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. (d) Push the SET/COAST or RES/ACC switch OFF. (e) Operate each switch as listed in the table below. (f) Read the blinking pattern of the CRUISE MAIN indicator light. (g) After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed 1st. CRUISE MAIN Indicator Light Blinking Pattern Operation Method 0.25 sec. 1 Push SET/COAST switch ON CRUISE CONTROL SYSTEM Light ON 0.25 sec. SET/COAST switch circuit is normal 1sec. OFF ON 2 Push RES/ACC switch ON Light RES/ACC switch circuit is normal OFF Push CANCEL switch ON ON Switch ON OFF Turn stop light switch ON Depress brake pedal Turn PNP switch OFF (Shift to except D position) ON Light OFF Turn clutch switch OFF (Depress clutch pedal) Drive at about 40 km/h (25 mph)or higher Light Drive at about 40 km/h (25 mph) or below Light 4 CANCEL switch circuit is normal Switch OFF Light 3 Diagnosis Stop light switch circuit is normal PNP switch circuit is normal Switch ON Switch OFF Clutch switch circuit is normal ON OFF Vehicle Speed Sensor is normal ON OFF 2001 AVALON (RM808U) Author
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: 711 DI-560 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI08L-15 PROBLEM SYMPTOMS TABLE Symptom Suspect AreaSuspect Area See page SET not occourring or CANCEL occurring. (DTC is Normal) 1. 2. 3. 4. 5. 6. 7. Vehicle Speed Sensor Control Switch Circuit (Cruise control switch) Stop Light Switch Circuit Park/Neutral Position Switch Circuit Actuator Motor Circuit Cruise Control Cable Cruise Control ECU DI-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 ECU DI-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 ECU DI-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 ECU DI-581 DI-581 IN-30 Cruise control not cancelled, even when brake pedal is depressed. 1. 2. 3. 4. Cruise Control Cable Stop Light Switch Circuit Actuator Motor Circuit Cruise Control ECU DI-596 DI-578 DI-561 IN-30 Cruise control not cancelled, even when transmission is shifted to ”N” postion. 1. 2. 3. 4. Cruise Control Cable Park/Neutral Position Switch Circuit Actuator Motor Circuit Cruise Control ECU DI-596 DI-584 DI-561 IN-30 Control switch does not operate. (SET/COAST, ACC/RES, CANCEL not possible) 1. 2. 3. 4. Cruise Control Cable Control Switch Circuit Actuator Motor Circuit Cruise Control ECU DI-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. 2. 3. 4. Cruise Control Cable Vehicle Speed Signal Abnormal Actuator Motor Circuit Cruise Control ECU DI-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 ECU DI-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 ECU DI-581 DI-581 IN-30 DTC memory is erased. 1. Cruise Control ECU IN-30 DTC is not output, or is output when should not be. 1. Diagnosis Circuit 2. Cruise Control ECU DI-594 IN-30 Cruise MAIN indicator light remains ON or falls to light up. 1. Cruise MAIN Indicator Light Switch Circuit DI-592 2001 AVALON (RM808U) Author
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: 716 DI-558 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI1KT-08 TERMINALS OF ECU C15 I00293 Symbols (Terminals No.) Wiring Color STP ↔ GND (C15-2 ↔ C15-16) G W ↔ W-B G-W WB D ↔ GND (C15-3 ↔ C15-16) Y R ↔ W-B Y-R WB PI ↔ GND (C15-4 ↔ C15-16) TC ↔ GND (C15-5 ↔ C15-16) ECT ↔ GND (C15-6 ↔ C15-16) GR R ↔ W-B GR-R WB LG-R ↔ W-B G Y ↔ W-B G-Y WB MC ↔ GND (C15-7 ↔ C15-16) R ↔ W-B WB L ↔ GND (C15-8 ↔ C15-16) G B ↔ W-B G-B WB B ↔ GND (C15-9 ↔ C15-16) Y-R ↔ W-B CCS ↔ GND (C15-10 ↔ C15-16) W ↔ W-B Condition STD Voltage (V) Depress brake pedal 10 - 16 V Release brake pedal Below 1 V Shift to positions except D Below 1 V Shift to D position 10 - 16 V Ignition switch ON Cruise control main switch ON Below 1.2 V Ignition switch ON Cruise control main switch OFF 10 - 16 V Ignition switch ON 10 - 16 V Ignition switch ON Connect terminals Tc and E1 of diagnostic check connector Below 1 V During driving Gear position 3rd 10 - 16 V During driving Gear position O/D Below 1 V During cruise control driving COAST switch held ON 9 - 15 V During cruise control driving ACC switch held ON Below 1 V During cruise control driving 9 - 15 V Except during cruise control driving Below 1 V Ignition switch ON 10 - 16 V Ignition switch ON 10 - 16 V Ignition switch ON MAIN switch held ON Below 1 V Ignition switch ON SET/COAST switch held ON 4.7 - 7.7 V Ignition switch ON RES/ACC switch held ON 2.6 - 4.2 V 2001 AVALON (RM808U) Author
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: 714 DI-559 DIAGNOSTICS CAN ↔ GND (C15-1 ↔ C15-16) W L ↔ W-B W-L WB SPD ↔ GND (C15 12 ↔ C15-16) (C15-12 C15 16) V-W V W ↔ W-B WB IDL ↔ GND (C15-13 ↔ C15-16) OD ↔ GND (C15-14 ↔ C15-16) MO ↔ GND (C15-15 ↔ C15-16) GND ↔ Body Ground (C15-16 ↔ Body Ground) - CRUISE CONTROL SYSTEM Ignition switch ON Cancel switch OFF 10 - 16 V Ignition switch ON Cancel switch ON Below 1 V Engine start Car stoppage. Below 1.5 V or 4.7 - 16 V During driving (Pulse generated). Y ↔ W-B WB GR ↔ W-B WB P ↔ W-B WB W-B ↔ Body Ground 3-7V Ignition switch ON Throttle valve fully opened. 10 - 16 V Ignition switch ON Throttle valve fully closed. Below 1.5 V During cruise control driving OD switch ON. 10 - 16 V During cruise control driving OD switch OFF (3rd driving) Below 1 V During cruise control driving ACC switch hold ON 9 - 15 V During cruise control driving COAST switch hold ON Below 1 V Constant Below 1 V 2001 AVALON (RM808U) Author
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: 715 DI-148 DIAGNOSTICS - ENGINE DI6TD-01 ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to terminal IGSW of the ECM and the EFI main relay (Marking: EFI) control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI main relay. This signal causes current to flow to the coil, closing the contacts of the EFI main relay and supplying power to terminal +B of the ECM. If the ignition switch is turned off, the ECM continues to switch on the EFI main relay for a maximum of 2 seconds for the initial setting of the IAC valve. WIRING DIAGRAM W-R B-O 6 7 ECM Driver Side J/B IG Switch 7 1C 12 1B B-O 2 IGSW E8 16 +B E8 Engine Room J/B AM2 2 2G B 5 EFI Relay 3 EFI No.1 1 F6 Fusible Link Block 2 1 W-R 4 IF1 2 2F B-W 6 IF1 B-W 17 II1 L-O 2B 4 L-O J7 J/C BR BR A FL Main A Battery ED B+ 8 MREL E8 17 E5 E1 A W-B 1 F7 2F 4 EFI No.2 7 2C BR EC EB A11671 2001 AVALON (RM808U) Author
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: 304 DI-149 DIAGNOSTICS - ENGINE INSPECTION PROCEDURE 1 Check voltage between terminals +B and E1 of ECM connectors. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals +B and E1 of the ECM connectors. OK: Voltage: 9 - 14 V ON +B E1 (-) (+) A02040 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-22 ). NG 2 Check for open in harness and connector between terminal E1 of ECM and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK 3 Check voltage between terminal IGSW of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal IGSW of the ECM connector and body ground. OK: Voltage: 9 - 14 V ON IGSW (-) (+) A02344 OK Go to step 5. NG 2001 AVALON (RM808U) Author
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: 305 DI-150 DIAGNOSTICS 4 - ENGINE Check AM2 fuse (See page DI-1 17, step 10). NG Check for short in all harness and components connected to AM2 fuse. OK 5 Check ignition switch (See page BE-16 ). NG Replace ignition switch. OK Check and repair harness and connector between battery and ignition switch, and ignition switch and ECM. 6 Check voltage between terminal MREL of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal MREL of the ECM connector and body ground. OK: Voltage: 9 - 14 V ON MREL (-) (+) A02345 NG Check and replace ECM (See page IN-30 ). OK 7 Check EFI No.1 fuse (See page DI-136 , step 2). NG Check for short in all harness and components connected to EFI No.1 fuse. 2001 AVALON (RM808U) Author
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: 306 DI-151 DIAGNOSTICS - ENGINE OK 8 Check EFI No.2 fuse. Engine Room J/B EFI No.2 Fuse PREPARATION: Remove the EFI No.2 fuse from the engine room J/B. CHECK: Check the continuity of the EFI No.2 fuse. OK: Continuity NG A11423 Check for short in all harness and components connected to EFI No.2 fuse. OK 9 Check EFI main relay (Marking: EFI) (See page SF-60 ). NG Replace EFI main relay. OK 10 Check for open and short in harness and connector between terminal MREL of ECM and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and repair harness or connector between EFI No.1 fuse and battery. 2001 AVALON (RM808U) Author
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: 307 DI-152 DIAGNOSTICS - ENGINE DI6TE-01 Fuel Pump Control Circuit CIRCUIT DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to the starter relay (Marking: ST) coil and also current flows to terminal STA of ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit opening relay (Marking: C/OPN), the relay switches on, power is supplied to the fuel pump and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the fuel pump also keeps operating. EFI No.1 EFI Relay C/OPN Relay Fuel Pump ECM FC Tr MREL IG Switch IGSW AM2 ST Park/ Neutral Position Switch (STA Signal) MAIN FL Main (NE Signal) STA NE Battery ST Relay Starter A11425 2001 AVALON (RM808U) Author
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: 308 DI-153 DIAGNOSTICS - ENGINE WIRING DIAGRAM ECM IG Switch B-O W-R 7 W-R 4 IF1 6 W-B Driver Side R/B No.6 Engine Room J/B B B-R AM2 2 2G 3 5 EFI No.1 2F 4 6 13 2C 2 1 EFI Relay 6 6 G-B 3 FC E8 E01 L-O 1 ID2 L-B L-B 4 Fuel Pump From Terminal MREL of ECM W-B 1 2 C/OPN Relay 1 2B 4 3 5 6 W-B From Battery 1 IF1 B-R 7 2C 5 A J11 J/C ED BK A11672 INSPECTION PROCEDURE TOYOTA hand-held tester: 1 Connect TOYOTA hand-held tester, and check operation of fuel pump. ON BE6653 A02330 A02405 PREPARATION:1 (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA handheld tester main switch ON. (c) Use the ACTIVE TEST mode to operate the fuel pump. CHECK: Check that the pulsation damper screw rises up when the fuel pump is operated by the TOYOTA hand-held tester. OK: The pulsation damper screw rises up. OK Check for starter signal circuit (See page DI-142 ). NG 2001 AVALON (RM808U) Author
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: 309 DI-154 DIAGNOSTICS 2 - ENGINE Check for ECM power source circuit (See page DI-148 ). NG Repair or replace. OK 3 Check circuit opening relay (Marking: C/OPN) (See page SF-63 ). NG Replace circuit opening relay. OK 4 Check voltage between terminal FC of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF-83 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal FC of the ECM connector and body ground. OK: Voltage: 9 - 14 V ON FC (-) (+) A02064 OK Go to step 5. NG Check for open in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay (Marking: C/OPN), and circuit opening relay and ECM (See page IN-30 ). 5 Check fuel pump (See page SF-6 ). NG Repair or replace fuel pump. 2001 AVALON (RM808U) Author
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: 310 DI-155 DIAGNOSTICS - ENGINE OK 6 Check for open in harness and connector between circuit opening relay (Marking: C/OPN) and fuel pump, and fuel pump and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). OBD II scan tool (excluding TOYOTA hand-held tester): 1 Check operation of fuel pump. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: (a) Connect between terminal FC of the ECM connector and body ground. (b) Check that the pulsation damper screw rises up when connecting between terminal FC of the ECM connector and body ground. OK: The pulsation damper screw rises up. ON FC OK Check for starter signal circuit (See page DI-142 ). A02042 NG 2 Check for ECM power source circuit (See page DI-148 ). 2001 AVALON (RM808U) Author
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: 311 DI-156 DIAGNOSTICS NG - ENGINE Repair or replace. OK 3 Check circuit opening relay (Marking: C/OPN) (See page SF-63 ). NG Replace circuit opening relay. OK 4 Check voltage between terminal FC of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF-83 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal FC of the ECM connector and body ground. OK: Voltage: 9 - 14 V ON FC (-) (+) A02064 OK Go to step 5. NG Check for open in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay (Marking: C/OPN), and circuit opening relay and ECM (See page IN-30 ). 5 Check fuel pump (See page SF-6 ). NG Repair or replace fuel pump. OK 2001 AVALON (RM808U) Author
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: 312 DI-157 DIAGNOSTICS 6 - ENGINE Check for open in harness and connector between circuit opening relay (Marking: C/OPN) and fuel pump, and fuel pump and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 313 DI-145 DIAGNOSTICS - ENGINE DI08E-09 IACV Control Circuit CIRCUIT DESCRIPTION This circuit opens and closes the IACV (Intake Air Control Valve) in response to the engine load in order to increase the intake efficiency (ACIS: Acoustic Control Induction System). When the engine speed is 3,700 rpm or less and the throttle valve opening angle is 30° or more, the ECM turns the two VSV ON or OFF and operate the IACV. IACV No.1, No.2 closed (VSV: OFF) IACV No.1 open (VSV: ON) IACV No.2 closed (VSV: OFF) IACV No.2 3 IACV No.1 5 Throttle Valve Opening Angle 1 30° Throttle Valve 2 4 2,700 rpm 3,700 rpm Engine Speed 6 IACV No.1, No.2 open (VSV: ON) FI7011 FI6570 A06092 WIRING DIAGRAM Engine Room J/B B From Battery 2 2G W-B 2F 4 ED ECM EFI Relay 5 3 EFI No.1 2 EFI No.2 1 9 2B 2B 4 B-W L-O From Terminal MREL of ECM 17 ACIS B-W R-Y E4 1 2 VSV for ACIS No.1 E01 15 ACI1 W-R E5 1 2 VSV for ACIS No.2 B-W E01 A11667 2001 AVALON (RM808U) Author
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: 301 DI-146 DIAGNOSTICS - ENGINE INSPECTION PROCEDURE TOYOTA hand-held tester: 1 Connect TOYOTA hand-held tester, and check operation of VSV for ACIS. ON VSV is ON VSV is OFF Air Air E E F F BE6653 FI7073 FI7074 Air Filter A00307 PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the TOYOTA hand-held tester to the DLC3. (c) Turn the ignition switch ON and TOYOTA hand-held tester main switch ON. (d) Select the INTAKE CTRL VSV from the ACTIVE TEST menu on the TOYOTA hand-held tester. CHECK: Check the operation of the VSV when the VSV is operated by the TOYOTA hand-held tester. OK: VSV is ON: Air from port E flows out through port F. VSV is OFF: Air from port E flows out through the air filter. OK Check vacuum tank (See page SF-46 ). NG 2 Check VSV for ACIS (See page SF-68 ). NG Replace VSV for ACIS. OK 3 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK 2001 AVALON (RM808U) Author
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: 302 DI-147 DIAGNOSTICS - ENGINE Check and replace ECM (See page IN-30 ). OBD II scan tool (excluding TOYOTA hand-held tester): 1 Check VSV for ACIS (See page SF-68 ). NG Replace VSV for ACIS. OK 2 Check voltage between terminals ACIS, ACI1 of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals ACIS, ACI1 of the ECM connector and body ground. OK: Voltage: 9 - 14 V ON ACI1 ACIS (+) (-) A11824 NG Check for open and short in harness and connector between EFI main relay (Marking: EFI) and ECM (See page IN-30 ). OK 3 Check vacuum tank (See page SF-58 ). NG Repair or replace. OK Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 303 DI-23 DIAGNOSTICS - ENGINE DI07F-09 CIRCUIT INSPECTION DTC P0100 Mass Air Flow Circuit Malfunction CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. B+ Thermister Power Transister Platinum Hot Wire A B Output Voltage FI6929 S05741 A06106 DTC No. P0100 DTC Detecting Condition Trouble Area Open or short in mass air flow meter circuit with more than 3 sec. engine speed 4,000 rpm or less
Open or short in mass air flow meter circuit
Mass air flow meter
ECM If the ECM detects DTC P0100 it operates the fail-safe function, keeping the ignition timing and injection volume constantly and making it possible to drive the vehicle. HINT: After confirming DTC P0100, use the OBD II scan tool or TOYOTA hand-held tester to confirm the mass air flow ratio from the CURRENT DATA. Mass Air Flow Value (gm/sec.) 0.0 271.0 or more Malfunction
Mass air flow meter power source circuit open
VG circuit open or short
E2G circuit open 2001 AVALON (RM808U) Author
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: 179 DI-24 DIAGNOSTICS - ENGINE WIRING DIAGRAM ECM Engine Room J/B B From Battery W-B EFI Relay 2 EFI No.1 EFI No.2 2G 5 3 2F 4 2 2 2A 2B 4 1 B-W From Terminal MREL of ECM ED 1 L-O 10 VG E5 3 19 R-B E2G E5 2 R E2 Mass Air Flow Meter A11668 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 Connect OBD II scan tool or TOYOTA hand-held tester, and read value of mass air flow rate. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand-held tester main switch ON. (c) Start the engine. CHECK: Read the mass air flow rate on the OBD II scan tool or TOYOTA hand-held tester. RESULT: Mass Air Flow Rate (gm/sec.) Type I Type II 0.0 271.0 or more Type I Go to step 2. Type II Go to step 5. 2001 AVALON (RM808U) Author
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: 180 DI-25 DIAGNOSTICS 2 - ENGINE Check voltage of mass air flow meter power source. PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal 4 of the mass air flow meter connector and body ground. OK: Voltage: 9 - 14 V ON (+) (-) BE6653 S05337 4 A00436 NG Check for open in harness and connector between EFI main relay (Marking: EFI) and mass air flow meter (See page IN-30 ). OK 3 Check voltage between terminal VG of ECM connector and body ground. VG (+) (-) A02017 PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Start the engine. CHECK: Measure the voltage between terminal VG of the ECM connector and body ground while the engine is idling. OK: Voltage: 1.1 - 1.5 V (P or N position and A/C switch OFF) OK Check and replace ECM (See page IN-30 ). NG 4 Check for open and short in harness and connector between mass air flow meter and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK 2001 AVALON (RM808U) Author
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: 181 DI-26 DIAGNOSTICS - ENGINE Replace mass air flow meter. 5 Check continuity between terminal E2G of ECM connector and body ground. PREPARATION: Remove the glove compartment (See page SF-82 ). CHECK: Check the continuity between terminal E2G of the ECM connector and body ground. OK: Continuity (1 Ω or less) E2G A02018 NG Check and replace ECM (See page IN-30 ). OK 6 Check for open in harness and connector between mass air flow meter and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Replace mass air flow meter. 2001 AVALON (RM808U) Author
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: 182 DI-27 DIAGNOSTICS - ENGINE DI07G-09 DTC P0101 Mass Air Flow Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0100 on page DI-23 . DTC No. P0101 DTC Detecting Condition Trouble Area Conditions (a), (b) and (c) continue 10 sec. or more with engine speed NE < 900: (2 trip detection logic) (a) Throttle valve fully closed (b) Mass air flow meter output  2.2 V (c) THW  70°C
Mass air flow meter Conditions (a) and (b) continue 10 sec. or more with engine speed 1,500 rpm or more: (2 trip detection logic) (a) VTA  0.63 V (b) Mass air flow meter output
1.06 V 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 P0101) being output? NO Replace mass air flow meter. YES Go to relevant DTC chart (See page DI-14 ). 2001 AVALON (RM808U) Author
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: 183 DI-28 DIAGNOSTICS - ENGINE DI07H-10 DTC P0110 Intake Air Temp. Circuit Malfunction CIRCUIT DESCRIPTION Fig. 1 30 20 10 Resistance kΩ 5 Acceptable 3 2 1 0.5 0.3 0.2 0.1 - 20 (- 4) 0 (32) 20 (68) 40 (104) 60 (140) 80 100 (176) (212) Temp. °C (F°) FI4741 DTC No. P0110 The intake air temperature sensor is built into mass air flow meter and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value (See Fig. 1). The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from terminal THA via resistor R. That is, resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0110, it operates the fail-safe function in which the intake air temperature is assumed to be 20°C (68°F). DTC Detecting Condition Open or short in intake air temp. sensor circuit Trouble Area
Open or short in intake air temp. sensor circuit
Intake air temp. sensor (built into mass air flow meter)
ECM HINT: After confirming DTC P0110, use the OBD II scan tool or TOYOTA hand-held tester to confirm the intake air temperature form the CURRENT DATA. Temperature Displayed Malfunction -40 °C ( -40°F ) Open circuit 140°C ( 284°F ) or more Short circuit 2001 AVALON (RM808U) Author
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: 184 DI-29 DIAGNOSTICS - ENGINE WIRING DIAGRAM ECM Intake Air Temp. Sensor (Built into Mass Air Flow Meter) 5V 4 L-B 5 W 22 E5 18 E5 R THA E2 E1 A00310 A09772 INSPECTION PROCEDURE HINT:

If DTCs P0110, P0115, P0120 and P1410 are output simultaneously, E2 (sensor ground) may be open. 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 Connect OBD II scan tool or TOYOTA hand-held tester, and read value of intake air temperature. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand-held tester main switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Same as actual intake air temperature. HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand-held tester indicates -40°C (−40°F).
If there is short circuit, OBD II scan tool or TOYOTA hand-held tester indicates 140°C (284°F) or more. NG -40 °C (-40°F) ... Go to step 2. 140°C (284°F) or more ... Go to step 4. OK Check for intermittent problems (See page DI-3 ). 2001 AVALON (RM808U) Author
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: 185 DI-30 DIAGNOSTICS 2 - ENGINE Check for open in harness or ECM. ON Intake Air Temp. Sensor ECM 5V 22 THA 1 E5 18 E2 E5 2 BE6653 FI7055 A00210 PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Temperature value: 140°C (284°F) or more OK Confirm good connection at sensor. If OK, replace mass air flow meter. NG 3 Check for open in harness or ECM. ON ECM Intake Air Temp. Sensor 5V 22 THA E5 18 E2 E5 THA E2 A02019 PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Connect between terminals THA and E2 of the ECM connector. HINT: The mass air flow meter connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN-30 ). (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Temperature value: 140°C (284°F) or more OK Open in harness between terminal E2 or THA, repair or replace harness. NG Confirm good connection at ECM. If OK, check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 186 DI-31 DIAGNOSTICS 4 - ENGINE Check for short in harness and ECM. ON Intake Air Temp. Sensor ECM 5V 22 E5 THA 18 E2 E5 BE6653 FI7054 PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Temperature value: -40°C (-40°F) A00212 OK Replace mass air flow meter. NG 5 Check for short in harness or ECM. ON ECM 5V Intake Air Temp. Sensor THA E2 PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Disconnect the E5 connector from the ECM. HINT: Mass air flow meter connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Temperature value: -40°C (-40°F) OK E5 Connector Repair or replace harness or connector. A02043 NG Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 187 DI-32 DIAGNOSTICS - ENGINE DI07I-09 DTC P0115 Engine Coolant Temp. Circuit Malfunction CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temperature circuit malfunction shown on page DI-28 . If the ECM detects the DTC P0115, it operates the fail-safe function in which the engine coolant temperature is assumed to be 80°C (176°C). DTC No. P0115 DTC Detecting Condition Trouble Area
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM Open or short in engine coolant temp. sensor circuit HINT: After confirming DTC P0115, use the OBD II scan tool or TOYOTA hand-held tester to confirm the engine coolant temperature from the CURRENT DATA. Temperature Displayed Malfunction -40 °C (-40°F) Open circuit 140°C (284°F) or more Short circuit WIRING DIAGRAM ECM Engine Coolant Temp. Sensor 5V 2 G-Y 14 E5 THW 1 W 18 E5 E2 E1 A00310 A09772 INSPECTION PROCEDURE HINT:

If DTCs P0110, P0115, P0120 and P1410 are output simultaneously, E2 (sensor ground) may be open. 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. 2001 AVALON (RM808U) Author
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: 188 DI-33 DIAGNOSTICS 1 - ENGINE Connect OBD II scan tool or TOYOTA hand-held tester, and read value of engine coolant temperature. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand-held tester main switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Same as actual engine coolant temperature. HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand-held tester indicates -40°C (-40°F).
If there is short circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG -40 °C (-40°F) ... Go to step 2. 140°C (284°F) or more ... Go to step 4. OK Check for intermittent problems (See page DI-3 ). 2 Check for open in harness or ECM. ON ECM Engine Coolant Temp. Sensor 5V 2 14 E5 THW 18 E2 E5 1 BE6653 FI7055 A00214 PREPARATION: (a) Disconnect the engine coolant temp. sensor connector. (b) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Temperature value: 140°C (284°F) or more OK Confirm good connection at sensor. If OK, replace engine coolant temperature sensor. NG 2001 AVALON (RM808U) Author
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: 189 DI-34 DIAGNOSTICS 3 - ENGINE Check for open in harness or ECM. ON ECM Engine Coolant Temp. Sensor 5V 2 14 THW E5 1 18 E2 E5 E2 THW A02020 PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Connect between terminals THW and E2 of the ECM connector. HINT: The engine coolant temperature sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN-30 ). (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Temperature value: 140°C (284°F) or more OK Open in harness between terminal E2 or THW, repair or replace harness. NG Confirm good connection at ECM. If OK, check and replace ECM (See page IN-30 ). 4 Check for short in harness and ECM. ON ECM 5V Engine Coolant Temp. Sensor 14 E5 THW 18 E2 E5 BE6653 FI7054 A00216 PREPARATION: (a) Disconnect the engine coolant temperature sensor connector. (b) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Temperature value: -40°C (-40°F) OK Replace engine coolant temperature sensor. NG 2001 AVALON (RM808U) Author
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: 190 DI-35 DIAGNOSTICS 5 - ENGINE Check for short in harness or ECM. ON ECM 5V Engine Coolant Temp. Sensor THW E2 PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Disconnect the E5 connector from the ECM. HINT: The engine coolant temperature sensor connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: Temperature value: -40°C (-40°F) E5 Connector A02043 OK Repair or replace harness or connector. NG Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 191 DI-36 DIAGNOSTICS - ENGINE DI07J-09 DTC P0116 Engine Coolant Temp. Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI−32. DTC No. DTC Detecting Condition Trouble Area If THW -7°C (19.4°F), 20 min. or more after starting engine, engine coolant temp. sensor value is 20°C (68°F) or less (2 trip detection logic) If THW -7°C (19.4°F), and <10°C (50°F), 5 min. or more after starting engine, engine coolant temp. sensor value is 20°C (95°F) or less (2 trip detection logic) If THW 10°C (50°F), 2 min. or more after starting engine, engine coolant temp. sensor value is 30°C (86°F) or less (2 trip detection logic) P0116 When THW
35°C (95°F) or more and less than 60°C (140°F), and THA
- 6.7°C (19.9°F) or more, when starting engine, conditions (a) and (b) continue: (2 trip detection logic) (a) Vehicle speed is changing (Not stable) (b) THW change is lower than 3°C (5.4°F) from THW since when starting engine
Cooling system
Engine coolant temp. sensor In case that reading value of water temp. sensor will not change more than 1°C (1.8°F) even after repeating 6 trips (detection logic) of adjusting speed pattern with THW more than 60°C (140°F) when engine starts. INSPECTION PROCEDURE HINT:
If DTCs P0115 and P0116 are output simultaneously, engine coolant temperature sensor circuit may be open. Perform troubleshooting of DTC P0115 first. 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 P0116) being output? YES Go to relevant DTC chart (See page DI-14 ). NO 2 Check thermostat (See page CO-1 1). NG Replace thermostat. 2001 AVALON (RM808U) Author
: Date
: 192 DI-37 DIAGNOSTICS - ENGINE OK Replace engine coolant temperature sensor. 2001 AVALON (RM808U) Author
: Date
: 193 DI-38 DIAGNOSTICS - ENGINE DI6T1-01 DTC P0120 Throttle/Pedal position Sensor/Switch ”A” Circuit Malfunction CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 - 5.2 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air-fuel ratio correction, power increase correction and fuel-cut control etc. ECM Throttle Position Sensor VC VTA E2 P24296 DTC No. P0120 DTC Detecting Condition Trouble Area
Open or short in throttle position sensor circuit
Throttle position sensor
ECM Condition (a) or (b) continues: (a) VTA 0.1 V (b) VTA 4.9 V HINT: After confirming DTC P0120, use the OBD II scan tool or TOYOTA hand-held tester to confirm the throttle valve opening percentage and closed throttle position switch condition. Throttle valve opening position expressed as percentage Throttle valve fully closed Throttle valve fully open 0% 0% Approx. 100 % Approx. 100 % T bl A Trouble Area
VC circuit open
VTA circuit open or short
E2 circuit open WIRING DIAGRAM ECM Throttle Position Sensor 5V 1 L-R 2 E5 3 LG 23 VTA1 E5 2 W 18 E5 VC E2 S05019 A09773 INSPECTION PROCEDURE HINT:
If DTCs P0110, P0115 and P0120 are output simultaneously, E2 (sensor ground) bay be open. 2001 AVALON (RM808U) Author
: Date
: 194 DI-39 DIAGNOSTICS
- ENGINE 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 Connect OBD II scan tool or TOYOTA hand-held tester, and read throttle valve opening percentage. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand-held tester main switch ON. CHECK: Read the throttle valve opening percentage. OK: FI7052 OK Throttle Valve Throttle valve opening position expressed as percentage Fully open Approx. 75 % Fully closed Approx. 10 % Check for intermittent problems (See page DI-3 ). NG 2 Check voltage between terminal 1 of wire harness side connector and body ground. PREPARATION: (a) Disconnect the throttle position sensor connector. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal 1 (VC) of the wire harness side connector and body ground. OK: Voltage: 4.5 - 5.5 V ON 1 (+) (-) BE6653 S05338 A00437 NG Go to step 5. OK 3 Check throttle position sensor (See page SF-33 ). 2001 AVALON (RM808U) Author
: Date
: 195 DI-40 DIAGNOSTICS NG - ENGINE Replace throttle position sensor. OK 4 Check voltage between terminals VTA and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VTA1 and E2 of the ECM connector. OK: ON E2 VTA (+) (-) A02021 NG Throttle Valve Voltage Fully closed 0.3 - 1.0 V Fully open 2.7 - 5.2 V Check for open and short in harness and connector in VTA circuit between ECM and throttle position sensor (See page IN-30 ). OK Check and replace ECM (See page IN-30 ). 5 Check voltage between terminals VC and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 - 5.5 V ON E2 VC (+) (-) A02022 NG Check and replace ECM (See page IN-30 ). OK 2001 AVALON (RM808U) Author
: Date
: 196 DI-41 DIAGNOSTICS - ENGINE Check for open in harness and connector in VC circuit between ECM and throttle position sensor (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 197 DI-42 DIAGNOSTICS - ENGINE DI07L-09 DTC P0121 Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0120 on page DI−38. DTC No. P0121 DTC Detecting Condition Trouble Area 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. 2001 AVALON (RM808U) Author
: Date
: 198 DI-43 DIAGNOSTICS - ENGINE DI07M-14 DTC P0125 Insufficient Coolant Temp. for Closed Loop Fuel Control CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The A/F sensor has the characteristic that provides output voltage* approximately proportional to the existing air-fuel ratio. The A/F sensor output voltage* is used to provide feedback for the ECM to control the airfuel ratio. By the A/F sensor output, the ECM can determine the deviation amount from the stoichiometric air-fuel ratio and control the proper injection time immediately. If the A/F sensor is malfunctioning, ECM is unable to perform accurate air-fuel ratio control. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low), current flows to the heater to heat the sensor for accurate oxygen concentration detection. *: The voltage value changes at the inside of the ECM only. Atmosphere Platinum Electrode Solid Electrolyte (Zirconia Element) Platinum Electrode Heater ECM Monitored A/F Sensor Voltage Housing Coating (Ceramic) (V) 4.0 3.8 3.6 3.4 3.2 3.0 2.8 2.6 2.4 12 13 14 15 16 17 18 19 Air-Fuel Ratio Cover Exhaust Gas A00477 DTC No. P0125 DTC Detecting Condition After engine is warmed up, A/F sensor output* does not change when conditions (a), (b), (c) and (d) continue for at least 1.5 min: *: Output value changes at inside of the ECM only (a) Engine speed: 1,500 rpm or more (b) Vehicle speed: 40 - 100 km/h (25 - 62 mph) (c) Throttle valve is not fully closed (d) 140 sec. or more after starting engine Trouble Area
Open or short in A/F sensor (bank 1, 2 sensor 1) circuit
A/F sensor (bank 1, 2 sensor 1)
Air inducation system
Fuel pressure
Injector
Gas leakage on exhaust sytem
ECM HINT:

After confirming DTC P0125, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of the A/F sensor (bank 1, 2 sensor 1) from the CURRENT DATA. The ECM controls the voltage of the AFR+, AFL+, AFR- and AFL- terminals of the ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without the OBDII scan tool or TOYOTA hand-held tester. 2001 AVALON (RM808U) Author
: Date
: 199 DI-44 DIAGNOSTICS
- ENGINE OBD II scan tool (excluding TOYOTA hand-held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand-held tester. WIRING DIAGRAM Engine Room J/B A/F 2 From Battery B EFI No.1 2 2G 1 4 3 B-W 1 EFI Relay 3 5 2F 4 13 2B 2 2 EFI No.2 9 2B 2B 4 1 2 1 4 3 B-W W-B B-W J5 J/C BR B BR 21 IK2 1 BR 4 3 B II2 BR A J7 J/C BR ED A B BR 8 IK2 LG 9 HTS E7 19 IK2 B 8 OXS E7 A EB Converter From Terminal MREL of ECM LG 10 to Analog-Digital L 2 Converter 4 HAFL E5 12 AFL+ E5 3.3 V 21 AFLE5 3.0 V L-O B-W Heated Oxygen Sensor (Bank 1 Sensor 2) to Analog-Digital E05 B-W 16 II2 16 IK2 11 AFR+ E5 3.3 V 20 AFRE5 3.0 V BR A/F Sensor (Bank 2 Sensor 1) 3 HAFR E5 E04 B-R A/F Relay 3 5 B-W B-R 12 2B B-R ECM A/F Sensor (Bank 1 Sensor 1) E03 E1 EC A11670 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. 2001 AVALON (RM808U) Author
: Date
: 200 DI-45 DIAGNOSTICS 1 - ENGINE Are there any other codes (besides DTC P0125) being output? YES Go to relevant DTC chart (See page DI-14 ). NO 2 Connect the OBD II scan tool or TOYOTA hand-held tester, and read value for voltage output of A/F sensor (bank 1, 2 sensor 1). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (b) Warm up the A/F sensor with the engine speed at 2,500 rpm for approx. 90 sec. CHECK: Read the voltage value of the A/F sensor on the screen of OBDII scan tool or TOYOTA hand-held tester when you perform all the following conditions. HINT: The voltage of the AFR+ or AFL+ terminal of the ECM is fixed at 3.3 V and the voltage of the AFR- or AFLterminal is fixed at 3.0 V. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AFR+, AFL+/AFR-, AFL-) of the ECM. OK: Condition A/F Sensor Voltage Value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (0.660 V*)
Not remains at 3 3.8 8 V (0 (0.76 76 V*) or more
Not remains at 2.8 V (0.56 V*) or less *: When you use OBD II scan tool (excluding TOYOTA hand-held tester) HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (0.56 V*), it is normal.
During fuel cut, there is a case that the output voltage of the A/F sensor is above 3.8 V (0.76 V*), it is normal.
If the output voltage of the A/F sensor remains at 3.30 V (0.660 V*) even after performing all the above conditions, the A/F sensor circuit may be open.
If the output voltage of the A/F sensor remains at 3.8 V (0.76 V*) or more, or 2.8 V (0.56 V*) or less even after performing all the above conditions, the A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand-held tester). OK Go to step 9. NG 2001 AVALON (RM808U) Author
: Date
: 201 DI-46 DIAGNOSTICS 3 - ENGINE Check for open and short in harness and connector between ECM and A/F sensor (bank 1, 2 sensor 1) (See page IN-30 ). NG Repair or replace harness or connector. OK 4 Check resistance of A/F sensor heater (bank 1, 2 sensor 1) (See page SF-79 ). NG Replace A/F sensor. OK 5 Check air induction system (See page SF-1 ). NG Repair or replace. OK 6 Check fuel pressure (See page SF-6 ). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF-1 ). OK 7 Check injector injection (See page SF-23 ). NG Replace injector. OK 2001 AVALON (RM808U) Author
: Date
: 202 DI-47 DIAGNOSTICS 8 - ENGINE Check gas leakage on exhaust system. NG Repair or replace OK Replace A/F sensor (bank 1, 2 sensor 1). 9 Perform confirmation driving pattern (See page DI-106 ). Go 10 Is there DTC P0125 being output again? YES Check and replace ECM (See page IN-30 ). NO 11 Did vehicle runs out of fuel in past? NO Check for intermittent problems (See page DI-3 ). YES DTC P0125 is caused by running out of fuel. 2001 AVALON (RM808U) Author
: Date
: 203 DI-48 DIAGNOSTICS - ENGINE DI6T2-01 DTC P0128 Thermostat Malfunction CIRCUIT DESCRIPTION If the water temperature becomes 75°C (167°F) or more, it is abnormal. If not due to the thermostat malfunction, it is abnormal. DTC No. P0128 DTC Detecting Condition Trouble Area
Thermostat
Cooling system
Engine coolant temp. sensor
ECM Condition (a), (b) or (c): (a) After starting engine at 20°C (68°F) (b) After engine is warmed up (c) THW < 75°C (167°F) 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 Check thermostat (See page CO-1 1). NG Replace thermostat. YES 2 Are there any other codes (besides DTC P0128) being output? YES Go to relevant DTC chart (See page DI−14). NG Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 204 DI-49 DIAGNOSTICS - ENGINE DI07Q-09 DTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI-43 . DTC No. DTC Detecting Condition Trouble Area P0136 Voltage output of heated oxygen sensor remains at 0.4 V or more or 0.55 V or less when vehicle is driven at 50 km/h (31 mph) or more after engine is warmed up (2 trip detection logic)
Open or short in heated oxygen sensor circuit
Heated oxygen sensor HINT: Bank 1 refers to the bank that includes cylinder No.1. Sensor 2 refers to the sensor farther away from the engine body.

WIRING DIAGRAM Refer to DTC P0125 on page DI-43 . 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 P0136) being output? YES Go to relevant DTC chart (See page DI-14 ). NO 2 Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN-30 ). NG Repair or replace harness or connector. OK 2001 AVALON (RM808U) Author
: Date
: 205 DI-50 DIAGNOSTICS 3 - ENGINE Check output voltage of heated oxygen sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (b) Warm up the engine to normal operating temperature. CHECK: Read the voltage output of the heated oxygen sensor when the engine is suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 min. using the accelerator pedal. OK: Heated oxygen sensor output voltage: Alternates from 0.4 V or less to 0.6 V or more. OK Check that each connector is properly connected. NG Replace heated oxygen sensor. 2001 AVALON (RM808U) Author
: Date
: 206 DI-51 DIAGNOSTICS - ENGINE DI6T3-01 DTC P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI-43 . DTC No. DTC Detecting Condition Trouble Area When heater operates, heater current exceeds 2.35 A (2 trip detection logic) P0141 Heater current of 0.2 A or less when heater operates (2 trip detection logic)
Open or short in heater circuit of heated oxygen sensor
Heated H t d oxygen sensor heater h t
ECM HINT: Bank 1 refers to the bank that includes cylinder No.1. Sensor 2 refers to the sensor farther away from the engine body.

WIRING DIAGRAM Refer to DTC P0125 on page DI-43 . 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 Check voltage between terminal HTS of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal HTS of the ECM connector and body ground. OK: Voltage: 9 - 14 V ON HTS (+) (-) A06104 OK Check and replace ECM (See page IN-30 ). NG 2 Check resistance of heated oxygen sensor heater (See page SF-81 ). NG Replace heated oxygen sensor. 2001 AVALON (RM808U) Author
: Date
: 207 DI-52 DIAGNOSTICS - ENGINE OK Check and repair harness or connector between EFI main relay (Marking: EFI) and heated oxygen sensor, and heated oxygen sensor and ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 208 DI-58 DIAGNOSTICS - ENGINE DI07S-10 DTC P0300 Random/Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected DTC P0305 Cylinder 5 Misfire Detected DTC P0306 Cylinder 6 Misfire Detected CIRCUIT DESCRIPTION Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in the crankshaft rotation for each cylinder. The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. When the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the MIL lights up. If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks when misfiring occurs. DTC No. P0300 P0301 P0302 P0303 P0304 P0305 P0306 DTC Detecting Condition Misfiring of random cylinders is detected during any particular 200 or 1,000 revolutions For any particular 200 revolutions for engine, misfiring is detected which can cause catalyst overheating (This causes MIL to blink) For any particular 1,000 revolutions of engine, misfiring is detected which causes a deterioration in emission (2 trip detection logic) Trouble Area
Open or short in engine wire
Connector connection
Vacuum hose connection
Ignition system
Injector
Fuel pressure
Mass air flow meter
Engine coolant temp. temp sensor
Compression pressure
Valve clearance
Valve timing
ECM 2001 AVALON (RM808U) Author
: Date
: 214 DI-59 DIAGNOSTICS - ENGINE HINT: When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no Random Misfire code is recorded, it indicates that the misfires were detected and recorded at different times. WIRING DIAGRAM Engine Room J/B B Driver Side J/B W-R 6 IG Switch 7 4 IF1 B-O 11 2C W-R 7 2C 1 AM2 2 2F W-B No.2 B-W 2 B-W 2 B-W 2 B-W 2 1 F7 Fusible Link Block Y No.3 1 W No.4 1 G No.5 1 G No.6 1 W-B B 1 F6 W-B W-B FL Main ECM B-W IG2 B-W B-W 2 1J 7 B-O 1C IG2 Relay 3 5 B-W 2 2G J8 Injector J/C 5 2 B-W B-W L E5 #10 L 2B 1 2 D No.1 D 6 #20 R B-W 4 E5 1 2 ED 1 #30 E4 2 #40 E4 3 #50 E4 4 #60 E4 21 E01 E4 31 E02 E4 EB Battery A11083 CONFIRMATION DRIVING PATTERN (a) (b) (c) (d) Connect the TOYOTA hand-held tester or OBD II scan tool. Record the DTC and the freeze frame data. Use the TOYOTA hand-held tester to set to the check mode (See page DI-3 ). Drive the vehicle several times with the engine speed, load and its surrounding range shown with the ENGINE SPD, CALC LOAD in the freeze frame data or the MISFIRE RPM, MISFIRE LOAD in the data list. If you have no TOYOTA hand-held tester, turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. HINT: In order to memorize DTC of misfire, it is necessary to drive around MISFIRE RPM, MISFIRE LOAD in the data list for the following period of time. Engine Speed Time Idling 3 minutes 30 seconds or more 1,000 rpm 3 minutes or more 2,000 rpm 1 minute 30 seconds or more 3,000 rpm 1 minute or more 2001 AVALON (RM808U) Author
: Date
: 215 DI-60 DIAGNOSTICS (e) - ENGINE Check whether there is misfire or not by monitoring DTC and the freeze frame data. After that, record them. Turn the ignition switch OFF and wait at least 5 seconds. (f) INSPECTION PROCEDURE HINT:
If is case that DTC besides misfire is memorized simultaneously, first perform the troubleshooting for them. Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool. Because freeze frame data 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. When the vehicle is brought to the workshop and the misfire is not occurred, misfire can be confirmed by reproducing the condition or freeze frame data. Also, after finishing the repair, confirm that there is no misfire. (See the confirmation driving pattern) When either of SHORT FT #1, LONG FT #1, SHORT FT #2 or LONG FT #2 in the freeze frame data is besides the range of ±20 %, there is a possibility that the air-fuel ratio is inclining either to ”rich” (-20 % or less) or ”lean” (+20 % or more). When COOLANT TEMP in the freeze frame data is less than 80°C (176°F), there is a possibility or misfire only during warming up. In the case that misfire cannot be reproduced, the reason may be because of the driving with lack or fuel, the use of improper fuel, a stain of ignition plug, and etc.




1 Check wire harness, connector and vacuum hose in engine room. CHECK: (a) Check the connection conditions of wire harness and connector. (b) Check the disconnection, piping and break of vacuum hose. NG Repair or replace, then confirm that there is no misfire (See the confirmation driving pattern). OK 2001 AVALON (RM808U) Author
: Date
: 216 DI-61 DIAGNOSTICS 2 - ENGINE Check spark plug and spark of misfiring cylinder. 1.1 mm B02101 B04941 A06102 PREPARATION: (a) Remove the ignition coil (See page IG-5 ). (b) Remove the spark plug. CHECK: (a) Check spark plug type. (b) Check the electrode for carbon deposits. (c) Check electrode gap. OK: (a) Iridium-tipped spark plug Recommended spark plug: DENSO made: SK20R11 NGK made: IFR6A11 (b) No large carbon deposit present. Not wet with gasoline or oil. (c) Electrode gap: 1.1 mm (0.043 in.) PREPARATION: (a) Install the spark plug to the ignition coil, and connect the ignition coil connector. (b) Disconnect the injector connector. (c) Ground the spark plug. CHECK: Check if spark occurs while engine is being cranked. OK: Spark jumps across electrode gap. NG Replace or check ignition system (See page IG-1 ). OK 3 Check voltage of ECM terminal for injector of failed cylinder. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between applicable terminal of the ECM connector and body ground. OK: Voltage: 9 - 14 V ON #40 #30 #20 #10 #60 #50 (+) (-) A02024 2001 AVALON (RM808U) Author
: Date
: 217 DI-62 DIAGNOSTICS - ENGINE Reference: INSPECTION USING OSCILLOSCOPE With the engine idling, check the waveform between terminals #10 - #60 and E01 of the ECM connector. HINT: The correct waveform is as shown. Injector Signal Waveform (Magnification) 10 V /Division 10 V /Division GND FI6588 FI6538 GND 1 msec./Division (Idling) Injection duration 100 msec./Division (Idling) OK A00064 Go to step 5. NG 4 Check resistance of injector of misfiring cylinder (See page SF-19 ). NG Replace injector. OK Check for open and short in harness and connector between injector and ECM (See page IN-30 ). 5 Check fuel pressure (See page SF-6 ). NG Check and repair fuel pump, fuel pipe line and filter (See page SF-1 ). 2001 AVALON (RM808U) Author
: Date
: 218 DI-63 DIAGNOSTICS - ENGINE OK 6 Check injector injection (See page SF-23 ). NG Replace injector. OK 7 Check mass air flow meter (See page SF-31 ) and engine coolant temperature sensor (See page SF-73 ). NG Repair or replace. OK Check compression pressure (See page EM-3 ), valve clearance (See page EM-4 ) and valve timing (See page EM-21 ). 2001 AVALON (RM808U) Author
: Date
: 219 DI-64 DIAGNOSTICS - ENGINE DI07T-09 DTC P0325 Knock Sensor 1 Circuit Malfunction (Bank 1) DTC P0330 Knock Sensor 2 Circuit Malfunction (Bank 2) CIRCUIT DESCRIPTION Each of knock sensor is fitted to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. DTC Detecting Condition Trouble Area P0325 No knock sensor 1 signal to ECM with engine speed between 2,000 rpm and 5,600 rpm
Open or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM P0330 No knock sensor 1 signal to ECM with engine speed between 2,000 rpm and 5,600 rpm
Open or short in knock sensor 2 circuit
Knock sensor 2 (looseness)
ECM If the ECM detects the above diagnosis conditions, it operates the fail-safe function in which the corrective retard angle value is set to the maximum value. WIRING DIAGRAM ECM Knock Sensor 1 (on Right Bank) 1 W 1 EB1 W 27 KNKR E4 E1 Knock Sensor 2 (on Left Bank) 1 W 2 EB1 W 28 KNKL E4 E1 A03315 INSPECTION PROCEDURE HINT:

DTC P0325 is for the right bank knock sensor circuit. DTC P0330 is for the left bank knock sensor circuit. 2001 AVALON (RM808U) Author
: Date
: 220 DI-65 DIAGNOSTICS
- ENGINE 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 Connect OBD II scan tool or TOYOTA hand-held tester, and check knock sensor circuit. Knock Sensor 1 ECM EB1 1 1 27 28 1 2 2 KNKR E4 PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (b) Disconnect the wire from wire connector EB1. (c) Connect the terminals of the disconnected EB1 male connector and EB1 female as follows. KNKL Male connector ↔ Female connector E4 Terminal 1 ↔ Terminal 2 Male Female Connector Connector Terminal 2 ↔ Terminal 1 (d) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand-held tester main switch ON. (e) After the engine is warmed up, perform quick racing to 4,000 rpm 3 times. CHECK: Check the DTC. RESULT: EB1 FI7050 S06024 S06025 0.5 V /Division Type I DTC same as when vehicle brought in P0325 → P0325 or P0330 → P0330 Type II DTC different to when vehicle brought in P0325 → P0330 or P0330 → P0325 A00304 Reference: INSPECTION USING OSCILLOSCOPE
With the engine racing (4,000 rpm), check the waveform between terminals KNKR, KNKL of the ECM connector and body ground. HINT: The correct waveform is as shown. KNK Signal Waveform 0V 5 msec./Division 200 mV /Division
HINT: If normal mode vibration frequency is not 7.1 kHz, the sensor is malfunctioning. 0V FI6510 FI6607 Spread the time on the horizontal axis, and confirm that period of the wave is 141 µsec. (Normal mode vibration frequency of knock sensor: 7.1 kHz) 100 µsec./Division Type II Go to step 3. A00113 2001 AVALON (RM808U) Author
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: 221 DI-66 DIAGNOSTICS - ENGINE Type I 2 Check for open and short in harness and connector between EB1 connector and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). 3 Check for open and short in harness and connector between EB1 connector and knock sensor (See page IN-30 ). HINT:

If DTC P0325 has changed to P0330, check the knock sensor circuit on the right bank side. If DTC P0330 has changed to P0325, check the knock sensor circuit on the left bank side. NG Repair or replace harness or connector. OK Replace knock sensor. 2001 AVALON (RM808U) Author
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: 222 DI-67 DIAGNOSTICS - ENGINE DI07U-09 DTC P0335 Crankshaft Position Sensor ”A” Circuit Malfunction CIRCUIT DESCRIPTION Crankshaft position sensor (NE signal) consists of a magnet, iron core and pickup coil. The NE signal plate has 34 teeth and is installed the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G (VV) signal, and the actual crankshaft angle and the engine speed by the NE signal. DTC No. DTC Detecting Condition Trouble Area No crankshaft position sensor signal to ECM during cranking (2 trip detection logic) P0335
Open or short in crankshaft position sensor circuit
Crankshaft position osition sensor
Crankshaft timing pulley
ECM No crankshaft position sensor signal to ECM with engine speed 600 rpm or more (2 trip detection logic) WIRING DIAGRAM ECM Right Bank VVT Sensor (Camshaft Position Sensor) 1 B-W 10 VV1+ E4 B-W 16 NE+ E5 L 24 NEE5 L 2 Crankshaft Position Sensor 1 L C 2 C J8 J/C C C E2 Left Bank VVT Sensor (Camshaft Position Sensor) 1 B-W 22 VV2+ E4 L 2 A11084 INSPECTION PROCEDURE HINT:

Perform troubleshooting of DTC P0335 first. If no trouble is found, troubleshoot the following mechanical systems. 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. 2001 AVALON (RM808U) Author
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: 223 DI-68 DIAGNOSTICS 1 - ENGINE Check resistance of crankshaft position sensor (See page IG-9 ). VV1, VV2 and NE Signal Waveforms VV1 2V /Division GND VV2 GND NE GND 20 msec./Division (Idling) A11663 Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check the waveforms between terminals VV1 and NE-, VV2 and NE-, and NE and NE- of the ECM connectors. HINT: The correct waveforms are as shown. NG Replace crankshaft position sensor. OK 2 Check for open and short in harness and connector between ECM and crankshaft position sensor (See page IN-30 ). NG Repair or replace harness or connector. OK 3 Inspect sensor installation and signal plate teeth of crankshaft timing pulley. NG Tighten sensor. Replace crankshaft timing pulley. OK Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 224 DI-69 DIAGNOSTICS - ENGINE DI07V-09 DTC P0340 Camshaft Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION Camshaft position sensor (G (VV) signal) consists of a magnet, iron core and pickup coil. The G (VV) signal plate has 3 teeth, on its outer circumference and is installed the camshaft timing gear. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is installed the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G (VV) signal and the actual crankshaft angle and the engine speed by the NE signal. DTC No. DTC Detecting Condition Trouble Area No camshaft position sensor signal to ECM during cranking (2 trip detection logic) P0340 No camshaft position sensor signal to ECM with engine speed 600 rpm or more
Open or short in camshaft position sensor circuit
Camshaft position osition sensor
Camshaft timing gear
ECM WIRING DIAGRAM Refer to DTC P0335 on page DI-67 . 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 Check resistance of camshaft position sensor (See page IG-1 ). Reference: INSPECTION USING OSCILLOSCOPE Refer to DTC P0335 on page DI-67 . NG Replace camshaft position sensor. OK 2 Check for open and short in harness and connector between ECM and camshaft position sensor (See page IN-30 ). NG Repair or replace harness or connector. 2001 AVALON (RM808U) Author
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: 225 DI-70 DIAGNOSTICS - ENGINE OK 3 Inspect sensor installation and signal plate teeth of camshaft timing gear. NG Tighten sensor. Replace camshaft timing gear. OK Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 226 DI-71 DIAGNOSTICS - ENGINE DI6T5-01 DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1) CIRCUIT DESCRIPTION The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Waveform of A/F Sensor Normal Catalyst Waveform of Heated Oxygen Sensor behind Catalyst Abnormal Catalyst A01674 DTC No. DTC Detecting Condition P0420 After engine and catalyst are warmed up, and while vehicle is driven within set vehicle and engine speed range, waveform of heated oxygen sensor (bank 1 sensor 2) alternates flutteringly between rich and lean (2 trip detection logic) Trouble Area
Gas leakage on exhaust system
A/F sensor (bank 1, 2 sensor 1)
Heated oxygen sensor (bank 1 sensor 2)
Three-way catalytic converter 2001 AVALON (RM808U) Author
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: 227 DI-72 DIAGNOSTICS - ENGINE CONFIRMATION ENGINE RACING PATTERN Engine Speed (c) (d) 3,000 rpm 2,000 rpm Idling IG SW OFF (b) (a) Time Warmed up 3 min. or so 2 sec. 2 sec. Check A00479 (a) (b) (c) (d) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. Start engine and warm it up with all the accessories switched OFF until the water temperature is stable. Race the engine at 2,500 - 3,000 rpm for about 3 min. When racing the engine at 3,000 rpm for 2 sec. and 2,000 rpm for 2 sec. alternately, check the waveform of the heated oxygen sensor (bank 1 sensor 2). 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 P0420) being output? YES Go to relevant DTC chart (See page DI-14 ). NO 2 Check gas leakage on exhaust system. NG Repair or replace. OK 2001 AVALON (RM808U) Author
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: 228 DI-73 DIAGNOSTICS 3 - ENGINE Check A/F sensor (bank 1, 2 sensor 1) (See page SF-79 ). NG Repair or replace. OK 4 Check heated oxygen sensor (bank 1 sensor 2) (See page SF-81 ). NG Repair or replace. OK Replace three-way catalytic converter (See page EC-15 ). 2001 AVALON (RM808U) Author
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: 229 DI-74 DIAGNOSTICS - ENGINE DI6T6-01 DTC P0440 Evaporative Emission Control System Malfunction DTC P0442 Evaporative Emission Control System Leak Detected (Small Leak) CIRCUIT DESCRIPTION The vapor pressure sensor, VSV for canister closed valve (CCV) and VSV for pressure switching valve are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0440 or P0442 is recorded by the ECM when evaporative emissions leak from the components within the dotted line in Fig. 1 below, or when the vapor pressure sensor malfunctions. Fig. 1 ECM VSV for CCV VSV for EVAP (5) Vapor Pressure Sensor VSV for Pressure Switching Valve (6) (4) (1) (2) Fuel Tank Over Fill Check Valve (10) (7) (8) (11) (9) (3) Charcoal Canister Fuel Tank A10140 DTC No. P0440 P0442 DTC Detecting Condition After cold starting and when generating certain swift pressure value in fuel tank enabling not to hold that value (2 trip detection logic) Trouble Area
Hose or tube cracked, hole, damaged or loose seal ((3) in Fig. 1)
Fuel tank cap incorrectly installed
Fuel tank cap cracked or damaged
Vacuum hose cracked, holed, blocked, damaged or disconnected ((1) or (2) in Fig. 1)
Fuel tank cracked, holed or damaged
Charcoal canister cracked, holed or damaged
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
Fuel tank over fill check valve cracked or damaged
ECM 2001 AVALON (RM808U) Author
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: 230 DI-75 DIAGNOSTICS - ENGINE WIRING DIAGRAM ECM Vapor Pressure Sensor 3 4 ID1 L-R 2 L-R 20 ID1 W 2 VC E5 L-R 5 ID1 P 1 15 II2 17 PTNK E8 P 14 II2 W 5V 18 E2 E5 W E1 Engine Room J/B EFI Relay 5 EFI No.1 W-B 4 2F 3 EFI No.2 VSV for EVAP 6 2B 2 1 ED 2B 4 From Terminal MREL of ECM 2 1 9 B-W 2B 7 EVP1 E5 B-R B-W B-W G 2 B-W From Battery 2 2G 1 18 II1 G 10 CCV E8 VSV for CCV E01 E01 ID1 3 L-O B B-W 2 P-B 1 6 ID1 P-B 3 TBP E7 VSV for Pressure Switching Valve E01 A11666 INSPECTION PROCEDURE HINT:



If DTC P0441, P0446, P0450 or P0451 is output after DTC P0440 or P0442, first troubleshoot DTC P0441, P0446, P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 or P0442 next. Ask the customer whether, after the MIL came on, the customer found the fuel tank cap loose and tightened it. Also ask the customer whether the fuel tank cap was loose when refuelling. If the fuel tank cap was loose, it was the cause of the DTC. If the fuel tank cap was not loose or if the customer was not sure if it was loose, troubleshoot according to the following procedure. 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. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the vapor pressure sensor. 2001 AVALON (RM808U) Author
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: 231 DI-76 DIAGNOSTICS 1 - ENGINE Check whether hose close to fuel tank have been modified, and check whether there are signs of any accident near fuel tank or charcoal canister. CHECK: Check for cracks, deformation and loose connection of the following parts:
Fuel tank
Charcoal canister
Fuel tank filler pipe
Hoses and tubes around fuel tank and charcoal canister A10193 NG Repair or replace. OK 2 Check that fuel tank cap is TOYOTA genuine parts. NG Replace to TOYOTA genuine parts. OK 3 Check that fuel tank cap is correctly installed. NG Correctly install fuel tank cap. OK 4 Check fuel tank cap (See page EC-6 ). NG Replace fuel tank cap. OK 2001 AVALON (RM808U) Author
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: 232 DI-77 DIAGNOSTICS 5 - ENGINE Check filler neck for damage. PREPARATION: Remove the fuel tank cap. CHECK: Visually inspect the filler neck for damage. NG Replace filler pipe. OK 6 Check vacuum hoses between vapor pressure sensor and fuel tank, charcoal canister and VSV for pressure switching valve, and VSV for pressure switching valve and charcoal canister. CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole and damage. NG Repair or replace. OK 7 Check hose and tube between fuel tank and charcoal canister. CHECK: (a) Check for proper connection of the fuel tank and fuel evap pipe (See page EC-6 ), fuel evap pipe and fuel tube under the floor, fuel tube under the floor and charcoal canister. (b) Check the hose and tube for cracks, hole and damage. NG Repair or replace. OK 8 Check charcoal canister for cracks, hole and damage (See page EC-6 ). NG Replace charcoal canister. 2001 AVALON (RM808U) Author
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: 233 DI-78 DIAGNOSTICS - ENGINE OK 9 Check voltage between terminals VC and E2 of ECM connector. CHECK: (a) Remove the grove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 - 5.5 V ON (+) VC (-) E2 A02022 NG Check and replace ECM (See page IN-30 ). OK 10 Check voltage between terminals PTNK and E2 of ECM connectors. ON E2 (-) (+) PTNK Type A Disconnect Vacuum Disconnect Type B Vacuum B00802 B01504 A10956 PREPARATION: (a) Remove the grove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals PTNK and E2 of the ECM connectors. (1) Disconnect the vacuum hose from the vapor pressure sensor. (2) Using the MITYVAC (Hand-Held Vacuum Pump), apply a vacuum of 4.0 kPa (30 mmHg, 1.18 in.Hg) to the vapor pressure sensor. NOTICE: The vacuum applied to the vapor pressure sensor must be less than 66.7 kPa (500 mmHg, 19.7 in.Hg). OK: (1) Voltage: 2.9 - 3.7 V (2) Voltage: 0.5 V or less OK Go to step 12. NG 2001 AVALON (RM808U) Author
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: 234 DI-79 DIAGNOSTICS 11 - ENGINE Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. 12 Check fuel tank and fuel tank over fill check valve for cracks and damage. NG Replace fuel tank or fuel tank over fill check valve. OK It is likely that vehicle user did not properly close fuel tank cap. Please explain to customer how to properly install fuel tank cap. 2001 AVALON (RM808U) Author
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: 235 DI-80 DIAGNOSTICS - ENGINE DI6T7-01 DTC P0441 Evaporative Emission Control System Incorrect Purge Flow DTC P0446 Evaporative Emission Control System Vent Control Malfunction CIRCUIT DESCRIPTION The vapor pressure sensor, VSV for canister closed valve (CCV), VSV for pressure switching valve are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTCs P0441 and P0446 are recorded by the ECM when evaporative emissions leak from the components within the dotted line in Fig. 1 below, or when there is a malfunction in either the VSV for EVAP, the VSV for pressure switching valve, or in the vapor pressure sensor itself. Fig. 1 ECM Vapor Pressure Sensor VSV for Pressure Switching Valve (6) VSV for CCV VSV for EVAP (5) Fuel Tank Over Fill Check Valve (1) (4) (10) (2) (7) (8) (11) (9) (3) Charcoal Canister Fuel Tank A10142 2001 AVALON (RM808U) Author
: Date
: 236 DI-81 DIAGNOSTICS DTC No. - ENGINE DTC Detecting Condition Trouble Area Pressure in charcoal canister and fuel tank does not drop during purge control (2 trip detection logic) P0441 During purge cut-off, negative pressure incomming in the charcoal canister and fuel tank will not stop. (2 trip detection logic) When VSV for pressure switching valve is ON, ECM judges that there is no continuity between vapor pressure sensor, fuel tank and charcoal canister (2 trip detection logic) P0446 When VSV for pressure switching valve is turned OFF, pressure in fuel tank is maintained at atmospheric pressure (2 trip detection logic) When VSV for CCV is ON, pressure in charcoal canister and fuel tank is maintained at atmospheric pressure (2 trip detection logic)
Vacuum hose cracks, holed blocked, damaged or disconnected ((1), (2), (3), (4), (5), (6), (7), (8), (9), (10) and (11) in Fig 1) Fig.
Fuel tank cap incorrectly installed
Fuel tank cap cracked or damaged
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
Open or short in VSV circuit for EVAP
VSV for EVAP
Open O or short h t in i VSV circuit i it for f CCV
VSV for CCV
Open or short in VSV circuit for pressure switching valve
VSV for pressure switching g valve
Fuel tank cracked, holed or damaged
Charcoal canister cracked, holed or damaged
Fuel tank over fill check valve cracked damaged
ECM WIRING DIAGRAM Refer to DTC P0440 or P0442 on page DI-74 . INSPECTION PROCEDURE HINT:
If DTC P0441, P0446, P0450 or P0451 is output after DTC P0440 or P0442,first troubleshoot DTC P0441, P0446, P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 or P0442 next. 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. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the vapor pressure sensor.

TOYOTA hand-held tester: 1 Check whether hose close to fuel tank have been modified, and check whether there are signs of any accident near fuel tank or charcoal canister (See page DI-74 , step 1). NG Repair or replace. OK 2 Check that fuel tank cap is TOYOTA genuine parts (See page DI-74 , step 2). NG Replace to TOYOTA genuine parts. 2001 AVALON (RM808U) Author
: Date
: 237 DI-82 DIAGNOSTICS - ENGINE OK 3 Check that fuel tank cap is correctly installed (See page DI-74 , step 3). NG Correctly install fuel tank cap. OK 4 Check fuel tank cap (See page EC-6 , step 4). NG Replace fuel tank cap. OK 5 Check filler neck for damage (See page DI-74 , step 5). NG Replace filler pipe. OK 6 Check vacuum hoses between vapor pressure sensor and fuel tank, charcoal canister and VSV for pressure switching valve, and VSV for pressure switching valve and charcoal canister (See page DI-74 , step 6). NG Repair or connect VSV or sensor connector. OK 7 Check hose and tube between fuel tank and charcoal canister (See page DI-74 , step 7). 2001 AVALON (RM808U) Author
: Date
: 238 DI-83 DIAGNOSTICS NG - ENGINE Repair or replace. OK 8 Check VSV connector for EVAP, VSV connector for CCV, VSV connector for pressure switching valve and vapor pressure sensor connector for looseness and disconnection. NG Repair or connect VSV or sensor connector. OK 9 Check vacuum hoses ((8), (9), (10) and (11) in Fig. 1 in circuit description). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 10 Check voltage between terminals VC and E2 of ECM connector (See page DI-74 , step 9). NG Check and replace ECM (See page IN-30 ). OK 11 Check voltage between terminals PTNK and E2 of ECM connectors (See page DI-74 , step 10). OK Go to step 13. 2001 AVALON (RM808U) Author
: Date
: 239 DI-84 DIAGNOSTICS - ENGINE NG 12 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. 13 Check purge flow. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Select the ACTIVE TEST mode on the TOYOTA handheld tester. (c) Disconnect the vacuum hose for the VSV for the EVAP from the charcoal canister. (d) Start the engine. CHECK: When the VSV for the EVAP is operated by the TOYOTA handheld tester, check whether the disconnected hose applies suction to your finger. OK: VSV is ON: Disconnected hose applies suction to your finger. VSV is OFF: Disconnected hose applies no suction to your finger. VSV is ON VSV is OFF OK Go to step 17. A00230 NG 14 Check vacuum hose between intake manifold and VSV for EVAP, and VSV for EVAP and charcoal canister. CHECK: (a) Check that the vacuum hose is connected correctly. 2001 AVALON (RM808U) Author
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: 240 DI-85 DIAGNOSTICS (b) (c) - ENGINE Check the vacuum hose for looseness and disconnection. Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 15 Check operation of VSV for EVAP (See page SF-65 ). OK Go to step 16. NG Replace VSV and charcoal canister, and then clean vacuum hoses between throttle body and VSV for EVAP, and VSV for EVAP and charcoal canister. 16 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for EVAP, and VSV for EVAP and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). 17 Check VSV for CCV. ON Air E Air E F F BE6653 A10149 A10150 PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Disconnect the vacuum hose for the VSV for the CCV from the charcoal canister. (c) Turn the ignition switch ON and push the TOYOTA handheld tester main switch ON. (d) Select the ACTIVE TEST mode on the TOYOTA handheld tester. VSV is ON VSV is OFF A10281 2001 AVALON (RM808U) Author
: Date
: 241 DI-86 DIAGNOSTICS - ENGINE CHECK: Check the VSV operation when it is operated by the TOYOTA hand-held tester. OK: VSV is ON: Air does not flow from port E to port F. VSV is OFF: Air from port E flows out through port F. OK Go to step 21. NG 18 Check vacuum hose between VSV for CCV and charcoal canister. CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole damage, and blockage. NG Repair or replace. OK 19 Check operation of VSV for CCV (See page SF-70 ). OK Go to step 20. NG Replace VSV and charcoal canister, and then clean vacuum hose between charcoal canister and VSV for CCV. 20 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for CCV, and VSV for CCV and ECM (See page IN-30 ). NG Repair or replace harness or connector. 2001 AVALON (RM808U) Author
: Date
: 242 DI-87 DIAGNOSTICS - ENGINE OK Check and replace ECM (See page IN-30 ). 21 Check VSV for pressure switching valve. ON Air E F BE6653 A10143 A10144 Air E F VSV is ON VSV is OFF A10801 PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA handheld tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA handheld tester. CHECK: Check the VSV operation when it is operated by the TOYOTA hand-held tester. OK: VSV is ON: Air from port E flows out through port F. VSV is OFF: Air does not flow from port E to port F. OK Go to step 24. NG 22 Check operation of VSV for pressure switching valve (See page SF-72 ). OK Go to step 23. NG Replace VSV and charcoal canister, and then clean vacuum hoses between charcoal canister and VSV for pressure switching valve, and VSV for pressure switching valve and fuel tank. 23 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for pressure switching valve, and VSV for pressure switching valve and ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 243 DI-88 DIAGNOSTICS NG - ENGINE Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). 24 Check fuel tank. VSV for EVAP ON OFF VSV for CCV ON OFF VSV for pressure Switching Valve ON OFF 1.2 V E2 A10620 A10574 30 sec. (-) Measure Voltage (+) PTNK A11937 PREPARATION: (a) Remove the grove compartment (See page SF-82 ). (b) Connect the TOYOTA hand-held tester to the DLC3. (c) Select the ACTIVE TEST mode on the TOYOTA handheld tester. (d) Start the engine. (e) The VSV for the CCV is ON by the TOYOTA hand-held tester. (f) The VSV for the EVAP and the VSV for the pressure switching valve are ON by the TOYOTA hand-held tester and hold the VSV for the EVAP until voltage between terminals PTNK and E2 becomes 1.2 V. CHECK: Measure the voltage between terminals PTNK and E2 of the ECM connectors 30 sec. after switching the VSV for the EVAP and the VSV for the pressure switching valve from ON to OFF. OK: Voltage: When there is no sharp change of the voltage with the voltage of more or less 1.2 V NG Replace fuel tank. OK 2001 AVALON (RM808U) Author
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: 244 DI-89 DIAGNOSTICS 25 - ENGINE Check charcoal canister. VSV for EVAP ON OFF ON VSV for CCV OFF VSV for pressure ON Switching Valve OFF 1.2 V E2 A10621 A10574 30 sec. (-) (+) Measure Voltage PTNK A11938 PREPARATION: (a) Remove the grove compartment (See page SF-82 ). (b) Connect the TOYOTA hand-held tester to the DLC3. (c) Select the ACTIVE TEST mode on the TOYOTA handheld tester. (d) Start the engine. (e) The VSV for the CCV and the VSV for the pressure switching valve are ON by the TOYOTA hand-held tester. (f) The VSV for the EVAP is ON by the TOYOTA hand-held tester and hold the VSV for the EVAP until voltage between terminals PTNK and E2 becomes 1.2 V. CHECK: Measure the voltage between terminals PTNK and E2 of the ECM connectors 30 sec. after switching the VSV for the EVAP from ON to OFF. OK: Voltage: When there is no sharp change of the voltage with the voltage of more or less 1.2 V NG Replace charcoal canister. OK 26 Remove charcoal canister and check it (See page EC-6 ). NG Replace charcoal canister. OK 27 Check fuel tank over fill check valve (See page EC-6 ). NG Replace fuel tank over fill check valve or fuel tank. OK 2001 AVALON (RM808U) Author
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: 245 DI-90 DIAGNOSTICS - ENGINE Check and replace charcoal canister (See page IN-30 ). OBD II scan tool (excluding TOYOTA hand-held tester): 1 Check whether hose close to fuel tank have been modified, and check whether there are signs of any accident near fuel tank or charcoal canister (See page DI-74 , step 1). NG Repair or replace. OK 2 Check that fuel tank cap is TOYOTA genuine parts (See page DI-74 , step 2). NG Replace to TOYOTA genuine parts. OK 3 Check that fuel tank cap is correctly installed (See page DI-74 , step 3). NG Correctly install fuel tank cap. OK 4 Check fuel tank cap (See page EC-6 , step 4). NG Replace fuel tank cap. OK 5 Check filler neck for damage (See page DI-74 , step 5). 2001 AVALON (RM808U) Author
: Date
: 246 DI-91 DIAGNOSTICS NG - ENGINE Replace filler pipe. OK 6 Check vacuum hoses between vapor pressure sensor and fuel tank, charcoal canister and VSV for pressure switching valve, and VSV for pressure switching valve and charcoal canister (See page DI-74 , step 6). NG Repair or connect VSV or sensor connector. OK 7 Check hose and tube between fuel tank and charcoal canister (See page DI-74 , step 7). NG Repair or replace. OK 8 Check VSV connector for EVAP, VSV connector for CCV, VSV connector for pressure switching valve and vapor pressure sensor connector for looseness and disconnection. NG Repair or connect VSV or sensor connector. OK 9 Check vacuum hoses ((8), (9), (10) and (11) in Fig. 1 in circuit description). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole damage, and blockage. NG Repair or replace. 2001 AVALON (RM808U) Author
: Date
: 247 DI-92 DIAGNOSTICS - ENGINE OK 10 Check voltage between terminals VC and E2 of ECM connector (See page DI-74 , step 9). NG Check and replace ECM (See page IN-30 ). OK 11 Check voltage between terminals PTNK and E2 of ECM connectors (See page DI-74 , step 10). OK Go to step 13. NG 12 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. 2001 AVALON (RM808U) Author
: Date
: 248 DI-93 DIAGNOSTICS 13 - ENGINE Check VSV for EVAP. PREPARATION: (a) Remove the glove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Check the VSV function. (1) Connect between terminal EVP1 of the ECM connector and body ground (ON). (2) Disconnect between terminal EVP1 of the ECM connector and body ground (OFF). OK: (1) VSV is ON: Air from port E flows out through port F. (2) VSV is OFF: Air does not flow from port E to port F. ON EVP1 ON Air OFF Air E F E F VSV is ON VSV is OFF OK Go to step 16. A02028 NG 14 Check operation of VSV for EVAP (See page SF-65 ). OK Go to step 15. NG Replace VSV and clean vacuum hoses between throttle body and VSV for EVAP, and VSV for EVAP and charcoal canister, and then check charcoal canister. 15 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for EVAP, and VSV for EVAP and ECM (See page IN-30 ). NG Repair or replace harness or connector. 2001 AVALON (RM808U) Author
: Date
: 249 DI-94 DIAGNOSTICS - ENGINE OK Check and replace ECM (See page IN-30 ). 16 Check VSV for CCV. PREPARATION: (a) Remove the grove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Check the VSV function. (1) Connect between terminal CCV of the ECM connector and body ground (ON). (2) Disconnect between terminal CCV of the ECM connector and body ground (OFF). OK: VSV is ON: Air does not flow from port E to port F. VSV is OFF: Air from port E flows out through port F. ON CCV OFF ON Air E F BE6653 A10310 A10281 Air E F VSV is ON VSV is OFF A10951 OK Go to step 19. NG 17 Check operation of VSV for CCV (See page SF-70 ). OK Go to step 18. NG Replace VSV and charcoal canister, and then clean vacuum hose between charcoal canister and VSV for CCV. 2001 AVALON (RM808U) Author
: Date
: 250 DI-95 DIAGNOSTICS 18 - ENGINE Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for CCV, and VSV for CCV and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). 19 Check VSV for pressure switching valve. PREPARATION: (a) Remove the grove compartment (See page SF-82 ). (b) Turn the ignition switch ON. CHECK: Check the VSV function. (1) Connect between terminal TBP of the ECM connector and body ground (ON). (2) Disconnect between terminal TBP of the ECM connector and body ground (OFF). OK: (1) VSV is ON: Air from port E flows out through port F. (2) VSV is OFF: Air does not from flow port E to port F. ON TBP OFF ON Air Air E F F BE6653 A10604 A10278 E VSV is ON VSV is OFF A10952 OK Go to step 22. NG 20 Check operation of VSV for pressure switching valve (See page SF-72 ). OK Go to step 21. 2001 AVALON (RM808U) Author
: Date
: 251 DI-96 DIAGNOSTICS - ENGINE NG Replace VSV and charcoal canister, and then clean vacuum hoses between charcoal canister and VSV for pressure switching valve, and VSV for pressure switching valve and fuel tank. 21 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for pressure switching valve, and VSV for pressure switching valve and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). 22 Check the fuel tank over fill check valve (See page EC-6 ). NG Replace fuel tank over fill check valve or fuel tank. OK Check and replace charcoal canister (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 252 DI-97 DIAGNOSTICS - ENGINE DI081-04 DTC P0450 Evaporative Emission Control System Pressure Sensor Malfunction DTC P0451 Evaporative Emission Control System Pressure Sensor Range/Performance CIRCUIT DESCRIPTION The vapor pressure sensor, VSV for canister closed valve (CCV) and VSV for pressure switching valve are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0450 or P0451 is recorded by the ECM when the vapor pressure sensor malfunction. ECM Vapor Pressure Sensor VSV for CCV VSV for EVAP VSV for Pressure Switching Valve Charcoal Canister Fuel Tank Over Fill Check Valve Fuel Tank A10145 DTC No. DTC Detecting Condition P0450 10 seconds or less after engine starting condition vapor pressure sensor fixed value continues for fixed value or more: (2 trip detection logic) P0451 Vapor pressure sensor output extremely changes under conditions of (a) and (b): (2 trip detection logic) (a) Vehicle speed: 0 km/h (0mph), Engine speed: Idling and VSV for pressure switching valve is OFF (b) vavor pressure sensor value
opening pressure valve of charcoal canister Trouble Area
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM 2001 AVALON (RM808U) Author
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: 253 DI-98 DIAGNOSTICS - ENGINE WIRING DIAGRAM Refer to DTC P0440 or P0442 on page DI-74 . INSPECTION PROCEDURE HINT:
If DTC P0441, P0446, P0450 or P0451 is output after DTC P0440 or P0442, first trouble shoot DTC P0441, P0446 P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 or P0442 next. 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. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor.

1 Check voltage between terminals VC and E2 of ECM connector (See page DI-74 , step 9). NG Check and replace ECM (See page IN-30 ). OK 2 Check voltage between terminals PTNK and E2 of ECM connectors (See page DI-74 , step 10). OK Check and replace ECM (See page IN-30 ). NG 3 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN-30 ). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. 2001 AVALON (RM808U) Author
: Date
: 254 DI-99 DIAGNOSTICS - ENGINE DI082-09 DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION This sensor is mounted in the combination meter. It contains a magnet which is rotated by the speedometer cable. Turning the reed switch ON and OFF 4 times for every revolution of the speedometer. It is then transmitted to the Engine ECM. The Engine ECM determines the vehicle speed based on the frequency of these pulse signals. 4-Pulse From Speed Sensor ABS Actuator & ECU 4-Pulse Engine ECM Multi Display A00022 DTC No. P0500/61 DTC Detecting Condition Trouble Area No vehicle speed sensor signal to Engine & ECT ECU under th following the f ll i g conditions: diti (2 ( trip t i detection d t ti logic) l gi ) Vehicle is being driven
Combination meter
Open O or short h t iin speed d sensor circuit i it
ECM WIRING DIAGRAM ECM Multi Display 5V J/B No.3 18 M3 V-W 1 3F 1 3C V-W 22 SPD E7 A11086 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. 2001 AVALON (RM808U) Author
: Date
: 255 DI-100 DIAGNOSTICS 1 - ENGINE Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG Check speedometer circuit (See page BE-43 ). OK 2 Check for short in harness and connector between terminal SPD of ECM and body ground. E7 Connector SPD PREPARATION: (a) Remove the glove compartment (See page SF-83 ). (b) Disconnect the E7 connector from the ECM. CHECK: Check the continuity between terminal SPD of the ECM connector and body ground. OK: No continuity (1 MΩ or higher) A02030 NG Repair or replace harness or connector. OK 3 Check voltage between terminal SPD of ECM connector and body ground. ON E7 Connector (-) (+) SPD A02029 PREPARATION: (a) Remove the glove compartment (See page SF-83 ). (b) Disconnect the E7 connector from the ECM. (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminal SPD of the ECM connector and body ground. OK: Voltage: 9 - 14 V NG Check for open in harness and connector between J/B No.3 and ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 256 DI-101 DIAGNOSTICS - ENGINE OK 4 Check for open in harness and connector between J/B No.3 and combination meter (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 257 DI-102 DIAGNOSTICS - ENGINE DI083-09 DTC P0505 Idle Control System Malfunction CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed. Intake Air Chamber Throttle Valve From Air Cleaner Signal ECM IAC Valve Valve To Cylinders P01559 DTC No. DTC Detecting Condition Trouble Area
Open or short in IAC valve circuit
IAC valve is stuck or closed
Open or short in A/C signal circuit
Air induction system
ECM Idle speed continues to vary greatly from the target speed (2 trip detection logic) P0505 WIRING DIAGRAM ECM Engine Room J/B B W-B From Battery 2 2G 2F 4 EFI EFI Relay EFI No.2 No.1 5 3 2 1 ED IAC Valve G-B 1 2A 2B 4 B-W 1 2 26 RSO E4 BR 3 L-O E01 A BR J7 J/C A A From Terminal MREL of ECM EB EC A11664 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. 2001 AVALON (RM808U) Author
: Date
: 258 DI-103 DIAGNOSTICS 1 - ENGINE Check idle speed. When using TOYOTA hand-held tester: PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all the accessories. (c) Switch off the A/C. (d) Shift transmission into the N range or neutral position. (e) Connect the TOYOTA hand-held tester to the DLC3 on the vehicle and select the ACTIVE TEST mode. CHECK: Check the difference of the engine speed between the ones, less than 5 sec. and more than 5 sec. after switching the TE1 from OFF to ON by the TOYOTA hand-held tester. OK: Difference of engine speed: More than 100 rpm When not using TOYOTA hand-held tester: PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all the accessories. (c) Switch off the A/C. (d) Shift transmission into the N range or neutral position. (e) Connect the OBDII scan tool to DLC3 on the vehicle. (f) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 CHECK: Check the difference of engine speed between the ones, less than 5 sec. and more than 5 sec. after connecting terminals TE1 and E1 of the DLC1. OK: Difference of engine speed: More than 100 rpm OK Go to step 6. NG 2 Check voltage between terminal RSO of ECM connector and body ground. ON E4 Connector (+) (-) RSO A07628 PREPARATION: (a) Remove the glove compartment (See page SF-83 ). (b) Disconnect the E4 connector from the ECM. (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminal RSO of the ECM connector and body ground. OK: Voltage: 9 - 14 V 2001 AVALON (RM808U) Author
: Date
: 259 DI-104 DIAGNOSTICS OK - ENGINE Go to step 4. NG 3 Check IAC valve (See page SF-43 ). NG Replace IAC valve. OK Check for open and short in harness and connector between engine room J/B and IAC valve, and IAC valve and ECM (See page IN-30 ). 4 Check operation of IAC valve (See page SF-46 ). NG Repair or replace IAC valve. OK 5 Check blockage of IAC valve and passage to bypass throttle valve. NG Repair or replace IAC valve. OK Check and replace ECM (See page IN-30 ). 6 Check for A/C signal circuit (See page DI-824 ). NG Repair or replace. 2001 AVALON (RM808U) Author
: Date
: 260 DI-105 DIAGNOSTICS - ENGINE OK Check air induction system (See page SF-1 ). 2001 AVALON (RM808U) Author
: Date
: 261 DI-106 DIAGNOSTICS - ENGINE DI2H7-03 DTC P1130 A/F Sensor Circuit Range/Performance Malfunction (Bank 1 Sensor 1) DTC P1150 A/F Sensor Circuit Range/Performance Malfunction (Bank 2 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI-43 . DTC No. DTC Detecting Condition Voltage output* of A/F sensor remains at 3.8 V or more, or 2.8 V or less, during engine running after the engine is warmed up (2 trip detection logic) *: Output value changes at inside of ECM only P1130 P1150 Voltage output* of A/F sensor does not change from 3.30 V, during engine running after the engine is warmed up (2 trip detection logic) *: Output value changes at the inside of ECM only Trouble Area
Open or short in A/F sensor circuit
A/F sensor
Air induction system
Fuel pressure
Injector
ECM Open or short in A/F sensor circuit (2 trip detection logic) HINT:



After confirming DTC P1130, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of A/F sensor (AFS B1 S1/O2S B1 S1) from the CURRENT DATA. The A/F sensor’s output voltage and the short−term fuel trim value can be read using the OBD II scan tool or TOYOTA hand−held tester. The ECM controls the voltage of the AFR+, AFL+, AFR− and AFL− terminals of the ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without the OBDII scan tool or TOYOTA hand-held tester. OBD II scan tool (excluding TOYOTA hand−held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand−held tester. WIRING DIAGRAM Refer to DTC P0125 on page DI-43 . 2001 AVALON (RM808U) Author
: Date
: 262 DI-107 DIAGNOSTICS - ENGINE CONFIRMATION DRIVING PATTERN Vehicle Speed 60 - 120 km/h (38 - 75 mph) Idling IG SW OFF (d) (c) (a)(b) 3 - 5 min. Time A00364 (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Switch the TOYOTA hand-held tester from the normal mode to the check mode (See page DI-3 ). (c) Start the engine and warm it up with all the accessory switches OFF. (d) Drive the vehicle at 60 - 120 km/h (38 - 75 mph) and engine speed at 1,400 - 3,200 rpm for 3 - 5 min. HINT: If a malfunction exists, the MIL will light up during step (d). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand-held tester, turn the ignition switch OFF after performing steps (c) and (d), then perform steps (c) and (d) again. INSPECTION PROCEDURE HINT:


If DTC P1130 is displayed, check Bank 1 Sensor 1 circuit. If DTC P1150 is displayed, check Bank 2 Sensor 1 circuit. 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 P1130, P1150) being output? YES Go to relevant DTC chart (See page DI-14 ). NO 2001 AVALON (RM808U) Author
: Date
: 263 DI-108 DIAGNOSTICS 2 - ENGINE Check output voltage of A/F sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (b) Warm up the A/F sensor with the engine speed at 2,500 rpm for approx. 90 sec. CHECK: Read the voltage value of the A/F sensor on the screen of OBDII scan tool or TOYOTA hand-held tester when you perform all the following conditions. HINT: The voltage of the AFR+ or AFL+ terminal of the ECM is fixed at 3.3 V and the voltage of the AFR- or AFLterminal is fixed at 3.0 V. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AFR+, AFL+/AFR-, AFL-) of the ECM. OK: Condition A/F Sensor Voltage Value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (0.660 V*)
Not remains at 3.8 3 8 V (0.76 (0 76 V*) or more
Not remains at 2.8 V (0.56 V*) or less *: When you use OBD II scan tool (excluding TOYOTA hand-held tester) HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (0.56 V*), it is normal.
During fuel cut, there is a case that the output voltage of the A/F sensor is above 3.8 V (0.76 V*), it is normally.
If the output voltage of the A/F sensor remains at 3.30 V (0.660 V*) even after performing all the above conditions, the A/F sensor circuit may be open.
If the output voltage of the A/F sensor remains at 3.8 V (0.76 V*) or more, or 2.8 V (0.56 V*) or less even after performing all the above conditions, the A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand-held tester). OK Go to step 9. NG 3 Check for open and short in harness and connector between ECM and A/F sensor (See page IN-30 ). NG Repair or replace harness or connector. OK 2001 AVALON (RM808U) Author
: Date
: 264 DI-109 DIAGNOSTICS 4 - ENGINE Check resistance of A/F sensor heater (See page SF-79 ). NG Replace A/F sensor. OK 5 Check air induction system (See page SF-1 ). NG Repair or replace. OK 6 Check fuel pressure (See page SF-6 ). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF-1 ). OK 7 Check injector injection (See page SF-23 ). NG Replace injector. OK Replace A/F sensor. 8 Perform confirmation driving pattern (See page DI-106 ). Go 2001 AVALON (RM808U) Author
: Date
: 265 DI-1 10 DIAGNOSTICS 9 - ENGINE Is there DTC P1130 or P1150 being output again? YES Check and replace ECM (See page IN-30 ). NO 10 Did vehicle runs out of fuel in past? NO Check for intermittent problems (See page DI-3 ). YES DTC P1130 or P1150 is caused by running out of fuel. 2001 AVALON (RM808U) Author
: Date
: 266 DI-1 11 DIAGNOSTICS - ENGINE DI2H8-03 DTC P1133 A/F Sensor Circuit Response Malfunction (Bank 1 Sensor 1) DTC P1153 A/F Sensor Circuit Response Malfunction (Bank 2 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI-43 . DTC No. DTC Detecting Condition Trouble Area P1133 P1153 After engine is warmed up, and during vehicle driving at engine speed 1,400 rpm or more and vehicle speed 60 km/h (38 mph) or more, if the response characteristic of A/F sensor becomes deteriorated (2 trip detection logic)
Open or short in A/F sensor circuit
A/F sensor
Air induction system
Fuel pressure
Injector
ECM WIRING DIAGRAM Refer to DTC P0125 on page DI-43 . 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 P1133, P1153) being output? YES Go to relevant DTC chart (See page DI-14 ). NO 2 Connect OBDII scan tool or TOYOTA hand-held tester, and read value for voltage output of A/F sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (b) Warm up the A/F sensor with the engine speed at 2,500 rpm for approx. 90 sec. CHECK: Read the voltage of the A/F sensor on the screen of the OBD II scan tool or TOYOTA hand-held tester when you perform all the following conditions. 2001 AVALON (RM808U) Author
: Date
: 267 DI-1 12 DIAGNOSTICS - ENGINE HINT: The voltage of the AFR+ or AFL+ terminal of the ECM is fixed at 3.3 V and the voltage of the AFR- or AFLterminal is fixed at 3.0 V. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AFR+, AFL+/AFR-, AFL-) of the ECM. OK: Condition A/F Sensor Voltage value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (0.660 V*)
Not remains at 3.8 3 8 V (0.76 (0 76 V*) or more
Not remains at 2.8 V (0.56 V*) or less *: When you use the OBD II scan tool (excluding TOYOTA hand-held tester) HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (0.56 V*), it is normal.
During fuel cut, there is a case that the output voltage of the A/F sensor is above 3.8 V (0.76 V*), it is normal.
If the output voltage of the A/F sensor remains at 3.30 V (0.660 V*) even after performing all the above conditions, the A/F sensor circuit may be open.
If the output voltage of the A/F sensor remains at 3.8 V (0.76V*) or more, or 2.8 V (0.56 V*) or less even after performing all the above conditions, the A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand-held tester). OK Go to step 9. NG 3 Check for open and short in harness and connector between ECM and A/F sensor (See page IN-30 ). NG Repair or replace harness or connector. OK 4 Check resistance of A/F sensor heater (See page SF-79 ). NG Replace A/F sensor. OK 2001 AVALON (RM808U) Author
: Date
: 268 DI-1 13 DIAGNOSTICS 5 - ENGINE Check air induction system (See page SF-1 ). NG Repair or replace. OK 6 Check fuel pressure (See page SF-6 ). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF-1 ). OK 7 Check injector injection (See page SF-23 ). NG Replace injector. OK Replace A/F sensor. 8 Perform confirmation driving pattern (See page DI-106 ). Go 9 Is there DTC P1133 or P1153 being output again? YES Check and replace ECM (See page IN-30 ). NO 2001 AVALON (RM808U) Author
: Date
: 269 DI-1 14 DIAGNOSTICS 10 - ENGINE Did vehicle runs out of fuel in past? NO Check for intermittent problems (See page DI-3 ). YES DTC P1133 or P1153 is caused by running out of fuel. 2001 AVALON (RM808U) Author
: Date
: 270 DI-1 15 DIAGNOSTICS - ENGINE DI2H9-03 DTC P1135 A/F Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) DTC P1155 A/F Sensor Heater Circuit Malfunction (Bank 2 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI-43 . DTC No. DTC Detecting Condition Trouble Area When the heater operates, heater current exceeds 8 A (2 trip detection logic) P1135 P1155 Heater current of 0.25 A or less when the heater operates (2 trip detection logic)
Open or short in heater circuit of A/F sensor
A/F sensor h heater t
ECM WIRING DIAGRAM Refer to DTC P0125 on page DI-43 . 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 Check voltage between terminals HAFL, HAFR of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF-83 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals HAFL, HAFR of the ECM connector and body ground. OK: Voltage: 9 - 14 V ON HAFL HAFR (+) (-) A02032 OK Check and replace ECM (See page IN-30 ). NG 2 Check resistance of A/F sensor heater (See page SF-79 ). 2001 AVALON (RM808U) Author
: Date
: 271 DI-1 16 DIAGNOSTICS NG - ENGINE Replace A/F sensor. OK 3 Check A/F sensor heater relay (Marking: A/F) (See page SF-61 ). NG Replace A/F sensor heater relay. OK Check and repair harness or connector between A/F sensor heater relay and A/F sensor, and A/F sensor and ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 272 DI-1 17 DIAGNOSTICS - ENGINE DI6T8-01 DTC P1300 Igniter Circuit Malfunction (No.1) DTC P1305 Igniter Circuit Malfunction (No.2) DTC P1310 Igniter Circuit Malfunction (No.3) DTC P1315 Igniter Circuit Malfunction (No.4) DTC P1320 Igniter Circuit Malfunction (No.5) DTC P1325 Igniter Circuit Malfunction (No.6) CIRCUIT DESCRIPTION A Direct Ignition System (DIS) has been adopted. The DIS improves the ignition timing accuracy, reduces high-voltage loss, and enhances the the overall reliability of the ignition system by eliminating the distributor. The DIS is a 1-cylinder ignition system which ignites one cylinder with one ignition coil. In the 1-cylinder ignition system, the one spark plug is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the spark plug. The spark of the spark plug pass from the center elecrtode to the ground electrode. The ECM determines ignition timing and outputs the ignition signals (IGT) for each cylinder. Based on IGT signals, the power transistors in the igniter cuts off the current to the primary coil in the ignition coil is supplied to the spark plug that are connected to the end of the secondary coil. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM. DTC No. P1300 P1305 P1310 P1315 P1320 P1325 DTC Detecting Condition Condition (a) is repeated 3 times consecutively during 6 consecutively IGT signals while engine is running (a) IGF signal is not input to ECM for 2 or more ignitions Trouble Area
Ignition system
Open or short in IGF or IGT circuit from ignition coil with igniter
Ignition coil with igniter
ECM 2001 AVALON (RM808U) Author
: Date
: 273 DI-1 18 DIAGNOSTICS - ENGINE WIRING DIAGRAM Engine Room J/B Ignition Coil with Igniter W-B B-Y B-W B-W B-Y W-B FL Main B-Y 12 E4 IGT2 13 E4 IGT3 B-Y W-B 1 F6 Fusible Link Block W-B 1 F7 ECM 11 E4 IGT1 B-W 2 W-B 4 1B-W No.1 B-Y GR 3 2 1B-W W-B 4 No.2 B-Y B-R 2 3 1B-W W-B 4 No.3 LG-B B-Y 2 3 1B-W W-B 4 No.4 L-Y B-Y 3 2 1B-W W-B 4 B-Y No.5 L 3 2 1 B-W W-B 4 No.6 B-Y LG 2 3 B-W 4 2F B-W 7 1 AM2 B-W B-W IG Switch IG2 W-B 6 4 W-R 7 2C IF1 8 2B B-Y W-R 11 2C IG2 Reray 3 5 W-B B Driver Side J/B 7 2 B-O B-O 1C 1J 2 2G 14 E4 IGT4 15 E4 IGT5 16 E4 IGT6 25 E4 IGF 1 Battery Noise Filter ED EC A11669 INSPECTION PROCEDURE HINT:








If DTC P1300 is displayed, check No.1 ignition coil with igniter circuit. If DTC P1305 is displayed, check No.2 ignition coil with igniter circuit. If DTC P1310 is displayed, check No.3 ignition coil with igniter circuit. If DTC P1315 is displayed, check No.4 ignition coil with igniter circuit. If DTC P1320 is displayed, check No.5 ignition coil with igniter circuit. If DTC P1325 is displayed, check No.6 ignition coil with igniter circuit. If DTCs P1300, P1315 and P1325, are output simultaneously, IGF1 circuit may be open or short. If DTCs P1305, P1310 and P1320, are output simultaneously, IGF2 circuit may be open or short. 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 Check spark plug and spark (See page DI-58 ). 2001 AVALON (RM808U) Author
: Date
: 274 DI-1 19 DIAGNOSTICS NG - ENGINE Go to step 4. OK 2 Check for open and short in harness and connector in IGF and IGT signal circuits between ECM and ignition coil with igniter (See page IN-30 ). NG Repair or replace harness or connector. OK 3 Disconnect ignition coil with igniter connector, and check voltage between terminals IGF of ECM connector and body ground. ON IGF (+) (-) A02033 PREPARATION: (a) Remove the glove compartment (See page SF-83 ). (b) Disconnect the ignition coil with the igniter connector. (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminals IGF of the ECM connector and body ground. OK: Voltage: 4.5 - 5.5 V OK Replace ignition coil with igniter. NG Check and replace ECM (See page IN-30 ). 4 Check for open and short in harness and connector in IGT signal circuit between ECM and ignition coil with igniter (See page IN-30 ). NG Repair or replace harness or connector. 2001 AVALON (RM808U) Author
: Date
: 275 DI-120 DIAGNOSTICS - ENGINE OK 5 Check voltage between terminals IGT1 - IGT6 of ECM connector and body ground. ON IGT5 IGT4 IGT3 IGT2 IGT1 IGT6 (+) (-) PREPARATION: (a) Remove the glove compartment (See page SF-83 ). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals IGT1 - IGT6 of the ECM connector and body ground when the engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V A07629 IGT Signal Waveform 5 V/ Division IGT GND Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check the waveform between terminals IGT1 - IGT6 and E1 of the ECM connector. HINT: Correct waveform appears as shown, with rectangle waves. GND IGF NG 20 msec./ Division Check and replace ECM (See page IN-30 ). A06097 OK 6 Disconnect ignition coil with igniter connector, and check voltage between terminals IGT1 - IGT6 of ECM connector and body ground. ON IGT5 IGT4 IGT3 IGT2 IGT1 IGT6 (+) (-) A07629 PREPARATION: (a) Remove the glove compartment (See page SF-83 ). (b) Disconnect the ignition coil with the igniter connector. (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminals IGT1 - IGT6 of the ECM connector and body ground when the engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V NG Check and replace ECM (See page IN-30 ). OK 2001 AVALON (RM808U) Author
: Date
: 276 DI-121 DIAGNOSTICS 7 - ENGINE Check ignition coil with igniter power source circuit. PREPARATION: Disconnect the ignition coil with the igniter connector. CHECK: Measure the voltage between terminal 1 of the ignition coil with the igniter connector and body ground when the ignition switch is turned to ON and START position. OK: Voltage: 9 - 14 V ON 1 START (+) (-) BE6653 A01761 A01861 NG Repair ignition coil with igniter power source circuit. OK 8 Check for open and short in harness and connector between ignition switch and ignition coil with igniter (See page IN-30 ). NG Repair or replace harness or connector. OK 9 Check IG2 fuse. PREPARATION: Remove the IG2 fuse from the engine room J/B. CHECK: Check the continuity of the IG2 fuse. OK: Continuity Engine Room J/B IG2 Fuse NG A11423 Check for short in all harness and components connected to IG2 fuse. OK 2001 AVALON (RM808U) Author
: Date
: 277 DI-122 DIAGNOSTICS 10 - ENGINE Check AM2 fuse. PREPARATION: Remove the AM2 fuse from the engine room J/B. CHECK: Check the continuity of the AM2 fuse. OK: Continuity Engine Room J/B AM2 Fuse NG A11423 Check for short in all harness and components connected to AM2 fuse. OK 11 Check ignition relay (Marking: IG2) (See page IG-10 ). NG Replace ignition relay. OK Replace ignition coil with igniter. 2001 AVALON (RM808U) Author
: Date
: 278 DI-123 DIAGNOSTICS - ENGINE DI085-09 DTC P1335 Crankshaft Position Sensor Circuit Malfunction (During engine running) CIRCUIT DESCRIPTION Refer to DTC P0335 on page DI-67 . DTC No. P1335 DTC Detecting Condition No crankshaft position sensor signal to ECM with engine speed 1,000 rpm or more Trouble Area
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Crankshaft timing pulley
ECM WIRING DIAGRAM Refer to DTC P0335 on page DI-67 . INSPECTION PROCEDURE Refer to DTC P0335 on page DI-67 . 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. 2001 AVALON (RM808U) Author
: Date
: 279 DI-124 DIAGNOSTICS - ENGINE DI6T9-01 DTC P1345 VVT Sensor/Camshaft Position Sensor Circuit Malfunction (Bank 1) DTC P1350 VVT Sensor/Camshaft Position Sensor Circuit Malfunction (Bank 2) CIRCUIT DESCRIPTION VVT sensor (VV signal) consists of a magnet, iron core and pickup coil. The VV signal plate has 3 teeth on its outer circumference and is installed the camshaft timing gear. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The actual camshaft angle is detected by the VVT sensor and it provides feedback to the ECM to control the intake valve timing in response to during condition. DTC No. DTC Detecting Condition Trouble Area No VVT sensor (Camshaft position sensor) signal to ECM during cranking at 4 sec. or more P1345 P1350 No VVT sensor (Camshaft position sensor) signal to ECM with 5 sec. or more engine speed 600 rpm or more While crankshaft rotates twice, VVT sensor (Camshaft position sensor) signal will be input to ECM 5 times.
Open or short in VVT sensor (camshaft position sensor) circuit
VVT sensor (camshaft position sensor)
Camshaft timing gear
ECM WIRING DIAGRAM Refer to DTC P0335 on page DI-67 . INSPECTION PROCEDURE HINT:


If DTC P1345 is displayed, check left bank VVT sensor (camshaft position sensor). If DTC P1350 is displayed, check right bank VVT sensor (camshaft position sensor). 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 Check resistance of VVT sensor (See page IG-7 ). VV1, VV2 and NE Signal Waveforms VV1 2V /Division GND VV2 GND NE GND 20 msec./Division (Idling) A11663 Reference: INSPECTION USING OSCILLOSCOPE During idling, check the waveforms between terminals VV1 and NE+, and VV2 and NE- of the ECM connector. HINT:
The correct waveforms are as shown.
The waveform frequency is shortened as the engine speed becomes higher. NG Replace VVT sensor. 2001 AVALON (RM808U) Author
: Date
: 280 DI-125 DIAGNOSTICS - ENGINE OK 2 Check for open and short in harness and connector between ECM and VVT sensor (See page IN-30 ). NG Repair or replace harness or connector. OK 3 Inspect sensor installation and signal plate teeth of camshaft timing gear. NG Tighten sensor. Replace camshaft timing gear. OK Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 281 DI-126 DIAGNOSTICS - ENGINE DI6TA-01 DTC P1346 VVT Sensor/Camshaft Position Sensor Circuit Range/Performance Problem (Bank 1) DTC P1351 VVT Sensor/Camshaft Position Sensor Circuit Range/Performance Problem (Bank 2) CIRCUIT DESCRIPTION Refer to DTC P1345, P1350 on page DI-124 . DTC No. DTC Detection Condition Trouble Area P1346 Deviation in crankshaft position sensor signal and VVT sensor (bank 1) signal (2 trip detection logic) P1351 Deviation in crankshaft position sensor signal and VVT sensor (bank 2) signal (2 trip detection logic)
Mechanical system malfunction (Jumping teeth of timing belt, b lt stretched) belt t t h d)
ECM WIRING DIAGRAM Refer to DTC P1345, P1350 on page DI-124 . 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 Check valve timing (Check for loose and jumping teeth of timing belt) (See page EM-15 ). NG Adjust valve timing (Repair or replace timing belt). OK Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 282 DI-127 DIAGNOSTICS - ENGINE DI6TB-01 DTC P1349 VVT System Malfunction (Bank 1) DTC P1354 VVT System Malfunction (Bank 2) CIRCUIT DESCRIPTION VVT system controls the intake valve timing to proper timing in response to driving condition. ECM controls Oil Control Valve (OCV) to make the intake valve timing properly, and, oil pressure controlled with OCV is supplied to the VVT controller, and then, VVT controller changes relative position between the camshaft and the crankshaft. DTC No. DTC Detecting Condition Trouble Area P1349 P1354 Condition (a) or (b) continues for after the engine is warmed up and engine speed at 400 - 4,000 rpm: (a) Valve timing does not change from of current valve timing (b) Current valve timing is fixed
Valve timing
OCV
VVT controller assembly
ECM WIRING DIAGRAM ECM Right Bank OCV 1 R-B 6 E4 OC1+ 2 R 5 E4 OC1- 1 R-L 29 E4 OC2+ 2 R-W 18 E4 OC2- Left Bank OCV A07621 A09776 INSPECTION PROCEDURE HINT:


If DTC P1349 is displayed, check left bank VVT system circuit. If DTC P1354 is displayed, check right bank VVT system circuit. 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. 2001 AVALON (RM808U) Author
: Date
: 283 DI-128 DIAGNOSTICS - ENGINE TOYOTA hand-held tester: 1 Check valve timing (See page EM-15 ). NG Repair valve timing. OK 2 Check operation of OCV. PREPARATION: (a) Start the engine and warmed it up. (b) Connect the TOYOTA hand-held tester and select the VVT from the ACTIVE TEST menu. CHECK: Check the engine speed when operate the OCV by the TOYOTA hand-held tester. OK: OCV is OFF: Normal engine speed OCV is ON: Rough idle or engine stall OK VVT system is OK.* *: DTCs P1349 and P1354 are also output after the foreign object is caught in some part of the system in the engine oil and the system returns to normal in a short time. As ECM controls so that foreign objects are ejected, there is no problem about VVT. There is also no problem since the oil filter should get the foreign object in the engine oil. NG 3 Check voltage between terminals OCV+ and OCV- of ECM connector. OCV Signal Waveform 5 V/ Division (A) (A) (A) GND 1 m sec./Division A02397 Reference: INSPECTION USING OSCILLOSCOPE Turn the ignition switch ON, and check the waveform between terminals OCV+ and OCV- of the ECM connector. HINT:
The correct waveform is as shown.
The waveform frequency (A) is lengthened as the engine speed becomes higher. NG Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 284 DI-129 DIAGNOSTICS - ENGINE OK 4 Check VVT controller assembly. PREPARATION: (a) Remove the timing belt (See page EM-15 ). (b) Remove the cylinder head cover. (c) Remove the OCV (See page EM-31 ). (d) Drain oil into the VVT controller assembly (See page EM-31 ). CHECK: Check whether the oil into VVT controller assembly is drained or not. OK: The oil into VVT controller assembly is drained. NG Replace VVT controller assembly, and then go to step 5. NG Replace OCV, and then go to step 6. OK 5 Check OCV (See page SF-51 ). OK 6 Check blockage of OCV, oil check valve and oil pipe No.1. NG Repair or replace. OK 7 Check whether or not DTC P1349/P1354 is stored. PREPARATION: (a) Clear the DTC (See page DI-3 ). (b) Perform simulation test. 2001 AVALON (RM808U) Author
: Date
: 285 DI-130 DIAGNOSTICS - ENGINE CHECK: Check whether or not DTC P1349/P1354 is stored (See page DI-3 ). OK: DTC P1349/P1354 is not stored. OK VVT system is OK.* *: DTCs P1349 and P1354 are also output after the foreign object is caught in some part of the system in the engine oil and the system returns to normal in a short time. As ECM controls so that foreign objects are ejected, there is no problem about VVT. There is also no problem since the oil filter should get the foreign object in the engine oil. NG Replace ECM OBD II scan tool (excluding TOYOTA hand-held tester): 1 Check valve timing (See page EM-15 ). NG Repair valve timing. OK 2001 AVALON (RM808U) Author
: Date
: 286 DI-131 DIAGNOSTICS 2 - ENGINE Check operation of OCV. PREPARATION: Start the engine. CHECK: (a) Check the engine speed when disconnecting the OCV connector. (b) Check the engine speed when applying battery positive voltage between the terminals of the OCV. RESULT: OCV Connector (a) (b) Result Check (a) Check (b) 1 Normal engine speed Rough idle or engine stall 2 A06076 2 Except 1 Go to step 4. 1 3 Check voltage between terminals OCV+ and OCV- of ECM connector. OCV Signal Waveform 5 V/ Division (A) (A) (A) GND 1 msec./Division A02397 Reference: INSPECTION USING OSCILLOSCOPE Turn the ignition switch ON, check the waveform between terminals OCV+ and OCV- of the ECM connector. HINT:
The correct waveform is as shown.
The waveform frequency (A) is lengthened as the engine speed becomes higher. OK VVT system is OK.* *: DTCs P1349 and P1354 are also output after the foreign object is caught in some part of the system in the engine oil and the system returns to normal in a short time. As ECM controls so that foreign objects are ejected, there is no problem about VVT. There is also no problem since the oil filter should get the foreign object in the engine oil. NG 2001 AVALON (RM808U) Author
: Date
: 287 DI-132 DIAGNOSTICS - ENGINE Check and replace ECM (See page IN-30 ). 4 Check VVT controller assembly. PREPARATION: (a) Remove the timing belt (See page EM-15 ). (b) Remove the cylinder head cover. (c) Remove the OCV (See page EM-31 ). (d) Drain oil into the VVT controller assembly (See page EM-31 ). CHECK: Check whether the oil into VVT controller assembly is drained or not. OK: The oil into VVT controller assembly is drained. NG Replace VVT controller assembly, and then go to step 5. NG Replace OCV, and then go to step 6. OK 5 Check OCV (See page SF-51 ). OK 6 Check blockage of OCV, oil check valve and oil pipe No.1. NG Repair or replace. OK 7 Check whether or not DTC P1349/P1354 is stored. PREPARATION: (a) Clear the DTC (See page DI-3 ). (b) Perform simulation test. 2001 AVALON (RM808U) Author
: Date
: 288 DI-133 DIAGNOSTICS - ENGINE CHECK: Check whether or not DTC P1349/P1354 is stored (See page DI-3 ). OK: DTC P1349/P1354 is not stored. OK VVT system is OK.* *: DTCs P1349 and P1354 are also output after the foreign object is caught in some part of the system in the engine oil and the system returns to normal in a short time. As ECM controls so that foreign objects are ejected, there is no problem about VVT. There is also no problem since the oil filter should get the foreign object in the engine oil. NG Replace ECM. 2001 AVALON (RM808U) Author
: Date
: 289 DI-134 DIAGNOSTICS - ENGINE DI088-09 DTC P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). DTC No. DTC Detecting Condition Trouble Area P1520 Stop light switch does not turn off when repeating driving at 30 km or more 10 time or more after depressing brake (2 trip detection logic)
Short in stop light switch signal circuit
Stop light switch
ECM WIRING DIAGRAM 1 1G STOP 11 1D G-W 1E 4 1 F10 Fusible Link Block ALT ECM G-W 5 IK1 G-W 7 B 1 F6 FL Main 2 3 3C J/B No.3 W Stop Light Switch G-W Driver Side J/B 3 5 R 1D 1B 2 1 Light Failure Sensor G-W 15 STP E8 16 4C J/B No.4 Driver Side J/B 3 3F E1 16 4F G-W To Stop Light Battery A11416 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 Check operation of stop light. CHECK: Check if the stop lights go on and off normally when the brake pedal is operated and released. NG Check and repair stop light circuit. 2001 AVALON (RM808U) Author
: Date
: 290 DI-135 DIAGNOSTICS - ENGINE OK 2 Check STP signal. When using TOYOTA hand-held tester: PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA handheld tester main switch ON. CHECK: Read the STP signal on the TOYOTA hand-held tester. OK: ON Brake Pedal Depressed Brake Pedal Released ON STP (-) Brake Pedal STP Signal Depressed ON Released OFF When not using TOYOTA hand-held tester: PREPARATION: Turn the ignition switch ON. CHECK: Check the voltage between terminal STP of the ECM connector and body ground. OK: (+) A02037 OK Brake Pedal Voltage Depressed 7.5 - 14 V Released Below 1.5 V Check for intermittent problems (See page DI-3 ). NG 3 Check harness and connector between ECM and stop light switch (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 291 DI-136 DIAGNOSTICS - ENGINE DI089-09 DTC P1600 ECM BATT Malfunction CIRCUIT DESCRIPTION Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air-fuel ratio adaptive control value memory, etc. DTC No. P1600 DTC Detecting Condition Trouble Area
Open in back up power source circuit
ECM Open in back up power source circuit HINT: If DTC P1600 appear, the ECM does not store another DTC. WIRING DIAGRAM ECM Fusible Link Block 1 F6 B Engine Room J/B 1 F7 B 2 2G EFI No.1 10 2B B-R 8 II1 B-R 1 E8 BATT FL Main Battery A11417 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. 2001 AVALON (RM808U) Author
: Date
: 292 DI-137 DIAGNOSTICS 1 - ENGINE Check voltage between terminal BATT of ECM connector and body ground. PREPARATION: Remove the glove compartment (See page SF-82 ). CHECK: Measure the voltage between terminal BATT of the ECM connector and body ground. OK: Voltage: 9 - 14 V LOCK BATT (-) (+) A02038 OK Check and replace ECM (See page IN-30 ). NG 2 Check EFI No.1 fuse. PREPARATION: Remove the EFI No.1 fuse from the engine room J/B. CHECK: Check the continuity of the EFI No.1 fuse. OK: Continuity Engine Room J/B EFI No.1 Fuse NG A11423 Check for short in all harness and components connected to EFI No.1 fuse. OK Check and repair harness or connector between battery and EFI No.1 fuse, and EFI No.1 fuse and ECM. 2001 AVALON (RM808U) Author
: Date
: 293 DI-138 DIAGNOSTICS - ENGINE DI6TC-01 DTC P1656 OCV Circuit Malfunction (bank 1) DTC P1663 OCV Circuit Malfunction (bank 2) CIRCUIT DESCRIPTION Refer to DTC P1349, P1354 on page DI-127 . DTC No. P1656 P1663 DTC Detecting Condition Trouble Area
Open or short in OCV circuit
OCV
ECM Open or short in oil control valve circuit WIRING DIAGRAM Refer to DTC P1349, P1354 on page DI-127 . INSPECTION PROCEDURE HINT:


If DTC P1656 dysplayed, check left bank OCV circuit. If DTC P1663 dysplayed, check right bank OCV circuit. 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. TOYOTA hand-held tester: 1 Check OCV circuit. PREPARATION: (a) Start the engine and warmed it up. (b) Connect the TOYOTA hand-held tester and select the VVT from the ACTIVE TEST menu. CHECK: Check the engine speed when operate the OCV by the TOYOTA hand-held tester. OK: VVT system is OFF (OCV is OFF): Normal engine speed VVT system is ON (OCV is ON): Rough idle or engine stalled OK Check for intermittent problems (See page DI-3 ). NG 2001 AVALON (RM808U) Author
: Date
: 294 DI-139 DIAGNOSTICS 2 - ENGINE Check operation of OCV. A06076 A11891 PREPARATION: (a) Start the engine and warmed it up. (b) Disconnect the OCV connector. (c) Apply battery positive voltage between terminals of the OCV. CHECK: Check the engine speed. OK: Rough idle or engine stalled. NG Replace OCV. OK 3 Check voltage between terminals OCV+ and OCV- of ECM connector (See page DI-127 , step 3). NG Check and replace ECM (See page IN-30 ). OK 4 Check for open and short in harness and connector between OCV and ECM (See page IN-30 ). NG Repair or replace. OK Check for intermittent problems (See page DI-3 ). 2001 AVALON (RM808U) Author
: Date
: 295 DI-140 DIAGNOSTICS - ENGINE OBD II scan tool (excluding TOYOTA hand-held tester): 1 Check operation of OCV. A06076 A11891 PREPARATION: (a) Start the engine and warmed it up. (b) Disconnect the OCV connector. (c) Apply battery positive voltage between terminals of the OCV. CHECK: Check the engine speed. OK: Rough idle or engine stalled NG Replace OCV. OK 2 Check voltage between terminals OCV+ and OCV- of ECM connector (See page DI-127 , step 3). NG Check and replace ECM (See page IN-30 ). OK 3 Check for open and short in harness and connector between OCV and ECM (See page IN-30 ). NG Repair or replace. OK Check for intermittent problems (See page DI-3 ). 2001 AVALON (RM808U) Author
: Date
: 296 DI-141 DIAGNOSTICS - ENGINE DI08A-09 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch go on when the shift lever is in the N or P shift position. When it goes on, terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. DTC No. P1780 DTC Detecting Condition When driving under conditions (a) and (b) for 30 sec. or more the park/neutral position switch is ON (N position): (2 trip d t ti logic) detection l i ) (a) Vehicle speed: 40 km/h (25 mph) or more (b) Engine speed: 1,500 - 4,000 rpm Trouble Area
Short in park/neutral position switch circuit
Park/neutral P k/ t l position iti switch it h
ECM HINT: After confirming DTC P1780, use the TOYOTA hand-held tester to confirm the PNP switch signal from the CURRENT DATA. WIRING DIAGRAM Refer to DTC P1780 on page DI-199 . INSPECTION PROCEDURE Refer to DTC P1780 on page DI-199 . 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. 2001 AVALON (RM808U) Author
: Date
: 297 DI-53 DIAGNOSTICS - ENGINE DI6T4-03 DTC P0171 System too Lean (Fuel Trim) DTC P0172 System too Rich (Fuel Trim) DTC P0174 System too Lean (A/F Lean Malfunction, Bank2) DTC P0175 System too Rich (Bank2) CIRCUIT DESCRIPTION Fuel trim refers to the feedback compensation value compared to the basic injection time. Fuel trim includes short-term fuel trim and long-term fuel trim. Short-term fuel trim is the short-term fuel compensation used to maintain the air-fuel ratio at its ideal theoretical value. The signal from the A/F sensor is approximately proportional to the existing air-fuel ratio, and ECM comparing it with the ideal theoretical value, the ECM reduces fuel volume immediately if the air-fuel ratio is rich and increases fuel volume if it is lean. Long-term fuel trim compensates the deviation from the central value of the short-term fuel trim stored up by each engine tolerance, and the deviation from the central value due to the passage of time and changes of using environment. If both the short-term fuel trim and long-term fuel trim exceed a certain value, it is detected as a malfunction and the MIL lights up. DTC No. P0171 P0174 P0172 P0175 DTC Detecting Condition Trouble Area When air-fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on rich side (2 trip detection logic)
Air induction system
Injector blockage
Mass air flow meter
Engine coolant temp. sensor
Fuel pressure
Gas leakage on exhaust system
Open or short in A/F sensor (bank 1, 2 sensor 1) circuit
A/F sensor (bank 1, 2 sensor 1)
ECM When air-fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on lean side (2 trip detection logic)
Injector leak, blockage
Mass air flow meter
Engine coolant temp. sensor
Ignition system
Fuel pressure
Gas leakage on exhaust system
Open or short in A/F sensor (bank 1, 2 sensor 1) circuit
A/F sensor (bank 1, 2 sensor 1)
ECM Author
: Date
: 209 DI-54 DIAGNOSTICS - ENGINE HINT:
When the DTC P0171 or P0174 is recorded, the actual air-fuel ratio is on the lean side. When DTC P0172 or P0175 is recorded, the actual air-fuel ratio is on the rich side. If the vehicle runs out of fuel, the air-fuel ratio is lean and DTC P0171 or P0174 is recorded. The MIL then comes on. If the total of the short-term fuel trim value and the long-term fuel trim value is within ± 35 % (80°C (176°F) or more), the system is functioning normally. The A/F sensors (bank 1, 2 sensor 1) output voltage and the short-term fuel trim value can be read using the OBD II scan tool or hand-held tester. The ECM controls the voltage of AFR+, AFL+, AFR- and AFL- terminals of ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or handheld tester. OBD II scan tool (excluding hand-held tester) displays the one fifth of the A/F sensors (bank 1, 2 sensor 1) output voltage which is displayed on the hand-held tester.




WIRING DIAGRAM Refer to DTC P0125 on page DI-43 . 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 Check air induction system (See page SF-1 ). NG Repair or replace. OK 2 Check injector injection (See page SF-23 ). NG Replace injector. OK Author
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: 210 DI-55 DIAGNOSTICS 3 - ENGINE Check mass air flow meter (See page SF-31 ) and engine coolant temperature sensor (See page SF-73 ). NG Repair or replace. OK 4 Check for spark and ignition (See page IG-1 ). NG Repair or replace. OK 5 Check fuel pressure (See page SF-6 ). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter. OK 6 Check gas leakage on exhaust system. NG Repair or replace. OK Author
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: 211 DI-56 DIAGNOSTICS 7 - ENGINE Check output voltage A/F sensor (bank 1, 2 sensor 1). PREPARATION: (a) Connect the OBDII scan tool or TOYOTA hand-held tester to the DLC3. (b) Warm up the A/F sensor with the engine speed at 2,500 rpm for approx. 90 sec. CHECK: Read the voltage value of the A/F sensor on the screen of OBDII scan tool or TOYOTA hand-held tester when you perform all the following conditions. HINT: The voltage of the AFR+ or AFL+ terminal of the ECM is 3.3 fixed the AFR- or AFL- terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AFR+, AFL+/AFR-, AFL-) of the ECM. OK: Condition A/F Sensor Voltage value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (0.660 V*)
Not remains at 3.8 3 8 V (0.76 (0 76 V*) or more
Not remains at 2.8 V (0.56 V*) or less *: When you use OBDII scan tool (excluding TOYOTA hand-held tester) HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (0.56 V*), it is normal.
During fuel cut, there is a case that the output voltage of the A/F sensor is above 3.8 V (0.76 V*), it is normal.
If the output voltage of the A/F sensor remains at 3.30 V (0.660 V*) even after performing all the above conditions, the A/F sensor circuit may be open.
If the output voltage of the A/F sensor remains at 3.8 V (0.76 V*) or more, or 2.8 V (0.56 V*) or less even after performing all the above conditions, the A/F sensor circuit may be short. *: When you use the OBDII scan tool (excluding TOYOTA hand-held tester). OK Go to step 9. NG Author
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: 212 DI-57 DIAGNOSTICS 8 - ENGINE Check for open and short in harness and connector between ECM and A/F sensors (bank 1, 2 sensor 1) (See page IN-30 ). NG Repair or replace harness or connector. OK Replace A/F sensor. 9 Perform confirmation driving pattern (See page DI-106 ). Go 10 Is there DTC P0171, P0172, P0174 or P0175 being output again? YES Check and replace ECM (See page IN-30 ). NO 11 Did vehicle runs out of fuel in past? NO Check for intermittent problems (See page DI-3 ). YES DTC P0171, P0172, P0174 or P0175 is caused by running out of fuel. Author
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: 213 DI-142 DIAGNOSTICS - ENGINE DI08B-09 Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after-start injection control. WIRING DIAGRAM Engine Room J/B ECM IG Switch B-W W-R 8 7 4 W-R 7 IF1 2C B Park/Neutral Position Switch 7 II1 B-W B-R 5 6 B-R 1 F7 Fusible Link 1 F6 Block 4 2 2G AM2 MAIN 5 1 6 2A 3 2 1 2 ST Relay 3 2B 10 W-B 2C B J1 J/C 4 B 2D W-B 2F 4 II2 8 2A 7 E8 STA B B-R FL Main B-R 1 S2 Battery 1 S1 B-R W-B E1 Starter ED A11665 INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the problem symptoms table on page DI-22 . 2001 AVALON (RM808U) Author
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: 298 DI-143 DIAGNOSTICS - ENGINE TOYOTA hand-held tester: 1 Connect TOYOTA hand-held tester, and check STA signal. PREPARATION: (a) Connect the TOYOTA hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand-held tester main switch ON. CHECK: Read the STA signal on the TOYOTA hand-held tester while the starter operates. OK: Ignition Switch Position ON START STA Signal OFF ON OK Proceed to next circuit inspection shown on problem symptom table (See page DI-22 ). NG 2 Check for open in harness and connector between ECM and starter relay (Marking: ST) (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). OBD II scan tool (excluding TOYOTA hand-held tester): 1 Check voltage between terminal STA of ECM connector and body ground. PREPARATION: Remove the glove compartment (See page SF-83 ). CHECK: Measure the voltage between terminal STA of the ECM connector and body ground during the engine cranking. OK: Voltage: 6 V or more START STA (-) (+) A02045 OK Proceed to next circuit inspection shown on problem symptom table (See page DI-22 ). 2001 AVALON (RM808U) Author
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: 299 DI-144 DIAGNOSTICS - ENGINE NG 2 Check for open in harness and connector between ECM and starter relay (Marking: ST) (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 300 DI-2 DIAGNOSTICS - ENGINE DI079-04 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Date Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Driveability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other km miles No initial combustion Back fire Other No complete combustion High ( rpm) Low ( Muffler explosion (after-fire) rpm) Surging Others Dates Problem Occurred Constant Other Condition When Problem Occurs Problem Frequency Sometimes ( times per day/month) Weather Fine Cloudy Rainy Snowy Outdoor Temperature Hot Warm Cool Cold (approx. Place Highway Rough road Engine Temperature Engine Operation Cold Suburbs Other Warming up Inner city After warming up Starting Just after starting ( Constant speed Driving A/C switch ON/OFF Other Condition of MIL Normal Mode (Precheck) Once only Various/Other °F/ °C) Uphill Downhill Any temperature min.) Idling Acceleration Other Racing Deceleration Remains on Sometimes light up Does not light up Normal Malfunction code(s) (code Freezed frame data ( ) Malfunction code(s) (code Freezed frame data ( ) ) DTC Inspection Check Mode Normal ) 2001 AVALON (RM808U) Author
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: 158 DI-14 DIAGNOSTICS - ENGINE DI07B-20 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for the codes listed in the table below. For details of each code, turn to the page referred to under the ’’See page ’’ for the respective ’’DTC No.’’ in the DTC chart. SAE CONTROLLED DTC No. (See page) Detection Item Trouble Area MIL*1 Memory P0100 (DI-23 ) Mass Air Flow Circuit Malfunction  Open or short in mass air flow meter circuit  Mass air flow meter  ECM   P0101 (DI-27 ) Mass Air Flow Circuit Range/ Performance Problem  Mass air flow meter   P0110 (DI-28 ) Intake Air Temp. Circuit Malfunction  Open or short in intake air temp. sensor circuit  Intake air temp. sensor (built into mass air flow meter)  ECM   P0115 (DI-32 ) Engine Coolant Temp. Circuit Malfunction  Open or short in engine coolant temp. sensor circuit  Engine coolant temp. sensor  ECM   P0116 (DI-36 ) Engine Coolant Temp. Circuit Range/Performance Problem  Cooling system  Engine coolant temp. sensor   P0120 (DI-38 ) Throttle/Pedal Position Sensor/ Switch ”A” Circuit Malfunction  Open or short in throttle position sensor circuit  Throttle position sensor  ECM   P0121 (DI-42 ) Throttle/Pedal Position Sensor/ Switch ”A” Circuit Range/Performance Problem  Throttle position sensor   Insufficient Coolant Temp. for Closed Loop Fuel Control  Open or short in A/F sensor (bank 1, 2 sensor 1) circuit  A/F sensor (bank 1, 2 sensor 1)  Air induction system  Fuel pressure  Injector  Gas leakage on exhaust system  ECM   P0128 (DI-48 ) Thermostat Malfunction  Thermostat  Cooling system  Engine coolant temp. sensor  ECM P0136 (DI-49 ) Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2)  Open or short in heated oxygen sensor circuit  Heated oxygen sensor   P0141 (DI-51 ) Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2)  Open or short in heater circuit of heated oxygen sensor  Heated oxygen sensor heater  ECM   P0125 (DI-43 ) Author
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: 170 DI-15 DIAGNOSTICS - ENGINE System too Lean (Fuel Trim)  Air induction system  Injector blockage  Mass air flow meter  Engine coolant temp. sensor  Fuel pressure  Gas leakage on exhaust system  Open or short in A/F sensor (bank 1, 2 sensor 1) circuit  A/F sensor (bank 1, 2 sensor 1)  ECM   P0172 (DI-53 ) System too Rich (Fuel Trim)  Injector leak, blockage  Mass air flow meter  Engine coolant temp. sensor  Ignition system  Fuel pressure  Gas leakage on exhaust system  Open or short in A/F sensor (bank 1, 2 sensor 1) circuit  A/F sensor (bank 1, 2 sensor 1)  ECM   P0174 (DI-53 ) System too Lean (A/F Lean Malfunction)  Same as DTC P0171   P0175 (DI-53 ) System too Rich (A/F Rich Malfunction)  Same as DTC P0172   P0300 (DI-58 ) Random/Multiple Cylinder Misfire Detected P0301 (DI-58 ) Cylinder 1 Misfire Detected P0302 (DI-58 ) Cylinder 2 Misfire Detected P0303 (DI-58 ) Cylinder 3 Misfire Detected *2  P0304 (DI-58 ) Cylinder 4 Misfire Detected P0305 (DI-58 ) Cylinder 5 Misfire Detected P0306 (DI-58 ) Cylinder 6 Misfire Detected P0325 (DI-64 ) Knock Sensor 1 Circuit Malfunction (Bank 1)  Open or short in knock sensor 1 circuit  Knock sensor 1 (looseness)  ECM   P0330 (DI-64 ) Knock Sensor 2 Circuit Malfunction (Bank 2)  Open or short in knock sensor 2 circuit  Knock sensor 2 (looseness)  ECM   P0335 (DI-67 ) Crankshaft Position Sensor ”A” Circuit Malfunction  Open or short in crankshaft position sensor circuit  Crankshaft position sensor  Crankshaft timing pulley  ECM   P0340 (DI-69 ) Camshaft Position Sensor Circuit Malfunction  Open or short in camshaft position sensor circuit  Camshaft position sensor  Camshaft timing gear  ECM   P0420 (DI-71 ) Catalyst System Efficiency Below Threshold (Bank 1)  Gas leakage on exhaust system  A/F sensor (bank 1, 2 sensor 1)  Heated oxygen sensor (bank 1 sensor 2)  Three-way catalytic converter   P0171 (DI-53 )  Open or short in engine wire  Connector connection  Vacuum V h hose connection ti  Ignition system  Injector  Fuel pressure  Mass air flow meter  Engine coolant temp. sensor  Compression pressure  Valve V l clearance l  Valve timing  ECM Author
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: 171 DI-16 DIAGNOSTICS Evaporative Emission Control System Malfunction   P0441 (DI-80 ) Evaporative Emission Control System Incorrect Purge Flow  Vacuum hose cracked, holed blocked, damaged or disconnected ((1), (2), (3), (4), (5), (6), (7), (8), (9), (10) and (11) in Fig. 1)  Fuel tank cap incorrectly installed  Fuel tank cap cracked or damaged  Open or short in vapor pressure sensor circuit  Vapor pressure sensor  Open or short in VSV circuit for EVAP  VSV for EVAP  Open or short in VSV circuit for CCV  VSV for CCV  Open or short in VSV circuit for pressure switching valve  VSV for pressure switching valve  Fuel tank cracked, holed or damaged  Charcoal canister cracked, holed or damaged  Fuel tank over fill check valve cracked or damaged  ECM   P0442 (DI-74 ) Evaporative Emission Control System Leak Detected (Small Leak)  Same as DTC No. P0440   P0446 (DI-80 ) Evaporative Emission Control System Vent Control Malfunction  Same as DTC No. P0441   P0450 (DI-97 ) Evaporative Emission Control System Pressure Sensor Malfunction Evaporative Emission Control System Pressure Sensor Range/ Performance   P0451 (DI-97 )  Open or short in vapor pressure sensor circuit  Vapor V pressure sensor  ECM P0500 (DI-99 ) Vehicle Speed Sensor Malfunction  Combination meter  Open or short in speed sensor circuit  ECM   Idle Control System Malfunction  Open or short in IAC valve circuit  IAC valve is stuck or closed  Open or short in A/C signal circuit  Air induction system  ECM   P0505 (DI-102 ) *2: ENGINE  Hose or tube cracked, holed, damaged or insufficient seal  Fuel tank cap incorrectly installed  Fuel tank cap cracked or damaged  Vacuum hose cracked, holed, blocked, damaged or disconnected  Fuel tank cracked, holed or damaged  Charcoal canister cracked, holed or damaged  Open or short in vapor pressure sensor circuit  Vapor pressure sensor  Fuel tank over fill check valve cracked or damaged  ECM P0440 (DI-74 ) *1: - MIL lights up MIL light up or blinking Author
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: 172 DI-17 DIAGNOSTICS - ENGINE MANUFACTURER CONTROLLED DTC No. (See page) MIL* Memory A/F Sensor Circuit Range/Performance Malfunction (Bank 1 Sensor 1)  Open or short in A/F sensor circuit  A/F sensor  Air induction system  Fuel pressure  Injector  ECM   P1133 (DI-1 11) A/F Sensor Circuit Response Malfunction (Bank 1 Sensor 1)  Open or short in A/F sensor circuit  A/F sensor  Air induction system  Fuel pressure  Injector  ECM   P1135 (DI-1 15) A/F Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)  Open or short in heater circuit of A/F sensor  A/F sensor heater  ECM   P1150 (DI-106 ) A/F Sensor Circuit Range/Performance Malfunction (Bank 2 Sensor 1)  Same as DTC No. P1130   P1153 (DI-1 11) A/F Sensor Circuit Response Malfunction (Bank 2 Sensor 1)  Same as DTC No. P1133   P1155 (DI-1 15) A/F Sensor Heater Circuit Malfunction (Bank 2 Sensor 1)  Same as DTC No. P1135   Igniter Circuit Malfunction (No.1)  Ignition system  Open or short in IGF1 or IGT1 circuit from No.1 ignition coil with igniter to ECM  No.1 ignition coil with igniter  ECM   Igniter Circuit Malfunction (No.2)  Ignition system  Open or short in IGF2 or IGT2 circuit from No.2 ignition coil with igniter to ECM  No.2 ignition coil with igniter  ECM   Igniter Circuit Malfunction (No.3)  Ignition system  Open or short in IGF2 or IGT3 circuit from No.3 ignition coil with igniter to ECM  No.3 ignition coil with igniter  ECM   Igniter Circuit Malfunction (No.4)  Ignition system  Open or short in IGF1 or IGT4 circuit from No.4 ignition coil with igniter to ECM  No.4 ignition coil with igniter  ECM   Igniter Circuit Malfunction (No.5)  Ignition system  Open or short in IGF2 or IGT5 circuit from No.5 ignition coil with igniter to ECM  No.5 ignition coil with igniter  ECM   Igniter Circuit Malfunction (No.6)  Ignition system  Open or short in IGF1 or IGT6 circuit from No.6 ignition coil with igniter to ECM  No.6 ignition coil with igniter  ECM   P1130 (DI-106 ) P1300 (DI-1 17) P1305 (DI-1 17) P1310 (DI-1 17) P1315 (DI-1 17) P1320 (DI-1 17) P1325 (DI-1 17) Detection Item Trouble Area Author
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: 173 DI-18 DIAGNOSTICS - ENGINE P1335 (DI-123 ) Crankshaft Position Sensor Circuit Malfunction (During engine running)  Open or short in crankshaft position sensor circuit  Crankshaft position sensor  Camshaft timing gear  ECM -  P1345 (DI-1 11) VVT Sensor/Camshaft position Sensor Circuit Malfunction (Bank 1)  Open or short in VVT sensor (camshaft position Sensor) circuit  VVT sensor (camshaft position Sensor)  ECM   P1346 (DI-126 ) VVT Sensor/Camshaft position Sensor Circuit Range/Performance Problem (Bank 1)  Mechanical system (Jumping teeth of timing belt, belt stretched)  ECM   P1349 (DI-127 ) VVT System Malfunction (Bank 1)  Valve timing  OCV  VVT controller assembly  ECM   P1350 (DI-124 ) VVT Sensor/Camshaft position Sensor Circuit Malfunction (Bank 2)  Same as DTC No. P1345   P1351 (DI-126 ) VVT Sensor/Camshaft position Sensor Circuit Range/Performance Problem (Bank 2)  Same as DTC No. P1346   P1354 (DI-127 ) VVT System Malfunction (Bank 2)  Same as DTC No. P1349   P1520 (DI-134 ) Stop Light Switch Signal Malfunction  Short in stop light switch signal circuit  Stop light switch  ECM   P1600 (DI-136 ) ECM BATT Malfunction  Open in back up power source circuit  ECM   P1656 (DI-138 ) OCV Circuit Malfunction (Bank 1) P1663 (DI-138 ) OCV Circuit Malfunction (Bank 2)  Open or short in OCV circuit  OCV  ECM   P1780 (DI-141 ) Park/Neutral Position Switch Malfunction  Short in park/neutral position switch circuit  Park/neutral position switch  ECM   B2795 (DI-605 ) Unmatched Key Code  Immobiliser system -  B2796 (DI-606 ) No Communication in Immobiliser System  Immobiliser system -  B2797 (DI-609 ) Communication Malfunction No.1  Immobiliser system -  *: 


MIL lights up. -


MIL does not light up. Author
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: 174 DI-1 DIAGNOSTICS - ENGINE ENGINE DI078-07 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Titles inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Vehicle Brought to Workshop 1 Customer Problem Analysis P. DI-2 2 Connect the OBD II scan tool or TOYOTA hand-held tester to DLC3 P. DI-3 If the display indicates a communication fault in the tool, inspect DLC3 P. DI-3 3 Check DTC and Freezed Frame Data (Precheck) Record or Print DTC and Freezed Frame Data P. DI-3 4 Clear DTC and Freezed Frame Data P. DI-3 5 Visual Inspection 6 Setting the Check Mode Diagnosis P. DI-3 7 Problem Symptom Confirmation If the engine does not start, perform steps 10 and 12 first Malfunction occurs. 9 10 DTC Check P. DI-3 Normal Malfunction code. 11 Basic Inspection P. DI-3 12 14 8 Malfunction does not occur. Symptom Simulation P. IN-20 Problem Symptoms Table P. DI-22 Parts Inspection 15 DTC Chart P. DI-14 13 Circuit Inspection P. DI-23 Check for Intermittent Problems P. DI-3 Identification of Problem 16 Adjustment, Repair 17 Confirmation Test End 2001 AVALON (RM808U) Author
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: 157 DI-19 DIAGNOSTICS - ENGINE DI07C-09 PARTS LOCATION DLC1 ECM OCV (Bank 1) Knock Sensor 2 VSV for EVAP IAC Valve Engine Coolant Temp. Sensor Heated Oxygen Sensor (Bank 1 Sensor 2) VSV for No.2 ACIS Combination Meter Injector DLC3 Throttle Position Sensor Crankshaft Position Sensor Ignition Coil with lgniter Mass Air Flow Meter OCV (Bank 2) VSV for CCV VSV for No.1 ACIS VVT Sensor (Bank 1) VVT Sensor (Bank 2) Knock Sensor 1 Park/Neutral Position Switch VSV for Pressure Switching Valve A/F Sensor (Bank 1 Sensor 1) A/F Sensor (Bank 2 Sensor 1) Canister Vapor Pressure Sensor A11424 2001 AVALON (RM808U) Author
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: 175 DI-3 DIAGNOSTICS - ENGINE DI07A-09 PRE-CHECK 1. (a) DIAGNOSIS SYSTEM Description
When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect the vehicle to the OBD II scan tool complying with SAE J1978 or TOYOTA handheld tester, and read off various data output from the vehicle’s ECM.
S05349 TOYOTA Hand-Held tester A10838 OBD II regulations require that the vehicle’s onboard computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission control system/components or in the powertrain control components which affect vehicle emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is detected, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory (See page DI-14 ). If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automatize but the DTC remain recorded in the ECM memory.
To check the DTC, connect the OBD II scan tool or TOYOTA hand-held tester to the Data Link Connector 3 (DLC3) on the vehicle. The OBD II scan tool or TOYOTA hand-held tester also enables you to erase the DTC and check freezed frame data and various forms of engine data (For operating instructions, see the OBD II scan tool’s instruction book.). DTC include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits (See DTC chart on page DI-14 ). 2001 AVALON (RM808U) Author
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: 159 DI-4 DIAGNOSTICS - ENGINE
The diagnosis system operates in normal mode during normal vehicle use. It also has a check mode for technicians to simulate malfunction symptoms and troubleshoot. Most DTC use 2 trip detection logic* to prevent erroneous detection, and ensure thorough malfunction detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a malfunction that is only detected once or momentarily (TOYOTA hand-held tester only). (See step 2)
*2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory. (1st trip) If the same malfunction is detected again during the second drive test, this second detection causes the MIL to light up. (2nd trip) the 2 trip repeats the same mode a 2nd time (However, the ignition switch must be turned OFF between the 1st trip and 2nd trip.).
Freeze frame data: Freeze frame data records the engine condition when a misfire (DTCs P0300 - P0306) or fuel trim malfunction (DTCs P0171 and P0172) or other malfunction (first malfunction only), is detected. Because freeze frame data records the engine conditions (fuel system, calculated load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) 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. Priorities for troubleshooting: If troubleshooting priorities for multiple DTCs are given in the applicable DTC chart, these should be followed. If no instructions are given, troubleshoot DTCs according to the following priorities. (1) DTC other than fuel trim malfunction (DTCs P0171 and P0172), and misfire (DTCs P0300 - P0306). (2) Fuel trim malfunction (DTCs P0171 and P0172). (3) Misfire (DTCs P0300 - P0306). 2001 AVALON (RM808U) Author
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: 160 DI-5 DIAGNOSTICS (b) 1 2 3 4 5 6 7 8 - ENGINE Check the DLC3. The vehicle’s ECM uses ISO 9141-2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. 9 10 11 12 1314 15 16 DLC3 A04550 Terminal No. Connection/Voltage or Resistance Condition 7 Bus  Line/Pulse generation During transmission 4 Chassis Ground ↔ Body Ground/1 Ω or less Always 5 Signal Ground ↔ Body Ground/1 Ω or less Always 16 Battery Positive ↔ Body Ground/9 - 14 V Always HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the OBD II scan tool or TOYOTA hand-held tester to the DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 2. (a) S05349 INSPECT DIAGNOSIS (Normal Mode) Check the MIL. (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE-53 ). (2) When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE:
If there is no DTC in the normal mode, check the 1st trip DTC using Continuous Test Results function (Mode 7 for SAE J1979) or the OBD II scan tool or TOYOTA hand-held tester. 2001 AVALON (RM808U) Author
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: 161 DI-6 DIAGNOSTICS - ENGINE
TOYOTA hand-held tester only: When the diagnosis system is switched from the normal mode to the check mode, it erases all DTC and freezed frame data recorded in the normal mode. So before switching modes, always check the DTC and freezed frame data, and note them down. (1) Prepare the OBD II scan tool (complying with SAE J 1978) or TOYOTA hand-held tester. (2) Connect the OBD II scan tool or TOYOTA handheld tester to the DLC3 at the lower center of the instrument panel. (3) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand-held tester switch ON. (4) Use the OBD II scan tool or TOYOTA hand-held tester to check the DTC and freezed frame data and note them down (For operating instructions, see the OBD II scan tool’s instruction book.). If there is no DTC in the normal mode, check the 1st trip DTC using Continuous Test Results function (Mode 7 for SAE J1979) on the OBD II scan tool or TOYOTA hand-held tester. (5) See page DI-14 to confirm the details of the DTC. NOTICE:
When simulating symptoms with an OBD II scan tool (excluding TOYOTA hand-held tester) to check the DTC, use the normal mode. For code on the DTC chart subject to ”2 trip detection logic”, perform the following either action.
Turn the ignition switch OFF after the symptom is simulated the 1st time. Then repeat the simulation process again. When the problem has been simulated twice, the MIL lights up and the DTCs are recorded in the ECM.
Check the 1st trip DTC using Mode 7 (Continuous Test Results) for SAE J1979. (c) Clear the DTC. The DTCs and freezed frame data will be erased by either action.
Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand-held tester to erase the codes. (See the OBD II scan tool’s instruction book for operating instructions.)
Disconnecting the battery terminals or EFI fuse. 2001 AVALON (RM808U) Author
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: 162 DI-7 DIAGNOSTICS - ENGINE NOTICE: If the TOYOTA hand-held tester switches the ECM from the normal mode to the check mode or vice-versa, or if the ignition switch is turned from ON to ACC or OFF during the check mode, the DTCs and freezed frame data will be erased. 3. INSPECT DIAGNOSIS (Check Mode) HINT: TOYOTA hand-held tester only: Compared to the normal mode, the check mode has an increased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. Check the DTC. (1) Initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transmission in P or N position
A/C switched OFF (2) Turn the ignition switch OFF. (3) Prepare the TOYOTA hand-held tester. (4) Connect the TOYOTA hand- held tester to the DLC3 at the lower center of the instrument panel. (5) Turn the ignition switch ON and push the TOYOTA hand-held tester switch ON. (6) Switch the TOYOTA hand-held tester from the normal mode to the check mode (Check that the MIL flashes.). NOTICE: If the TOYOTA hand-held tester switches the ECM from the normal mode to the check mode or vice-versa, or if the ignition switch is turned from ON to ACC or OFF during the check mode, the DTC and freezed frame data will be erased. (7) Flashing (8) ON OFF 0.13 Seconds FI3605 Start the engine (The MIL goes out after the engine start.). Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTC, etc. (9) After simulating the malfunction conditions, use the TOYOTA hand-held tester diagnosis selector to check the DTC and freezed frame data, etc. 2001 AVALON (RM808U) Author
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: 163 DI-8 DIAGNOSTICS - ENGINE HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from the check mode to the normal mode, so all DTC, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. 4. FAIL-SAFE CHART If any of the following codes is recorded, the ECM enters fail-safe mode. DTC No. Fail-Safe Operation Fail-Safe Deactivation Conditions P0100 Ignition timing fixed at 10° BTDC Returned to normal condition P0110 Intake air temp. is fixed at 20°C (68°F) Returned to normal condition P0115 Engine coolant temp. is fixed at 80°C (176°F) Returned to normal condition P0120 VTA is fixed at 0° The following condition must be repeated at least 2 times consecutively 0.1 V
VTA
0.95 V, SPD = 0 km/h P0135 P0141 P0155 P1135 P1155 The heater circuit in witch an abnormality is detected is turned off Ignition switch OFF P0325 P0330 Max. timing retardation Ignition switch OFF P1300 Fuel cut Returned to normal condition 5. CHECK FOR INTERMITTENT PROBLEMS TOYOTA hand-held tester only: By putting the vehicle’s ECM in the check mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (1) Clear the DTC (See step 2). (2) Set the check mode (See step 3). (3) Perform a simulation test (See page IN-20 ). (4) Check the connector and terminal (See page IN-30 ). (5) Handle the connector (See page IN-30 ). 6. BASIC INSPECTION When the malfunction code is not confirmed in the DTC check, troubleshooting should be performed in order for all possible circuits to be considered as the cause of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting. 1 Is battery positive voltage 11 V or more when engine is stopped? NO Charge or replace battery. YES 2 Is engine cranked? 2001 AVALON (RM808U) Author
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: 164 DI-9 DIAGNOSTICS - ENGINE NO Proceed to page ST-18 , and continue to troubleshoot. NO Go to step 7. YES 3 Does engine start? YES 4 Check air filter. PREPARATION: Remove the air filter. CHECK: Visually check that the air filter is not dirty or excessive oily. HINT: If necessary, clean the air filter with compressed air. First blow from inside thoroughly, then blow from outside of the air filter. Outside Inside P00495 NG Repair or replace. OK 5 Check idle speed. PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all the accessories. (c) Switch off the A/C. (d) Shift the transmission into the N position. (e) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3 on the vehicle. CHECK: Use the CURRENT DATA to check the idle speed. OK: Idle speed: 650 - 750 rpm NG Proceed to problem symptoms table on page DI-22 . 2001 AVALON (RM808U) Author
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: 165 DI-10 DIAGNOSTICS - ENGINE OK 6 Check ignition timing. DLC1 TE1 E1 SST DLC1 P12915 P12952 PREPARATION: (a) Warm up engine to normal operating temperature. (b) Switch off all the accessories. (c) Switch off the A/C. (d) Shift the transmission into the N position. (e) Keep the engine speed at idle. (f) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 (g) Using a timing light, connect the tester to check wire. CHECK: Check the ignition timing. OK: Ignition timing: 10° BTDC at idle A00209 NG Proceed to page IG-1 , and continue to troubleshoot. OK Proceed to problem symptoms table on page DI-22 . 7 Check fuel pressure. A02330 PREPARATION: (a) Be sure that enough fuel is in the tank. (b) Connect the TOYOTA hand-held tester to the DLC3. (c) Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. (d) Use the ACTIVE TEST mode to operate the fuel pump. (e) If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See page SF-6 ). CHECK: Check that the pulsation damper screw rises up when the fuel pump operates. NG Proceed to page SF-6 , and continue to troubleshoot. 2001 AVALON (RM808U) Author
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: 166 DI-1 1 DIAGNOSTICS - ENGINE OK 8 Check for spark. B04941 PREPARATION: (a) Remove the ignition coil from the spark plug. (b) Remove the spark plug. (c) Install the spark plug to the ignition coil. (d) Disconnect the injector connector. (e) Be sure to ground the screw of the spark plug securely. CHECK: Check if spark occurs while the engine is being cranked. NOTICE:
Do not crash the electrode gap.
To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 - 10 seconds at a time. NG Proceed to page IG-1 , and continue to troubleshoot. OK Proceed to problem symptoms table on page DI-22 . 7. ENGINE OPERATING CONDITION NOTICE: The values given below for ”Normal Condition” are representative values, so a vehicle may still be normal even if its value varies differ from those listed here. So do not decide whether a part is faulty or not solely according to the ”Normal Condition” here. (a) CARB mandated signals. TOYOTA hand-held tester display Measurement Item Normal Condition* FUEL SYS #1 Fuel System Bank 1 OPEN: Air-fuel ratio feedback stopped CLOSED: Air-fuel ratio feedback operating Idling after warming up: CLOSED FUEL SYS #2 Fuel System Bank 2 OPEN: Air-fuel ratio feedback stopped CLOSED: Air-fuel ratio feedback operating Idling after warming up: CLOSED CALC LOAD Calculator Load: Current intake air volume as a proportion of max. intake air volume Idling: 13.1 - 18.7 % Racing without load (2,500rpm): 11.7 - 17.3 % Engine Coolant Temp. Sensor Value After warming up: 80 - 95°C (176 - 203°F) SHORT FT #1 Short-term Fuel Trim Bank 1 0 ± 20 % LONG FT #1 Long-term Fuel Trim Bank 1 0 ± 20 % COOLANT TEMP 2001 AVALON (RM808U) Author
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: 167 DI-12 DIAGNOSTICS - ENGINE SHORT FT #2 Short-term Fuel Trim Bank 2 0 ± 20 % LONG FT #2 Long-term Fuel Trim Bank 2 0 ± 20 % ENGINE SPD Engine Speed Idling: 650 - 750 rpm VEHICLE SPD Vehicle Speed Vehicle stopped: 0 km/h (0 mph) IGN ADVANCE Ignition Advance: Ignition Timing of Cylinder No.1 Idling: BTDC 10 - 25.0° Intake Air Temp. Sensor Value Equivalent to Ambient Temp. Air Flow Rate Through Mass Air Flow Meter Idling: 3.3 - 4.7 gm/sec. Racing without load (2,500 rpm): 10.4 - 15.4 gm/sec. Voltage Output of Throttle Position Sensor Calculated as a percentage: 0 V → 0 %, 5 V → 100 % Throttle valve fully closed: 7 - 11 % Throttle valve fully open: 65 - 75 % O2FT B1 S1 Oxygen Sensor Fuel Trim Bank 1 Sensor 1 (Same as SHORT FT #1) 0 ± 20 % O2S B1 S2 Voltage Output of Oxygen Sensor Bank 1 Sensor 2 Driving 50 km/h (31 mph): 0.05 - 0.95 V O2FT B2 S1 Oxygen Sensor Fuel Trim Bank 2 Sensor 1 (Same as SHORT FT #2) 0 ± 20 % A/FS B1 S1 Voltage Output of A/F Sensor Bank 1 Sensor 1 Idling: 2.8 - 3.8 V A/FS B2 S1 Voltage Output of A/F Sensor Bank 2 Sensor 1 Idling: 2.8 - 3.8 V A/FFT B1 S1 A/F Sensor Fuel Trim Bank 1 Sensor 1 (Same as SHORT FT #1) 0 ± 20 % A/FFT B2 S1 A/F Sensor Fuel Trim Bank 2 Sensor 1 (Same as SHORT FT #1) 0 ± 20 % INTAKE AIR MAF THROTTLE POS ∗: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. (b) TOYOTA Enhanced Signals. TOYOTA hand-held tester display Measurement Item Normal Condition* MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 rpm MISFIRE LOAD Engine load for first misfire range Misfire 0: 0 g/r Fuel injection time for cylinder No.1 Idling: 1.6 - 2.9 ms Intake Air Control Valve Duty Ratio Opening ratio rotary solenoid type IAC valve Idling: 27 - 47 % Starter Signal Cranking: ON CTP SIG Closed Throttle Position Signal Throttle fully closed: ON A/C SIG A/C Switch Signal A/C ON: ON PNP SW Park/Neutral Position Switch Signal P or N position: ON Electrical Load Signal Defogger switch ON: ON Stop Light Switch Signal Stop light switch ON: ON Power Steering Oil Pressure Switch Signal Turn steering wheel: ON FC IDL Fuel Cut Idle: Fuel cut when throttle valve fully closed, during deceleration Fuel cut operating: ON FC TAU INJECTOR IAC DUTY RATIO STARTER SIG ELCTRCL LOAD SIG STOP LIGHT SW PS OIL PRESS SW Fuel Cut TAU: Fuel cut during very light load Fuel cut operating: ON CYL#1 - CYL#6 Abnormal revolution variation for each cylinder 0% IGNITION Total number of ignition for every 1,000 revolutions 0 - 3,000 Intake Air Control Valve VSV Signal VSV operating: ON A/C CUT SIG A/C Cut Signal A/C S/W OFF: ON FUEL PUMP Fuel Pump Signal Idling: ON INTAKE CTRL VSV 2001 AVALON (RM808U) Author
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: 168 DI-13 DIAGNOSTICS - ENGINE EVAP (PURGE) VSV EVAP VSV Signal VSV operating: Above 30 % VAPOR PRESS VSV Vapor Pressure VSV Signal VSV operating: ON TOTAL FT B1 Total Fuel Trim Bank 1: Average value for fuel trim system of bank 1 Idling: 0.8 - 1.2 TOTAL FT B2 Total Fuel Trim Bank 1: Average value for fuel trim system of bank 2 Idling: 0.8 - 1.2 ∗: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. 2001 AVALON (RM808U) Author
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: 169 DI-22 DIAGNOSTICS - ENGINE DI07E-09 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page Engine does not crank (Does not start) 15.Starter 16.Starter relay ST-18 ST-20 No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. ECM DI-148 DI-152 IN-30 No complete combustion (Does not start) 1. Fuel pump control circuit DI-152 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression DI-142 DI-152 EM-3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI-142 DI-152 Hot engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI-142 DI-152 High engine idle speed (Poor idling) 1. A/C signal circuit (Compressor circuit) 2. ECM power source circuit DI-824 DI-148 Low engine idle speed (Poor idling) 1. A/C signal circuit (Compressor circuit) 2. Fuel pump control circuit DI-824 DI-152 Rough idling (Poor idling) 1. Compression 2. Fuel pump control circuit EM-3 DI-152 Hunting (Poor idling) 1. ECM power source circuit 2. Fuel pump control circuit DI-148 DI-152 Hesitation/Poor acceleration (Poor driveability) 1. Fuel pump control circuit 2. A/T faulty DI-152 DI-158 Surging (Poor driveability) 1. Fuel pump control circuit DI-152 Soon after starting (Engine stall) 1. Fuel pump control circuit DI-152 During A/C operation (Engine stall) 1. A/C signal circuit (Compressor circuit) 2. ECM DI-824 IN-30 Unable to refuel/Difficult to refuel 1. ORVR system EC-6 2001 AVALON (RM808U) Author
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: 178 DI-20 DIAGNOSTICS - ENGINE DI4DE-02 TERMINALS OF ECM ECM Terminals E4 9 8 7 6 5 E5 4 3 2 7 6 5 4 3 1 E6 2 1 21 20 19 18 17 16 15 14 13 12 11 10 16 15 14 13 12 11 10 9 8 31 30 29 24 23 22 28 27 26 25 24 23 22 21 20 19 18 17 6 5 4 3 2 E7 1 9 8 7 6 5 4 E8 3 2 1 7 6 5 4 3 2 1 12 11 10 9 8 7 19 18 17 16 15 14 13 12 11 10 15 14 13 12 11 10 9 8 17 16 28 27 26 25 24 23 22 21 20 19 18 15 14 13 22 21 20 17 16 A02016 Symbols (Terminal No.) Wiring Color Condition STD Voltage (V) BATT (E8-1) - E1 (E5-17) B-R ↔ BR Always 9 - 14 +B (E8-16) - E1 (E5-17) B-W ↔ BR IG switch ON 9 - 14 VC (E5-2) - E2 (E5-18) L-R ↔ W IG switch ON 4.5 - 5.5 LG ↔ W IG switch ON, Throttle valve fully closed 0.3 - 1.0 VTA1 (E5-23) (E5 23) - E2 (E5-18) (E5 18) IG switch ON, Throttle valve fully open 2.7 - 5.2 VG (E5-10) - E2G (E5-19) R ↔ R-B Idling, A/C switch OFF 1.1 - 1.5 VV1+ (E4-10) B-W ↔ L - NE- (E5-24) VV2+ (E4-22) - NE- (E5-24) B-W ↔ L OC1+ (E4-6) - OC1- (E4-5) R-B ↔ R - OC2- (E4-18) Pulse generation (See page DI-124 ) Idling Pulse generation (See page DI-124 ) IG switch ON P l generation Pulse ti (See page DI-127 ) B-W ↔ L NE+ (E5-16) - NE- (E5-24) OC2+ (E4-29) Idli Idling R-L ↔ R-W THA (E5-22) - E2 (E5-18) L-B ↔ W Idling, Intake air temp. 20°C (68°F) 0.5 - 3.4 THW (E5-14) - E2 (E5-18) G-Y ↔ W Idling, Engine coolant temp. 80°C (176°F) 0.2 - 1.0 STA (E8-7) - E1 (E5-17) B-R ↔ BR Cranking #10 #20 #30 #40 #50 #60 L ↔ W-B R ↔ W-B Y ↔ W-B WB W ↔ W-B G ↔ W-B G ↔ W-B (E5-5) (E5-6) (E4 1) (E4-1) (E4-2) (E4-3) (E4-4) - E01 E01 E01 E01 E01 E01 (E4-21) (E4-21) (E4-21) (E4 21) (E4-21) (E4-21) (E4-21) IGT1 (E4-11) - E1 (E5-17) GR ↔ BR IGT2 (E4-12) - E1 (E5-17) B-R ↔ BR IGT3 (E4-13) - E1 (E5-17) LG-B ↔ BR IGT4 (E4-14) - E1 (E5-17) L-Y ↔ BR IGT5 (E4-15) - E1 (E5-17) L ↔ BR IGT6 (E4-16) - E1 (E5-17) LG ↔ BR IGF (E4-25) - E1 (E5-17) B-Y ↔ BR 6.0 or more IG switch ON 9 - 14 Idling Pulse generation (See page DI-58 ) Idli Idling Pulse generation ((See page g DI-1 17)) IG switch ON ACIS (E8-17) - E01 (E4-21) R-Y ↔ W-B ACI1 (E5-15) - E01 (E4-21) W-R ↔ W-B FC (E8-3) (E8 3) - E01 (E4-21) (E4 21) G B ↔ W-B G-B WB 4.5 - 5.5 Pulse generation (See page DI-1 17) Idling IG switch it h ON 9 - 14 IG switch ON 9 - 14 Idling 0 - 3.0 2001 AVALON (RM808U) Author
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: 176 DI-21 DIAGNOSTICS - ENGINE EVP1 (E5-7) - E01 (E4-21) B-R ↔ W-B IG switch ON 9 - 14 CCV (E8-10) - E01 (E4-21) G ↔ W-B IG switch ON 9 - 14 RSO (E4-26) - E01 (E4-21) G-B ↔ W-B IG switch ON, Disconnect E11 connector from ECM 9 - 14 OXS (E7-8) - E1 (E5-17) B ↔ BR HTS (E7-9) (E7 9) - E03 (E4(E4 30) LG ↔ W W-B B KNKR (E4-27) - E1 (E5-17) W ↔ BR KNKL (E4-28) - E1 (E5-17) W ↔ BR NSW (E7-20) (E7 20) - E1 (E5-17) (E5 17) B W ↔ BR B-W TACH (E7-27) - E1 (E5-17) B ↔ BR TBP (E7-3) - E01 (E4-21) PTNK (E8-17) (E8 17) - E2 (E5-18) (E5 18) SIL (E8-4) - E1 (E5-17) P-B ↔ W-B P↔W W ↔ BR Maintain engine speed at 2,500 rpm for 3 min. after warming up Idling Pulse generation (See page DI-71 ) Below 3.0 IG switch ON 9 - 14 Pulse generation (See page DI-64 ) Idli Idling IG switch ON, Other shift position in P, N 9 - 14 IG switch ON, Shift position in P, N 0 Idling Pulse generation IG switch ON, Disconnect vacuum hose from vapor pressure sensor IG switch ON 9 - 14 2.9 - 3.7 IG switch ON, Apply vacuum 4.0 kPa (30 mmHg, 1.18 in.Hg) During transmission 0.5 or less Pulse generation IG switch ON, Brake pedal depressed 7.5 - 14 IG switch ON, Brake pedal released Below 1.5 IG switch it h ON 3 0 - 3.6 3.0 36 IG switch it h ON 2 7 - 3.3 2.7 33 Idling Below 3.0 STP (E8-15) (E8 15) - E1 (E5-17) (E5 17) G W ↔ BR G-W AFR+ (E5-11) - E1 (E5-17) B-R ↔ BR AFL+ (E5-12) - E1 (E5-17) B-W ↔ BR AFR- (E5-20) - E1 (E5-17) BR ↔ BR AFL- (E5-21) - E1 (E5-17) L ↔ BR HAFR (E5 (E5-3) 3) - E04 (E5-1) (E5 1) HAFL (E5-4) - E05 (E5-8) B R ↔ W-B B-R WB B-R ↔ W-B KSW (E7-23) (E7 23) - E1 (E5-17) (E5 17) R Y ↔ BR R-Y CODE (E7-28) - E1 (E5-17) P-G ↔ BR At time of inserting key IGSW (E8-2) - E1 (E5-17) B-O ↔ BR IG switch ON TXCT (E7-18) - E1 (E5-17) L-Y ↔ BR At time of inserting key Pulse generation IMLD (E8-22) - E1 (E5-17) V-W ↔ BR In condition without key inserted Pulse generation MREL (E8-8) - E1 (E5-17) L-O ↔ BR IG switch ON IG switch ON 9 - 14 At time of inserting key Below 1.5 In condition without key inserted 4-5 Pulse generation 9 - 14 9 - 14 2001 AVALON (RM808U) Author
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: 177 DI-605 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI1AS-20 CIRCUIT INSPECTION DTC B2795/99 Unmatched Key Code This DTC is output when an unregistered key is inserted. When this DTC is output, delete DTC and insert the key that a customer keeps to check that B2795 is output. When a key that outputs B2795 is found, register this key. when B2795 is not output, there is a possibility that the unregistered key has been inserted before. (ECM is normal.) Inquire a customer the condition of using the system to find the cause of the trouble. (Example: Another key has been inserted, etc..) DTC No. B2795/99 DTC Detecting Condition Trouble Area
Key No communication INSPECTION PROCEDURE 1 Delete DTC and insert all the presently available keys to check whether the engine starts or not. HINT: When inserting the key that does not start the engine, DTC (B 2795) is stored in memory. RESULT: OK OK All keys starts the engine. NG A specific key does not start the engine. No problem. HINT: If the result is ”OK”, please confirm whether or not customers have ever inserted the unregistered key or the immobiliser key (with transponder chip) of other vehicle in the ignition key cylinder, and find out the cause of detecting DTC. NG Register the key that does not start the engine. 2001 AVALON (RM808U) Author
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: 761 DI-606 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI1AT-23 DTC B2796/99 No Communication in Immobiliser system CIRCUIT DESCRIPTION This code is stored in memory when inserting the key that does not have a transponder chip or if communication between the key and ECM is impossible. DTC No. B2796/99 DTC Detecting Condition Trouble Area
Key
Transponder Key Coil
Transponder Key Amplifier
Wire harness
ECM No communication WIRING DIAGRAM T6 Transponder Key Amplifier TXCT RXCK CODE ECM 18 E7 TXCT 4 L-Y 19 E7 RXCK 3 L-O 28 E7 CODE 2 P-G I11736 2001 AVALON (RM808U) Author
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: 762 DI-607 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE 1 Delete DTC and insert all the presently available keys to check whether the engine starts or not. RESULT: A A All keys start the engine. B A specific key does not start the engine. In this case, DTC (B 2796) is stored in memory. C All keys do not start the engine. In this case, DTC (B 2796) is stored in memory. No problem at this time. HINT: If the result is ”A”, please confirm whether or not customers have ever inserted the key (without transponder chip) of other vehicle in the ignition key cylinder, and find out the cause of detecting DTC. B The transponder chip of a specific key is defective. Replace the key. C 2 Check transponder key coil (See page BE-181 ). NG Replace transponder key coil. OK 3 Check harness and connector between transponder key amplifier and ECM. NG Repair or replace harness and connector. OK 2001 AVALON (RM808U) Author
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: 763 DI-608 DIAGNOSTICS 4 - ENGINE IMMOBILISER SYSTEM Does it operate normally after replacement of transponder key amplifier? Yes Replace transponder key amplifier. No Replace ECM. 2001 AVALON (RM808U) Author
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: 764 DI-609 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI6LC-01 DTC B2797/99 Communication Malfunction No.1 CIRCUIT DESCRIPTION This code is detected when although the communication has been performed normally, an error occurs. (Example. Some noise is included in communication line.) DTC No. B2797/99 DTC Detecting Condition Trouble Area
Wire Harness
Transponder Key Amplifier
ECM Communication error WIRING DIAGRAM T6 Transponder Key Amplifier TXCT RXCK CODE ECM 18 E7 TXCT 4 L-Y 19 E7 RXCK 3 L-O 28 E7 CODE 2 P-G I11736 2001 AVALON (RM808U) Author
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: 765 DI-610 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE 1 Noise check PREPARATION: Insert the already registered master key in the key cylinder. CHECK: Using an oscilloscope or hand-held tester, check that noise is included in the signals sent to the CODE terminal of Engine and ECT ECU. OK: No noise is detected. Noise I02681 NG Try to find the cause of the noise and remove it. OK 2 Does the system operate normally after replacement of transponder key amplifier? Yes Replace transponder key amplifier. No Replace ECM. 2001 AVALON (RM808U) Author
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: 766 DI-613 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI6LE-01 Transponder key coil circuit CIRCUIT DESCRIPTION DTC No. B2798/99 Detection Item Trouble Area
Key
Transponder Key Coil
Transponder Key Amplifier
Wire harness
ECM Communication error WIRING DIAGRAM T6 Transponder Key Amplifier 2 ANT2 Transponder Key Coil 1 ANT1 I13607 2001 AVALON (RM808U) Author
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: 769 DI-614 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE 1 Check transponder key coil (See page BE-181 ). NG Replace transponder key coil. OK 2 Check harness and connector between transponder key amplifier and ECM. NG Repair of replace harness and connector. OK 3 Does the system operate normally after replacement of transponder key amplifier? Yes Replace transponder key amplifier. No Replace ECM. 2001 AVALON (RM808U) Author
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: 770 DI-61 1 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI6LD-01 Power source circuit CIRCUIT DESCRIPTION This circuit provides power to operate the Transponder Key ECU WIRING DIAGRAM Engine Room J/B EFI Relay 4 2F 2 2G B 4 2B 1 2 EFI NO. 1 EFI NO. 2 5 3 2 2F T6 Transponder Key Amplifier L-O B-W 6 IF1 1 +B B-W F7 1 W-B J/B No. 4 FL Block F6 1 W-B B 8 4D 5 W-B GND B J6 J/C FL MAIN B ED 8 4F Battery W-B II I13606 2001 AVALON (RM808U) Author
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: 767 DI-612 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE 1 Check EFI fuse. CHECK: Check continuity of EFI fuse. OK: Continuity NG Replace the failure fuse. OK 2 Check voltage between terminals EFI and GND of Transponder Key ECU connector. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the Transponder Key ECU connector. CHECK: Measure voltage between terminals +B and GND. OK: Voltage: 10 - 14 V OK Proceed to next circuit inspection shown in problem symptoms table (See page DI-604 ). NG 3 Check wireharness and connector between Transponder Key ECU and body ground. NG Repair or replace wireharness or connector. OK Check and repair wirehareness and connector between Transponder Key ECU and Battery. 2001 AVALON (RM808U) Author
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: 768 DI-598 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI1AK-12 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE IMMOBLISER Check Sheet Inspector’s : Name Registration No. Registration Year Customer’s Name / / Frame No. Date Vehicle Brought In / km miles Odometer Reading / Date Problem First Occurred / Frequency Problem Occurs Continuous / Intermittent ( times a day) Immobiliser is not set. (Engine starts with key codes other than the registered key code.) Symptoms Engine does not start. Check Item Malfunction Indicator Lamp Normal Remains ON Does not Light Up 1st Time Normal Code Malfunction Code (Code ) 2nd Time Normal Code Malfunction Code (Code ) DTC Check 2001 AVALON (RM808U) Author
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: 754 DI-601 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI1AM-17 DIAGNOSTIC TROUBLE CODE CHART DTC No. (See Page) Detection Item Trouble Area Unmatched key code
Key
Unregistered key inserted before B2796 (DI-606 ) No communication in immobiliser system
Key
Transponder key coil
Amplifier
Wirehaness
ECM B2797 (DI-609 ) Communication malfunction
Communication contents
Unregistered key inserted before B2795 (DI-605 ) HINT: To reduce the unnecessary exchange of ECM, check that a trouble occurs with the original ECM at the time of excanging ECM and the trouble will disappear with a new ECM. 2001 AVALON (RM808U) Author
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: 757 DI-597 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM ENGINE IMMOBILISER SYSTEM DI1AJ-18 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. 1 Customer Problem Analysis P. DI-598 2 Check and Clear DTC (Pre check) P. DI-599 Symptom does not occur 3 Problem Symptom Confirmation 4 Symptom Simulation P. IN-20 7 Problem Symptoms Table P. DI-604 Symptom occurs 5 Normal code DTC Check P. DI-601 Malfunction code 6 DTC Chart P. DI-601 8 Circuit Inspection and Part Inspection P. DI-605 - DI-613 Identification of Problem 9 10 Repair Confirmation Test End Step 2, 5 : Diagnostic steps permitting the use of the hand-held tester or break-out-box. 2001 AVALON (RM808U) Author
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: 753 DI-602 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI1AN-06 PARTS LOCATION Engine Room Junction Block
EFI Fuse ECM Security Indicator Ignition Switch Assembly Instrument Panel Junction Block
Transponder Key Amplifier
IGN Fuse
Transponder Key Coil
Key Unlock Warning Switch I12540 2001 AVALON (RM808U) Author
: Date
: 758 DI-599 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI6LA-01 PRE-CHECK 1. (a) DIAGNOSIS SYSTEM Description ECM controls the function of immobiliser on this vehicle. Data of the immobiliser or DTC can be read form DLC3 of the vehicle. When a trouble occurs on immobiliser, check engine warning light does not light up but DTC inspection is performed. Therefore when there seems to be a trouble on immobiliser, use hand-held tester or SST to check and troubleshoot it. (b) Check the DLC3. The vehicle’s ECM uses ISO 14230 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 14230 format. Hand-held Tester DLC3 F07887 DLC3 N09214 Terminal No. Connection / Voltage or Resistance Condition 7 Bus
Line / Pulse generation During transmission 4 Chassis Ground ↔ Body Ground / 1 Ω or less Always 16 Battery Positive ↔ Body Ground / 9 ∼ 14 V Always HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the hand-held tester to DLC3, turned the ignition switch ON and operated the handheld tester, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 2001 AVALON (RM808U) Author
: Date
: 755 DI-600 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM 2. INSPECT DIAGNOSIS (Normal Mode) (a) Check the DTC using hand-held tester. NOTICE: Hand- held tester only: When the diagnosis system is switched from normal mode to check mode, it erases all DTCs and freezed frame data recorded in normal mode. So before switching modes, always check the DTCs and freezed frame data, and note them down. (1) Prepare the hand-held tester. (2) Connect the hand-held tester to DLC3. (3) Turn the ignition switch ON and push the hand-held tester main switch ON. (4) Use the hand-held tester to check the DTCs and freezed frame data, note them down. (For operating instructions, see the hand-held tester instruction book.) (5) See page DI-601 to confirm the details of the DTCs. (b) Clear the DTC. The following operations will erase the DTCs and freeze frame data. (1) Operating the OBD ll scam tool (complying with SAEJ1978) or hand-held tester to erase the codes. (See the OBD ll scan tool’s instruction book for operating instructions.) (2) Disconnecting the battery terminals or EFI fuse. 2001 AVALON (RM808U) Author
: Date
: 756 DI-604 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI1AP-17 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page Immobiliser is not set. (Engine starts with key codes other than the registered key code.) 1. ECM IN-30 Engine does not start. 1. Key 2. Wire harness 3. Transponder key coil 4. Amplifier 5. ECM *1 IN-30 DI-613 Security indicator is always ON. 1. Security indicator 2. Wire harness 3. ECM *2 IN-30 IN-30 Security indicator is always ON. (Although code has been registered in the automatic registration mode, indicator is not OFF.) 1. Wire harness 2 Transponder key coil 3. Amplifier 4. ECM IN-30 DI-613 Security indicator is OFF. (When DTC of immobiliser is output) 1. Wire harness 2 Transponder key coil 3. Amplifier 4. ECM IN-30 DI-613 Security indicator is OFF. (When DTC of immobiliser is not output) 1. Wire harness 2. ECM IN-30 IN-30 Security indicator is abnormally blinking. 1. Wire harness 2. ECM IN-30 IN-30 IN-30 IN-30 IN-30 *1 : Check that the key which did not start the engine has been registered and that it is possible to start with other already registered key. *2 : Finish the automatic registration mode because the mode might still remain. 2001 AVALON (RM808U) Author
: Date
: 760 DI-603 DIAGNOSTICS - ENGINE IMMOBILISER SYSTEM DI6LB-01 TERMINALS OF ECM E4 E5 E6 E7 E8 D01054 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) CODE ↔ E1 (E7-28 ↔ E5-17) P-G ↔ BR Ignition Switch ON 10 - 14 TXCT ↔ E1 (E7-18 ↔ E5-17) L-Y ↔ BR Ignition Switch ON 10 - 14 IGSW ↔ E1 (E8-2 ↔ E5-17) B-O ↔ BR Ignition Switch ON 10 - 14 RXCK ↔ E1 (E7-19 ↔ E5-17) L-O ↔ BR Ignition Switch ON 10 - 14 2001 AVALON (RM808U) Author
: Date
: 759 DI-494 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI0FY-1 1 CIRCUIT INSPECTION +B Power Source Circuit CIRCUIT DESCRIPTION This is the power source for motors such as the slide motor, reclining motor, front vertical motor and rear vertical motor. WIRING DIAGRAM Power Seat ECU J14 J/C 9 IA1 BR 9 BC1 BR B B BR BR 19 P21 SGND Driver Side J/B 1 1G W PWR SEAT 8 1I A 1 BC1 L-O L-O 8 P20 +B J14 J/C 11 W-B BC1 1 F6 A J13 J/C L-O FL Block 1 F10 7 ID2 B C W-B 7 C P20 GND W-B A J11 J/C FL MAIN BR IH Battery BK I13620 2001 AVALON (RM808U) Author
: Date
: 650 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-495 INSPECTION PROCEDURE 1 Check voltage between terminals +B and GND of Seat Position Control ECU connector. PREPARATION: Remove Seat Position Control ECU with connectors still connected. CHECK: Measure voltage between terminals +B and GND of Seat Position Control ECU connector. OK: Voltage: 10 - 14 V 8 (+B) 7 (GND) (-) (+) I11589 OK Proceed to next circuit inspection shown on problem symptom table (See page DI-493 ). NG 2 Check continuity between terminals GND of Seat Position Control ECU connector and body ground. CHECK: Measure resistance between terminals GND of Seat Position Control ECU connector and body ground. OK: Resistance: Continuity (below 1 Ω) (-) 8 (GND) (+) I11590 NG Repair or replace harness or connector. OK 2001 AVALON (RM808U) Author
: Date
: 651 DI-496 3 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) Check POWER SEAT fuse. NG Check for short in all the harness and components connected to the POWER SEAT fuse, and repair them (See attached wiring diagram). OK Check and repair harness or connector between Seat Position Control ECU and battery. 2001 AVALON (RM808U) Author
: Date
: 652 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-497 DI0G1-09 ECU Power Source Circuit CIRCUIT DESCRIPTION This circuit provides power for ECU operation and is also the power source for the sensor. WIRING DIAGRAM BR 9 IA1 BR Power Seat ECU J14 J/C 9 BC1 B 19 P21 SGND B BR BR J/B No. 3 W-G 5 3C 14 3E W-G Driver Side J/B 9 1B A ECU-B 5 BC1 9 1J W-L 1 2C DCC 1 F6 1 F7 2 2G B FL MAIN B BR IH W-G Engine Room J/B J13 J/C A 25 P21 SYSB Battery FL Block I13626 2001 AVALON (RM808U) Author
: Date
: 653 DI-498 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) INSPECTION PROCEDURE 1 Check voltage between terminals SYSB and SGND of Seat Position Control ECU connector. (-) (+) 19 (SGND) 25 (SYSB) PREPARATION: Remove Seat Position Control ECU with connectors still connected. CHECK: Measure voltage between terminals SYSB and SGND of Seat Position Control ECU connector. OK: Voltage: 10 - 14 V I11592 OK Proceed to next circuit inspection shown on problem symptom table (See page DI-493 ). NG 2 Check continuity between terminals SGND of Seat Position Control ECU connector and body ground. CHECK: Measure resistance between terminal SGND of Seat Position Control ECU connector and body ground. OK: Resistance: Continuity (below 1 Ω) (-) (+) 19 (SGND) I11591 NG Repair or replace harness or connector. OK 2001 AVALON (RM808U) Author
: Date
: 654 DIAGNOSTICS 3 - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-499 Check ECU-B No. 2 fuse. NG Check for short in all the harness and components connected to ECU-B No. 2 fuse and repair them (See attached wiring diagram). OK Check and repair harness or connector between Seat Position Control ECU and battery. 2001 AVALON (RM808U) Author
: Date
: 655 DI-508 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI0GF-09 Ignition Switch Circuit CIRCUIT DESCRIPTION This circuit sends an ignition switch ON or OFF signal to the ECU. WIRING DIAGRAM Power Seat ECU Driver Side J/B IG1 RELAY GAUGE NO. 1 2 1 1 1G 3 1B 4 2 1D 4 1C 3 R-B 8 ID1 5 B AM1 2 5 I15 Ignition Switch W-L Engine Room J/B 1 2H 1 2G R-B 13 P21 IG W-R Engine Room R/B No. 5 1 R-B 7 BC1 7 IF1 2 AM1 IG1 4 W-L FL Block B-L 1 F8 ALT 1 F6 FL MAIN B F10 1 W IG Battery W-B I14526 2001 AVALON (RM808U) Author
: Date
: 664 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-509 INSPECTION PROCEDURE 1 Check voltage between terminal IG of Seat Position Control ECU connector and body ground. (-) PREPARATION: Remove Seat Position Control ECU with connectors still connected. CHECK: Measure voltage between terminal IG of Seat Position Control ECU connector and body ground when ignition switch is ON and OFF. OK: (+) 13 (IG) I11595 Ignition switch Voltage ON 10 ∼ 14 V OFF 0V OK Proceed to next circuit inspection shown in problem symptom table (See page DI-493 ). NG Check for short in all the harness and components connected to GAUGE fuse. NG 2 Check GAUGE fuse. NG Check and repair harness or connector between Seat Position Control ECU and battery. 2001 AVALON (RM808U) Author
: Date
: 665 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-515 DI6KZ-01 Mirror switch circuit CIRCUIT DESCRIPTION This circuit detects the conditions of the mirror selection switch and the mirror position switch. WIRING DIAGRAM R5 Power Seat ECU Remoto Control Mirror Switch E MSW M+ 9 W-L 8 P 7 Y-G 3 IA1 15 IA1 14 IA1 W-L P Y-G 10 BC1 W-L 3 BC1 4 BC1 P Y-G 18 P21 MIRE 1 P21 MIRB 2 P21 MIRG I13619 2001 AVALON (RM808U) Author
: Date
: 671 DI-516 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) INSPECTION PROCEDURE 1 Check mirror switch (See page BE-1 14). NG Replace the mirror switch. OK 2 Check wireharness and connector between mirror switch and power seat control ECU. NG Repair or replace wireharness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-493 ). 2001 AVALON (RM808U) Author
: Date
: 672 DI-500 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI0G4-08 Motor Circuit CIRCUIT DESCRIPTION The Seat Position Control ECU controls the 4 motors for slide, front vertical, rear vertical and reclining. WIRING DIAGRAM Power Seat ECU J14 J/C C 7 P20 GND C W-B W-B 1 P20 RCL- R-B P24 Power Seat Motor 1 2 R-W 2 P20 RCL+ Reclining Control BC1 11 9 L-W P22 W-B P20 FRV- Power Seat Motor L-R 1 2 Front Vertical Control 3 P20 SLD- L-B P25 A J11 J/C Power Seat Motor L 2 1 4 P20 SLD+ Slide Control 6 P20 LFT+ L-Y BK 10 P20 FRV+ P23 Power Seat Motor R 2 1 5 P20 LFT- Rear Vertial Control I13625 2001 AVALON (RM808U) Author
: Date
: 656 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-501 INSPECTION PROCEDURE 1 Check motor. Slide Motor 2 1 1 2 N21468 PREPARATION: (a) Remove seat. (b) Disconnect each motor connector. CHECK: Check seat movement when battery positive voltage is applied to each motor. Slide Motor CHECK: Connect battery
to terminal 2 and battery  to terminal 1 of the slide motor connector. OK: The seat moves forward. CHECK: Connect battery  to terminal 2 and battery
to terminal 1 of the slide motor connector. OK: The seat moves backward. 2001 AVALON (RM808U) Author
: Date
: 657 DI-502 DIAGNOSTICS Front Vertical Motor Rear Vertical Motor Reclining Motor 2 1 2 1 2 1 2 1 2 1 2 1 N21467 N21465 N21466 I00528 - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) Front Vertical Motor CHECK: Connect battery
to terminal 2 and battery  to terminal 1 of the front vertical motor connector. OK: The front of the seat cushion rises. CHECK: Connect battery  to terminal 2 and battery
to terminal 1 of the front vertical motor connector. OK: The front of the seat cushion lowers. Rear Vertical Motor CHECK: Connect battery
to terminal 2 and battery  to terminal 1 of the rear vertical motor connector. OK: The front of the seat cushion rises. CHECK: Connect battery  to terminal 2 and battery
to terminal 1 of the rear vertical motor connector. OK: The front of the seat cushion lowers. Reclining Motor CHECK: Connect battery
to terminal 2 and battery  to terminal 1 of the reclining motor connector. OK: The seat back returns to up right. CHECK: Connect battery  to terminal 2 and battery
to terminal 1 of the reclining motor connector. OK: The seat back is reclining. NG Replace motor. OK 2001 AVALON (RM808U) Author
: Date
: 658 DIAGNOSTICS 2 - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-503 Check harness and connector between Seat Position Control ECU and motor (See page DI-489 ). NG Repair or replace harness or connector. OK Proceed to next circuit inspection shown on problem symptom table (See page DI-493 ). 2001 AVALON (RM808U) Author
: Date
: 659 DI-506 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI0G9-08 Position Sensor Circuit CIRCUIT DESCRIPTION 1 pulse output per one turn of motor 8V 0V ECU Position Sensor (in Motor) BE3991 The position sensor senses movement of the seat and send pulse signals to the ECU. The position sensor sends pulse to the ECU in proportion to the amount of seat movement, as shown in the diagram on the left. The ECU uses the number of pulses to constantly calculate the position relative to the memory position and returns the seat to the memorized position. If a malfunction occurs in a position sensor and a sensor signal is not input to the ECU even when the motor operates, the ECU prohibits return operation. WIRING DIAGRAM See page DI-504 . INSPECTION PROCEDURE 1 Check position sensor. Example: Slide Motor Motor (+) 2 Sensor 1 3 (-) 2 (-) 1 (+) N14754 PREPARATION: Disconnect the connector of the sensor and the connector of the motor leading to the sensor. CHECK: (a) Connect positive
lead to terminal 3 of sensor and negative  lead to terminal 2. (b) Measure voltage between terminal 1 of sensor and body ground when battery positive voltage is applied between terminals 1 and 2 of motor connector. HINT: When the battery positive voltage is applied to the motor connector terminals,
and  are interchangeable. OK: Condition Voltage Motor stopped (Check several times with the motor in a different position each time.) 0 V or battery positive voltage according to stop position. with motor turning half of battery positive voltage NG Replace position sensor. OK 2001 AVALON (RM808U) Author
: Date
: 662 DIAGNOSTICS 2 - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-507 Check harness and connectors between Seat Position Control ECU and position sensors (See page IN-30 ). NG Repair or replace harness or connectors. OK Check and replace Seat Position Control ECU. 2001 AVALON (RM808U) Author
: Date
: 663 DI-504 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI0G6-09 Position Sensor Power Source Circuit CIRCUIT DESCRIPTION This circuit provides power to the slide, front vertical and reclining position sensors. WIRING DIAGRAM J14 J/C B B BR L-R BR 3 BC1 9 BR IA1 9 BR A J3 J/C J14 L J/C A 3 R A A R P29 Front Vertical Control A 2 1 L-B BR BR B 3 BR 3 P21 SSRS 5 P21 PVCC 4 P21 SSFV R P30 Rear Vertical Control 2 1 L-W BR 3 16 P21 SSRR R P32 Slide Control 2 1 B A IH Power Seat ECU P31 Power Seat Position Sensor Reclining Control 2 1 17 P21 SSRL R I13624 2001 AVALON (RM808U) Author
: Date
: 660 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-505 INSPECTION PROCEDURE 1 Check voltage between terminal PVCC of Seat Position Control ECU connector and body ground. (-) (+) 5 (PVCC) I11593 PREPARATION: Remove Seat Position Control ECU with connectors still connected. CHECK: While operating the Power Seat Control Switch and moving the seat, check voltage between terminal PVCC of Seat Position Control ECU connector and body ground. OK: Voltage: 7.2 - 8.8 V OK Proceed to next circuit inspection shown on problem symptom table (See page DI-493 ). NG 2 Check harness and connector connected to terminal PVCC of Seat Position Control ECU (See page IN-30 ). CHECK: Check for open or short in the harness and check connectors for the position sensor power source circuit outlined in the diagram with a thick line (-). NG Repair or replace harness or connector. OK Check and replace Seat Position Control ECU. 2001 AVALON (RM808U) Author
: Date
: 661 DI-510 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI0GG-06 Power Seat Control Switch Circuit CIRCUIT DESCRIPTION When the power seat control switch is operated, a signal is sent from the power seat control switch to the ECU and the ECU sends a signal to the motor to make it operate. Even if a malfunction should occur with the position sensor and return operation is prohibited, manual operation will occur as normal. WIRING DIAGRAM Power Seat ECU P18 Power Seat Switch 12 P21 RCLR 2 G 10 P21 RCLF 3 G-B 24 P21 FDWN 5 R-B 23 P21 FUP 10 B-Y 8 P21 SLDR 6 B-R 6 P21 SLDF 9 B 22 P21 LUP 7 R-W 11 P21 LDWN 8 R-Y 7 P21 GND W-B C C W-B 1 C W-B J14 J/C 11 BC1 W-B A J11 J/C BK I13623 2001 AVALON (RM808U) Author
: Date
: 666 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-51 1 INSPECTION PROCEDURE 1 Check voltage between each terminal of the Power Seat Control Switch and SGND of Seat Position Control ECU connector. 11 (LDWN) 10 (RCLF) 8 (SLDR) 12 (RLCR) (+) 6 (SLDF) 19 (SGND) 24 (FDWN) 22 (LUP) (-) 23 (FUP) I11594 PREPARATION: Remove Seat Position Control ECU with connectors still connected. CHECK: Measure voltage between each terminal of the Power Seat Control Switch and SGND of Seat Position Control ECU connector. (The illustration shows inspection of the reclining as an example.) OK: At each terminal with switch ON 0V At each terminal with switch OFF 10 ∼ 14 V OK Proceed to next circuit inspection shown in problem symptom table (See page DI-493 ). NG 2 Check power seat control switch. Reclining Forward Front Front Vertical Up Rear Back Lifter Up PREPARATION: (a) Remove seat. (b) Disconnect power seat control switch. CHECK: Check continuity between terminals when switch operated. OK: Driver’s seat slide switch: Switch position Tester connection Specified condition FRONT 1-9 Continuity BACK 1-6 Continuity Driver’s seat front vertical switch: Down Down Switch position Tester connection Specified condition UP 1-5 Continuity DOWN 1 - 10 Continuity Driver’s seat lifter switch: I04159 Switch position Tester connection Specified condition UP 1-8 Continuity DOWN 1-7 Continuity 2001 AVALON (RM808U) Author
: Date
: 667 DI-512 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) Driver’s seat reclining switch: Switch position Tester connection FORWARD 1-3 Continuity Specified condition REAR 1-2 Continuity Passenger ’s slide switch: Switch position Tester connection Specified condition FRONT 1-9 Continuity BACK 1-6 Continuity Passenger ’s front vertical switch: Switch position Tester connection Specified condition UP 1 - 10 Continuity DOWN 1-5 Continuity Passenger ’s lifter switch: Switch position Tester connection Specified condition UP 1-7 Continuity DOWN 1-8 Continuity Passenger ’s reclining switch: Switch position Tester connection FORWARD 1-3 Continuity REAR 1-2 Continuity NG Specified condition Replace power seat control switch. OK 3 Check harness and connectors between Seat Position Control ECU and power seat control switch (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace Seat Position Control ECU. 2001 AVALON (RM808U) Author
: Date
: 668 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-513 DI0GH-06 Seat Memory Switch CIRCUIT DESCRIPTION Seat memory switch send memory and return signals to the seat position control ECU. WIRING DIAGRAM S14 Seat Memory Switch Power Seat ECU 2 20 4 P21 Y 1 21 3 P21 G-W MMRY SW1 9 1 P21 G-Y E SW2 MMRY 7 2 P21 W-B SWE I13621 INSPECTION PROCEDURE 1 Check voltage between each terminal of the seat memory switch and SGND of Seat Position Control ECU connector. (+) (-) 21 (SW1) 20 (SW2) 9 (MMRY) 19 (SGND) I11616 PREPARATION: Remove Seat Position Control ECU with connectors still connected. CHECK: Measure voltage between terminal of the seat memory switch and SGND of Seat Position Control ECU connector. (The illustration shows inspection of the Memory 1 as an example.) OK: At each terminal with switch ON 0V At each terminal with switch OFF 10 ∼ 14 V OK Proceed to next circuit inspection shown in problem symptom table (See page DI-493 ). 2001 AVALON (RM808U) Author
: Date
: 669 DI-514 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) NG 2 Check seat memory switch. PREPARATION: Disconnect seat memory switch connector. CHECK: Check continuity of each terminal. OK: (Example) Inspection of SET Switch 2 1 N21463 NG Switch position Terminal SET switch ON 1-2 Memory switch 1 2-3 Memory switch 2 2-4 Replace seat memory switch. OK 3 Check harness and connectors between Seat Position Control ECU and seat memory switch (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace Seat Position Control ECU. 2001 AVALON (RM808U) Author
: Date
: 670 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-489 DI0FR-06 CUSTOMER PROBLEM ANALYSIS CHECK POWER SEAT CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date of Vehicle Brought in / / / Date Problem First Occurred
Continuous How Often Problem Occurs Problem Symptom
Manual Function does not operate.
Return Function does not operate. km Mile Odometer Reading
Slide
Front Vertical /
Intermittent ( Times a day)
Rear Vertical
Slide
Front Vertical
Does not operate in any conditions
Only with key inserted
Only with key not inserted
Only with memory & return switch 1 or 2
Reclining
Rear Vertical
Memory function does not operate.
Position return function does not stop when brake pedal is depressed. 2001 AVALON (RM808U) Author
: Date
: 645 DI-488 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI0FP-07 HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following page. Vehicle Brought to Workshop 1 Customer Problem Analysis Titles inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. P. DI-489 Symptom does not occur 2 Problem Symptom Confirmation 3 Symptom Simulation P. IN-20 Symptom occur 4 Problem Symptom Table P. DI-493 5 Circuit Inspection Parts Inspection P. DI-494 - DI-513 Identification of Problem 6 7 Repair Confirmation Test Step 5, 7 : Diagnostic steps permitting the use of the hand-held tester and breakout-box. End 2001 AVALON (RM808U) Author
: Date
: 644 DI-490 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI0FT-05 PARTS LOCATION Engine Room Junction Block
ECU-B NO. 1 Fuse Instrument Panel Junction Block
PWR SEAT M-Fuse Reclining Motor Power Seat Control ECU Rear Vertical Motor Lumbar Support Switch Slide Motor Power Seat Control Switch Front Vertical Motor Seat Memory Switch I12537 2001 AVALON (RM808U) Author
: Date
: 646 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-493 DI0FV-08 PROBLEM SYMPTOMS TABLE Perform troubleshooting of the circuits for the applicable problem symptom in the order given in the chart below. Proceed to the page located for each circuit. HINT:
If the instruction ”Proceed to next circuit inspection shown on problem symptom table” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check.
If the trouble still reappears even though there are no abnormalities in any of the other circuits, then check and replace the Seat Position Control ECU as the last step. Symptom Suspect Area See page Both manual & return functions do not operate(All functions). 3. 4. 5. 6. +B power source circuit Power seat control switch circuit Motor circuit Power seat control ECU DI-494 DI-510 DI-500 IN-30 Both manual & return functions do not operate(One function only). 1. Motor circuit 2. Power seat control ECU DI-500 IN-30 One or all functions do not operate for manual operation only. 1. Power seat control switch circuit 2. Power seat control ECU DI-510 IN-30 Memory function does not operate. 1. Power seat memory switch circuit 2. Ignition switch circuit 3. Power seat control ECU DI-510 DI-508 IN-30 Return operation does not stop when brake pedal is depressed. 1. Stop light switch circuit 2. Power seat control ECU DI-662 IN-30 Only return function does not operate or operates a little, then stops (All return functions). 1. 2. 3. 4. DI-513 DI-497 DI-504 IN-30 Only return function does not operate or operates a little, then stops (Only one return function). 1. Position sensor circuit 2. Power seat control ECU Power seat memory switch circuit ECU power source circuit Position sensor power source circuit Power seat control ECU DI-506 IN-30 2001 AVALON (RM808U) Author
: Date
: 649 DIAGNOSTICS - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) DI-491 DI6KY-01 TERMINALS OF ECU P21 P20 I11581 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) SSFV ↔ SGND (P21-4 ↔ P21-19) L-B ↔ BR Front vertical operation 0V↔8V SSRL ↔ SGND (P21-17 ↔ P21-19) L-W ↔ BR Rear vertical operation 0V↔8V SSRR ↔ SGND (P21-16 ↔ P21-19) L-R ↔ BR Reclining operation 0V↔8V PVCC ↔ SGND (P21-5 ↔ P21-19) R ↔ BR FDWN ↔ Body Ground (P21-24 ↔ Body Ground) RB R-B IG ↔ Body Ground (P21-13 ↔ Body Ground) Power seat operation 8V Seat lowered using front vertical SW Below 1 V Others 10 - 14 V R-B Ignition SW ON 10 - 14 V SYSB ↔ Body Ground (P21-25 ↔ Body Ground) W-G Always 10 - 14 V MPX1 ↔ Body B d Ground G d (P21-14 ↔ Body Ground) G-W SGND ↔ Body Ground (P21-19 ↔ Body Ground) BR SSRS ↔ SGND (P21-3 ↔ P21-19) L ↔ BR SLDF ↔ Body Ground (P21-6 ↔ Body Ground) B SLDR ↔ Body Ground (P21-8 ↔ Body Ground) BR B-R LUP ↔ Body Ground (P21-22 ↔ Body Ground) RW R-W LDWN ↔ Body Ground (P21-11 ↔ Body Ground) RY R-Y FUP ↔ Body Ground (P21-23 ↔ Body Ground) BY B-Y RCLF ↔ Body Ground (P21-10 ↔ Body Ground) GB G-B RCLR ↔ Body Ground (P21-12 ↔ Body Ground) G RCL ↔ GND RCL(P20-1 ↔ P20-7) 0 V ↔ 12 V Multiplex communication circuit signals R B ↔ W-B R-B WB Others Resistance (Approx. 2.5 kΩ) Always Below 1 V Slide operation 0V↔8V Seat moved forward using slide SW Below 1 V Others 10 - 14 V Seat moved to rear using slide SW Below 1 V Others 10 - 14 V Seat raised using rear vertical SW Below 1 V Others 10 - 14 V Seat lowered using rear vertical SW Below 1 V Others 10 - 14 V Seat raised using front vertical SW Below 1 V Others 10 - 14 V Seat moved forward using reclining SW Below 1 V Others 10 - 14 V Seat moved to rear using reclining SW Below 1 V Others 10 - 14 V Seat moved to rear using reclining SW 10 - 14 V Others Below 1 V 2001 AVALON (RM808U) Author
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: 647 DI-492 DIAGNOSTICS RCL+ ↔ GND (P20-2 ↔ P20-7) R W ↔ W-B R-W WB SLD ↔ GND SLD(P20-3 ↔ P20-7) L B ↔ W-B L-B WB SLD+ ↔ GND (P20-4 ↔ P20-7) L ↔ W-B WB LFT ↔ GND LFT(P20-5 ↔ P20-7) R ↔ W-B WB LFT+ ↔ GND (P20-6 ↔ P20-7) L Y ↔ W-B L-Y WB - POWER SEAT CONTROL SYSTEM (w/ Driving Position Memory) Seat moved forward using reclining SW 10 - 14 V Others Below 1 V Seat moved to rear using slide SW 10 - 14 V Others Below 1 V Seat moved forward using slide SW 10 - 14 V Others Below 1 V Seat lowered using rear vertical SW 10 - 14 V Others Below 1 V Seat raised using rear vertical SW 10 - 14 V Others Below 1 V GND ↔ Body Ground (P20-7 ↔ Body Ground) W-B AIways Below 1 V +B ↔ Body Ground (P20-8 ↔ Body Ground) L-O Always 10 - 14 V Seat lowered using front vertical SW 10 - 14 V Others Below 1 V Seat raised using front vertical SW 10 - 14 V Others Below 1 V Set switch position is OFF. 10 - 14 V Set switch position is ON. Below 1 V Memory Switch 1 position is OFF. 10 - 14 V Memory Switch 1 position is ON. Below 1 V Memory Switch 2 position is OFF. 10 - 14 V Memory Switch 2 position is ON. Below 1 V FRV ↔ GND FRV(P20-9 ↔ P20-7) L W ↔ W-B L-W WB FRV+ ↔ GND (P20-10 ↔ P20-7) L R ↔ W-B L-R WB MMRY ↔ SWE (P21-9 ↔ P21-7) G Y ↔ W-B G-Y WB SW1 ↔ SWE (P21-21 ↔ P21-7) G W ↔ W-B G-W WB SW2 ↔ SWE (P21-20 ↔ P21-7) Y ↔ W-B WB 2001 AVALON (RM808U) Author
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: 648 DI-362 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4CK-03 CIRCUIT INSPECTION DTC B0100/13 Short in D Squib Circuit CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0100/13 is recorded when a short is detected in the D squib circuit. DTC No. B0100/13 DTC Detecting Condition Trouble Area
Short circuit between D+ wire harness and D- wire harness of squib
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly D Squib 1 Y-B 2 Y 14 C6 D+ 13 C6 D- Spiral Cable H01451 2001 AVALON (RM808U) Author
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: 518 DI-363 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check D squib circuit. Airbag Sensor Assembly Spiral Cable D Squib D- D+ (-) H01001 H02142 PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the spiral cable (See page DI-349 ). CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D-. OK: Resistance: 1 MΩ or Higher (+) H02193 NG Go to step 5. OK 2001 AVALON (RM808U) Author
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: 519 DI-364 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Spiral Cable D Squib →← ACC ON or DTC B0100/13 DLC1 E1 Tc H01002 AB0118 AB0119 R13006 FI1390 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not relevant to this check. H07478 NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
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: 520 DI-365 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Airbag Sensor Assembly Spiral Cable D Squib ACC ON or DLC1 E1 DTC B0100/13 Tc H01003 AB0118 AB0119 R13006 FI1390 H01136 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (b) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI-349 ). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI-349 ). OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 521 DI-366 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly Spiral Cable ←→ D Squib D- D+ (-) PREPARATION: (a) Disconnect the connector between the airbag sensor assembly and the spiral cable. (b) Release the airbag activation prevention mechanism of the spiral cable connector on the airbag sensor assembly side (See page DI-349 ). CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D-. OK: Resistance: 1 MΩ or Higher (+) H01000 H02142 H02195 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib D- (-) D+ PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the spiral cable (See page DI-349 ). CHECK: For the connector (on the spiral cable side) between the airbag sensor assembly and the spiral cable, measure the resistance between D+ and D-. OK: Resistance: 1 MΩ or Higher (+) NG H01004 R14286 H01138 Repair or replace harness or connector between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
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: 522 DI-367 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4CL-02 DTC B0101/14 Open in D Squib Circuit CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each components, see OPERATION on page RS-3 . DTC B0101/14 is recorded when an open is detected in the D squib circuit. DTC No. DTC Detecting Condition B0101/14 Trouble Area
Open circuit in D+ wire harness or D- wire harness of squib
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-362 . INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI-475 ) 2 Check D squib circuit. CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D-. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Spiral Cable D Squib ←→ D- (-) D+ (+) H01001 R14286 H01139 NG Go to step 5. OK 2001 AVALON (RM808U) Author
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: 523 DI-368 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Spiral Cable D Squib Airbag Sensor Assembly →← D- D+ ACC ON or DLC1 E1 DTC B0101/14 Tc H01002 AB0069 AB0118 AB0119 R13006 W02044 H01140 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D- of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI-349 ). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI-349 ). OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 524 DI-369 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. D Squib Airbag Sensor Assembly Spiral Cable →← ACC ON or DLC1 E1 DTC B0101/14 Tc H01003 AB0118 AB0119 R13006 W02044 H01141 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI-349 ). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI-349 ). OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
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: 525 DI-370 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Spiral Cable D Squib ←→ D- Airbag Sensor Assembly D+ H01000 R14286 H01142 PREPARATION: Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D-. OK: Resistance: Below 1 Ω NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib D+ D- (-) H01004 R14286 CHECK: For the connector (on the spiral cable side) between the airbag sensor assembly and the spiral cable, measure the resistance between D+ and D-. OK: Resistance: Below 1 Ω (+) NG Repair or replace harness or connector between airbag sensor assembly and spiral cable. H01143 OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 526 DI-371 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4DM-02 DTC B0102/11 Short in D Squib Circuit (to Ground) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0102/11 is recorded when a ground short is detected in the D squib circuit. DTC No. B0102/11 DTC Detecting Condition Trouble Area
Short circuit in D squib wire harness (to ground)
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-362 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check D squib circuit. CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Spiral Cable D Squib D+ (-) H01001 H02145 (+) NG Go to step 5. H02198 OK 2001 AVALON (RM808U) Author
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: 527 DI-372 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Spiral Cable D Squib Airbag Sensor Assembly →← ACC D- ON D+ or DLC1 E1 DTC B0102/11 Tc H01002 H02144 AB0069 AB0118 AB0118 R13006 W02042 H11569 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D- of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 528 DI-373 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Airbag Sensor Assembly Spiral Cable D Squib ACC ON or DLC1 E1 DTC B0102/11 Tc H01003 AB0118 AB0119 R13006 W02042 H01128 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 529 DI-374 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly Spiral Cable D Squib PREPARATION: Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: For the connector (on the spiral cable side) between the steering wheel pad and the spiral cable, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher ←→ D+ (-) (+) H01000 H02145 H02200 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib CHECK: For the connector (on the spiral cable side) between the spiral cable and the airbag sensor assembly, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher D+ (-) (+) H01004 R14301 H06304 NG Repair or replace harness between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 530 DI-375 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4DN-02 DTC B0103/12 Short in D Squib Circuit (to B+) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0103/12 is recorded when a B+ short is detected in the D squib circuit. DTC No. DTC Detecting Condition B0103/12 Trouble Area
Short circuit in D squib wire harness (to B+)
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-362 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check D squib circuit. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the voltage between D+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly Spiral Cable D Squib D+ (-) AB0119 H01001 H02146 (+) NG Go to step 5. H11570 OK 2001 AVALON (RM808U) Author
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: 531 DI-376 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Spiral Cable D Squib Airbag Sensor Assembly ACC ON D+ D- or DLC1 E1 H01002 H02144 AB0118 AB0119 R13006 W02043 DTC B0103/12 Tc H02218 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D- of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 532 DI-377 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Airbag Sensor Assembly Spiral Cable D Squib ACC ON or DLC1 E1 DTC B0103/12 Tc H01003 AB0118 AB0019 R13006 W02043 H01132 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 533 DI-378 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly Spiral Cable D Squib ←→ ON D+ (-) PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the voltage between D+ and body ground. OK: Voltage: 0 V (+) H01000 AB0119 H02146 H02202 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. ON Airbag Sensor Assembly Spiral Cable D Squib CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and airbag sensor assembly, measure the voltage between D+ and body ground. OK: Voltage: 0 V D+ (-) (+) AB0119 H01004 R14288 NG H08261 Repair or replace harness between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 534 DI-379 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4CO-03 DTC B0105/53 Short in P Squib Circuit CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0105/53 is recorded when a short is detected in the P squib circuit. DTC No. B0105/53 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P Squib 1 Y-R 10 C6 P+ 2 Y-G 11 C6 P- H01454 2001 AVALON (RM808U) Author
: Date
: 535 DI-380 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P squib circuit. PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the front passenger airbag assembly and the airbag sensor assembly (See page DI-349 ). CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and P-. OK: Resistance: 1 MΩ or Higher P Squib Airbag Sensor Assembly P- P+ (-) R14286 H02142 (+) H02251 NG Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 536 DI-381 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON or DLC1 DTC B0105/53 E1 H01023 AB0118 R13006 - Tc AB0119 H01077 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not relevant to this check. H07479 NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 537 DI-382 DIAGNOSTICS 4 Airbag Sensor Assembly →← ACC ON or DLC1 DTC B0105/53 E1 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib H01024 AB0118 R13006 - Tc AB0119 H01077 H01202 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 seconds. (b) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI-349 ). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI-349 ). OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 538 DI-383 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4CP-03 DTC B0106/54 Open in P Squib Circuit CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0106/54 is recorded when an open is detected in the P squib circuit. DTC No. B0106/54 DTC Detecting Condition Trouble Area
Open circuit in P+ wire harness or P- wire harness of squib
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-379 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P squib circuit. CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and P-. OK: Resistance: Below 1 Ω P Squib Airbag Sensor Assembly P- (-) R14286 H02142 P+ (+) NG H02251 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 539 DI-384 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON P+ P- or DLC1 E1 DTC B0106/54 Tc H01023 H02144 AB0118 AB0119 R13006 H01078 H02253 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P- of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 540 DI-385 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib Airbag Sensor Assembly →← ACC ON or DLC1 DTC B0106/54 E1 Tc H01024 AB0118 AB0119 R13006 H01078 H01205 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 541 DI-386 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4CQ-02 DTC B0107/51 Short in P Squib Circuit (to Ground) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0107/51 is recorded when ground short is detected in the P squib circuit. DTC No. B0107/51 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness (to ground)
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-379 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P squib circuit. CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and body ground. OK: Resistance: 1 MΩ or Higher P Squib Airbag Sensor Assembly P+ (-) H01227 H02145 (+) NG H02254 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 542 DI-387 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON P+ P- or DLC1 DTC B0107/51 E1 Tc H01023 H02144 AB0118 AB0118 R13006 H01075 H02255 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P- of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 543 DI-388 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← ACC Airbag Sensor Assembly ON or DLC1 E1 - DTC B0107/51 Tc H01024 AB0118 AB0119 R13006 H01075 H01196 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 544 DI-389 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4CR-02 DTC B0108/52 Short in P Squib Circuit (to B+) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0108/52 is recorded when a B+ short is detected in the P squib circuit. DTC No. B0108/52 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness (to B+)
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-379 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P squib circuit. Airbag Sensor Assembly P Squib ON P+ (-) H01022 AB0119 H02146 CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the voltage between the P+ and body ground. OK: Voltage: 0 V (+) NG H04524 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 545 DI-390 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON P+ P- or DLC1 E1 DTC B0108/52 Tc H01023 H02144 AB0118 AB0118 R13006 H01076 H02257 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P- of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 546 DI-391 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← Airbag Sensor Assembly ACC ON or DLC1 E1 - DTC B0108/52 Tc H01024 AB0118 AB0119 R13006 H01076 H01199 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 547 DI-392 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6MS-01 DTC B0110/43 Short in Side Squib (RH) Circuit CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0110/43 is recorded when a short is detected in the side squib (RH) circuit. DTC No. B0110/43 DTC Detecting Condition Trouble Area
Short circuit between FR+ wire harness and FR- wire harness of squib
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly Side Squib (RH) 1 Y-R 2 C7 FR+ 2 Y-G 1 C7 FR- H01454 2001 AVALON (RM808U) Author
: Date
: 548 DI-393 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check side squib (RH) circuit. PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the side airbag assembly (RH) (See page DI-349 ). CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between FR+ and FR-. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Squib (RH) FR- FR+ (-) H01019 H09668 (+) H12946 NG Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 549 DI-394 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 E1 DTC B0110/43 Tc H01020 AB0118 AB0119 R13006 H01069 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not relevant to this check. H07481 NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 550 DI-395 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 E1 DTC B0110/43 Tc H01021 AB0118 AB0119 R13006 H01069 H01179 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 second. (b) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI-349 ). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI-349 ). OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 551 DI-396 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6MT-01 DTC B0111/44 Open in Side Squib (RH) Circuit CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0111/44 is recorded when an open is detected in the side squib (RH) circuit. DTC No. B0111/44 DTC Detecting Condition Trouble Area
Open circuit in FR+ wire harness or FR- wire harness of squib
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-392 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check front side squib (RH) circuit. CHECK: For the connector (on the front side airbag assembly side) between the front side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between FR+ and FR-. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Squib (RH) FR- FR+ (-) H01019 H09668 (+) NG H12947 Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 552 DI-397 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ACC ON FR+ FR- or DLC1 H01020 H09671 AB0118 AB0119 R13006 H01070 E1 DTC B0111/44 Tc H12948 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FR+ and FR- of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 553 DI-398 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01070 DTC B0111/44 Tc H01182 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front side airbag assembly (RH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 554 DI-399 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6MU-01 DTC B0112/41 Short in Side Squib (RH) Circuit (to Ground) CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0112/41 is recorded when ground short is detected in the side squib (RH) circuit. DTC No. B0112/41 DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to ground)
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-392 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check side squib (RH) circuit. CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between FR+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Squib (RH) FR+ (-) H01019 H09669 (+) NG H12949 Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 555 DI-400 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ACC ON FR+ FR- or DLC1 E1 - DTC B0112/41 Tc H01020 H09671 AB0118 AB0119 R13006 H01067 H12950 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FR+ and FR- of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 556 DI-401 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 DTC B0112/41 E1 Tc H01021 AB0118 AB0119 R13006 H01067 H01173 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 557 DI-402 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6MV-01 DTC B0113/42 Short in Side Squib (RH) Circuit (to B+) CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0113/42 is recorded when a B+ short is detected in the side squib (RH) circuit. DTC No. B0113/42 DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to B+)
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-392 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-349 ). 2 Check side squib (RH) circuit. CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the voltage between FR+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly Squib (RH) FR+ (-) AB0119 H01019 H09670 (+) NG H12951 Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 558 DI-403 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ACC ON FR+ FR- or DLC1 E1 - DTC B0113/42 Tc H01020 H09671 AB0118 AB0119 R13006 H01068 H12952 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FR+ and FR- of the connector (on the front side airbag assembly side) between the front side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 559 DI-404 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Squib (RH) ACC Airbag Sensor Assembly →← ON or DLC1 E1 DTC B0113/42 Tc H01021 AB0118 AB0119 R13006 H01068 H01176 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front side airbag assembly (RH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 560 DI-405 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6MW-01 DTC B0115/47 Short in Side Squib (LH) Circuit CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0115/47 is recorded when a short is detected in the side squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area B0115/47
Short circuit between FL+ wire harness and FL- wire harness of squib
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly Side Squib (LH) 1 Y-R 5 C5 FL+ 2 Y-G 6 C5 FL- H01454 2001 AVALON (RM808U) Author
: Date
: 561 DI-406 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check side squib (LH) circuit. PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the side airbag assembly (LH) (See page DI-349 ). CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between FL+ and FL-. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Squib (LH) FL- (-) H01019 H09668 FL+ (+) H12953 NG Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 562 DI-407 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Airbag Sensor Assembly Squib (LH) ACC ON or DLC1 DTC B0115/47 E1 Tc H01017 AB0118 AB0119 R13006 H01073 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not relevant to this check. H07483 NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 563 DI-408 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) →← ACC Airbag Sensor Assembly ON or DLC1 E1 DTC B0115/47 Tc H01018 AB0118 AB0119 R13006 H01073 H01190 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front side airbag assembly (LH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 second. (b) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI-349 ). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI-349 ). OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 564 DI-409 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6MX-01 DTC B0116/48 Open in Side Squib (LH) Circuit CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0116/48 is recorded when an open is detected in the side squib (LH) circuit. DTC No. B0116/48 DTC Detecting Condition Trouble Area
Open circuit in FL+ wire harness or FL- wire harness of squib
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-405 . INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI-475 ) 2 Check side squib (LH) circuit. CHECK: For the connector (on the front side airbag assembly side) between the front side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between FL+ and FL-. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Squib (LH) FL+ FL- (-) H01019 H09668 (+) NG H12954 Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 565 DI-410 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (LH) →← Airbag Sensor Assembly FL- FL+ ACC ON or DLC1 DTC B0116/48 E1 Tc H01017 H09671 AB0118 AB0119 R13006 H01074 H12955 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FL+ and FL- of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not relevant to this check. NG Replace side airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 566 DI-41 1 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 DTC B0116/48 Tc H01018 AB0118 AB0119 R13006 H01074 H01193 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 567 DI-412 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6MY-01 DTC B0117/45 Short in Side Squib (LH) Circuit (to Ground) CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0117/45 is recorded when ground short is detected in the side squib (LH) circuit. DTC No. B0117/45 DTC Detecting Condition Trouble Area
Short circuit in side squib (LH) wire harness (to ground)
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-405 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check side squib (LH) circuit. CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between FL+ and body ground. OK: Resistance: 1 MΩ or Higher Squib (LH) Airbag Sensor Assembly FL+ (-) H01016 H09669 (+) NG H12956 Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 568 DI-413 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Squib (LH) Airbag Sensor Assembly FL+ FL- ACC ON or DLC1 E1 DTC B0117/45 Tc H01017 H09671 AB0118 AB0119 R13006 H01071 H12957 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FL+ and FL- of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI-349 ). OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 569 DI-414 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 DTC B0117/45 Tc H01018 AB0118 AB0119 R13006 H01071 H01185 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front side airbag assembly (LH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not relevant to this check. NG Replace front side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 570 DI-415 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6MZ-01 DTC B0118/46 Short in Side Squib (LH) Circuit (to B) CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0118/46 is recorded when a B+ short is detected in the side squib (LH) circuit. DTC No. B0118/46 DTC Detecting Condition Trouble Area
Short circuit in side squib (LH) wire harness (to B+)
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-405 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check side squib (LH) circuit. ON Airbag Sensor Assembly Squib (LH) CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the voltage between FL+ and body ground. OK: Voltage: 0 V FL+ (-) AB0119 H01016 H09670 (+) NG H12958 Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 571 DI-416 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (LH) →← Airbag Sensor Assembly ACC ON FL+ FL- or DLC1 H01017 H09671 AB0118 AB0119 R13006 H01072 DTC B0118/46 E1 Tc H12959 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect FL+ and FL- of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 572 DI-417 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) Airbag Sensor Assembly →← ACC ON or DLC1 DTC B0118/46 E1 Tc H01018 AB0118 AB0119 R13006 H01072 H01234 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 573 DI-418 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4D0-03 DTC B0130/63 Short in P/T Squib (RH) Circuit CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0130/63 is recorded when a short is detected in the P/T squib (RH) circuit. DTC No. B0130/63 DTC Detecting Condition Trouble Area
Short circuit between PR+ wire harness and PR- wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P/T Squib (RH) 1 Y-B 5 C7 PR+ 2 Y 6 C7 PR- H01454 2001 AVALON (RM808U) Author
: Date
: 574 DI-419 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P/T squib (RH) circuit. PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the seat belt pretensioner (RH) (See page DI-349 ). CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and PR-. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly P/T Squib (RH) PR+ (+) H01019 H02141 PR- (-) H02203 NG Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 575 DI-420 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly P/T Squib (RH) →← ACC ON or DTC B0130/63 DLC1 E1 H01020 AB0118 AB0119 R13006 H01082 Tc PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not relevant to this check. H07485 NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 576 DI-421 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ACC ON or DLC1 DTC B0130/63 E1 Tc H01021 AB0118 AB0119 R13006 H01082 H01214 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 second. (b) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI-349 ). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI-349 ). OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 577 DI-422 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4D1-03 DTC B0131/64 Open in P/T Squib (RH) Circuit CIRCUIT DESCRIPTION The P/T squib circuit (RH) consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0131/64 is recorded when an open is detected in the P/T squib (RH) circuit. DTC No. B0131/64 DTC Detecting Condition Trouble Area
Open circuit in PR+ wire harness or PR- wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-418 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P/T squib (RH) circuit. P/T Squib (RH) PR+ (+) H01019 H02141 CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and PR-. OK: Resistance: Below 1 Ω Airbag Sensor Assembly PR- NG (-) H02205 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 578 DI-423 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly P/T Squib (RH) →← PR+ PR- ACC ON or DLC1 E1 H01020 H02139 AB0118 AB0119 R13006 H01083 DTC B0131/64 Tc H02206 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR- of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 579 DI-424 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). Airbag Sensor Assembly P/T Squib (RH) →← ACC ON or DLC1 E1 DTC B0131/64 Tc H01021 AB0118 AB0119 R13006 H01083 H01217 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 580 DI-425 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4D2-02 DTC B0132/61 Short in P/T Squib (RH) Circuit (to Ground) CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0132/61 is recorded when a ground short is detected in the P/T squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (RH) wire harness (to ground)
P/T squib (RH) malfunction
Airbag sensor assembly malfunction B0132/61
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-418 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P/T squib (RH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly P/T Squib (RH) PR+ (-) (+) NG H01019 H08392 H08393 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 581 DI-426 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly P/T Squib (RH) →← PR+ PR- ACC ON or DLC1 E1 H01020 H02139 AB0118 AB0119 R13006 H01079 DTC B0132/61 Tc H02208 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR- of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 582 DI-427 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). Airbag Sensor Assembly P/T Squib (RH) →← ACC ON or DLC1 E1 DTC B0132/61 Tc H01021 AB0118 AB0119 R13006 H01079 H01208 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 583 DI-428 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4D3-02 DTC B0132/62 Short in P/T Squib (RH) Circuit (to B+) CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0133/62 is recorded when a B+ short is detected in the P/T squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (RH) wire harness (to B+)
P/T squib (RH) malfunction
Airbag sensor assembly malfunction B0133/62
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-418 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P/T squib (RH) circuit. CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the voltage between PR+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly P/T Squib (RH) PR+ (-) (+) NG H01019 AB0119 H08394 H08268 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 584 DI-429 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly P/T Squib (RH) →← PR+ PR- ACC ON or DLC1 E1 - H01020 H02139 AB0118 AB0119 R13006 H01081 DTC B0133/62 Tc H02210 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR- of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 585 DI-430 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). Airbag Sensor Assembly P/T Squib (RH) →← ACC ON or DLC1 E1 DTC B0133/62 Tc H01021 AB0118 AB0119 R13006 H01081 H01211 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 586 DI-431 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4D4-03 DTC B0135/73 Short in P/T Squib (LH) Circuit CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0135/73 is recorded when a short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area B0135/73
Short circuit between PL+ wire harness and PL- wire harness of squib
P/T squib (LH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P/T Squib (LH) 1 Y-B 2 C5 PL+ 2 Y 1 C5 PL- H01454 2001 AVALON (RM808U) Author
: Date
: 587 DI-432 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P/T squib (LH) circuit. Airbag Sensor Assembly P/T Squib (LH) PL+ (+) H01016 H02141 PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the seat belt pretensioner (LH) (See page DI-349 ). CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and PL-. OK: Resistance: 1 MΩ or Higher PL- (-) H02211 NG Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
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: 588 DI-433 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) →← Airbag Sensor Assembly ACC ON or DLC1 DTC B0135/73 E1 H01017 AB0118 AB0119 R13006 H01086 Tc PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not relevant to this check. H07487 NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 589 DI-434 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). →← P/T Squib (LH) ACC Airbag Sensor Assembly ON or DLC1 E1 DTC B0135/73 Tc H01018 AB0118 AB0119 R13006 H01086 H01229 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to LOOK, and wait at least for 20 second. (b) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear the DTC stored in memory (See page DI-349 ). (d) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check the DTC (See page DI-349 ). OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
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: 590 DI-435 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4D5-03 DTC B0136/74 Open in P/T Squib (LH) Circuit CIRCUIT DESCRIPTION The P/T squib circuit (LH) consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0136/74 is recorded when an open is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in PL+ wire harness or PL- wire harness of squib
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0136/74
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-431 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P/T squib (LH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and PL-. OK: Resistance: Below 1 Ω Airbag Sensor Assembly P/T Squib (LH) PL+ (+) H01016 H02141 PL- NG (-) H02213 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
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: 591 DI-436 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) Airbag Sensor Assembly PL+ PL- ACC ON or DLC1 DTC B0136/74 E1 - H01017 H02139 AB0118 AB0119 R13006 H01087 Tc H02214 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL- of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 592 DI-437 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). P/T Squib (LH) →← ACC Airbag Sensor Assembly ON or DLC1 DTC B0136/74 E1 Tc H01018 AB0118 AB0119 R13006 H01087 H01232 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
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: 593 DI-438 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4D6-02 DTC B0137/71 Short in P/T Squib (LH) Circuit (to Ground) CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0137/71 is recorded when a ground short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (LH) wire harness (to ground)
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0137/71
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-431 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P/T squib (LH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and body ground. OK: Resistance: 1 MΩ or Higher P/T Squib (LH) Airbag Sensor Assembly (-) PL+ (+) NG H01016 H08392 H08396 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
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: 594 DI-439 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← P/T Squib (LH) PL+ PL- Airbag Sensor Assembly ACC ON or DLC1 E1 DTC B0137/71 Tc H01017 H02139 AB0118 AB0119 R13006 H01084 H02216 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL- of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 595 DI-440 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). →← P/T Squib (LH) ACC Airbag Sensor Assembly ON or DLC1 DTC B0137/71 E1 Tc H01018 AB0118 AB0119 R13006 H01084 H01220 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
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: 596 DI-441 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4D7-02 DTC B0138/72 Short in P/T Squib (LH) Circuit (to B+) CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS-3 . DTC B0138/72 is recorded when a B+ short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (LH) wire harness (to B+)
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0138/72
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI-431 . INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check P/T squib (LH) circuit. ON Airbag Sensor Assembly P/T Squib (LH) (-) CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the voltage between PL+ and body ground. OK: Voltage: 0 V PL+ (+) NG AB0119 H01016 H08394 H08269 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
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: 597 DI-442 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) →← Airbag Sensor Assembly PL+ PL- ACC ON or DLC1 E1 H01017 H02139 AB0118 AB0119 R13006 H01085 DTC B0138/72 Tc H02217 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL- of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 2001 AVALON (RM808U) Author
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: 598 DI-443 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). P/T Squib (LH) →← Airbag Sensor Assembly ACC ON or DLC1 DTC B0138/72 E1 Tc H01018 AB0118 AB0119 R13006 H01085 H01222 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. 2001 AVALON (RM808U) Author
: Date
: 599 DI-444 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI4D8-02 DTC B1100/31 Airbag Sensor Assembly Malfunction CIRCUIT DESCRIPTION The airbag sensor assembly consists of a airbag sensor, safing sensor, drive circuit, diagnosis circuit and ignition control, etc. It receives signals from the airbag sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1100/31 is recorded when occurrence of a malfunction in the airbag sensor assembly is detected. DTC No. DTC Detecting Condition Trouble Area
Airbag sensor assembly malfunction B1100/31
Airbag sensor assembly INSPECTION PROCEDURE HINT: When a malfunction code other than code B1100/31 is displayed at the same time, first repair the malfunction indicated by the malfunction code other than code B1100/31. 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check voltage at IG2 and ACC of airbag sensor assembly. ON Airbag Sensor Assembly ACC (-) IG2 (+) AB0119 H01298 H01299 CHECK: (a) Turn the ignition switch to ON. (b) Measure the voltage between body ground and each of terminals IG2 and ACC of the airbag sensor assembly connector. OK: Voltage: 10 - 14 V NG Check that an abnormality occurs on the battery and charging system. OK 2001 AVALON (RM808U) Author
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: 600 DI-445 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1100/31 output again? ACC ON or DLC1 E1 DTC B1100/31 Tc AB0118 AB0119 R13006 FI1394 H00022 PREPARATION: Clear the DTC (See step 5 on page DI-349 ). CHECK: (a) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (b) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Repeat operation in step (a) and (b) at least 5 times. (d) Check the DTC (See page DI-349 ). HINT: Codes other than code B1100/31 may be output at this time, but they are not relevant to this check. NO Using simulation method, reproduce malfunction symptoms (See page IN-20 ). YES Replace airbag sensor assembly. 2001 AVALON (RM808U) Author
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: 601 DI-446 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6N0-01 DTC B1140/32 Side Airbag Sensor Assembly (RH) Malfunction CIRCUIT DESCRIPTION The side airbag sensor assembly (RH) consists of the safing sensor, diagnosis circuit and lateral deceleration sensor, etc. It receives signals from the lateral deceleration sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1140/32 is recorded when occurrence of a malfunction in the side airbag sensor assembly (RH) is detected. DTC No. B1140/32 DTC Detecting Condition Trouble Area
Side airbag sensor assembly (RH)
Airbag sensor assembly
Wire harness
Side airbag sensor assembly (RH) malfunction WIRING DIAGRAM Side Airbag Sensor Assembly (RH) GR 7 C7 ESR 3 LG 9 C7 SSR- 2 L-Y 10 C7 SSR+ 1 P 12 C7 VUPR 4 ESR SSR- SSR+ VUPR Airbag Sensor Assembly H01450 Author
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: 602 DI-447 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Is DTC B1140/32 out put? ACC ON or DLC1 DTC B1140/32 E1 Tc AB0118 AB0119 R13006 H09528 H09527 CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. NO The malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. YES 2 Is connector of side airbag sensor assembly (RH) properly connected? 3 Prepare for inspection (See step 1 on DI-475 ). Author
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: 603 DI-448 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. PREPARATION: (a) Disconnect the side airbag sensor assembly (RH) connector. (b) Using a service wire, connect SSR+ and ESR of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (RH) and airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the resistance between SSR+ and ESR. OK: Resistance: Below 1 Ω Side Airbag Sensor Assembly (RH) ←→ Airbag Sensor Assembly Airbag Sensor Assembly SSR+ ESR (+) (-) H01015 H01058 H01036 SSR+ ESR H01160 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. OK Author
: Date
: 604 DI-449 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. PREPARATION: Using a service wire, connect VUPR and SSR- of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (RH) and airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the resistance between VUPR and SSR-. OK: Resistance: Below 1 Ω Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly VUPR Airbag Sensor Assembly SSR- VUPR (+) SSR- (-) H01015 H01059 H01037 H01161 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. OK Author
: Date
: 605 DI-450 DIAGNOSTICS 6 - SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness (to ground). Side Airbag Sensor Assembly (RH) CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the resistance between body ground and each of SSR+, VUPR and SSR-. OK: Resistance: 1M Ω or Higher Airbag Sensor Assembly Airbag Sensor Assembly VUPR SSR- (+) (-) H01013 H01038 SSR+ H01162 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. OK 7 Check wire harness (to B+). ON Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly Airbag Sensor Assembly SSR+ AB0119 H01013 H01039 (-) VUPR (+) CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the voltage between the body ground and each of SSR+, VUPR, ESR and SSR-. OK: Voltage: 0 V SSRESR H08270 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. OK Author
: Date
: 606 DI-451 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1140/32 out put again? Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly →← →← ACC ON or DLC1 E1 H01012 AB0118 AB0119 R13006 H01065 DTC B1140/32 Tc H01164 PREPARATION: (a) Connect the connector to the side airbag sensor assembly (RH). (b) Connect the connector to the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. YES Go to step 9. NO From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author
: Date
: 607 DI-452 DIAGNOSTICS 9 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01012 AB0118 AB0119 R13006 H01065 DTC B1140/32 Tc H01164 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the side airbag sensor (RH) from the connector and connect the side airbag sensor (LH) to the connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author
: Date
: 608 DI-453 DIAGNOSTICS 10 - SUPPLEMENTAL RESTRAINT SYSTEM Check side airbag sensor assembly (RH). →← Side Airbag Sensor Assembly (RH) ACC Airbag Sensor Assembly ON or DLC1 E1 DTC B1141/33 Tc H01007 AB0118 AB0119 R13006 H01066 H01170 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag sensor (RH) to the connector that the side airbag sensor (LH) was connected to. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. NG Replace side airbag sensor assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author
: Date
: 609 DI-454 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6N1-01 DTC B1141/33 Side Airbag Sensor Assembly (LH) Malfunction CIRCUIT DESCRIPTION The side airbag sensor assembly (LH) consists of the safing sensor, diagnosis circuit and lateral deceleration sensor, etc. It receives signals from the lateral deceleration sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1141/33 is recorded when occurrence of a malfunction in the side airbag sensor assembly (LH) is detected. DTC No. B1141/33 DTC Detecting Condition Trouble Area
Side airbag sensor assembly (LH) malfunction
Side airbag sensor assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly 4 GR-L 12 C5 ESL 3 LG-B 10 C5 SSL- 2 L-W 9 C5 SSL+ 1 P-L 7 C5 VUPL ESL SSL- SSL+ VUPL H01450 Author
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: 610 DI-455 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Is DTC B1141/33 out put? ACC ON or DLC1 DTC B1141/33 E1 Tc AB0118 AB0119 R13006 H09530 CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. H09529 NO The malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. YES 2 Is connector of side airbag sensor assembly (LH) properly connected? 3 Prepare for inspection (See step 1 on page DI-475 ). Author
: Date
: 611 DI-456 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. ←→ Side Airbag Sensor Assembly (LH) SSL+ Airbag Sensor Assembly Airbag Sensor Assembly ESL PREPARATION: (a) Disconnect the side airbag sensor assembly (LH). (b) Using a service wire, connect SSL+ and ESL of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the resistance between SSL+ and ESL. OK: Resistance: Below 1 Ω ESL (+) H01010 H01058 H01050 (-) SSL+ H01166 NG Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. OK Author
: Date
: 612 DI-457 DIAGNOSTICS 5 SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. PREPARATION: Using a service wire, connect VUPL and SSL- of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the resistance between VUPL and SSL-. OK: Resistance: Below 1 Ω Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly VUPL SSL- SSL(+) H01010 H01059 H01051 - Airbag Sensor Assembly VUPL (-) H01167 NG Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. OK Author
: Date
: 613 DI-458 DIAGNOSTICS 6 - SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness (to ground). CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the resistance between body ground and each of SSL+, VUPL and SSL-. OK: Resistance: 1 MΩ or Higher SIde Airbag Sensor Assembly (LH) Airbag Sensor Assembly Airbag Sensor Assembly SSL+ SSL- VUPL (+) (-) H01008 H01052 H01168 NG Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. OK 7 ON Check wire harness (to B+). Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly Airbag Sensor Assembly SSLESL H01008 AB0119 H01053 CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the voltage between body ground and each of SSL+, ESL, VUPL and SSL-. OK: Voltage: 0 V SSL+ VUPL (+) (-) H08271 NG Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. OK Author
: Date
: 614 DI-459 DIAGNOSTICS 8 SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1141/33 out put again? Side Airbag Sensor Assembly (LH) →← ACC Airbag Sensor Assembly →← ON or DLC1 E1 - DTC B1141/33 Tc H01007 AB0118 AB0119 R13006 H01066 H01170 PREPARATION: (a) Connect the connector to the side airbag sensor assembly (LH). (b) Connect the connector to the airbag sensor assembly. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. YES Go to step 9. NO From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author
: Date
: 615 DI-460 DIAGNOSTICS 9 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Side Airbag Sensor Assembly (RH) ACC Airbag Sensor Assembly ON or DLC1 E1 - DTC B1141/33 Tc H01007 AB0118 AB0119 R13006 H01066 H01170 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the side airbag sensor (LH) from the connector and connect the side airbag sensor (RH) to the connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author
: Date
: 616 DI-461 DIAGNOSTICS 10 - SUPPLEMENTAL RESTRAINT SYSTEM Check side airbag sensor assembly (LH). Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01012 AB0118 AB0119 R13006 H01065 DTC B1140/32 Tc H01164 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag sensor (LH) to the connector that the side airbag sensor (RH) was connected to. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See step 5 on page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. NG Replace side airbag sensor assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author
: Date
: 617 DI-462 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6N2-01 DTC B1156/B1157/15 Front Airbag Sensor (RH) Malfunction CIRCUIT DESCRIPTION The front airbag sensor (RH) circuit consists of the airbag sensor assembly and front airbag sensor (RH). For details of the function of each component, see OPERATION on page RS-3 . DTC B1156/B1157/15 is recorded when malfunction is detected in the front airbag sensor (RH) circuit. DTC No. B1156/B1157/15 DTC Detecting Condition Trouble Area
Front airbag sensor (RH)
Airbag sensor assembly
Wire harness
Front airbag sensor (RH) malfunction WIRING DIAGRAM Airbag Sensor Assembly Front Airbag Sensor (RH) SR+ SR- 2 B-W 9 C6 +SR 1 BR-W 20 C6 -SR H02751 2001 AVALON (RM808U) Author
: Date
: 618 DI-463 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check wire harness (to B+). Airbag Sensor Assembly Front Airbag Sensor (RH) Airbag Sensor Assembly ON (+) CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the voltage between body ground and each of SR+ and SR-. OK: Voltage: Below 1 V SR+ NG H01370 AB0119 H03363 (-) SR- Repair or replace harness or connector between front airbag sensor (RH) and airbag sensor assembly. H10968 OK 3 Check wire harness (to ground). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between body ground and each of SR+ and SR-. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Front Airbag Sensor (RH) (+) Airbag Sensor Assembly SR+ NG (-) H01370 H03361 SR- Repair or replace harness or connector between front airbag sensor (RH) and airbag sensor assembly. H10969 OK 2001 AVALON (RM808U) Author
: Date
: 619 DI-464 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between SR+ and SR-. OK: Resistance: 1 MΩ or Higher Front Airbag Sensor (RH) Airbag Sensor Assembly Airbag Sensor Assembly SR+ (+) (-) NG SR- H01370 H03356 H10970 Repair or replace harness or connector between front airbag sensor (RH) and airbag sensor assembly. OK 5 Check wire harness. Front Airbag Sensor (RH) Airbag Sensor Assembly SR+ SR- (+) (-) H09526 H09521H03356 Airbag Sensor Assembly SR+ PREPARATION: Using a service wire, connect SR+ and SR- of the connector (on the front airbag sensor (RH) side) between the airbag sensor assembly and the front airbag sensor (RH). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between SR+ and SR-. OK: Resistance: Below 1 Ω SRH10971 NG Repair or replace harness or connector between front airbag sensor (RH) and airbag sensor assembly. OK 2001 AVALON (RM808U) Author
: Date
: 620 DI-465 DIAGNOSTICS 6 SUPPLEMENTAL RESTRAINT SYSTEM Check front airbag sensor (RH). CHECK:. For the connector (on the front airbag sensor (RH)), measure the resistance between SR+ and SR-. OK: Resistance: 300 - 1500 Ω Front Airbag Sensor (RH) Airbag Sensor Assembly SR+ H01371 H01009 - (+) SR- (-) H01155 NG Replace front airbag sensor (RH). OK 2001 AVALON (RM808U) Author
: Date
: 621 DI-466 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Front Airbag Sensor (RH) Airbag Sensor Assembly →← ACC →← ON or DLC1 DTC B1156/B1157/15 E1 Tc H01369 AB0118 AB0119 R13006 H01063 H10976 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front airbag sensor (RH) connector and airbag sensor assembly connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B1156/B1157/15 is not output. HINT: Codes other than code B1156/B1157/15 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 622 DI-467 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI6N3-01 DTC B1158/B1159/16 Front Airbag Sensor (LH) Malfunction CIRCUIT DESCRIPTION The front airbag sensor (LH) circuit consists of the airbag sensor assembly and front airbag sensor (LH). For details of the function of each component, see OPERATION on page RS-3 . DTC B1158/B1159/16 is recorded when malfunction is detected in the front airbag sensor (LH) circuit. DTC No. B1158/B1159/16 DTC Detecting Condition Trouble Area
Front airbag sensor (LH)
Wire harness
Airbag sensor assembly
Engine room main wire harness
Front airbag sensor (LH) malfunction WIRING DIAGRAM Front Airbag Sensor (LH) +SL -SL 2 1 Airbag Sensor Assembly W-R BR 1 IF2 W-R 2 IF2 BR 15 C6 +SL 26 C6 -SL H02750 2001 AVALON (RM808U) Author
: Date
: 623 DI-468 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Check wire harness (to B+). Airbag Sensor Assembly Front Airbag Sensor (LH) ON Airbag Sensor Assembly SL+ (+) NG (-) H03355 AB0119 H08065 CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the voltage between body ground and each of SL+ and SL-. OK: Voltage: Below 1 V SL- Go to step 8. H10972 OK 3 Check wire harness (to ground). Airbag Sensor Assembly Front Airbag Sensor (LH) (+) H03353 H08399 (-) Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between body ground and each of SL+ and SL-. OK: Resistance: 1 MΩ or Higher SL+ NG SL- Go to step 9. H10973 OK 2001 AVALON (RM808U) Author
: Date
: 624 DI-469 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. Front Airbag Sensor (LH) Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between SL+ and SL-. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly (+) SL+ (-) SL- H03355 H08058 H10974 NG Go to step 10. OK 5 Check wire harness. Front Airbag Sensor (LH) Airbag Sensor Assembly SL+ Airbag Sensor Assembly SL- (+) (-) H03355 H09521H08058 SL+ PREPARATION: Using a service wire, connect SL+ and SL- of the connector (on the front airbag sensor (LH) side) between the airbag sensor assembly and the front airbag sensor (LH). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between SL+ and SL-. OK: Resistance: Below 1 Ω SLH10975 NG Go to step 11. OK 2001 AVALON (RM808U) Author
: Date
: 625 DI-470 DIAGNOSTICS 6 - SUPPLEMENTAL RESTRAINT SYSTEM Check front airbag sensor (LH). Airbag Sensor Assembly CHECK: For the connector (on the front airbag sensor (LH)), measure the resistance between SL+ and SL-. OK: Resistance: 300 - 1500 Ω Front Airbag Sensor (LH) SL+ H04504 H01062 (+) SL- (-) H08346 NG Replace front airbag sensor (LH). OK 2001 AVALON (RM808U) Author
: Date
: 626 DI-471 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Front Airbag Sensor (LH) Airbag Sensor Assembly →← ACC →← ON or DLC1 E1 DTC B1158/B1159/16 Tc H02757 AB0118 AB0119 R13006 H01064 H10977 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front airbag sensor (LH) connector and airbag sensor assembly connector. (d) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear the DTC stored in memory (See page DI-349 ). (c) Turn the ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn the ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check the DTC (See page DI-349 ). OK: DTC B1158/B1159/16 is not output. HINT: Codes other than code B1158/B1159/16 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 627 DI-472 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness (to B+). Front Airbag Sensor (LH) ←→ Airbag Sensor Assembly Engine Room Main Wire Harness ON SL+ (-) SL- (+) PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: (a) Turn the ignition switch to ON. (b) For the connector (on the LH front door wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the voltage between body ground and each of SL+ and SL-. OK: Voltage: Below 1 V NG H03354 AB0119 H06141 H08272 Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 9 Check engine room main wire harness (to ground). Front Airbag Sensor (LH) Airbag Sensor Assembly Engine Room Main Wire Harness SL+ (-) SL- PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between body ground and each of SL+ and SL-. OK: Resistance: 1 MΩ or Higher (+) NG H03354 H06140 Repair or replace engine room main wire harness. H08258 OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 2001 AVALON (RM808U) Author
: Date
: 628 DI-473 DIAGNOSTICS 10 SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness. Front Airbag Sensor (LH) Engine Room Main Wire Harness ←→ Airbag Sensor Assembly SL- SL+ H03354 H09519 - (+) PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between SL+ and SL-. OK: Resistance: 1 MΩ or Higher (-) H09520 NG Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 2001 AVALON (RM808U) Author
: Date
: 629 DI-474 DIAGNOSTICS 11 - SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness. Engine Room Main Wire Harness Front Airbag Sensor (LH) Airbag Sensor Assembly ←→ SL+ SL- SL+ SL- (+) H03352 H09521 H09519 (-) PREPARATION: (a) Disconnect the engine room main wire harness connector on the airbag sensor assembly side. (b) Using a service wire, connect SL+ and SL- of the connector (on the engine room main wire harness side) between the engine room main wire harness and the front airbag sensor (LH). CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between SL+ and SL-. OK: Resistance: Below 1 Ω H09522 NG Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 2001 AVALON (RM808U) Author
: Date
: 630 DI-475 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI1NV-16 DTC Normal Source Voltage Drop CIRCUIT DESCRIPTION The SRS is equipped with a voltage-increase circuit (DC-DC converter) in the airbag sensor assembly in case the source voltage drops. When the battery voltage drops, the voltage-increase circuit (DC-DC converter) functions to increase the voltage of the SRS to normal voltage. The diagnosis system malfunction display for this circuit is different from other circuits that is when the SRS warning light remains lit up and the DTC is a normal code, source voltage drop is indicated. Malfunction in this circuit is not recorded in the airbag sensor assembly, and the source voltage returns to normal, the SRS warning light automatically goes off. DTC No. Diagnosis (Normal) Source voltage drop 2001 AVALON (RM808U) Author
: Date
: 631 DI-476 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM WIRING DIAGRAM Airbag Sensor Assembly I15 Ignition Switch 7 IF1 W-L 4 IF1 W-L Driver Side J/B W-G 1C 2 AM1 ACC 3 10 W-R 7 AM2 1F SRS-ACC 7 B-O 1C IG2 6 GR 6 C6 ACC B-O 5 C6 IG2 10 1 1F FL Block 7 2C W-R AM1 5 5 2 B AM2 1 2H 2 2G B 1 F7 1 2G B-L 1 F8 ALT 1 Engine Room R/B No. 5 Engine Room J/B 1 F6 B FL MAIN Battey H12003 2001 AVALON (RM808U) Author
: Date
: 632 DI-477 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. LOCK Airbag Sensor Assembly P Squib D Squib Spiral Cable Front Airbag Sensor (LH) Front Airbag Sensor (RH) P/T Squib (LH) Side Airbag Sensor (LH) Side Squib (LH) PREPARATION: (a) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (b) Remove the steering wheel pad (See page SR-12 ). (c) Disconnect the connector of the front passenger airbag assembly (See page RS-28 ). (d) Disconnect the connector of the side airbag assembly RH and LH (See page RS-42 and RS-56 ). (e) Disconnect the connector of the seat belt pretensioner RH and LH (See page BO-128 ). (f) Disconnect the connectors of the airbag sensor assembly (See page RS-63 and RS-68 ). (g) Disconnect the connector of the front airbag sensor RH and LH (See page RS-73 ). (h) Disconnect the connector of the side airbag sensor assembly RH and LH (See page RS-78 ). CAUTION: Store the steering wheel pad, front passenger airbag assembly and side airbag assemlby with the front surface facing upward. P/T Squib (RH) Side Airbag Sensor (RH) Side Squib (RH) H06508 H01026 H06509 2001 AVALON (RM808U) Author
: Date
: 633 DI-478 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM Check source voltage. ON Airbag Sensor Assembly ACC (-) IG2 (+) AB0119 H01298 H01299 PREPARATION: Connect negative (-) terminal cable to the battery. CHECK: (a) Turn ignition switch ON. (b) Measure the voltage between body ground and each of IG2 and ACC on the sensor and operate electric system (defogger, wiper, headlight, heater blower, etc.). OK: Voltage: 10 - 14 V NG Check harness between battery and airbag sensor assembly, and check battery and charging system. OK 3 Does SRS warning light turn off? ON H01249 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Connect the steering wheel pad connector. (c) Connect the front passenger airbag assembly connector. (d) Connect the side airbag assembly connectors. (e) Connect the seat belt pretensioner connectors. (f) Connect the airbag sensor assembly connectors. (g) Connect the front airbag sensor connectors. (h) Connect the side airbag sensor assembly connectors. (i) Turn the ignition switch to ON. CHECK: Operate electric system (defogger, wiper, headlight, heater blower, etc.) and check that SRS warning light goes off. NO Check for DTCs. If a DTC is output, perform troubleshooting for the DTC. If a normal code is output, replace airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 634 DI-479 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI5RJ-04 SRS Warning Light Circuit Malfunction CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from the LOCK position to ACC or ON position, and then turns off automatically. If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by blinking the SRS warning light. WIRING DIAGRAM DLC1 AB B-Y Airbag Sensor Assembly 5 5 II2 B-Y 10 1I M7 SRS Warning Light LG-B B-Y 6 5 12 1A 5 B-Y 1F 3 C6 LA Driver Side J/B 4 IJ1 LG-B 2 2G 1 2B B SRS WRN Engine Room J/B 1 F7 FL Block 1 FL MAIN F6 B Battery H12004 2001 AVALON (RM808U) Author
: Date
: 635 DI-480 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE Always lights up, when ignition switch is in LOCK position 1 Prepare for inspection (See step 1 on page DI-475 ). 2 Does SRS warning light turn off? Airbag Sensor Assembly LOCK AB0117 H01293 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. (d) Connect negative (-) terminal cable to the battery. CHECK: Check operation of SRS warning light. H01295 NO Check SRS warning light circuit or terminal AB circuit of DLC1. YES Replace airbag sensor assembly. 2001 AVALON (RM808U) Author
: Date
: 636 DI-481 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM Does not light up, when ignition switch is turned to ACC or ON 1 Check ECU-B Fuse. Fuse N14677 PREPARATION: Remove the ECU-B fuse. CHECK: Check continuity of the ECU-B fuse. OK: Continuity HINT:
Fuse may be burnt out even if it appears to be OK during visual inspection.
If fuse is OK, install it. NG Go to step 5. OK 2 Prepare for inspection (See step 1 on page DI-475 ). 3 Check SRS warning light circuit. Airbag Sensor Assembly ON (+) LA (-) AB0119 H01300 PREPARATION: (a) Connect negative (-) terminal cable to the battery. (b) Turn the ignition switch to ACC or ON. CHECK: Measure the voltage between body ground and LA terminal of the harness side connector of the airbag sensor assembly. OK: Voltage: 10 - 14 V H01301 NG Check SRS warning light bulb or repair SRS warning light circuit. OK 2001 AVALON (RM808U) Author
: Date
: 637 DI-482 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM Does SRS warning light come on? PREPARATION: (a) Disconnect negative (-) terminal cable from the battery. (b) Connect the airbag sensor assembly connector. (c) Connect negative (-) terminal cable to the battery, and wait at least for 2 seconds. (d) Turn the ignition switch to ACC or ON. CHECK: Check operation of the SRS warning light. P Squib D Squib Spiral Cable Front Airbag Sensor (LH) Front Airbag Sensor (RH) P/T Squib (LH) Side Airbag Sensor (LH) Side Squib (LH) P/T Squib (RH) Side Airbag Sensor (RH) Side Squib (RH) ON H08325 AB0119 H11969 Airbag Sensor Assembly H13045 NO Check terminal LA of airbag sensor assembly. If normal, replace airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use simulation method to check. 2001 AVALON (RM808U) Author
: Date
: 638 DI-483 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM Is new ECU-B fuse burnt out again? NO Using simulation method, reproduce malfunction symptoms (See page IN-20 ). YES Check harness between ECU- B fuse and SRS warning light. 2001 AVALON (RM808U) Author
: Date
: 639 DI-484 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI1BQ-18 Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting terminals Tc and E1 of the DLC1 the airbag sensor assembly is set in the DTC output mode. The DTCs are displayed by blinking the SRS warning light. WIRING DIAGRAM DLC2 Tc 4 Airbag Sensor Assembly LG-R 13 3A 4 3B 4 3G LG-R Driver Side J/B 5 6 1I 1F P-B 19 C6 Tc J/B No. 3 LG-R J/B No. 4 6 4H 6 4A LG-R 22 II2 LG-R 11 Tc DLC1 E1 3 W-B EB H12005 2001 AVALON (RM808U) Author
: Date
: 640 DI-485 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE If the DTC is not displayed, do the following troubleshooting. 1 Does SRS warning light light up for approx. 6 seconds? LOCK ACC ON PREPARATION: Check operation of the SRS warning light after ignition switch is turned from LOCK position to ACC or ON position. or AB0117 AB0118 AB0119 H11969 H13046 NO Check SRS warning light system (See page DI-479 ). YES 2 Check voltage between terminals Tc and E1 of DLC1. ACC ON or E1 (-) AB0118 AB0119 R14305 Tc PREPARATION: Turn the ignition switch to ACC or ON. CHECK: Measure the voltage between terminals Tc and E1 of DLC1. OK: Voltage: 10 - 14 V (+) H00030 OK Go to step 4. NG 2001 AVALON (RM808U) Author
: Date
: 641 DI-486 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM Check voltage between terminal Tc of DLC1 and body ground. CHECK: Measure the voltage between terminal Tc of DLC1 and body ground. OK: Voltage: 10 - 14 V ON ACC Tc or (-) (+) OK AB0118 AB0119 R14304 H00031 Check harness between terminal E1 of DLC1 and body ground. NG 4 Check airbag sensor assembly. LOCK ACC ON or Airbag Sensor Assembly Tc AB0117 AB0118 AB0119 H01302 H01303 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. (d) Insert service wire into terminal Tc from back side as shown in the illustration. (e) Connect the airbag sensor assembly connector with service wire. (f) Connect negative (-) terminal cable to the battery. (g) Turn the ignition switch to ACC or ON and wait at least for 20 seconds. (h) Connect service wire of terminal Tc to body ground. CHECK: Check operation of the SRS warning light. OK: SRS waning light comes on. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. OK Check harness between the airbag sensor assembly and DLC1. NG Replace airbag sensor assembly. 2001 AVALON (RM808U) Author
: Date
: 642 DI-487 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM If the DTC is displayed without a DTC check procedure, perform the following troubleshooting. 1 Check resistance between terminal Tc of airbag sensor assembly and body ground. Airbag Sensor Assembly LOCK Tc (-) (+) AB0119 H01304 H01305 PREPARATION: (a) Turn the ignition switch to LOCK. (b) Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. CHECK: Check resistance between terminal Tc of the airbag sensor assembly connector and body ground. OK: Resistance: 1 MΩ or Higher NG Repair or replace harness or connector. OK Replace airbag sensor assembly. 2001 AVALON (RM808U) Author
: Date
: 643 DI-348 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI15Z-10 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name Supplemental Restraint System Check Sheet Registration No. Customer’s Name Registration Year / / Frame No. Date Vehicle Brought In / / km Miles Odometer Reading / Date Problem Occurred Weather Fine Temperature Cloudy Rainy Snowy / Other Approx. Starting Vehicle Operation Driving Idling [ Constant speed Other Acceleration Deceleration ] Road Conditions Details Of Problem Vehicle Inspection and Repair History Prior to Occurrence of Malfunction (Including Supplemental Restraint System) Diagnosis System Inspection SRS Warning Light Inspection 1st Time Remains ON Sometimes Lights Up Does Not Light Up 2nd Time Remains ON Sometimes Lights Up Does Not Light Up 1st Time Normal Code Malfunction Code [ Code. ] 2nd Time Normal Code Malfunction Code [ Code. ] DTC Inspection 2001 AVALON (RM808U) Author
: Date
: 504 DI-355 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI161-31 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below (Proceed to the page given for that circuit.). DTC No. (See Page) Detection Item
Short in D squib circuit
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (RH) circuit (to ground)
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (RH) circuit (to B+)
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (LH) circuit
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink B0100/13 (DI-362 )
Open in D squib circuit B0101/14 (DI-367 )
Short in D squib circuit (to ground) B0102/11 (DI-371 )
Short in D squib circuit (to B+) B0103/12 (DI-375 ) B0105/53 (DI-379 ) B0106/54 (DI-383 ) B0107/51 (DI-386 ) B0108/52 (DI-389 ) B0110/43 (DI-392 ) B0111/44 (DI-396 ) B0112/41 (DI-402 ) B0113/42 (DI-402 ) B0115/47 (DI-405 ) B0116/48 (DI-409 ) SRS Warning Light Trouble Area
Short in P squib circuit
Open in P squib circuit
Short in P squib circuit (to ground)
Short in P squib circuit (to B+)
Short in side squib (RH) circuit
Open in side squib (RH) circuit
Open in side squib (LH) circuit 2001 AVALON (RM808U) Author
: Date
: 511 DI-356 DIAGNOSTICS DTC No. (See Page) B0117/45 (DI-412 ) B0118/46 (DI-415 ) B0130/63 (DI-418 ) B0131/64 (DI-422 ) B0132/61 (DI-425 ) B0133/62 (DI-428 ) B0135/73 (DI-431 ) B0136/74 (DI-435 ) B0137/71 (DI-438 ) B0138/72 (DI-441 ) B1100/31 (DI-444 ) B1140/32 (DI-446 ) B1141/33 (DI-454 ) B1156/B1157/ 15 (DI-462 ) B1158/B1159/ 16 (DI-467 ) Normall N (DI-475 ) Detection Item - SUPPLEMENTAL RESTRAINT SYSTEM SRS Warning Light Trouble Area
Short in side squib (LH) circuit (to ground)
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (LH) circuit (to B+)
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit (to ground)
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit (to B+)
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit (to ground)
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit (to B+)
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Airbag sensor assembly malfunction
Airbag sensor assembly
Side airbag sensor assembly (RH) malfunction
Side airbag sensor assembly (RH)
Airbag sensor assembly
Wire harness Blink
Side airbag sensor assembly (LH) malfunction
Side airbag sensor assembly (LH)
Airbag sensor assembly
Wire harness Blink
Front airbag sensor (RH) malfunction
Front airbag sensor (RH)
Airbag sensor assembly
Wire harness ON
Front airbag sensor (LH)
Airbag sensor assembly
Instrument panel wire harness
Engine room main wire harness ON
Open in P/T squib (RH) circuit
Open in P/T squib (LH) circuit
Front airbag sensor (LH) malfunction
System normal
Voltage source drop ON OFF
Battery
Airbag sensor assembly ON 2001 AVALON (RM808U) Author
: Date
: 512 DI-357 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM HINT:


When the SRS warning light remains lit up and the DTC is the normal code, this means a voltage source drops. This malfunction is not stored in memory by the airbag sensor assembly and if the power source voltage returns to normal, the SRS warning light will automatically go out. When 2 or more codes are indicated, the codes will be displayed in numeral order starting from the lowest numbered code. If a code not listed on the chart is displayed, the airbag sensor assembly is faulty. 2001 AVALON (RM808U) Author
: Date
: 513 DI-347 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM DI1MX-12 HOW TO PROCEED WITH TROUBLESHOOTING Vehicle Brought to Workshop 1 Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. Customer Problem Analysis P. DI-348 2 Warning Light Check Remains OFF P. DI-349 Remains ON 3 4 DTC Check (Read Present DTC) DTC Check (Read Past DTC) P. DI-349 P. DI-349 5 DTC Chart P. DI-355 6 Circuit Inspection Normal 7 P. DI-362 to DI-484 Malfunction Code Symptom Simulation P. IN-20 Warning Light Remains OFF Warning Light ON Identification of Problem 8 Repair DTC Check P. DI-349 9 10 Clear DTC (Present and Past DTC) P. DI-349 Warning Light Check Remains ON P. DI-349 Remains OFF 11 DTC Check (Read Past DTC) P. DI-349 Confirmation Test END Step 3, 4, 6, 8, 9, 11 : Diagnostic steps permitting the use of the TOYOTA hand-held tester. 2001 AVALON (RM808U) Author
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: 503 DI-358 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI1N1-10 PARTS LOCATION Front Airbag Sensor (RH) Front Passenger Airbag Assembly Accessory Meter (Warning Light) Spiral Cable Side Airbag Assembly (RH) Front Airbag Sensor (LH) Side Airbag Sensor Assembly (RH) Steering Wheel Pad (with Airbag) Side Airbag Sensor Assembly (LH) Seat Belt Pretensioner (RH) Airbag Sensor Assembly Seat Belt Pretensioner (LH) Side Airbag Assembly (LH) H11973 2001 AVALON (RM808U) Author
: Date
: 514 DI-349 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI1MZ-1 1 PRE-CHECK 1. (a) (b) SRS WARNING LIGHT CHECK Turn the ignition switch to the ACC or ON position and check that the SRS warning light lights up. Check that the SRS warning light goes out after approx. 6 seconds. HINT:
H11969
When the ignition switch is at ACC or ON and the SRS warning light remains on or flashes, the airbag sensor assembly has detected a malfunction code. If, after approx. 6 seconds have elapsed, the SRS warning light sometimes lights up or the SRS warning light lights up even when the ignition switch is OFF, a short in the SRS warning light circuit can be considered likely. Proceed to ”SRS warning light circuit malfunction” on page DI-479 . 2. (a) DLC1 E1 Tc R13006 DTC CHECK (Using diagnosis check wire) Present troubles codes: Output the DTC. (1) Turn the ignition switch to the ACC or ON position and wait for approx. 20 seconds. (2) Using SST, connect terminals Tc and E1 of the DLC1. SST 09843-18020 NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. (b) Past troubles codes: Output the DTC. (1) Using service wire, connect terminals Tc and E1 of the DLC1. SST 09843-18020 (2) Turn the ignition switch to the ACC or ON position and wait for approx. 20 seconds. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. 2001 AVALON (RM808U) Author
: Date
: 505 DI-350 DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM (c) Normal Code 0.25 ON OFF 0.25 Code 11 and 31 0.5 - 4.0 2.5 ON OFF 1.5 0.5 DTC 11 Repeat DTC 31 AT0716 AB0056 H08231 TOYOTA Hand-Held Tester DLC3 F07887 Read the DTC. Read the 2-digit DTC as indicated by the number of times the SRS warning light blinks. As an example, the blinking patterns, normal, 11 and 31 are shown in the illustration.
Normal code indication The light will blink 2 times per second.
Malfunction code indication The first blinking output indicates the first digit of a 2-digit DTC. After a 1.5-second pause, the second blinking output will indicate the second digit. If there are 2 or more codes, there will be a 2.5-second pause between each code. After all the codes have been output, there will be a 4.0-second pause and they will all be repeated. HINT:
In the event of a number of trouble codes, indication will start from the smallest numbered code.
If a DTC is not output or a DTC is output without terminal connection, proceed to the Tc terminal circuit inspection on page DI-484 . 3. (a) (b) DTC CHECK (Using TOYOTA hand-held tester) Hook up the TOYOTA hand-held tester to the DLC3. Read the DTCs by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand-held tester operator’s manual for further details. 4. DTC CLEARANCE (Not using service wire) When the ignition switch is turned off, the diagnostic trouble code is cleared. HINT: DTC might not be cleared by turning the ignition switch OFF. In this case, proceed to the next step. 5. DTC CLEARANCE (Using service wire) (a) Connect the 2 service wires to terminals Tc and AB of check connector. (b) Turn the ignition switch to ACC or ON and wait for approx. 6 seconds. 2001 AVALON (RM808U) Author
: Date
: 506 DI-351 DIAGNOSTICS (c) - SUPPLEMENTAL RESTRAINT SYSTEM Starting with the Tc terminal, ground alternately terminal Tc and terminal AB twice each in cycles of 1.0 second. Make sure that the terminals are grounded. Ensure the terminal Tc remain grounded. HINT: When alternately grounding terminals Tc and AB, release ground from one terminal and immediately ground the other terminal within an interval of 0.2 seconds. If DTCs are not cleared, repeat the above procedure until the codes are cleared. Terminal OFF AB Tc Tc 1 second Body Ground 1 second (±0.5 sec.) (±0.5 sec.) 1 3 5 OFF AB Body Ground 2 4 50 m sec. Several Seconds ON OFF 50 m sec. H01461 H11969 H12011 TOYOTA Hand-Held Tester (d) Several seconds after doing the clearing procedure, the SRS warning light will blink in a 50 - m sec. cycle to indicate the codes which have been cleared. 6. (a) (b) DTC CLEARANCE (Using TOYOTA hand-held tester) Hook up the TOYOTA hand-held tester to the DLC3. Clear the DTCs by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand-held tester operation’s manual for further details. DLC3 F07887 2001 AVALON (RM808U) Author
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: 507 DI-352 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 7. RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the squib connector. NOTICE:
Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure.
If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. 2001 AVALON (RM808U) Author
: Date
: 508 DI-353 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 7 Side Airbag Assembly (RH) (Squib) 8 Seat Belt Pretensioner (RH) 9 Side Airbag Sensor Assembly (RH) 10 Front Airbag Sensor (RH) 2 Airbag Sensor Assembly 6 1 Front Passenger Airbag Assembly (Squib) Spiral Cable 3 5 4 12 Steering Wheel Pad (Squib) 11 Front Airbag Sensor (LH) 13 Side Airbag Sensor Assembly (LH) 14 Seat Belt Pretensioner (LH) 15 Side Airbag Assembly (LH) (Squib) H11971 2001 AVALON (RM808U) Author
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: 509 DI-354 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM Airbag Sensor Assembly Connector 2 1 Short Spring 3 Short Spring Short Spring Before Release After Release Paper Connector 4 Before Release After Release Paper Short Spring Connector 5 6 Paper Short Spring Connector 7 15 Paper Short Spring H01356 H01233 AB0130 AB0045 AB0046 H02248 H02249 H09672 H09658 H12012 2001 AVALON (RM808U) Author
: Date
: 510 DI-361 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI164-28 PROBLEM SYMPTOMS TABLE Proceed with troubleshooting of each circuit in the table below. Symptom Suspect Area See page
With the ignition switch in ACC or ON position, the SRS warning light sometimes lights up after approx. 6 seconds have elapsed.
SRS warning light is always lit up even when ignition switch is in the LOCK position.
SRS warning light circuit DI-479
Tc terminal circuit DI-484
With the ignition switch in ACC or ON position, the SRS warning light does not light up.
DTC is not displayed.
SRS warning light is always lit up at the time of DTC check procedure.
DTC is displayed without Tc and E1 terminal connection. 2001 AVALON (RM808U) Author
: Date
: 517 DI-359 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM DI1N2-13 TERMINALS OF ECU C6 C5 B A 6 5 4 B C7 3 2 1 9 8 7 6 5 4 3 2 1 25 24 23 22 21 20 19 18 12 11 10 9 8 7 6 5 4 3 2 1 17 16 15 14 13 12 12 11 10 9 8 7 28 27 26 A 11 10 B A H01357 No. Symbol A - Electrical Connector Check Mechanism Terminal Name B - Electrical Connector Check Mechanism C5 - 1 PL- Squib (Seat Belt Pretensioner, LH) C5 - 2 PL+ Squib (Seat Belt Pretensioner, LH) C5 - 5 FL+ Squib (Side, LH) C5 - 6 FL- Squib (Side, LH) C5 - 7 VUPL Side Airbag Sensor (LH) C5 - 9 SSL+ Side Airbag Sensor (LH) C5 - 10 SSL- Side Airbag Sensor (LH) C5 - 12 ESL Side Airbag Sensor (LH) C6 - 3 LA C6 - 4 GSW C6 - 5 IG2 Power Source (IGN Fuse) C6 - 6 ACC Power Source (CIG Fuse) C6 - 9 +SR Front Airbag Sensor (RH) C6 - 10 P+ Squib (Passenger) SRS Warning Light Body ECU C6 - 11 P- Squib (Passenger) C6 - 12 SIL Diagnosis C6 - 13 D- Squib (Driver) C6 - 14 D+ Squib (Driver) C6 - 15 +SL Front Airbag Sensor (LH) C6 - 19 Tc C6 - 20 -SR Front Airbag Sensor (RH) C6 - 26 -SL Front Airbag Sensor (LH) C6 - 27 E1 Ground Diagnosis 2001 AVALON (RM808U) Author
: Date
: 515 DI-360 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM No. Symbol Terminal Name C6 - 28 E2 C7 - 1 FR- Squib (Side, RH) C7 - 2 FR+ Squib (Side, RH) C7 - 5 PR+ Squib (Pretensioner, RH) C7 - 6 PR- Squib (Pretensioner, RH) C7 - 7 ESR Side Airbag Sensor (RH) C7 - 9 SSR- Side Airbag Sensor (RH) C7 - 10 SSR+ Side Airbag Sensor (RH) C7 - 12 VUPR Side Airbag Sensor (RH) Ground 2001 AVALON (RM808U) Author
: Date
: 516 DI-534 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI01W-13 ECU Power Source Circuit CIRCUIT DESCRIPTION This circuit provides power to operate the theft deterrent ECU. WIRING DIAGRAM T4 Driver Side J/B 9 1J W-L 2C 1 ECU-B J/B No. 3 9 1B Engine Room J/B 5 3C W-G Theft Deterrent ECU 5 3D 2 W-G +B1 Driver Side J/B 1 1G DCC W DOOR NO. 1 10 1 +B2 1B L-R 2G 2 J/B No. 4 B 1 Fusible Link Block 1 F7 F6 1 ALT F10 7 4B 12 E W-B W-B A J9 J/C B FL MAIN Battery 20 4A IJ I13633 2001 AVALON (RM808U) Author
: Date
: 690 DI-535 DIAGNOSTICS - THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check DOME and DOOR No. 1 fuses. DOME Fuse DOOR No.1 Fuse I14465 PREPARATION: Remove DOOR No. 1 and DOME fuse from instrument panel J/B. CHECK: Check continuity of DOME and DOOR No. 1 fuses. OK: Continuity NG Check for short in all the harness and components connected to the DOME and DOOR No. 1 fuses (See attached wiring diagram). OK 2 Check voltage between terminals each of +B1 and +B2 and E of theft deterrent ECU connector. 1 (+B2) 11 (E) 2 (+B1) PREPARATION: Disconnect the theft deterrent ECU connector. CHECK: Measure voltage between terminals each of +B1 and +B2 and E of theft deterrent ECU connector. OK: Voltage: 10 - 14 V I11587 OK Proceed to next circuit inspection shown on problem symptom table (See page DI-531 ). NG 2001 AVALON (RM808U) Author
: Date
: 691 DI-536 DIAGNOSTICS 3 - THEFT DETERRENT SYSTEM Check for open in harness and connector between ECU and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and repair harness and connector between ECU and battery. 2001 AVALON (RM808U) Author
: Date
: 692 DI-547 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI6L4-01 Engine Hood Courtesy Switch Circuit CIRCUIT DESCRIPTION The engine hood courtesy switch is built into the engine hood lock assembly and goes ON when the engine hood is opened and goes OFF when the engine hood is closed. WIRING DIAGRAM T4 E3 Engine Hood Courtesy Switch 2 Theft Deterrent ECU 18 IF3 1 W-B B 6 B DSWH B J1 J/C B W-B 4 2D 4 2F Engine Room J/B W-B ED I13628 2001 AVALON (RM808U) Author
: Date
: 703 DI-548 DIAGNOSTICS - THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check engine hood courtesy switch. PREPARATION: (a) Remove engine hood lock assembly. (b) Disconnect engine hood courtesy switch connector. CHECK: Check continuity between terminals 1 and 2 when engine hood lock is locked and unlocked. OK: 1 (+) 2 (-) Engine hood lock Tester connection Specified condition LOCK - No continuity UNLOCK 1-2 Continuity I00298 NG Replace engine hood courtesy switch. OK 2 Check harness and connector between theft deterrent ECU and switch, switch and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU (See page IN-30 ). 2001 AVALON (RM808U) Author
: Date
: 704 DI-540 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI022-14 Ignition Switch Circuit CIRCUIT DESCRIPTION When the ignition switch is turned to the ACC position, battery positive voltage is applied to the terminal ACC of the ECU. Also, if the ignition switch is turned to the ON position, battery positive voltage is applied to the terminals ACC and IG of the ECU. When the battery positive voltage is applied to the terminal ACC of the ECU while the theft deterrent system is activated, the warning stops. Furthermore, power supplied from the terminals ACC and IG of the ECU is used as power for the door courtesy switch, and position switch, etc. WIRING DIAGRAM J/B No. 3 T4 J/B No. 4 11 2 3C 3F Y-R 18 4H Y-R Theft Deterrent ECU 18 4B 14 Y-R IG Driver Side J/B IG1 RELAY 1 1G 1 ECU-IG NO. 2 2 3 1B 4 3 13 I15 Ignition Switch 1B 4 1C 4 IG1 AM1 2 W-R W-L W W-B 1 F6 FL Block ALT 7 IF1 F10 1 1 F8 W-L Engine Room R/B No. 5 5 FL MAIN 2 AM1 1 5 Engine Room J/B IG Battery B-L 1 2G B 1 2H I14527 2001 AVALON (RM808U) Author
: Date
: 696 DI-541 DIAGNOSTICS - THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check CIG and ECU-IG fuses. PREPARATION: (a) Remove the fuse box opening cover. (b) Remove ECU-IG fuses from instrument panel J/B. CHECK: Check continuity of ECU-IG fuses. OK: Continuity ECU-IG Fuse NG I14465 Check for short in all the harness and components connected to the ECU-IG fuses (See attached wiring diagram). OK 2 Check voltage between terminal IG of theft deterrent ECU and body ground. (-) (+) 14 (IG) PREPARATION: (a) Disconnect the theft deterrent ECU connectors. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal IG of theft deterrent ECU connector and body ground. OK: Voltage: 10 - 14 V I11586 NG Check and repair harness and connector between theft deterrent ECU and battery (See page IN-30 ). OK Check and replace theft deterrent ECU. 2001 AVALON (RM808U) Author
: Date
: 697 DI-532 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI6L1-01 CIRCUIT INSPECTION Indicator Light Circuit CIRCUIT DESCRIPTION When the theft deterrent system is preparing to set, this circuit lights up the indicator light. When the system has been set, it continuously turns the indicator light on for 0.75 secs. and turns it off for 1.25 secs., thus blinking the indicator light. WIRING DIAGRAM Theft Deterrent ECU C9 Security Indicator J/B No. 3 W-B 7 3A 7 3G 21 W-B 22 V 10 IC1 V-W 12 T4 IND A A J5 J/C W-B IG I13634 INSPECTION PROCEDURE 1 Check indicator light. PREPARATION: Remove combination meter. CHECK: Connect the positive (+) lead from the battery to terminal B22 and the negative (-) lead to terminal B21 of combination meter connector then check indicator light comes ON. (See combination meter on page BE-43 ) NG Replace combination meter. OK 2001 AVALON (RM808U) Author
: Date
: 688 DI-533 DIAGNOSTICS 2 - THEFT DETERRENT SYSTEM Check harness and connector between theft deterrent ECU and indicator light, indicator light and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptom table (See page DI-531 ). 2001 AVALON (RM808U) Author
: Date
: 689 DI-542 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI6L3-01 Key Unlock Warning Switch Circuit CIRCUIT DESCRIPTION The key unlock warning switch goes ON when the ignition key is inserted in the key cylinder and goes OFF when the ignition key is removed. The ECU operates the key confinement prevention function while the key unlock warning switch is ON. WIRING DIAGRAM T4 Theft Deterrent ECU U1 Key Unlock Warning Switch J/B No. 3 22 3D 9 3D 1 W-B 2 R-Y J/B No. 4 2 4B 2 4A 4 R-Y KSW W-B IG I13630 2001 AVALON (RM808U) Author
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: 698 DI-543 DIAGNOSTICS - THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check key unlock warning switch. PREPARATION: Disconnect key unlock warning switch connector. CHECK: Check continuity between terminal 1 and 2 of key unlock warning switch connector, when the key is inserted to the key cylinder or removed. OK: OFF ON 21 43 I01663 Switch position Tester connection Specified condition ON (Key inserted) 1-2 Continuity OFF (Key removed) - No continuity NG Replace key unlock warning switch. OK 2 Check harness and connectors between ECU and key unlock warning switch, key unlock warning switch and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown in problem symptom table (See page DI-531 ). 2001 AVALON (RM808U) Author
: Date
: 699 DI-544 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI024-12 Luggage Compartment Door Key Lock and Unlock Switch Circuit CIRCUIT DESCRIPTION The luggage compartment door key lock and unlock switch goes ON when the luggage compartment door key cylinder is turned to the unlock side with the key. WIRING DIAGRAM L4 L6 Theft Deterrent ECU Luggage Compartment Door Key Unlock Switch 1 W-B 2 G-W 1 IK2 3 G-W LGV A J10 J/C BN I13629 2001 AVALON (RM808U) Author
: Date
: 700 DI-545 DIAGNOSTICS - THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal 1 of luggage compartment door key lock and unlock switch connector and body ground. ON 1 AB0119 I11584 I11584 PREPARATION: (a) Remove luggage compartment door trim. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal 1 of luggage compartment door key lock and unlock switch connector and body ground, when the key is turned to the unlock side and not turned respectively. OK: OK Key operation Voltage Turned to the unlock side 0V Not turned Battery positive voltage Check and replace theft deterrent ECU.*1 NG 2 Check luggage compartment door key lock and unlock switch. 2 PREPARATION: Disconnect luggage compartment door key lock and unlock switch connector. CHECK: Check continuity between terminals 1 and 2, when the key is turned to the unlock side and not turned respectively. OK: 1 I11585 Key operation Tester connection Specified condition Turned to unlock 1-2 Continuity Not turned - No continuity NG Repair or replace luggage compartment door key lock and unlock switch. OK 2001 AVALON (RM808U) Author
: Date
: 701 DI-546 DIAGNOSTICS 3 - THEFT DETERRENT SYSTEM Check harness and connector between theft deterrent ECU and key lock and unlock switch, key lock and unlock switch and body ground (See page IN-30 ). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptom table (See page DI-531 ). 2001 AVALON (RM808U) Author
: Date
: 702 DI-537 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI6L2-01 Theft Deterrent Horn Circuit CIRCUIT DESCRIPTION When the theft deterrent system is activated, the relay in the ECU turns ON and OFF cycles of approximately 0.2 sec., causing the theft deterrent horn to blow (See the wiring diagram below). In this condition, if any of the following operations is done, the relay in the ECU turns OFF, thus stopping the theft deterrent horn from blowing: (1) Unlock the front LH or RH door with key. (2) Turn the ignition switch to ACC or ON position. (3) Unlock the doors with the wireless door lock control system. (4) Wait for approximately 60 seconds. (5) Push the panic switch of the wireless door lock control system. WIRING DIAGRAM Driver Side J/B HORN 2 5 2C 2G B T4 Theft Deterrent ECU B-R 7 IF3 B-R 24 SH FL Block 1 F7 1 F6 W 25 SH- B FL MAIN T2 1 Battery Theft Deferrent Horn I13632 2001 AVALON (RM808U) Author
: Date
: 693 DI-538 DIAGNOSTICS - THEFT DETERRENT SYSTEM INSPECTION PROCEDURE HINT: The flow chart below is based on the premise that the horns blow normally whenever the horn switch is operated. If horn operation is not normal when the horn switch is operated, check the horn switch. 1 Check voltage between terminal SH of theft deterrent ECU connector and body ground. PREPARATION: Disconnect the theft deterrent ECU connectors. CHECK: Measure voltage between terminal SH of theft deterrent ECU connector and body ground. OK: Voltage: 10 - 14 V 24 (SH) (-) (+) I11588 NG Check and repair harness and connector between theft deterrent ECU and horn relay. OK 2 Check voltage between terminal 1 of theft deterrent horn connector and body ground. (-) PREPARATION: Remove the theft deterrent horn and disconnect the connector. CHECK: Measure voltage between terminal 1 of theft deterrent horn connector and body ground. OK: Voltage: 10 - 14 V (+) 1 I11582 NG Check and repair harness and connector between HORN fuse and theft deterrent horn. OK 2001 AVALON (RM808U) Author
: Date
: 694 DI-539 DIAGNOSTICS 3 - THEFT DETERRENT SYSTEM Check theft deterrent horn. CHECK: Connect positive (+) lead to terminal 1 and negative (-) lead to ground to theft deterrent horn connector. OK: Theft deterrent horn blows. (-) 1 (+) I11583 NG Replace theft deterrent horn. OK 4 Check harness and connector between theft deterrent ECU and theft deterrent horn (See page IN-30 ). NG Check and repair harness or connector. OK Check and replace theft deterrent ECU. 2001 AVALON (RM808U) Author
: Date
: 695 DI-518 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI01Q-10 CUSTOMER PROBLEM ANALYSIS CHECK THEFT DETERRENT SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date of Vehicle Brought in / / / Date Problem First Occurred
Constant
Once only Frequency Problem Occurs Weather Conditions When Problem Occurred km Mile Odometer Reading
Sometimes ( / Times per day, month)
Fine
Cloudy
Rainy
Various/Others
Hot
Warm
Cool Outdoor temperature
Cold (Approx. °F ( °C)) Weather
Snowy Problem Symptom
Theft deterrent system cannot be set.
Indicator light does not flash when the theft deterrent system is set. (It stays on or does not light at all.)
Theft deterrent system does not operate.
When unlocked using the door lock knob.
When the engine hood is opened.
System cannot be canceled once set.
When door is unlocked using key or wireless door lock control system.
When the key is inserted in the ignition key cylinder and turned to ACC or ON position. (However, only when the system has never operated)
When the luggage compartment door is opened with the key.
System cannot be canceled during warning operation.
When door is unlocked using key or wireless door lock control system.
When the key is inserted in the ignition key cylinder and turned to ACC or ON position. Malfunction
Horns only
Theft deterrent horn only
Headlights only
Taillights only
Starter cut only
Door lock operation only
Warning operation starts when the system is set and the door or luggage compartment door is opened with the key.
Others. 2001 AVALON (RM808U) Author
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: 674 DI-517 DIAGNOSTICS - THEFT DETERRENT SYSTEM THEFT DETERRENT SYSTEM DI01P-1 1 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshooting of the theft deterrent system is based on the premise that the door lock control system is operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that the door lock control system is operating normally. For troubleshooting use a volt/ohm meter. Be sure to use troubleshooting procedure appropriate to the diagnostic tool being used. Perform troubleshooting in accordance with the procedure on the following page. Vehicle Brought to Workshop 1 Customer Problem Analysis Titles inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. P. DI-518 Symptom does not occur 2 Problem Symptom Confirmation 3 Symptom Simulation P. IN-20 Symptom occur 4 Problem Symptom Table P. DI-531 5 Circuit Inspection P. DI-532 ∼ DI-544 Identification of Problem 6 7 Repair Confirmation Test Step 5, 7 : Diagnostic steps permitting the use of the hand-held tester and breakout-box. End 2001 AVALON (RM808U) Author
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: 673 DI-529 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI6L0-01 PARTS LOCATION Theft Deterrent Horn Enjine Room Junction Block
HORN Fuse
HORN Relay
Headlight Control Relay Engine Hood Courtesy Switch Security Indicator Theft Deterrent ECU Driver Side Junction Block
DOME Fuse
ECU-IG No.1 Fuse
ECU-IG No.2 Fuse
Taillight Control Relay
Body ECU Door Lock Assembly
Door Lock Motor
Door Unlock Detection Switch Ignition Switch
Key Unlock Warning Switch Luggage Compartment Door Key Lock and Unlock Switch Door Lock Assembly
Door Lock Motor
Door Unlock Detection Switch
Luggage Compartment Door Lock Motor
Luggage CompartmentDoor Courtesy Switch I11668 2001 AVALON (RM808U) Author
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: 685 DI-519 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI4DL-03 PRE-CHECK 1. THEFT DETERRENT SYSTEM When the system is set to the theft deterrent mode and any of the following conditions are met, the system sounds the horns and flashes the headlights and the taillights for approx. 1 minute. At the same time the system locks all doors (If all door are not locked at once, the system repeats door locking operation every 6.38 seconds during the one minute alarm time). There are 2 modes in this system, which are active mode and passive mode. All initial setting are performed in active mode. It can be switched to passive mode by specified operation. (See step 4. CHANGING METHOD OF PASSIVE MODE) Condition:  Any of the doors (Including the engine hood and luggage compartment door) is unlocked or opened without the key. *1  The battery terminal is disconnected and reconnected.  The system receives panic signal from remote keyless entry. *2 *1: Only active arming mode. *2: When the ignition key is not inserted in the key cylinder. There are 4 conditions in this system which are disarming condition, disarming preparation condition, arming condition and alarming condition. (a) Disarming condition: (1) When a user is near the vehicle. (2) When the alarming function does not operate. (3) When theft deterrent function is not performed. (b) Disarming preparation condition: (1) Time from a user locks a door to be leaves the vehicle. (2) Time until transferring to disarming condition. (3) Theft deterrent function is not performed. (c) Arming condition: (1) When a user leaves the vehicle completely. (2) When theft deterrent function is possible. 2001 AVALON (RM808U) Author
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: 675 DI-520 DIAGNOSTICS (d) - THEFT DETERRENT SYSTEM Alarming condition: Is this condition, once theft is detected, it is informed using light and sound to people around the vehicle. Refer to the table for alarming method or time. Horn Security horn Al Alarming i method th d Headlight Taillight Alarming time 60 seconds Alarming output Continuous 0.40 secs. (ON) 0.40 secs. (OFF) In the arming condition when either of doors is unlocked and with not key in the key cylinder, force lock signal is output. 2001 AVALON (RM808U) Author
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: 676 DI-521 DIAGNOSTICS 2. - THEFT DETERRENT SYSTEM ACTIVE ARMING MODE Disarming condition (Key not inserted in ignition cylinder.) Any of the following conditions is met
When all doors and engine hood are closed, lock all the doors using a key.
When all doors and engine hood are closed, lock all the doors using wireless remote function.
When all doors and engine hood are closed, open and close either of doors and engine hood then close and lock all doors and engine hood. Disarming preparation condition Any of the following conditions is met
Close and open either of all doors and engine hood.
Lock and unlock either of doors.
Insert a key into the ignition key cylinder.
Reconnect the battery. Any of the following conditions is met
30 seconds elapse when the engine hood is closed and all doors are locked. Arming condition Any of the following conditions is met
Unlock the locked doors using the wireless remote function.
Unlock the locked doors using the key.
Insert the key into the ignition key cylinder and turn the ignition key ON. Any of the following conditions is met
Either of closed doors opens.
Either of locked doors is unlocked by any operation other than key or wireless remote function.
The closed engine hood is opened.
The battery is reconnected.
Ignition switch turned to ON. Alarming condition In this mode, once theft is detected, it is informed using light and sound to people around the vehicle. The alarming time described above passes. Any of the following conditions is met
Unlock the locked doors using the wireless remote function.
Unlock the locked doors using the key.
Insert the key into the ignition key cylinder and turn the ignition key ON. 2001 AVALON (RM808U) Author
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: 677 DI-522 DIAGNOSTICS - THEFT DETERRENT SYSTEM Indicator light output: Condition Indicator light Disarming condition OFF Arming preparation condition ON Arming condition OFF Alarming condition ON HINT: Even in disarming condition, the indicator light flash. (Due to the signal output form immobilizer system). The indicator always flashes receiving the signal from the immobilizer system at any time in the arming condition. Flashing frequency: 0.2 seconds (ON) 1.8 seconds (OFF) 3.   PASSIVE ARMING MODE This mode can be switched according to the specified operation. All initially set modes (when shipped from factory) are active mode. (No passive mode) 2001 AVALON (RM808U) Author
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: 678 DI-523 DIAGNOSTICS - THEFT DETERRENT SYSTEM Disarmed state (A) Perform any of the following and the system will go to Disarmed state (B):
Remove the key from the ignition, close the driver’s door, then the ignition OFF. Disarmed state (B) Perform any of the following and the system will return to Disarmed state (A):
Push the unlock switch on the wireless remote.
Put the key in the lock on the driver’s or the passenger door and turn it towards unlock.
Put the key in the ignition.
Reconnect the battery.
Turn the ignition from OFF to ON. Perform any of the following and the system will go to Arming preparation:
Close all the doors, hood and luggage compartment door. Arming preparation Perform any of the following and the system will return to Disarmed state (B):
Open any of the doors, the hood or the luggage compartment door. Perform any of the following and the system will return to Disarmed state (A):
Push the unlock switch on the wireless remote.
Put the key in the lock on the driver’s or the passenger door and turn it towards unlock.
Put the key in the ignition.
Reconnect the battery.
Turn the ignition from OFF to ON. Perform any of the following and the system will go to Armed state:
Allow 30 seconds to elapse with all the doors, hood and luggage compartment door closed. Armed state Perform any of the following and the system will return to Disarmed state (A):
Push the unlock switch on the wireless remote.
Put the key in the lock on the driver’s or the passenger door and turn it towards unlock.
Put the key in the ignition and turn it ON.
Run the engine at 550 rpm or faster for more than 10 seconds. Perform any of the following and the system will go on to Alarm sounding:
Open any of the doors and allow the entry delay time to pass.
Open the hood.
Open the luggage compartment door with something other than the key or wireless remote.
Reconnect the battery. Perform any of the following and the system will return to Disarmed state (B):
Open the luggage compartment door with the wireless remote.
Open the luggage compartment door with the Key. 2001 AVALON (RM808U) Author
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: 679 DI-524 DIAGNOSTICS - THEFT DETERRENT SYSTEM Alarm sounding Perform any of the following and the system will return to Armed state:
The alarm sounding period passes. Perform any of the following and the system will return to Disarmed state (A):
Push the unlock switch on the wireless remote.
Put the key in the lock on the driver’s or the passenger door and turn it towards unlock.
Put the key in the ignition and turn it ON.
Run the engine at 550 rpm or faster for more than 10 seconds. Perform any of the following and the system will return to Disarmed state (B):
Open the luggage compartment door with the wireless remote.
Open the luggage compartment door with the Key. 2001 AVALON (RM808U) Author
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: 680 DI-525 DIAGNOSTICS - THEFT DETERRENT SYSTEM HINT: In arming condition either closed door is opened, entry delay occurs. (14 secs.) During this time, the mode transfers to disarming condition when the condition described above * is met. When the condition is not met, the system judges theft occurs, the mode transfers to alarming condition. Door Close Open Indicator ON OFF Alarming output ON OFF Entry delay time System condition Arming condition Alarming condition Indicator light output: Condition Indicator light Disarming condition OFF Arming preparation condition ON Arming condition (Entry delay time) OFF (ON) Alarming condition ON HINT: Even in disarming condition, the indicator light flash. (Due to the signal output form immobilizer system). The indicator always flashes receiving the signal from the immobilizer system at any time in the arming condition. Flashing frequency: 0.2 seconds (ON) 1.8 seconds (OFF) 2001 AVALON (RM808U) Author
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: 681 DI-526 DIAGNOSTICS  - THEFT DETERRENT SYSTEM Transfer to active mode: In each passive mode, when ”disarming condition of active mode → arming preparation transfer condition” is met, the active mode transfers to each condition. In this case, active mode continues till disarming condition. Passive mode when transfer condition is met. Active mode transfer condition Disarming condition Arming preparation condition Arming preparation condition Arming preparation condition Arming condition (During entry delay time) Arming condition (After alarming time has elapsed, arming condition) Alarming condition After alarming time has elapsed, arming condition 2001 AVALON (RM808U) Author
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: 682 DI-527 DIAGNOSTICS 4. - THEFT DETERRENT SYSTEM CHANGING METHOD OF PASSIVE MODE (ON or OFF) Remove the ignition key from key cylinder. All the doors, engine hood and luggage compartment door are closed and unlocked. Any of doors is locked and unlocked by turns 3 times by the key or remote control. Input to the vehicle Output from the vehicle Within 30 sec. Driver’s side door is opened. Driver’s side knob for door lock is locked and unlocked 3 times. Within 2 sec. The system starts force lock at once after 2 sec. Driver’s side knob for door lock is unlocked. Within 20 sec. Driver’s side door is closed and opened 2 times Driver’s side door is closed and opened 3 to 5 times 3 times Driver’s side knob for door lock is locked and unlocked. The system starts force lock at once after 2 secs. 5 times Driver’s side knob for door lock is locked and unlocked. * 0 sec. Within 2 sec. 4 times * 14 sec. * 30 sec. The system starts force lock at once after 2 sec. PASSIVE MODE OFF PASSIVE MODE ON HINT:
Initial mode is PASSIVE MODE OFF.
If there is a different signal in the middle of changing. It is invalid. *: Entry delay time 2001 AVALON (RM808U) Author
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: 683 DI-528 DIAGNOSTICS Hand-held tester 5. (a) ECU (b) Break-out-box N09348 - THEFT DETERRENT SYSTEM ECU TERMINAL VALUES MEASUREMENT BY USING BREAK-OUT-BOX AND HAND-HELD TESTER Hook up the break-out-box and hand-held tester to the vehicle. Read the ECU input/ output values by following the prompts on the tester screen. HINT: Hand-held tester has a ”Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the hand-held tester / break-out-box operator’s manual for further details. 2001 AVALON (RM808U) Author
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: 684 DI-531 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI01U-1 1 PROBLEM SYMPTOMS TABLE Proceed to the reference page shown in the matrix chart below for each malfunction symptom and troubleshoot for each circuit. HINT: Troubleshooting of the theft deterrent system is based on the premise that the door lock control system is operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that the door lock control system is operating normally. Symptom Suspect Area See page 1. 2. 3. 4. Indicator light circuit ECU power source circuit Key unlock warning switch circuit Luggage compartment door key lock and unlock switch circuit 5. Engine hood courtesy switch circuit DI-532 DI-534 DI-542 DI-544 The indicator light does not blink when system is set. Indicator light circuit DI-532 When the system is set (The system does not operate when the rear door is unlocked). Door unlock detection switch circuit DI-686 DI-708 DI-643 When the system is set (The system does not operate when the luggage compartment door is opened by a method other than the key). Luggage compartment door courtesy switch circuit DI-647 When the system is set (The system does not operate when the engine hood is opened). Engine hood courtesy switch circuit DI-547 When the system is set (It is not canceled when the ignition key is turned to ACC or ON position (Except Europe Models)). Ignition switch circuit DI-540 When the system is set (It still operates when the luggage compartment door is opened with the key (Except Europe Models)). Luggage compartment door key lock and unlock switch circuit DI-544 While the system is in warning operation (Horns do not sound). Horn relay circuit DI-672 While the system is in warning operation (Headlights do not flash). Headlight control relay circuit DI-635 While the system is in warning operation (Taillights do not flash). Taillight control relay circuit DI-633 While the system is in warning operation (The door lock is not locked). Door unlock detection switch circuit DI-686 DI-708 DI-643 System is still set even when a rear door is open Door courtesy switch circuit DI-639 Even when the system is not set (Horns sound). Horn relay circuit DI-672 Even when the system is not set (Headlights stay on). Headlight control relay circuit DI-635 Even when the system is not set (Taillights stay on). Taillight control relay circuit DI-633 The theft deterrent system cannot be set 2001 AVALON (RM808U) Author
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: 687 DI-530 DIAGNOSTICS - THEFT DETERRENT SYSTEM DI1AH-13 TERMINALS OF ECU T4 I11580 Symbols (Terminals No.) DSWH ↔ E (T4-6 ↔ T4-12) KSW ↔ E (T4-4 ↔ T4-12) Wiring Color B ↔ W-B WB R Y ↔ W-B R-Y WB Condition STD Value Engine hood courtesy switch ”ON” (Engine hood opened) Below 1 Ω Engine hood courtesy switch ”OFF” (Engine hood closed) 1 MΩ or higher Key unlock warning switch ”ON” (Key inserted) Below 1 Ω Key unlock warning switch ”OFF” (Key removed) 1 MΩ or higher Luggage compartment door key lock and unlock switch ”ON” Below 1 Ω Luggage compartment door key lock and unlock switch ”OFF” 1 MΩ or higher LGU ↔ E (T4-3 ↔ T4-12) G W ↔ W-B G-W WB +B1 ↔ Body ground (T4-2 ↔ Body ground) W-G ↔ W-B Always 10 - 14 V IG ↔ E (T4-14 ↔ T4-12) Y-R ↔ W-B Ignition switch is turned to ”ON” position 10 - 14 V +B2 ↔ Body ground (T4-1 ↔ Body ground) L-R ↔ Body ground Always 10 - 14 V IND ↔ E (T4-12 ↔ T4-12) V-W ↔ W-B During set preparation E ↔ Body ground (T4-12 ↔ Body ground) W-B ↔ Body ground Always 10 - 14 V B-R ↔ W Always 10 - 14 V SH ↔ SH(T4-24 ↔ T4-25) MPX1 ↔ Body ground (T4-10 ↔ Body ground) V ↔ Body ground 3-5V Multiplex communication circuit - 2001 AVALON (RM808U) Author
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: 686 EC-1 EMISSION CONTROL - EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM EC01H-03 PURPOSE The emission control systems are installed to reduce the amount of CO, HC and NOx exhausted from the engine ((3) (4) and (5)), to prevent the atmospheric release of blow-by gas-containing HC (1) and evaporated fuel containing HC being released from the fuel tank (2). The function of each system is shown in these table. System (1) Positive Crankcase Ventilation (2) Evaporative Emission Control (3) Warm Up Three-Way Catalytic Converter (4) Three-Way Catalytic Converter (5) Sequential Multiport Fuel injection* Abbreviation PCV EVAP WU-TWC TWC SFI Function Reduces HC Reduces evaporated HC Reduces HC, CO and NOx Reduces HC, CO and NOx Injects a precisely timed, optimum amount of fuel for reduced exhaust emissions Remark: * For inspection and repair of the SFI system, refer to the SF section of this manual. 2001 AVALON (RM808U) Author
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: 1095 EC-5 EMISSION CONTROL - EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EC0BF-02 COMPONENTS Charcoal Canister VSV Connector for Pressure Switching Valve EVAP Line Hose Vapor Pressure Sensor Vent Line Hose Air Inlet Line Hose Vapor Pressure Sensor Connector Purge Line Hose Air Drain Hose VSV for Pressure Switching Valve 39.2 (400, 29) Charcoal Canister N·m (kgf·cm, ft·lbf) : Specified torque Fuel Hose B08627 2001 AVALON (RM808U) Author
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: 1099 EC-6 EMISSION CONTROL - EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EC0B4-03 INSPECTION 1. VISUALLY INSPECT LINES AND CONNECTORS Visually check for loose connections, sharp bends or damage. 2. VISUALLY INSPECT FUEL TANK FILLER PIPE Visually check for deformation, cracks or fuel leakage. 3. INSPECT FUEL TANK CAP Visually check if the cap and/or gasket are deformed or damaged. If necessary, repair or replace the cap. Gasket B01082 4. (a) Vacuum Gauge (b) INSPECT EVAP SYSTEM LINE Warm up the engine and stop the engine. Allow the engine to warm up to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. B06544 (c) TOYOTA Hand-Held Tester: Forced driving of the VSV for the EVAP. (1) Connect a TOYOTA hand-held tester to the DLC3. (2) Start the engine. (3) Push the TOYOTA hand-held tester main switch ON. (4) Use the ACTIVE TEST mode on the TOYOTA hand-held tester to operate the VSV for the EVAP. (d) If you have no TOYOTA Hand-Held Tester: Forced driving of the VSV for the EVAP. (1) Disconnect the VSV connector for the EVAP. (2) Connect the positive (+) and negative (-) leads from the battery to the VSV terminals for the EVAP. (3) Start the engine. TOYOTA Hand-Held Tester DLC3 A10838 Battery B06722 2001 AVALON (RM808U) Author
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: 1100 EC-7 EMISSION CONTROL (e) B06545 Air Drain Hose EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM Check the vacuum at idle. Vacuum: Maintain at 0.368 - 19.713 in.Hg (5 - 268 in.Aq) for over 5 seconds HINT: If the vacuum does not change, you can conclude that the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (f) TOYOTA Hand-Held Tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the TOYOTA hand-held tester from the DLC3. (g) If you have no TOYOTA Hand-Held Tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the positive (+) and negative (-) leads from the battery from the VSV terminals for the EVAP. (3) Connect the VSV connector for the EVAP. (h) Disconnect the vacuum gauge from the EVAP service port on the purge line. (i) Connect a pressure gauge to the EVAP service port on the purge line. (j) Hose Clipper - Check the pressure. (1) Close off the air drain hose at the marked position of the canister with a hose clipper or similar instrument. B08626 (2) Add the pressure (13.5 - 15.5 in.Aq) from the EVAP service port. Pressure: 2 minutes after the pressure is added, the gauge should be over 7.7 - 8.8 in.Aq. Pressure Gauge Pressure B06546 HINT: If you can’t add pressure, you can conclude that the hose connecting the VSV
canister
fuel tank has slipped off or the VSV is open. 2001 AVALON (RM808U) Author
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: 1101 EC-8 EMISSION CONTROL (3) Fuel Tank Cap - EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM Check if the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: If the pressure does not decrease when the filler cap is removed, then you can conclude that the hose connecting the service port to the fuel tank is blocked, etc. (k) Disconnect the pressure gauge from the EVAP service port on the purge line. B06547 EVAP Line Hose Air Disconnect B08623 Purge Line Hose EVAP Line Hose 5. CHECK AIRTIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the EVAP line hose from the charcoal canister side and then pressurize and make the internal pressure in the fuel tank 4 kPa (41 gf/cm2, 0.58 psi). (b) Check that the internal pressure of the fuel tank can be hold for 1 minute. (c) Check the connected portions of each hose and pipe. (d) Check the installed parts on the fuel tank. If there is no abnormality, replace the fuel tank and filler pipe. (e) Reconnect the EVAP line hose to the charcoal canister. 6. (a) (b) (c) Disconnect Disconnect Purge Port Air Cap B08624 INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE Disconnect the purge line hose and EVAP line hose from the charcoal canister. Plug the cap to the air drain hose. Pressurize 4 kPa (41 gf/cm2, 0.58 psi) to the purge port and check that there is ventilation through the EVAP line hose. HINT: In the condition that the fuel fuel is full, as the float value of the fill check valve is closed and has no ventilation, it is necessary to check the fuel amount (volume). (d) Check if there is any struck in the vent line hose and EVAP line hose. If there is no stuck in hoses, replace the fuel cutoff valve and fill check valve. (e) Reconnect the purge line hose and EVAP line hose to the charcoal canister. 2001 AVALON (RM808U) Author
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: 1102 EC-9 EMISSION CONTROL Air Inlet Line Hose 7. (a) (b) (c) 8. (a) Disconnect Air B08625 (b) (c) (d) (e) Push Pinch A (f) (g) (h) A - EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM CHECK AIR INLET LINE Disconnect the air inlet line hose from the charcoal canister. Check that there is ventilation in the air inlet line. Reconnect the air inlet line hose to the charcoal canister. REMOVE CHARCOAL CANISTER ASSEMBLY Disconnect the VSV connector for the pressure switching valve. Disconnect the vapor pressure sensor connector. Disconnect the fuel hose from the vapor pressure sensor. Disconnect the purge line hose, EVAP line hose and air inlet line hose from the charcoal canister. Disconnect the vent line hose from the charcoal canister. (1) Push the connector deep inside. (2) Pinch portion A. (3) Pull out the connector. Remove the 2 charcoal canister mounting bolts. Remove the vapor pressure sensor mounting bolt. Remove the charcoal canister assembly. Pinch B01253 9. (a) INSPECT CHARCOAL CANISTER Visually check the charcoal canister for cracks or damage. (b) Inspect the charcoal canister operation. (1) Plug the vent port with the cap. (2) While holding the purge port closed, blow air (1.76 kPa, 18 gf/cm2, 0.26 psi) into the EVAP port and check that air flows from the air drain port. B08620 Purge Port Vent Port EVAP Port Air Drain Port Cap Air B08621 2001 AVALON (RM808U) Author
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: 1103 EC-10 EMISSION CONTROL Air Inlet Port Air Drain Port Air Purge Port - EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (3) While holding the purge port and the air drain port closed, blow air (1.76 kPa, 18 gf/cm2, 0.26 psi) into the EVAP port and check that air does not flow from the air inlet port. (4) Apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the purge port, check that the vacuum does not decrease when the air inlet port is closed, and check that the vacuum decreases when the air inlet port is released. EVAP Port B08622 Air Inlet Port Purge Port Vacuum B08673 Air Inlet Port Purge Port EVAP Port Vacuum B08670 (5) While holding the air inlet port closed, apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP port and check that air flows into the purge port. If operation is not as specified, replace the charcoal canister. (6) Remove the hose and cap from vent port. 10. INSPECT VSV FOR EVAP (See page SF-65 ) 11. INSPECT VSV FOR CANISTER CLOSED VALVE (CCV) (See page SF-70 ) 12. INSPECT VSV FOR PRESSURE SWITCHING VALVE (See page SF-72 ) 13. INSPECT VAPOR PRESSURE SENSOR (See page SF-75 ) 14. REINSTALL CHARCOAL CANISTER ASSEMBLY 2001 AVALON (RM808U) Author
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: 1104 EC-4 EMISSION CONTROL - POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM EC04N-02 INSPECTION PCV Valve 1. (a) INSPECT PCV VALVE Remove the PCV valve. S05053 (b) (c) Install clean hose to the PCV valve. Inspect the PCV valve operation. (1) Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. Clean Hose Cylinder Head side P02006 (2) Intake Manifold Side Blow air into the intake manifold side, and check that air passes through with difficulty. If operation is not as specified, replace the PCV valve. (d) Remove clean hose from the PCV valve. (e) Reinstall the PCV valve. P02477 2. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. P12931 2001 AVALON (RM808U) Author
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: 1098 EC-3 EMISSION CONTROL - PARTS LAYOUT AND SCHEMATIC DRAWING EC01J-03 DRAWING EVAP Service Port Purge Line Vapor Pressure Sensor VSV for EVAP EVAP Line Vent Line VSV for Pressure Switching Valve Fuel Tank Charcoal Canister VSV for Canister Closed Valve (CCV) Air Drain Hose Air Inlet Line Air Cleaner A/F Sensor (Bank 1 Sensor 1) A/F Sensor (Bank 2 Sensor 1) WU-TWC Heated Oxygen Sensor (Bank 1 Sensor 2) WU-TWC TWC B08913 2001 AVALON (RM808U) Author
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: 1097 EC-2 EMISSION CONTROL - PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING EC04L-03 LOCATION PCV Valve Vacuum Surge Tank EVAP Service Port VSV for EVAP VSV for Canister Closed Valve (CCV) Vapor Pressure Sensor Charcoal Canister Vent Line VSV for Pressure Switching Valve EVAP Line Fuel Tank Fill Check Valve Fuel Tank Cap Air Drain Hose Filler Pipe Purge Line Cut Off Valve Air Inlet Line B07254 2001 AVALON (RM808U) Author
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: 1096 EMISSION CONTROL - THREE-W AY CATALYTIC CONVERTER (TWC) SYSTEM EC-15 EC04T-03 COMPONENTS  Gasket Heated Oxygen Sensor (Bank 1 Sensor 2) 44 (450, 33)  Gasket 43 (440, 32) 43 (440, 32) Compression Spring Damper TWC Compression Spring Center Exhaust Pipe N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part Heated Oxygen Sensor (Bank 1 Sensor 2) HINT:
Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
After installing the heated oxygen sensor, check that the sensor wire is not twisted, if it is twisted, remove the heated oxygen sensor and reinstall it. B07459 2001 AVALON (RM808U) Author
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: 1109 EC-14 EMISSION CONTROL - THREE-W AY CATALYTIC CONVERTER (TWC) SYSTEM THREE-W AY CATALYTIC CONVERTER (TWC) SYSTEM EC04S-01 ON-VEHICLE INSPECTION 1. INSPECT EXHAUST PIPE ASSEMBLY (a) Check the connections for looseness or damage. (b) Check the clamps for weakness, cracks or damage. 2. INSPECT TWC Check for dents or damage. If any part of the protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. 3. INSPECT TWC HEAT INSULATOR (a) Check the heat insulator for damage. (b) Check for adequate clearance between the catalytic converter and heat insulator. 2001 AVALON (RM808U) Author
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: 1108 EC-12 EMISSION CONTROL - WARM UP THREE-W AY CATALYTIC CONVERTER (WU-TWC) SYSTEM EC0BI-02 COMPONENTS WU-TWC for Bank 1 43 (440, 32) Compression Spring
Gasket
Gasket
Gasket
WU-TWC Front Exhaust Pipe 62 (630, 46) Stay
62 (630, 46) 33 (330, 24) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B07452 2001 AVALON (RM808U) Author
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: 1106 EMISSION CONTROL - WARM UP THREE-W AY CATALYTIC CONVERTER (WU-TWC) SYSTEM EC-13 WU-TWC for Bank 2 A/F Sensor Connector
Gasket LH Exhaust Manifold (with WU-TWC) 49 (500, 63) x6 LH Exhaust Manifold Heat Insulator
Gasket A/F Sensor 44 (450, 33) LH Exhaust Manifold Stay
62 (630, 46) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B07458 2001 AVALON (RM808U) Author
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: 1107 EMISSION CONTROL - WARM UP THREE-W AY CATALYTIC CONVERTER (WU-TWC) SYSTEM EC-1 1 WARM UP THREE-WAY CATALYTIC CONVERTER (WU-TWC) SYSTEM EC0BH-01 ON-VEHICLE INSPECTION 1. INSPECT EXHAUST PIPE ASSEMBLY (a) Check the connections for looseness or damage. (b) Check the clamps for weakness, cracks or damage. 2. INSPECT WU-TWC Check for dents or damage. If any part of the protector is damaged or dented to the extent that it contacts the WU-TWC, repair or replace it. 3. INSPECT WU-TWC HEAT INSULATOR (a) Check the heat insulator for damage. (b) Check for adequate clearance between the catalytic converter and heat insulator. 2001 AVALON (RM808U) Author
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: 1105 EM-1 ENGINE MECHANICAL - CO/HC CO/HC EM0CB-03 INSPECTION HINT: This check is used only to determine whether or not the idle CO/ HC complies with regulations. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected (f) SFI system wiring connectors fully plugged (g) Ignition timing check correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. CO/HC Meter 5. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. A10537 2001 AVALON (RM808U) Author
: Date
: 985 EM-2 ENGINE MECHANICAL - CO/HC 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. CO HC Problems Causes Normal High Rough idle 3. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs 4. Incorrect valve clearance 5. Leaky intake and exhaust valves 6. Leaky cylinders Low High Rough 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 High High Rough 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 2001 AVALON (RM808U) Author
: Date
: 986 EM-3 ENGINE MECHANICAL - COMPRESSION COMPRESSION EM0CC-03 INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE IGNITION COILS (See page IG-5 ) 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the 6 spark plugs. 4. (a) (b) (c) Compression Gauge P19471 CHECK CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,500 kPa (15.3 kgf/cm2, 218 psi) Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less (e) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. REINSTALL SPARK PLUGS 6. INSTALL IGNITION COILS (See page IG-5 ) 2001 AVALON (RM808U) Author
: Date
: 987 EM-81 ENGINE MECHANICAL - CYLINDER BLOCK CYLINDER BLOCK EM04B-04 COMPONENTS Knock Sensor Connector Knock Sensor 39 (400, 29) Engine Wire Band No.2 ECT Switch Connector Engine Wire Water Inlet Housing (With Water Inlet) x8 8 (80, 69 in.·lbf)  Gasket Cylinder Block Side Cover 28 (290, 21) No.2 Idler Pulley Bracket 9 (90, 78 in.·lbf) Water Seal Plate  Gasket Water Pump 18 (180, 13)
Engine Coolant Drain Union Oil Filter Union 8 (80, 69 in.·lbf)  O-Ring Oil Pump  Crankshaft Front Oil Seal x9 Oil Filter
Oil Pressure Switch Oil Pressure Switch Connector Crankshaft Position Sensor Connector 25 (250, 18) A/C Compressor Housing Bracket No.1 Oil Pan 10 mm Head 8 (80, 69 in.·lbf) 12 mm Head 19.5 (200, 14) x 17 Generator 10 mm Head 8 (80, 69 in.·lbf) 12 mm Head 19.5 (200, 14) 19.5 (200, 14) Engine Wire  Gasket 8 (80, 69 in.·lbf) Oil Strainer  Gasket No.2 Oil Pan x 10 N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part
Precoated part Drain Plug 45 (460, 33) 8 (80, 69 in.·lbf) A10521 2001 AVALON (RM808U) Author
: Date
: 1065 EM-82 ENGINE MECHANICAL - CYLINDER BLOCK No.1 Piston Ring No.2 Piston Ring Oil Ring (Side Rail) Oil Ring (Expander)  Snap Ring Piston Pin Piston  Snap Ring  Connecting Rod Bushing Connecting Rod Connecting Rod Bearing Connecting Rod Cap See Page EM-101 1st 24.5 (250, 18) 2nd Turn 90°  Crankshaft Rear Oil Seal x6  Seal Washer 8 (80, 69 in.·lbf) Rear Oil Seal Retainer Cylinder Block Upper Crankshaft Thrust Washer Upper Main Bearing Crankshaft Lower Crankshaft Thrust Washer Lower Main Bearing Main Bearing Cap 27 (275, 20) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part See Page EM-101 1st 22 (225, 16) 2nd Turn 90°  Seal Washer A09697 2001 AVALON (RM808U) Author
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: 1066 EM-83 ENGINE MECHANICAL - CYLINDER BLOCK EM0ZN-02 DISASSEMBLY A05415 1. REMOVE DRIVE PLATE Remove the 8 bolts, rear plate, drive plate and front spacer. 2. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 3. REMOVE TIMING BELT AND PULLEYS (See page EM-15 ) 4. REMOVE CYLINDER HEAD (See page EM-31 ) 5. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 6. DISCONNECT OIL PRESSURE SWITCH CONNECTOR 7. DISCONNECT OIL LEVEL SENSOR CONNECTOR 8. (a) (b) S04921 REMOVE ENGINE WIRE Disconnect the 2 wire clamps from the wire brackets. Remove the 2 bolts and nut, and disconnect the engine wire. 9. REMOVE GENERATOR, ADJUSTING BAR AND BRACKET ASSEMBLY Remove the 3 nuts, the generator, adjusting bar and bracket assembly. 10. REMOVE OIL PRESSURE SWITCH (See page LU-1 ) 11. REMOVE A/C COMPRESSOR HOUSING BRACKET Remove the 2 bolts and compressor housing bracket. A05252 12. REMOVE NO.2 IDLER PULLEY BRACKET Remove the 2 bolts and idler pulley bracket. P18761 2001 AVALON (RM808U) Author
: Date
: 1067 EM-84 ENGINE MECHANICAL 13. (a) (b) SST - CYLINDER BLOCK REMOVE KNOCK SENSORS Disconnect the 2 knock sensor connectors. Using SST, remove the 2 knock sensors. SST 09816-30010 P12389 A05253 Water Seal Plate Oil Filter Union 12 mm Hexagon Wrench 14. REMOVE WATER INLET HOUSING (a) Remove the engine wire band. (b) Disconnect the engine wire clamp from the bracket. (c) Remove the 8 bolts, 2 nuts and water inlet housing. 15. REMOVE WATER PUMP (See page CO-6 ) 16. REMOVE NO.2 OIL PAN (See page LU-9 ) 17. REMOVE OIL STRAINER (See page LU-3 ) 18. REMOVE NO.1 OIL PAN (See page LU-3 ) 19. REMOVE OIL PUMP (See page LU-9 ) 20. REMOVE OIL FILTER (See page LU-3 ) 21. REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the oil filter union. 22. REMOVE WATER SEAL PLATE Remove the 2 nuts and seal plate. 23. REMOVE ENGINE COOLANT DRAIN UNION Coolant Drain Union P18763 24. REMOVE CYLINDER BLOCK SIDE COVER Remove the 3 bolts, 2 nuts, cylinder block side cover and gasket. A02010 25. (a) (b) REMOVE REAR OIL SEAL RETAINER Remove the 6 bolts. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap. P12508 2001 AVALON (RM808U) Author
: Date
: 1068 EM-85 ENGINE MECHANICAL P12695 - CYLINDER BLOCK 26. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 - 0.30 mm (0.0059 - 0.0118 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 20.80 - 20.85 mm (0.8189 - 0.8209 in.) 27. (a) (b) REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap bolts. A09694 (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the connecting rod cap. P12707 (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. P12696 2001 AVALON (RM808U) Author
: Date
: 1069 EM-86 ENGINE MECHANICAL (f) Plastigage - CYLINDER BLOCK Lay a strip of Plastigage across the crank pin. P12728 (g) P12697 Install the connecting rod cap with the 2 bolts (See page EM-101 ). Torque: 1st: 24.5 N·m (250 kgf·cm, 18 ft·lbf) 2nd: Turn extra 90° NOTICE: Do not turn the crankshaft. (h) Remove the 2 bolts, connecting rod cap and lower bearing (See steps (b) and (c)). (i) Measure the Plastigage at its widest point. Standard oil clearance: 0.038 - 0.064 mm (0.0015 - 0.0025 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. P12698 HINT: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked ”1”, ”2”, ”3” and ”4” accordingly. Reference: Standard bearing center wall thickness: Mark Number Mark Number Mark (j) mm (in.) ”1” 1.484 - 1.487 (0.0584 - 0.0585) ”2” 1.487 - 1.490 (0.0585 - 0.0587) ”3” 1.490 - 1.493 (0.0587 - 0.0588) ”4” 1.493 - 1.496 (0.0588 - 0.0589) Completely remove the Plastigage. A10523 2001 AVALON (RM808U) Author
: Date
: 1070 EM-87 ENGINE MECHANICAL 28. (a) (b) - CYLINDER BLOCK REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: A05258 P12799

Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. 29. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 - 0.24 mm (0.0016 - 0.0095 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 1.930 - 1.980 mm (0.0760 - 0.0780 in.) 30. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE (a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the several passes and in the sequence shown. P12585 8 6 2 14 13 10 9 1 4 12 16 11 15 7 5 (b) Uniformly loosen and remove the 16 main bearing cap bolts in several passes and in the sequence shown. (c) Using a screwdriver, pry out main bearing caps. Remove the 4 main bearing caps, lower bearings and (No.2 main bearing cap only) 2 lower thrust washers. 3 P12752 P12603 2001 AVALON (RM808U) Author
: Date
: 1071 EM-88 ENGINE MECHANICAL - CYLINDER BLOCK NOTICE: Pull up the main bearing cap little by little to the right and the left by turns and pay attention not to damage the joint surface of the cylinder block and the main bearing cap. HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers in correct order. Joint Surface S06200 (d) Lift out the crankshaft. HINT: Keep the upper bearings together with the cylinder block. (e) Clean each main journal and bearing. (f) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. P12495 (g) (h) Plastigage Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. P12980 (i) P12954 Install the 4 main bearing caps. (See page EM-101 ) Torque: 12 pointed head bolts: 1st: 22 N·m (225 kgf·cm, 16 ft·lbf) 2nd: Turn extra 90° Hexagon head bolts: 27 N·m (275 kgf·cm, 20 ft·lbf) NOTICE: Do not turn the crankshaft. (j) Remove the main bearing caps. (See steps (a) to (c) ) (k) Measure the Plastigage at its widest point. Standard oil clearance: No.1 and No.4 journals 0.014 - 0.034 mm (0.0006 - 0.0013 in.) No.2 and No.3 journals 0.026 - 0.046 mm (0.0010 - 0.0018 in.) Maximum clearance: P12993 No.1 and No.4 journals 0.05 mm (0.0020 in.) No.2 and No.3 journals 0.06 mm (0.0024 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. 2001 AVALON (RM808U) Author
: Date
: 1072 EM-89 ENGINE MECHANICAL No.2 No.1 - CYLINDER BLOCK HINT: If using a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. The No.1 and No.4 journal bearings have 5 standard bearing sizes, marked ”3”, ”4”, ”5”, ”6” and ”7” accordingly. The No.2 and No.3 journal bearings have 5 standard bearing sizes, marked ”1”, ”2”, ”3”, ”4” and ”5” accordingly. No.3 No.4 Number Mark No.2 No.3 No.4 No.1 No.1 and No.4 journal bearings Total number 0-5 6 - 11 Use bearing ”3” ”4” EXAMPLE: Number Mark Number Mark Cylinder block (A) + Crankshaft (B) ” ”: Number mark 12 - 17 18 - 23 24 - 28 ”5” ”6” ”7” Cylinder block ”06” (A) + Crankshaft ”08” (B) = Total number 14 (Use bearing ”5”) P12734 No.1 and No.4 journal standard bearings selection chart Cylinder block number mark Crankshaft number mark 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 00 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 01 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 02 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 03 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 04 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 05 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 06 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 07 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 08 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 09 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 10 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 11 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 12 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 EXAMPLE: Cylinder block ”06”, Crankshaft ”08” = Use bearing ”5” 2001 AVALON (RM808U) Author
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: 1073 EM-90 ENGINE MECHANICAL - CYLINDER BLOCK No.2 and No.3 journal bearings Total number Cylinder block (A) + Crankshaft (B) 0-5 6 - 11 Use bearing ”1” ”2” EXAMPLE: ” ”: Number mark 12 - 17 18 - 23 24 - 28 ”3” ”4” ”5” Cylinder block ”06” (A) + Crankshaft ”08” (B) = Total number 14 (Use bearing ”3”) No.2 and No.3 journal standard bearings selection chart Cylinder block number mark Crankshaft number mark 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 00 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 01 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 02 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 03 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 04 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 05 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 06 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 07 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 08 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 09 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 10 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 11 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 12 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 EXAMPLE: Cylinder block ”06”, Crankshaft ”08” = Use bearing ”3” 2001 AVALON (RM808U) Author
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: 1074 EM-91 ENGINE MECHANICAL - CYLINDER BLOCK Reference Item Mark mm (in.) Cylinder block main journal bore diameter (A) ”00” ”01” ”02” ”03” ”04” ”05” ”06” ”07” ”08” ”09” ”10” ”11” ”12” ”13” ”14” ”15” ”16” 66.000 (2.5984) 66.001 (2.5985) 66.002 (2.5985) 66.003 (2.5985) 66.004 (2.5986) 66.005 (2.5986) 66.006 (2.5987) 66.007 (2.5987) 66.008 (2.5987) 66.009 (2.5988) 66.010 (2.5988) 66.011 (2.5989) 66.012 (2.5989) 66.013 (2.5989) 66.014 (2.5990) 66.015 (2.5990) 66.016 (2.5990) Crankshaft main journal diameter (B) ”00” ”01” ”02” ”03” ”04” ”05” ”06” ”07” ”08” ”09” ”10” ”11” ”12” 61.000 (2.4016) 60.999 (2.4015) 60.998 (2.4015) 60.997 (2.4015) 60.996 (2.4014) 60.995 (2.4014) 60.994 (2.4013) 60.993 (2.4012) 60.992 (2.4012) 60.991 (2.4012) 60.990 (2.4012) 60.989 (2.4011) 60.988 (2.4011) Standard bearing center wall thickness ”1” ”2” ”3” ”4” ”5” ”6” ”7” 2.486 - 2.489 (0.0979 - 0.0980) 2.489 - 2.492 (0.0980 - 0.0981) 2.492 - 2.495 (0.0981 - 0.0982) 2.495 - 2.498 (0.0982 - 0.0983) 2.498 - 2.501 (0.0983 - 0.0985) 2.501 - 2.504 (0.0985 - 0.0986) 2.504 - 2.507 (0.0986 - 0.0987) (l) 31. (a) (b) Completely remove the Plastigage. REMOVE CRANKSHAFT Lift out the crankshaft. Remove the 4 upper main bearings and 2 upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order. 2001 AVALON (RM808U) Author
: Date
: 1075 EM-92 ENGINE MECHANICAL - CYLINDER BLOCK 32. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. P12404 33. (a) REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. (b) HINT: Arrange the piston rings in the correct order only. P12405 A09698 34. (a) DISCONNECT CONNECTING ROD FROM PISTON Using a small screwdriver, pry out the 2 snap rings. (b) Gradually heat the piston to approx. 60°C (140°F). (c) Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. P12403 60°C P12416 HINT:

The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. P12415 2001 AVALON (RM808U) Author
: Date
: 1076 EM-93 ENGINE MECHANICAL - CYLINDER BLOCK EM0ZO-02 INSPECTION P12499 1. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. CLEAN CYLINDER BLOCK Using a soft brush and solvent, thoroughly clean the cylinder block. NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45°C (113°F) or less. 3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.07 mm (0.0028 in.) If warpage is greater than maximum, replace the cylinder block. Z09222 4. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block. P12498 2001 AVALON (RM808U) Author
: Date
: 1077 EM-94 ENGINE MECHANICAL - CYLINDER BLOCK 5. INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 87.500 - 87.512 mm (3.4449 - 3.4453 in.) Maximum diameter: 87.52 mm (3.4457 in.) If the diameter is greater than maximum, replace the cylinder block. 1 Thrust Direction Front 2 1 A 2 Axial Direction 10 mm (0.39 in.) B C 10 mm (0.39 in.) Z09220 6. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. P12500 7. INSPECT 12 POINTED HEAD MAIN BEARING CAP BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.500 - 7.600 mm (0.2953 - 0.2992 in.) Minimum diameter: 7.20 mm (0.2835 in.) If the diameter is less than minimum, replace the bolt. P12497 8. (a) P12507 CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top. A10532 2001 AVALON (RM808U) Author
: Date
: 1078 EM-95 ENGINE MECHANICAL (b) P12491 - CYLINDER BLOCK Using a groove cleaning tool or broken ring, clean the piston ring grooves. A10534 (c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. P12505 A10535 RH Piston 41.2 mm LH Piston 9. (a) INSPECT PISTON OIL CLEARANCE Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 41.2 mm (1.622 in.) from the piston head. Piston diameter: 87.453 - 87.467 mm (3.4430 - 3.4436 in.) (b) Measure the cylinder bore diameter in the thrust directions. (See step 5.) (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.033 - 0.059 mm (0.0013 - 0.0023 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block. HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with ”R”, the LH piston with ”L”. A10526 10. INSPECT PISTON RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between new piston right and the wall of the ring groove. Ring groove clearance: No.1 0.010 - 0.060 mm (0.0004 - 0.0028 in.) No.2 0.020 - 0.060 mm (0.0008 - 0.0024 in.) If the clearance is not as specified, replace the piston. P12504 A10533 2001 AVALON (RM808U) Author
: Date
: 1079 EM-96 ENGINE MECHANICAL - CYLINDER BLOCK 11. (a) (b) INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block. (c) Using a feeler gauge, measure the end gap. Standard end gap: 105 mm P12583 No.1 0.25 - 0.35 mm (0.0098 - 0.0138 in.) No.2 0.35 - 0.45 mm (0.0138 - 0.0177 in.) for G2 mark 0.55 - 0.65 mm (0.0217 - 0.0256 in.) for 2T mark Oil (Side rail) 0.15 - 0.40 mm (0.0059 - 0.0157 in.) Maximum end gap: No.1 0.95 mm (0.0374 in.) No.2 1.05 mm (0.0413 in.) for G2 mark 1.25 mm (0.0492 in.) for 2T mark Oil (Side rail) 1.00 mm (0.0394 in.) EM7639 If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. 12. INSPECT PISTON PIN FIT At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb. P12506 13. INSPECT CONNECTING ROD ALIGNMENT Using a rod aligner and feeler gauge, check the connecting rod alignment.
Check for out-of-alignment. Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the connecting rod assembly. Z04012 2001 AVALON (RM808U) Author
: Date
: 1080 EM-97 ENGINE MECHANICAL - CYLINDER BLOCK
Check for twist Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly. Z04011 14. (a) INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 in.) (b) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 - 22.006 mm (0.8660 - 0.8664 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) EM6525 (c) EM0227 15. INSPECT CONNECTING ROD BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.2 - 7.3 mm (0.284 - 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than minimum, replace the bolt. EM6347 16. (a) (b) INSPECT CRANKSHAFT FOR CIRCLE RUNOUT Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft. P12406 2001 AVALON (RM808U) Author
: Date
: 1081 EM-98 ENGINE MECHANICAL - CYLINDER BLOCK 17. (a) P12493 INSPECT MAIN JOURNALS AND CRANK PINS Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: 60.988 - 61.000 mm (2.4011 - 2.4016 in.) Crank pin diameter: 52.992 - 53.000 mm (2.0862 - 2.0866 in.) If the diameter is not as specified, check the oil clearance. (See page EM-83 ) If necessary, replace the crankshaft. (b) Check each main journal and crank pin for taper and outof-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than maximum, replace the crankshaft. 2001 AVALON (RM808U) Author
: Date
: 1082 EM-101 ENGINE MECHANICAL - CYLINDER BLOCK EM0ZQ-02 REASSEMBLY HINT:


1. (a) Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts. ASSEMBLE PISTON AND CONNECTING ROD Using a small screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. A05260 (b) Gradually heat the piston to about 60°C (140°F). (c) (d) Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. 60°C P12417 RH Piston Front Mark (Cavity) (e) HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Front Mark (Mold Mark) LH Piston Front Mark (Cavity) Front Mark (Mold Mark) A10527 2001 AVALON (RM808U) Author
: Date
: 1085 EM-102 ENGINE MECHANICAL No.1 No.2 2. (a) (b) Code Mark Code Mark - CYLINDER BLOCK INSTALL PISTON RINGS Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark: No.1 T or G1 No.2 2T or G2 A10524 (c) RH Piston Lower Side Rail Front Mark No.2 Compression Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends. Expander No.1 Compression Upper Side Rail LH Piston Lower Side Rail No.2 Compression Front Mark Expander No.1 Compression Upper Side Rail A10525 3. (a) (b) INSTALL CONNECTING ROD BEARINGS Align the bearing claw with the groove of the connecting rod or connecting cap. Install the bearings in the connecting rod and connecting rod cap. P12402 No.1 and No.4 No.2 and No.3 Upper Lower 22.4 mm 19.0 mm Z09177 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.) bearings 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. 2001 AVALON (RM808U) Author
: Date
: 1086 EM-103 ENGINE MECHANICAL - CYLINDER BLOCK (a) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings. NOTICE: Install the bearing with the oil hole in the cylinder block. P12599 (b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings. HINT: A number is marked on each main bearing cap to indicate the installation position. Mark 1, 2, 3 or 4 A05263 5. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.2 journal position of the cylinder block with the oil grooves facing outward. P12600 6. PLACE CRANKSHAFT ON CYLINDER BLOCK 7. PLACE MAIN BEARING CAPS AND LOWER THRUST WASHERS ON CYLINDER BLOCK Install the 2 thrust washers on the No.2 bearing cap with the grooves facing outward. P12495 (a) A05264 2001 AVALON (RM808U) Author
: Date
: 1087 EM-104 ENGINE MECHANICAL - CYLINDER BLOCK (b) Temporarily place the 4 main bearing caps level and let them in their proper locations. (c) Apply a light coat of engine oil on the threads and under the main bearing cap bolts for the 12 pointed head. Temporarily install the 8 main bearing cap bolts to the inside positions. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block will become less than 6 mm (0.23 in.) by making the 2 internal main bearing cap bolts as a guide. A10530 (d) (e) Less than 6 mm A09696 (f) 8. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. INSTALL 12 POINTED HEAD MAIN BEARING CAP BOLTS HINT:

A10529 The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any of the main bearing cap bolts is broken or deformed, replace it. (a) 9 11 3 15 7 13 1 5 2 4 6 14 10 12 8 16 P12753 (c) (d) Painted Mark 90° Front Apply a light coat of engine oil on the threads and under the main bearing cap bolts. (b) Install and uniformly tighten the 16 main bearing cap bolts in several passes and in the sequence shown. Torque: 22 N·m (225 kgf·cm, 16 ft·lbf) If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. 90° (e) Mark the front of the main bearing cap bolts with paint. Retighten the main bearing cap bolts by 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. P25741 2001 AVALON (RM808U) Author
: Date
: 1088 EM-105 ENGINE MECHANICAL 9. 4 1 2 3 (a) (b) 7 6 5 10. 8 - CYLINDER BLOCK INSTALL HEXAGON HEAD MAIN BEARING CAP BOLTS Install a new seal washer to the main bearing cap bolt. Install and uniformly tighten the 8 main bearing cap bolts in several passes and in the sequence shown. Torque: 27 N·m (275 kgf·cm, 20 ft·lbf) CHECK CRANKSHAFT THRUST CLEARANCE (See page EM-83 ) P12586 11. INSTALL PISTON AND CONNECTING ROD ASSEMBLES Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with ”R”, the LH piston with ”L”. Front Mark (Cavity) RH Piston Front Mark (Cavity) LH Piston A10528 12. (a) (b) PLACE CONNECTING ROD CAP ON CONNECTING ROD Match the numbered connecting rod cap with the connecting rod. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod. P12699 (c) Front 13. HINT:
Protrusion
Check that the protrusion of the connecting rod cap is facing in the correct direction. INSTALL CONNECTING ROD CAP BOLTS The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any of the connecting rod cap bolts is broken or deformed, replace it. P12801 2001 AVALON (RM808U) Author
: Date
: 1089 EM-106 ENGINE MECHANICAL - CYLINDER BLOCK (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. P12697 (c) (d) (e) Painted Mark 90° 90° Front (f) 14. P25743 15. (a) Mark the front of the connecting cap bolts with paint. Retighten the cap bolts by 90° as shown. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly. CHECK CONNECTING ROD THRUST CLEARANCE (See page EM-83 ) INSTALL REAR OIL SEAL RETAINER 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 surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non-residue solvent, clean both sealing surfaces. (b) A A B Seal Width 2 - 3 mm B P12911 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 application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) Install the oil seal retainer with the 6 bolts. Uniformly tighten 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) 2001 AVALON (RM808U) Author
: Date
: 1090 EM-107 ENGINE MECHANICAL 17. (a) Seal Packing (b) P12477 A A B Seal Width 3 - 5 mm CYLINDER BLOCK INSTALL ENGINE COOLANT DRAIN UNION Apply seal packing to 2 or 3 threads. Seal packing: Part No. 08826-00100 or equivalent Install the drain union. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) HINT: After applying the specified torque, rotate the drain union clockwise 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 surfaces and sealing groove.
Thoroughly clean all components to remove all the loose material.
Using a non-residue solvent, clean both sealing surfaces. (b) B - Z09223 (c) 19. 20. 21. 22. 23. 24. 25. 26. (a) Apply seal packing to the seal plate 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.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. Install the seal plate with the 2 nuts. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) INSTALL OIL FILTER UNION Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) INSTALL OIL FILTER (See page LU-3 ) INSTALL OIL PUMP (See page LU-15 ) INSTALL NO.1 OIL PAN (See page LU-15 ) INSTALL OIL STRAINER (See page LU-15 ) INSTALL NO.2 OIL PAN (See page LU-15 ) INSTALL WATER PUMP (See page CO-8 ) INSTALL WATER INLET HOUSING Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and cylinder block.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material. 2001 AVALON (RM808U) Author
: Date
: 1091 EM-108 ENGINE MECHANICAL
(b) Seal Width 3 - 5 mm P12909 9 1 6 (d) (e) (f) (g) 7 8 5 2 10 4 CYLINDER BLOCK Using a non-residue solvent, clean both sealing surfaces. 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 application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) 3 - 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) Connect the No.2 ECT switch connector. Connect the engine wire clamp to the water inlet. Install the engine wire band. Install the engine wire clamp. A05253 27. (a) SST (b) 28. 29. P12389 INSTALL KNOCK SENSORS Using SST, install the 2 knock sensors. SST 09816-30010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Connect the 2 knock sensor connectors. INSTALL NO.2 IDLER PULLEY BRACKET Torque: 28 N·m (290 kgf·cm, 21 ft·lbf) INSTALL A/C COMPRESSOR HOUSING BRACKET Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1092 EM-109 ENGINE MECHANICAL 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. (a) (b) - CYLINDER BLOCK INSTALL OIL PRESSURE SWITCH (See page LU-1 ) INSTALL GENERATOR, BRACKET AND ADJUSTING BAR ASSEMBLY Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) INSTALL ENGINE WIRE CONNECT OIL LEVEL SENSOR CONNECTOR CONNECT OIL PRESSURE SWITCH CONNECTOR CONNECT CRANKSHAFT POSITION SWITCH CONNECTOR INSTALL CYLINDER HEAD (See page EM-59 ) INSTALL TIMING PULLEYS AND BELT (See page EM-21 ) REMOVE ENGINE STAND INSTALL DRIVE PLATE Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the front spacer, drive plate and rear plate on the crankshaft. P00601 (c) 1 5 7 Install and uniformly tighten the 8 bolts in several passes and in the sequence shown. Torque: 83 N·m (850 kgf·cm, 61 ft·lbf) 4 3 6 8 2 A05416 2001 AVALON (RM808U) Author
: Date
: 1093 EM-99 ENGINE MECHANICAL - CYLINDER BLOCK EM0ZP-02 REPLACEMENT SST 1. (a) REPLACE CONNECTING ROD BUSHING Using SST and a press, press out the bushing. SST 09222-30010 (b) Align the oil holes of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222-30010 EM6363 (c) Oil Hole EM6364 (d) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See page EM-93 ) between the bushing and piston pin. (e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. REPLACE CRANKSHAFT FRONT OIL SEAL (See page LU-13 ) EM6535 2. P00326 3. REPLACE CRANKSHAFT REAR OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal which are as follows: (a) If the rear oil seal retainer is removed from the cylinder block. (1) Using a screwdriver and hammer, tap out the oil seal. P12589 2001 AVALON (RM808U) Author
: Date
: 1083 EM-100 ENGINE MECHANICAL - CYLINDER BLOCK (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) (3) Apply MP grease to the oil seal lip. SST P12570 (b) If the rear oil seal retainer is installed to the cylinder block. (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Cut Position P12808 (3) (4) Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) SST P12810 2001 AVALON (RM808U) Author
: Date
: 1084 EM-26 ENGINE MECHANICAL - CYLINDER HEAD CYLINDER HEAD EM042-03 COMPONENTS RH Fender Apron Seal V-Bank Cover Fastener 64 (650, 47) Generator Drive Belt V-Bank Cover Engine Moving Control Rod 32 (320, 23) No.2 RH Engine Mounting Bracket PS Pump Drive Belt Air Cleaner Hose w/ Resonator 43 (440, 32) PS Pump Vacuum Hose Front Exhaust Pipe
Gasket
Gasket
Gasket
62 (630, 46) Compression Spring Stay 43 (440, 32)
N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part 62 (630, 46) 33 (330, 24) A10835 2001 AVALON (RM808U) Author
: Date
: 1010 EM-27 ENGINE MECHANICAL - CYLINDER HEAD 19.5 (200, 14) 39 (400,29) PS Pressure Tube Throttle Body Bracket Throttle Position Sensor Connector Brake Booster Vacuum Hose IAC Valve 43 (440,32) Connector VSV Connector for No.1 ACIS No.1 Engine Hanger Engine Wire VSV Connector for EVAP Accelerator Cable Ground Cable Ground Strap Ground Cable PCV Hose Air Intake Chamber Assembly Throttle Cable Water Bypass Hose Vacuum Purge Hose Hose Intake Manifold Assembly
Gasket DLC1 VSV Connector for No.2 ACIS Engine Coolant 15 (150,11) ECT Sender Reservoir Hose Water Bypass Gauge Connector Hose Upper Radiator ECT Sensor Hose Connector Fuel Hose Clamp
Retainer Fuel Inlet Hose Grand Strap Connector Heater Hose 15 (150,11) Injector Connector Water Outlet
Gasket Ignition Coil
Gasket Ignition Coil Connector Gasket Spark Plug N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A10522 2001 AVALON (RM808U) Author
: Date
: 1011 EM-28 ENGINE MECHANICAL - CYLINDER HEAD Timing Belt No.2 Timing Belt Cover Gasket RH Engine Mounting Bracket Timing Belt Guide 28 (290, 21) No.2 Generator Bracket No.1 Timing Belt Cover Gasket Crankshaft Pulley 215 (2,200, 159) Engine Wire Protector No.2 Idler Pulley RH Camshaft Timing Pulley 125 (1,300, 94) *88 (900, 65) 43 (440, 32) LH Camshaft Timing Pulley 125 (1,300, 94) Dust Boot Timing Belt Tensioner 27 (280, 20) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part * For use with SST A05070 2001 AVALON (RM808U) Author
: Date
: 1012 EM-29 ENGINE MECHANICAL - CYLINDER HEAD Engine Wire Engine Wire Engine Wire RH Exhaust Manifold
Gasket RH Exhaust Manifold Stay Camshaft Timing Oil Control Valve x6 Cylinder Head Rear Plate 49 (500, 36) PS Pump Bracket
O-Ring Camshaft Position Sensor
O-Ring 43 (440, 32)
O-Ring
O-Ring Gasket No.3 Timing Belt Cover Collar Bushing Water Inlet Pipe
O-Ring Camshaft Position Sensor x6
Gasket Engine Wire LH Exhaust Manifold Stay x6 Oil Dipstick Guide 49 (500, 36) LH Exhaust Manifold
O-Ring N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A06660 2001 AVALON (RM808U) Author
: Date
: 1013 EM-30 ENGINE MECHANICAL - CYLINDER HEAD LH Cylinder Head Cover Adjusting Shim Valve Lifter Keeper Spring Retainer Valve Spring Spring Seat
Oil Seal Gasket
Spark Plug Tube Gasket
Valve Guide Bushing Valve RH Cylinder Head Cover LH Intake Camshaft Camshaft Sub-Gear Gasket Snap Ring LH Exhaust Camshaft Wave Washer Camshaft Gear Spring Wave Washer Snap Ring Camshaft Sub-Gear RH Intake Camshaft Camshaft Gear Spring Oil Control Valve Filter
Gasket Cylinder Head Rear Cover See Page EM-59 1st 54 (550, 40) 2nd Turn 90° RH Exhaust Camshaft x8 18 (185, 13)
Gasket Semi-Circular Plug
Gasket Semi-Circular Plug RH Cylinder Head LH Cylinder Head 16 (160, 12)
Gasket Cylinder Head Rear Cover Camshaft Bearing Cap Oil Control Valve Filter
Camshaft Oil Seal
RH Cylinder Head Gasket
LH Cylinder Head Gasket
150 (1,530, 110) Intake Camshaft Camshaft Timing Gear (VVT-i) NOTICE: N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Do not remove or install the camshaft timing gear (VVT-i) beside changing VVT-i or the camshaft. A05703 2001 AVALON (RM808U) Author
: Date
: 1014 EM-40 ENGINE MECHANICAL - CYLINDER HEAD EM0ZF-02 DISASSEMBLY 1. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in the correct order. P12683 2. (a) (b) REMOVE VALVES Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 (09202-00010) Remove the spring retainer, valve spring and valve. (c) Using needle-nose pliers, remove the oil seal. (d) Using compressed air and a magnetic finger, remove the spring seat by blowing air. SST A05224 P12686 Magnetic Finger HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order. P12720 3. REMOVE CYLINDER HEAD REAR COVER Remove the 6 bolts, rear cover and gasket. A05276 2001 AVALON (RM808U) Author
: Date
: 1024 EM-41 ENGINE MECHANICAL - CYLINDER HEAD 4. REMOVE OIL CONTROL VALVE FILTER Remove the plug, gasket and valve filter. A05275 2001 AVALON (RM808U) Author
: Date
: 1025 EM-42 ENGINE MECHANICAL - CYLINDER HEAD EM0ZG-02 INSPECTION 1. (a) CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. A05225 (b) Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air. A05226 2. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. A05230 3. CLEAN COMBUSTION CHAMBERS Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. A05233 4. CLEAN CYLINDER HEADS Using a soft brush and solvent, thoroughly clean the cylinder head. A05232 2001 AVALON (RM808U) Author
: Date
: 1026 EM-43 ENGINE MECHANICAL - CYLINDER HEAD 5. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings. P12755 6. INSPECT FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylinder head. A05231 7. INSPECT FOR CRACKS Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block contact surface for cracks. If cracked, replace the cylinder head. A05227 8. (a) (b) CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM0580 2001 AVALON (RM808U) Author
: Date
: 1027 EM-44 ENGINE MECHANICAL - CYLINDER HEAD 9. (a) INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.510 - 5.530 mm (0.2169 - 0.2177 in.) (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: P12754 (c) Z00052 Intake 5.470 - 5.485 mm (0.2154 - 0.2159 in.) Exhaust 5.465 - 5.480 mm (0.2152 - 0.2157 in.) Subtract the valve stem diameter measurement from the guide bushing guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 - 0.060 mm (0.0010 - 0.0024 in.) Exhaust 0.030 - 0.065 mm (0.0012 - 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing. 10. (a) (b) INSPECT AND GRIND VALVES Grind the valve enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° 44.5° Z00054 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. Margin Thickness EM0181 2001 AVALON (RM808U) Author
: Date
: 1028 EM-45 ENGINE MECHANICAL (d) Overall Length EM2534 - CYLINDER HEAD Check the valve overall length. Standard overall length: Intake 95.45 mm (3.5779 in.) Exhaust 95.40 mm (3.7559 in.) Minimum overall length: Intake 94.95 mm (3.7382 in.) Exhaust 94.90 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. EM0255 11. (a) (b) INSPECT AND CLEAN VALVE SEATS Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. 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. A05228 (c) Width P12729 45° 30° 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. 1.0 - 1.4 mm Z03988 2001 AVALON (RM808U) Author
: Date
: 1029 EM-46 ENGINE MECHANICAL (2) 75° 45° - CYLINDER HEAD If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. 1.0 - 1.4 mm Z03989 (d) (e) Hand-lap the valve and valve seat with an abrasive compound. After hand-lapping, clean the valve and valve seat. P12705 12. (a) INSPECT VALVE SPRINGS Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the valve spring. Deviation EM0988 (b) Using vernier calipers, measure the free length of the valve spring. Free length: 45.50 mm (1.7913 in.) If the free length is not as specified, replace the valve spring. EM0801 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 186 - 206 N (19.0 - 21.0 kgf, 41.9 - 46.3 lbf) at 33.8 mm (1.331 in.) If the installed tension is not as specified, replace the valve spring. EM0281 2001 AVALON (RM808U) Author
: Date
: 1030 EM-47 ENGINE MECHANICAL - CYLINDER HEAD 13. (a) (b) INSPECT CAMSHAFT FOR RUNOUT Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the camshaft. A05704 14. INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 42.932 - 43.032 mm (1.6902 - 1.6942 in.) Exhaust 42.764 - 42.864 mm (1.6836 - 1.6876 in.) Minimum cam lobe height: EM2011 Intake 42.78 mm (1.6842 in.) Exhaust 42.61 mm (1.6776 in.) If the cam lobe height is less than minimum, replace the camshaft. 15. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. Journal diameter: 26.959 - 26.975 mm (1.0613 - 1.0620 in.) If the journal diameter is not as specified, check the oil clearance. EM2538 16. INSPECT CAMSHAFT BEARINGS Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. A05236 2001 AVALON (RM808U) Author
: Date
: 1031 EM-48 ENGINE MECHANICAL 17. (a) (b) (c) Plastigage - CYLINDER HEAD INSPECT CAMSHAFT JOURNAL OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal. A05239 (d) Install the bearing caps. (See page EM-59 ) Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. A05237 (f) Measure the Plastigage at its widest point. Standard oil clearance: Intake 0.035 - 0.072 mm (0.0014 - 0.0028 in.) Exhaust 0.025 - 0.062 mm (0.0010 - 0.0024 in.) Maximum oil clearance: A05240 Intake 0.10 mm (0.0039 in.) Exhaust 0.09 mm (0.0035 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (g) Completely remove the Plastigage. (h) Remove the camshafts. 18. (a) (b) A05238 INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. (See page EM-59 ) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 - 0.090 mm (0.0016 - 0.0035 in.) Maximum thrust clearance: 0.12 mm (0.0047 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 2001 AVALON (RM808U) Author
: Date
: 1032 EM-49 ENGINE MECHANICAL (c) - CYLINDER HEAD Remove the camshafts. 19. (a) A05241 INSPECT CAMSHAFT GEAR BACKLASH 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 camshafts. (c) Remove the camshafts. 20. INSPECT CAMSHAFT TIMING GEAR (VVT-i) (a) Mount the hexagon wrench head portion of the camshaft in a vise. A05739 (b) (c) A05705 Check that VVT-i will not turn. 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/cm3, 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. 2001 AVALON (RM808U) Author
: Date
: 1033 EM-50 ENGINE MECHANICAL (e) (f) (g) - CYLINDER HEAD Under the condition of (d), turn VVT-i to the advance angle side (the white arrow marked direction in the illustration) with your hand. Except the position where the lock pin meets at the maximum 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° 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. Free Distance EM3322 22. (a) INSPECT VALVE LIFTERS AND LIFTER BORES 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.) P12685 (b) EM6368 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. P12400 2001 AVALON (RM808U) Author
: Date
: 1034 EM-51 ENGINE MECHANICAL - CYLINDER HEAD 24. INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and air intake chamber for warpage. Maximum warpage: Cylinder Head Side Air intake chamber side 0.15 mm (0.0059 in.) Cylinder head side 0.08 mm (0.0031 in.) If warpage is greater than maximum, replace the manifold. Air Intake Chamber Side Z09167 25. INSPECT EXHAUST MANIFOLDS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.50 mm (0.0196 in.) If warpage is greater than maximum, replace the manifold. RH Side LH Side A07443 26. INSPECT 12 POINTED HEAD CYLINDER HEAD BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard outside diameter: 8.95 - 9.05 mm (0.3524 - 0.3563 in.) Minimum outside diameter: 8.75 mm (0.3445 in.) If the diameter is less than minimum, replace the bolt. P12496 2001 AVALON (RM808U) Author
: Date
: 1035 EM-59 ENGINE MECHANICAL - CYLINDER HEAD EM0ZJ-02 INSTALLATION 1. (a) PLACE CYLINDER HEAD ON CYLINDER BLOCK Place 2 new cylinder head gaskets in position on the cylinder block. NOTICE: Be careful of the installation direction. (b) Place the 2 cylinder heads in position on the cylinder head gaskets. A10520 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 specification, replace the cylinder head bolt. 12 Pointed Head Bolt 7 2 4 6 5 3 1 8 Front 5 3 1 8 7 2 4 6 A05218 90° (d) (e) Painted Mark Front (f) Mark the front of the cylinder head bolt head with paint. Retighten the cylinder head bolts by 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. A05223 2001 AVALON (RM808U) Author
: Date
: 1043 EM-60 ENGINE MECHANICAL 3. (a) Recessed Head Bolt (b) - CYLINDER HEAD INSTALL RECESSED HEAD CYLINDER HEAD BOLTS Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Using an 8 mm hexagon wrench, install the cylinder head bolt on each cylinder head, then repeat for the other side, as shown. Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf) 8 mm Hexagon Wrench Front A05221 4. (a) ASSEMBLE EXHAUST CAMSHAFTS Mount the hexagonal wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. P12595 (b) (3) (2) Install the camshaft gear spring (1) and camshaft subgear (2). HINT: Attach the pins on the gears to the gear spring ends. (c) Install the wave washer (3). (1) Z09320 (d) Using snap ring pliers, install the snap ring. P12590 2001 AVALON (RM808U) Author
: Date
: 1044 EM-61 ENGINE MECHANICAL - CYLINDER HEAD (e) SST Main Gear Sub-Gear P12974 90° Exhaust Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) (f) Align the gear teeth of the main gear and sub-gear, and tighten the service bolt. 5. INSTALL CAMSHAFTS OF RH CYLINDER HEAD NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept leveled while it is being installed. If the camshaft is not kept leveled, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Install the exhaust camshaft. (1) Apply new engine oil to the thrust portion and journal of the camshaft. (2) Place the exhaust camshaft at 90° angle of timing mark (2 dot marks) on the cylinder head. (3) Apply MP grease to a new oil seal lip. A05201 (4) Exhaust Install the oil seal to the camshaft. Front P12804 (5) (6) Remove any old packing (FIPG) material. Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No. 08826-00080 or equivalent Exhaust Seal Packing A02008 2001 AVALON (RM808U) Author
: Date
: 1045 EM-62 ENGINE MECHANICAL Exhaust - CYLINDER HEAD (b) Install the 5 bearing caps in their proper locations. (c) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. 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) A05283 Exhaust (d) 7 A05202 (e) Intake Install the Intake camshaft. (1) Apply new engine oil to the thrust portion and journal of the camshaft. (2) Align the timing marks (2 dot marks) of the camshaft drive and driven gears. (3) Place the intake camshaft on the cylinder head. Align A05203 (4) Intake Install the 5 bearing caps in their proper locations. A05204 Intake (5) 9 5 10 1 6 3 7 2 Apply a light coat of engine oil on the threads and under the heads of the 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) 4 8 A05196 2001 AVALON (RM808U) Author
: Date
: 1046 EM-63 ENGINE MECHANICAL Intake Service Bolt A05195 90° CYLINDER HEAD (7) Remove the service bolt. 6. INSTALL CAMSHAFTS OF LH CYLINDER HEAD NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept leveled while it is being installed. If the camshaft is not kept leveled, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Exhaust - Install the exhaust camshaft. (1) Apply new engine oil to the thrust portion and journal of the camshaft. (2) Place the exhaust camshaft at 90° angle of timing mark (1 dot mark) on the cylinder head. (3) Apply MP grease to a new oil seal lip. A05208 (4) Exhaust Install the oil seal to the camshaft. Front P12805 (5) (6) Remove any old packing (FIPG) material. Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No. 08826-00080 or equivalent Exhaust Seal Packing A02008 (7) Exhaust Install the 5 bearing caps in their proper locations. A05209 2001 AVALON (RM808U) Author
: Date
: 1047 EM-64 ENGINE MECHANICAL Exhaust 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) 10 5 6 2 3 7 CYLINDER HEAD (8) 9 1 - 4 8 A05210 (b) Intake Install the intake camshaft. (1) Apply new engine oil to the thrust portion and journal 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. Align A05211 (4) Intake Install the 5 bearing caps in their proper locations. A05214 Intake 6 10 2 4 (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) 9 5 1 3 8 7 A05213 Intake Service Bolt (7) Remove the service bolt. 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. 7. A05198 2001 AVALON (RM808U) Author
: Date
: 1048 EM-65 ENGINE MECHANICAL - CYLINDER HEAD 8. (a) (b) INSTALL SEMI-CIRCULAR PLUGS Remove any old packing (FIPG) material. Apply seal packing to the semi-circular plug grooves. Seal packing: Part No. 08826-00080 or equivalent (c) Install the 2 semi-circular plugs to the cylinder heads. 9. (a) INSTALL CYLINDER HEAD COVERS Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes. Install the 2 cylinder head covers. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) INSTALL PS PUMP BRACKET Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) Seal Packing A05215 Semi-Circular Plug Front A05217 : Seal Packing Front (b) (c) RH Side 10. LH Side A05216 2001 AVALON (RM808U) Author
: Date
: 1049 EM-66 ENGINE MECHANICAL 11. (a) (b) (c) Manifold Stay - CYLINDER HEAD INSTALL RH EXHAUST MANIFOLD 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) Install the exhaust manifold stay with the bolt and nut. Alternately tighten the bolt and nut. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) Connect the A/F sensor connector. A06661 12. (a) (b) (c) (d) New O-Ring (e) INSTALL OIL DIPSTICK AND GUIDE Install a new O-ring to the dipstick guide. Apply soapy water to the O-ring. Push in the dipstick guide end into the guide hole of the No.1 oil pan. Install the dipstick guide with the bolt. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) Install the dipstick. A07283 13. (a) Manifold Stay (b) (c) INSTALL LH EXHAUST MANIFOLD 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) Install the exhaust manifold stay with the bolt and nut. Alternately tighten the bolt and nut. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) Connect the A/F sensor connector. A07281 Rear Plate Inlet Pipe A05188 14. (a) (b) (c) (d) INSTALL WATER INLET PIPE Install a new O-ring to the water inlet pipe. Apply soapy water to the O-ring. Connect the water inlet pipe to the water inlet. 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. 2001 AVALON (RM808U) Author
: Date
: 1050 EM-67 ENGINE MECHANICAL L = 72 mm (2.83 in.) L = 180 mm (7.09 in.) L = 133 mm (5.24 in.) L = 180 mm (7.09 in.) Join Line Join Line L = 335 mm (13.19 in.) L = Length A05194 - CYLINDER HEAD
Thoroughly clean all components to remove all the loose material.
Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. NOTICE: When joining 2 gaskets, do not leave a gap between them. Cut off any excess gasket.
After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover. (b) Install the timing belt cover with the 6 bolts. Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf) (c) Install the 3 engine wire clamps to the timing belt cover. 20. INSTALL NO.2 IDLER PULLEY (See page EM-21 ) 21. INSTALL CAMSHAFT TIMING PULLEYS (See page EM-21 ) 22. INSTALL TIMING BELT (See page EM-21 ) 23. INSTALL SPARK PLUGS 24. INSTALL IGNITION COILS 25. (a) (b) (c) New Gasket Z14262 INSTALL WATER OUTLET Install 2 new gaskets. Connect the water outlet to the bypass hose. Install the water outlet with the 2 bolts, 2 nuts and 2 plate washers. Alternately tighten the bolts and nuts. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) NOTICE: Do not scratch the seal surface of the water outlet with the stud bolt. (d) Connect the ECT sender gauge connector. (e) Connect the ECT sensor connector. (f) Connect the ground strap connector. (g) Connect the upper radiator hose. (h) Connect the engine coolant reservoir hose. 2001 AVALON (RM808U) Author
: Date
: 1051 EM-68 ENGINE MECHANICAL 2 8 6 4 7 7 3 5 CYLINDER HEAD 26. (a) 10 9 1 - 11 A07428 8 mm Hexagon Wrench INSTALL INTAKE MANIFOLD ASSEMBLY Install the intake manifold, delivery pipe and injectors assembly with the 9 bolts, 2 plate washers and 2 nuts. Uniformly 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. (a) INSTALL AIR INTAKE CHAMBER ASSEMBLY 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) Install the throttle body bracket with the 2 bolts. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) Connect the PCV hose to the PCV valve on the RH cylinder head. Connect the ground strap and cable to the intake air control valve for the ACIS. Connect the ground cable and strap with the nut. Torque: 14.5 N·m (145 kgf·cm, 10 ft·lbf) Connect the ground cable to the air intake chamber. Connect the brake booster vacuum hose to the throttle body. Connect the 2 water bypass hoses to the throttle body. Connect the air assist hose to the throttle body. Connect the purge hose to the emission control valve set. Connect the 2 vacuum hoses to the vacuum tank for ACIS. Connect the engine wire clamp to the emission control valve set. A09699 Engine Hanger (c) Throttle Body Bracket (d) (e) A09695 (f) (g) (h) (i) (j) (k) (l) (m) 2001 AVALON (RM808U) Author
: Date
: 1052 EM-69 ENGINE MECHANICAL - CYLINDER HEAD (n) (o) (p) (q) (r) (s) (t) Install the PS pressure tube with the 2 nuts. Connect the throttle position sensor connector. Connect the IAC valve connector. Connect the No.1 VSV connector for the ACIS. Connect the No.2 VSV connector for the ACIS. Connect the VSV connecter for the EVAP. 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 RESONATOR 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 2001 AVALON (RM808U) Author
: Date
: 1053 EM-56 ENGINE MECHANICAL - CYLINDER HEAD EM0ZI-02 REASSEMBLY HINT:


Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones. 1. INSTALL SPARK PLUG TUBES HINT: When using a new cylinder head, spark plug tubes must be installed. (a) Apply adhesive to the end of the spark plug tube. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Adhesive 10 - 15 mm (0.39 - 0.59 in.) P11511 (b) Protrusion Using a press, press in a new spark plug tube until there is 42.4 - 43.4 mm (1.669 - 1.709 in.) protruding from the camshaft bearing cap installation surface of the cylinder head. NOTICE: Avoid pressing a new spark plug tube in too far by measuring the amount of the protrusion while pressing. P12572 2. INSTALL PCV PIPES HINT: When using a new cylinder head, PCV pipe must be installed. Using a wooden block and hammer, tap in a new PCV pipe until its top side is flush with the cylinder head edge. NOTICE: Be careful not to damage the cylinder head edge. Flush P12869 3. (a) (b) INSTALL OIL CONTROL VALVE FILTER Assemble the valve filter and plug. Install the plug with new gasket. Torque: 45 N·m (460 kgf·cm, 33 ft·lbf) A05418 2001 AVALON (RM808U) Author
: Date
: 1040 EM-57 ENGINE MECHANICAL - CYLINDER HEAD 4. INSTALL CYLINDER HEAD REAR COVER Install the rear cover and gasket with the 6 bolts. Torque: 10 N·m (100 kgf·cm, 7.3 ft·lbf) A05276 5. (a) SST INSTALL VALVES Using SST, push in a new oil seal. SST 09201-41020 P12719 Intake Mark ”NOK” or ”FN , IN” Light Brown Surface HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray. NOTICE: Pay much attention when assembling the oil seal for intake and exhaust. Assembling the wrong one may cause a failure. Exhaust Gray Surface Z19062 (b) Install the valve (1), spring seat (2), valve spring (3) and spring retainer (4). (c) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-00010) (4) (3) (2) (1) P12668 SST A05224 2001 AVALON (RM808U) Author
: Date
: 1041 EM-58 ENGINE MECHANICAL - CYLINDER HEAD (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. A05246 2001 AVALON (RM808U) Author
: Date
: 1042 EM-31 ENGINE MECHANICAL - CYLINDER HEAD EM0ZE-02 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 ) 5 mm Hexagon Wrench A10518 6. (a) (b) (c) 7. 8. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (j) (l) REMOVE V-BANK COVER Using a 5 mm hexagon wrench, remove the 3 cap nuts. Loosen the V-bank cover fastener counterclockwise. Remove the V-bank cover. REMOVE AIR CLEANER HOSE WITH RESONATOR REMOVE AIR INTAKE CHAMBER ASSEMBLY Disconnect the accelerator cable. Disconnect the throttle cable. Disconnect the throttle position sensor connector. Disconnect the IAC valve connector. Disconnect the No.1 VSV connector for the ACIS. Disconnect the No.2 VSV connector for the ACIS. Disconnect the VSV connector for the EVAP. Disconnect the DLC1 from the bracket on the intake air control valve. Remove the 2 nuts, and disconnect the PS pressure tube from the No.1 engine hanger. Disconnect the PCV hose from the PCV valve on the RH cylinder head. Disconnect the ground strap and cable from the intake air control valve for the ACIS. Disconnect the ground cable from the air intake chamber. (l) (k) A06658 2001 AVALON (RM808U) Author
: Date
: 1015 EM-32 ENGINE MECHANICAL (m) (p) (m) (n) (n) (n) (r) (o) (o) (p) (q) (q) A07505 (r) - CYLINDER HEAD Disconnect the brake booster vacuum hose from the throttle body. Disconnect the 2 water bypass hoses from the throttle body. Disconnect the air assist hose from the throttle body. Disconnect the purge hose from the pipe on the emission control valve set. Disconnect the 2 vacuum hoses from the vacuum tank for the ACIS. Disconnect the engine wire clamp from the emission control valve set. (s) (t) Remove the 2 bolts and No.1 engine hanger. Remove the 2 bolts and throttle body bracket. (u) Using an 8 mm hexagon wrench, remove the 2 bolts, 2 nuts, the air intake chamber assembly and gasket. Engine Hanger Throttle Body Bracket A09695 8 mm Hexagon Wrench A09699 9. REMOVE INTAKE MANIFOLD ASSEMBLY (a) Disconnect the 6 injector connectors. (b) Disconnect the fuel inlet hose from the fuel filter. CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF-1 ) (c) Disconnect the heater hose from the intake manifold. (c) (b) A05074 2001 AVALON (RM808U) Author
: Date
: 1016 EM-33 ENGINE MECHANICAL - CYLINDER HEAD (d) A07428 Remove the 9 bolts, 2 nuts, 2 plate washers, the intake manifold, delivery pipes and injectors assembly. NOTICE:
Be careful not to drop the injectors when removing the delivery pipes.
Pay attention to put any hung load on the injector to and from the side direction. 10. REMOVE WATER OUTLET (a) Disconnect the ECT sender gauge connector. (b) Disconnect the ECT sensor connector. (c) Disconnect the ground strap connector. (d) Disconnect the upper radiator hose. (e) Disconnect the engine coolant reservoir hose. (f) (g) (h) 11. 12. 13. 14. Gasket P20049 15. 16. (a) Clamp Clamp (b) 17. 18. Remove the 2 bolts, 2 nuts and 2 plate washers. Disconnect the water bypass hose, and remove the water outlet. Remove the 2 gaskets. REMOVE IGNITION COILS REMOVE SPARK PLUGS REMOVE TIMING BELT (See page EM-15 ) REMOVE CAMSHAFT TIMING PULLEYS (See page EM-15 ) REMOVE NO.2 IDLER PULLEY (See page EM-15 ) REMOVE NO.3 TIMING BELT COVER Disconnect the 3 engine wire clamps from the timing belt cover. Remove the 6 bolts and timing belt cover. REMOVE CAMSHAFT POSITION SENSORS REMOVE CAMSHAFT TIMING OIL CONTROL VALVES Clamp A05077 19. DISCONNECT ENGINE WIRE PROTECTOR FROM REAR SIDE Remove the nut, and disconnect the engine wire protector from the RH cylinder head. A10531 2001 AVALON (RM808U) Author
: Date
: 1017 EM-34 ENGINE MECHANICAL - CYLINDER HEAD 20. DISCONNECT ENGINE WIRE AND PROTECTOR FROM RH SIDE Remove the 5 nuts, and disconnect the engine wire and protector from the RH cylinder head cover. A10519 21. DISCONNECT ENGINE WIRE PROTECTOR FROM LH SIDE Remove the 2 bolts, and disconnect the engine wire protector from the LH cylinder head cover. A05205 Rear Plate Inlet Pipe 22. DISCONNECT CYLINDER HEAD REAR PLATE FROM LH CYLINDER HEAD Remove the 2 bolts, and disconnect the rear plate. 23. DISCONNECT WATER INLET PIPE FROM LH CYLINDER HEAD AND WATER INLET (a) Remove the bolt, and disconnect the inlet pipe from the water inlet. (b) Remove the O-ring from the inlet pipe. A07596 24. REMOVE PS PUMP BRACKET Remove the 3 bolts and pump bracket. A05189 25. (a) (b) (c) REMOVE RH EXHAUST MANIFOLD Disconnect the A/F sensor connector. Remove the bolt, nut and exhaust manifold stay. Remove the 6 nuts, exhaust manifold and gasket. Manifold Stay A06661 2001 AVALON (RM808U) Author
: Date
: 1018 EM-35 ENGINE MECHANICAL Manifold Stay - CYLINDER HEAD 26. (a) (b) (c) REMOVE LH EXHAUST MANIFOLD Disconnect the A/F sensor connector. Remove the bolt, nut and exhaust manifold stay. Remove the 6 nuts, exhaust manifold and gasket. 27. (a) REMOVE OIL DIPSTICK AND GUIDE Remove the bolt holding the dipstick guide to the LH cylinder head. Pull out the dipstick guide together with the dipstick from the No.1 oil pan. Remove the O-ring from the dipstick guide. A07281 (b) (c) O-Ring A07283 A05193 28. REMOVE CYLINDER HEAD COVERS Remove the 9 bolts, cylinder head cover and gasket. Remove the 2 cylinder head covers. 29. REMOVE CAMSHAFTS OF RH CYLINDER HEAD NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept leveled while it is being installed. If the camshaft is not kept leveled, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Intake Align Remove the intake camshaft. (1) Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench. A05280 2001 AVALON (RM808U) Author
: Date
: 1019 EM-36 ENGINE MECHANICAL Main Gear Intake A05195 Secure the exhaust camshaft sub-gear to the main gear with a service bolt. Recommended service bolt: (3) 6 1 10 (4) 5 8 Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 - 20 mm (0.63 - 0.79 in.) HINT: When removing the camshaft, mark certain that the torsional spring force of the sub-gear has been eliminated by the above operation. 2 Intake CYLINDER HEAD (2) Sub-Gear Service Bolt - Uniformly loosen and remove the 10 bearing cap bolts in several passes and in the sequence shown. Remove the 5 bearing caps and intake camshaft. 9 4 7 3 A05207 Exhaust (b) 1 2 5 9 6 7 10 3 8 4 A05197 Remove the exhaust camshaft. (1) Uniformly loosen and remove the 10 bearing cap bolts in several passes and in the sequence shown. (2) Remove the 5 bearing caps, oil seal and exhaust camshaft. 30. REMOVE CAMSHAFTS OF LH CYLINDER HEAD NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept leveled while it is being installed. If the camshaft is not kept leveled, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. 2001 AVALON (RM808U) Author
: Date
: 1020 EM-37 ENGINE MECHANICAL (a) Intake Align - CYLINDER HEAD Remove the intake camshaft. (1) Align the timing marks (1 dot mark) of the camshaft drive and driven gears by turning the camshaft with a wrench. A05284 Intake (2) Secure the exhaust camshaft sub-gear to the main gear with a service bolt. Recommended service bolt: Service Bolt Thread diameter Main Gear Sub-Gear Intake A05198 1 5 6 9 (c) 10 7 Thread pitch 1.0 mm Bolt length 16 - 20 mm (0.63 - 0.79 in.) HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation. (b) 2 6 mm Uniformly loosen and remove the 10 bearing cap bolts in several passes and in the sequence shown. Remove the 5 bearing caps and intake camshaft. 8 3 4 A05199 Exhaust (d) 2 6 10 5 9 7 4 1 HINT:

8 3 Remove the exhaust camshaft. (1) Uniformly loosen and remove the 10 bearing cap bolts in several passes and in the sequence shown. (2) Remove the 5 bearing caps, oil seal and exhaust camshaft. Arrange the camshafts in the correct order. Arrange the bearing caps in the correct order. A05200 2001 AVALON (RM808U) Author
: Date
: 1021 EM-38 ENGINE MECHANICAL - CYLINDER HEAD 31. (a) DISASSEMBLE EXHAUST CAMSHAFTS Mount the hexagonal wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. P12596 (b) Using SST, turn the sub-gear counterclockwise, and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) (c) (d) Using snap ring pliers, remove the snap ring. Remove the wave washer, camshaft sub-gear, and camshaft gear spring. SST P12797 HINT: Arrange the camshaft sub-gears and gear springs (RH and LH side). P12590 32. (a) Recessed Heat Bolt REMOVE CYLINDER HEADS Using an 8 mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then repeat for the other side, as shown. 8 mm Hexagon Wrench Front A05222 2001 AVALON (RM808U) Author
: Date
: 1022 EM-39 ENGINE MECHANICAL - CYLINDER HEAD (b) Uniformly loosen and remove the 8 cylinder head (12 pointed head) bolts on each cylinder head in several passes and in the sequence shown, then repeat for the other side, as shown. Remove the 16 cylinder head bolts and plate washers. NOTICE: Head warpage or cracking could result from removing bolts in an incorrect order. 12 Pointed Head Bolt 2 7 5 3 4 6 8 1 Front 4 6 8 1 2 7 5 3 A05219 (c) P12424 Lift the cylinder head from the dowels on the cylinder block and place the 2 cylinder heads on wooden blocks on a bench. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. 2001 AVALON (RM808U) Author
: Date
: 1023 EM-52 ENGINE MECHANICAL - CYLINDER HEAD EM0ZH-02 REPLACEMENT 1. (a) REPLACE VALVE GUIDE BUSHINGS Gradually heat the cylinder head to 80 - 100°C (176 212°F). (b) Using SST and a hammer, tap out the guide bushing. SST 09201-01055, 09950-70010 (09951-07100) (c) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. 80 - 100°C A05234 SST P12803 P12956 Both intake and exhaust Bushing bore diameter mm (in.) Bushing size 10.295 - 10.313 (0.4053 - 0.4060) Use STD 10.345 - 10.363 (0.4073 - 0.4080) Use O/S 0.05 Intake 34.5 mm (1.358 in.) (d) Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 10.313 mm (0.4060 in.), machine the bushing bore to the following dimension: 10.345 - 10.363 mm (0.4073 - 0.4080 in.) If the bushing bore diameter of the cylinder head is greater than 10.363 mm (0.4080 in.), replace the cylinder head. HINT: Different bushings are used for the intake and exhaust. (e) Gradually heat the cylinder head to 80 - 100°C (176 212°F). Exhaust 40.5 mm (1.594 in.) P11510 2001 AVALON (RM808U) Author
: Date
: 1036 EM-53 ENGINE MECHANICAL (f) SST - CYLINDER HEAD Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201-01055, 09950-70010 (09951-07100) Protrusion height: Intake 11.1 - 11.3 mm (0.437 - 0.453 in.) Exhaust 8.9 - 9.3 mm - (0.350 - 0.366 in.) P12802 (g) Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM-42 ) between the guide bushing and valve stem. Z09124 2. REPLACE CAMSHAFT TIMING GEAR (VVT-i) NOTICE: Do not remove or install the camshaft timing gear (VVT-i) beside changing VVT-i or the camshaft. (a) Mount the hexagon wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. A05739 (b) A05740 Using a 46 mm socket wrench, remove the lock nut by turning it clockwise. NOTICE:
Remove it under the condition that the lock pin is operated and lock at the maximum delay angle position.
The lock nut have LH threads.
Never use any tool other than the socket wrench, otherwise that may result in deforming the cam angle rotor portion. (c) Remove the camshaft VVT-i. HINT: In case of having difficulty to remove VVT-i, apply a slight hitting using a plastic-faced hammer and then remove it. NOTICE: Never remove the 3 bolts on the gear. 2001 AVALON (RM808U) Author
: Date
: 1037 EM-54 ENGINE MECHANICAL - CYLINDER HEAD (d) Align the knock pin and knock pin groove and install VVTi on the camshaft. NOTICE: Install it under the condition that the lock pin is operated and lock at the maximum delay angle position. Align A05706 (e) A05738 Apply the engine oil on the nut, the placing surface of VVT-i and the screw portion. HINT: Be sure to apply the oil, otherwise the prescribed torque cannot be obtained. (f) Using a 46 mm socket wrench, install and torque a new lock nut by turning it counterclockwise. Torque: 150 N·m (1,530 kgf·cm, 110 ft·lbf) NOTICE:
Must change the nuts to the new ones when to change VVT-i.
The lock nut have LH threads.
Never use any tool other than the socket wrench, otherwise that may result in deforming the cam angle rotor portion. 3. (a) (b) REPLACE SPARK PLUG TUBE GASKETS Bend up the tab on the ventilation baffle plate which prevents the gasket from the slipping out. Using a screwdriver and hammer, tap out the gasket. (c) Using needle-nose pliers, pry out the gasket. A05245 A05243 2001 AVALON (RM808U) Author
: Date
: 1038 EM-55 ENGINE MECHANICAL (d) SST (e) (f) - CYLINDER HEAD Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. SST 09608-03071 Apply a light coat of MP grease to the gasket lip. Return the ventilation plate tab to its original position. A05244 2001 AVALON (RM808U) Author
: Date
: 1039 EM-70 ENGINE MECHANICAL - ENGINE UNIT ENGINE UNIT EM0ZK-02 COMPONENTS No.1 ECT Switch Wire Connector No.2 Cooling Fan Connector Radiator Upper Hose RH Fender No.1 Cooling Fan Connector Apron No.3 Engine Room Seal Relay Block V-Bank Cover Upper Radiator Support Lower Radiator Support Generator Drive Belt Hood Air Cleaner Cap Assembly Washer Hose for Windshield Air Hose Radiator Assembly
O-Ring MAF Meter Connector Air Filter Vacuum Hose Drain Plug PS Pump Drive Belt Air Cleaner Case 43 (440, 32) Hold-Down Clamp PS Pump A/C Compressor Connector A/C Compressor Battery Insulator Generator Drive Belt Adjusting Bar Bracket Battery 25 (250, 18) LH Fender Apron Seal VSV for Active Control Engine Mount EVAP Hose Assembly Battery Tray A/T Oil Cooler Hose Radiator Lower Hose
Gasket
Gasket Actuator Cover Front Exhaust Pipe Cruise Control Actuator
Gasket Accelerator Cable 62 (630, 46) Compression Spring
Stay 43 (430, 32) 33 (330, 24)
62 (630, 46) Cruise Control Actuator Connector N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A10837 2001 AVALON (RM808U) Author
: Date
: 1054 EM-71 ENGINE MECHANICAL - ENGINE UNIT RH Drive Shaft LH Drive Shaft Tie Rod End
49 (500, 36) 64 (650, 47) 294 (3,000, 217)
Engine Moving Control Rod Lower Suspension Arm 32 (320, 23) 64 (650, 47) No.2 RH Engine Mounting Bracket 127 (1,300, 94) Rear Engine Mounting Insulator Engine and Transaxle Assembly Front Engine Mounting Insulator 66 (670, 48) 64 (650, 47) Transaxle Control Cable 48 (490, 35) 44 (450, 32) for Silver Color 66 (670, 49) for Green Color 64 (650, 47) Engine Mounting Absorber N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A10839 2001 AVALON (RM808U) Author
: Date
: 1055 EM-76 ENGINE MECHANICAL - ENGINE UNIT EM0M5-03 INSPECTION 1. (a) A07436 INSPECT FRONT ENGINE MOUNTING INSULATOR 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 between the terminals. Resistance: 19 - 21 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Ohmmeter Continuity A07507 (b) Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. Ohmmeter No Continuity A07508 (c) Air Inspect the VSV operation. (1) Check that air flows from port G to port E and port H. G E H A07509 (2) (3) Apply battery positive voltage across the terminals. 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 ) Air F H E Battery A07566 2001 AVALON (RM808U) Author
: Date
: 1060 EM-77 ENGINE MECHANICAL - ENGINE UNIT EM0ZM-02 INSTALLATION 1. ASSEMBLE ENGINE AND TRANSAXLE 2. INSTALL REAR ENGINE MOUNTING INSULATOR Install the mounting insulator with the 4 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) 3. INSTALL FRONT ENGINE MOUNTING INSULATOR Install the mounting insulator with the 4 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) 4. Lower A07437 INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE (a) Attach the engine sling device to the engine hangers. (b) Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting. NOTICE: Be careful not to hit the park/neutral position switch. (c) Keep the engine level, and align RH and LH mountings with the body bracket. 5. INSTALL NO.2 RH ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD (a) Temporarily install the No.2 RH engine mounting bracket and engine moving control rod with the 3 bolts. A07434 A B (b) D (c) C Tighten the bolt (A). Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) Tighten the other 3 bolts (B, C and D). Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) for bolts B and C 32 N·m (320 kgf·cm, 23 ft·lbf) for bolt D A07435 6. CONNECT FRONT ENGINE MOUNTING INSULATOR Connect the mounting insulator with the 3 bolts. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) for silver color bolt 66 N·m (670 kgf·cm, 49 ft·lbf) for green color bolt A07432 2001 AVALON (RM808U) Author
: Date
: 1061 EM-78 ENGINE MECHANICAL - ENGINE UNIT 7. INSTALL ENGINE MOUNTING ABSORBER Install the engine mounting absorber with the 4 bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) A07431 8. (a) (b) CONNECT REAR ENGINE MOUNTING INSULATOR Connect the mounting insulator with the 4 nuts. Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) Install the 2 hole plugs. P18752 9. CONNECT LH ENGINE MOUNTING INSULATOR Connect the mounting insulator with the 4 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) 10. REMOVE ENGINE SLING DEVICE 11. CONNECT TRANSAXLE CONTROL CABLE TO TRANSAXLE A07430 12. (a) (b) (c) INSTALL PS PUMP Install the PS pump with the 2 bolts. Torque: 43 N·m (440 kgf·cm, 31 ft·lbf) Install the drive belt. Connect the PS pressure tube with the 2 nuts. P18775 13. (a) A B C A A Bracket A A10833 (b) (c) 14. INSTALL A/C COMPRESSOR Install the A/C compressor and drive belt adjusting bar bracket with the 5 bolts and nut. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) for bolt A 18 N·m (185 kgf·cm, 13 ft·lbf) for bolt B 25 N·m (250 kgf·cm, 18 ft·lbf) for nut C Install the drive belt. Connect the A/C compressor connector. INSTALL DRIVE SHAFTS (See page SA-24 ) 2001 AVALON (RM808U) Author
: Date
: 1062 EM-79 ENGINE MECHANICAL - ENGINE UNIT 15. (a) S04497 CONNECT ENGINE WIRE TO CABIN 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. (a) (b) (c) A07300 INSTALL FRONT EXHAUST PIPE Temporarily install 3 new gaskets and the front exhaust pipe with the 2 bolts, 2 compression springs and 4 nuts. Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) 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) 2001 AVALON (RM808U) Author
: Date
: 1063 EM-80 ENGINE MECHANICAL - ENGINE UNIT (d) Install the support stay with the 2 bolts. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) 18. INSTALL RADIATOR (See page CO-22 ) 19. INSTALL CRUISE CONTROL ACTUATOR 20. INSTALL AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE 21. CONNECT ACCELERATOR CABLE 22. 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. 23. INSTALL ENGINE FENDER APRON SEALS 24. INSTALL BATTERY TRAY AND BATTERY 25. INSTALL HOOD 26. FILL ENGINE WITH OIL 27. FILL WITH ENGINE COOLANT 28. START ENGINE AND CHECK FOR LEAKS 29. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 30. RECHECK ENGINE COOLANT AND OIL LEVELS 2001 AVALON (RM808U) Author
: Date
: 1064 EM-72 ENGINE MECHANICAL - ENGINE UNIT EM0ZL-02 REMOVAL 5 mm Hexagon Wrench A10518 1. 2. 3. 4. 5. REMOVE BATTERY AND TRAY REMOVE HOOD REMOVE ENGINE FENDER APRON SEALS DRAIN ENGINE COOLANT DRAIN ENGINE OIL 6. (a) (b) (c) 7. 8. REMOVE V-BANK COVER Using a 5 mm hexagon wrench, remove the 3 cap nuts. Loosen the V-bank cover fastener counterclockwise. Remove the V-bank cover. DISCONNECT ACCELERATOR CABLE REMOVE AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE REMOVE CRUISE CONTROL ACTUATOR REMOVE RADIATOR (See page CO-17 ) 9. 10. 11. (a) (b) (c) A07300 (d) 12. (a) (b) (c) (d) (e) (f) (g) (h) (i) REMOVE FRONT EXHAUST PIPE Remove the 2 bolts holding the support stay to the support bracket. Remove the 2 bolts and 2 compression springs holding the front exhaust pipe to the center exhaust pipe. Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds. Remove the front exhaust pipe and 3 gaskets. DISCONNECT CONNECTORS, CABLE, CLAMPS AND HOSES Remove the bolt and disconnect the ground strap from the LH fender apron. Disconnect the 2 ground strap connectors from the RH fender apron. Disconnect the ground cable from the A/T. Disconnect the engine wire protector clamp from the battery body bracket. Disconnect the engine wire clamp from the bracket on the RH fender apron. Disconnect the brake booster vacuum hose from the throttle body. Disconnect the engine coolant reservoir hose from the water outlet. Disconnect the heater hose from the intake manifold. Disconnect the heater hose from the water inlet housing. 2001 AVALON (RM808U) Author
: Date
: 1056 EM-73 ENGINE MECHANICAL - ENGINE UNIT (j) Disconnect the fuel inlet hose from the fuel filter. CAUTION: Perform disconnecting operation of the fuel tube connector (quick type) after observing the precautions (See page SF-1 ). (k) Disconnect the EVAP hose assembly from the pipe on the emission control valve set. (l) Disconnect the 2 vacuum hoses from the vacuum tank for the ACIS. 13. (a) (b) (c) 14. DISCONNECT ENGINE WIRE FROM CABIN Remove the glove compartment. Disconnect the 5 ECM connectors. Disconnect the grommet from the cowl panel, and pull out the engine wire. REMOVE DRIVE SHAFTS (See page SA-16 ) S04497 15. (a) (b) (c) (d) 16. Bracket DISCONNECT A/C COMPRESSOR FROM ENGINE Disconnect the A/C compressor connector. Remove the drive belt. Remove the 5 bolts, nut and drive belt adjusting bar bracket. Disconnect the A/C compressor from the engine. DISCONNECT TRANSAXLE CONTROL CABLE FROM TRANSAXLE A10833 17. (a) (b) (c) DISCONNECT PS PUMP FROM ENGINE Remove the 2 nuts, and disconnect the PS pressure tube from the No.1 engine hanger. Loosen the 2 bolts, and remove the drive belt. Remove the 2 bolts, and disconnect the PS pump from the engine. P18775 18. DISCONNECT TRANSAXLE FROM LH ENGINE MOUNTING INSULATOR Remove the 4 bolts holding the transaxle to the mounting insulator. A07430 2001 AVALON (RM808U) Author
: Date
: 1057 EM-74 ENGINE MECHANICAL 19. (a) (b) - ENGINE UNIT DISCONNECT REAR ENGINE MOUNTING BRACKET FROM FRONT FRAME Remove the 2 hole plugs. Remove the 4 nuts holding the front frame to the mounting bracket. P18752 20. REMOVE ENGINE MOUNTING ABSORBER Remove the 4 bolts and mounting absorber. A07431 21. DISCONNECT FRONT ENGINE MOUNTING INSULATOR FROM FRONT FRAME Remove the 3 bolts holding the mounting insulator to the front frame. A07432 22. (a) Engine Hanger A07433 ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS Install the No.2 engine hanger in the correct direction. Part No.: No.2 engine hanger 12282-20020 Bolt 90080-11331 Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) (b) Attach the sling device to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. 2001 AVALON (RM808U) Author
: Date
: 1058 EM-75 ENGINE MECHANICAL - ENGINE UNIT 23. REMOVE ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET Remove the 4 bolts, control rod and mounting bracket. A07435 24. Lift A07438 REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE (a) Lift the engine out of the vehicle slowly and carefully. NOTICE:
Be careful not to hit the PNP switch.
Make sure the engine is clear of all wiring, hoses and cables. (b) Place the engine and transaxle assembly onto the stand. 25. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE Remove the 4 bolts and mounting insulator. 26. REMOVE REAR ENGINE MOUNTING INSULATOR AND BRACKET ASSEMBLY FROM ENGINE Remove the 4 bolts, the mounting insulator and bracket assembly. 27. SEPARATE ENGINE AND TRANSAXLE 2001 AVALON (RM808U) Author
: Date
: 1059 EM-1 10 ENGINE MECHANICAL - EXHAUST SYSTEM EXHAUST SYSTEM EM0ZR-02 COMPONENTS Heated Oxygen Sensor (Bank 1 Sensor 2) HINT: Heat Insulator
Before installing the oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns. Pipe Support
After installing the sensor wire is not twisted. Bracket If it is twisted, remove the oxygen sensor and reinstall it. Type A Pipe Support Bracket Type B Pipe Support Bracket 39 (400, 29) 33 (330, 24) Ring Heat Insulator 22 (220,16) Tailpipe Heat Insulator Heat Insulator  Gasket Ring Center Exhaust Pipe Damper Heated Oxygen Sensor (Bank 1 Sensor 2) 19 (190, 14) 44 (450, 33) 33 (330, 24) Compression Spring 43 (440, 32) Ring 21 (210, 15) No.1 Exhaust Pipe Support Bracket  Bracket  Gasket  Gasket Stay Compression Spring   N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part 43 (440, 32)  62 (630, 46) 33 (330, 24) 62 (630, 46) Front Exhaust Pipe A10836 2001 AVALON (RM808U) Author
: Date
: 1094 EM-12 ENGINE MECHANICAL - IDLE SPEED IDLE SPEED EM0CF-02 INSPECTION 1. (a) (b) (c) (d) (e) (f) (g) (h) (i) 2. 3. (a) (b) INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All accessories switched OFF All vacuum lines properly connected SFI system wiring connectors fully plugged Ignition timing check correctly Transmission in neutral position Air conditioning switched OFF CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL (See page EM-10 ) INSPECT IDLE SPEED Race the engine speed at 2,500 rpm for approx. 90 seconds. Check the idle speed. Idle speed: 650 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL 2001 AVALON (RM808U) Author
: Date
: 996 EM-10 ENGINE MECHANICAL - IGNITION TIMING IGNITION TIMING EM15O-01 INSPECTION 5 mm Hexagon Wrench A10518 1. 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. 2. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 3. TOYOTA Hand-Held Tester (a) (b) DLC3 CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand-held tester or OBDII scan tool operator’s manual for further details. A10838 4. CONNECT TIMING LIGHT TO ENGINE Connect the clip of a timing light to the lead wire as shown. 5. CHECK IDLE SPEED (a) Race the engine speed at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed: 650 ± 50 rpm Lead Wire A10536 E1 DLC1 SST 6. (a) INSPECT IGNITION TIMING Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 (b) Using a timing light, check the ignition timing. Ignition timing: 8 - 12° BTDC @ idle (Transmission in neutral position) Remove the SST from the DLC1. SST 09843-18020 TE1 DLC1 A07285 (c) A05184 2001 AVALON (RM808U) Author
: Date
: 994 EM-1 1 ENGINE MECHANICAL 7. - IGNITION TIMING FURTHER CHECK IGNITION TIMING Ignition timing: 10 - 25° BTDC @ idle (Transmission in neutral position) HINT: The timing mark moves in a range between 10° and 25°. 8. DISCONNECT TIMING LIGHT FROM ENGINE 9. DISCONNECT TOYOTA HAND- HELD TESTER OR OBDII SCAN TOOL 10. REINSTALL 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. 2001 AVALON (RM808U) Author
: Date
: 995 EM-13 ENGINE MECHANICAL - TIMING BELT TIMING BELT EM03Y-03 COMPONENTS RH Fender Apron Seal 64 (650, 47) Generator Drive Belt Engine Moving Control Rod 32 (320, 23) No.2 RH Engine Mounting Bracket PS Pump Drive Belt Engine Coolant Reservoir Hose Ground Strap Connector N·m (kgf·cm, ft·lbf) : Specified torque A10834 2001 AVALON (RM808U) Author
: Date
: 997 EM-14 ENGINE MECHANICAL - TIMING BELT Timing Belt No.2 Timing Belt Cover RH Engine Mounting Bracket Timing Belt Guide 28 (290, 21) No.2 Generator Bracket No.1 Timing Belt Cover Crankshaft Pulley Gasket 215 (2,200, 159) Engine Wire Protector RH Camshaft Timing Pulley No.2 Idler Pulley (1,300, 94) 125 *88 (900, 65) 43 (440, 32) LH Camshaft Timing Pulley No.1 Idler Pulley 125 (1,300, 94) Plate Washer Dust Boot
34 (350, 25) Timing Belt Plate Crankshaft Timing Pulley N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part
Precoated part * For use with SST 27 (280, 20) Timing Belt Tensioner A06659 2001 AVALON (RM808U) Author
: Date
: 998 EM-19 ENGINE MECHANICAL - TIMING BELT EM0ZC-02 INSPECTION NO! EM3336 1. INSPECT TIMING BELT NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water or steam.
Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there are any defects, as shown in the illustrations, check these points: (a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and proper installation. (b) If the belt teeth are cracked or damaged, check to see if either camshaft is locked. (c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump. (d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. (e) If there is noticeable wear on the belt teeth, check timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. (a) INSPECT IDLER PULLEYS Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. P20042 A02309 (b) Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. P12604 2001 AVALON (RM808U) Author
: Date
: 1003 EM-20 ENGINE MECHANICAL 3. (a) - TIMING BELT INSPECT TIMING BELT TENSIONER Visually check the seal portion of the tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. P18782 (b) Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn’t move. If the push rod moves, replace the tensioner. NOTICE: Never hold the tensioner push rod facing downward. P18764 (c) Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 - 10.8 mm (0.394 - 0.425 in.) If the protrusion is not as specified, replace the tensioner. Protrusion P18770 2001 AVALON (RM808U) Author
: Date
: 1004 EM-21 ENGINE MECHANICAL - TIMING BELT EM0ZD-02 INSTALLATION Inward Sensor A05060 Plate Washer 10 mm Hexagon Wrench 1. (a) INSTALL CRANKSHAFT TIMING PULLEY Align the pulley set key with the key groove of the timing pulley, and slide on the timing pulley. (b) Install the timing pulley, facing the sensor side inward. NOTICE: Do not scratch the sensor part of the crankshaft timing pulley. (c) Install the timing belt plate with the bolt. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 2. (a) (b) INSTALL NO.1 IDLER PULLEY Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a 10 mm hexagon wrench, install the plate washer and idler pulley with the pivot bolt. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) Check that the pulley bracket moves smoothly. A01802 3. (a) (b) 4. (a) (b) INSTALL NO.2 IDLER PULLEY Install the idler pulley with the bolt. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) Check that the idler pulley moves smoothly. INSTALL RH CAMSHAFT TIMING PULLEY Face the flange side of the timing pulley outward. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. A05055 (c) RH SST Fulcrum Length Using SST, install the pulley bolt. SST 09249-63010, 09960-10010 (09962-01000, 09963-01000) Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.). SST A05061 2001 AVALON (RM808U) Author
: Date
: 1005 EM-22 ENGINE MECHANICAL LH - TIMING BELT 5. (a) (b) INSTALL LH CAMSHAFT TIMING PULLEY Face the flange side of the timing pulley inward. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. (c) Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 125 N·m (1,300 kgf·cm, 94 ft·lbf) 6. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Crankshaft Timing Pulley Position: (1) Temporarily install the crankshaft pulley bolt to the crankshaft. (2) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. (b) Camshaft Timing Pulley Positions: Using SST, turn the camshaft pulley, align the timing marks of the timing pulley and No.3 timing belt cover. SST 09960-10010 (09962-01000, 09963-01000) SST A05056 P18811 SST A05063 2001 AVALON (RM808U) Author
: Date
: 1006 EM-23 ENGINE MECHANICAL 5th 2nd 6th 3rd 4th 1st A02338 TIMING BELT 7. INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (b) Face the front mark on the timing belt forward. (c) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. (d) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys. (e) Install the timing belt in this order: 1st: Crankshaft timing pulley 2nd: Water pump pulley 3rd: LH camshaft timing pulley 4th: No.2 idler pulley 5th: RH camshaft timing pulley 6th: No.1 idler pulley 8. (a) (c) SET TIMING BELT TENSIONER Using a press, slowly press in the push rod using 981 9,807 N (100 - 1,000 kgf, 200 - 2,205 lbf) of pressure. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. Release the press. (d) Install the dust boot to the tensioner. 9. (a) (b) INSTALL TIMING BELT TENSIONER Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts. Torque: 27 N·m (280 kgf·cm, 20 ft·lbf) Remove the 1.27 mm hexagon wrench from the tensioner. (b) 1.27 mm Hexagon Wrench - A05064 A05065 (c) 1.27 mm Hexagon Wrench A05066 2001 AVALON (RM808U) Author
: Date
: 1007 EM-24 ENGINE MECHANICAL - TIMING BELT 10. (a) CHECK VALVE TIMING Slowly turn the crankshaft 2 revolutions, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. P18808 (b) A05052 Check that the timing marks of the RH and LH timing pulleys with the timing marks of the No.3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. (c) Remove the crankshaft pulley bolt. 11. INSTALL RH ENGINE MOUNTING BRACKET Torque: 28 N·m (290 kgf·cm, 21 ft·lbf) 12. INSTALL NO.2 TIMING BELT COVER (a) Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps:
Using a screwdriver and gasket scraper, remove all the old gasket material.
Thoroughly clean all components to remove all the loose material.
Length = 1,410 mm (55.51 in.) (b) (c) P12983 Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration.
After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover. Install the timing belt cover with the 5 bolts. Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf) Install the engine wire protector clamps to the No.3 timing belt cover. 13. INSTALL TIMING BELT GUIDE Install the timing belt guide, facing the cup side outward. P18815 2001 AVALON (RM808U) Author
: Date
: 1008 EM-25 ENGINE MECHANICAL - TIMING BELT 14. (a) INSTALL NO.1 TIMING BELT COVER Check that the timing belt cover gaskets have cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps:
Using a screwdriver and gasket scraper, remove all the old gasket material.
Thoroughly clean all components to remove all the loose material. Length = 240 mm (9.45 in.)
Join Line Join Line Length = 460 mm (18.11 in.) P12982 Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. NOTICE: When joining 2 gaskets, do not leave a gap between them. Cut off any excess gasket.
After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover. (b) Install the timing belt cover with the 4 bolts. Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf) 15. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 215 N·m (2,200 kgf·cm, 159 ft·lbf) SST A04693 P18816 16. INSTALL NO.2 GENERATOR BRACKET Install the generator bracket with the pivot bolt and nut. Do not tighten the bolt yet. Torque: (Nut): 28 N·m (290 kgf·cm, 21 ft·lbf) 17. INSTALL NO.2 RH ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD (See page EM-77 ) 18. CONNECT GROUND STRAP CONNECTORS 19. CONNECT ENGINE COOLANT RESERVOIR HOSE TO WATER OUTLET 20. INSTALL PS PUMP DRIVE BELT 21. INSTALL GENERATOR DRIVE BELT (See page CH-16 ) 22. INSTALL RH FENDER APRON SEAL 23. INSTALL RH FRONT WHEEL 24. VEHICLE ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smoothly operation. 2001 AVALON (RM808U) Author
: Date
: 1009 EM-15 ENGINE MECHANICAL - TIMING BELT EM03Z-03 REMOVAL 1. 2. 3. REMOVE RH FRONT WHEEL REMOVE RH FENDER APRON SEAL REMOVE GENERATOR DRIVE BELT (See page CH-6 ) 4. REMOVE PS PUMP DRIVE BELT Loosen the 2 bolts, and remove the drive belt. 5. DISCONNECT ENGINE COOLANT RESERVOIR HOSE FROM WATER OUTLET 6. DISCONNECT GROUND STRAP CONNECTORS 7. REMOVE ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET (See page EM-72 ) P18754 8. (a) (b) REMOVE NO.2 GENERATOR BRACKET Loosen the generator pivot bolt. Remove the nut and bracket. 9. (a) REMOVE CRANKSHAFT PULLEY Using SST, remove the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 (b) Using SST, remove the pulley. SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05020) P18816 SST P18817 SST P18819 2001 AVALON (RM808U) Author
: Date
: 999 EM-16 ENGINE MECHANICAL - TIMING BELT 10. REMOVE NO.1 TIMING BELT COVER Remove the 4 bolts and timing belt cover. 11. REMOVE TIMING BELT GUIDE P18820 12. (a) Clamp Clamp (b) REMOVE NO.2 TIMING BELT COVER Disconnect the engine wire protector clamps from the No.3 timing belt cover. Remove the 5 bolts and timing belt cover. A05050 13. REMOVE RH ENGINE MOUNTING BRACKET Remove the 2 bolts, nut and mounting bracket. P18814 14. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Temporarily install the crankshaft pulley bolt to the crankshaft. (b) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. P18808 (c) Check that timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360°). (d) Remove the crankshaft pulley bolt. A05052 2001 AVALON (RM808U) Author
: Date
: 1000 EM-17 ENGINE MECHANICAL - TIMING BELT 15. IF REUSING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before removing the timing belt, place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys, and place a new front mark on the timing belt. A01804 16. REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts, and remove them, the tensioner and dust boot. 17. REMOVE TIMING BELT A05053 18. (a) REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the bolt and RH timing pulley. SST 09249-63010, 09960-10010 (09962-01000, 09963-01000) LH (b) Using SST, remove the LH timing pulley. SST 09960-10010 (09962-01000, 09963-01000) SST HINT: Arrange the camshaft timing pulleys (RH and LH sides). RH SST A05054 A05056 19. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. A05055 2001 AVALON (RM808U) Author
: Date
: 1001 EM-18 ENGINE MECHANICAL Plate Washer 10 mm Hexagon Wrench - TIMING BELT 20. REMOVE NO.1 IDLER PULLEY Using a 10 mm hexagon wrench, remove the bolt, idler pulley and plate washer. A01802 21. (a) (b) REMOVE CRANKSHAFT TIMING PULLEY Remove the bolt and timing belt plate. Using SST, remove the crankshaft timing pulley. SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010) NOTICE: Do not scratch the sensor part of the crankshaft timing pulley. SST P20026 2001 AVALON (RM808U) Author
: Date
: 1002 EM-4 ENGINE MECHANICAL - VALVE CLEARANCE VALVE CLEARANCE EM03V-03 INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE RH FENDER APRON SEAL 2. DRAIN ENGINE COOLANT 3. 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. 4. REMOVE AIR INTAKE CHAMBER ASSEMBLY (See page EM-31 ) 5. REMOVE IGNITION COILS 6. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET 7. REMOVE CYLINDER HEAD COVERS (See page EM-31 ) 8. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the No.1 timing belt cover. (b) Check that the valve lifters on the No.1 (IN and EX) are loose. If not, turn the crankshaft 1 revolution (360°) and align the mark as above. P18805 9. (a) 3 3 RH EX RH IN 1 1 Front 66 INSPECT VALVE CLEARANCE Check only those valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. (2) Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.15 - 0.25 mm (0.006 - 0.010 in.) Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.) LH IN LH EX 2 2 A05273 2001 AVALON (RM808U) Author
: Date
: 988 EM-5 ENGINE MECHANICAL - VALVE CLEARANCE (b) Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) (c) Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) 10. (a) ADJUST VALVE CLEARANCE Remove the adjusting shim. (1) Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. (2) Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. 5 5 RH EX RH IN 2 2 3 3 Front LH IN LH EX 4 4 A05272 1 1 RH EX RH IN 5 5 Front 4 4 LH IN LH EX 6 6 A05274 Upward Notch P12919 2001 AVALON (RM808U) Author
: Date
: 989 EM-6 ENGINE MECHANICAL - VALVE CLEARANCE (3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) Front of No.1 and No.2 Cylinder SST (A) HINT:
SST (B)
Others Apply SST (B) at a slight angle on the side marked with ”9” or ”7”, at the position shown in the illustration. When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. SST (A) SST (B) Z09456 SST (B)
Using a small screwdriver and magnetic finger, remove the adjusting shim. (b) Determine the replacement adjusting shim size according to these Formula or Charts: (1) Using a micrometer, measure the thickness of the removed shim. (2) Calculate the thickness of a new shim so the valve clearance comes within the specified value. T .......... Thickness of used shim A .......... Measured valve clearance N .......... Thickness of new shim Intake N = T + (A - 0.20 mm (0.008 in.)) Exhaust N = T + (A - 0.30 mm (0.012 in.)) (3) Select a new shim with a thickness as close as possible to the calculated values. Magnetic Finger P12920 EM0494 HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 in.), from 2.500 mm (0.0984 in.) to 3.300 mm (0.1299 in.). 2001 AVALON (RM808U) Author
: Date
: 990 EM-7 ENGINE MECHANICAL SST (A) (c) SST (B) (d) 11. P12979 12. 13. 14. 15. (a) (b) 16. 17. 18. - VALVE CLEARANCE Install a new adjusting shim. (1) Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. (2) Press down the valve lifter with SST (A), and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) Recheck the valve clearance. REINSTALL CYLINDER HEAD COVERS (See page EM-59 ) CONNECT UPPER RADIATOR HOSE TO WATER OUTLET REINSTALL IGNITION COILS REINSTALL AIR INTAKE CHAMBER ASSEMBLY (See page EM-59 ) INSTALL V-BANK COVER Using a 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts. Press down the V-bank cover fastener. REFILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS REINSTALL RH FENDER APRON SEAL 2001 AVALON (RM808U) Author
: Date
: 991 EM-8 2001 AVALON (RM808U) Adjusting Shim Selection Chart (Intake) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL - Author
: Shim No. Thickness Shim No. mm (in.) Thickness Date
: M00063 992 Intake valve clearance (Cold): 0.15 - 0.25 mm (0.006 - 0.010 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No.12 shim. HINT: New shims have the thickness in millimeters imprinted on the face. VALVE CLEARANCE New shim thickness 2001 AVALON (RM808U) Adjusting Shim Selection Chart (Exhaust) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL - Author
: Shim No. Thickness Shim No. mm (in.) Thickness VALVE CLEARANCE New shim thickness Date
: HINT: New shims have the thickness in millimeters imprinted on the face. EM-9 M00064 993 Exhaust valve clearance (Cold): 0.25 - 0.35 mm (0.010 - 0.014 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No.10 shim. IG-6 IGNITION - CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR IG09Q-03 COMPONENTS V-Bank Cover Camshaft Position Sensor (Bank 1)
O-Ring 8 (80, 69 in.·lbf) Camshaft Position Sensor (Bank 2) Camshaft Position Sensor Connector Camshaft Position Sensor Connector
O-Ring Air Cleaner Hose w/ Resonator 8 (80, 69 in.·lbf) Vacuum Hose N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B07461 2001 AVALON (RM808U) Author
: Date
: 1249 IG-7 IGNITION - CAMSHAFT POSITION SENSOR IG0DN-02 REPLACEMENT 5 mm Hexagon Wrench 1. (a) (b) (c) 2. 3. (a) REMOVE V-BANK COVER Using a 5 mm hexagon wrench, remove the 3 cap nuts. Loosen the V-bank cover fastener counterclockwise. Remove the V-bank cover. REMOVE AIR CLEANER HOSE WITH RESONATOR REMOVE CAMSHAFT POSITION SENSORS Disconnect the 2 camshaft position sensor connectors. (b) Remove the bolt and camshaft position sensor. Remove the 2 camshaft position sensors. Remove the O-rings from the camshaft position sensors. REINSTALL NEW CAMSHAFT POSITION SENSORS Install new O-rings to new camshaft position sensors. Install the camshaft position sensor with the bolt. Install the 2 camshaft position sensors. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) Connect the 2 camshaft position sensor connectors. REINSTALL AIR CLEANER HOSE WITH RESONATOR REINSTALL V-BANK COVER Using 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts. Press down the V-bank cover fastener. A10518 (c) 4. (a) (b) B06698 (c) 5. 6. (a) (b) 2001 AVALON (RM808U) Author
: Date
: 1250 IG-8 IGNITION - CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR IG067-03 COMPONENTS Crankshaft Position Sensor Connector 8 (80, 69 in.·lbf) Crankshaft Position Sensor RH Fender Apron Seal N·m (kgf·cm, ft·lbf) : Specified torque B07462 2001 AVALON (RM808U) Author
: Date
: 1251 IG-9 IGNITION - CRANKSHAFT POSITION SENSOR IG068-02 REPLACEMENT 1. 2. (a) REMOVE RH FENDER APRON SEAL REMOVE CRANKSHAFT POSITION SENSOR Disconnect the crankshaft position sensor connector. (b) 3. (a) Remove the bolt and crankshaft position sensor. REINSTALL NEW CRANKSHAFT POSITION SENSOR Install a new crankshaft position sensor with the bolt. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) Connect the crankshaft position sensor connector. REINSTALL RH FENDER APRON SEAL (b) 4. B06520 2001 AVALON (RM808U) Author
: Date
: 1252 IG-4 IGNITION - IGNITION COIL IGNITION COIL IG09O-03 COMPONENTS V-Bank Cover Ignition Coil Connector 8 (80, 69 in.·lbf) Ignition Coil (w/ Igniter) Gasket N·m (kgf·cm, ft·lbf) : Specified torque B07460 2001 AVALON (RM808U) Author
: Date
: 1247 IG-5 IGNITION - IGNITION COIL IG0DM-02 REPLACEMENT 5 mm Hexagon Wrench 1. (a) (b) (c) 2. (a) REMOVE V-BANK COVER Using a 5 mm hexagon wrench, remove the 3 cap nuts. Loosen the V-bank cover fastener counterclockwise. Remove the V-bank cover. REMOVE IGNITION COILS Disconnect the 6 ignition coil connectors. (b) Remove the bolt, and pull out the ignition coil. Remove the 6 ignition coils. REINSTALL NEW IGNITION COILS Connect a new ignition coil to the spark plug, and attach the ignition coil to the cylinder head cover, and install the bolt. Install the 6 ignition coils. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) Connect the 6 ignition coil connectors. REINSTALL V-BANK COVER Using 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts. Press down the V-bank cover fastener. A10518 3. (a) B06515 (b) 4. (a) (b) 2001 AVALON (RM808U) Author
: Date
: 1248 IG-10 IGNITION - IGNITION RELAY (No.2) IGNITION RELAY (No.2) Engine Room J/B SF0DX-04 INSPECTION 1. REMOVE IGNITION RELAY (Marking: IG2) Ignition Relay B09783 2. (a) Continuity Ohmmeter Ohmmeter 2 1 5 3 No Continuity INSPECT IGNITION RELAY 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. S04970 (b) 2 Ohmmeter 1 5 3 Battery 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. 3. REINSTALL IGNITION RELAY Continuity S04969 2001 AVALON (RM808U) Author
: Date
: 1253 IG-1 IGNITION - IGNITION SYSTEM IGNITION SYSTEM IG0DL-02 ON-VEHICLE INSPECTION NOTICE: ”Cold” and ”Hot” in these sentences express the temperature of the coils themselves. ”Cold” is from -10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). 1. INSPECT SPARK TEST Check that the spark occurs. (1) Remove the ignition coils (with igniters) (See page IG-5 ). (2) Remove the spark plugs. (3) Install the spark plug to the ignition coil, and connect the ignition coil connector. (4) Ground the spark plug. (5) See if spark occurs while engine is being cranked. NOTICE: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 5 - 10 seconds at time. If the spark does not occur, do the test as follows: SPARK TEST NO CHECK CONNECTIONS OF IGNITION COIL (WITH IGNITER) CONNECTORS Connect securely. BAD OK CHANGE IT TO NORMAL IGNITION COIL (WITH IGNITER) AND PERFORM SPARK TEST AGAIN Replace ignition coil (with igniter). OK NO CHECK POWER SUPPLY TO IGNITION COILS (WITH IGNITER) 1. Turn ignition switch to ON. 2. Check that there is battery positive voltage at ignition coil positive (+) terminal. Check wiring between ignition switch to ignition coils (with igniters). BAD OK Replace camshaft position sensor. CHECK RESISTANCE OF SENSORS (See steps 4 and 5) Replace crankshaft position sensor. Resistance: Cold Hot Camshaft position sensor 835 - 1,400 Ω 1,060 - 1,645 Ω Crankshaft position sensor 1,630 - 2,740 Ω 2,065 - 3,225 Ω BAD OK CHECK IGT SIGNAL FROM ECM (See page DI-1 17) OK Check wiring between ECM and ignition BAD coils (with igniters), and then try another ECM. TRY ANOTHER IGNITION COIL (WITH IGNITER) 2001 AVALON (RM808U) Author
: Date
: 1244 IG-2 IGNITION - IGNITION SYSTEM 2. INSPECT SPARK PLUGS NOTICE:
Never use a wire brush for cleaning.
Never attempt to adjust the electrode gap on a used spark plug.
Spark plugs should be replaced every 193,000 km (120,000 miles). (a) Remove the 6 ignition coils (with igniters) (See page IG-5 ). (b) Megger Ground IG0147 Inspect the electrode.
Using a megger (insulation resistance meter), measure the insulation resistance. Standard correct insulation resistance: 10 MΩ or more If the resistance is less than specified, proceed to step (d). HINT: If a megger is not available, these simple method of inspection provides fairly accurate results.
Simple Method:
Quickly race the engine to 4,000 rpm 5 times.
Remove the spark plug (See step (c)).
Visually check the spark plug. If the electrode is dry ... OK If the electrode is wet ... Proceed to step (d)
Reinstall the spark plug (See step (g)). B02629 (c) (d) Using a 16 mm plug wrench, remove the 6 spark plugs. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: 16 mm Plug Wrench DENSO made SK20R11 NGK made IFR6A11 P13225 (e) 1.1 mm B02630 Inspect the electrode gaps. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.1 mm (0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on the used plug. 2001 AVALON (RM808U) Author
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: 1245 IG-3 IGNITION IG0152 Ohmmeter - IGNITION SYSTEM (f) Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. (g) Using a 16 mm plug wrench, install the 6 spark plugs. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) (h) Reinstall the 6 ignition coil (See page IG-5 ). 3. INSPECT IGNITION COILS (WITH IGNITERS) (See step 1.) 4. (a) (b) (c) (d) B06521 INSPECT CAMSHAFT POSITION SENSORS Remove the V-bank cover. Remove the air cleaner hose w/ resonator. Disconnect the sensor connectors. Using an ohmmeter, measure the resistance between terminals. Resistance: Cold 835 - 1,400 Ω Hot 1,060 - 1,645 Ω If the resistance is not as specified, replace the sensor. (e) Reconnect the sensor connectors. (f) Reinstall the air cleaner hose w/ resonator. (g) Reinstall the V-bank cover. 5. (a) (b) Ohmmeter P14244 INSPECT CRANKSHAFT POSITION SENSOR Remove the sensor (See page IG-9 ). Using an ohmmeter, measure the resistance between the terminals. Resistance: Cold 1,630 - 2,740 Ω Hot 2,065 - 3,225 Ω If the resistance is not as specified, replace the sensor. (c) Reinstall the sensor (See page IG-9 ). 2001 AVALON (RM808U) Author
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: 1246 IN-10 INTRODUCTION - FOR ALL OF VEHICLES FOR ALL OF VEHICLES IN0ED-02 PRECAUTION 1. (a) Negative Cable BO4111 (b) FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The AVALON is equipped with an SRS (Supplemental Restraint System), such as the driver airbag, front passenger airbag assembly, side airbag assembly and seat belt pretensioner. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual. GENERAL NOTICE (1) Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery (See page DI-349 ). (2) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable from the battery, the SRS may deploy.) When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the each memory system. Then when work is finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back-up power supply from another battery. 2001 AVALON (RM808U) Author
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: 10 IN-1 1 INTRODUCTION - FOR ALL OF VEHICLES (3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly and seat belt pretensioner should be inspected (See page RS- 15, RS- 30, RS- 44, RS- 57 and BO-130 ). (4) Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. (5) Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. (6) Never disassemble and repair the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly or seat belt pretensioner. (7) If the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly or seat belt pretensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly or seat belt pretensioner to hot air or flames. (9) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. (10) Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. (11) After work on the supplemental restraint system is completed, check the SRS warning light (See page DI-349 ). (c) SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to SR-22 of this manual concerning correct steering wheel installation. Marks F03856 2001 AVALON (RM808U) Author
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: 11 IN-12 INTRODUCTION (d) Example: - FOR ALL OF VEHICLES STEERING WHEEL PAD (with Airbag) (1) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. Storing the pad with its metallic surface facing upward may lead to a serious accident if the airbag deploys for some reason. In addition do not store a steering wheel pad on top of another one. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the steering wheel pad and the pad should not be cleaned with detergents of any kind. (4) Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work. (6) When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See page RS-17 ). Carry out the operation in a safe place away from electrical noise. Correct Wrong B09710 Example: Z13950 2001 AVALON (RM808U) Author
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: 12 IN-13 INTRODUCTION (e) - FOR ALL OF VEHICLES FRONT PASSENGER AIRBAG ASSEMBLY (1) Always store a removed or new front passenger airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the assembly before starting work. (6) When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS-32 ). Perform the operation in a safe place away from electrical noise. Example: Correct Wrong B02921 Example: Z13951 2001 AVALON (RM808U) Author
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: 13 IN-14 INTRODUCTION (f) Example: Correct - FOR ALL OF VEHICLES SIDE AIRBAG ASSEMBLY (1) Always store a removed or new side airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag deploys. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the side airbag assembly and the surface should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the seat before starting work. (6) When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS-45 ). Perform the operation in a safe place away from electrical noise. Wrong B02922 Example: N21642 2001 AVALON (RM808U) Author
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: 14 IN-15 INTRODUCTION (g) - FOR ALL OF VEHICLES SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner to activate, which is very dangerous.) (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner in another vehicle. (4) Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) and away from electrical noise without high humidity. (5) When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting work. (6) When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be activated before disposal (See page BO-131 ). Perform the operation in a safe place away from electrical noise. (7) The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal. However never apply water to the seat belt pretensioner. Example: B02121 2001 AVALON (RM808U) Author
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: 15 IN-16 INTRODUCTION (h) (i) - FOR ALL OF VEHICLES AIRBAG SENSOR ASSEMBLY (1) Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint system. (3) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery, even if only loosing the set bolts of the airbag sensor assembly. WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page RS-82 . 2001 AVALON (RM808U) Author
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: 16 IN-17 INTRODUCTION - FOR ALL OF VEHICLES 2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. (a) Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. (c) Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. (e) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off. (g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil. 3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic system. (2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. 4. FOR USING OBD II SCAN TOOL OR TOYOTA HAND-HELD TESTER CAUTION: Observe the following items for safety reasons:
Before using the OBD II scan tool or TOYOTA hand-held tester, the OBD II scan tool’s instruction book or TOYOTA hand-held tester’s operator manual should be read thoroughly.
Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA handheld tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
Two persons are required when test driving with the OBD II scan tool or TOYOTA hand-held tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or TOYOTA hand-held tester. 2001 AVALON (RM808U) Author
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: 17 IN-18 INTRODUCTION - FOR ALL OF VEHICLES 5. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) & VEHICLE SKID CONTROL (VSC) SYSTEM NOTICE:
When replacing the steering angle sensor or ECU, or when adjusting the front wheel alignment or steering wheel center point in accordance with the removing and installing or replacing the suspension, axle, or steering parts, make sure to perform the steering angle sensor zero point calibration (See page DI-252 ).
Do not remove or install the VSC related parts unless necessary. Otherwise, there is a possibility that the setting of the VSC to be affected.
When working on the VSC related operation, make sure to check that the preparations before and after work are completed according to the following instruction.
When using a drum tester such as a speedometer tester or chassis dynamometer, etc., or jacking up the front wheels and driving the wheels, always push in the TRAC & VSC cut (”VSC OFF”) switch and turn the TRAC & VSC system OFF. (a) Press the VSC OFF switch. (b) Check that the VSC OFF indicator light comes ON. HINT: The VSC OFF indicator light should be always OFF when the engine is restarted. B09711 (c) Begin measurements. (d) Press the VSC OFF switch again to change the TRAC & VSC system to operational condition and check that the VSC OFF indicator light goes off. B09808 HINT:

The SLIP indicator light blinks when the TRAC system is operational. The SLIP indicator light blinks and the VSC buzzer sounds when the VSC system is operational. B09711 2001 AVALON (RM808U) Author
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: 18 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN-19 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05Y-17 GENERAL INFORMATION A large number of ECU controlled systems are used in the AVALON. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This manual is designed through emphasis of the above standpoint to help service technicians perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled systems: The troubleshooting procedure and how to make use of it are described on the following pages. System Page 1. Engine DI-1 2. Automatic Transaxle DI-158 3. Anti-Lock Brake System With Electronic Brake Force Distribution (EBD) DI-210 4. ABS With EBD & BA & TRAC & VSC System DI-250 5. Supplemental Restraint System DI-347 6. Power Seat Control System (w/ Driving position memory) DI-488 7. Theft Deterrent System DI-517 8. Cruise Control System DI-549 9. Engine Immobilizer System DI-597 10.Body Control System DI-615 11.Driver Door Control System DI-676 12.Passenger Door Control System DI-700 13.Multiplex Communication System DI-718 14.Air Conditioning System DI-752 FOR USING OBD II SCAN TOOL OR TOYOTA HAND-HELD TESTER
Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly.
If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus
line) or ECU power circuit of the vehicle. (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s Manual. 2001 AVALON (RM808U) Author
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: 19 IN-20 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05W-19 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. Vehicle Brought to Workshop 1 2 1 Ask the customer about the conditions and the environment when the problem occurred. Customer Problem Analysis Symptom Confirmation and Diagnostic Trouble Code Check 3 Symptom Simulation 2, 3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. (When the problem symptoms do not appear during confirmation, use the symptom simulation method described later on.) 4 Diagnostic Trouble Code Chart 5 6 Problem Symptoms Table Circuit Inspection or Parts Inspection 7 Repair 8 Confirmation Test End 4, 5, 6 Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the problem symptoms table. 7 Check and repair the affected system or part in accordance with the instructions in Step 6. 8 After completing repairs, confirm that the problem has been eliminated. (If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) 2001 AVALON (RM808U) Author
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: 20 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN-21 1. CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis




What ----- Vehicle model, system name When ----- Date, time, occurrence frequency Where ----- Road conditions Under what conditions? ----- Running conditions, driving conditions, weather conditions How did it happen? ----- Problem symptoms (Sample) Engine control system check sheet. CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Data Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Drive ability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other No initial combustion Back fire Other High ( Muffler explosion (after-fire) km miles No complete combustion rpm) Low ( rpm) Surging Others Data Problem Constant Sometimes ( times per day/month) 2001 AVALON (RM808U) Author
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: 21 IN-22 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the AVALON fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the AVALON. System Diagnostic Trouble Code Check Input Signal Check (Sensor Check) Diagnostic Test Mode (Active Test)  (with Check Mode)  (with Check Mode)             Engine Automatic Transaxle Anti-Lock Brake System With Electronic Brake Force Distribution (EBD) ABS With EBD & BA & TRAC & VSC System Supplemental Restraint System Cruise Control System Engine Immobilizer System Multiplex Communication System Air Conditioning System  In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check (Make a note of and then clear) Diagnostic Trouble Code Display Confirmation of Symptoms Diagnostic Trouble Code Check Problem symptoms Same diagnostic trouble code is exist displayed Normal code is displayed Normal Code Display Problem Condition Problem is still occurring in the diagnostic circuit The problem is still occurring in a place other than in the diagnostic circuit (The diagnostic trouble code displayed first is either for a past problem or it is a secondary problem) No problem symptoms exist The problem occurred in the diagnostic circuit in the past Problem symptoms Normal code is exist displayed The problem is still occurring in a place other than in the diagnostic circuit No problem symptoms exist The problem occurred in a place other than in the diagnostic circuit in the past Normal code is displayed 2001 AVALON (RM808U) Author
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: 22 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN-23 Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Diagnostic trouble code check Making a note of and clearing of the diagnostic trouble codes displayed Symptom confirmation Problem symptoms exist No problem symptoms exist Simulation test using the symptom simulation methods Diagnostic trouble code check
Diagnostic trouble code displayed
Problem symptoms exist
Normal code displayed
Problem symptoms exist Troubleshooting of problem indicated by diagnostic trouble code Troubleshooting of each problem symptom
Normal code displayed
No problem symptoms exist System Normal If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (See page IN-30 ). 2001 AVALON (RM808U) Author
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: 23 IN-24 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 3. SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. Shake Slightly WIRE HARNESS Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly. Swing Slightly PARTS AND SENSOR Vibrate Slightly Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check that the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. V07268 2001 AVALON (RM808U) Author
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: 24 INTRODUCTION 2 - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs. M a l f u n ction NOTICE: (1) Do not heat to more than 60 °C (140 °F). (Temperature is limited not to damage the components.) (2) Do not apply heat directly to parts in the ECU. 3 IN-25 WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in a high-humidity condition. Sprinkle water onto the vehicle and check to see if the malfunction occurs. NOTICE: (1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. (2) Never apply water directly onto the electronic components. HINT: If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be taken. 4 OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the malfunction occurs. ON B02389 B02390 2001 AVALON (RM808U) Author
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: 25 IN-26 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 4. DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.
DTC No. Indicates the diagnostic trouble code.
Page or Instructions Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs.
Trouble Area Indicates the suspect area of the problem.
Detection Item Indicates the system of the problem or contents of the problem. DTC CHART (SAE Controlled) HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.” in the DTC chart. DTC No. (See page) Detection Item Trouble Area MIL* P0100 (DI-24) Mass Air Flow Circuit Malfunction
Open or short in mass air flow meter circuit
Mass air flow meter
ECM P0101 (DI-28) Mass Air Flow Circuit Range/ Performance Problem
Mass air flow meter P0110 (DI-29) Intake Air Temp. Circuit Malfunction
Open or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM P0115 (DI-33) Engine Coolant Temp. Circuit Malfunction
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM P0116 (DI-37) Engine Coolant Temp. Circuit Range/ Performance Problem
Engine coolant temp. sensor
Cooling system Throttle/ Pedal Position Sensor/Switch ”A” Circuit Malfunction
Open or short in throttle position sensor circuit
Throttle position sensor
ECM Throttle/ Pedal Position Sensor/ Switch ”A” Circuit Range / Performance Problem
Throttle position sensor Memory 2001 AVALON (RM808U) Author
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: 26 INTRODUCTION - IN-27 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 5. PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system.
Page Indicates the page where the flow chart for each circuit is located.
Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers.
Problem Symptom
Circuit or Part Name Indicates the circuit or part which needs to be checked. PROBLEM SYMPTOMS TABLE Symptom See page Suspect Area Engine does not crank (Does not start) 1. Starter and starter relay ST-2 ST-17 No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. Engine control module (ECM) DI-147 DI-151 IN-29 No complete combustion (Does not start) 1. Fuel pump control circuit DI-151 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression DI-144 DI-151 EM-3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI-144 DI-151 Hot engine 1. Starter signal circuit 2. Fuel pump control circuit DI-144 DI-151 High engine idle speed (Poor idling) 1. A/C signal circuit (Compressor circuit) 2. ECM power source circuit AC-88 idling) 1. A/C signal circuit 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit 2001 AVALON (RM808U) Author
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: 27 IN-28 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 6. CIRCUIT INSPECTION How to read and use each page is shown below.
Diagnostic Trouble Code No. and Detection Item
Circuit Description The major role and operation, etc. of the circuit and its component parts are explained. DTC P0325 Knock Sensor 1 Circuit Malfunction CIRCUIT DESCRIPTION Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. P0325 DTC Detecting Condition Trouble Area No knock sensor 1 signal to ECM with engine speed, 1,200 rpm or more.
Open or short in knock sensor1 circuit
Knock sensor 1 (looseness)
ECM If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle value is set to the maximum value.
Indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem. WIRING DIAGRAM ECM Knock Sensor 1 GR 12 KNK E6 E1
Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. V08423 2001 AVALON (RM808U) Author
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: 28 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
Indicates the position of the ignition switch during the check. ON LOCK Ignition Switch ON Ignition Switch LOCK (OFF) START ACC Ignition Switch ACC Ignition Switch START IN-29
Inspection Procedure Use the inspection procedure to determine if the circuit is normal or abnormal, and, if it is abnormal, use it to determine whether the problem is located in the sensors, actuators, wire harness or ECU. INSPECTION PROCEDURE 1 Check continuity between terminal KNK of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF-68). (b) Disconnect the E6 connector of ECM. LOCK KNK CHECK: Measure resistance between terminal KNK of ECM connector and body ground. E6 Connector OK: Resistance: 1 MΩ or higher AB0117 A00265 A00255 OK Go to step 3. NG 2 Check knock sensor (See page SF-61). OK Replace knock sensor.
Indicates the place to check the voltage or resistance.
Indicates the connector position to checked, from the front or back side. Wire Harness Check from the connector back side. (with harness) Check from the connector front side. (without harness) In this case, care must be taken not to bend the terminals.
Indicates the condition of the connector of ECU during the check. KNK E6 Connector E6 Connector Connector being checked is connected. KNK Connector being checked is disconnected. V08425 2001 AVALON (RM808U) Author
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: 29 IN-30 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05X-1 1 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. FI0046 FI0047 FI0048 CONNECTOR CONNECTION AND TERMINAL INSPECTION
For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures on the following pages.
When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method.
The instructions ”Check wire harness and connector” and ”Check and replace ECU” which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector, a connector terminal pulled out, etc. HINT:
It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators
Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. 2001 AVALON (RM808U) Author
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: 30 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN-31 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. FI7187 Sensor Side ECU Side 3. (a) CONTINUITY CHECK (OPEN CIRCUIT CHECK) Disconnect the connectors at both ECU and sensor sides. (b) Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ω or less IN0379 ECU Side Sensor Side HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. IN0378 4. (a) (b) ECU Side Sensor Side IN0380 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. (a) (b) Pull Lightly Looseness of Crimping IN0381 RESISTANCE CHECK (SHORT CIRCUIT CHECK) Disconnect the connectors on both ends. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 1 MΩ or higher (c) VISUAL CHECK AND CONTACT PRESSURE CHECK Disconnect the connectors at both ends. Check for rust or foreign material, etc. in the terminals of the connectors. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. 2001 AVALON (RM808U) Author
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: 31 IN-32 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (d) Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. Fig. 1 ECU Sensor C B 1 2 OPEN 1 1 2 2 A 1 2 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform ”(a) Continuity Check” or ”(b) Voltage Check” to locate the section. Z17004 (a) Fig. 2 ECU C 1 2 Sensor B 1 2 A 1 2 Z17005 Check the continuity. (1) Disconnect connectors ”A” and ”C” and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector ”A” and terminal 1 of connector ”C” → No continuity (open) Between terminal 2 of connector ”A” and terminal 2 of connector ”C” → Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. (2) Fig. 3 ECU Sensor C 1 2 B2 1 2 1 B1 1 2 A 1 2 B04722 Disconnect connector ”B” and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector ”A” and terminal 1 of connector ”B1” → Continuity Between terminal 1 of connector ”B2” and terminal 1 of connector ”C” → No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 2001 AVALON (RM808U) Author
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: 32 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN-33 (b) Fig. 4 Sensor 5V A C 5V B 1 1 1 2 2 2 0V 5V Z17007 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a ”continuity check with ground”. Fig. 5 C SHORT B 1 1 2 2 Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector ”A” at the ECU 5V output terminal, terminal 1 of connector ”B”, and terminal 1 of connector ”C”, in that order. If the results are: 5V: Between Terminal 1 of connector ”A” and Body Ground 5V: Between Terminal 1 of connector ”B” and Body Ground 0V: Between Terminal 1 of connector ”C” and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of ”B” and terminal 1 of ”C”. A 1 2 Z17008 Fig. 6 ECU Sensor C 1 2 B 1 2 A 1 2 Z17009 Check the continuity with ground. (1) Disconnect connectors ”A” and ”C” and measure the resistance between terminal 1 and 2 of connector ”A” and body ground. In the case of Fig. 6: Between terminal 1 of connector ”A” and body ground → Continuity (short) Between terminal 2 of connector ”A” and body ground → No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. 2001 AVALON (RM808U) Author
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: 33 IN-34 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (2) Fig. 7 Sensor C 1 2 B2 1 2 B1 1 2 A 1 2 ECU Z17808 Disconnect connector ”B” and measure the resistance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground. In the case of Fig. 7: Between terminal 1 of connector ”A” and body ground → No continuity Between terminal 1 of connector ”B2” and body ground → Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. (1) Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ω or less Example Ground IN0383 (2) ECU Side Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. Ground W/H Side Ground IN0384 2001 AVALON (RM808U) Author
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: 34 IN-1 INTRODUCTION - HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN00U-36 GENERAL INFORMATION 1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN-20 . Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Filler Cap Float Clevis Pin  Gasket Reservoir Boot  Grommet Slotted Spring Pin Clip 12 (120, 9) Clevis 15 (155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part N17080 2001 AVALON (RM808U) Author
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: 1 IN-2 INTRODUCTION - HOW TO USE THIS MANUAL The procedures are presented in a step-by-step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Task heading : what to do 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. SST 09350-30020 (09350-06120) Illustration: what to do and where Set part No. Detailed text : Component part No. how to do task (b) Measure the stroke applying and releasing the compressed air (392
785 kPa, 4
8 kgf/cm 2 or 57
114 psi) as shown in the illustration. Piston stroke: 1.40
1.70 mm (0.0551
0.0669 in.) Specification This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick reference. 8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) 2001 AVALON (RM808U) Author
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: 2 IN-3 INTRODUCTION - IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN0CN-07 VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER 1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label A B B02930 2. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration. N09862 2001 AVALON (RM808U) Author
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: 3 IN-4 INTRODUCTION - REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN0CO-08 GENERAL INFORMATION BASIC REPAIR HINT (a) Use fender, seat and floor covers to keep the vehicle clean and prevent damage. (b) During disassembly, keep parts in the appropriate order to facilitate reassembly. (c) FI1066 (d) (e) (f) Seal Lock Adhesive Z11554 Installation and removal of battery terminal: (1) Before performing electrical work, disconnect the negative (-) terminal cable from the battery. (2) If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative (-) terminal cable. (3) When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. (5) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are connected securely and correctly. Non-reusable parts (1) Always replace cotter pins, gaskets, O-rings, oil seals, etc. with new ones. (2) Non-reusable parts are indicated in the component illustrations by the ”” symbol. Precoated parts Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. 2001 AVALON (RM808U) Author
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: 4 IN-5 INTRODUCTION - REPAIR INSTRUCTIONS (3) (g) (h) (i) Medium Current Fuse and High Current Fuse Equal Amperage Rating (j) Precoated parts are indicated in the component illustrations by the ”
” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in Preparation section in this manual. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M-FUSE HIGH CURRENT FUSE H-FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB V00076 2001 AVALON (RM808U) Author
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: 5 IN-6 INTRODUCTION (k) (l) WRONG - REPAIR INSTRUCTIONS Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN-8 ).  Cancel the parking brake on the level place and shift the transmission in Neutral (or N position).  When jacking up the front wheels of the vehicle at first place stoppers behind the rear wheels.  When jacking up the rear wheels of the vehicle at first place stoppers before the front wheels.  When either the front or rear wheels only should be jacked up, set rigid racks and place stoppers in front and behind the other wheels on the ground.  After the vehicle is jacked up, be sure to support it on rigid racks . It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (2) To disconnect vacuum hoses, pull off the end, not the middle of the hose. (3) To pull apart electrical connectors, pull on the connector itself, not the wires. Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. When steam cleaning an engine, protect the electronic components, air filter and emission-related components from water. Never use an impact wrench to remove or install temperature switches or temperature sensors. CORRECT IN0253 WRONG CORRECT (4) (5) IN0252 (6) 2001 AVALON (RM808U) Author
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: 6 IN-7 INTRODUCTION - (7) (8) (m) Example: (n) IN0002 REPAIR INSTRUCTIONS When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak air. Installation and removal of vacuum hose: (1) When disconnecting vacuum hoses, use tags to identify how they should be reconnected to. (2) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. Unless otherwise stated, all resistance is measured at an ambient temperature of 20°C (68°F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running, measurement should be made when the engine has cooled down. 2001 AVALON (RM808U) Author
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: 7 IN-8 INTRODUCTION - REPAIR INSTRUCTIONS IN0CP-07 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front..................... Front crossmember Rear..................... Rear axle beam CAUTION : When jacking-up the rear and front, make sure the car is not carrying any extra weight. PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand and swing arm type lift H12928 2001 AVALON (RM808U) Author
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: 8 IN-9 INTRODUCTION - REPAIR INSTRUCTIONS PLATE TYPE LIFT L B Attachment C A HINT : Left and right set position Place the vehicle over the center of the lift. Front and rear set position
Align the cushion gum ends of the plate with the attachment lower ends (A, C).
Align the attachment upper end (B) with the front jack supporting point (L). Attachment dimensions 85 mm (3.35 in.) 70 mm (2.76 in.) 100 mm (3.94 in.) 200 mm (7.87 in.) H12929 2001 AVALON (RM808U) Author
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: 9 IN-35 INTRODUCTION - TERMS TERMS IN04Q-08 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning ABS Anti-Lock Brake System AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential A/F Air-Fuel Ratio AHC Active Height Control Suspension ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna APPROX. Approximately A/T Automatic Transmission (Transaxle) ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B/L Bi-Level B/S Bore-Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve Calif. California CB Circuit Breaker CCo Catalytic Converter For Oxidation CD Compact Disc CF Cornering Force CG Center Of Gravity CH Channel COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System CTR Center C/V Check Valve CV Control Valve 2001 AVALON (RM808U) Author
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: 35 IN-36 INTRODUCTION - TERMS CW Curb Weight DC Direct Current DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection DLI Distributorless Ignition DOHC Double Over Head Cam DP Dash Pot DS Dead Soak DSP Digital Signal Processor EBD Electronic Brake Force Distribution ECAM Engine Control And Measurement System ECD Electronic Controlled Diesel ECDY Eddy Current Dynamometer ECU Electronic Control Unit ED Electro-Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E/G Engine EGR-VM Egr-V acuum Modulator ELR Emergency Locking Retractor ENG Engine ESA Electronic Spark Advance ETCS Electronic Throttle Control System EVP Evaporator E-VR V Electric Vacuum Regulating Valve EXH Exhaust FE Fuel Economy FF Front-Engine Front-Wheel-Drive F/G Fuel Gage FIPG Formed In Place Gasket FL Fusible Link F/P Fuel Pump FPU Fuel Pressure Up Fr Front FR Front-Engine Rear-Wheel-Drive F/W Flywheel FW/D Flywheel Damper FWD Front-Wheel-Drive GAS Gasoline GND Ground HAC High Altitude Compensator H/B 2001 AVALON (RM808U) Hatchback Author
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: 36 IN-37 INTRODUCTION - TERMS H-FUSE High Current Fuse HI High HID High Intensity Discharge (Head Lamp) HSG Housing HT Hard Top HWS Heated Windshield System IAC Idle Air Control IC Integrated circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent I/P Instrument Panel IRS Independent Rear Suspension J/B Junction Block J/C Junction Connector KD Kick-Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left-Hand LHD Left-Hand Drive L/H/W Length, Height, Width LLC Long-Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP & PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAX. Maximum MIC Microphone MIL Malfunction Indicator Lamp MIN. Minimum MP Multipurpose MPX Multiplex Communication System M/T Manual Transmission MT Mount MTG Mounting N Neutral NA Natural Aspiration No. Number O/D 2001 AVALON (RM808U) Overdrive Author
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: 37 IN-38 INTRODUCTION - TERMS OEM Original Equipment Manufacturing OHC Overhead Camshaft OHV Overhead Valve OPT Option O/S Oversize P & BV Proportioning And Bypass Valve PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PS Power Steering PTO Power Take-Of f R&P Rack And Pinion R/B Relay Block RBS Recirculating Ball Type Steering R/F Reinforcement RFS Rigid Front Suspension RRS Rigid Rear Suspension RH Right-Hand RHD Right-Hand Drive RLY Relay ROM Read Only Memory Rr Rear RR Rear-Engine Rear-Wheel Drive RWD Rear-Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard STJ Cold-Start Fuel Injection SW Switch SYS System T/A Transaxle TACH Tachometer TBI Throttle Body Electronic Fuel Injection TC Turbocharger TCCS TOYOTA Computer-Controlled System TCV Timing Control Valve TDC 2001 AVALON (RM808U) Top Dead Center Author
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: 38 IN-39 INTRODUCTION - TERMS TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension TIS Total Information System For Vehicle Development T/M Transmission TMC TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge U/D Underdrive U/S Undersize VCV Vacuum Control Valve VENT Ventilator VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve w/ With WGN Wagon W/H Wire Harness w/o Without 1st First 2nd Second 2WD Two Wheel Drive Vehicle (4x2) 4WD Four Wheel Drive Vehicle (4x4) 2001 AVALON (RM808U) Author
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: 39 IN-40 INTRODUCTION - TERMS IN0CI-02 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE ABBREVIATIONS TOYOTA TERMS ( )--ABBREVIATIONS SAE TERMS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner, A/CL AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure HAC CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position - CTOX Continuous Trap Oxidizer - CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection (Diesel) Direct Injection (DI) DI Distributor Ignition DLC1 DLC2 DLC3 Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 1: Check Connector 2: Total Diagnosis Comunication Link (TDCL) 3: OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode - ECL Engine Control Level - ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition TOYOTA Distributorless Ignition (TDI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control - FEEPROM Flash Electrically Erasable Programmable Read Only Memory - FEPROM Flash Erasable Programmable Read Only Memory - FF Flexible Fuel - FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) - - - 2001 AVALON (RM808U) Author
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: 40 IN-41 INTRODUCTION - TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel-Shutoff - ISC Idle Speed Control - KS Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Lamp MST Manifold Surface Temperature - MVZ Manifold Vacuum Zone - NVRAM Non-V olatile Random Access Memory - O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On-Board Diagnostic On-Board Diagnostic System (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module - PNP Park/Neutral Position - PROM Programmable Read Only Memory - PSP Power Steering Pressure - PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass E-ABV SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter - SRI Service Reminder Indicator - SRT System Readiness Test - ST Scan Tool - TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch 2001 AVALON (RM808U) Indirect Injection (IDL) - - Torque Converter Author
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: 41 IN-42 INTRODUCTION - TERMS TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three-W ay Catalytic Converter Three-W ay Catalytic (TWC) Manifold Converter CCRO TWC+OC Three-W ay + Oxidation Catalytic Converter CCR + CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU-OC Warm Up Oxidation Catalytic Converter - WU-TWC Warm Up Three-Way Catalytic Converter - 3GR Third Gear - 4GR Fourth Gear - - 2001 AVALON (RM808U) Author
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: 42 LU-1 LUBRICATION - OIL AND FILTER OIL AND FILTER Recommended Viscosity (SAE): LU0G0-02 INSPECTION 10W-30 5W-30 PREFERRED °F -20 °C -29 0 -18 20 -7 40 4 60 16 80 27 100 38 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE B00319 SST 1. CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SJ, Energy-Conserving or ILSAC multigrade engine oil. SAE 5W - 30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 2. CHECK ENGINE OIL LEVEL After warm up the engine and then 5 minutes after the engine stop, oil level should be between the low level and full level marks on the dipstick. If low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL PRESSURE GAUGE (a) Using SST, remove the oil pressure switch. SST 09816-30010 B08674 (b) Oil Pressure Gauge Install the oil pressure gauge. B08675 4. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 5. CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm2, 4.3 psi) or more At 3,000 rpm 294 - 539 kPa (3.0 - 5.5 kgf/cm2, 43 - 78 psi) 2001 AVALON (RM808U) Author
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: 1226 LU-2 LUBRICATION 6. Adhesive (a) (b) (c) P12478 7. - OIL AND FILTER REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH Remove the oil pressure gauge. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using SST, install the oil pressure switch. SST 09816-30010 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) START ENGINE AND CHECK FOR LEAKS 2001 AVALON (RM808U) Author
: Date
: 1227 LU-3 LUBRICATION - OIL AND FILTER LU01Q-03 REPLACEMENT CAUTION:
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites. 1. (a) (b) DRAIN ENGINE OIL Remove the oil filler cap. Remove the oil drain plug, and drain the oil into a container. 2. (a) REPLACE OIL FILTER Using SST, remove the oil filter. SST 09228-07501 Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. B06524 SST (b) (c) B06486 (d) SST (e) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten it an additional 3/4 turn. SST 09228-07501 Additional 3/4 Turn B06479 2001 AVALON (RM808U) Author
: Date
: 1228 LU-4 LUBRICATION 3. (a) (b) - OIL AND FILTER REFILL WITH ENGINE OIL Clean and install the oil drain plug with a new gasket. Torque: 45 N·m (460 kgf·cm, 33 ft·lbf) Fill with fresh engine oil. Capacity: Drain and refill w/ Oilfilter change w/o Oilfilter change Dry fill (c) 4. 5. 4.7 liters (5.0 US qts, 4.1 lmp. qts) 4.5 liters (4.8 US qts, 4.0 lmp. qts) 5.2 liters (5.5 US qts, 4.6 lmp. qts) Install the oil filler cap. START ENGINE AND CHECK FOR OIL LEAKS RECHECK ENGINE OIL LEVEL 2001 AVALON (RM808U) Author
: Date
: 1229 LU-5 LUBRICATION - OIL PUMP OIL PUMP LU01R-04 COMPONENTS 64 (650, 47) RH Fender Apron Seal Engine Moving Control Rod Generator Drive Belt 32 (320, 23) No.2 RH Engine Mounting Bracket PS Pump Drive Belt 43 (440, 32) PS Pump Drive Belt Adjusting Strut Generator Connector Generator A/C Compressor Connector A/C Compressor Bracket 21 (210, 15) Generator Drive Belt Adjusting Bar Bracket  Gasket Front Exhaust Pipe  Gasket  Compression Spring 62 (630, 46) 43 (440, 32) Stay 33 (330, 24)  62 (630, 46) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part B09034 2001 AVALON (RM808U) Author
: Date
: 1230 LU-6 LUBRICATION - OIL PUMP Timing Belt No.2 Timing Belt Cover RH Engine Mounting Bracket Timing Belt Guide 28 (290, 21) No.2 Generator Bracket No.1 Timing Belt Cover Crankshaft Pulley Gasket Engine Wire Protector RH Camshaft Timing Pulley No.2 Idler Pulley 125 (1,300, 94) 215 (2,200, 159) *88 (900, 65) 43 (440, 32) LH Camshaft Timing Pulley No.1 Idler Pulley 125 (1,300, 94) Plate Washer
Dust Boot 34 (350, 25) Timing Belt Plate Crankshaft Timing Pulley B06519 27 (280, 20) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part
Precoated part * For use with SST Timing Belt Tensioner B08672 2001 AVALON (RM808U) Author
: Date
: 1231 LU-7 LUBRICATION - OIL PUMP No.3 Timing Belt Cover Gasket 8.5 (85, 74 in.·lbf) Collar Bushing x6  O-Ring Engine Wire x6 8 (80, 69 in.·lbf) Crankshaft Position Sensor Oil Pump Crankshaft Position Sensor Connector Oil Pan Baffle Plate A/C Compressor Housing Bracket 8 (80, 69 in.·lbf) x9 x 17 No.1 Oil Pan 19.5 (200, 14) 10 mm Head 8 (80, 69 in.·lbf) 12 mm Head 19.5 (200, 14) No.1 Exhaust Pipe Support Bracket  Gasket 10 mm Head 8 (80, 69 in.·lbf) 12 mm Head 19.5 (200, 14) 14 mm Head 37.2 (380, 27) 8 (80, 69 in.·lbf)  Gasket Oil Strainer No.2 Oil Pan Drain Plug 45 (460, 33) x 10 8 (80, 69 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part B08905 2001 AVALON (RM808U) Author
: Date
: 1232 LU-8 LUBRICATION - OIL PUMP Oil Pump Body Cover Drive Rotor Oil Pump Body x 10 Driven Rotor  Crankshaft Front Oil Seal Relief Valve Spring Plug 49.1 (500, 36) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part B08678 2001 AVALON (RM808U) Author
: Date
: 1233 LU-1 1 LUBRICATION - OIL PUMP LU01T-03 DISASSEMBLY 1. REMOVE RELIEF VALVE Remove the plug, spring and relief valve. B04138 2. REMOVE DRIVE AND DRIVEN ROTORS Remove the 10 screws, pump body cover, drive and driven rotors. B04139 2001 AVALON (RM808U) Author
: Date
: 1236 LU-12 LUBRICATION - OIL PUMP LU01U-03 INSPECTION 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assembly. B04140 Mark 2. PLACE DRIVE AND DRIVEN ROTORS INTO OIL PUMP BODY Place the drive and driven rotors into the oil pump body with the mark facing upward. B04141 3. INSPECT ROTOR SIDE CLEARANCE Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard side clearance: 0.030 - 0.090 mm (0.0012 - 0.0035 in.) Maximum side clearance: 0.15 mm (0.0059 in.) If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. B04142 4. INSPECT ROTOR TIP CLEARANCE Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: 0.110 - 0.240 mm (0.0043 - 0.0094 in.) Maximum tip clearance: 0.35 mm (0.0138 in.) If the tip clearance is greater than maximum, replace the rotors as a set. B04143 5. INSPECT ROTOR BODY CLEARANCE Using a feeler gauge, measure the clearance between the driven rotor and body. Standard body clearance: 0.250 - 0.325 mm (0.0098 - 0.0128 in.) Maximum body clearance: 0.40 mm (0.0157 in.) If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. B04144 2001 AVALON (RM808U) Author
: Date
: 1237 LU-15 LUBRICATION - OIL PUMP LU0IC-01 INSTALLATION 1. (a) INSTALL OIL PUMP 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 surfaces 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 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. B A C A B HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. Seal Width 2 - 3 mm C B04145 (c) Place a new O-ring on the cylinder block. New O-Ring P18779 2001 AVALON (RM808U) Author
: Date
: 1240 LU-16 LUBRICATION (d) (e) B04146 2. 3. 4. (a) (b) Region ”X” Region ”Y” B A A Seal Width 3 - 4 mm B B04147 - OIL PUMP 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. 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) INSTALL CRANKSHAFT POSITION SENSOR Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) INSTALL BAFFLE PLATE TO NO.1 OIL PAN Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) INSTALL NO.1 OIL PAN 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 surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Region ”X” is at the outer side of the bolt hole. Region ”Y” 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 application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall 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) 2001 AVALON (RM808U) Author
: Date
: 1241 LU-17 LUBRICATION - OIL PUMP (d) Install the No.1 exhaust pipe support bracket with the 2 bolts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) 5. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 6. INSTALL NO.2 OIL PAN (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the No.1 and No.2 oil pans.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non-residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces. (b) A A Apply seal packing to the No.2 oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent
Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) Install the No.2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 7. INSTALL TIMING PULLEYS (See page EM-21 ) 8. INSTALL TIMING BELT (See page EM-21 ) B Seal Width 4 - 5 mm B P12568 2001 AVALON (RM808U) Author
: Date
: 1242 LU-18 LUBRICATION 9. (a) (b) (c) 10. 11. 12. 13. 14. 15. 16. 17. - OIL PUMP INSTALL ADJUSTING STRUT AND PS PUMP DRIVE BELT Temporarily install the adjusting strut with the bolt and nut. Install the drive belt with the pivot and adjusting bolts. Torque: 43.1 N·m (440 kgf·cm, 32 ft·lbf) Tighten the nut. Torque: 43.1 N·m (440 kgf·cm, 32 ft·lbf) INSTALL A/C COMPRESSOR (See page EM-77 ) INSTALL GENERATOR (See page CH-1 ) INSTALL RH FENDER APRON SEAL INSTALL FRONT EXHAUST PIPE (See page EM-77 ) INSTALL RH FRONT WHEEL FILL ENGINE WITH OIL START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE OIL LEVEL 2001 AVALON (RM808U) Author
: Date
: 1243 LU-14 LUBRICATION - OIL PUMP LU01W-03 Mark REASSEMBLY 1. (a) B04141 INSTALL DRIVE AND DRIVEN ROTORS Place the drive and driven rotors into pump body with the marks facing the pump body cover side. (b) Install the pump body cover with the 10 screws. 2. INSTALL RELIEF VALVE Insert the relief valve and spring into the pump body hole, and install the plug. Torque: 49.1 N·m (500 kgf·cm, 36 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1239 LU-9 LUBRICATION - OIL PUMP LU0IB-01 REMOVAL HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. 1. DRAIN ENGINE OIL 2. REMOVE RH FRONT WHEEL 3. REMOVE RH FENDER APRON SEAL 4. REMOVE FRONT EXHAUST PIPE (See page EM-72 ) 5. REMOVE GENERATOR FROM ENGINE (See page CH-6 ) 6. REMOVE A/C COMPRESSOR FROM ENGINE (See page EM-72 ) 7. Pivot Bolt (a) Adjusting Strut Adjusting Bolt (b) 8. 9. 10. P18778 REMOVE PS PUMP DRIVE BELT AND ADJUSTING STRUT Loosen the pivot and adjusting bolts, and remove the drive belt. Remove the bolt, nut and adjusting strut. REMOVE TIMING BELT (See page EM-15 ) REMOVE TIMING PULLEYS (See page EM-15 ) REMOVE NO.3 TIMING BELT COVER (See page EM-31 ) 11. REMOVE A/C COMPRESSOR HOUSING BRACKET Remove the 2 bolts and housing bracket. B04135 12. (a) REMOVE NO.2 OIL PAN Remove the 10 bolts and 2 nuts. P18801 2001 AVALON (RM808U) Author
: Date
: 1234 LU-10 LUBRICATION - OIL PUMP (b) SST SST Insert the blade of SST between the No.1 and No.2 oil pans, and cut off applied sealer and remove the No.1 oil pan. SST 09032-00100 NOTICE:
Be careful not to the damage the No.2 oil pan contact surface of the No.1 oil pan.
Be careful not to damage the No.2 oil pan flange. P12716 13. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. P18802 14. (a) (b) REMOVE NO.1 OIL PAN Remove the 2 bolts and No.1 exhaust pipe support bracket. Remove the 17 bolts and 2 nuts. B04136 (c) Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. 15. REMOVE BAFFLE PLATE FROM NO.1 OIL PAN 16. REMOVE CRANKSHAFT POSITION SENSOR B04137 17. (a) (b) (c) Pry REMOVE OIL PUMP Remove the 9 bolts. Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap. Remove the O-ring. P20050 2001 AVALON (RM808U) Author
: Date
: 1235 LU-13 LUBRICATION - OIL PUMP LU01V-03 REPLACEMENT REPLACE CRANKSHAFT FRONT OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal which are as follows: (a) If the oil pump is removed from the cylinder block. (1) Using a screwdriver, pry out the oil seal. P12413 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09223-00010 (3) Apply MP grease to the oil seal lip. SST P12392 (b) If the oil pump is installed to the cylinder block. (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Cut Position P12475 (3) (4) Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09223-00010 SST P12473 2001 AVALON (RM808U) Author
: Date
: 1238 MA-8 MAINTENANCE - BODY BODY MA01P-02 INSPECTION 1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten the following parts:
Front seat mount bolts Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) MA0676 B00995
Front suspension member-to-body mounting bolts Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) B08916 2. (a) B09029 (b) (c)
Rear suspension member-to-body mounting nuts Torque: 51 N·m (520 kgf·cm, 38 ft·lbf) FINAL INSPECTION Check the operation of the body parts:
Hood: Auxiliary catch operates properly Hood locks securely when closed
Front and rear doors: Door lock operates properly Doors close properly
Luggage compartment door: Door lock operates properly
Seats: Seat adjusts easily and locks securely in any position Front seat back locks securely in any position Folding-down rear seat backs lock securely Road test:
Check the engine and chassis for abnormal noises.
Check that the vehicle dose not wander or pull to one side.
Check that the brakes work properly and do not drag.
Do setting of the parking brake shoes and drum. Be sure to deliver a clean car and especially check:
Steering wheel
Shift lever knob
All switch knobs
Door handles
Seats 2001 AVALON (RM808U) Author
: Date
: 50 MA-6 MAINTENANCE - BRAKE BRAKE MA01N-01 INSPECTION B00632 1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Check in a well lighted area. Check the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or left before checking the front brake. (a) Check all brake lines and hoses for:
Damage
Wear
Deformation
Cracks
Corrosion
Leaks
Bends
Twists (b) Check all clamps for tightness and connections for leakage. (c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the lines installed in grommets pass through the center of the grommets. 2. INSPECT FRONT BRAKE PADS AND DISCS (See page BR-26 ) 3. INSPECT REAR BRAKE PADS AND DISCS (See page BR-35 ) 4. INSPECT PARKING BRAKE LININGS AND DRUMS (See page BR-45 ) 2001 AVALON (RM808U) Author
: Date
: 48 MA-7 MAINTENANCE - CHASSIS CHASSIS MA01O-02 INSPECTION 1. (a) (b) INSPECT STEERING LINKAGE Check the steering wheel free-play (See page SR-8 ). Check the steering linkage for looseness or damage. Check that:
Tie rod ends do not have excessive play.
Dust seals and boots are not damaged.
Boot clamps are not loose. 2. INSPECT SRS AIRBAG (See pages RS-15 , RS-30 ) 3. INSPECT STEERING GEAR HOUSING OIL Check the steering gear housing for oil leakage. 4. INSPECT DRIVE SHAFT BOOTS Check the drive shaft boots for clamp looseness, leakage or damage. 5. (a) B08915 INSPECT BALL JOINTS AND DUST COVERS Inspect the ball joints for excessive looseness.
Jack up the front of the vehicle and place wooden blocks with a height of 180 - 200 mm (7.09 - 7.87 in.) under the front tires.
Lower the jack until there is about half a load on the front coil spring. Place stands under the vehicle for safety.
Check that the front wheels are pointing straight ahead, and block them with chocks.
Using a lever, pry up the end of the lower arm, and check the amount of play. Maximum ball joint vertical play: 0 mm (0 in.) If there is play, replace the ball joint. (b) Check the dust cover for damage. 6. CHECK TRANSAXLE FLUID Visually check the transaxle for fluid leakage. If leakage is found, check for the cause and repair. 7. REPLACE TRANSAXLE FLUID (See page DI-160 ) 2001 AVALON (RM808U) Author
: Date
: 49 MA-5 MAINTENANCE - ENGINE ENGINE MA01M-02 INSPECTION HINT: Inspect these items when the engine is cold. 1. REPLACE TIMING BELT (See page EM-15 ) 2. INSPECT DRIVE BELTS (See pages CH-1 , SR-3 and AC-17 ) 3. REPLACE SPARK PLUGS (See page IG-1 ) 4. (a) Outside Inside P00495 INSPECT AIR FILTER Visually check that the air filter is not excessively dirty or oily. (b) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow off the outside of the air filter. 5. REPLACE AIR FILTER Replace the air filter with a new one. 6. REPLACE ENGINE OIL AND OIL FILTER (See page LU-3 ) 7. REPLACE ENGINE COOLANT (See page CO-2 ) 8. REPLACE GASKET IN FUEL TANK CAP (See page EC-6 ) 9. INSPECT FUEL LINES AND CONNECTIONS (See page EC-6 ) 10. INSPECT EXHAUST PIPES AND MOUNTINGS (See page EC-14 ) 11. ADJUST VALVE CLEARANCE (See page EM-4 ) 2001 AVALON (RM808U) Author
: Date
: 47 MA-2 MAINTENANCE - INSIDE VEHICLE INSIDE VEHICLE MA002-16 GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted.
Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. (b) Check the headlight aim. 3. WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly. 4. HORN Check that it is working. 5. WINDSHIELD GLASS Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak. 7. WINDSHIELD DEFROSTER Check that air comes out from the defroster outlet when operating the heater or air conditioner at defroster mode. 8. REAR VIEW MIRROR Check that it is mounted securely. 9. SUN VISORS Check that they move freely and are mounted securely. 10. STEERING WHEEL Check that it has the specified free-play. Be alert for changes in steering condition, such as hard steering, excessive free-play or strange noises. 11. SEATS (a) Check that the seat adjusters operate smoothly. (b) Check that all latches lock securely in any position. (c) Check that the head restraints move up and down smoothly and that the locks hold securely in any latch position. (d) For fold-down seat backs, check that the latches lock securely. 12. SEAT BELTS (a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. 2001 AVALON (RM808U) Author
: Date
: 44 MA-3 MAINTENANCE - INSIDE VEHICLE 13. ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. 14. BRAKE PEDAL (See page BR-6 ) (a) Check the pedal for smooth operation. (b) Check that the pedal has the proper reserve distance and free-play. (c) Check the brake booster function. 15. BRAKES At a safe place, check that the brakes do not pull to one side when applied. 16. PARKING BRAKE (See page BR-9 ) (a) Check that the parking brake pedal has the proper travel. (b) On a safe incline, check that the vehicle is held securely with only the parking brake applied. 17. AUTOMATIC TRANSMISSION ”PARK” MECHANISM (a) Check the lock release mechanism of the selector lever for proper and smooth operation. (b) On a safe incline, check that the vehicle is held securely with the selector lever in ”P” position and all brakes released. 2001 AVALON (RM808U) Author
: Date
: 45 MA-2 MAINTENANCE - INSIDE VEHICLE INSIDE VEHICLE MA002-16 GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted.
Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. (b) Check the headlight aim. 3. WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly. 4. HORN Check that it is working. 5. WINDSHIELD GLASS Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak. 7. WINDSHIELD DEFROSTER Check that air comes out from the defroster outlet when operating the heater or air conditioner at defroster mode. 8. REAR VIEW MIRROR Check that it is mounted securely. 9. SUN VISORS Check that they move freely and are mounted securely. 10. STEERING WHEEL Check that it has the specified free-play. Be alert for changes in steering condition, such as hard steering, excessive free-play or strange noises. 11. SEATS (a) Check that the seat adjusters operate smoothly. (b) Check that all latches lock securely in any position. (c) Check that the head restraints move up and down smoothly and that the locks hold securely in any latch position. (d) For fold-down seat backs, check that the latches lock securely. 12. SEAT BELTS (a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. 2001 AVALON (RM808U) Author
: Date
: 44 MA-3 MAINTENANCE - INSIDE VEHICLE 13. ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. 14. BRAKE PEDAL (See page BR-6 ) (a) Check the pedal for smooth operation. (b) Check that the pedal has the proper reserve distance and free-play. (c) Check the brake booster function. 15. BRAKES At a safe place, check that the brakes do not pull to one side when applied. 16. PARKING BRAKE (See page BR-9 ) (a) Check that the parking brake pedal has the proper travel. (b) On a safe incline, check that the vehicle is held securely with only the parking brake applied. 17. AUTOMATIC TRANSMISSION ”PARK” MECHANISM (a) Check the lock release mechanism of the selector lever for proper and smooth operation. (b) On a safe incline, check that the vehicle is held securely with the selector lever in ”P” position and all brakes released. 2001 AVALON (RM808U) Author
: Date
: 45 MA-1 MAINTENANCE - OUTSIDE VEHICLE OUTSIDE VEHICLE MA001-12 GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted.
Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. TIRES (a) Check the pressure with a gauge. If necessary, adjust. (b) Check for cuts, damage or excessive wear. 3. WHEEL NUTS When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them. 4. TIRE ROTATION Check the owner’s manual supplement in which the maintenance schedule is shown. 5. WINDSHIELD WIPER BLADES Check for wear or cracks whenever they do not wipe clean. If necessary, replace. 6. FLUID LEAKS (a) Check underneath for leaking fuel, oil, water or other fluid. (b) If you smell gasoline fumes or notice any leak, have the cause found and corrected. 7. DOORS AND ENGINE HOOD (a) Check that all doors including the trunk lid operate smoothly, and that all latches lock securely. (b) Check that the engine hood secondary latch secures the hood from opening when the primary latch is released. 2001 AVALON (RM808U) Author
: Date
: 43 MA-4 MAINTENANCE - UNDER HOOD UNDER HOOD MA003-12 GENERAL MAINTENANCE 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted.
Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. WINDSHIELD WASHER FLUID Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL Check that the coolant level is between the ”FULL” and ”LOW” lines on the see-through reservoir. 4. RADIATOR AND HOSES (a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs. (b) Check the hoses for cracks, kinks, rot or loose connections. 5. BATTERY ELECTROLYTE LEVEL Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. 6. BRAKE FLUID LEVEL Check that the brake fluid level is near the upper level line on the see-through reservoirs. 7. ENGINE DRIVE BELTS Check drive belt for fraying, cracks, wear or oiliness. 8. ENGINE OIL LEVEL Check the level on the dipstick with the engine turned off. 9. POWER STEERING FLUID LEVEL
Check the level.
The level should be in the ”HOT” or ”COLD” range depending on the fluid temperature. 10. AUTOMATIC TRANSMISSION FLUID LEVEL (a) Park the vehicle on a level surface. (b) With the engine idling and the parking brake applied, shift the selector into all positions from ”P” to ”L”, and then shift into ”P” position. (c) Pull out the dipstick and wipe off the fluid with a clean rag. Re-insert the dipstick and check that the fluid level is in the ”HOT” range. (d) Do this check with the fluid at normal driving temperature (70 - 80°C, 158 - 176°F). HINT: Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at high speeds, in hot weather, in heavy traffic or pulling a trailer. 11. EXHAUST SYSTEM If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected. 2001 AVALON (RM808U) Author
: Date
: 46 PP-65 PREPARATION - AIR CONDITIONING PP0B8-04 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Sensor, ECT switch Torque wrench Dial indicator Magnetic clutch Plastic hammer Magnetic clutch 2001 AVALON (RM808U) Author
: Date
: 115 PP-66 PREPARATION - AIR CONDITIONING PP0B9-09 LUBRICANT Item Compressor oil Capacity Classification - ND-OIL 8 or equivalent When replacing condenser 40 cc (1.4 fl.oz.) When replacing evaporator 40 cc (1.4 fl.oz.) When replacing compressor 120 cc (4.1 fl.oz.) 2001 AVALON (RM808U) Author
: Date
: 116 PP-64 PREPARATION - AIR CONDITIONING PP0B7-02 RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester. 09216-00021 Belt Tension Gauge . 2001 AVALON (RM808U) Author
: Date
: 114 PP-62 PREPARATION - AIR CONDITIONING AIR CONDITIONING PP2DG-02 SST (Special Service Tools) 07110-58060 Air Conditioner Service Tool Set (07117-58060) Refrigerant Drain Service Valve (07117-58070) T-Joint (07117-58080) Quick Disconnect Adapter High pressure side (07117-58090) Quick Disconnect Adapter Low pressure side (07117-88060) Refrigerant Charging Hose High pressure side (Color: Red) (07117-88070) Refrigerant Charging Hose Low pressure side (Color: Blue) (07117-88080) Refrigerant Charging Hose Utility (Color: Green) 07112-66040 Magnetic Clutch Remover 07112-76060 Magnetic Clutch Stopper 95994-10010 Snap Ring Pliers (DENSO Part No.) 95994-10020 Snap Ring Pliers (DENSO Part No.) 2001 AVALON (RM808U) Author
: Date
: 112 PP-63 PREPARATION - AIR CONDITIONING 07116-38360 Gas Leak Detector Assembly 09870-00015 A/C Quick Joint Puller No.1 09870-00025 A/C Quick Joint Puller No.2 2001 AVALON (RM808U) Author
: Date
: 113 PP-30 PREPARATION - AUTOMATIC TRANSAXLE PP0M3-02 EQUIPMENT Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Hexagon Wrench (10 mm) Torque wrench OBD II scan tool 2001 AVALON (RM808U) Author
: Date
: 80 PP-31 PREPARATION - AUTOMATIC TRANSAXLE PP0M4-05 LUBRICANT Item Automatic transaxle fluid (w/o Differential oil) Dry fill Drain and refill Capacity Classification 8.0 liters (8.5 US qts, 7.0 Imp. qts) 4.75 liters (5.0 US qts, 4.2 Imp. qts) ATF D-II or DEXRON®III (DEXRON®II) 2001 AVALON (RM808U) Author
: Date
: 81 PP-29 PREPARATION - AUTOMATIC TRANSAXLE PP0M2-06 RECOMMENDED TOOLS 09082-00050 TOYOTA Electrical Tester Set. 09090-04020 Engine Sling Device 2001 AVALON (RM808U) Author
: Date
: 79 PP-28 PREPARATION - AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE PP0M1-02 SST (Special Service Tools) 09223-15020 Oil Seal & Bearing Replacer 09308-00010 Oil Seal Puller Side gear shaft oil seal 09316-6001 1 Transmission & Transfer Bearing Replacer RH side bearing Replacer Pipe RH side gear shaft oil seal (09316-0001 1) 09350-32014 TOYOTA Automatic Transmission Tool Set (09351-32010) One-way Clutch Test Tool (09351-32020) Stator Stopper (09351-32130) Handle Automatic Transmission Oil Pressure Gauge Set Line pressure (09992-00231) Adaptor C Line pressure (09992-00271) Gauge Assy Line pressure 09992-00095 2001 AVALON (RM808U) Author
: Date
: 78 PP-55 PREPARATION - BODY ELECTRICAL PP0B4-01 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Engine oil level warning switch, Seat heater Syphon Brake fluid level warning switch Oil bath Engine oil level warning switch Bulb (3 W) Fuel sender gauge Bulb (3.4 W) Seat belt warning relay Bulb (21 W) Turn signal flasher relay Dry cell battery Fuel sender gauge Heat light Seat heater Torque wrench Masking tape Rear window defogger wire Tin foil Rear window defogger wire 2001 AVALON (RM808U) Author
: Date
: 105 PP-54 PREPARATION - BODY ELECTRICAL PP0B3-01 RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester. 09041-00030 Torx Driver T30 . For removing and installing steering wheel pad 09042-00010 Torx Socket T30 . For removing and installing steering wheel pad 2001 AVALON (RM808U) Author
: Date
: 104 PP-56 PREPARATION - BODY ELECTRICAL PP0VH-01 SSM (Special Service Materials) 08888-88888 DuPont Paste No. 4817 or equivalent Rear window defogger 2001 AVALON (RM808U) Author
: Date
: 106 PP-53 PREPARATION - BODY ELECTRICAL BODY ELECTRICAL PP0B2-01 SST (Special Service Tools) 09843-18020 Diagnosis Check Wire 2001 AVALON (RM808U) Author
: Date
: 103 PP-59 PREPARATION - BODY PP0AZ-04 EQUIPMENT Clip remover Torque wrench Hog ring pliers Tape To avoid surface damage Adhesive tape To avoid surface damage Double-stick tape Adhesive Cleaner Shop rag Knife Sealer gun Brush Putty spatula Glass plate or similar object Wooden block or similar object Heat light Piano wire Tire Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Seat belt pretensioner Tire with disk wheel Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Seat belt pretensioner Vinyl bag Seat belt pretensioner 2001 AVALON (RM808U) Author
: Date
: 109 PP-60 PREPARATION - BODY PP0B0-01 LUBRICANT Item MP grease Capacity Classification - - 2001 AVALON (RM808U) Author
: Date
: 110 PP-58 PREPARATION - BODY PP2DM-01 RECOMMENDED TOOLS 09050-20010 Air Riveter. (09050-02010) Dust Cap. (09050-02020) Nose Piece No.1. 2001 AVALON (RM808U) Author
: Date
: 108 PP-61 PREPARATION - BODY PP2DL-01 SSM (Special Service Materials) 08833-00070 Adhesive 1324, THREE BOND 1324 or equivalent 08850-00801 Windshield Glass Adhesive Set or equivalent 2001 AVALON (RM808U) Author
: Date
: 111 PP-57 PREPARATION - BODY BODY PP0UX-01 SST (Special Service Tools) 09082-00700 SRS Airbag Deployment Tool 09082-00740 Airbag Deployment Wire Sub-harness No.2 09804-24010 Luggage Compartment Door Torsion Bar Tool 09812-00010 Door Hinge Set Bolt Wrench 2001 AVALON (RM808U) Author
: Date
: 107 PP-59 PREPARATION - BODY PP0AZ-04 EQUIPMENT Clip remover Torque wrench Hog ring pliers Tape To avoid surface damage Adhesive tape To avoid surface damage Double-stick tape Adhesive Cleaner Shop rag Knife Sealer gun Brush Putty spatula Glass plate or similar object Wooden block or similar object Heat light Piano wire Tire Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Seat belt pretensioner Tire with disk wheel Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Seat belt pretensioner Vinyl bag Seat belt pretensioner 2001 AVALON (RM808U) Author
: Date
: 109 PP-60 PREPARATION - BODY PP0B0-01 LUBRICANT Item MP grease Capacity Classification - - 2001 AVALON (RM808U) Author
: Date
: 110 PP-58 PREPARATION - BODY PP2DM-01 RECOMMENDED TOOLS 09050-20010 Air Riveter. (09050-02010) Dust Cap. (09050-02020) Nose Piece No.1. 2001 AVALON (RM808U) Author
: Date
: 108 PP-61 PREPARATION - BODY PP2DL-01 SSM (Special Service Materials) 08833-00070 Adhesive 1324, THREE BOND 1324 or equivalent 08850-00801 Windshield Glass Adhesive Set or equivalent 2001 AVALON (RM808U) Author
: Date
: 111 PP-57 PREPARATION - BODY BODY PP0UX-01 SST (Special Service Tools) 09082-00700 SRS Airbag Deployment Tool 09082-00740 Airbag Deployment Wire Sub-harness No.2 09804-24010 Luggage Compartment Door Torsion Bar Tool 09812-00010 Door Hinge Set Bolt Wrench 2001 AVALON (RM808U) Author
: Date
: 107 PP-40 PREPARATION - BRAKE PP0UB-03 EQUIPMENT Torque wrench Micrometer Brake disc Dial indicator Brake disc Brake drum gauge Brake disc 2001 AVALON (RM808U) Author
: Date
: 90 PP-41 PREPARATION - BRAKE PP0UC-02 LUBRICANT Item Brake fluid Capacity Classification - SAE J1703 or FMVSS No. 116 DOT3 2001 AVALON (RM808U) Author
: Date
: 91 PP-39 PREPARATION - BRAKE PP2DR-01 RECOMMENDED TOOLS 09042-00030 Torx Socket T20 . 09082-00040 TOYOTA Electrical Tester. 09905-00013 Snap Ring Pliers . 09017-12301 Deep Socket Wrench 30 mm . 2001 AVALON (RM808U) Author
: Date
: 89 PP-38 PREPARATION - BRAKE BRAKE PP2DQ-01 SST (Special Service Tools) 09023-00100 Union Nut Wrench 10 mm 09737-0001 1 Brake Booster Push Rod Gauge 09737-00020 Brake Booster Push Rod Wrench 09751-3601 1 Brake Line Union Nut 10 x 12 mm Wrench 09843-18020 Diagnosis Check Wire 09992-00242 Turbocharger Pressure Gauge 09992-00350 Brake Reservoir Pressure Adapter 2001 AVALON (RM808U) Author
: Date
: 88 PP-27 PREPARATION - CHARGING PP0S6-01 EQUIPMENT Ammeter (A) Battery specific gravity gauge Except maintenance free battery Belt tension gauge OBDII scan tool Torque wrench Vernier calipers Rotor (Slip ring) 2001 AVALON (RM808U) Author
: Date
: 77 PP-26 PREPARATION - CHARGING PP0S5-01 RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester. 2001 AVALON (RM808U) Author
: Date
: 76 PP-25 PREPARATION - CHARGING CHARGING PP0S4-02 SST (Special Service Tools) 09285-76010 Injection Pump Camshaft Bearing Cone Replacer Rotor rear bearing cover 09286-4601 1 Injection Pump Spline Shaft Puller Rectifier end frame 09950-60010 Replacer Set (09951-00520) Replacer 52 Rotor front bearing 09820-00021 Alternator Rear Bearing Puller 09820-00030 Alternator Rear Bearing Replacer 09820-63010 Alternator Pulley Set Nut Wrench Set Rotor rear bearing 2001 AVALON (RM808U) Author
: Date
: 75 PP-15 PREPARATION - COOLING PP0RT-02 COOLANT Item Engine coolant Capacity Classification 9.0 liters (9.5 US qts, 7.9 lmp. qts) Toyota Long Life Coolant” or equivalent 2001 AVALON (RM808U) Author
: Date
: 65 PP-14 PREPARATION - COOLING PP0RS-01 EQUIPMENT Heater ECT switch Radiator cap tester Thermometer ECT switch Torque wrench 2001 AVALON (RM808U) Author
: Date
: 64 PP-13 PREPARATION - COOLING PP0RR-03 RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester. 2001 AVALON (RM808U) Author
: Date
: 63 PP-12 PREPARATION - COOLING COOLING PP0JZ-06 SST (Special Service Tools) 09230-01010 Radiator Service Tool Set 09231-14010 Punch 2001 AVALON (RM808U) Author
: Date
: 62 PP-7 PREPARATION - EMISSION CONTROL EMISSION CONTROL PP0RL-02 EQUIPMENT Hose clipper MITYVAC (Hand-held vacuum pump) Pressure gauge Torque wrench Vacuum gauge 2001 AVALON (RM808U) Author
: Date
: 57 PP-6 PREPARATION - ENGINE MECHANICAL PP0RJ-01 EQUIPMENT Caliper gauge CO/HC meter Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune-up tester Heater Magnetic finger Micrometer OBDII scan tool Piston ring compressor Piston ring expander Plastigage Precision straight edge Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter Vernier calipers 2001 AVALON (RM808U) Author
: Date
: 56 PP-5 PREPARATION - ENGINE MECHANICAL PP0RI-03 RECOMMENDED TOOLS 09040-0001 1 Hexagon Wrench Set . 09090-04020 Engine Sling Device 09200-00010 Engine Adjust Kit . 09258-00030 Hose Plug Set . 09904-00010 Expander Set . For suspending engine Plug for the vacuum hose, fuel hose etc. 2001 AVALON (RM808U) Author
: Date
: 55 PP-2 PREPARATION - ENGINE MECHANICAL ENGINE MECHANICAL PP0RH-04 SST (Special Service Tools) 09201-01055 Valve Guide Bushing Remover & Re placer 5.5 09201-41020 Valve Stem Oil Seal Replacer 09202-70020 Valve Spring Compressor (09202-00010) 09213-54015 (91651-60855) Attachment Crankshaft Pulley Holding Tool Bolt 09222-30010 Connecting Rod Bushing Remover & Replacer 09223-00010 Cover & Seal Replacer Crankshaft front oil seal 09223-15030 Oil Seal & Bearing Replacer Crankshaft rear oil seal 09248-55040 Valve Clearance Adjust Tool Set (09248-05410) Valve Lifter Press (09248-05420) Valve Lifter Stopper 2001 AVALON (RM808U) Author
: Date
: 52 PP-3 PREPARATION - ENGINE MECHANICAL 09249-63010 Torque Wrench Adaptor RH camshaft timing pulley 09330-00021 Companion Flange Holding Tool Crankshaft pulley 09608-03071 Replacer Spark plug tube gasket 09816-30010 Oil Pressure Switch Socket Knock sensor 09843-18020 Diagnosis Check Wire 09950-50012 Puller C Set (09951-05010) Hanger 150 Crankshaft pulley Crankshaft timing pulley (09952-05010) Slide Arm Crankshaft pulley Crankshaft timing pulley (09953-05010) Center Bolt 100 Crankshaft pulley Crankshaft timing pulley (09953-05020) Center Bolt 150 Crankshaft pulley Crankshaft timing pulley (09954-05010) Claw No.1 Crankshaft timing pulley (09954-05020) Claw No.2 Crankshaft pulley 09950-70010 Handle Set 2001 AVALON (RM808U) Author
: Date
: 53 PP-4 PREPARATION (09951-07100) 09960-10010 - ENGINE MECHANICAL Handle 100 Valve guide bushing Crankshaft rear oil seal Variable Pin Wrench Set (09962-01000) Variable Pin Wrench Arm Assy Camshaft timing pulley Camshaft sub-gear (09963-01000) Pin 10 Camshaft timing pulley (09963-00500) Pin 5 Camshaft sub-gear 2001 AVALON (RM808U) Author
: Date
: 54 PP-21 PREPARATION - IGNITION PP0S0-01 EQUIPMENT Megger insulation resistance meter Spark plug Spark plug cleaner 2001 AVALON (RM808U) Author
: Date
: 71 PP-20 PREPARATION - IGNITION IGNITION PP0RZ-01 RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester. 09200-00010 Engine Adjust Kit . 2001 AVALON (RM808U) Author
: Date
: 70 PP-18 PREPARATION - LUBRICATION PP0RW-01 EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench 2001 AVALON (RM808U) Author
: Date
: 68 PP-19 PREPARATION - LUBRICATION PP0RX-01 LUBRICANT Item Engine oil Dry fill Drain and refill w/ Oil filter change w/o Oil filter change Capacity Classification 5.2 liters (5.5 US qts, 4.6 lmp. qts) 4.7 liters (5.0 US qts, 4.1 lmp. qts) 4.5 liters (4.8 US qts, 4.0 lmp. qts) API grade SH Energy-Conserving II or SJ, Energy-Conserving or ILSAC multigrade engine oil. SAE 5W-30 is the best choice for your vehicle, for good fuel economy and good starting in cold weather. 2001 AVALON (RM808U) Author
: Date
: 69 PP-17 PREPARATION - LUBRICATION PP0RV-02 RECOMMENDED TOOLS 09200-00010 Engine Adjust Kit . 2001 AVALON (RM808U) Author
: Date
: 67 PP-16 PREPARATION - LUBRICATION LUBRICATION PP0RU-02 SST (Special Service Tools) 09032-00100 Oil Pan Seal Cutter No.2 oil pan 09228-07501 Oil Filter Wrench 09816-30010 Oil Pressure Switch Socket 2001 AVALON (RM808U) Author
: Date
: 66 PP-1 PREPARATION - MAINTENANCE MAINTENANCE PP0RG-01 EQUIPMENT Mirror Brake hose Torque wrench 2001 AVALON (RM808U) Author
: Date
: 51 PP-1 PREPARATION - MAINTENANCE MAINTENANCE PP0RG-01 EQUIPMENT Mirror Brake hose Torque wrench 2001 AVALON (RM808U) Author
: Date
: 51 PP-52 PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM PP0MS-01 EQUIPMENT Torque wrench Bolt: Length: 35 mm (1.38 in.) Pitch: 1.0 mm (0.039 in.) Diam.: 6.0 mm (0.236 in.) Airbag disposal Tire Airbag disposal Width: 185 mm (7.28 in.) Inner diam.: 360mm (14.17 in.) Tire with disc wheel Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.) Airbag disposal Vinyl bag Airbag disposal 2001 AVALON (RM808U) Author
: Date
: 102 PP-51 PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM PP0V2-01 RECOMMENDED TOOLS 09042-00020 Torx Socket T40 . 09082-00050 TOYOTA Electrical Tester Set. 09082-00040 TOYOTA Electrical Tester. (09083-00150) Airbag sensor assembly Test Lead Set Seat belt pretensioner connector 2001 AVALON (RM808U) Author
: Date
: 101 PP-50 PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM PP0MQ-03 SST (Special Service Tools) 09082-00700 SRS Airbag Deployment Tool 09082-00750 Airbag Deployment Wire Sub-harness No.3 09082-00760 Airbag Deployment Wire Sub-harness No.4 09843-18020 Diagnosis Check Wire 2001 AVALON (RM808U) Author
: Date
: 100 PP-36 PREPARATION - SUSPENSION AND AXLE PP08X-02 EQUIPMENT Dial indicator with magnetic base Drill Torque wrench 2001 AVALON (RM808U) Author
: Date
: 86 PP-37 PREPARATION - SUSPENSION AND AXLE PP08Y-04 LUBRICANT Item Capacity Outboard joint grease Color=Gray Inboard joint grease Color=Yellow ocher 105 - 125 g (3.7 - 4.4 oz.) 170 - 190 g (6.0 - 6.7 oz.) Application 2001 AVALON (RM808U) Author
: Date
: 87 PP-35 PREPARATION - SUSPENSION AND AXLE PP08W-02 RECOMMENDED TOOLS 09025-00010 Torque Wrench (30 kgf-cm) 09042-00010 Torx Socket T30 . 09905-00012 Snap Ring No.1 Expander . 09905-00013 Snap Ring Pliers . 2001 AVALON (RM808U) Author
: Date
: 85 PP-32 PREPARATION - SUSPENSION AND AXLE SUSPENSION AND AXLE PP2EQ-01 SST (Special Service Tools) 09238-47012 Water Pump Bearing Remover & Replacer Front suspension 09240-00020 Wire Gauge Set Front drive shaft 09309-36010 Transmission Rear Bearing Replacer Front drive shaft 09310-35010 Countershaft Bearing Replacer Front axle 09316-2001 1 Transfer Bearing Replacer Front drive shaft 09316-6001 1 Transmission & Transfer Bearing Replacer Front axle Front suspension (09316-0001 1) Replacer Pipe (09316-00041) Replacer ”C” 09506-35010 Differential Drive Pinion Rear Bearing Replacer Front drive shaft 09520-00031 Rear Axle Shaft Puller Front axle 09521-24010 Drive Shaft Boot Clamping Tool Front drive shaft 09527-1701 1 Rear Axle Shaft Bearing Remover Front axle 2001 AVALON (RM808U) Author
: Date
: 82 PP-33 PREPARATION 09608-16042 - SUSPENSION AND AXLE Front Hub Bearing Adjusting Tool (09608-02021) Bolt & Nut (09608-02041) Retainer Front drive shaft 09608-32010 Steering Knuckle Oil Seal Replacer Front axle Front suspension 09610-20012 Pitman Arm Puller Front axle 09628-1001 1 Ball Joint Puller Front axle Rear axle 09628-6201 1 Ball Joint Puller Front axle Front suspension 09649-17010 Steering Knuckle Tool Front suspension 09710-04081 Base Front suspension 09727-30021 Coil Spring Compressor Front suspension Rear suspension 09729-22031 Front Spring Upper Seat Holder Front suspension 09950-00020 Bearing Remover Front axle Front drive shaft 09950-60010 Replacer Set Front axle 2001 AVALON (RM808U) Author
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: 83 PP-34 PREPARATION - (09951-00400) Replacer 40 09950-70010 Handle Set (09951-07100) Handle 100 SUSPENSION AND AXLE Front axle 2001 AVALON (RM808U) Author
: Date
: 84 PP-1 1 PREPARATION - SFI PP0RP-02 COOLANT Item Engine coolant Capacity Classification 9.0 liters (9.5 US qts, 7.9 lmp. qts) ”TOYOTA Long Life Coolant” or equivalent 2001 AVALON (RM808U) Author
: Date
: 61 PP-10 PREPARATION - SFI PP0RO-01 EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector OBDII scan tool Soft brush Throttle body Sound scope Injector Torque wrench Vacuum gauge 2001 AVALON (RM808U) Author
: Date
: 60 PP-9 PREPARATION - SFI PP0RN-03 RECOMMENDED TOOLS 09040-0001 1 Hexagon Wrench Set . 09082-00040 TOYOTA Electrical Tester. 09200-00010 Engine Adjust Kit . 09258-00030 Hose Plug Set . Plug for the vacuum hose, fuel hose etc. 2001 AVALON (RM808U) Author
: Date
: 59 PP-8 PREPARATION - SFI SFI PP0RM-04 SST (Special Service Tools) 09023-12700 Union Nut Wrench 17mm 09268-41047 Injection Measuring Tool Set (09268-41300) Clamp Injector 09268-45014 EFI Fuel Pressure Gauge 09817-1601 1 Back-up Light Switch Tool 09842-30070 Wiring ”F” EFI Inspection 09843-18020 Diagnosis Check Wire Knock sensor 2001 AVALON (RM808U) Author
: Date
: 58 PP-47 PREPARATION - STEERING PP0V6-02 EQUIPMENT Belt tension gauge Drive belt Caliper gauge PS vane pump Vernier calipers PS vane pump Dial indicator PS gear Feeler gauge PS vane pump Micrometer PS vane pump Torque wrench 2001 AVALON (RM808U) Author
: Date
: 97 PP-48 PREPARATION - STEERING PP0V7-02 LUBRICANT Item Capacity Classification Power steering fluid Total 0.8 liters (0.8 US qts, 0.7 lmp.qts) ATF DEXRON® II or III 2001 AVALON (RM808U) Author
: Date
: 98 PP-46 PREPARATION - STEERING PP0V5-02 RECOMMENDED TOOLS 09025-00010 Torque Wrench (30 kgf-cm) PS vane pump PS gear 09042-00010 Torx Socket T30 . Tilt steering column 09904-00010 Expander Set . 09905-00012 Snap Ring No.1 Expander . 09905-00013 Snap Ring Pliers . 2001 AVALON (RM808U) Author
: Date
: 96 PP-49 PREPARATION - STEERING PP0V8-01 SSM (Special Service Materials) 08833-00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent PS gear 2001 AVALON (RM808U) Author
: Date
: 99 PP-42 PREPARATION - STEERING STEERING PP0V4-05 SST (Special Service Tools) 09023-38200 Union Nut Wrench 12mm PS gear 09023-38400 Union Nut Wrench 14mm PS vane pump PS gear 09249-63010 Torque Wrench Adaptor PS vane pump 09521-24010 Drive Shaft Boot Clamping Tool PS gear 09527-2001 1 Rear Axle Shaft Bearing Remover PS gear 09612-00012 Rack & Pinion Steering Rack Housing Stand PS gear 09612-07010 Main Shaft Retaining Ring Remover & Replacer Tilt steering column 09612-2201 1 Tilt Handle Bearing Replacer PS gear 09612-24014 Steering Gear Housing Overhaul Tool Set PS gear (09613-2201 1) Steering Rack Shaft Bushing Puller 09616-0001 1 Steering Worm Bearing Adjusting Socket PS gear 09631-10021 Rack Stopper Wrench PS gear 2001 AVALON (RM808U) Author
: Date
: 92 PP-43 PREPARATION - STEERING 09631-12071 Steering Rack Oil Seal Test Tool PS gear 09631-20081 Seal Ring Tool PS gear 09631-33010 Steering Rack Cover ”I” PS gear 09640-10010 Power Steering Pressure Gauge Set Power steering fluid (09641-01010) Gauge Assy (09641-01030) Attachment B (09641-01060) Attachment E 09910-00015 Puller Set (09911-0001 1) Puller Clamp (09912-00010) Puller Slide Hammer Tilt steering column 09922-10010 Variable Open Wrench PS gear 09950-50012 Puller C Set Tilt steering column (09951-05010) Hanger 150 2001 AVALON (RM808U) Author
: Date
: 93 PP-44 PREPARATION - STEERING (09952-05010) Slide Arm (09953-05020) Center Bolt 150 (09954-05020) Claw No.2 09950-60010 Replacer Set (09951-00180) Replacer 18 PS gear (09951-00240) Replacer 24 PS gear (09951-00250) Replacer 25 PS gear (09951-00260) Replacer 26 PS gear (09951-00290) Replacer 29 PS gear (09951-00310) Replacer 31 PS gear (09951-00320) Replacer 32 PS gear (09951-00330) Replacer 33 PS vane pump (09951-00340) Replacer 34 PS gear 2001 AVALON (RM808U) Author
: Date
: 94 PP-45 PREPARATION - STEERING (09951-00400) Replacer 40 PS gear (09951-00430) Replacer 43 PS gear (09952-06010) Adapter PS gear 09950-70010 Handle Set (09951-07100) Handle 100 PS vane pump (09951-07200) Handle 200 PS gear (09951-07360) Handle 360 PS gear Variable Pin Wrench Set PS vane pump 09960-10010 (09962-01000) Variable Pin Wrench Arm Assy (09963-01000) Pin 10 2001 AVALON (RM808U) Author
: Date
: 95 PP-24 PREPARATION - STARTING PP0S3-01 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V-block Commutator Vernier calipers Commutator, Brush 2001 AVALON (RM808U) Author
: Date
: 74 PP-23 PREPARATION - STARTING PP0S2-01 RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester. 2001 AVALON (RM808U) Author
: Date
: 73 PP-22 PREPARATION - STARTING STARTING PP0S1-01 SST (Special Service Tools) 09286-4601 1 Injection Pump Spline Shaft Puller Armature bearing 09810-38140 Starter Magnet Switch Nut Wrench 14 Terminal nut 09820-00030 Alternator Rear Bearing Replacer Armature front bearing 2001 AVALON (RM808U) Author
: Date
: 72 SS-39 SERVICE SPECIFICATIONS - AIR CONDITIONING AIR CONDITIONING SS05V-08 SERVICE DATA 600 ± 50 g (21.16 ± 1.76 oz.) Refrigerant charge volume Drive belt tension New belt 165 ± 22lbf Used belt 88 ± 22 lbf Idle-up speed Magnetic clutch clearance Magnetic clutch not engaged 700 ± 50 rpm Magnetic clutch engaged 700 ± 50 rpm 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) 2001 AVALON (RM808U) Author
: Date
: 155 SS-40 SERVICE SPECIFICATIONS - AIR CONDITIONING SS05W-07 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 10 100 7 Compressor x Suction hose 10 100 7 Condenser x Disaharge hose 5.4 55 48 in.·lbf Condenser x Liquid tube 5.4 55 48 in.·lbf Expansion valve x Evaporator 5.4 55 48in.·lbf Compressor x Engine 25 250 18 Compressor x Compressor bracket 25 250 18 Drive belt adjusting bar bracket x Compressor 25 250 18 Pivot bolt 56 560 41 Adjusting lock bolt 18 185 13 Pressure switch x Liquied tube 10 100 7 Pressure plate x Compressor 13.2 135 9 Compressor x Discharge hose 2001 AVALON (RM808U) Author
: Date
: 156 SS-24 SERVICE SPECIFICATIONS - AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE SS0BL-04 SERVICE DATA Line pressure (wheel locked) Engine idling D position R position at stall (Throttle valve fully opened) D position R position 1,138 - 1,236 kPa (11.6 - 12.6 kgf/cm2, 165 - 179 psi) 1,716 - 1,854 kPa (17.5 - 18.9 kgf/cm2, 249 - 269 psi) 2,325 − 2,775 rpm Engine stall revolution Time lag 401 - 461 kPa (4.1 - 4.7 kgf/cm2, 58 - 66 psi) 804 - 882 kPa (8.2 - 9.0 kgf/cm2, 117 - 128 psi) N → D position N → R position Less than 1.2 seconds Less than 1.5 seconds Engine idle speed (A/C OFF) N position Throttle cable adjustment (Throttle valve fully opened) Drive plate runout Torque converter clutch runout Torque converter clutch installation distance Between boot and face and inner cable stopper 0 - 1 mm (0 - 0.04 in.) Max. Max. Lock-up point (Throttle valve opening 5%) 3rd gear (O/D main switch OFF) Lock-up ON Lock-up OFF O/D gear Lock-up ON Lock-up OFF Shift schedule D position (Throttle valve fully opened) (Throttle valve fully closed) 2 position (Throttle valve fully opened) L position (Throttle valve fully opened) 700 ± 50 rpm 1→2 2→3 3 → O/D O/D → 3 3→2 2→1 3 → O/D O/D → 3 0.3 mm (0.0118 in.) 0.20 mm (0.0079 in.) More than 13.7 mm (0.539 in.) 65 - 70 km/h (40 - 43 mph) 57 - 62 km/h (35 - 39 mph) 65 - 70 km/h (40 - 43 mph) 57 - 62 km/h (35 - 39 mph) 65 - 71 km/h (40 - 44 mph) 122 - 131 km/h (76 - 81 mph) 188 - 198 km/h (117 - 123 mph) 181 - 191 km/h (112 - 119 mph) 113 - 122 km/h (70 - 76 mph) 54 - 59 km/h (34 - 37 mph) 38 - 43 km/h (24 - 27 mph) 22 - 27 km/h (14 - 17 mph) 1→2 3→2 2→1 65 - 71 km/h (40 - 44 mph) 132 - 141 km/h (82 - 88 mph) 54 - 59 km/h (34 - 37 mph) 3→2 2→1 115 - 124 km/h (71 - 77 mph) 59 - 64 km/h (37 - 40 mph) 2001 AVALON (RM808U) Author
: Date
: 140 SS-25 SERVICE SPECIFICATIONS - AUTOMATIC TRANSAXLE SS0BM-04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front side engine mounting insulator x Front frame assembly 80 820 59 Rear engine mounting insulator x Front frame assembly 66 670 48 LH transaxle mounting insulator x Front frame assembly 80 820 59 Engine mounting insulator x Front frame assembly 48 490 35 66 48 670 490 48 35 Torque converter clutch x Drive plate 41 420 30 Valve body x Transaxle case 11 110 8 10 11 100 110 7 8 Oil pan x Transaxle case 7.8 80 69 in.·lbf Oil pan drain plug 49 500 36 5.4 6.9 55 70 48 in.·lbf 61 in.·lbf Connector clamp x Valve body 6.6 67 58 in.·lbf Manual valve body x Transaxle case 11 110 8 Line pressure test plug x Transaxle case 7.5 80 69 in.·lbf Detent spring x Manual valve body 11 110 8 Oil pipe bracket x Transaxle case 10 100 7 Steering gear housing x Front frame assembly 181 1,850 134 Stabilizer bar bracket x Front frame assembly 19 195 14 Stabilizer bar link x Stabilizer bar 39 400 29 Lower suspension arm x Lower ball joint 127 1,300 94 Tie rod end x Steering knuckle 49 500 36 Drive shaft lock nut 294 3,000 217 Transaxle x Engine 17 mm bolt 14 mm bolt Oil strainer x Valve body (See page AX-35 ) Bolt A Bolt B Park/Neutral position switch x Transaxle case Bolt Nut Direct clutch speed sensor x Transaxle case 11 110 8 Exhaust manifold bracket x Transaxle case 20 200 15 Exhaust manifold plate 20 200 15 181 32 36 1,850 330 370 134 24 27 Front exhaust pipe x Exhaust center pipe 43 440 32 Exhaust manifold x Front exhaust pipe 62 630 46 Exhaust front pipe support stay x Exhaust front pipe support bracket 33 330 24 Starter x Torque converter clutch housing 39 400 29 Transaxle control shaft lever x Park/neutral position switch 15 150 11 Throttle cable adjusting nut 15 150 11 Drive plate x Crankshaft 83 850 61 Shift control cable x Transaxle control shaft lever 15 150 11 Throttle cable retaining plate set bolt 5.4 55 48 in.·lbf Shift solenoid valve No. 1, No. 2, SL, SLN x Valve body 6.6 67 58 in.·lbf Front wheel nut 103 1,050 76 Exhaust front pipe support bracket x Body 21 210 15 PS reservoir pipe x Front frame 10 100 7 Front frame assembly x Body 19 mm bolt 14 mm bolt Nut 2001 AVALON (RM808U) Author
: Date
: 141 SS-26 SERVICE SPECIFICATIONS - AUTOMATIC TRANSAXLE Engine hood x Hood hinge 26 265 19 Engine hanger x Engine 20 200 14 Cruise control actuator x Body 13 130 9 RH drive shaft x Rear side engine mounting insulator 32 330 24 Hole cover x Torque converter clutch housing 41 420 30 Floor shift assembly x Body 12 120 9 2001 AVALON (RM808U) Author
: Date
: 142 SS-35 SERVICE SPECIFICATIONS - BODY ELECTRICAL BODY ELECTRICAL SS05U-04 SERVICE DATA AUTOMATIC LIGHT CONTROL SENSOR (Connector disconnected) 1 - Ground Ignition switch LOCK or ACC) No voltage 1 - Ground (Ignition switch ON) Battery positive voltage 4 - Ground Ignition switch LOCK or ACC) No voltage 4 - Ground (Ignition switch ON) 5.2 - 9.0V SPEEDOMETER (ON-VEHICLE) USA: Standard indication (mph) Allowable range (mph) 20 18 - 24 40 38 - 44 60 56 - 66 80 78 - 88 100 98 - 110 120 118 - 132 Standard indication (km/h) Allowable range (km/h) 20 17 - 24 40 38 - 46 60 57.5 - 67 80 77 - 88 CANADA: 100 96 - 109 120 115 - 130 140 134 - 151.5 160 153 - 173 TACHOMETER (ON-VEHICLE)/ DC 13.5 V 25 °C at (77 °F) Standard indication Allowable range 700 630 - 770 1,000 900 - 1,100 2,000 1,850 - 2,150 3,000 2,800 - 3,200 4,000 3,800 - 4,200 5,000 4,800 - 5,200 6,000 5,750 - 6,250 7,000 6,700 - 7,300 A-B Approx. 250 Ω C-D Approx. 250 Ω F: Approx. 91.1 (1.36) ± 3.0 (0.12) Approx. 2.0±1.0 1/2: Approx. 34.1 (2.06) ± 3.0 (0.12) Approx. 26.1±3.0 E: Approx. 30.8 (5.31) ± 3.0 (0.12) Approx. 48.7±1.0 FUEL RECEIVER GAUGE FUEL SENDER GAUGE Float position mm (in.) Resistance (Ω) 2001 AVALON (RM808U) Author
: Date
: 151 SS-36 SERVICE SPECIFICATIONS - BODY ELECTRICAL ENGINE COOLANT TEMPERATURE SENDER GAUGE (Resistance) Temperature °C (°F) Resistance (Ω) A-B Approx. 250 Ω C-D Approx. 250 Ω LIGHT FAILURE RELAY (Wire Harness Side) 3 - Ground (Light control switch OFF) No voltage 3 - Ground (Light control switch TAIL or HEAD) Battery positive voltage 4 - Ground (Ignition switch LOCK or ACC) No voltage 4 - Ground (Ignition switch ON) Battery positive voltage 7 - Ground (Stop light switch OFF) No voltage 7 - Ground (Stop light switch ON) Battery positive voltage 8 - Ground (Ignition switch LOCK or ACC) No voltage 8 - Ground (Ignition switch ON) Battery positive voltage SLIDING ROOF CONTROL RELAY AND SWITCH (Wire Harness Side) 8 - Ground (Ignition switch LOCK or ACC) * No voltage 8 - Ground (Ignition switch ON) Battery positive voltage 5 - Ground (Constant) Battery positive voltage *: Exceptions: For 60 seconds after the ignition switch ON→OFF (ACC) or until driver or passenger door is opened after the ignition switch ON→OFF (ACC). 2001 AVALON (RM808U) Author
: Date
: 152 SS-37 SERVICE SPECIFICATIONS - BODY BODY SS0G3-06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf FRONT BUMPER - - - Front bumper upper reinforcement x Body 11 115 8 Front bumper upper reinforcement x Side support 5.4 55 48 in.·lbf Side support x Body 11 115 8 Front bumper reinforcement x Body 13 130 9 Front bumper cover x Body 5.4 55 48 in.·lbf Fog light assembly x Front bumper cover 8.3 85 74 in.·lbf REAR BUMPER - - - Rear bumper arm mounting bracket x Body 33 340 25 Rear bumper reinforcement x Rear bumper arm mounting bracket 33 340 25 Rear bumper cover x Body 5.4 55 48 in.·lbf - - - Hood x Hood hinge 13 130 9 Hood lock x Body 6.9 70 61 in.·lbf HOOD SUPPORT - - - Hood support x Hood 17 175 13 Hood support x Body 17 175 13 FRONT DOOR - - - Outside rear view mirror x Door panel 7.8 80 69 in.·lbf Door check x Body 25 260 19 Door glass x Window regulator assembly 5.4 55 48 in.·lbf Window regulator assembly x Door panel 5.4 55 48 in.·lbf HOOD Door lock x Door panel Bolt: 4.9 50 43 in.·lbf Door lock x Door panel Nut: 5.4 55 48 in.·lbf Outside handle x Door panel 5.4 55 48 in.·lbf Outside handle x Key cylinder 5.4 55 48 in.·lbf Door hinge x Body 25 260 19 Door hinge x Door panel 25 260 19 REAR DOOR - - - Door check x Body 25 260 19 Door glass x Window regulator assembly 5.4 55 48 in.·lbf Window regulator assembly x Door panel 5.4 55 48 in.·lbf Door lock x Door panel 5.4 55 48 in.·lbf Outside handle x Door panel 5.4 55 48 in.·lbf Door hinge x Body 25 260 19 Door hinge x Door panel 25 260 19 LUGGAGE COMPARTMENT DOOR AND HINGE - - - Luggage compartment door x Door hinge arm 7.8 80 69 in.·lbf Door lock x Luggage compartment door 5.4 55 48 in.·lbf Door lock striker x Body 5.4 55 48 in.·lbf 2001 AVALON (RM808U) Author
: Date
: 153 SS-38 SERVICE SPECIFICATIONS - BODY FRONT WIPER AND WASHER - - - Wiper arm x Wiper motor and link assembly 24 248 18 Wiper motor and link assembly x Body 7.0 71 62 in.·lbf Wiper motor x Wiper link 7.5 76 66 in.·lbf SLIDING ROOF - - - Sliding roof glass assembly x Drive cable 4.0 41 35 in.·lbf Drive gear x Body 5.4 55 48 in.·lbf Sliding roof bracket x Body 5.4 55 48 in.·lbf Sliding roof bracket x Sliding roof assembly 5.4 55 48 in.·lbf Sliding roof assembly x Body 5.4 55 48 in.·lbf INSTRUMENT PANEL - - - Front passenger airbag assembly x Instrument panel reinforcement 20 204 15 Steering wheel set nut 50 510 37 FRONT SEAT - - - Front seat assembly x Body 37 375 27 Front seat cushion x Front seat adjuster 18 185 13 Front seatback x Front seat adjuster 43 440 32 Front seatback x Center armrest 41 420 30 REAR SEAT - - - 5.9 60 52 in.·lbf Rear seatback x Center armrest Rear seatback x Body Center 41 420 30 Rear seatback x Body LH, RH Side 18 185 13 SEAT BELT - - - Front seat outer belt shoulder anchor x Adjuster anchor 41 420 30 Front seat outer belt floor anchor x Body 41 420 30 Front seat outer belt retractor x Body Upper bolt 7.5 76 66 in.·lbf Front seat outer belt retractor x Body Lower bolt 41 420 30 Front seat adjustable anchor x Body 41 420 30 Front seat inner belt x Seat adjuster 41 420 30 Front seat center belt x Seat adjuster 41 420 30 Rear seat outer belt floor anchor x Body 41 420 30 Rear seat outer belt retractor x Body 41 420 30 2001 AVALON (RM808U) Author
: Date
: 154 SS-30 SERVICE SPECIFICATIONS - BRAKE BRAKE SS0FS-03 SERVICE DATA Brake pedal height (from asphalt sheet) 153.3 - 163.3 mm (6.035 - 6.429 in.) Brake pedal freeplay 1 - 6 mm (0.04 - 0.24 in.) Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) More than 75 mm (3.0 in.) Brake booster push rod to piston clearance (w/ SST) 0 mm (0 in.) Front brake pad thickness STD 11.0 mm (0.433 in.) Minimum 1.0 mm (0.039 in.) Front brake disc thickness STD 28.0 mm (1.102 in.) Minimum 26.0 mm (1.024 in.) Front brake disc runout Maximum 0.05 mm (0.0020 in.) Rear brake pad thickness STD 10.0 mm (0.394 in.) Minimum 1.0 mm (0.039 in.) Rear brake disc thickness STD 12.0 mm (0.472 in.) Minimum 10.5 mm (0.413 in.) Rear brake disc runout Maximum 0.15 mm (0.0059 in.) Rear brake disc inside diameter STD 170 mm (6.69 in.) Maximum 171 mm (6.73 in.) Parking brake shoe lining thickness STD 2.0 mm (0.079 in.) Minimum 1.0 mm (0.039 in.) Parking brake pedal travel at 294 N (30 kgf, 66 lbf) 3 - 6 clicks Parking brake clearance between rear shoe and lever Less than 0.35 mm (0.0138 in.) Parking brake adjusting shim thickness 0.3 mm (0.012 in.) 0.6 mm (0.024 in.) 0.9 mm (0.035 in.) 2001 AVALON (RM808U) Author
: Date
: 146 SS-31 SERVICE SPECIFICATIONS - BRAKE SS0FT-05 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 10 100 7 Master cylinder x Reservoir 1.7 17.5 15.2 in.·lbf Master cylinder x Brake booster 13 130 9 15 20 155 200 11 15 Brake booster clevis lock nut 25 260 19 Brake booster x Pedal bracket 13 130 9 Brake pedal x Pedal bracket 39 400 29 Front brake caliper installation bolt 34 350 25 Bleeder plug 8.3 85 74 in.·lbf Front brake torque plate x Steering knuckle 107 1,090 79 Front brake caliper x Flexible hose 29 300 22 Flexible hose x Shock absorber bracket 29 300 22 Rear brake caliper installation bolt 34 350 25 Rear brake caliper x Flexible hose 29 300 22 Rear brake torque plate x Rear axle carrier 47 475 34 Parking brake pedal bracket x Body 61 620 45 ABS actuator x ABS actuator bracket 13 130 9 ABS actuator x ECU 3.0 31 27 in.·lbf ABS & VSC actuator x Actuator bracket 13 130 9 ABS (& VSC) actuator bracket x Body 19 195 14 Front speed sensor installation bolt 8.0 82 71 in.·lbf Rear speed sensor installation bolt 8.0 82 71 in.·lbf ABS speed sensor harness clamp bolt 5.4 55 48 in.·lbf 8.0 13 82 130 71 in.·lbf 9 Precharge pump brackt x Body 19 195 14 Precharge pump x Master cylinder pressure sensor 81 830 60 Master cylinder x Piston stopper bolt Brake line union nut Precharge pump x Precharge pump bracket w/o VSC 10 mm 12 mm Bolt Nut 2001 AVALON (RM808U) Author
: Date
: 147 SS-22 SERVICE SPECIFICATIONS - CHARGING CHARGING SS0ET-02 SERVICE DATA Battery Drive belt Generator Specific gravity (Except maintenance-free battery) Voltage (Maintenance-free battery) 1.25 - 1.29 at 20°C (68°F) 12.5 - 12.9 V Tension New belt Used belt Rated output Rotor coil resistance Slip ring diameter Brush exposed length Voltage regulator at 20°C (68°F) Regulating voltage 175 ± 5 lbf 115 ± 20 lbf at 20°C (68°F) STD Minimum STD Minimum 12 V 100 A 2.1 - 2.5 Ω 14.2 - 14.4 mm (0.559 - 0.567 in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) 13.2 - 14.8 V 2001 AVALON (RM808U) Author
: Date
: 138 SS-23 SERVICE SPECIFICATIONS - CHARGING SS0EU-02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Bearing retainer x Drive end frame 3.0 31 27 in.·lbf Rectifier end frame x Drive end frame 4.5 46 40 in.·lbf Cord clamp x Rectifier end frame 5.4 55 48 in.·lbf 110.5 1,125 81 Rectifier holder x Coil lead on rectifier end frame 2.9 30 26 in.·lbf Voltage regulator and brush holder x Rectifier end frame 2.0 20 18 in.·lbf Plate terminal x Rectifier holder 3.9 39 35 in.·lbf Rear end cover x Rectifier holder 4.4 45 39 in.·lbf Terminal insulator x Rectifier holder 4.1 42 36 in.·lbf Generator x Generator bracket 56 570 41 Generator x Adjusting bar 18 180 13 Generator wire x Generator 9.8 100 86 in.·lbf Generator pulley x Rotor 2001 AVALON (RM808U) Author
: Date
: 139 SS-14 SERVICE SPECIFICATIONS - COOLING COOLING SS0EL-01 SERVICE DATA Thermostat Valve opening pressure Valve lift Radiator cap Relief valve opening pressure Cooling fan Rotating amperage at 95°C (203°F) 80 - 84°C (176 - 183°F) 10.0 mm (0.394 in.) or more STD 83 - 113 kPa (0.85 - 1.15 kgf/cm2, 12.1 - 16.4 psi) Minimum 69 kPa (0.7 kgf/cm2, 10.0 psi) at 20°C (68°F) No.1 No.2 5.1 - 6.3 A 9.2 - 11.0 A 2001 AVALON (RM808U) Author
: Date
: 130 SS-15 SERVICE SPECIFICATIONS - COOLING SS0EM-01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf RH engine drain plug x EGR cooler 7 70 61 in.·lbf LH engine drain plug x Union on cylinder block 13 130 9 Water pump x Cylinder block 6 60 53 in.·lbf Water inlet x Water inlet housing 8 80 69 in.·lbf Water inlet pipe x LH cylinder head 19.5 200 14 Radiator support x Body 12.8 130 9 No.1 cooling fan shroud x Radiator 5.0 50 44 in.·lbf No.1 cooling fan x Cooling fan motor 6.2 63 55 in.·lbf No.2 cooling fan shroud x Radiator 5.0 50 44 in.·lbf 2001 AVALON (RM808U) Author
: Date
: 131 SS-1 1 SERVICE SPECIFICATIONS - EMISSION CONTROL EMISSION CONTROL SS0EI-02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 39.2 400 29 LH exhaust manifold x Cylinder head 49 500 63 LH exhaust manifold x A/F sensor 44 450 33 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 Front exhaust pipe stay x Front exhaust pipe support bracket 33 330 24 Center exhaust pipe x Tail pipe 43 440 32 Heated oxygen sensor x Front exhaust pipe 44 450 33 Charcoal canister x Body 2001 AVALON (RM808U) Author
: Date
: 127 SS-6 SERVICE SPECIFICATIONS - ENGINE MECHANICAL ENGINE MECHANICAL SS0EF-02 SERVICE DATA Compression pressure at 250 rpm STD 1,500 kPa (15.3 kgf/cm2, 218 psi) Minimum 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference of pressure between each cylinder 100 kPa (1.0 kgf/cm2, 15 psi) or less Valve clearance Adjusting shim for repair part Ignition timing at cold Intake Exhaust Mark 2.500 Mark 2.550 Mark 2.600 Mark 2.650 Mark 2.700 Mark 2.750 Mark 2.800 Mark 2.850 Mark 2.900 Mark 2.950 Mark 3.000 Mark 3.050 Mark 3.100 Mark 3.150 Mark 3.200 Mark 3.250 Mark 3.300 w/ Terminals TE1 and E1 connected of DLC1 0.15 - 0.25 mm (0.006 - 0.010 in.) 0.25 - 0.35 mm (0.010 - 0.014 in.) 2.500 mm (0.0984 in.) 2.550 mm (0.1004 in.) 2.600 mm (0.1024 in.) 2.650 mm (0.1043 in.) 2.700 mm (0.1063 in.) 2.750 mm (0.1083 in.) 2.800 mm (0.1102 in.) 2.850 mm (0.1122 in.) 2.900 mm (0.1142 in.) 2.950 mm (0.1161 in.) 3.000 mm (0.1181 in.) 3.050 mm (0.1201 in.) 3.100 mm (0.1220 in.) 3.150 mm (0.1240 in.) 3.200 mm (0.1260 in.) 3.250 mm (0.1280 in.) 3.300 mm (0.1299 in.) 8 - 12° BTDC @ idle Idle speed - 650 ± 50 rpm Timing belt tensioner Protrusion from housing side 10.0 - 10.8 mm (0.394 - 0.425 in.) Cylinder head Warpage Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing bore diameter Maximum 0.10 mm (0.039 in.) STD O/S 0.05 30°, 45°, 75° 45° 1.0 - 1.4 mm (0.039 - 0.055 in.) 10.295 - 10.313 mm (0.4053 - 0.4080 in.) 10.345 - 10.363 mm (0.4073 - 0.4080 in.) 12 pointed head cylinder head bolt diameter at tension portion STD 8.95 - 9.05 mm (0.3524 - 0.3563 in.) Minimum 8.75 mm (0.3445 in.) Valve guide bushing Inside diameter Outside diameter for repair part Valve Valve overall length Valve face angle Stem diameter Stem oil clearance Margin thickness STD O/S 0.05 5.510 - 5.530 mm (0.2169 - 0.2177 in.) 10.333 - 10.344 mm (0.4068 - 0.4072 in.) 10.383 - 10.394 mm (0.4088 - 0.4092 in.) STD Intake Exhaust Minimum Intake Exhaust 95.45 mm (3.5779 in.) 95.40 mm (3.7559 in.) 94.95 mm (3.7382 in.) 94.90 mm (3.7362 in.) 44.5° Intake 5.470 - 5.485 mm (0.2154 - 0.2159 in.) Exhaust 5.465 - 5.480 mm (0.2152 - 0.2157 in.) STD Intake 0.025 - 0.060 mm (0.0010 - 0.0024 in.) Exhaust 0.030 - 0.065 mm (0.0012 - 0.0026 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD 1.0 mm (0.039 in.) Maximum 0.5 mm (0.020 in.) 2001 AVALON (RM808U) Author
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: 122 SS-7 SERVICE SPECIFICATIONS - ENGINE MECHANICAL Valve spring Deviation Free length Installed tension at 33.8 mm (1.331 in.) Maximum 2.0 mm (0.079 in.) 45.50 mm (1.7913 in.) 186 - 206 N (19.0 - 21.0 kgf, 41.9 - 46.3 lbf) Valve lifter Lifter diameter Lifter bore diameter Oil clearance 30.966 - 30.976 mm (1.2191 - 2.2195 in.) 31.000 - 31.016 mm (1.2205 - 1.2211 in.) STD 0.024 - 0.050 mm (0.0009 - 0.0020 in.) Maximum 0.07 mm (0.0028 in.) Camshaft Thrust clearance Journal oil clearance Journal diameter Circle runout Cam lobe height Camshaft gear backlash Camshaft gear spring end free distance STD Maximum STD Intake Exhaust Maximum Intake Exhaust 0.040 - 0.090 mm (0.0016 - 0.0035 in.) 0.12 mm (0.0047 in.) 0.035 - 0.072 mm (0.0014 - 0.0028 in.) 0.025 - 0.062 mm (0.0010 - 0.0024 in.) 0.10 mm (0.0039 in.) 0.09 mm (0.0035 in.) 26.949 - 26.965 mm (1.0610 - 1.0616 in.) Maximum 0.06 mm (0.0024 in.) STD Intake 42.11 - 42.21 mm (1.6579 - 1.6618 in.) Exhaust 41.96 - 42.06 mm (1.6520 - 1.6559 in.) Minimum Intake 41.96 mm (1.6520 in.) Exhaust 41.81 mm (1.6461 in.) STD 0.020 - 0.200 mm (0.0008 - 0.0079 in.) Maximum 0.30 mm (0.0188 in.) 18.2 - 18.8 mm (0.712 - 0.740 in.) Air intake chamber Warpage Maximum 0.10 mm (0.0039 in.) Intake manifold Warpage Air intake chamber side Cylinder head side Maximum 0.15 mm (0.0059 in.) Maximum 0.08 mm (0.0031 in.) Exhaust manifold Warpage Maximum 0.50 mm (0.0196 in.) Cylinder block Cylinder head surface warpage Cylinder bore diameter Maximum 0.07 mm (0.0028 in.) 87.500 - 87.512 mm (3.4449 - 3.4453 in.) Maximum 87.52 mm (3.4457 in.) 12 pointed head main bearing cap bolt diameter at tension portion STD 7.500 - 7.600 mm (0.2953 - 0.2992 in.) Minimum 7.20 mm (0.2835 in.) Piston and piston ring Piston diameter AISIN made at 23.2 mm (0.913 in.) from the piston head 87.406 - 87.416 mm (3.4412 - 3.4416 in.) at 41.2 mm (1.622 in.) from the piston head Piston oil clearance AISIN made STD Maximum MAHLE made STD Maximum Piston ring groove clearance No.1 No.2 Piston ring end gap STD No.1 No.2 Oil Maximum No.1 No.2 Oil 87.453 - 87.467 mm (3.4430 - 3.4436 in.) MAHLE made 0.084 - 0.106 mm (0.0033 - 0.0042) 0.13 mm (0.0051 in.) 0.033 - 0.059 mm (0.0013 - 0.0023) 0.08 mm (0.0031 in.) 0.020 - 0.070 mm (0.0008 - 0.0028 in.) 0.020 - 0.060 mm (0.0008 - 0.0024 in.) 0.25 - 0.35 mm (0.0098 - 0.0138 in.) 0.35 - 0.45 mm (0.0138 - 0.0177 in.) 0.15 - 0.40 mm (0.0059 - 0.0157 in.) 0.95 mm (0.0374 in.) 1.05 mm (0.0413 in.) 1.00 mm (0.0394 in.) 2001 AVALON (RM808U) Author
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: 123 SS-8 SERVICE SPECIFICATIONS Connecting rod Thrust clearance Connecting rod thickness Connecting rod bearing center wall thickness Reference - ENGINE MECHANICAL STD 0.15 - 0.30 mm (0.0059 - 0.0118 in.) Maximum 0.35 mm (0.0138 in.) 20.80 - 20.85 mm (0.8189 - 0.8209 in.) Mark 1 Mark 2 Mark 3 Mark 4 Connecting rod oil clearance STD Maximum Rod bend Maximum per 100 mm (3.94 in.) Rod twist Maximum per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Bushing oil clearance STD Maximum Connecting rod bolt diameter at tension portion STD Minimum Crankshaft 1.484 - 1.487 mm (0.0584 - 0.0585 in.) 1.487 - 1.490 mm (0.0585 - 0.0587 in.) 1.490 - 1.493 mm (0.0587 - 0.0588 in.) 1.493 - 1.496 mm (0.0588 - 0.0589 in.) 0.038 - 0.064 mm (0.0015 - 0.0025 in.) 0.08 mm (0.0031 in.) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.) 22.005 - 22.014 mm (0.8663 - 0.8667 in.) 21.997 - 22.006 mm (0.8660 - 0.8664 in.) 0.005 - 0.011 mm (0.0002 - 0.0004 in) 0.05 mm (0.0020 in.) 7.2 - 7.3 mm (0.284 - 0.287 in.) 7.0 mm (0.276 in.) Thrust clearance STD 0.04 - 0.24 mm (0.0016 - 0.0095 in.) Maximum 0.30 mm (0.0118 in.) Thrust washer thickness 1.930 - 1.980 mm (0.0760 - 0.0780 in.) Main journal oil clearance STD No.1 and No.4 0.016 - 0.036 mm (0.0006 - 0.0014 in.) No.2 and No.3 0.028 - 0.048 mm (0.0011 - 0.0019 in.) Maximum No.1 and No.4 0.05 mm (0.0020 in.) No.2 and No.3 0.06 mm (0.0024 in.) Main journal diameter 60.988 - 61.000 mm (2.4011 - 2.4016 in.) Main bearing center wall thickness Reference Mark 1 2.485 - 2.488 mm (0.0978 - 0.0980 in.) Mark 2 2.488 - 2.491 mm (0.0980 - 0.0981 in.) Mark 3 2.491 - 2.494 mm (0.0981 - 0.0982 in.) Mark 4 2.494 - 2.497 mm (0.0982 - 0.0983 in.) Mark 5 2.497 - 2.500 mm (0.0983 - 0.0984 in.) Mark 6 2.500 - 2.503 mm (0.0984 - 0.0985 in.) Mark 7 2.503 - 2.506 mm (0.0985 - 0.0987 in.) Crank pin diameter 52.992 - 53.000 mm (2.0863 - 2.0866 in.) Circle runout Maximum 0.06 mm (0.0024 in.) Main journal taper and out-of-round Maximum 0.02 mm (0.0008 in.) Crank pin taper and out-of-round Maximum 0.02 mm (0.0008 in.) 2001 AVALON (RM808U) Author
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: 124 SS-9 SERVICE SPECIFICATIONS - ENGINE MECHANICAL SS0EG-02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Timing belt plate x Oil pump 8 80 69 in.·lbf No.1 idler pulley x Oil pump 34 350 25 No.2 idler pulley x No.2 idler pulley bracket 43 440 32 125 88 1,300 900 94 65 Timing belt tensioner x Oil pump 27 280 20 RH engine mounting bracket x Cylinder block 28 290 21 No.2 timing belt cover x No.3 timing belt cover 8.5 85 74 in.·lbf No.1 timing belt cover x Oil pump 8.5 85 74 in.·lbf Crankshaft pulley x Crankshaft 215 2,200 159 No.2 generator bracket x Engine RH mounting bracket 28 290 21 54 Turn 90° 18.5 550 Turn 90° 185 40 Turn 90° 13 Camshaft bearing cap x Cylinder head 16 160 12 Cylinder head cover x Cylinder head 8 80 69 in.·lbf Exhaust manifold x Cylinder head 49 500 36 Camshaft timing pulley x Camshaft for SST Cylinder head x Cylinder block 12 pointed head 1st 2nd Recessed head Exhaust manifold stay x Exhaust manifold California Except California 34 20 350 200 25 15 Exhaust manifold stay x Transmission housing California Except California 34 20 350 200 25 15 No.1 EGR pipe x RH exhaust manifold 12 120 9 No.1 EGR pipe x EGR cooler 12 120 9 PS pump bracket x RH cylinder head 43 440 32 Oil dipstick guide x LH cylinder head 8 80 69 in.·lbf 19.5 200 14 8 80 69 in.·lbf Water inlet pipe x LH cylinder head Cylinder head rear plate x LH cylinder head No.3 timing belt cover x Cylinder head 8.5 85 74 in.·lbf Water outlet x Intake manifold 15 150 11 Fuel inlet hose x Fuel filter 29 300 21 Intake manifold x Cylinder head 15 150 11 Air intake chamber x Intake manifold 43 440 32 No.2 EGR pipe x Air intake chamber 12 120 9 No.2 EGR pipe x EGR cooler 12 120 9 No.1 engine hanger x Air intake chamber 39 400 29 No.1 engine hanger x RH cylinder head 39 400 29 Air intake chamber stay x Air intake chamber 19.5 200 14 Air intake chamber stay x RH cylinder head 19.5 200 14 12 pointed head 1st 2nd 6 pointed head 22 Turn 90° 27 225 Turn 90° 275 16 Turn 90° 20 1st 2nd 24.5 Turn 90° 250 Turn 90° 18 Turn 90° Rear oil seal retainer x Cylinder block 8 80 69 in.·lbf EGR cooler x Cylinder block 9 90 78 in.·lbf Main bearing cap x Cylinder block Connecting rod cap x Connecting rod 2001 AVALON (RM808U) Author
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: 125 SS-10 SERVICE SPECIFICATIONS - ENGINE MECHANICAL Engine coolant drain union x Cylinder block 39 400 29 Water seal plate x Cylinder block 18 180 13 Oil filter union x Cylinder block 30 310 22 Water inlet housing x Cylinder block 8 80 69 in.·lbf Knock sensor x Cylinder block 39 400 29 No.2 idler pulley bracket x Cylinder block 28 290 21 A/C compressor housing bracket x Cylinder block 25 250 18 Generator bracket x Cylinder block 43 440 32 Drive plate x Crankshaft 83 850 61 Transaxle x Engine 64 650 47 37.2 380 27 Drive plate x Torque convertor clutch 41 420 30 Flywheel housing under cover x Transaxle 7.8 80 69 in.·lbf Rear engine mounting insulator x Cylinder block 64 650 47 Front engine mounting insulator x Cylinder block 64 650 47 Engine moving control rod x RH engine mounting bracket 64 650 47 Engine moving control rod x RH fender apron 64 650 47 RH engine mounting stay x Water outlet 32 320 23 RH engine mounting stay x Engine moving control rod 32 320 23 RH engine mounting stay x No.2 RH engine mounting bracket 32 320 23 Front engine mounting insulator x Front frame 44 66 450 670 32 49 Engine mounting absorber x Front frame 48 490 35 Engine mounting absorber x Transaxle 48 490 35 Rear engine mounting insulator x Front frame 66 670 48 LH engine mounting insulator x Transaxle 64 650 47 PS pump x PS pump bracket 43 440 31 A/C compressor x Housing bracket 25.5 260 19 A/C compressor x No.1 oil pan 25.5 260 19 Generator adjusting bar x Drive belt adjusting bar bracket 18 185 13 Fuel inlet hose x Fuel filter 29 300 21 20.6 210 15 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 Center exhaust pipe x Tailpipe 56 570 41 Front exhaust pipe bracket x Sub frame 33 330 24 Front exhaust pipe support bracket x Front exhaust pipe stay 33 330 24 No.1 oil pan x Transaxle Front exhaust pipe support bracket x No.1 oil pan Silver color bolt Green color bolt 2001 AVALON (RM808U) Author
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: 126 SS-18 SERVICE SPECIFICATIONS - IGNITION IGNITION SS03U-04 SERVICE DATA Firing order - Spark plug Recommended spark plug 1-2-3-4-5-6 DENSO NGK Correct electrode gap for new plug Maximum electrode gap for used plug SK20R11 IFR6A11 1.1 mm (0.043 in.) 1.3 mm (0.051 in.) Camshaft position sensor Resistance at cold at hot 835 - 1,400 Ω 1,060 - 1,645 Ω Crankshaft position sensor Resistance at cold at hot 1,630 - 2,740 Ω 2,065 - 3,225 Ω 2001 AVALON (RM808U) Author
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: 134 SS-19 SERVICE SPECIFICATIONS - IGNITION SS0EQ-01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head 18 180 13 Ignition coil x Cylinder head 8 80 69 in.·lbf Camshaft position sensor x Cylinder head 8 80 69 in.·lbf Crankshaft position sensor x Oil pump 8 80 69 in.·lbf 2001 AVALON (RM808U) Author
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: 135 SS-16 SERVICE SPECIFICATIONS - LUBRICATION LUBRICATION SS0EN-01 SERVICE DATA Oil pressure Oil pump at idle speed at 3,000 rpm Side clearance Body clearance Tip clearance STD Maximum STD Maximum STD Maximum 29 kPa (0.3 kgf/cm2, 43 psi) or more 294 - 539 kPa (3.0 - 5.5 kgf/cm2, 43 - 78 psi) 0.030 - 0.090 mm (0.0012 - 0.0035 in.) 0.15 mm (0.0059 in.) 0.100 - 0.175 mm (0.0039 - 0.0069 in.) 0.30 mm (0.0118 in.) 0.110 - 0.240 mm (0.0043 - 0.0094 in.) 0.35 mm (0.0138 in.) 2001 AVALON (RM808U) Author
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: 132 SS-17 SERVICE SPECIFICATIONS - LUBRICATION SS0EO-01 TORQUE SPECIFICATION Part tightened Oil pressure switch x Cylinder block No.2 oil pan x Drain plug N·m kgf·cm ft·lbf 13 130 9 45 460 33 36.8 375 37 8 19.5 80 200 69 in.·lbf 14 8 80 69 in.·lbf 19.5 200 14 8 19.5 80 200 69 in.·lbf 14 8 80 69 in.·lbf 37.2 380 27 Oil strainer x Main bearing cap 8 80 69 in.·lbf Oil strainer x Oil pump 8 80 69 in.·lbf No.2 oil pan x No.1 oil pan 8 80 69 in.·lbf Oil pump x Relief valve plug Oil pump x Cylinder block 10 mm head 12 mm head Oil pan baffle plate x No.1 oil pan No.1 oil pan x Cylinder block No.1 oil pan x Oil pump No.1 oil pan x Rear oil seal retainer No.1 oil pan x Transaxle 10 mm head 12 mm head Flywheel housing under cover x Transaxle 7.8 80 69 in.·lbf A/C compressor housing bracket x Cylinder block 25 250 18 PS pump x PS pump bracket 43.1 440 32 PS pump drive belt adjusting strut x PS pump 43.1 440 32 PS pump drive belt adjusting strut x Oil pump 43.1 440 32 21 210 15 Exhaust pipe bracket x No.1 oil pan 2001 AVALON (RM808U) Author
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: 133 SS-4 SERVICE SPECIFICATIONS - MAINTENANCE MAINTENANCE SS0ED-01 SERVICE DATA Front axle and suspension ball joint vertical play maximum 0 mm (0 in.) 2001 AVALON (RM808U) Author
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: 120 SS-5 SERVICE SPECIFICATIONS - MAINTENANCE SS0EE-01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front seat mount bolts 37 375 27 Front suspension member x Body 181 1,850 134 Rear suspension member x Body 51 520 38 2001 AVALON (RM808U) Author
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: 121 SS-34 SERVICE SPECIFICATIONS - SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM SS061-54 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Steering wheel 50 510 37 Steering wheel pad 8.8 90 78 in.·lbf Front passenger airbag assembly x Center bracket 20 205 15 Front passenger airbag assembly x Instrument panel reinforcement 20 205 15 Seatback frame assembly x Seat adjuster assembly 43 440 32 Seat cushion assembly x Seat adjuster assembly 19 194 14 Front seat inner belt x Seat adjuster assembly 42 430 31 Seat armrest assembly 41 410 30 Front seat installation bolt 37 375 27 Airbag sensor assembly 20 205 15 Front airbag sensor 20 205 15 Side airbag sensor assembly 20 205 15 7.4 41 75 420 65 in.·lbf 30 Front seat outer belt retractor Upper bolt Lower bolt 2001 AVALON (RM808U) Author
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: 150 SS-27 SERVICE SPECIFICATIONS - SUSPENSION AND AXLE SUSPENSION AND AXLE SS04W-07 SERVICE DATA Cold tire inflation pressure P205/65R15 92H P205/60R16 91H Front, rear Front, rear Front*1 Rear*2 Vehicle height -0 °37’ ± 45’ (-0.62° ± 0.75°) 45’ (0.75°) or less Right-left error 2°10’ ± 45’ (2.17° ± 0.75°) 45’ (0.75°) or less Right-left error 13°04’ ± 45’ (13.07° ± 0.75°) 45’ (0.75°) or less Caster Steering axis inclination 0° ± 12’ (0° ± 0.2°, 0 ± 2 mm, 0 ± 0.08 in.) Rack end length difference 1.5 mm (0.059 in.) or less Toe-in (total) Wheel angle Inside wheel Outside wheel: Reference Camber Rear wheel alignment F t axle Front l Front drive shaft F t suspension Front i R Rear axle l R Rear suspension i Right-left error Toe-in (total) 213 mm (8.39 in.) 266 mm (10.47 in.) Right-left error Camber Front Wheel alignment 210 kPa (2.1 kgf/cm2, 31 psi) 220 kPa (2.2 kgf/cm2, 32 psi) 35°45’ ± 1° (35.75° ± 1°) 31°23’ (31.38°) -0 °43’ ± 45’ (-0.72° ± 0.75°) 45’ (0.75°) or less 0°24’ ± 12’ (0.4° ± 0.2°, 4 ± 2 mm, 0.16 ± 0.08 in.) No. 2 lower suspension arm length difference 1 mm (0.04 in.) or less Axle bearing backlash Maximum 0.05 mm (0.0020 in.) Axle hub deviation Maximum 0.05 mm (0.0020 in.) Drive shaft standard length LH RH 586.0 ± 2.0 mm (23.071 ± 0.079 in.) 881.6 ± 2.0 mm (34.709 ± 0.079 in.) Lower ball joint turning torque 1.0 - 3.4 N·m (10 - 35 kgf·cm, 8.7 - 30 in.·lbf) Stabilizer bar link ball joint turning torque 0.05 - 1.0 N·m (0.5 - 10 kgf·cm, 0.4 - 8.7 in.·lbf) Axle bearing backlash Maximum 0.05 mm (0.0020 in.) Axle hub deviation Maximum 0.07 mm (0.0028 in.) No. 2 lower suspension arm length 512.3 mm (20.169 in.) Stabilizer bar link ball joint turning torque 0.05 - 1.0 N·m (0.5 - 10 kgf·cm, 0.4 - 8.7 in.·lbf) *1: Front measuring point Measure the distance from the ground to the center of the front side lower suspension arm mounting bolt. *2: Rear measuring point Measure the distance from the ground to the center of the front side strut rod mounting bolt. 2001 AVALON (RM808U) Author
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: 143 SS-28 SERVICE SPECIFICATIONS - SUSPENSION AND AXLE SS04X-06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Hub nut 103 1,050 76 Tie rod end lock nut 74 750 54 Steering knuckle x Shock absorber 211 2,150 156 Steering knuckle x Brake caliper 107 1,090 79 Steering knuckle x Tie rod end 49 500 36 Axle hub x Drive shaft 294 3,000 217 Lower ball joint x Lower suspension arm 127 1,300 94 Lower ball joint x Steering knuckle 123 1,250 90 Steering knuckle x Dust cover 8.3 85 74 in.·lbf ABS speed sensor set bolt 8.0 82 71 in.·lbf 32 330 24 Suspension support x Body 80 820 59 Suspension support x Piston rod 49 500 36 Flexible hose and ABS speed sensor wire harness x Shock absorber 29 300 22 Lower suspension arm set bolt 206 2,100 152 Stabilizer bar bracket x Suspension member 19 195 14 Stabilizer bar link set nut 39 400 29 Hub nut 103 1,050 76 Brake caliper x Rear axle carrier 47 475 34 Axle hub set bolt 80 820 59 Shock absorber x Rear axle carrier New nut Reused nut (Apply engine oil to the threads.) 255 196 2,600 2,000 188 145 No. 1, No. 2 lower suspension arm x Rear axle carrier 181 1,850 134 Strut rod x Rear axle carrier 113 1,150 83 ABS speed sensor set bolt 8.0 82 71 in.·lbf ABS speed sensor wire harness x Shock absorber 5.4 55 48 in.·lbf Flexible hose x Shock absorber 29 300 22 Rear seat belt set bolt 41 420 30 Rear seatback set bolt 18 185 13 Suspension support x Body 39 400 29 Suspension support x Piston rod 49 500 36 Center exhaust pipe set bolt 43 440 32 Parking brake cable set bolt 5.4 55 48 in.·lbf FRONT AXLE FRONT DRIVE SHAFT Drive shaft center bearing lock bolt FRONT SUSPENSION REAR AXLE REAR SUSPENSION No. 2 lower suspension arm lock nut 56 570 41 No. 1, No. 2 lower suspension arm x Suspension member 181 1,850 134 Strut rod x Body 113 1,150 83 Suspension member x Body 51 520 38 Suspension member lower stopper x Body 38 390 28 2001 AVALON (RM808U) Author
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: 144 SS-29 SERVICE SPECIFICATIONS - SUSPENSION AND AXLE Stabilizer bar bracket x Suspension member 19 195 14 Stabilizer bar link set nut 39 400 29 2001 AVALON (RM808U) Author
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: 145 SS-12 SERVICE SPECIFICATIONS - SFI SFI SS0EJ-02 SERVICE DATA at no vacuum 301 - 347 kPa (3.1 - 3.5 kgf/cm2, 44 - 50 psi) Fuel pressure regulator Fuel pressure Fuel pump Resistance at 20°C (68°F) 0.2 - 3.0 Ω Injector Resistance Injection volume Difference between each cylinder Fuel leakage at 20°C (68°F) 13.4 - 14.2 Ω 60 - 73 cm3 (3.4 - 4.5 cu in.) per 15 sec. 13 cm3 (0.8 cu in.) or less 1 drop or less per 12 minutes MAF meter Resistance (THA - E2) Throttle body Throttle opener setting speed Throttle position sensor Resistance Throttle valve fully closed Throttle valve fully open - Camshaft timing oil control valve Resistance at 20°C (68°F) 6.9 - 7.9 Ω VSV for EVAP Resistance at 20°C (68°F) 27 - 33 Ω VSV for ACIS Resistance at 20°C (68°F) 33 - 39 Ω VSV for canister closed valve Resistance at 20°C (68°F) at 120°C (248°F) 25 - 30 Ω 33 - 42 Ω VSV for pressure switching valve Resistance at 20°C (68°F) at 120°C (248°F) 37 - 44 Ω 51 - 62 Ω Vapor Pressure Sensor Power source voltage ECT sensor Resistance A/F sensor Heater coil resistance at 20°C (68°F) at 800°C (1472°F) 0.8 - 1.4 Ω 1.8 - 3.2 Ω Heated oxygen sensor Heater coil resistance at 20°C (68°F) at 800°C (1472°F) 11 - 16 Ω 23 - 32 Ω Fuel cut rpm Fuel return rpm at -20°C (-4°F) at 20°C (68°F) at 60°C (140°F) 13.6 - 18.4 kΩ 2.21 - 2.69 kΩ 0.49 - 0.67 kΩ 1,100 - 1,700 rpm VTA - E2 VTA - E2 VC - E2 0.2 - 6.3 kΩ 2.0 - 10.2 kΩ 2.5 - 5.9 kΩ 4.5 - 5.5 V at -20°C (-4°F) at 0°C (32°F) at 20°C (68°F) at 40°C (104°F) at 60°C (140°F) at 80°C (176°F) 10 - 20 kΩ 4 - 7 kΩ 2 - 3 kΩ 0.9 - 1.3 kΩ 0.4 - 0.7 kΩ 0.2 - 0.4 kΩ 1,200 rpm 2001 AVALON (RM808U) Author
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: 128 SS-13 SERVICE SPECIFICATIONS - SFI SS0EK-02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 29 300 21 28 285 21 4 40 35 in.·lbf Fuel filter x Fuel pump bracket 2.0 20 17 in.·lbf Fuel pressure regulator x Fuel pump bracket 2.0 20 17 in.·lbf Delivery pipe x Intake manifold 10 100 7 No.1 fuel pipe x Intake manifold 19.5 200 14 39 400 29 Throttle body x Throttle body bracket 19.5 200 14 Throttle body x Air intake chamber 19.5 200 14 Throttle body x No.1 intake air control valve 6.9 70 61 in.·lbf Camshaft timing oil control valve x Cylinder head 7.5 80 66 in.·lbf No.2 intake air control valve x Air intake chamber 14.5 145 10 ECT sensor x Water outlet 20 200 14 Knock sensor x Cylinder block 39 400 29 A/F sensor x Exhaust manifold 44 440 32 Heated oxygen sensor x Exhaust pipe 44 440 31 Fuel line (Union bolt type) Fuel line (Flare nut type) Fuel pump assembly x Fuel tank Fuel tank band x Body using SST 2001 AVALON (RM808U) Author
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: 129 SS-32 SERVICE SPECIFICATIONS - STEERING STEERING SS0G9-03 SERVICE DATA DRIVE BELT Drive belt tension* New belt 120 - 185 lbf Drive belt tension* Used belt 95 - 135 lbf POWER STEERING FLUID Fluid level rise Maximum 5 mm (0.20 in.) Minimum 7,845 kPa (80 kgf/cm2, 1,138 psi) Fluid pressure at idle speed with valve closed STEERING WHEEL Steering wheel freeplay Maximum 30 mm (1.18 in.) Steering effort at idle speed Reference 5.9 N·m (60 kgf·cm, 52 in.·lbf) POWER STEERING VANE PUMP Vane pump rotating torque 0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less Oil clearance between pump shaft and bushing Oil clearance between pump shaft and bushing STD 0.03 - 0.05 mm (0.0012 - 0.0020 in.) Maximum 0.07 mm (0.0028 in.) Vane plate height Minimum 8.6 mm (0.339 in.) Vane plate thickness Minimum 1.397 mm (0.0550 in.) Vane plate length Minimum 14.991 mm (0.5902 in.) Clearance between the rotor groove and plate Vane plate length Spring free length Maximum 0.035 mm (0.0014 in.) Pump rotor and cam ring mark None 14.999 - 15.001 mm (0.59051 - 0.59059 in.) 1 14.997 - 14.999 mm (0.59043 - 0.59051 in.) 2 14.995 - 14.997 mm (0.59035 - 0.59043 in.) 3 14.993 - 14.995 mm (0.59027 - 0.59035 in.) 4 14.991 - 14.993 mm (0.59020 - 0.59027 in.) Minimum 32.3 mm (1.272 in.) POWER STEERING GEAR Steering rack runout Total preload (Control valve rotating torque) Maximum 0.03 mm (0.0012 in.) 0.8 - 1.4 N·m (8 - 14 kgf·cm, 6.9 - 12.2 in.·lbf) *: For use with belt tension gauge 2001 AVALON (RM808U) Author
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: 148 SS-33 SERVICE SPECIFICATIONS - STEERING SS0GA-06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf TILT STEERING COLUMN Tilt lever lock shaft 9.0 90 78 in.·lbf Turn signal bracket x Steering column upper tube 7.5 75 65 in.·lbf Shift lever housing x Column tube assembly 10 100 7 Shift lever set bolt 11 110 8 Shift lock solenoid bracket x Shift lever housing 3.4 35 30 in.·lbf Shift lock switch guide 2.8 29 25 in.·lbf Universal joint assembly x Main shaft assembly 35 360 26 Steering column assembly set nut 25 260 19 Intermediate shaft sub-assembly x Control valve shaft 35 360 26 Universal joint assembly x Intermediate shaft sub-assembly 35 360 26 Steering wheel set nut 50 510 37 Steering wheel pad set screw (Torx screw) 8.8 90 78 in.·lbf Rear housing set bolt 17 170 12 Pressure port union 83 850 62 Suction port union set bolt 13 130 9 Front bracket x Rear bracket 43 440 32 Vane pump pulley set nut 44 450 33 Pressure feed tube x PS vane pump assembly 52 530 38 Oil pressure switch 21 210 15 POWER STEERING VANE PUMP PS vane pump set bolt A bolt 29 (43) 300 (440) 22 (32) PS vane pump set bolt B bolt 43 440 32 23 (25) 230 (250) 17 (18) 7.8 80 69 in.·lbf Control valve housing set bolt 18 180 13 Self-locking nut 25 250 18 Rack housing cap 59 600 43 Rack guide spring cap lock nut 50 (69) 510 (700) 37 (51) Rack x Rack end 60 (83) 610 (850) 45 (61) 74 750 54 12 (13) 120 (130) 9 (9) PS gear assembly set bolt 181 1,850 134 Stabilizer bar set bolt 19 190 14 28 (25) 290 (250) 21 (18) Pressure feed tube clamp plate set nut 10 100 7 Intermediate shaft sub-assembly x Control valve shaft 35 360 26 Tie rod end x Steering knuckle 49 500 36 Pressure feed tube x Pressure feed tube Clamp plate set nut POWER STEERING GEAR Tie rod end lock nut Turn pressure tube union nut Pressure feed and return tubes x Control valve housing ( ): For use without SST 2001 AVALON (RM808U) Author
: Date
: 149 SS-20 SERVICE SPECIFICATIONS - STARTING STARTING SS0ER-01 SERVICE DATA Starter Rated voltage and output power No-load characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout Magnetic switch Contact plate for wear Current rpm STD Minimum STD Minimum 12 V 1.4 kW 90 A or less at 11.5 V 3,000 rpm or more 15.5 mm (0.610 in.) 10 mm (0.394 in.) 17.6 - 23.5 N (1.79 - 2.41 kgf, 4.0 - 5.3 lbf) 11.8 N (1.20 kgf, 2.7 lbf) STD Minimum STD Minimum Maximum 30.0 mm (1.181 in.) 29.0 mm (1.142 in.) 0.6 mm (0.024 in.) 0.2 mm (0.008 in.) 0.05 mm (0.0020 in.) Maximum 0.9 mm (0.035 in.) 2001 AVALON (RM808U) Author
: Date
: 136 SS-21 SERVICE SPECIFICATIONS - STARTING SS0ES-01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf End cover x Field frame 1.5 15 13 in.·lbf Starter housing x Magnetic switch 5.9 60 52 in.·lbf Field frame x Armature assembly 5.9 60 52 in.·lbf Lead wire x Terminal C of starter 5.9 60 52 in.·lbf Starter mounting bolt 39 400 29 Terminal nut x Terminal C of starter 17 173 12 Terminal nut x Terminal 30 of starter 17 173 12 Magnetic switch end cover x Magnetic switch housing 2.5 25 22 in.·lbf 2001 AVALON (RM808U) Author
: Date
: 137 SS-1 SERVICE SPECIFICATIONS - STANDARD BOLT STANDARD BOLT SS0ZS-01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt 4 Class 4T No Mark No Mark No Mark 5 5T 6 6T w/ Washer w/ Washer 7 7T 8 8T 9 9T 10 10T 11 11T B06431 2001 AVALON (RM808U) Author
: Date
: 117 SS-3 SERVICE SPECIFICATIONS - STANDARD BOLT SS0ZU-01 HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut 4N No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 6N 6N 7N (5T) * 8N 8N 10N (7T) 10N No Mark 11N 11N 12N 12N *: Nut with 1 or more marks on one side surface of the nut. B06432 HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more 2001 AVALON (RM808U) Author
: Date
: 119 SS-2 SERVICE SPECIFICATIONS - STANDARD BOLT SS0ZT-01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Class Diameter mm Pitch mm Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 4T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 5 12.5 26 47 74 115 55 130 260 480 760 1,150 48 in.·lbf 9 19 35 55 83 6 14 29 53 84 - 60 145 290 540 850 - 52 in.·lbf 10 21 39 61 - 5T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 6.5 15.5 32 59 91 140 65 160 330 600 930 1,400 56 in.·lbf 12 24 43 67 101 7.5 17.5 36 65 100 - 75 175 360 670 1,050 - 65 in.·lbf 13 26 48 76 - 6T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 8 19 39 71 110 170 80 195 400 730 1,100 1,750 69 in.·lbf 14 29 53 80 127 9 21 44 80 125 - 90 210 440 810 1,250 - 78 in.·lbf 15 32 59 90 - 7T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 10.5 25 52 95 145 230 110 260 530 970 1,500 2,300 8 19 38 70 108 166 12 28 58 105 165 - 120 290 590 1,050 1,700 - 9 21 43 76 123 - 8T 8 10 12 1.25 1.25 1.25 29 61 110 300 620 1,100 22 45 80 33 68 120 330 690 1,250 24 50 90 9T 8 10 12 1.25 1.25 1.25 34 70 125 340 710 1,300 25 51 94 37 78 140 380 790 1,450 27 57 105 10T 8 10 12 1.25 1.25 1.25 38 78 140 390 800 1,450 28 58 105 42 88 155 430 890 1,600 31 64 116 11T 8 10 12 1.25 1.25 1.25 42 87 155 430 890 1,600 31 64 116 47 97 175 480 990 1,800 35 72 130 2001 AVALON (RM808U) Author
: Date
: 118 SF-54 SFI - ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF0ZZ-02 COMPONENTS No.1 V-Bank Cover 19.5 (200, 14) Brake Booster Vacuum Hose 19.5 (200, 14)
Gasket Air Intake Chamber Stay Fuel Vapor Feed Hose Throttle Body Throttle Position Sensor Connector Vacuum Hose Vacuum Hose IAC Valve Connector Accelerator Cable Air Assist Hose Water Bypass Hose Throttle Cable Air Cleaner Hose w/ Resonator N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B09088 2001 AVALON (RM808U) Author
: Date
: 1163 SF-55 SFI - ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) No.1 Protector No.1 Intake Air Control Valve
O-Ring 6.9 (70, 61 in.·lbf)
Gasket 6.9 (70, 61 in.·lbf) No.1 Throttle Body
Gasket
O-Ring No.2 Throttle Body N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B09124 2001 AVALON (RM808U) Author
: Date
: 1164 SF-56 SFI - ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) No.2
Gasket No.2 Intake Air Control Valve 14.5 (145, 10) DLC1 Bracket DLC1 Actuator Vacuum Hose Ground Strap Ground Cable N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B06500 2001 AVALON (RM808U) Author
: Date
: 1165 SF-58 SFI - ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF06E-03 INSPECTION No.1 1. (a) Vacuum INSPECT INTAKE AIR CONTROL VALVE With 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum applied to the actuator, check that the actuator rod moves. (b) One minute after applying the vacuum in (a), check that the actuator rod does not return. If the operation is not as specified, replace the intake air control valve. No.2 Vacuum B06702 B06701 Air B06747 2. INSPECT VACUUM TANK LOCATION: The LH side member under the battery tray. (a) Check that air flows from port B to port A. (b) Check that air does not flow from port A to port B. Air S05689 Vacuum (c) Plug port B with your finger, and apply 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum to port A, and check that there is no change is vacuum after one minute. If the operation is not as specified, replace the vacuum tank. 3. INSPECT VSV (See page SF-68 ) S05688 2001 AVALON (RM808U) Author
: Date
: 1167 SF-59 SFI - ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF06F-03 INSTALLATION 1. INSTALL NO.1 INTAKE AIR CONTROL VALVE (See pages SF-40 and SF-42 ) 2. (a) INSTALL NO.2 INTAKE AIR CONTROL VALVE Install the No.2 intake air control valve. (1) Install a new gasket to the air intake chamber. New Gasket B04803 Seal Packing (2) Seal Packing Rubber S05052 (b) (c) Apply a light coat of engine oil to the rubber portions. (3) Apply seal packing to the positions of the intake air control valve shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent (4) Install the intake air control valve, DLC1 bracket, ground strap and cable with the 4 nuts. Torque: 14.5 N·m (145 kgf·cm, 10 ft·lbf) Connect the DLC1. Connect the actuator vacuum hose. 2001 AVALON (RM808U) Author
: Date
: 1168 SF-53 SFI - ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) No.1 Vacuum Gauge SF06B-05 ON-VEHICLE INSPECTION No.2 B09120 B06677 Vacuum Gauge B09122 (d) No.1 Approx. 27.6 kPa No.2 B09121 B06678 INSPECT INTAKE AIR CONTROL VALVE (a) Using a 3-way connector, connect vacuum gauge to the actuator hose. (b) Start the engine. (c) While the engine is idling, check that the vacuum gauge needle does not move. Rapidly depress the accelerator pedal to fully open position and check that the vacuum gauge needle momentarily fluctuates up to approx. 26.7 kPa (200 mmHg, 7.9 in.Hg). (The actuator rod is pulled out.) Approx. 27.6 kPa B09123 2001 AVALON (RM808U) Author
: Date
: 1162 SF-57 SFI - ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF06D-03 REMOVAL (b) 1. REMOVE NO.1 INTAKE AIR CONTROL VALVE (See pages SF-36 and SF-40 ) 2. (a) (b) REMOVE NO.2 INTAKE AIR CONTROL VALVE Disconnect the actuator vacuum hose. Disconnect the DLC1 from the DLC1 bracket. (c) Remove the intake air control valve. (1) Remove the 4 nuts and DLC1 bracket, and disconnect the ground strap and cable. (2) Remove the intake air control valve by prying a screwdriver between the intake air control valve and air intake chamber. (3) Remove the gasket. (a) B06470 B06471 2001 AVALON (RM808U) Author
: Date
: 1166 SF-78 SFI - AIR-FUEL RATIO (A/F) SENSOR AIR-FUEL RATIO (A/F) SENSOR SF103-01 COMPONENTS Bank 1 Sensor 1 A/F Sensor A/F Sensor Connector 44 (450, 32) N·m (kgf·cm, ft·lbf) : Specified torque Bank 2 Sensor 1 B06683 A/F Sensor Connector LH Exhaust Manifold Heat Insulator A/F Sensor 44 (450, 32) N·m (kgf·cm, ft·lbf) : Specified torque B06681 2001 AVALON (RM808U) Author
: Date
: 1187 SF-79 SFI - AIR-FUEL RATIO (A/F) SENSOR SF104-01 Bank 1 Sensor 1 Ohmmeter +B HT Bank 2 Sensor 1 Ohmmeter INSPECTION INSPECT HEATER RESISTANCE OF A/F SENSORS (Bank 1 sensor 1, Bank 2 Sensor 1) (a) Disconnect the A/F sensor connector. (b) Using an ohmmeter measure the resistance between terminals +B and HT. Resistance: At 20°C (68°F) 0.8 - 1.4 Ω At 800°C (1,472°F) 1.8 - 3.2 Ω If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (c) Reconnect the A/F sensor connector. HT +B B06682 2001 AVALON (RM808U) Author
: Date
: 1188 SF-61 SFI - A/F SENSOR HEATER RELAY A/F SENSOR HEATER RELAY SF16D-01 INSPECTION 1. 2. A/F Sensor Heater Relay REMOVE RELAY BOX COVER REMOVE A/F SENSOR HEATER RELAY (Marking: A/F HTR) B09127 Continuity Ohmmeter Ohmmeter 2 1 5 3 3. (a) INSPECT A/F SENSOR HEATER RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04947 2 Ohmmeter 1 5 3 Battery 4. (a) (b) INSPECT A/F SENSOR HEATER RELAY OPERATION Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL A/F SENSOR HEATER RELAY 6. REINSTALL RELAY BOX COVER Continuity S04946 2001 AVALON (RM808U) Author
: Date
: 1170 SF-62 SFI - CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY SF0MD-02 COMPONENTS Circuit Opening Relay Front Door Inside Scuff Plate Cowl Side Trim B09128 2001 AVALON (RM808U) Author
: Date
: 1171 SF-63 SFI - CIRCUIT OPENING RELAY SF16E-01 INSPECTION 1. Continuity Ohmmeter Ohmmeter 2 1 5 3 REMOVE CIRCUIT OPENING RELAY 2. (a) INSPECT CIRCUIT OPENING RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04947 2 Ohmmeter 1 5 3. (a) (b) INSPECT CIRCUIT OPENING RELAY OPERATION Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL CIRCUIT OPENING RELAY 3 Battery Continuity S04946 2001 AVALON (RM808U) Author
: Date
: 1172 SF-49 SFI - CAMSHAFT TIMING OIL CONTROL VALVE SF0SM-05 COMPONENTS V-Bank Cover 7.5 (80, 66 in.·lbf) RH Camshaft Timing Oil Control Valve RH Camshaft Timing Oil Control Valve Connector RH Camshaft Timing Oil Control Valve
O-Ring
O-Ring LH Camshaft Timing Oil Control Valve Connector N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B09119 2001 AVALON (RM808U) Author
: Date
: 1158 SF-51 SFI - CAMSHAFT TIMING OIL CONTROL VALVE SF0SO-03 INSPECTION 1 INSPECT CAMSHAFT OIL CONTROL VALVE OPERATION Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2, and check the movement of the valve. 2 B01689 Battery positive voltage is applied Valve moves in direction Battery positive voltage is cut off Valve moves in direction If operation is not as specified, replace the valve. 2001 AVALON (RM808U) Author
: Date
: 1160 SF-52 SFI - CAMSHAFT TIMING OIL CONTROL VALVE SF0SP-06 INSTALLATION Installation is in the reverse order of removal (See page SF-50 ). 2001 AVALON (RM808U) Author
: Date
: 1161 SF-48 SFI - CAMSHAFT TIMING OIL CONTROL VALVE CAMSHAFT TIMING OIL CONTROL VALVE Ohmmeter SF0SL-03 ON-VEHICLE INSPECTION B06690 INSPECT OIL CONTROL VALVE RESISTANCE (a) Remove the V-bank cover. (b) Disconnect the oil control valve connector. (c) Using an ohmmeter, measure the resistance between the terminals. Resistance: 6.9 - 7.9 Ω at 20°C (68°F) If the resistance is not as specified, replace the valve. (d) Reconnect the oil control valve connector. (e) Reinstall the V-bank cover. 2001 AVALON (RM808U) Author
: Date
: 1157 SF-50 SFI - CAMSHAFT TIMING OIL CONTROL VALVE SF0ZY-03 REMOVAL 5 mm Hexagon Wrench 1. REMOVE V-BANK COVER (a) Using a 5 mm hexagon wrench, remove the 3 cap nuts. (b) Loosen the V-bank cover fastener counterclockwise. HINT: At the time of installation, please refer to the following items. Press down the V-bank cover fastener. (c) Remove the V-bank cover. A10518 2. (a) (b) (c) B06691 REMOVE CAMSHAFT TIMING OIL CONTROL VALVES Disconnect the 2 camshaft oil control valve connectors. Remove the bolt, camshaft oil control valve and O-ring. Remove the 2 camshaft oil control valves. Torque: 7.5 N·m (80 kgf·cm, 66 in.·lbf) Remove the O-ring from the each camshaft oil control valve. HINT: At the time of installation, please refer to the following items. Use a new O-ring. 2001 AVALON (RM808U) Author
: Date
: 1159 SF-82 SFI - ENGINE CONTROL MODULE (ECM) ENGINE CONTROL MODULE (ECM) SF0MX-02 COMPONENTS ECM ECM Connector Glove Compartment Cowl Side Trim Front Door Inside Scuff Plate B09665 2001 AVALON (RM808U) Author
: Date
: 1191 SF-83 SFI - ENGINE CONTROL MODULE (ECM) SF0MY-01 INSPECTION 1. 2. 3. REMOVE ECM INSPECT ECM (See page DI-20 ) REINSTALL ECM 2001 AVALON (RM808U) Author
: Date
: 1192 SF-73 SFI - ENGINE COOLANT TEMPERATURE (ECT) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF06Q-05 INSPECTION 19 mm Deep Socket Wrench ECT Switch Gasket DRAIN ENGINE COOLANT 2. (a) (b) REMOVE ECT SENSOR Disconnect the ECT sensor connector. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. B06679 Ohmmeter 30 20 10 Resistance kΩ 1. 5 3 2 Acceptable 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (c) Connect the ECT sensor connector. 5. REFILL WITH ENGINE COOLANT 1 0.5 0.3 0.2 0.1 -20 (-4) S01196 S01699 0 20 40 60 80 100 (32) (68) (104) (140) (176) (212) Temperature °C (°F) Z17274 2001 AVALON (RM808U) Author
: Date
: 1182 SF-60 SFI - EFI MAIN RELAY EFI MAIN RELAY SF16C-01 INSPECTION 1. 2. EFI Main Relay REMOVE RELAY BOX COVER REMOVE EFI MAIN RELAY (Marking: EFI) B09125 Continuity Ohmmeter Ohmmeter 2 1 5 3 3. (a) INSPECT EFI MAIN RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04947 2 Ohmmeter 1 5 3 Battery 4. (a) (b) INSPECT EFI MAIN RELAY OPERATION Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Continuity S04946 2001 AVALON (RM808U) Author
: Date
: 1169 SF-84 SFI - FUEL CUT RPM FUEL CUT RPM SF071-05 INSPECTION 5 mm Hexagon Wrench A10518 1. 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. 2. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 3. TOYOTA Hand-Held Tester (a) (b) DLC3 CONNECT LEXUS HAND-HELD TESTER OR OBDII SCAN TOOL Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand-held tester or OBDII scan tool operator’s manual for further details. A10838 4. (a) (b) (c) Sound Scope B06523 INSPECT FUEL CUT OFF PRM Increase the engine speed to at least 3,500 rpm. Use a sound scope to check for injector operating noise. Check that when the throttle lever is released, injector operation noise stops momentarily and then resumes. HINT: Measure with the A/C OFF. Fuel return rpm: 1,200 rpm 5. DISCONNECT LEXUS HAND-HELD TESTER OR OBDII SCAN TOOL 6. REINSTALL V-BANK COVER (a) Using 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts. (b) Press down the V-bank cover fastener. 2001 AVALON (RM808U) Author
: Date
: 1193 SF-16 SFI - FUEL PRESSURE REGULATOR FUEL PRESSURE REGULATOR SF0LJ-02 COMPONENTS Rear Seat Cushion Floor Service Hole Cover 4 (40, 35 in.·lbf) Fuel Pump & Sender Gauge Connector No.1 Fuel Tank Protector Fuel Tank Vent Tube Set Plate Fuel Pump Assembly
Gasket
O-Ring Fuel Pressure Regulator
O-Ring Fuel Filter N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B09788 2001 AVALON (RM808U) Author
: Date
: 1125 SF-18 SFI - FUEL PRESSURE REGULATOR SF0LL-01 INSTALLATION Installation is in the reverse order of removal (See page SF-17 ). 2001 AVALON (RM808U) Author
: Date
: 1127 SF-17 SFI - FUEL PRESSURE REGULATOR SF0LK-01 REMOVAL 1. 2. (a) B02379 B02380 REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK (See page SF-1 1) REMOVE FUEL FILTER Remove the screw, and pull out the fuel filter. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) Remove the O-ring from the fuel filter. (b) HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O-ring, and install it to the fuel filter. 3. REMOVE FUEL PRESSURE REGULATOR (a) Remove the screw, and pull out the pressure regulator. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) (b) Remove the O-ring from the pressure regulator. HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O-ring, and install it to the pressure regulator. 2001 AVALON (RM808U) Author
: Date
: 1126 SF-27 SFI - FUEL TANK AND LINE FUEL TANK AND LINE SF0LR-02 COMPONENTS CAUTION:  Always use new gaskets when replacing the fuel tank or component parts.  Apply the proper torque to all parts tightened. The Location of Fuel Tank Cushion x8 No.1 Fuel Tank Protector Fuel Tank Vent Tube Set Plate Heated Oxygen Sensor (Bank 1 Sensor 2) HINT:
Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
After installing the heated oxygen sensor, check that the sensor wire is not twisted, if it is twisted,remove the heated oxygen sensor and reinstall it. Charcoal Canister Fuel Inlet Pipe Shield Fuel Pump Fuel Tank Cap Vent Line Hose  Gasket EVAP Line Hose Fuel Outlet Tube Fuel Inlet Pipe  Gasket Fuel Inlet Hose Fuel Inlet Pipe Protector Fuel Tank Fuel Tank Band Heat Insulator 39 (400, 29)  Gasket 43 (440, 32)  Gasket Heated Oxygen Sensor (Bank 1 Sensor 2) 44 (450, 33) 43 (440, 32) Center Exhaust Pipe Compression Spring N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part B09083 2001 AVALON (RM808U) Author
: Date
: 1136 SF-28 SFI - FUEL TANK AND LINE SF0LS-01 INSPECTION Crack Leakage Deformation BO0919 Use SST 28 N·m (285 kgf·cm, 21 ft·lbf) SST INSPECT FUEL TANK AND LINE (a) Check the fuel lines for cracks or leakage, and all connections for deformation. (b) Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. (c) Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. (d) Check the filler neck for damage or fuel leakage. (e) Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Fulcrum Length 30 cm (11.81 in.) SST: 09631-22020 Z10162 2 - 7 mm (0.08 - 0.28 in.) Hose Pipe Clip 0 - 3 mm (0 - 0.12 in.) FU0041 2001 AVALON (RM808U) Author
: Date
: 1137 SF-10 SFI - FUEL PUMP SF0LE-02 COMPONENTS Rear Seat Cushion Floor Service Hole Cover Fuel Sender Gauge Connector Fuel Pump & Sender Gauge Connector Fuel Sender Gauge 4 (40, 35 in.·lbf) No.1 Fuel Tank Protector Fuel Pump Flange Fuel Tank Vent Tube Set Plate
O-Ring Ground Plate Fuel Filter Fuel Pump Assembly Fuel Pump
Gasket Lead Wire Housing Fuel Pump Filter
Clip Rubber Cushion ”C” Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B09787 2001 AVALON (RM808U) Author
: Date
: 1119 SF-12 SFI - FUEL PUMP SF0LG-01 DISASSEMBLY 1. 2. 3. DISCONNECT FUEL PUMP CONNECTOR DISCONNECT GROUND PLATE DISCONNECT FUEL SENDER GAUGE CONNECTOR S06028 4. REMOVE FUEL SENDER GAUGE Push down the portion of A with a finger, and push up the sender gauge. NOTICE: Be careful that the arm of the sender gauge should not bend. A Push S06033 5. REMOVE FUEL FILTER (a) Remove the screw, and pull out the fuel filter. (b) Remove the O-ring from the fuel filter. HINT: At the time of installation, please refer to the following items. Install the pump filter with a new clip. B02379 6. REMOVE FUEL PUMP FLANGE Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration. HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O-ring, and install it to the fuel filter. (3) (2) (1) S06030 7. REMOVE FUEL PUMP LEAD WIRE S06027 2001 AVALON (RM808U) Author
: Date
: 1121 SF-13 SFI - FUEL PUMP 8. (3) (1) (2) REMOVE ”C” BRACKET, RUBBER CUSHION AND FUEL PUMP Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration. S06029 9. REMOVE FUEL PUMP FILTER FROM FUEL PUMP (a) Using a small screwdriver, remove the clip. (b) Pull out the pump filter. HINT: At the time of installation, please refer to the following items. Install the pump filter with a new clip. FI6376 2001 AVALON (RM808U) Author
: Date
: 1122 SF-15 SFI - FUEL PUMP SF0LI-01 INSTALLATION Installation is in the reverse order of removal (See page SF-1 1). 2001 AVALON (RM808U) Author
: Date
: 1124 SF-6 SFI TOYOTA Hand-Held Tester - FUEL PUMP FUEL PUMP SF0LD-02 ON-VEHICLE INSPECTION 1. (a) (b) DLC3 A10838 CHECK FUEL PUMP OPERATION Connect a TOYOTA hand-held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand-held tester main switch ON. NOTICE: Do not start the engine. (c) Select the active test mode on the TOYOTA hand-held tester. (d) Please refer to the TOYOTA hand-held tester operator’s manual for further details. (e) If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See step 7). (f) B09075 HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check these parts:
Fusible link
Fuses
EFI main relay
Fuel pump
ECM
Wiring connections (g) Turn the ignition switch to LOCK. (h) Disconnect the TOYOTA hand- held tester from the DLC3. 2. (a) (b) Fuel Tube Connector Check that there is pressure in the fuel inlet hose from the fuel filter. (c) CHECK FUEL PRESSURE Check the battery positive voltage is above 12 V. Disconnect the negative (-) terminal cable from the battery. Purchase the new No.1 fuel pipe and take out the fuel tube connector from its pipe. Part No. 23801-20070 S05359 2001 AVALON (RM808U) Author
: Date
: 1115 SF-7 SFI (d) - FUEL PUMP Remove the fuel hose clamp. Fuel Hose Clamp B09076 (e) B09077 Disconnect the No.1 fuel pipe (fuel tube connector) from the fuel filter outlet. CAUTION:
Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions (See page SF-1 ).
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. (f) SST (Hose) SST SST Retainer No.1 Fuel Pipe Fuel tube Connector SST (Hose) B09078 Install SST (pressure gauge) as shown in the illustration by using SST and fuel tube connector. SST 09268-41047, 09268-45014 (g) Wipe off any splattered gasoline. (h) Reconnect the TOYOTA hand-held tester to the DLC3 (See step 1). (i) Reconnect the negative (-) terminal cable to the battery. (j) Measure the fuel pressure. Fuel pressure: 301 - 347 kPa (3.1 - 3.5 kgf/cm2, 44 - 50 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check these parts:
Fuel hoses and connections
Fuel pump
Fuel filter
Fuel pressure regulator (k) Disconnect the TOYOTA hand- held tester from the DLC3. (l) Start the engine. (m) Measure the fuel pressure at idle. Fuel pressure: 301 - 347 kPa (3.1 - 3.5 kgf/cm2, 44 - 50 psi) (n) Stop the engine. (o) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. 2001 AVALON (RM808U) Author
: Date
: 1116 SF-8 SFI (p) - FUEL PUMP After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST and fuel tube connector to prevent gasoline from splashing. SST 09268-41047, 09268-45014 (q) Reconnect the No.1 fuel pipe (fuel tube connector). CAUTION: Perform connecting operations of the tube connector (quick type) after observing the precautions (See page SF-1 ). B09079 (r) Fuel Hose Clamp B09076 Ohmmeter 4 5 Surely install the hose clamp to the fuel filter with ”click” sound. (s) After installing the clamp, check that the clamp is fixed by pulling up to the clamp. (t) Reconnect the negative (-) terminal cable to the battery. (u) Check for fuel leaks. 3. REMOVE REAR SEAT CUSHION 4. REMOVE FLOOR SERVICE HOLE COVER 5. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 6. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 - 3.0 Ω at 20°C (68°F) If the resistance is not as specified, replace the fuel pump. S04508 4 Battery 5 S04509 7. INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (-) lead to terminal 5. Check that the fuel pump operates. NOTICE:
These tests must be done quickly (within 10 seconds) to prevent the coil burning out.
Keep the fuel pump as far away from the battery as possible.
Always do the switching at the battery side. 2001 AVALON (RM808U) Author
: Date
: 1117 SF-9 SFI - FUEL PUMP If operation is not as specified, replace the fuel pump or lead wire. 8. RECONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 9. REINSTALL FLOOR SERVICE HOLE COVER 10. REINSTALL REAR SEAT CUSHION 2001 AVALON (RM808U) Author
: Date
: 1118 SF-14 SFI - FUEL PUMP SF0LH-01 REASSEMBLY Installation is in the reverse order of disassembly (See page SF-12 ). 2001 AVALON (RM808U) Author
: Date
: 1123 SF-1 1 SFI - FUEL PUMP SF0LF-01 REMOVAL CAUTION: Do not smoke or work near an open flame when working on the fuel pump. 1. REMOVE REAR SEAT CUSHION 2. REMOVE FLOOR SERVICE HOLE COVER (a) Take out the floor carpet. (b) Remove the 5 screws and service hole cover. HINT: At the time of installation, please refer to the following items. Check for fuel leakage. 3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR NOTICE: Do not lift the fuel pump up with the wire harness picking. 4. REMOVE NO.1 FUEL TANK PROTECTOR Remove the 2 bolts and No.1 fuel tank protector. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) 5. S04583 DISCONNECT FUEL TUBE (FUEL TUBE CONNECTOR) CAUTION:
Perform disconnecting and connecting operations of the fuel tube connector (quick type) after observing the precautions (See page SF-1 ).
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the vehicle compartment. 6. (a) Vinyl Bag B02519 REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK Remove the 6 bolts and fuel tank vent tube set plate. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) (b) Pull out the fuel pump assembly. (c) Remove the gasket from the pump assembly. NOTICE:
Do not damage the fuel pump filter.
Be careful that the arm of the sender gauge should not bent. HINT: At the time of installation, please refer to the following items. Install a new gasket to the pump assembly. 2001 AVALON (RM808U) Author
: Date
: 1120 SF-80 SFI - HEATED OXYGEN SENSOR HEATED OXYGEN SENSOR SF105-02 COMPONENTS Bench Seat Type Except Bench Seat Type Passenger’s Seat 37 (375, 27) 37 (375, 27) Connector for Seat Heated Oxygen Sensor Connector (Bank 1 Sensor 2) Heated Oxygen Sensor (Bank 1 Sensor 2) 44 (450, 32) Grommet N·m (kgf·cm, ft·lbf) : Specified torque B09136 2001 AVALON (RM808U) Author
: Date
: 1189 SF-81 SFI - HEATED OXYGEN SENSOR SF106-02 INSPECTION +B HT Ohmmeter B09137 INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR (Bank 1 Sensor 2) (a) Remove the passenger’s seat. (b) Disconnect the oxygen sensor connector. (c) Using an ohmmeter, measure the resistance between the terminals +B and HT. Resistance: At 20°C (68°F) 11 - 16 Ω At 800°C (1,472°F) 23 - 32 Ω If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (d) Reconnect the oxygen sensor connector. (e) Reinstall the passenger’s seat. 2001 AVALON (RM808U) Author
: Date
: 1190 SF-44 SFI - IDLE AIR CONTROL (IAC) VALVE SF067-05 COMPONENTS V-Bank Cover 19.5 (200, 14) Brake Booster Vacuum Hose 29 (300, 22)
Gasket Fuel Vapor Feed Hose Throttle Body Bracket Vacuum Hose Throttle Body Throttle Position Sensor Connector IAC Valve Connector Vacuum Hose Accelerator Cable Air Assist Hose Water Bypass Hose Throttle Cable Throttle Body Air Cleaner Hose w/ Resonator
Gasket IAC Valve N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B09118 2001 AVALON (RM808U) Author
: Date
: 1153 SF-46 SFI - IDLE AIR CONTROL (IAC) VALVE SF0ZX-01 INSPECTION Close INSPECT IAC VALVE OPERATION (a) Check that the IAC valve is halfly opened. (b) Connect the IAC valve connector to the IAC valve. (c) Turn the ignition switch ON. (d) Check that the IAC valve moves in 0.5 seconds by order of fully close, fully open and halfly open. If operation is not as specified, replace the IAC valve. (e) Turn the ignition switch OFF. (f) Disconnect the IAC valve connector from the IAC valve. Open Valve B06692 2001 AVALON (RM808U) Author
: Date
: 1155 SF-47 SFI - IDLE AIR CONTROL (IAC) VALVE SF06A-01 INSTALLATION Installation is in the reverse order of removal (See page SF-45 ). 2001 AVALON (RM808U) Author
: Date
: 1156 SF-43 SFI - IDLE AIR CONTROL (IAC) VALVE IDLE AIR CONTROL (IAC) VALVE SF0ZW-01 ON-VEHICLE INSPECTION 1. (a) E1 DLC1 (b) SST TE1 DLC1 A07285 Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 (c) After engine speed is kept at approx. 1,000 rpm for 5 seconds, check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) Remove the SST from the DLC1. SST 09843-18020 2. INSPECT AIR ASSIST SYSTEM (a) Initial conditions:
Engine at normal operating temperature
Idle speed checked correctly
Transmission in neutral position
A/C switch OFF (b) SST E1 DLC1 INSPECT IAC VALVE OPERATION Initial conditions:
Engine at normal operating temperature
Idle speed checked correctly
Transmission in neutral position
A/C switch OFF (c) (d) (e) TE1 Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 After engine speed is kept at 900 - 1,300 rpm for 10 seconds, check that it returns to idle speed. Stop the engine. Remove the V-bank cover. DLC1 A07285 (f) Plug Disconnect Plug B06684 Disconnect the air assist hose from the air pipe, and block off the IAC valve exit and the entry to the pipe. (g) Start the engine and check that the idle speed reaches 500 rpm or below (the engine may stall). If the idle does not reach 500 rpm or below, check for a leak between the air assist hoses, pipe and injectors. (h) Remove the SST from the DLC1. SST 09843-18020 (i) Reconnect the air assist hose to the air pipe. (j) Reinstall the V-bank cover. 2001 AVALON (RM808U) Author
: Date
: 1152 SF-45 SFI - IDLE AIR CONTROL (IAC) VALVE SF068-03 REMOVAL 1. REMOVE THROTTLE BODY (See page SF-36 ) 2. REMOVE IAC VALVE Remove the 4 screws, bracket, IAC valve and gasket. HINT: At the time of installation, please refer to the following items. Place a new gasket on the throttle body. B06512 2001 AVALON (RM808U) Author
: Date
: 1154 SF-20 SFI - INJECTOR SF073-04 COMPONENTS 39 (400, 19) PS Pressure Tube 19.5 (200, 14) V-Bank Cover Throttle Position Sensor Connector Throttle Body Bracket VSV Connector for No.1 ACIS Brake Booster Vacuum Hose Accelerator Cable 43 (440, 32) No.1 Engine Hanger Throttle Cable VSV Connector for EVAP IAC Valve Connector Ground Cable Ground Cable Ground Strap PCV Hose DLC1 Water Bypass Hose Purge Hose Vacuum Hose Air Cleaner Hose VSV Connector for No.2 ACIS w/ Resonator Air Intake Chamber Assembly
Gasket 19.5 (200, 14) Fuel Hose Clamp Air Assist Hose and Pipe
Retainer 10 (100, 7) Fuel Inlet Hose Delivery Pipe Spacer
O-Ring
Grommet Injector
O-Ring Injector Connector
Insulator N·m (kgf·cm, ft·lbf) : Specified
Non-reusable part B09080 2001 AVALON (RM808U) Author
: Date
: 1129 SF-23 SFI - INJECTOR SF075-05 INSPECTION Fuel Tube Connector 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clear of sparks during the test. SST (Union) SST (Clamp) SST (Hose) Fuel Filter (On Vehicle) Injector B09081 (a) Fuel Tube Connector Purchase the new No.1 fuel pipe and take out the fuel tube connector from its pipe. Part No. 23801-20070 S05359 (b) Fuel Tube Connector SST (Hose) Fuel Filter B09082 SST (Hose) SST (Union) O-Ring SST (Clamp) Vinyl Tube Connect SST (hose) and fuel tube connector to the fuel filter outlet. SST 09268-41047 CAUTION: Preform connecting operations of the fuel tube connector (quick type) after observing the precautions (See page SF-1 ). HINT: Use the vehicle fuel filter. (c) (d) Install the grommet and O-Ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-41047 Put the injector into a graduated cylinder. (e) HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. B06481 TOYOTA Hand-Held Tester DLC3 A10838 (f) (g) Connect the TOYOTA hand-held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA handheld tester main switch ON. NOTICE: Do not start the engine. (h) Select the ACTIVE TEST mode on the TOYOTA handheld tester. (i) Please refer to the TOYOTA hand-held tester operator’s manual for further details. 2001 AVALON (RM808U) Author
: Date
: 1132 SF-24 SFI (j) - INJECTOR If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See page SF-6 ). (k) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 60 - 73 cm3 (3.4 - 4.5 cu in.) per 15 sec. Difference between each injector: 13 cm3 (0.8 cu in.) or less If the injection volume is not as specified, replace the injector. SST (Wire) Battery B06483 2. (a) B06482 INSPECT LEAKAGE In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30070 Fuel drop: 1 drop or less per 12 minutes (b) Turn the ignition switch OFF. (c) Disconnect the negative (-) terminal cable from the battery. (d) Remove the SST and fuel tube connector. SST 09268-41047, 09842-30070 CAUTION:
Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions (See page SF-1 ).
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. (e) Disconnect the TOYOTA hand- held tester from the DLC3. 2001 AVALON (RM808U) Author
: Date
: 1133 SF-25 SFI - INJECTOR SF076-05 INSTALLATION New Insulator New O-Ring New O-Ring New Grommet 1. (a) (b) INSTALL INJECTORS AND DELIVERY PIPES Install new insulator and grommet to each injector. Apply a light coat of spindle oil or gasoline to 2 new Orings and install them to each injector. (c) (e) Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches an O-ring of the injector. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 6 injectors. Position the injector connector outward. (f) Place the 4 spacers in position on the intake manifold. (g) Apply a light coat of spindle oil or gasoline on the place where a intake manifold touches an O-ring of the injector. Place the delivery pipes and fuel pipe together with the 6 injectors in position on the intake manifold. Temporarily install the 4 bolts holding the delivery pipes to the intake manifold. Temporarily install the bolt holding the No.1 fuel pipe to the intake manifold. B06484 Turn (d) Push Connector B06485 Spacer Spacer S04510 (h) (i) (j) B06614 (k) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings. (l) Position the injector connector outward. Rotate Outward B06616 2001 AVALON (RM808U) Author
: Date
: 1134 SF-26 SFI (m) (n) - INJECTOR Tighten the 4 bolts holding the delivery pipes to the intake manifold. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Tighten the bolt holding the No.1 fuel pipe to the intake manifold. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) B01020 2. (a) CONNECT NO.1 FUEL PIPE Align the alignment marks (white paint) on the No.1 fuel pipe. Align B06618 (b) Connect the No.1 fuel pipe (fuel tube connector) to the fuel filter. CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. B09079 (c) Fuel Hose Clamp (d) Surely install the fuel hose clamp to the fuel filter with ”click” sound. After installing the clamp, check that the clamp is fixed by pulling up the clamp. B09076 3. 4. 5. 6. 7. (a) B06613 (b) 8. INSTALL AIR ASSIST HOSES AND PIPE CONNECT INJECTOR CONNECTORS INSTALL AIR INTAKE CHAMBER ASSEMBLY (See page EM-59 ) INSTALL AIR CLEANER HOSE WITH RESONATOR INSTALL V-BANK COVER Using 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts. Press down the V-bank cover fastener. CHECK FOR FUEL LEAKS 2001 AVALON (RM808U) Author
: Date
: 1135 SF-19 SFI - INJECTOR INJECTOR SF072-05 ON-VEHICLE INSPECTION 5 mm Hexagon Wrench 1. (a) (b) (c) REMOVE V-BANK COVER Using a 5 mm hexagon wrench, remove the 3 cap nuts. Loosen the V-bank cover fastener counterclockwise. Remove the V-bank cover. A10518 Sound Scope B06523 2. INSPECT INJECTOR OPERATION Check operation sound from each injector. (1) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed. (2) If you have no sound scope, you can check the injector operating vibration with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM. 3. (a) (b) Ohmmeter B06522 INSPECT INJECTOR RESISTANCE Disconnect the injector connector. Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 - 14.2 Ω at 20°C (68°F) If the resistance is not as specified, replace the injector. (c) Reconnect the injector connector. 4. REINSTALL V-BANK COVER (a) Using 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts. (b) Press down the V-bank cover fastener. 2001 AVALON (RM808U) Author
: Date
: 1128 SF-21 SFI - INJECTOR SF0ZR-02 REMOVAL 5 mm Hexagon Wrench 1. (a) (b) (c) 2. 3. REMOVE V-BANK COVER Using a 5 mm hexagon wrench, remove the 3 cap nuts. Loosen the V-bank cover fastener counterclockwise. Remove the V-bank cover. REMOVE AIR CLEANER HOSE WITH RESONATOR REMOVE AIR INTAKE CHAMBER ASSEMBLY (See page EM-31 ) 4. DISCONNECT INJECTOR CONNECTORS 5. REMOVE AIR ASSIST HOSES AND PIPE 6. (a) DISCONNECT NO.1 FUEL PIPE Remove the fuel hose clamp. A10518 S04505 B06613 Fuel Hose Clamp B09076 (b) B09077 Disconnect the No.1 fuel pipe (fuel tube connector) from the fuel filter outlet. CAUTION:
Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions (See page SF-1 ).
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. 2001 AVALON (RM808U) Author
: Date
: 1130 SF-22 SFI B06617 - INJECTOR 7. REMOVE DELIVERY PIPES AND INJECTORS NOTICE:
Be careful not to drop the injectors when removing the delivery pipes.
Pay attention to put any hung load on the injector to and from the side direction. (a) Remove the 5 bolts and delivery pipes together with the 6 injectors and No.1 fuel pipe. (b) Remove the 4 spacers from the intake manifold. (c) Pull out the 6 injectors from the delivery pipes. (d) Remove the 2 O-rings and 2 grommets from each injector. 2001 AVALON (RM808U) Author
: Date
: 1131 SF-76 SFI - KNOCK SENSOR KNOCK SENSOR SF06S-03 COMPONENTS 39 (400, 19) PS Pressure Tube Throttle Body Bracket Brake Booster Vacuum Hose 19.5 (200, 14) V-Bank Cover Air Cleaner Hose w/ Resonator 43 (440, 32) VSV Connector for No.1 ACIS Throttle Position Sensor Connector No.1 Engine Hanger VSV Connector for EVAP Ground Cable Ground Strap IAC Valve Connector Accelerator Cable Throttle Cable Ground Cable PCV Hose Air Intake Chamber Assembly Purge Hose
Gasket DLC1 Engine Coolant Reservoir Hose ECT Sensor Connector Fuel Hose Clamp Vacuum Hose VSV Connector for No.2 ACIS ECT Sender Gauge Connector Water Bypass Hose
Retainer 15 (150, 11) Upper Radiator Hose Heater Hose x9 Intake Manifold Assembly Grand Strap Connector 15 (150, 11) Water Outlet
Gasket
Gasket Injector Connector Knock Sensor Connector Knock Sensor 39 (400, 29) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B09135 2001 AVALON (RM808U) Author
: Date
: 1185 SF-77 SFI - KNOCK SENSOR SF102-02 INSPECTION 5 mm Hexagon Wrench 1. (a) (b) (c) 2. 3. REMOVE V-BANK COVER Using a 5 mm hexagon wrench, remove the 3 cap nuts. Loosen the V-bank cover fastener counterclockwise. Remove the V-bank cover. REMOVE AIR CLEANER HOSE WITH RESONATOR REMOVE INTAKE MANIFOLD ASSEMBLY AND WATER OUTLET (See page EM-31 ) 4. (a) (b) REMOVE KNOCK SENSORS Disconnect the knock sensor connector. Using SST, remove the knock sensor. SST 09817-1601 1 A10518 Knock Sensor 1 SST Knock Sensor 2 P20115 Ohmmeter P01630 5. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 6. REINSTALL KNOCK SENSORS (a) Using SST, install the knock sensor. SST 09817-1601 1 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (b) Connect the knock sensor connector. 7. REINSTALL WATER OUTLET AND INTAKE MANIFOLD ASSEMBLY (See page EM-59 ) 8. REINSTALL AIR CLEANER HOSE WITH RESONATOR 9. REINSTALL V-BANK COVER (a) Using 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts. (b) Press down the V-bank cover fastener. 2001 AVALON (RM808U) Author
: Date
: 1186 SF-29 SFI - MASS AIR FLOW (MAF) METER MASS AIR FLOW (MAF) METER SF05X-05 COMPONENTS MAF Meter Connector MAF Meter
O-Ring
Non-reusable part B09084 2001 AVALON (RM808U) Author
: Date
: 1138 SF-31 SFI - MASS AIR FLOW (MAF) METER SF05Z-03 E2 THA Ohmmeter INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. Resistance: B06674 Terminals Resistance Temperature THA - E2 13.6 - 18.4 kΩ -20 °C (-4°F) THA - E2 2.21 - 2.69 kΩ 20°C (68°F) THA - E2 0.49 - 0.67 kΩ 60°C (140°F) If the resistance is not as specified, replace the MAF meter. VG E2G Voltmeter Air B06675 2. (a) (b) (c) INSPECT MAF METER OPERATION Connect the MAF meter connector. Turn the ignition switch ON. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. (d) Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (e) Turn the ignition switch LOCK. (f) Disconnect the MAF meter connector. 2001 AVALON (RM808U) Author
: Date
: 1140 SF-32 SFI - MASS AIR FLOW (MAF) METER SF060-01 INSTALLATION Installation is in the reverse order of removal (See page SF-30 ). 2001 AVALON (RM808U) Author
: Date
: 1141 SF-30 SFI - MASS AIR FLOW (MAF) METER SF05Y-05 REMOVAL REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 screws, MAF meter and O-ring. HINT: At the time of installation use a new O-ring. B06723 2001 AVALON (RM808U) Author
: Date
: 1139 SF-1 SFI - SFI SYSTEM SFI SYSTEM SF0LC-03 PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. MAINTENANCE PRECAUTIONS (a) In event of engine misfire, these precautions should be taken. (1) Check proper connection to battery terminals, etc. (2) After repair work, check that the ignition coil terminals and all other ignition system lines are reconnected securely. (3) When cleaning the engine compartment, be especially careful to protect the electrical system from water. (b) Precautions when handling the oxygen sensor. (1) Do not allow oxygen sensor to drop or hit against an object. (2) Do not allow the sensor to come into contact with water. 5. IF VEHICLE IS EQUIPPED WITH A MOBILE RADIO SYSTEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 6. AIR INDUCTION SYSTEM (a) Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune. (b) Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of tune. 7. ELECTRONIC CONTROL SYSTEM (a) Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch to LOCK or disconnecting the negative (-) terminal cable from the battery. HINT: Always check the diagnostic trouble code before disconnecting the negative (-) terminal cable from the battery. 2001 AVALON (RM808U) Author
: Date
: 1110 SF-2 SFI (b) (c) (d) (e) (f) (g) (h) - SFI SYSTEM When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (-) cables. Do not permit parts to receive a severe impact during removal or installation. Handle all SFI parts carefully, especially the ECM. Do not be careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can cause further troubles. Do not open the ECM cover. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors. Parts should be replaced as an assembly. Care is required when pulling out and inserting wiring connectors. (1) Release the lock and pull out the connector, pulling on the connectors. (2) Fully insert the connector and check that it is locked. (i) Use SST for inspection or test of the injector or its wiring connector. SST 09842-30070 8. (a) FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. SST FI2553 Fuel Pump Connector S04600 (3) (4) (5) (6) Plug Put a container under the connection. Slowly loosen the connection. Disconnect the connection. Plug the connection with a rubber plug. S05039 2001 AVALON (RM808U) Author
: Date
: 1111 SF-3 SFI (b) - SFI SYSTEM When connecting the union bolt on the high pressure pipe union, observe the following procedures: (1) Always use 2 new gaskets. (2) Tighten the union bolt by hand. (3) Tighten the union bolt to the specified torque. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) New Gasket S05054 (c) Fulcrum Length 30 cm SST FI1654 New O-Ring Grommet CORRECT When connecting the flare nut on the high pressure pipe union, observe the following procedures: (1) Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. (2) Using SST, tighten the flare nut to specified torque. SST 09023-12700 NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Torque: 28 N·m (285 kgf·cm, 21 ft·lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). (d) Observe the following precautions when removing and installing the injectors. (1) Never reuse the O-ring. (2) When placing a new O-ring on the injector, take care not to damage it in any way. (3) Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. (e) Install the injector to the delivery pipe and intake manifold as shown in the illustration. Observe these precautions when disconnecting the fuel tube connector (quick type). (1) Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away. (2) Be sure to disconnect with hands. Delivery Pipe Injector WRONG FI6372 Delivery Pipe O-Ring (f) Insulator Grommet Spacer O-Ring B05295 2001 AVALON (RM808U) Author
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: 1112 SF-4 SFI (3) (4) - SFI SYSTEM When the connector and the pipe are stuck, pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away. S04583 (5) Vinyl Bag Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag. S05040 (g) Retainer Observe these precautions when connecting the fuel tube connector (quick type). (1) Do not reuse the retainer removed from the pipe. (2) Must use hands without using tools when to remove the retainer from the pipe. (3) Check if there is any damage or foreign objects on the connected part of the pipe. S05382 (4) Click Sound S05050 (h) Match the axis of the connector with axis of the pipe, and push in the connector until the retainer makes a ”click” sound. In case that the connections is tight, apply little amount of new engine oil on the tip of the pipe. (5) After having finished the connection, check if the pipe and the connector are securely connected by pulling them. (6) Check if there is any fuel leakage. Observe these precautions when handling nylon tube. (1) Pay attention not to turn the connector with force when connecting them. (2) Pay attention not to kink the nylon tube. (3) Do not remove the EPDM protector on the outside of the nylon tube. (4) Must not close the piping with the nylon tube by bending it. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O-ring of the injector. 2001 AVALON (RM808U) Author
: Date
: 1113 SF-5 SFI - SFI SYSTEM (i) TOYOTA Hand-Held Tester DLC3 A10838 Check that there are no fuel leaks after performing maintenance anywhere on the fuel system. (1) Connect a TOYOTA hand-held tester to the DLC3. (2) Turn the ignition switch ON and TOYOTA handheld tester main switch ON. NOTICE: Do not start the engine. (3) Select the active test mode on the TOYOTA handheld tester. (4) Please refer to the TOYOTA hand-held tester operator’s manual for further details. (5) If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector (See page SF-6 ). (6) Check that there are no leaks from any part of the fuel system. (7) Turn the ignition switch to LOCK. (8) Disconnect the TOYOTA hand-held tester from the DLC3. 2001 AVALON (RM808U) Author
: Date
: 1114 SF-34 SFI - THROTTLE BODY SF0ZS-03 COMPONENTS V-Bank Cover 19.5 (200, 14) Brake Booster Vacuum Hose 29 (300, 22)
Gasket Fuel Vapor Feed Hose Throttle Body Bracket Throttle Body Vacuum Hose Vacuum Hose IAC Valve Connector Throttle Position Sensor Connector Accelerator Cable Air Assist Hose Water Bypass Hose Throttle Cable Air Cleaner Hose w/ Resonator N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B09088 2001 AVALON (RM808U) Author
: Date
: 1143 SF-35 SFI - THROTTLE BODY Protector No.1 Intake Air Control Valve
O-Ring Throttle Position Sensor 6.9 (70, 61 in.·lbf)
Gasket 6.9 (70, 61 in.·lbf) No.1 Throttle Body
Gasket
O-Ring
Gasket Bracket No.2 Throttle Body IAC Valve N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B09089 2001 AVALON (RM808U) Author
: Date
: 1144 SF-38 SFI - THROTTLE BODY SF0ZU-02 INSPECTION Must Have Clearance Must Have No Clearance B09094 NOTICE: In case of changing, removing or installing the throttle body or IAC valve, must do this. 1. INSPECT THROTTLE BODY (a) Check that there is no clearance between each throttle stop screw and the throttle lever when applying the vacuum (53.3 kPa (400 mmHg, 15.7 in.Hg)) to the throttle opener using a MITYVAC (Hand-Held Vacuum Pump). Standard: Must have no clearance NOTICE: As the throttle stop screw is precisely adjusted, so do not adjust it. (b) Close Side Open Side Fully Opening Adjust Screw (Close Side) Under the condition of (1), check visually that there is a clearance between each adjust screw and the throttle lever on No.1 side. Adjust screw Reference value Close side About 0.13 mm (0.0051 in.) Open side About 0.22 mm (0.0087 in.) B05131 Feeler Gauge (c) Measure the clearance between the adjust screw on the close side when fully opening the throttle lever on No.2 side by hand and the throttle lever on No.1 side with a feeler gauge. Standard value: 0.25 - 0.45 mm (0.0098 - 0.0177 in.) In case of being out of standard value, perform the adjustment of step 2. B05132 2001 AVALON (RM808U) Author
: Date
: 1147 SF-39 SFI Throttle Stop Screw Adjust Screw (Close Side) Adjust Screw (Open Side) B09116 - THROTTLE BODY 2. ADJUST THROTTLE BODY (BALANCE) NOTICE: Do not adjust the throttle stop screw and throttle opener. (a) Beforehand checking. Recheck 1 - (a). (b) Adjustment of the adjust screw on the open side. (1) Using a 2 mm hexagon wrench, loosen the lock nut and screw, make clearance between the screw tip and the throttle lever on No.1 side. (2) Turn the screw to the screw torque direction gradually, and stop it at the position where to touch the lever at the very moment. NOTICE: If turning it too much to the torque direction, the No.1 lever goes off from the throttle stop screw causing the adjustment failure. (3) Close Side Open Side B05184 Turn it back from the position where it touches the lever to the screw loosing direction. Standard: Turn it back by rotating 1/4 (4) Tighten the lock nut. (c) Adjustment of the adjust screw on the close side. (1) Loosen the lock nut and screw, and make clearance between the screw tip and the throttle lever on No.1 side. (2) Turn the screw to the screw torque direction gradually, and stop it at the position where to touch the lever at the very moment. NOTICE: If turning it too much to the torque direction, the No.2 lever goes off from the throttle stop screw causing the adjustment failure. (3) Turn it back from the position where it touches the lever to the screw loosing direction. Standard: Turn it back by rotating 1/2 - 3/4 (4) Tighten the lock nut. (d) Completion checking. Check 1 - (c). 2001 AVALON (RM808U) Author
: Date
: 1148 SF-42 SFI - THROTTLE BODY SF065-03 INSTALLATION Installation is in the reverse order of removal (See page SF-36 ). 2001 AVALON (RM808U) Author
: Date
: 1151 SF-33 SFI - THROTTLE BODY THROTTLE BODY SF061-03 ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly. B09085 VTA Vacuum Ohmmeter E2 VC 2. (a) (b) (c) (d) B09086 (e) 3. (a) (b) INSPECT THROTTLE POSITION SENSOR Disconnect the sensor connector. Disconnect the vacuum hose from the throttle body. Apply vacuum to the throttle opener. Using an ohmmeter, measure the resistance between each terminal. Resistance: Throttle valve condition Between terminals Resistance Fully closed VTA - E2 0.2 - 6.3 kΩ Fully open VTA - E2 2.0 - 10.2 kΩ - VC - E2 2.5 - 5.9 kΩ Reconnect the vacuum hose to the throttle body. INSPECT THROTTLE OPENER Allow the engine to warm up to normal operating temperature. Check idle speed. Idle speed: 650 ± 50 rpm (c) Plug Disconnect B09087 Disconnect the vacuum hose from the throttle opener, and plug the hose end. (d) Check the throttle opener setting speed. Throttle opener setting speed: 1,100 - 1,700 rpm If the throttle opener setting is not as specified, replace the throttle body. (e) Stop the engine. (f) Reconnect the vacuum hose to the throttle opener. (g) Start the engine and check that the idle speed returns to the correct speed. 2001 AVALON (RM808U) Author
: Date
: 1142 SF-36 SFI - THROTTLE BODY REMOVAL 1. DRAIN ENGINE COOLANT SF0ZT-02 2. REMOVE V-BANK COVER (a) Using a 5 mm hexagon wrench, remove the 3 cap nuts. (b) Loosen the V-bank cover fastener counterclockwise. HINT: At the time of installation, please refer to the following items. Press down the V-bank cover fastener. (c) Remove the V-bank cover. 5 mm Hexagon Wrench A10518 3. (a) (b) (c) 4. REMOVE AIR CLEANER HOSE WITH RESONATOR Disconnect the PCV hose. Disconnect the vacuum hose (from the VSV for the active engine control mount). Loosen the 3 hose clamps, and remove the air cleaner hose with the resonator. DISCONNECT ACCELERATOR CABLE AND THROTTLE CABLE B09090 5. (a) (e) (b) (b) (c) (d) (e) (c) (d) B09091 (f) (g) (i) (k) (j) (f) REMOVE THROTTLE BODY Remove the bolt holding the throttle body to the throttle body bracket. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) Disconnect the throttle position sensor connector. Disconnect the IAC valve connector. Disconnect the wire clamp. Disconnect the brake booster vacuum hose. (g) (h) B09092 (h) (i) (j) (k) Disconnect the water bypass hose (from the intake manifold). Disconnect the water bypass hose (from the water inlet housing). Disconnect the air assist hose. Disconnect the fuel vapor feed hose (from the emission control valve set). Disconnect the vacuum hose (from the No.1 ACIS VSV). Disconnect the vacuum hose (from the vacuum tank for the ACIS). 2001 AVALON (RM808U) Author
: Date
: 1145 SF-37 SFI - THROTTLE BODY (l) Remove the 3 nuts, throttle body and gasket. HINT: At the time of installation, please refer to the following items. Place a new gasket on the air intake chamber. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) B09093 2001 AVALON (RM808U) Author
: Date
: 1146 SF-40 SFI - THROTTLE BODY SF16B-01 REPLACEMENT NOTICE:
Do not give a shock to the throttle position senor.
Do not disassemble or adjust the throttle opener. 1. (a) REPLACE THROTTLE POTION SENSOR Remove the 2 screws and throttle position sensor. (b) Reinstall a new throttle position sensor. (1) Check that the throttle valve is fully close. (2) Insert the sensor to the throttle body with it turned counterclockwise by 30° to 60° against the fullyclose valve position. (3) By turning the sensor clockwise, tighten the 2 screws. 2. (a) (b) (c) REPLACE IAC VALVE Remove the 4 screws, bracket, IAC valve and gasket. Place a new gasket on the No.1 throttle body. Reinstall a new IAC valve with the 4 screws and bracket. 3. (a) REPLACE THROTTLE BODIES Remove the 2 screws and protector. B06510 B06507 B06512 B06513 2001 AVALON (RM808U) Author
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: 1149 SF-41 SFI - THROTTLE BODY (b) Remove the 6 screws, No.1 throttle body, No.2 throttle body and 2 gaskets from the No.1 intake air control valve. (c) Place 2 new gaskets and 2 new O-rings as shown in the illustration. (d) Reinstall a new No.1 throttle body and No.2 throttle body with the 6 screws. Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf) B09117 New Gasket New O-Ring New Gasket New O-Ring B05128 B09117 2001 AVALON (RM808U) Author
: Date
: 1150 SF-66 SFI - VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF100-01 COMPONENTS No.1 V-Bank Cover Vacuum Hose VSV for No.1 ACIS VSV Connector for EVAP VSV Connector for No.1 ACIS VSV Connector for No.2 ACIS Emission Control Valve Set B06503 2001 AVALON (RM808U) Author
: Date
: 1175 SFI - VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF-67 No.2 V-Bank Cover VSV Connector for EVAP Emission Control Valve Set VSV Connector for No.2 ACIS VSV Connector for No.1 ACIS VSV for No.2 ACIS Vacuum Hose B06502 2001 AVALON (RM808U) Author
: Date
: 1176 SF-68 SFI - VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF06N-03 INSPECTION 1. 2. (a) (b) Ohmmeter REMOVE V- BANK COVER, AND EMISSION CONTROL VALVE SET REMOVE VSV Disconnect the 2 vacuum hoses from the VSV. Remove the screw and VSV. 3. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between each terminals. Resistance: 33 - 39 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Continuity S04525 Ohmmeter 4. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. No Continuity S04524 5. (a) Air INSPECT VSV OPERATION Check that air flows from port E to the filter. E Filter FI6393 Air E F Battery (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to port F. If operation is not as specified, replace the VSV. 6. REINSTALL VSV (a) Install the VSV with the screw. (b) Connect the 2 vacuum to the VSV. 7. REINSTALL EMISSION CONTROL VALVE SET 8. REINSTALL V-BANK COVER S04523 2001 AVALON (RM808U) Author
: Date
: 1177 SF-69 SFI - VSV FOR CANISTER CLOSED VALVE (CCV) VSV FOR CANISTER CLOSED VALVE (CCV) SF16F-01 COMPONENTS VSV Connector for Canister Closed Valve (CCV) Air Hose VSV for Canister Closed Valve (CCV)
O-Ring
Non-reusable part B09130 2001 AVALON (RM808U) Author
: Date
: 1178 SF-70 SFI - VSV FOR CANISTER CLOSED VALVE (CCV) SF16G-01 INSPECTION 1. Ohmmeter Continuity REMOVE VSV 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: At 20°C ( 68°F) 25 - 30 Ω At 120°C ( 248°F) 33 - 42 Ω If there is no continuity, replace the VSV. B09131 No Continuity Ohmmeter 3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. B09132 4. (a) A Air INSPECT VSV OPERATION Check that air flows from ports A to B. B B09133 Air (b) Apply battery positive voltage across the terminals. (c) Check that air does not flow from ports A to B. If operation is not as specified, replace the VSV. 5. REINSTALL VSV A B Battery B09134 2001 AVALON (RM808U) Author
: Date
: 1179 SF-64 SFI - VSV FOR EVAPORATIVE EMISSION (EVAP) VSV FOR EVAPORATIVE EMISSION (EVAP) SF06K-03 COMPONENTS EVAP Hose VSV for EVAP V-Bank Cover VSV Connector for EVAP VSV for No.2 ACIS VSV Connector for No.2 ACIS VSV Connector for No.1 ACIS Emission Control Valve Set B09129 2001 AVALON (RM808U) Author
: Date
: 1173 SF-65 SFI - VSV FOR EVAPORATIVE EMISSION (EVAP) SF06L-03 INSPECTION 1. 2. (a) (b) Ohmmeter REMOVE V-BANK COVER AND EMISSION CONTROL VALVE SET REMOVE VSV Disconnect the 2 EVAP hoses from the VSV. Remove the screw and VSV. 3. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 27 - 33 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Continuity S04522 Ohmmeter 4. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. No Continuity S04521 5. (a) Air INSPECT VSV OPERATION Check that air flows with difficulty from port E to port F. E F P18857 Air E F Battery (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to port F. If operation is not as specified, replace the VSV. 6. REINSTALL VSV (a) Install the VSV with the screw. (b) Connect the 2 EVAP hoses to the VSV. 7. REINSTALL EMISSION CONTROL VALVE SET 8. REINSTALL V-BANK COVER S04520 2001 AVALON (RM808U) Author
: Date
: 1174 SF-71 SFI - VSV FOR PRESSURE SWITCHING VALVE VSV FOR PRESSURE SWITCHING VALVE SF14G-01 COMPONENTS VSV for Pressure Switching Valve VSV Connector for Pressure Switching Valve Vacuum Hose B08633 2001 AVALON (RM808U) Author
: Date
: 1180 SF-72 SFI - VSV FOR PRESSURE SWITCHING VALVE SF14H-01 INSPECTION 1. Ohmmeter REMOVE VSV 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: Continuity At 20°C ( 68°F) 37 - 44 Ω At 120°C ( 248°F) 51 - 62 Ω If there is no continuity, replace the VSV. B08661 Ohmmeter No Continuity 3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. B08662 4. (a) F INSPECT VSV OPERATION Check that air does not flow from ports E to F. E Air B08663 (b) Apply battery positive voltage across the terminals. (c) Check that air flows from ports E to F. If operation is not as specified, replace the VSV. 5. REINSTALL VSV F E Air Battery B08664 2001 AVALON (RM808U) Author
: Date
: 1181 SF-74 SFI - VAPOR PRESSURE SENSOR VAPOR PRESSURE SENSOR SF101-02 COMPONENTS Vapor Pressure Sensor (Type A) Vapor Pressure Sensor (Type B) Vapor Pressure Sensor Connector Vacuum Hose Vacuum Hose Fuel Hose Charcoal Canister B08628 2001 AVALON (RM808U) Author
: Date
: 1183 SF-75 SFI - VAPOR PRESSURE SENSOR SF06R-03 Voltmeter INSPECTION 1. (a) (b) (c) Disconnect VC E2 B08629 (d) (e) 2. Type A Disconnect Pressure (a) (b) (c) Vacuum Type B Disconnect Pressure Vacuum ECM E2 PTNK (d) (e) INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR Disconnect the vapor pressure sensor connector. Turn the ignition switch ON. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V Turn the ignition switch OFF. Reconnect the vapor pressure sensor connector. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR Turn the ignition switch ON. Disconnect the fuel hose from the vapor pressure sensor. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under the following conditions: (1) Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V (2) Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V (3) Apply pressure (1.5 kPa (15 gf/cm2, 0.22 psi)) to the vapor pressure sensor. Voltage: 4.2 - 4.8 V Turn the ignition switch OFF. Reconnect the fuel hose to the vapor pressure sensor. B08630 2001 AVALON (RM808U) Author
: Date
: 1184 RS-67 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Column Shift) AIRBAG SENSOR ASSEMBLY (Column Shift) RS0LQ-01 COMPONENTS Lower Panel 20 (205, 15) Airbag Sensor Assembly 20 (205, 15) No. 2 Under Cover No. 1 Lower Panel Finish Panel Cowl Side Trim Front Door Scuff Plate N·m (kgf·cm, ft·lbf) : Specified torque H11909 2001 AVALON (RM808U) Author
: Date
: 1587 RS-69 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Column Shift) RS0LS-01 INSPECTION 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check (See page DI-349 ). 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check (See page DI-349 ). 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the airbag sensor assembly (See page DI-349 ). 2001 AVALON (RM808U) Author
: Date
: 1589 RS-71 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Column Shift) RS0LU-01 INSTALLATION NOTICE:
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed.
Never repair a sensor in order to reuse it. HINT: For step 2 to 7, refer to page BO-97 . 1. (a) LH Side: RH Side: H11910 INSTALL AIRBAG SENSOR ASSEMBLY Using a torx wrench, install the airbag sensor assembly with the 3 screws. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) (b) Connect the airbag sensor connectors. NOTICE:
Connection of the connector is done after the sensor assembly has been installed.
Make sure the sensor assembly is installed with the specified torque.
If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one.
When installing the senor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts.
After installing, shake the sensor assembly to check that there is no looseness. 2. INSTALL FINISH PANEL 3. INSTALL LOWER PANEL 4. INSTALL NO. 2 UNDER COVER 5. INSTALL NO. 1 LOWER PANEL 6. INSTALL COWL SIDE TRIM LH 7. INSTALL FRONT DOOR SCUFF PLATE LH 2001 AVALON (RM808U) Author
: Date
: 1591 RS-68 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Column Shift) RS0LR-01 REMOVAL NOTICE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) HINT: For step 1 to 6, refer to page BO-90 . 1. REMOVE FRONT DOOR SCUFF PLATE LH 2. REMOVE COWL SIDE TRIM LH 3. REMOVE NO. 1 LOWER PANEL 4. REMOVE NO. 2 UNDER COVER 5. REMOVE LOWER PANEL 6. REMOVE FINISH PANEL 7. REMOVE AIRBAG SENSOR ASSEMBLY (a) Disconnect the airbag sensor connectors. NOTICE: Disconnect the connectors with the airbag sensor assembly installed. (b) Using a torx wrench, remove the 4 screws and airbag sensor assembly. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) LH Side: RH Side: H11910 2001 AVALON (RM808U) Author
: Date
: 1588 RS-70 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Column Shift) RS0LT-01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly.
If the SRS has been deployed in a collision.
If the airbag sensor assembly has been found to be faulty in troubleshooting.
If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly, see page RS-68 and RS-71 . Be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1590 RS-62 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Floor Shift) AIRBAG SENSOR ASSEMBLY (Floor Shift) RS0LL-01 COMPONENTS Lower Panel 20 (205, 15) Airbag Sensor Assembly 20 (205, 15) No. 1 Lower Panel No. 2 Under Cover Upper Console Panel Front Console Box Cowl Side Trim Rear Console Box Front Door Scuff Plate LH N·m (kgf·cm, ft·lbf) : Specified torque H11908 2001 AVALON (RM808U) Author
: Date
: 1582 RS-64 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Floor Shift) RS0LN-01 INSPECTION 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check (See page DI-349 ). 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check (See page DI-349 ). 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the airbag sensor assembly (See page DI-349 ). 2001 AVALON (RM808U) Author
: Date
: 1584 RS-66 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Floor Shift) RS0LP-01 INSTALLATION NOTICE:
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed.
Never repair a sensor in order to reuse it. HINT: For step 2 to 9, refer to page BO-97 . 1. (a) LH Side: RH Side: H11910 INSTALL AIRBAG SENSOR ASSEMBLY Using a torx wrench, install the airbag sensor assembly with the 4 screws. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) (b) Connect the airbag sensor connectors. NOTICE:
Connection of the connector is done after the sensor assembly has been installed.
Make sure the sensor assembly is installed with the specified torque.
If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one.
When installing the senor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts.
After installing, shake the sensor assembly to check that there is no looseness. 2. INSTALL FRONT CONSOLE 3. INSTALL REAR CONSOLE BOX 4. INSTALL UPPER CONSOLE PANEL 5. INSTALL LOWER PANEL 6. INSTALL NO. 2 UNDER COVER 7. INSTALL NO. 1 LOWER PANEL 8. INSTALL COWL SIDE TRIM LH 9. INSTALL FRONT DOOR SCUFF PLATE LH 2001 AVALON (RM808U) Author
: Date
: 1586 RS-63 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Floor Shift) RS0LM-01 REMOVAL NOTICE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) HINT: For step 1 to 8, refer to page BO-90 . 1. REMOVE FRONT DOOR SCUFF PLATE LH 2. REMOVE COWL SIDE TRIM LH 3. REMOVE NO. 1 LOWER PANEL 4. REMOVE NO. 2 UNDER COVER 5. REMOVE LOWER PANEL 6. REMOVE UPPER CONSOLE PANEL 7. REMOVE REAR CONSOLE BOX 8. REMOVE FRONT CONSOLE BOX 9. REMOVE AIRBAG SENSOR ASSEMBLY (a) Disconnect the airbag sensor connectors. NOTICE: Disconnect the connectors with the airbag sensor assembly installed. (b) Using a torx wrench, remove the 4 screws and airbag sensor assembly. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) LH Side: RH Side: H11910 2001 AVALON (RM808U) Author
: Date
: 1583 RS-65 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR ASSEMBLY (Floor Shift) RS0LO-01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly.
If the SRS has been deployed in a collision.
If the airbag sensor assembly has been found to be faulty in troubleshooting.
If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly, see page RS-63 and RS-66 . Be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1585 RS-72 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT AIRBAG SENSOR FRONT AIRBAG SENSOR RS0ER-02 COMPONENTS Front Airbag Sensor RH 20 (205, 15) 20 (205, 15) Front Airbag Sensor LH 20 (205, 15) 20 (205, 15) Head Light RH Head Light LH N·m (kgf·cm, ft·lbf) : Specified torque H11911 2001 AVALON (RM808U) Author
: Date
: 1592 RS-74 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT AIRBAG SENSOR RS01N-28 INSPECTION H11883 LH 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check (See page DI-349 ). 2. VEHICLES INVOLVED IN COLLISION (a) Do a diagnostic system check (See page DI-349 ). (b) If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed:
Check the bracket deformation.
Check the paint peeling off the bracket.
Check the cracks, dents or chips in the case.
Check the cracks, dents, chipping and scratches in the connector.
Check the peeling off of the label or damage to the serial number. RH H11914 2001 AVALON (RM808U) Author
: Date
: 1594 RS-76 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT AIRBAG SENSOR RS0LW-01 INSTALLATION LH: 1. (a) INSTALL FRONT AIRBAG SENSOR LH AND RH Install the front airbag sensors with the 4 bolts. Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) NOTICE:
Connection of the connector is done after the sensor assembly has been installed.
Make sure the sensor is installed with the specified torque.
If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets or connector, replace the removed sensor with a new one.
The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnostic system. RH: H11912 H11913 H11907 HINT: Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle. (b) Connect the front airbag sensor connector. 2. INSTALL HEAD LIGHT Install head lights with the 4 bolts and 2 screws (See page BE-23 ). LH: RH: H11914 2001 AVALON (RM808U) Author
: Date
: 1596 RS-73 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT AIRBAG SENSOR RS0LV-01 REMOVAL NOTICE:
If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position, DTCs will be recorded.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never reuse the sensor involved in a collision when the SRS has deployed.
Never repair a sensor in order to reuse it. 1. LH: REMOVE FRONT AIRBAG SENSOR (a) Remove the 2 bolts, screw and head light LH. (b) Disconnect the connector. NOTICE: Disconnect the connector with sensor assembly installed. (c) Remove the 2 bolts and front airbag sensor LH. H11912 2. RH: REMOVE FRONT AIRBAG SENSOR (a) Remove the 2 bolts, screw and head light RH. (b) Disconnect the connector. NOTICE: Disconnect the connector with sensor assembly installed. (c) Remove the 2 bolts and front airbag sensor RH. H11913 2001 AVALON (RM808U) Author
: Date
: 1593 RS-75 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT AIRBAG SENSOR RS01O-16 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor.
If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.)
If the front airbag sensor has been found to be faulty in troubleshooting.
If the front airbag sensor has been found to be faulty during checking items (See page RS-74 ).
If the front airbag sensor has been dropped. CAUTION: For removal and installation of the front airbag sensor, see page RS-73 and RS-76 . Be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1595 RS-27 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY RS014-32 COMPONENTS Instrument Panel No. 4 Heater To Resister Duct Glove Box Lamp Center Bracket No. 5 Heater To Resister Duct 20 (205, 15) 20 (205, 15) Front Passenger Airbag Assembly No. 3 Resister No. 1 Safety Pad N·m (kgf·cm, ft·lbf) : Specified torque H11896 2001 AVALON (RM808U) Author
: Date
: 1547 RS-32 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSEMBLY RS0L7-01 DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a front passenger airbag assembly, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a front passenger airbag assembly which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-ofdoors and where it will not create a nuisance to nearby residents.
SST

AB0152


1. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assembly. The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front passenger airbag assembly with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front passenger airbag assembly with the deployed airbag. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. (a) Check functioning of the SST (See step 1-(a) on page RS-17 ). SST 09082-00700 Battery SST AB0158 2001 AVALON (RM808U) Author
: Date
: 1552 RS-33 SUPPLEMENTAL RESTRAINT SYSTEM (b) H11900 - FRONT PASSENGER AIRBAG ASSEMBLY Disconnect the airbag connector. (1) Using a screwdriver, pry out the glove compartment door finish plate inside the lower panel. HINT: Tape the screwdriver tip before use. (2) Remove the connector from the glove compartment door finish plate. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (3) Disconnect the airbag connector. (c) Install the SST. (1) Connect the connectors of the 2 SST to the front passenger airbag assembly connector. SST 09082-00700, 09082-00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST H11901 (2) Battery Move the SST to at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (3) NOTICE: Take care not to damage the SST wire harness. (4) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-) terminal. SST 10 m (33 ft) or more R13455 (d) Deploy the airbag. (1) Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. H03286 2001 AVALON (RM808U) Author
: Date
: 1553 RS-34 SUPPLEMENTAL RESTRAINT SYSTEM H11902 - FRONT PASSENGER AIRBAG ASSEMBLY CAUTION:
The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling the front passenger airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to the front passenger airbag assembly with the deployed airbag.
When scrapping a vehicle, deploy the airbag and scrap the vehicle with the front passenger airbag assembly still installed.
When moving a vehicle for scrapping which has the front passenger airbag assembly with the deployed airbag, use gloves and safety glasses. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 2. DEPLOYMENT WHEN DISPOSING OF FRONT PASSENGER AIRBAG ASSEMBLY ONLY NOTICE:
When disposing of the front passenger airbag assembly only, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) Remove the front passenger airbag assembly (See page RS-28 ). CAUTION:
When removing the front passenger airbag assembly, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery.
When storing the front passenger airbag assembly, keep the upper surface of the airbag deployment side facing upward. 2001 AVALON (RM808U) Author
: Date
: 1554 RS-35 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSEMBLY (b) Wire Harness Diameter Stripped Wire Harness Section AB0163 Using a service-purpose wire harness, tie down the front passenger airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the front passenger airbag assembly is tied down with too thin wire harness, it may snap. This is highly dangerous. Always use a wire harness which is at least 1.25 mm2 (0.0019 in2.). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 X (Diameter)2 divided by 4 (1) Pass the wire harness though the installation holes, as shown in the illustration. H11903 (2) Width Inner diam. H11904 Position the front passenger airbag assembly inside the tire with the airbag deployment side facing inside. Tire size: Must exceed the following dimensionsWidth: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:
Make sure that the wire harness is tight. It is very dangerous if looseness in the wire harness results in the front passenger airbag assembly coming free due to the shock from the airbag deploying.
Always tie down the front passenger airbag assembly with the airbag deployment side facing inside. NOTICE: The tire will be marked by the airbag deployment, so when disposing of the airbag use a redundant tire. 2001 AVALON (RM808U) Author
: Date
: 1555 RS-36 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSEMBLY (c) Check functioning of the SST (See step 1-(a) on page RS-17 ). SST 09082-00700 (d) Place the tires. (1) Place at least 2 tires under the tire to which the front passenger airbag assembly is tied. (2) Place at least 2 tires over the tire to which the front passenger airbag assembly is tied. The top tire should have the wheel installed. Battery SST AB0158 Tires (5 or more) H11905 (3) Tie the tires together with 2 wire harness. CAUTION: Make sure that the wire harness is tight. It is very dangerous if loose wire harnesses result in the tires coming free due to the shock from the airbag deploying. HINT: Place the SST connector and wire harness inside tires. Provide at least 1 m (3 ft) of slack for the wire harness. R05403 (e) Battery SST Front Passenger Airbag Assembly 10 m (33 ft) or more R09690 Install the SST. Connect the connectors of the 2 SST to the front passenger airbag assembly connector. SST 09082-00700, 09082-00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tires. (f) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. (2) Check that no one is within 10 m (33 ft) area around the tire which the front passenger airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 2001 AVALON (RM808U) Author
: Date
: 1556 RS-37 SUPPLEMENTAL RESTRAINT SYSTEM R09687 - FRONT PASSENGER AIRBAG ASSEMBLY (g) Dispose of the front passenger airbag assembly. CAUTION:
The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front passenger airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front passenger airbag assembly with the deployed airbag. (1) Remove the front passenger airbag assembly from the tire. (2) Place the front passenger airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 3. R09687 DEPLOYMENT WHEN DISPOSING OF FRONT PASSENGER AIRBAG ASSEMBLY WITH AIRBAG DEPLOYED IN COLLISION Dispose of the front passenger airbag assembly. CAUTION:
The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front passenger airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front passenger airbag assembly with the deployed airbag. (1) Remove the front passenger airbag assembly from the instrument panel (See page RS-28 ). (2) Place the front passenger airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way so as other general parts disposal. 2001 AVALON (RM808U) Author
: Date
: 1557 RS-30 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSEMBLY RS05Z-08 INSPECTION 1. (a) (b) H11879 2. (a) (b) Vehicles not involved in collision: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). Do a visual check which includes the following item with the front passenger airbag assembly installed in the vehicle. Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly, No. 1 safety pad and instrument panel. Vehicle involved in a collision and airbag is not deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle.
Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly.
Check cuts and cracks in wire harness, and for chipping in connectors. H11902
H11970 Check the deformation or cracks on the No. 1 safety pad, instrument panel, instrument panel reinforcement. HINT: If the No. 1 safety pad, instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. CAUTION: For removal and installation of the front passenger airbag assembly, see page RS-28 and RS-39 , and be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1550 RS-31 SUPPLEMENTAL RESTRAINT SYSTEM 3. (a) (b) H11970 - FRONT PASSENGER AIRBAG ASSEMBLY Vehicle involved in a collision and airbag is deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle.
Check the deformation or cracks on the instrument panel reinforcement.
Check the damage on the connector and wire harness. HINT: If the instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. CAUTION: For removal and installation of the front passenger airbag assembly, see page RS-28 and RS-39 , and be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1551 RS-39 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSEMBLY RS0L8-01 INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace them with new parts. 1. INSTALL NO. 1 SAFETY PAD (a) Install the No. 3 resister with the 2 screws. (b) (c) Install the No. 1 safety pad with the 5 screws. Install the wire harness to the No. 1 safety pad. H11899 2. (a) H12960 INSTALL FRONT PASSENGER AIRBAG ASSEMBLY Install the front passenger airbag assembly with the 6 nuts. CAUTION:
When installing the front passenger airbag assembly, take care that the wiring does not interfere with other parts and is not pinched between other parts.
Make sure that no foreign objects are trapped between the airbag bag and within the module. NOTICE: If the front passenger airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front passenger airbag assembly with a new one. (b) Install the center bracket with the 3 screws. (c) (d) (e) Install part of the instrument panel wire harness with the 2 screws. Install the No. 4 heater to resister duct with the 2 screws. Install the No. 5 heater to resister duct with the screw. H11897 2001 AVALON (RM808U) Author
: Date
: 1559 RS-40 SUPPLEMENTAL RESTRAINT SYSTEM 3. (a) (b) - FRONT PASSENGER AIRBAG ASSEMBLY INSTALL INSTRUMENT PANEL (See page BO-97 ) Install the bolt for connecting the front passenger airbag assembly to the center bracket. Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) Install the 2 bolts for mounting the front passenger airbag assembly to the instrument panel reinforcement. Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) H11906 4. (a) (b) (c) CONNECT AIRBAG CONNECTOR Connect the airbag connector. Set the connector on the glove compartment door finish plate. Install the glove compartment door finish plate to the lower panel. H12008 2001 AVALON (RM808U) Author
: Date
: 1560 RS-28 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSEMBLY RS0L6-01 REMOVAL NOTICE:
If the wiring connector of the SRS is disconnected and the ignition switch is in ON or ACC position, DTCs will be recorded.
Never use the airbag parts from another vehicle. When replacing parts, replace them with new parts. 1. (a) H11900 DISCONNECT AIRBAG CONNECTOR Using a screwdriver, pry out the glove compartment door finish plate inside the lower panel. HINT: Tape the screwdriver tip before use. (b) Remove the connector from the glove compartment door finish plate. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Disconnect the airbag connector. 2. REMOVE INSTRUMENT PANEL (See page BO-90 ) 3. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (a) Remove the screw and No. 5 heater to resister duct. (b) Remove the 2 screws and No. 4 heater to resister duct. (c) (d) Remove the 2 screws and part of instrument panel wire harness, as shown in the illustration. Remove the 2 screws and center bracket. H11897 (e) H11898 Remove the 6 nuts and front passenger airbag assembly, as shown in the illustration. CAUTION:
Do not store the front passenger airbag assembly with the airbag deployment side facing downward.
Never disassemble the front passenger airbag assembly. 4. REMOVE NO. 1 SAFETY PAD (a) Separate the wire harness from the No. 1 safety pad. 2001 AVALON (RM808U) Author
: Date
: 1548 RS-29 SUPPLEMENTAL RESTRAINT SYSTEM (b) (c) - FRONT PASSENGER AIRBAG ASSEMBLY Remove the 5 screws and No. 1 safety pad. Remove the 2 screws and No. 3 resister. H11899 2001 AVALON (RM808U) Author
: Date
: 1549 RS-38 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSEMBLY RS018-24 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the front passenger airbag assembly, No. 1 safety pad, instrument panel or instrument panel reinforcement. Case Replacing part If the airbag has been deployed. Front passenger airbag assembly If the front passenger airbag assembly has been found to be faulty in troubleshooting. Front passenger airbag assembly If the front passenger airbag assembly has been found to be faulty during checking items (See page RS-30 ). Front passenger airbag assembly If the instrument panel has been found to be faulty during checking items (See page RS-30 ). Instrument panel If the No. 1 safety pad has been found to be faulty during checking items (See page RS-30 ). No. 1 safety pad If the instrument panel reinforcement has been found to be faulty during checking items (See page RS-30 ). Instrument panel reinforcement If the front passenger airbag assembly has been dropped. Front passenger airbag assembly CAUTION: For replacement of the front passenger airbag assembly, see page RS-28 and RS-39 . Be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1558 RS-55 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Manual Adjuster Type) SIDE AIRBAG ASSEMBLY (Manual Adjuster Type) RS0LF-01 COMPONENTS Headrest Headrest Support Seatback Frame 43 (440, 32) Seatback Cover (w/ Pad) Inner Front Seat Cushion Shield Side Airbag Assembly 43 (440, 32)
Hog Ring Front Seat Cushion Shield 37 (375, 27) 37 (375, 27) Reclining adjuster Release Handle
Non-reusable part N·m (kgf·cm, ft·lbf) : Specified torque H11926 2001 AVALON (RM808U) Author
: Date
: 1575 RS-58 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Manual Adjuster Type) RS0LI-01 DISPOSAL See page RS-45 . 2001 AVALON (RM808U) Author
: Date
: 1578 RS-57 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Manual Adjuster Type) RS0LH-01 Cross Section INSPECTION 1. (a) (b) H11979 2. (a) Vehicles not involved in collision: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). Do a visual check which includes the following item with the seatback assembly installed in the vehicle. Check that there are no cuts or frayed in seams and outside of seatback cover. Vehicle involved in a collision and airbag is not deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). (b) H11978 Do a visual check which includes the following items with the seatback assembly removed from the vehicle.
Check cuts, tears and cracks of the side airbag assembly.
Check cuts and cracks in wire harness, and chipping in connectors. CAUTION: For removal and installation of the seatback assembly, see page RS-56 and RS-60 . Be sure to follow the correct procedure. 3. Vehicle involved in a collision and airbag is deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM (a) Do a diagnostic system check (See page DI-349 ). (b) Do a visual check which includes the following items with the seatback assembly removed from the vehicle.
Check the seatback installation part of the seat adjuster.
Check the damage to the connector and wire harness. HINT: If the seat adjuster is deformed, never repair it. Always replace it with new one. 2001 AVALON (RM808U) Author
: Date
: 1577 RS-60 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Manual Adjuster Type) RS0LK-01 INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace them with new parts. 1. (a) H11929 INSTALL SEATBACK ASSEMBLY Install the 4 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) NOTICE:
Make sure that the seatback assembly is installed with the specified torque.
If the seatback assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the seatback assembly with a new one.
When installing the seatback assembly, take care it is not pinched between other parts. (b) Install 3 new hog rings as shown in the illustration. HINT: When installing the hog rings, take care to prevent wrinkles as little as possible. H11928 (c) Install the wire harness of the side airbag assembly to the seat cushion assembly. 2. INSTALL INNER FRONT SEAT CUSHION SHIELD Install the inner front seat cushion shield with the 2 screws. 3. INSTALL FRONT SEAT CUSHION SHIELD Install the front seat cushion shield with the 2 screws. 4. INSTALL RECLINING ADJUSTER KNOBS 5. INSTALL HEADREST H11930 2001 AVALON (RM808U) Author
: Date
: 1580 RS-61 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Manual Adjuster Type) 6. INSTALL FRONT SEAT NOTICE: When mounting the seat to the vehicle, take care not to damage the airbag wire harness. (a) Connect the side airbag connector. (b) Slide the front seat to the most front position. NOTICE: Make sure that seat adjuster locks. (c) Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted rearmost position slip off. (d) Tighten the bolts on the front side temporarily, from the bolt on the inner side tighten them completely. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (e) Slide the seat to the most front position to install the bolts on the rear side. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1581 RS-56 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Manual Adjuster Type) RS0LG-01 REMOVAL NOTICE:
If the wiring connector of the SRS is disconnected and the ignition switch is at ON or ACC position, DTCs will be recorded.
Never use the airbag parts from another vehicle. When replacing parts, replace them with new parts. H11931 1. REMOVE FRONT SEAT (a) Remove the 4 seat track covers and 4 bolts. (b) Disconnect the side airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Remove the front seat. 2. REMOVE HEADREST 3. REMOVE RECLINING ADJUSTER KNOB 4. REMOVE FRONT SEAT CUSHION SHIELD Remove the 2 screws and front seat cushion shield. 5. REMOVE INNER FRONT SEAT CUSHION SHIELD Remove the 2 scerws and front seat cushion inner shield. H11927 6. REMOVE SEATBACK ASSEMBLY (a) Remove the hog rings. (b) Remove the wire harness of the side airbag assembly. NOTICE: When handling the airbag wire harness, take care not to damage the airbag wire harness. H11928 (c) Remove the 4 bolts and seatback assembly. H11929 2001 AVALON (RM808U) Author
: Date
: 1576 RS-59 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Manual Adjuster Type) RS0LJ-01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the seatback assembly or seatback cover. Case Replacing part If the side airbag has been deployed. Seatback assembly If the side airbag assembly has been found to be faulty in troubleshooting. Seatback assembly If the side airbag assembly has cuts during checking items (See page RS-57 ). Seatback assembly If the seatback cover has cuts and frayed seams during checking items (See page RS-57 ). Seatback cover If the side airbag assembly has been found to be faulty during checking items (See page RS-57 ). Seatback assembly If the seatback cover has been found to be faulty during checking items (See page RS-57 ). Seatback cover If the seatback assembly has been dropped. Seatback assembly CAUTION: For removal and installation of the seatback assembly, see page RS-56 and RS-60 . Be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1579 RS-41 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) SIDE AIRBAG ASSEMBLY (Power Adjuster Type) RS0L9-01 COMPONENTS Driver’s seat with bench type: No. 1 Seat Armrest Cover Headrest Seatback Frame Assembly Headrest Support 43 (440, 32) 41 (420, 30) Seat Armrest Assembly 42 (430, 31) Front Seat Inner Belt Reclining Adjuster Inside Cover Seatback Board
Hog Ring Side Airbag Assembly Front Seat Cushion Inner Shield 43 (440, 32) Seatback Cover (w/ Pad) 37 (375, 27) Front Seat Cushion Shield Power Seat Switch Knob Seat Cushion Assembly Driver’s seat with bench type: Seat Cushion Assembly 19 (194, 14) 19 (194, 14)
Non-reusable part N·m (kgf·cm, ft·lbf) : Specified torque H11925 2001 AVALON (RM808U) Author
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: 1561 RS-45 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) RS0LC-01 DISPOSAL HINT: When scrapping vehicles equipped with an SRS or disposing of the side airbag assembly always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a side airbag assembly which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-ofdoors and where it will not create a nuisance to nearby residents.
SST

AB0152


1. Battery SST When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool), perform the operation in a place away from electrical noise. SST 09082-00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the airbag assembly. The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling side airbag assembly with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a side airbag assembly with the deployed airbag. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. (a) Check functioning of the SST (See step 1-(a) on page RS-17 ). SST 09082-00700 AB0158 2001 AVALON (RM808U) Author
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: 1565 RS-46 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) (b) Disconnect the side airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H11931 (c) Install the SST. (1) Connect the connectors of the 2 SST to the airbag connector. SST 09082-00700, 09082-00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST H11932 (2) Battery Move the SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (3) NOTICE: Take care not to damage the SST wire harness. (4) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. SST 10 m (33 ft) or more R13455 (d) H11933 Deploy the airbag. (1) Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION:
The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling the side airbag assembly with the deployed airbag.
Do not apply water, etc. to the side airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation.
When scrapping a vehicle, deploy the airbag and scrap the vehicle with the side airbag assembly still installed. 2001 AVALON (RM808U) Author
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: 1566 RS-47 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) HINT: The airbag deploys simultaneously as the LED of SST activation switch lights up. 2. DEPLOYMENT WHEN DISPOSING OF SIDE AIRBAG ASSEMBLY NOTICE:
When disposing of the side airbag assembly only, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) Remove the seatback assembly (See page RS-42 ). (b) Remove the side airbag assembly from the seatback assembly. (1) Remove the hog rings. (2) Release the seatback cover hook from the seatback frame. (3) Remove the 2 bolts and side airbag assembly. CAUTION: When storing the side airbag assembly, keep the upper surface of the airbag deployment side facing upward. (c) Wire Harness Diameter Stripped Wire Harness Section AB0163 Using a service-purpose wire harness, tie down the side airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in2. or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the side airbag assembly, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.0019 in2.). HINT: To calculate the square of the stripped wire harness sectionSquare = 3.14 x (Diameter)2 divided by 4 2001 AVALON (RM808U) Author
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: 1567 RS-48 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) (1) Install the 2 nuts to the side airbag assembly. (2) Wind the wire harness around the stud bolts of the side airbag assembly as shown in the illustration. H11966 H11967 (3) H11968 Position the side airbag assembly inside the tire with the airbag deployment direction facing inside. Tire size: Must exceed the following dimensionsWidth: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:
Make sure the wire harness is tight. It is very dangerous when a loose wire harness results in the side airbag assembly coming free due to the shock from the airbag deploying.
Always tie down the side airbag assembly with the airbag deployment side facing inside. NOTICE: The tire will be marked by the airbag deployment, so when disposing of the airbag use a redundant tire. (d) Battery Check functioning of the SST (See step 1-(a) on page RS-17 ). SST 09082-00700 SST AB0158 2001 AVALON (RM808U) Author
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: 1568 RS-49 SUPPLEMENTAL RESTRAINT SYSTEM (e) Tires (5 or More) - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) Place the tires. (1) Place at least 2 tires under the tire to which the side airbag assembly is tied. (2) Place at least 2 tires over the tire to which the side airbag assembly is tied. The top tire should have the wheel installed. H01336 (3) Tie the tires together with 2 wire harness. CAUTION: Make sure that the wire harness are tight. It is very dangerous when loose wire harness results in the tires coming free due to the shock from the airbag deploying. HINT: Place the SST connector and wire harness inside tires. Secure at least 1 m (3 ft) of slack for the wire harness. R05403 (f) Battery SST Side Airbag Assembly 10 m (33 ft) or more H01337 H00544 Install the SST. Connect the connectors of the 2 SST to the side airbag assembly connector. SST 09082-00700, 09082-00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (g) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. (2) Check that no one is within 10 m (33 ft) area around the tire which the side airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. (h) Dispose of the side airbag assembly. CAUTION:
The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a side airbag assembly with the deployed airbag.
Do not apply water etc. to a side airbag assembly with the deployed airbag. 2001 AVALON (RM808U) Author
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: 1569 RS-50 SUPPLEMENTAL RESTRAINT SYSTEM
- SIDE AIRBAG ASSEMBLY (Power Adjuster Type) Always wash your hands with water after completing the operation. (1) Remove the side airbag assembly from the tire. (2) Place the side airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 3. H00544 DEPLOYMENT WHEN DISPOSING OF SIDE AIRBAG ASSEMBLY WITH AIRBAG DEPLOYED IN COLLISION Dispose of the side airbag assembly. CAUTION:
The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a side airbag assembly with the deployed airbag.
Do not apply water etc. to a side airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation. (1) Remove the side airbag assembly from the seat (See page RS-42 and see step 2. on page RS-45 ). (2) Place the side airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 2001 AVALON (RM808U) Author
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: 1570 RS-44 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) RS0LB-01 Cross Section INSPECTION 1. (a) (b) H11979 2. (a) Vehicles not involved in collision: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). Do a visual check which includes the following item with the seatback assembly installed in the vehicle. Check that there are no cuts or frayed in seams and outside of seatback cover. Vehicle involved in a collision and airbag is not deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). (b) H11978 Do a visual check which includes the following items with the seatback assembly removed from the vehicle.
Check cuts, tears and cracks of the side airbag assembly.
Check cuts and cracks in wire harness, and chipping in connectors. CAUTION: For removal and installation of the seatback assembly, see page RS-42 and RS-52 . Be sure to follow the correct procedure. 3. Vehicle involved in a collision and airbag is deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM (a) Do a diagnostic system check (See page DI-349 ). (b) Do a visual check which includes the following items with the seatback assembly removed from the vehicle.
Check the seatback installation part of the seat adjuster.
Check the damage to the connector and wire harness. HINT: If the seat adjuster is deformed, never repair it. Always replace it with new one. 2001 AVALON (RM808U) Author
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: 1564 RS-52 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) RS0LE-01 INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace them with new parts. 1. INSTALL SEATBACK ASSEMBLY (a) Temporarily install the seatback assembly. (b) Install the wire harness to the reclining adjuster inside cover and install the cover to the seat adjuster with the 2 screws. HINT: Do the same for LH and RH. H11923 (c) H11922 Install the 4 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) NOTICE:
Make sure that the seatback assembly is installed with the specified torque.
If the seatback assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the seatback assembly with a new one.
When installing the seatback assembly, take care it is not pinched between other parts. (d) 2. Install the new hog rings as shown in the illustration. INSTALL SEATBACK BOARD H11921 2001 AVALON (RM808U) Author
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: 1572 RS-53 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) 3. (a) INSTALL SEAT CUSHION ASSEMBLY Driver’s seat with bench type: Install the seat cushion assembly with the 5 bolts. (b) Except driver’s seat with bench type: Install the seat cushion assembly with 4 bolts. (c) Install the wire harness to the seat cushion assembly. H11918 H11917 H11924 4. INSTALL FRONT SEAT CUSHION INNER SHIELD Install the front seat inner shield with the 2 screws. 5. INSTALL FRONT SEAT INNER BELT H11920 6. INSTALL FRONT SEAT CUSHION SHIELD Install the front seat cushion shield with the 5 screws. 7. INSTALL POWER SEAT SWITCH KNOBS 8. Driver’s seat with bench type: INSTALL SEAT ARMREST ASSEMBLY Install the seat armrest assembly with bolt and cover. 9. INSTALL HEADREST H11919 2001 AVALON (RM808U) Author
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: 1573 RS-54 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) 10. INSTALL FRONT SEAT NOTICE: When mounting the seat to the vehicle, take care not to damage the airbag wire harness. (a) Connect the side airbag connector and power seat connector. (b) Slide the front seat to the most front position. NOTICE: Make sure that seat adjuster locks. (c) Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted rearmost position slip off. (d) Tighten the bolts on the front side temporarily, from the bolt on the inner side tighten them completely. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (e) Slide the seat to the most front position to install the bolts on the rear side. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) 2001 AVALON (RM808U) Author
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: 1574 RS-42 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) RS0LA-01 REMOVAL NOTICE:
If the wiring connector of the SRS is disconnected and the ignition switch is at ON or ACC position, DTCs will be recorded.
Never use the airbag parts from another vehicle. When replacing parts, replace them with new parts. H11931 1. REMOVE FRONT SEAT (a) Remove the 4 seat track covers and 4 bolts. (b) Disconnect the power seat and side airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Remove the front seat. 2. REMOVE HEADREST 3. Driver’s seat with bench type: REMOVE SEAT ARMREST ASSEMBLY Remove the cover, bolt and seat armrest assembly. 4. REMOVE POWER SEAT SWITCH KNOBS 5. REMOVE FRONT SEAT CUSHION SHIELD Remove the 5 screws and front seat cushion shield, as shown in the illustration. H11919 6. REMOVE FRONT SEAT INNER BELT 7. REMOVE FRONT SEAT CUSHION INNER SHIELD Remove the 2 screws and front seat inner belt. 8. REMOVE SEAT CUSHION ASSEMBLY (a) Remove the wire harness from the seat cushion assembly. H11920 2001 AVALON (RM808U) Author
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: 1562 RS-43 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) (b) Driver’s seat with bench type: Remove the 5 bolts and seat cushion assembly (c) 9. Except driver’s seat with bench type: Remove the 4 bolts and seat cushion assembly. REMOVE SEATBACK BOARD 10. (a) REMOVE SEATBACK ASSEMBLY Remove the hog rings, as shown in the illustration. H11918 H11917 H11921 (b) Remove the 4 bolts and seatback assembly. NOTICE: Do not apply unnatural force to the airbag harness. H11922 (c) (d) Remove the 2 screws and reclining adjuster inside cover. Separate the wire harness from the reclining adjuster inside cover. HINT: Do the same for LH and RH. H11923 2001 AVALON (RM808U) Author
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: 1563 RS-51 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG ASSEMBLY (Power Adjuster Type) RS0LD-01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the seatback assembly or seatback cover. Case Replacing part If the side airbag has been deployed. Seatback assembly If the side airbag assembly has been found to be faulty in troubleshooting. Seatback assembly If the side airbag assembly has cuts during checking items (See page RS-44 ). Seatback assembly If the seatback cover has cuts and frayed seams during checking items (See page RS-44 ). Seatback cover If the side airbag assembly has been found to be faulty during checking items (See page RS-44 ). Seatback assembly If the seatback cover has been found to be faulty during checking items (See page RS-44 ). Seatback cover If the seatback assembly has been dropped. Seatback assembly CAUTION: For removal and installation of the seatback assembly, see page RS-42 and RS-52 . Be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
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: 1571 RS-77 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG SENSOR ASSEMBLY SIDE AIRBAG SENSOR ASSEMBLY RS06C-08 COMPONENTS Side Airbag Sensor Assembly 20 (205, 15) Center Pillar Lower Garnish 7.4 (75, 65 in.·lbf) 41 (420, 30) Front Seat Outer Belt Retractor Rear Door Scuff Plate Front Door Scuff Plate Rear Seat Cushion N·m (kgf·cm, ft·lbf) : Specified torque H11915 2001 AVALON (RM808U) Author
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: 1597 RS-79 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG SENSOR ASSEMBLY RS06E-07 INSPECTION 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check (See page DI-349 ). 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check (See page DI-349 ). 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the side airbag sensor assembly (See page DI-349 ). 2001 AVALON (RM808U) Author
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: 1599 RS-81 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG SENSOR ASSEMBLY RS0LY-01 INSTALLATION NOTICE:
Never use SRS parts from another vehicle. When replacing parts, replace them with new ones.
Never reuse the side airbag sensor assembly involved in a collision when the airbag has deployed.
Never repair a sensor in order to reuse it. HINT: For step 2 to 6, refer to page BO-137 . 1. (a) H11916 INSTALL SIDE AIRBAG SENSOR Install the side airbag assembly with 3 bolts. Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) (b) Connect the connector. NOTICE:
Connection of the connector is done after the sensor assembly has been installed.
Make sure the sensor assembly is installed with the specified torque.
If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one.
When installing the sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts.
After installation, shake the sensor assembly to check that there is no looseness. 2. INSTALL RETRACTOR OF FRONT SEAT OUTER BELT Torque: Upper bolt: 7.4 N·m (75 kgf·cm, 65 in.·lbf) Lower bolt: 41 N·m (420 kgf·cm, 30 ft·lbf) 3. INSTALL CENTER PILLAR LOWER GARNISH 4. INSTALL FRONT DOOR SCUFF PLATE 5. INSTALL REAR DOOR SCUFF PLATE 6. INSTALL REAR SEAT CUSHION 2001 AVALON (RM808U) Author
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: 1601 RS-78 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG SENSOR ASSEMBLY RS0LX-01 REMOVAL NOTICE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) HINT: For step 1 to 5, refer to page BO-128 . 1. REMOVE REAR SEAT CUSHION 2. REMOVE REAR DOOR SCUFF PLATE 3. REMOVE FRONT DOOR SCUFF PLATE 4. REMOVE CENTER PILLAR LOWER GARNISH 5. REMOVE RETRACTOR OF FRONT SEAT OUTER BELT 6. REMOVE SIDE AIRBAG SENSOR ASSEMBLY (a) Disconnect the connector. NOTICE: Remove the connector with the sensor assembly installed. (b) Remove the 3 bolts and side airbag sensor assembly. H11916 2001 AVALON (RM808U) Author
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: 1598 RS-80 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIRBAG SENSOR ASSEMBLY RS06F-04 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the side airbag sensor assembly.
If the side airbag assembly has been deployed in a collision.
If the side airbag sensor assembly has been found to be faulty in troubleshooting.
If the side airbag sensor assembly has been dropped. CAUTION: For removal and installation of the side airbag sensor assembly, see page RS-78 and RS-81 . Be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
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: 1600 RS-3 SUPPLEMENTAL RESTRAINT SYSTEM - SRS AIRBAG RS0EF-02 OPERATION 1. STEERING WHEEL PAD (with AIRBAG) The inflater and bag of the SRS are stored in the steering wheel pad and cannot be disassembled. The inflater contains a squib, igniter charge, gas generator, etc., and inflates the bag when instructed by the airbag sensor assembly. H11878 2. SPIRAL CABLE (in COMBINATION SWITCH) A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel. Spiral Cable R09725 3. FRONT PASSENGER AIRBAG ASSEMBLY The inflater and bag of the SRS are stored in the front passenger airbag assembly and cannot be disassembled. The inflater contains a squib, igniter charge, gas generator, etc., and inflates the bag when instructed by the airbag sensor assembly. H11879 4. SIDE AIRBAG ASSEMBLY The inflater and bag of the SRS side airbag are stored in the side airbag assembly and cannot be disassembled. The inflater contains a squib, igniter charge, gas generator, etc., and inflates the bag when instructed by the side airbag sensor assembly. H11880 5. SEAT BELT PRETENSIONER The seat belt pretensioner system is a component of the front seat outer belt. The pretensioner contains a squib, gas generator, wire, piston, etc., and operates in the event of a frontal collision. The seat belt pretensioner cannot be disassembled. H11881 2001 AVALON (RM808U) Author
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: 1523 RS-4 SUPPLEMENTAL RESTRAINT SYSTEM - SRS AIRBAG 6. SRS WARNING LIGHT The SRS warning light is located on the accessory meter. It goes on to alert the driver of trouble in the system when a malfunction is detected in the airbag sensor assembly self-diagnosis. In normal operation conditions when the ignition switch is turned to the ACC or ON position, the light goes on for about 6 seconds and then goes off. H11969 7. AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the lower center finish panel. The airbag sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit, ignition control, drive circuit, etc. It receives signals from the airbag sensor, front airbag sensor, side airbag sensor assembly and door side airbag assembly and judges whether the SRS must be activated or not. The airbag sensor assembly cannot be disassembled. Floor Shift: Column Shift: H11882 8. FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the side members. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit, contact is made in the sensor, sending a signal to the airbag sensor assembly. The front airbag sensor cannot be disassembled. H11883 9. SIDE AIRBAG SENSOR ASSEMBLY The side airbag sensor assembly is mounted in the LH and RH center pillars. The side airbag sensor assembly consists of a lateral deceleration sensor, safing sensor, diagnosis circuit, etc. It sends signals to the airbag sensor assembly to judge whether the SRS side airbag must be activated or not. The side airbag sensor assembly cannot be disassembled. H11884 2001 AVALON (RM808U) Author
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: 1524 RS-5 SUPPLEMENTAL RESTRAINT SYSTEM - SRS AIRBAG 10. SRS CONNECTORS HINT: SRS connectors are located as shown in the following illustration. 7 Side Airbag Assembly (RH) (Squib) 8 Seat Belt Pretensioner (RH) 9 Side Airbag Sensor Assembly (RH) 10 Front Airbag Sensor (RH) 2 Airbag Sensor Assembly 6 1 Front Passenger Airbag Assembly (Squib) Spiral Cable 5 4 3 12 Steering Wheel Pad (Squib) 11 Front Airbag Sensor (LH) 13 Side Airbag Sensor Assembly (LH) 14 Seat Belt Pretensioner (LH) 15 Side Airbag Assembly (LH) (Squib) H11971 No. Item Application (1) Terminal Twin-Lock Mechanism Connectors 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 (2) Airbag Activation Prevention Mechanism Connectors 1, 2, 3, 4, 5, 6, 7, 15 (3) Electrical Connection Check Mechanism Connectors 1, 2, 3 (4) Connector Twin-Lock Mechanism Connectors 5 2001 AVALON (RM808U) Author
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: 1525 RS-6 SUPPLEMENTAL RESTRAINT SYSTEM (a) Housing (2) Female Male Z05953 SRS AIRBAG All connectors in the SRS are colored in yellow to distinguish them from other connectors. Connectors having special functions and specifically designed for the SRS are used in the locations shown on the previous page to ensure high reliability. These connectors use durable gold-plated terminals. (1) Spacer - Terminal Twin-Lock Mechanism Each connector has a two-piece component consisting of a housing and a spacer. This design enables the terminal to be locked securely by two locking devices (the retainer and the lance) to prevent terminals from coming out. Airbag Activation Prevention Mechanism Each connector contains a short spring plate. When the connector is disconnected, the short spring plate automatically connects positive (+) terminal and negative (-) terminal of the squib. When Connector is Connected When Connector is Disconnected Short Spring Plate Short Spring Plate Contacting Male Terminal Housing Housing Short Spring Plate ON Terminal Squib Connectors Squib Short Spring Plate Closed Circuit R10587 2001 AVALON (RM808U) Author
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: 1526 RS-7 SUPPLEMENTAL RESTRAINT SYSTEM - SRS AIRBAG HINT: The type of connector is shown in the diagram on the previous page. (3) SRS Warning Light Disconnection Detection Pin Airbag Sensor Assembly Electrical Connection Check Mechanism This mechanism electrically checks that connectors are connected correctly and completely. The electrical connection check mechanism is designed so that the disconnection detection pin connects with the diagnosis terminals when the connector housing lock is locked. R12076
Half Connection
Complete Connection Terminal for Diagnosis Terminal for Diagnosis Disconnection Detection Pin H01315 HINT: The illustration shows connectors ”1”, ”2” and ”3” in step 10. 2001 AVALON (RM808U) Author
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: 1527 RS-8 SUPPLEMENTAL RESTRAINT SYSTEM (4) - SRS AIRBAG Connector Twin-Lock Mechanism With this mechanism connectors (male and female connectors) are locked by 2 locking devices to increase the connection reliability. If the primary lock is incomplete, ribs interfere and prevent the secondary lock. Secondary Lock Primary Lock Complete (Secondary Lock Permitted) Primary Lock Incomplete (Secondary Lock Prevented) (b) Fig.1 Power Source Safing Sensor Fig.2 Lock Lock Primary Lock Squibs Twin-Lock Completed AB0089 When the vehicle is involved in a frontal collision in the hatched area (Fig. 1) and the shock is larger than the predetermined level, the SRS is activated automatically. A safing sensor is designed to go on at a smaller deceleration rate than the airbag sensor. As illustrated in Fig. 2, ignition is caused when current flows to the squib, which happens when a safing sensor and the deceleration sensor go on simultaneously. When a deceleration force acts on the sensors, 2 squibs in the driver airbag and front passenger airbag ignite and generate gas. The gas discharging into the driver airbag and front passenger airbag rapidly increases the pressure inside the bags, breaking open the steering wheel pad and instrument panel. Bag inflation then ends, and the bags deflate as the gas is discharged through discharge holes at the bag’s rear or side. Deceleration Sensor Z14034 2001 AVALON (RM808U) Author
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: 1528 RS-9 SUPPLEMENTAL RESTRAINT SYSTEM 11. Outer (a) (b) H01581 - SRS AIRBAG DISCONNECTION OF CONNECTORS FOR FRONT AIRBAG SENSOR AND SIDE AIRBAG SENSOR While holding both flank sides of the outer, slide the outer to the direction shown by an arrow. Lock of the connectors is released, then disconnect the connectors. HINT: Be sure to hold both flank sides of the outer. If holding the top and bottom sides, it will obstruct disconnection. Lock of connector is released Disconnection is completed H01582 12. CONNECTION OF CONNECTORS FOR FRONT AIRBAG SENSOR AND SIDE AIRBAG SENSOR Outer Outer H01583 (a) Align the male connector (of the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing. (b) As they are fitted in, the outer slides rearward. Press it until the outer returns to its original position again. If fitting stops half way, connectors will separate. (c) Be sure to insert until they are locked. After fitting in, pull them slightly to check that they are locked (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.). 2001 AVALON (RM808U) Author
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: 1529 RS-10 SUPPLEMENTAL RESTRAINT SYSTEM - SRS AIRBAG HINT:   13. (a) (b) (c) Do not fit in while holding the outer. When fitting in, the outer slides. Do not touch it. DISCONNECTION OF SIDE AIRBAG CONNECTOR Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. Slider Slider Disconnection is completed H01584 14. CONNECTION OF SIDE AIRBAG CONNECTOR Slider Slider H01585 2001 AVALON (RM808U) Author
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: 1530 RS-1 1 SUPPLEMENTAL RESTRAINT SYSTEM (a) (b) - SRS AIRBAG Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing. Be sure to insert until they are locked. After fitting in pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT:   As the slider slides, do not touch it. Be careful not to deform the release board. If the release board is deformed, replace it with a new one. 15. DISCONNECTION OF CONNECTORS FOR STEERING WHEEL PAD (with AIRBAG) AND FRONT PASSENGER AIRBAG ASSEMBLY Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. (a) (b) (c) Slider Slider Disconnection is completed H01586 2001 AVALON (RM808U) Author
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: 1531 RS-12 SUPPLEMENTAL RESTRAINT SYSTEM 16. (a) (b) - SRS AIRBAG CONNECTION OF CONNECTORS FOR STEERING WHEEL PAD (with AIRBAG) AND FRONT PASSENGER AIRBAG ASSEMBLY Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing. Be sure to insert until they are locked. After fitting in pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT:   Slider As the slider slides, do not touch it. Be careful not to deform the release board. If the release board is deformed, replace it with a new one. Slider H01587 2001 AVALON (RM808U) Author
: Date
: 1532 RS-1 SUPPLEMENTAL RESTRAINT SYSTEM - SRS AIRBAG SRS AIRBAG RS01Y-34 PRECAUTION CAUTION:
The AVALON is equipped with SRS, which comprises a driver airbag, front passenger airbag and side airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual.
Work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)
Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly directly to hot air or flames. NOTICE:
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor and side airbag sensor assembly should be inspected. (See page RS-15 , RS-30 , RS-44 , RS-57 , RS-64 , RS-69 , RS-74 and RS-79 )
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace it with new one.
Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.
After work on the SRS is completed, perform the SRS warning light check (See page DI-349 ).
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. This vehicle has power seat which are all equipped with memory function. However, it is not possible to make a record of the memory contents. So when the work is finished, it will be necessary to explain this fact to the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory in each memory system, never use a back- up power supply from outside the vehicle. 2001 AVALON (RM808U) Author
: Date
: 1521 RS-2 SUPPLEMENTAL RESTRAINT SYSTEM
- SRS AIRBAG If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 2001 AVALON (RM808U) Author
: Date
: 1522 RS-13 SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE STEERING WHEEL PAD AND SPIRAL CABLE RS00Y-47 COMPONENTS Column Upper Cover Spiral Cable Steering Wheel Steering Wheel Lower No. 2 Cover 50 (510, 37) Steering Wheel Lower No. 2 Cover Torx Screw 8.8 (90, 78 in.·lbf) Steering Wheel Pad Column Lower Cover N·m (kgf·cm, ft·lbf) : Specified torque H11885 2001 AVALON (RM808U) Author
: Date
: 1533 RS-17 SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE RS0L5-01 DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a steering wheel pad which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out-ofdoors and where it will not create a nuisance to nearby residents.
SST

AB0152


1. Battery When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082-00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a steering wheel pad with the deployed airbag. AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. SST AB0158 2001 AVALON (RM808U) Author
: Date
: 1537 RS-18 SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE (a) Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082-00700 SST AB0152 (1) Battery SST Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. AB0158 (2) Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. (3) Disconnect the SST from the battery. SST H01580 (b) Install the SST. CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad. (1) Remove the steering column lower cover. Remove the 3 screws and steering column lower cover as shown in the illustration. (2) Disconnect the airbag connector of the spiral cable. H11889 (3) Connect the connector of the SST to the airbag connector of the spiral cable. SST 09082-00700 NOTICE: To avoid damaging the connector of the SST and wire harness, do not lock the secondary lock of the twin lock. SST H11890 2001 AVALON (RM808U) Author
: Date
: 1538 RS-19 SUPPLEMENTAL RESTRAINT SYSTEM - (4) Battery STEERING WHEEL PAD AND SPIRAL CABLE Move the SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (5) NOTICE: Take care not to damage the SST wire harness. (6) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (-) terminal. SST 10 m (33 ft) or more R13455 (c) R06753 Deploy the airbag. (1) Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION:
The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a steering wheel pad with the deployed airbag.
When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed.
When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 2. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD ONLY NOTICE:
When disposing of the steering wheel pad (with airbag) only, never use the customers vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. 2001 AVALON (RM808U) Author
: Date
: 1539 RS-20 SUPPLEMENTAL RESTRAINT SYSTEM Connector H11891 Wire Harness Diameter Stripped Wire Harness Section AB0163 M H11892 STEERING WHEEL PAD AND SPIRAL CABLE (a) Remove the steering wheel pad (See page SR-12 ). CAUTION:
When removing the steering wheel pad, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery.
When storing the steering wheel pad, keep the upper surface of the pad facing upward. (b) Remove the connector on the rear surface of the steering wheel pad from the bracket. (c) Using a service-purpose wire harness tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in2. or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.0019 in2.). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2 divided by 4 (1) L - Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L: 35. mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE:
Tighten the bolts by hand until the bolts become difficult to turn.
Do not tighten the bolts too much. 2001 AVALON (RM808U) Author
: Date
: 1540 RS-21 SUPPLEMENTAL RESTRAINT SYSTEM - (2) STEERING WHEEL PAD AND SPIRAL CABLE Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION:
Tightly wind the wire harness around the bolts so that there is no slack.
If there is slackness in the wire harness, the steering wheel pad may come loose due to the shock when the airbag is deployed. This is highly dangerous. 2 Times or more H11893 (3) H11894 Battery Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION:
Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free due to the shock from the airbag deploying.
Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTICE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel. (d) Check functioning of the SST (See step 1-(a)). SST 09082-00700 SST AB0158 2001 AVALON (RM808U) Author
: Date
: 1541 RS-22 SUPPLEMENTAL RESTRAINT SYSTEM SST H11895 - STEERING WHEEL PAD AND SPIRAL CABLE (e) Install the SST. CAUTION: Place the disc wheel on the level ground. (1) Connect the connector of the SST to the steering wheel pad connector. SST 09082-00700, 09082-00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. (2) Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. 10 m (33 ft) or more R13763 (f) Y Y Weight X H00401 Cover the steering wheel pad with a cardboard box or tires.
Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTICE:
When dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied, X should be the following size. X = 460 mm (18.11 in.) + width of tire
If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. 2001 AVALON (RM808U) Author
: Date
: 1542 RS-23 SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE
Inner Diam. Width Tires (3 or More) R04211 Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimensionsWidth: 185 mm (7.87 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTICE: The tires may be marked by the airbag deployment, so use the redundant tires. (g) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. (2) (3) Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 10 m (33 ft) or more R13763 AB0166 (h) Dispose of the steering wheel pad (with airbag). CAUTION:
The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a steering wheel pad with the deployed airbag. (1) Remove the steering wheel pad from the disc wheel. (2) Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 2001 AVALON (RM808U) Author
: Date
: 1543 RS-24 SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE 3. AB0166 DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD WITH AIRBAG DEPLOYED IN COLLISION Dispose of the steering wheel pad (with airbag). CAUTION:
The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag, use gloves and safety glasses.
Use gloves and safety glasses when handling a steering wheel pad with deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a steering wheel pad with deployed airbag. (1) Remove the steering wheel pad from the steering wheel (See page SR-12 ). (2) Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 2001 AVALON (RM808U) Author
: Date
: 1544 RS-15 SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE RS0L4-01 INSPECTION 1. (a) (b) H11878 2. (a) (b) H11886 Vehicle not involved in collision: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). Do a visual check which includes the following item with the steering wheel pad (with airbag) installed in the vehicle. Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. Vehicle involved in collision and airbag is not deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle.
Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion.
Check cuts and cracks in wire harness, and chipping in connectors.
Check the deformation of the steering wheel.
Horn Button Contact Plate Check the deformation of the horn button contact plate of the steering wheel pad. HINT:
If the horn button contact plate of the steering wheel pad is deformed, never repair it. Always replace the steering wheel pad with a new one. H11887
There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. CAUTION: For removal and installation of the steering wheel pad, see page SR-12 and SR-22 , be sure to follow the correct procedure. H11888 2001 AVALON (RM808U) Author
: Date
: 1535 RS-16 SUPPLEMENTAL RESTRAINT SYSTEM 3. (a) (b) H11888 - STEERING WHEEL PAD AND SPIRAL CABLE Vehicle involved in collision and airbag is deployed: INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check (See page DI-349 ). Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle.
Check the deformation of the steering wheel.
Check the damage on the spiral cable connector and wire harness. HINT: There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. CAUTION: For removal and installation of the steering wheel pad, see page SR-12 and SR-22 , and be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1536 RS-26 SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE RS013-23 INSTALLATION HINT: For step 1 to 4, refer to page SR-22 . 1. INSTALL SPIRAL CABLE 2. INSTALL UPPER AND LOWER COLUMN COVERS 3. INSTALL STEERING WHEEL 4. INSTALL STEERING WHEEL PAD 2001 AVALON (RM808U) Author
: Date
: 1546 RS-14 SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE RS00Z-22 REMOVAL HINT: For step 1 to 4, refer to page SR-12 . 1. REMOVE STEERING WHEEL PAD 2. REMOVE STEERING WHEEL 3. REMOVE UPPER AND LOWER COLUMN COVERS 4. REMOVE SPIRAL CABLE 2001 AVALON (RM808U) Author
: Date
: 1534 RS-25 SUPPLEMENTAL RESTRAINT SYSTEM - STEERING WHEEL PAD AND SPIRAL CABLE RS012-28 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the steering wheel pad, steering wheel or spiral cable. Case Replacing part If the airbag has been deployed. Steering wheel pad If the steering wheel pad has been found to be faulty in troubleshooting. Steering wheel pad If the spiral cable has been found to be faulty in troubleshooting. Spiral cable If the steering wheel pad has been found to be faulty during checking items (See page RS-15 ). Steering wheel pad If the steering wheel has been found to be faulty during checking items (See page RS-15 ). Steering wheel If the spiral cable has been found to be faulty during checking items (See page RS-15 ). Spiral cable If the steering wheel pad has been dropped. Steering wheel pad CAUTION: For removal and installation of the steering wheel pad, see page SR-12 and SR-22 . Be sure to follow the correct procedure. 2001 AVALON (RM808U) Author
: Date
: 1545 RS-83 SUPPLEMENTAL RESTRAINT SYSTEM - WIRE HARNESS AND CONNECTOR RS06I-07 INSPECTION HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check (See page DI-349 ). 2. VEHICLES INVOLVED IN COLLISION (a) Do a diagnostic system check (See page DI-349 ). (b) Check breaks in all wires of the SRS wire harness, and exposed conductors. (c) Check to see if the SRS wire harness connectors are cracked or chipped. 2001 AVALON (RM808U) Author
: Date
: 1603 RS-82 SUPPLEMENTAL RESTRAINT SYSTEM - WIRE HARNESS AND CONNECTOR WIRE HARNESS AND CONNECTOR RS06H-10 LOCATION Front Airbag Sensor (RH) Front Passenger Airbag Assembly Accessory Meter (Warning Light) Spiral Cable Side Airbag Assembly (RH) Front Airbag Sensor (LH) Side Airbag Sensor Assembly (RH) Steering Wheel Pad (with Airbag) Side Airbag Sensor Assembly (LH) Seat Belt Pretensioner (RH) Airbag Sensor Assembly Seat Belt Pretensioner (LH) Side Airbag Assembly (LH) H11972 2001 AVALON (RM808U) Author
: Date
: 1602 RS-84 SUPPLEMENTAL RESTRAINT SYSTEM - WIRE HARNESS AND CONNECTOR RS06J-07 REPLACEMENT In the following cases,replace the wire harness or connector.
If any part of the SRS wire harness or any connector has been found to be faulty in troubleshooting.
If any part of the SRS wire harness or any connector has been found to be faulty during checking items (See page RS-83 ). CAUTION: If the wire harness used in the SRS is damaged, replace the whole wire harness assembly. 2001 AVALON (RM808U) Author
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: 1604 ST-2 STARTING - STARTER STARTER ST04N-03 COMPONENTS MAF Meter Connector Air Hose VSV Connector for Canister Close Valve Hold Down Clamp Air Cleaner Cap Battery Throttle Cable Clamp Battery Tray Cruise Control Cover Cruise Control Actuator Connector Starter Clamp Starter Cable Starter Connector Cruise Control Actuator B07463 2001 AVALON (RM808U) Author
: Date
: 1255 ST-3 STARTING - STARTER
Snap Ring Starter Housing Stop Collar Pinion Gear Compression Spring Spring Retainer Starter Clutch Compression Spring Starter Housing and Clutch Assembly Clutch Shaft Idler Gear Bearing Steel Ball Return Spring
Front Bearing Magnetic Switch Assembly Armature
Rear Bearing
O-Ring
O-Ring Field Frame (Field Coil) Brush Holder End Cover
Dust Protector
Non-reusable part B01154 2001 AVALON (RM808U) Author
: Date
: 1256 ST-4 STARTING - STARTER Magnetic Switch Assembly Terminal Insulator
Terminal C Kit Part Contact Plate Terminal Nut 17 (173, 13) Terminal Bolt Wave Washer Terminal Insulator O-Ring End Cover Plunger
Gasket Lead Terminal O-Ring Packing Terminal Insulator Terminal Bolt Wave Washer Terminal Nut
Terminal 30 Kit Part 17 (173, 13) Contact Plate Terminal Insulator N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part B06429 2001 AVALON (RM808U) Author
: Date
: 1257 ST-6 STARTING - STARTER ST04P-02 DISASSEMBLY 1. 2. (a) (b) REMOVE DUST PROTECTOR REMOVE FIELD FRAME AND ARMATURE Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) Remove the 2 through bolts. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) B01156 Protrusion Dictation (c) Pull out the field frame together with the armature. HINT: Align the protrusion of the field frame with the identation of the magnetic switch. (d) Remove the O-ring from the field frame. HINT: At the time of installation, please refer to the following items. Use a new O-ring. B01157 3. (a) REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Remove the 2 screws. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) B01158 (b) (e) (d) (c) (b) (c) (d) (e) Remove Remove Remove Remove the starter housing and clutch assembly. the return spring. the idler gear. the bearing. B01160 4. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. B01159 2001 AVALON (RM808U) Author
: Date
: 1259 ST-7 STARTING 5. (a) (b) - STARTER REMOVE BRUSH HOLDER Remove the 2 screws and end cover from the field frame. Torque: 1.5 N·m (15 kgf·cm, 13 in.·lbf) Remove the O-ring from the field frame. B01161 (c) Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. NOTICE: Check that the positive (+) lead wires are not grounded. 6. REMOVE ARMATURE FROM FIELD FRAME P13528 2001 AVALON (RM808U) Author
: Date
: 1260 ST-8 STARTING - STARTER ST04Q-02 INSPECTION Ohmmeter 1. (a) INSPECT ARMATURE COIL Check the commutator for open circuit. Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature. Continuity P10584 (b) Check the commutator for ground Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. 2. INSPECT COMMUTATOR (a) Check the commutator for dirty and burnt surfaces. If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe. Ohmmeter No Continuity P10585 (b) Check the commutator circle runout. (1) Place the commutator on V-blocks. (2) Using a dial gauge, measure the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. P10586 (c) Using vernier calipers, measure the commutator diameter. Standard diameter: 30.0 mm (1.181 in.) Minimum diameter: 29.0 mm (1.142 in.) If the diameter is less than minimum, replace the armature. P10587 (d) Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth: 0.6 mm (0.024 in.) Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade. ST0040 2001 AVALON (RM808U) Author
: Date
: 1261 ST-9 STARTING - STARTER 3. (a) INSPECT FIELD COIL Check the field coil for open circuit. Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame. Ohmmeter Continuity P10588 (b) Check the field coil for ground. Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame. Ohmmeter No Continuity P10589 4. INSPECT BRUSHES Using vernier calipers, measure the brush length. Standard length: 15.5 mm (0.610 in.) Minimum length: 10 mm (0.394 in.) If the length is less than minimum, replace the brush holder and field frame. Brush Holder Side Length Field Flame Side Length Z10079 ST0019 5. INSPECT BRUSH SPRINGS Check the brush spring road. Take the pull scale reading the instant the brush spring separates from the brush. Standard spring installed load: 17.6 - 23.5 N (1.79 - 2.41 kgf, 4.0 - 5.3 lbf) Minimum spring installed load: 11.8 N (1.20 kgf, 2.7 lbf) If the installed load is less than minimum replace the brush springs. 2001 AVALON (RM808U) Author
: Date
: 1262 ST-10 STARTING Ohmmeter No Continuity P13481 - STARTER 6. INSPECT BRUSH HOLDER Check the brush holder insulation. Using an ohmmeter, check that there is no continuity between the positive (+) and negative (-) brush holders. If there is continuity, repair or replace the brush holder. 7. INSPECT CLUTCH AND GEAR (a) Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the drive plate ring gear for wear or damage. (b) Check the clutch pinion gear. Hold the starter clutch and rotate the pinion gear counterclockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks. If necessary, replace the clutch assembly. Lock Free B01162 Terminal C Ohmmeter 8. (a) INSPECT MAGNETIC SWITCH Check the pull-in coil for open circuit. Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, check and replace the magnetic switch. Continuity Terminal 50 B01163 (b) Ohmmeter Continuity Terminal 50 Check the hold-in coil open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. 9. INSPECT BEARING Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing (See page ST-1 1). B01164 2001 AVALON (RM808U) Author
: Date
: 1263 ST-19 STARTING - STARTER ST04U-01 INSTALLATION Installation is in the reverse order of removal (See page ST-5 ). 2001 AVALON (RM808U) Author
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: 1272 ST-17 STARTING - STARTER ST04S-01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page ST-6 ). HINT: Use high temperature grease to lubricate the bearings, springs, steel ball and gears when assembling the starter. 2001 AVALON (RM808U) Author
: Date
: 1270 ST-5 STARTING - STARTER ST04O-02 REMOVAL 1. 2. 3. (a) (b) 4. (a) (b) (c) REMOVE AIR CLEANER CAP REMOVE BATTERY AND TRAY REMOVE CRUISE CONTROL ACTUATOR Disconnect the actuator connector and clamp. Remove the 3 bolts, and disconnect the actuator with the bracket. REMOVE STARTER Disconnect the starter connector. Remove the nut, and disconnect the starter cable. Remove the 2 bolts, throttle cable clamp and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1258 ST-1 1 STARTING - STARTER ST04R-03 REPLACEMENT 1. (a) REPLACE CLUTCH ASSEMBLY Disassemble the starter housing and the clutch assembly. (1) Mount a brass bar in a vice, and install the starter housing and clutch assembly to the brass bar. B01224 (2) (3) Push down the pinion gear. Using a plastic-faced hammer, tap down the stop collar. (4) Using a screwdriver, pry out the snap ring. (5) Remove the stop collar, pinion gear and compression spring. (6) Push down the starter housing, and remove the spring retainer. Remove the starter clutch from the starter housing. Remove the clutch shaft and compression spring from the starter clutch. B01225 B01226 Stop Collar Pinion Gear Compression Spring B01227 (7) (8) B01228 2001 AVALON (RM808U) Author
: Date
: 1264 ST-12 STARTING Starter Housing (b) Compression Spring Starter Clutch - STARTER Assemble the starter housing and the clutch assembly. (1) Install the compression spring and clutch shaft to the starter clutch. (2) Install the starter clutch to the starter housing. Clutch Shaft B01229 (3) Mount a brass bar in a vice, install the starter housing and clutch assembly to the brass bar. (4) Push down the starter housing, and install the spring retainer, compression spring, pinion gear and stop collar. (5) (6) Push down the pinion gear. Using snap ring pliers, install a new snap ring. (7) (8) Using pliers, compress the snap ring. Check that the snap ring fits correctly. B01230 Stop Collar Pinion Gear Compression Spring B01231 Spring Retainer B01670 B01232 B01233 2001 AVALON (RM808U) Author
: Date
: 1265 ST-13 STARTING - STARTER (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. B01165 SST 2. (a) REPLACE FRONT BEARING Using SST, remove the bearing. SST 09286-4601 1 P10595 (b) Using SST and a press, press in a new bearing. NOTICE: Be careful of the bearing installation direction. SST 09820-00030 Upward SST Downward P10596 3. (a) REPLACE REAR BEARING Using SST, remove the bearing. SST 09286-4601 1 (b) Using a press, press in a new bearing. P10593 P10594 2001 AVALON (RM808U) Author
: Date
: 1266 ST-14 STARTING 4. (a) - STARTER REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS Remove the 3 bolts, end cover, gasket and plunger. B01234 (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. B01235 (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 insulator (outside), O- ring, terminal bolt, contact plate and terminal insulator (inside). (3) Terminal 30: Remove the terminal nut, wave washer, terminal insulator (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 terminal insulator (outside). Install a new packing to a new terminal insulator, and install them. SST B01236 (1) Long Short (3) Inside (4) (2) (5) (6) (7) Identation Protrusion B06430 2001 AVALON (RM808U) Author
: Date
: 1267 ST-15 STARTING - STARTER 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) Long Short (7) (6) (5) (4) (2) (1) Inside Lead Terminal (3) B01238 Wooden Block 40 mm 37 mm 20 mm Contact Plate B01239 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 (outside). (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 calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied. Gauge pressure: 100 kgf Ram diameter (cm) 2 x 3.14 (π) 2 221 lbf 2 Ram diameter (in.) x 3.14 (π) 2 (kgf/cm2) = (psi) = (kPa) = (kgf/cm2) x 98.1 2001 AVALON (RM808U) (kPa) = (psi) x 6.9 Author
: Date
: 1268 ST-16 STARTING
- STARTER If the contact plate is not pressed down with the specified 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 inside of the insulator. SST B01240 (g) (h) Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. Install the plunger, new gasket, end cover and 3 bolts. Torque: 2.5 N·m (25 kgf·cm, 22 in.·lbf) B01241 2001 AVALON (RM808U) Author
: Date
: 1269 ST-18 STARTING - STARTER ST04T-02 Terminal C Battery Terminal 50 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. B01242 Disconnect Terminal C 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. Battery B01243 3. (a) (b) INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward. 4. (a) (b) DO NO-LOAD PERFORMANCE TEST Connect the battery and ammeter to the starter as shown. 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 Disconnect Battery B01244 Terminal 30 Battery Terminal 50 Ammeter B01245 2001 AVALON (RM808U) Author
: Date
: 1271 ST-20 STARTING - STARTER RELAY STARTER RELAY ST04V-02 INSPECTION 1. 2. REMOVE RELAY BOX COVER REMOVE STARTER RELAY (Marking: ST) Starter Relay B07464 Ohmmeter No 1 Continuity Continuity 5 Ohmmeter 3 2 3. (a) INSPECT STARTER RELAY 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. P07170 (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 Ohmmeter Continuity 1 5 3 2 Battery P07171 2001 AVALON (RM808U) Author
: Date
: 1273 ST-1 STARTING - STARTING SYSTEM STARTING SYSTEM ST04M-01 ON-VEHICLE INSPECTION NOTICE: Before changing the starter, check the following items again:
Connector connection
Accessory installation, e.g.: theft deterrent system 2001 AVALON (RM808U) Author
: Date
: 1254 SR-3 STEERING - DRIVE BELT DRIVE BELT SR0ED-03 INSPECTION P06717 DENSO Borroughs 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. Z00038 HINT:

CORRECT WRONG WRONG

P06723
”New belt” refers to a belt which has been used less than 5 minutes on a running engine. ”Used belt” refers to a belt which has been used on a running 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 minutes and recheck the belt tension. 2001 AVALON (RM808U) Author
: Date
: 1466 SR-4 STEERING - POWER STEERING FLUID POWER STEERING FLUID SR0EE-03 BLEEDING 1. 2. CHECK FLUID LEVEL (See page SR-5 ) JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS 3. TURN STEERING WHEEL With the engine stopped, turn the steering wheel slowly from lock to lock several times. 4. LOWER VEHICLE 5. START ENGINE Run the engine at idle for a few minutes. 6. TURN STEERING WHEEL (a) With the engine idling, turn the steering wheel to left or right full lock position and keep it there for 2-3 seconds, then turn the steering wheel to the opposite full lock position and keep it there for 2-3 seconds. (b) Repeat (a) several times. 7. STOP ENGINE Normal 8. CHECK FOR FOAMING OR EMULSIFICATION If the system has to be bled twice specifically because of foaming or emulsification, check for fluid leaks in the system. 9. CHECK FLUID LEVEL (See page SR-5 ) Abnormal R11741 2001 AVALON (RM808U) Author
: Date
: 1467 SR-5 STEERING - POWER STEERING FLUID SR0EF-04 INSPECTION HOT COLD R11740 Normal 1. (a) (b) CHECK FLUID LEVEL Keep the vehicle level. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON® II or III HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir. If the fluid is cold, check that it is within the COLD LEVEL range. (c) Start the engine and run it at idle. (d) Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) (e) Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system (See page SR-4 ). Abnormal R11741 (f) 5 mm (0.20 in.) or less Engine Idling Engine Stopped R11786 With the engine idling, measure the fluid level in the oil reservoir. (g) Stop the engine. (h) Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 in.) If a problem is found, bleed power steering system (See page SR-4 ). (i) Check the fluid level. 2001 AVALON (RM808U) Author
: Date
: 1468 SR-6 STEERING - POWER STEERING FLUID 2. (a) (b) CHECK STEERING FLUID PRESSURE Disconnect the pressure feed tube (See page SR-27 ). Connect SST to pressure feed tubes, as shown in the illustration below. SST 09640- 10010 (09641- 01010, 09641- 01030, 09641-01060) NOTICE: Check that the valve of the SST is in the open position. Attachment SST Pressure Feed Tube IN OUT R14662 (c) (d) (e) Bleed the power steering system (See page SR-4 ). Start the engine and run it at idle. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80 °C (176 °F) (f) Oil Reservoir PS Gear Closed PS Vane Pump SST With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 7,845 kPa (80 kgf/cm2, 1,138 psi) NOTICE:
Do not keep the valve closed for more than 10 seconds.
Do not let the fluid temperature become too high. Z15498 2001 AVALON (RM808U) Author
: Date
: 1469 SR-7 STEERING Oil Reservoir PS Gear Open PS Vane Pump SST - POWER STEERING FLUID (g) (h) With the engine idling, open the valve fully. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. Z15499 (i) Oil Reservoir Lock Position PS Gear Open PS Vane Pump SST Z15500 With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 7,845 kPa (80 kgf/cm2, 1,138 psi) NOTICE:
Do not maintain lock position for more than 10 seconds.
Do not let the fluid temperature become too high. (j) Disconnect the SST. SST 09640- 10010 (09641- 01010, 09641- 01030, 09641-01060) (k) Connect the pressure feed tube (See page SR-35 ). (l) Bleed the power steering system (See page SR-4 ). 2001 AVALON (RM808U) Author
: Date
: 1470 SR-37 STEERING - POWER STEERING GEAR POWER STEERING GEAR SR0ET-05 COMPONENTS 19 (190, 14) 19 (190, 14) Stabilizer Bar No. 1 Fuel Tube Protector 10 (100, 7) Clamp Plate Intermediate Shaft Sub-assembly 35 (360, 26)  O-Ring 181 (1,850, 134) Return Tube 49 (500, 36) 25 (250, 18) *28 (290, 21) Pressure Feed Tube 25 (250, 18) *28 (290, 21)  Cotter Pin 181 (1,850, 134) PS Gear Assembly N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part Power steering fluid * For use with SST 49 (500, 36)  Cotter Pin F09931 2001 AVALON (RM808U) Author
: Date
: 1500 SR-38 STEERING - POWER STEERING GEAR Rack Boot Clip Tie Rod End Rack Housing No. 2 Grommet  Clamp Rack Housing No. 2 Bracket Lock Nut 74 (750, 54) Rack Housing  Claw Washer Rack End Steering Rack 83 (850, 61) *60 (610, 44)  O-Ring  Teflon Ring  Oil Seal Rack End 83 (850, 61) *60 (610, 44)  Claw Washer Cylinder End Stopper Bushing  Wire Tie Rod End  Oil Seal Clip  O-Ring Lock Nut 74 (750, 54) Rack Boot N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part Molybdenum disulfide lithium base grease Power steering fluid * For use with SST  Clamp Z19562 2001 AVALON (RM808U) Author
: Date
: 1501 SR-39 STEERING - POWER STEERING GEAR 13 (130, 9) *12 (120, 9) Turn Pressure Tube 18 (180, 13)  O-Ring  Dust Seal Turn Pressure Tube  Control Valve Housing  O-Ring 18 (180, 13)  Oil Seal  Bearing Control Valve Assembly  Teflon Ring
Rack Guide Spring Cap Lock Nut 69 (700, 51) *50 (510, 37)  Oil Seal  Bearing  Gasket
Rack Guide Spring Cap Rack Guide Spring Rack Guide Sub-assembly Rack Housing  Bearing  Self-locking Nut 25 (250, 18)
Rack Housing Cap 59 (600, 43) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part
Precoated part Molybdenum disulfide lithium base grease Power steering fluid * For use with SST F09751 2001 AVALON (RM808U) Author
: Date
: 1502 SR-41 STEERING - POWER STEERING GEAR SR0EV-05 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. SECURE PS GEAR ASSEMBLY IN VISE Using SST, secure the PS gear assembly in a vise. SST 09612-00012 SST W04228 2. (a) SST (b) REMOVE 2 TURN PRESSURE TUBES Using SST, remove the 2 turn pressure tubes. SST 09023-38200 Remove the 4 O-rings from the 2 turn pressure tubes. F13587 3. (a) (b) (c) Matchmarks REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS Place matchmarks on the tie rod end and rack end. Loosen the lock nut, and remove the tie rod end and lock nut. Employ the same manner described above to the other side. R00429 4. W04230 Claw Washer REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS (a) Using a screwdriver, loosen the clamp. NOTICE: Be careful not to damage the rack boot. (b) Remove the clip and rack boot. (c) Employ the same manner described above to the other side. HINT: Mark the RH and LH rack boot. 5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS (a) Using a screwdriver and hammer, unstake the claw washer. NOTICE: Avoid any impact on the steering rack. R11644 2001 AVALON (RM808U) Author
: Date
: 1504 SR-42 STEERING - POWER STEERING GEAR (b) SST R11645 Rack Guide Spring Cap Lock Nut SST Using a spanner (24 mm) hold the steering rack steadily and using SST, remove the rack end. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. (c) Remove the claw washer. (d) Employ the same manner described above to the other side. HINT: Mark the RH and LH rack ends. 6. REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST, remove the rack guide spring cap lock nut. SST 09922-10010 NOTICE: Use SST 09922-10010 in the direction shown in the illustration. R11646 7. Rack Guide Spring Cap (a) (b) 8. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, RACK GUIDE SUB-ASSEMBLY Using SST, remove the rack guide spring cap. SST 09631-10021 Remove the rack guide spring and rack guide sub-assembly. REMOVE RACK HOUSING CAP SST R11647 9. REMOVE SELF-LOCKING NUT Using SST, stop the control valve shaft rotating and remove the self-locking nut. SST 09616-0001 1 10. REMOVE DUST SEAL SST R11648 2001 AVALON (RM808U) Author
: Date
: 1505 SR-43 STEERING 11. (a) Matchmarks (b) (c) 12. (a) R11553 - POWER STEERING GEAR REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY Place matchmarks on the control valve housing and rack housing. Remove the 2 bolts and control valve housing. Remove the gasket from the rack housing. REMOVE CONTROL VALVE ASSEMBLY To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft. (b) Press out the control valve assembly with the oil seal. NOTICE:
Place a shop rag between the valve housing and the blocks.
Be careful not to drop the valve assembly.
Be careful not to damage the oil seal lip. 13. REMOVE OIL SEAL Remove the oil seal from the control valve assembly. Press Vinyl Tape Shop Rag R11554 14. Matchmarks (a) REMOVE RACK HOUSING NO. 2 BRACKET AND RACK HOUSING NO. 2 GROMMET Place matchmarks on the rack housing No. 2 bracket and rack housing. R11649 (b) (c) Using a screwdriver, pry the clamp of the rack housing No. 2 bracket and remove the rack housing No. 2 bracket. Remove the rack housing No. 2 grommet from the rack housing No. 2 bracket. R11650 Cylinder End Stopper 15. (a) Wire (b) SST REMOVE CYLINDER END STOPPER Using SST, turn the cylinder end stopper clockwise until the wire end is visible through the service hole. SST 09631-10021 Using SST, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper. SST 09631-10021 R11651 2001 AVALON (RM808U) Author
: Date
: 1506 SR-44 STEERING 16. (a) Brass Bar Bushing (b) (c) - POWER STEERING GEAR REMOVE STEERING RACK AND BUSHING Using a brass bar and hammer, tap out the steering rack with the bushing. Remove the bushing from the steering rack. Remove the O-ring from the bushing. R11555 17. REMOVE OIL SEAL Using SST, press out the oil seal. SST 09950-60010 (09951-00290), 09950-70010 (09951-07360) SST Oil Seal F01791 2001 AVALON (RM808U) Author
: Date
: 1507 SR-45 STEERING - POWER STEERING GEAR SR0RV-02 INSPECTION Dial Indicator NOTICE: When using a vise, do not overtighten it. INSPECT STEERING RACK (a) Using a dial indicator, check the steering rack for runout and for teeth wear and damage. Maximum runout: 0.3 mm (0.012 in.) (b) Check the back surface for wear and damage. R10072 2001 AVALON (RM808U) Author
: Date
: 1508 SR-56 STEERING - POWER STEERING GEAR SR0EY-06 INSTALLATION 1. INSTALL PS GEAR ASSEMBLY (a) Install the PS gear assembly from the LH of the vehicle. NOTICE: Do not damage the turn pressure tubes. (b) Install the 2 gear assembly set bolts and nuts. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) HINT: Lift up the stabilizer bar and install the bolts. 2. INSTALL NO. 1 FUEL TUBE PROTECTOR Install the No. 1 fuel tube protector with 2 bolts and nut. 3. CONNECT STABILIZER BAR Connect the stabilizer bar with the 4 bolts. Torque: 19 N·m (190 kgf·cm, 14 ft·lbf) 4. (a) SST (b) CONNECT PRESSURE FEED AND RETURN TUBES Coat 2 new O-rings with power steering fluid and install them to the pressure feed and return tubes. Using SST, connect the pressure feed and return tubes. SST 09023-38400 Torque: 28 N·m (290 kgf·cm, 21 ft·lbf) HINT: Fulcrum Length F13589
Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
This torque value is effective in case that SST is parallel to a torque wrench. 5. CONNECT CLAMP PLATE Connect the clamp plate with nut. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 6. CONNECT INTERMEDIATE SHAFT SUB-ASSEMBLY (See page SR-22 ) 7. CONNECT RH AND LH TIE ROD ENDS (See page SA-13 ) 8. PLACE FRONT WHEELS FACING STRAIGHT AHEAD HINT: Do it with the front of the vehicle jacked up. 9. CENTER SPIRAL CABLE (See page SR-22 ) 10. INSTALL STEERING WHEEL (a) Align the matchmarks on the steering wheel and steering column main shaft. (b) Temporarily tighten the steering wheel set nut. (c) Connect the connector. 11. BLEED POWER STEERING SYSTEM (See page SR-4 ) 2001 AVALON (RM808U) Author
: Date
: 1519 SR-57 STEERING 12. 13. 14. 15. 16. - POWER STEERING GEAR CHECK STEERING WHEEL CENTER POINT TORQUE STEERING WHEEL SET NUT Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) INSTALL STEERING WHEEL PAD (See page SR-22 ) CHECK FRONT WHEEL ALIGNMENT (See page SA-4 ) w/ VSC: PERFORM STEERING ANGLE SENSOR ZERO POINT CALIBRATION (See page DI-252 ) 2001 AVALON (RM808U) Author
: Date
: 1520 SR-49 STEERING - POWER STEERING GEAR SR0RW-03 REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See page SR-37 ) 2. INSTALL OIL SEAL (a) Coat a new oil seal lip with power steering fluid. (b) Using SST, press in the oil seal. SST 09950- 60010 (09951- 00240, 09951- 00430, 09952-06010), 09950-70010 (09951-07360) NOTICE:
Make sure that the oil seal is installed facing in the correct direction.
Take care that the oil seal does not get reversed as you install it. Press SST SST Oil Seal W03561 3. (a) INSTALL STEERING RACK Install SST to the steering rack. SST 09631-33010 HINT: If necessary, scrape the burrs off the steering rack teeth end and burnish. (b) Coat the SST with power steering fluid. (c) Install the steering rack into the rack housing. NOTICE: Be careful not to damage the oil seal lip. (d) Remove SST. SST 09631-33010 Rack Teeth End SST W02101 4. (a) Vinyl Tape Bushing R11574 INSTALL BUSHING Coat a new O-ring with power steering fluid and install it to the bushing. (b) To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid. (c) Install the bushing. NOTICE:
Make sure that the bushing is installed facing in the correct direction.
Be careful not to damage the oil seal lip. 2001 AVALON (RM808U) Author
: Date
: 1512 SR-50 STEERING SST 5. (a) Wire (b) (c) - POWER STEERING GEAR INSTALL CYLINDER END STOPPER Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing. Install a new wire into the cylinder end stopper. Using SST, turn the cylinder end stopper clockwise 450 ± 50°. SST 09631-10021 Cylinder End Stopper R11656 6. (a) AIR TIGHTNESS TEST Install SST to the rack housing. SST 09631-12071 (b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds. (c) Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals. SST R00662 7. (a) R11657 INSTALL RACK HOUSING NO. 2 BRACKET AND RACK HOSING NO. 2 GROMMET Install the rack housing No. 2 grommet to the rack housing No. 2 bracket. HINT: Align the projection of the rack housing No. 2 grommet with the hole of the rack housing No. 2 bracket. (b) Align the matchmarks on the rack housing No. 2 bracket and rack housing. (c) Place the rack housing No. 2 bracket in a vise and install the vise to fasten the clamp. R11658 8. (a) INSTALL CONTROL VALVE ASSEMBLY To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft. (b) Coat the teflon rings with power steering fluid. (c) Install the control valve assembly into the control valve housing. NOTICE: Be careful not to damage the teflon rings and oil seal. Vinyl Tape R11575 2001 AVALON (RM808U) Author
: Date
: 1513 SR-51 STEERING - POWER STEERING GEAR 9. (a) (b) Press SST Oil Seal W03562 INSTALL OIL SEAL Coat a new oil seal lip with power steering fluid. Using SST, press in the oil seal. SST 09612-2201 1 NOTICE: Make sure that the oil seal is installed facing in the correct direction. 10. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY (a) Place a new gasket on the rack housing. (b) Align the matchmarks on the control valve housing and rack housing. (c) Install the 2 bolts. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) 11. INSTALL SELF-LOCKING NUT Using SST, stop the control valve shaft rotating and install a new self-locking nut. SST 09616-0001 1 Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 12. INSTALL DUST SEAL SST R11648 13. (a) Punch (b) (c) R11659 14. (a) (b) (c) INSTALL RACK HOUSING CAP Apply sealant to 2 or 3 threads of the rack housing cap. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the rack housing cap. Torque: 59 N·m (600 kgf·cm, 43 ft·lbf) Using a punch and hammer, stake the 2 parts of the rack housing cap. INSTALL RACK GUIDE SUB- ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP Install the rack guide sub- assembly and rack guide spring. Apply sealant to 2 or 3 threads of the rack guide spring cap. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Temporarily install the rack guide spring cap. 2001 AVALON (RM808U) Author
: Date
: 1514 SR-52 STEERING 15. (a) Rack Guide Spring Cap (b) - POWER STEERING GEAR ADJUST TOTAL PRELOAD To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends. Using SST, torque the rack guide spring cap. SST 09631-10021 Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) SST W03098 (c) Using SST, return the rack guide spring cap 12°. SST 09631-10021 (d) Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-0001 1 Using SST, loosen the rack guide spring cap until the rack guide spring is not functioning. SST 09631-10021 12° W03099 SST (e) W03100 (f) SST SST Rack Guide Spring Cap Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification. SST 09616-0001 1, 09631-10021 Preload (turning): 0.8 - 1.4 N·m (8 - 14 kgf·cm, 6.9 - 12.2 in.·lbf) W03101 2001 AVALON (RM808U) Author
: Date
: 1515 SR-53 STEERING - POWER STEERING GEAR 16. (a) Rack Guide Spring Cap Lock Nut SST Fulcrum Length SST W03102 INSTALL RACK GUIDE SPRING CAP LOCK NUT Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut. Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent (b) Temporarily install the rack guide spring cap lock nut. (c) Using SST, hold the rack guide spring cap and using another SST torque the rack guide spring cap lock nut. SST 09631-10021, 09922-10010 Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). (d) Recheck the total preload. Preload (turning): 0.8 - 1.4 N·m (8 - 14 kgf·cm, 6.9 - 12.2 in.·lbf) (e) Remove the RH and LH rack ends. 17. (a) INSTALL RH AND LH CLAW WASHERS AND RACK ENDS Install a new claw washer, and temporarily install the rack ends. HINT: Align the claws of the claw washers with the steering rack grooves. Claw R11667 (b) Fulcrum Length SST F03861 Using a spanner (24 mm), hold the steering rack steadily and using SST, torque the rack end. SST 09922-10010 Torque: 60 N·m (610 kgf·cm, 44 ft·lbf) NOTICE: Use SST 09922-10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). 2001 AVALON (RM808U) Author
: Date
: 1516 SR-54 STEERING - POWER STEERING GEAR (c) Using a brass bar and hammer, stake the claw washer. NOTICE: Avoid any impact on the steering rack. (d) Employ the same manner described above to the other side. Brass Bar R11668 18. (a) INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS Ensure that the steering rack hole is not clogged with grease. HINT: If the hole is clogged, the pressure inside the rack boot will change after it is assembled and the steering wheel is turned. R11669 2 mm (0.79 in.) or less (b) Install the rack boot, clip and a new clamp. NOTICE: Be careful not to damage or twist the rack boot. (c) Using SST, tighten the clamp as shown in the illustration. SST 09521-24010 (d) Employ the same manner described above to the other side. SST W04223 19. (a) (b) (c) Matchmarks INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned. After adjusting toe-in, torque the lock nut (See page SA-4 ). Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) Employ the same manner described above to the other side. R00429 2001 AVALON (RM808U) Author
: Date
: 1517 SR-55 STEERING 20. (a) Fulcrum Length (b) - POWER STEERING GEAR INSTALL 2 TURN PRESSURE TUBES Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes. Using SST, install the 2 turn pressure tubes. SST 09023-38200 Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) HINT:
SST F13588
Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). This torque value is effective in case that SST is parallel to a torque wrench. 2001 AVALON (RM808U) Author
: Date
: 1518 SR-40 STEERING - POWER STEERING GEAR SR0EU-05 REMOVAL NOTICE: Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable. 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE STEERING WHEEL PAD (See page SR-12 ) 3. REMOVE STEERING WHEEL (See page SR-12 ) 4. DISCONNECT RH AND LH TIE ROD ENDS (See page SA-9 ) 5. DISCONNECT INTERMEDIATE SHAFT SUB- ASSEMBLY (See page SR-12 ) 6. DISCONNECT CLAMP PLATE Remove the nut and clamp plate. 7. SST F13586 DISCONNECT PRESSURE FEED AND RETURN TUBES (a) Using SST, disconnect the pressure feed and return tubes. SST 09023-38400 (b) Remove the 2 O-rings from the pressure feed and return tubes. 8. DISCONNECT STABILIZER BAR Remove the 4 bolts and disconnect the stabilizer bar. HINT: Do not remove the stabilizer bar. 9. REMOVE NO. 1 FUEL TUBE PROTECTOR Remove the 2 bolts, nut and No. 1 fuel tube protector. 10. REMOVE PS GEAR ASSEMBLY (a) Remove the 2 PS gear assembly set bolts and nuts. HINT: Lift up the stabilizer bar and remove the bolts. (b) Remove the PS gear assembly from the LH of the vehicle. NOTICE: Do not damage the turn pressure tubes. 2001 AVALON (RM808U) Author
: Date
: 1503 SR-46 STEERING - POWER STEERING GEAR SR0RX-02 Press REPLACEMENT SST NOTICE: When using a vise, do not over tighten it. 1. IF NECESSARY, REPLACE OIL SEAL AND BEARING (a) Using SST, press out the oil seal and bearing from the control valve housing. SST 09950-60010 (09951-00250), 09950-70010 (09951-07200) Oil Seal Bearing F01792 (b) (c) Coat a new oil seal lip with power steering fluid. Using SST, press in the oil seal. SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07200) NOTICE: Make sure that the oil seal is installed facing in the correct direction. Press SST SST Oil Seal W03560 (d) Press SST (e) Bearing SST Coat a new bearing with molybdenum disulfide lithium base grease. Using SST, press in the bearing. SST 09950-60010 (09951-00180, 09951-00340, 09952-06010), 09950-70010 (09951-07200) F03877 Brass Bar 2. (a) IF NECESSARY, REPLACE 2 BEARINGS Using a brass bar and hammer, tap out the bearing from the rack housing. (b) Using SST, press out the bearing from the rack housing. SST 09950-60010 (09951-00260), 09950-70010 (09951-07200) Bearing F01794 Press SST Bearing F01795 2001 AVALON (RM808U) Author
: Date
: 1509 SR-47 STEERING (c) SST Press (d) Bearing SST - POWER STEERING GEAR Coat a new bearing with molybdenum disulfide lithium base grease. Using SST, press in the bearing. SST 09950-60010 (09951-00250, 09951-00310, 09952-06010), 09950-70010 (09951-07200) F03878 (e) Press SST (f) Coat a new bearing with molybdenum disulfide lithium base grease. Using SST, press in the bearing. SST 09950-60010 (09951-00320), 09950-70010 (09951-07200) Bearing F01797 3. (a) IF NECESSARY, REPLACE OIL SEAL Using SST, remove the oil seal from the bushing. SST 09527-2001 1, 09612-24014 (09613-22011) NOTICE: Be careful not to damage the bushing. Oil Seal SST Bushing SST F01798 (b) (c) Press SST Coat a new oil seal lip with power steering fluid. Using SST, press in the oil seal. SST 09950-60010 (09951-00240, 09951-00400, 09952-06010) NOTICE: Make sure that the oil seal is installed facing in the correct direction. Oil Seal SST F03863 4. IF NECESSARY, REPLACE TEFLON RING AND ORING (a) Using a screwdriver, remove the teflon ring and O-ring from the steering rack. NOTICE: Be careful not to damage the groove for the teflon ring. (b) Coat a new O-ring with power steering fluid and install it. R10955 2001 AVALON (RM808U) Author
: Date
: 1510 SR-48 STEERING - POWER STEERING GEAR (c) Expand a new teflon ring with your fingers. NOTICE: Be careful not to over expand the ring. R06172 (d) (e) Coat the teflon ring with power steering fluid. Install the teflon ring to the steering rack, and settle it down with your fingers. N00401 5. (a) Teflon Ring R11572 IF NECESSARY, REPLACE 4 TEFLON RINGS Using a screwdriver, remove the 4 teflon rings from the control valve assembly. NOTICE: Be careful not to damage the grooves for the teflon ring. (b) Expand 4 new teflon rings with your fingers. NOTICE: Be careful not to over expand the teflon ring. (c) Coat the teflon rings with power steering fluid. (d) Install the teflon rings to the control valve assembly, and settle them down with your fingers. (e) Carefully slide the tapered end of SST over the teflon rings until the teflon rings fit to the control valve assembly. SST 09631-20081 NOTICE: Be careful not to damage the teflon rings. SST Teflon Ring R11573 2001 AVALON (RM808U) Author
: Date
: 1511 SR-25 STEERING - POWER STEERING VANE PUMP POWER STEERING VANE PUMP SR0EN-06 COMPONENTS 43 (440, 32) *29 (300, 22) 7.8 (80, 69 in.·lbf) Drive Belt Connector Oil Pressure Switch 21 (210, 15) Union Bolt Clamp Plate 52 (530, 38) Pressure Feed Tube
Gasket 25 (250, 18) *22 (230, 17) Return Hose Pressure Feed Tube 43 (440, 32) PS Vane Pump Assembly Holder Clamp Plate Clamp Plate Front Fender Apron Seal RH N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part * For use with SST F08851 2001 AVALON (RM808U) Author
: Date
: 1488 SR-26 STEERING - POWER STEERING VANE PUMP Pressure Port Union 17 (170, 12) 83 (850, 62)
O-Ring Flow Control Valve Rear Housing Suction Port Union 13 (130, 9)
O-Ring Spring Rear Bracket
Gasket
O-Ring 43 (440, 32) Front Housing 17 (170, 12) Front Bracket 43 (440, 32) Vane Pump Rotor
Straight Pin Vane Pump Shaft Vane Pump Pulley x 10
Wave Washer Side Plate Cam Ring Vane Plate
Oil Seal
Snap Ring 44 (450, 33) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Power steering fluid F08852 2001 AVALON (RM808U) Author
: Date
: 1489 SR-28 STEERING - POWER STEERING VANE PUMP SR0EP-04 DISASSEMBLY F08853 NOTICE: When using a vise, do not overtighten it. 1. MEASURE PS VANE PUMP ROTATING TORQUE (a) Check that the pump rotates smoothly without abnormal noise. (b) Using a torque wrench, check the pump rotating torque. Rotating torque: 0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less 2. (a) (b) SST F08854 REMOVE VANE PUMP PULLEY Using SST, stop the pulley rotating and loosen the nut. Remove the nut and vane pump pulley from the vane pump shaft. SST 09960-10010 (09962-01000, 09963-01000) 3. REMOVE FRONT AND REAR BRACKETS Remove the 3 bolts, 2 nuts, front and rear brackets. 4. REMOVE SUCTION PORT UNION (a) Remove the bolt and suction port union. (b) Remove the O-ring from the suction port union. 5. REMOVE PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING (a) Remove the pressure port union, flow control valve and spring. (b) Remove the O-ring from the pressure port union. 6. REMOVE REAR HOUSING (a) Remove the 4 bolts and rear housing. (b) Remove the 2 O-rings from the rear housing. 7. REMOVE WAVE WASHER 8. REMOVE SIDE PLATE 9. REMOVE GASKET 10. REMOVE CAM RING, 10 VANE PLATES AND VANE PUMP ROTOR (a) Remove the cam ring and 10 vane plates. NOTICE: Take care not to drop the plate. (b) Using a screwdriver, remove the snap ring and vane pump rotor from the vane pump shaft. 11. REMOVE VANE PUMP SHAFT 12. REMOVE 2 STRAIGHT PINS Remove the 2 straight pins from the front housing. 2001 AVALON (RM808U) Author
: Date
: 1491 SR-29 STEERING - POWER STEERING VANE PUMP SR0RT-02 INSPECTION NOTICE: When using a vise, do not overtighten it. 1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING Using a micrometer and caliper gauge, measure the oil clearance. Standard clearance: 0.03 - 0.05 mm (0.0012 - 0.0020 in.) Maximum clearance: 0.07 mm (0.0028 in.) If it is more than the maximum, replace the front housing and vane pump shaft. Caliper Gauge Micrometer Vane Pump Shaft Bushing Front Housing R15196 Thickness 2. (a) INSPECT VANE PUMP ROTOR AND VANE PLATES Using a micrometer, measure the height, thickness and length of the vane plates. Minimum height: 8.6 mm (0.339 in.) Minimum thickness: 1.397 mm (0.0550 in.) Minimum length: 14.991 mm (0.5902 in.) (b) Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane plate. Maximum clearance: 0.035 mm (0.0014 in.) Height Length N00372 Feeler Gauge R10282 2001 AVALON (RM808U) Author
: Date
: 1492 SR-30 STEERING - POWER STEERING VANE PUMP If it is more than the maximum, replace the vane plate and/or vane pump rotor with the one having the same mark stamped on the cam ring. Inscribed mark: 1, 2, 3, 4 or None HINT: There are 5 vane plate lengths with the following vane pump rotor and cam ring marks: Inscribed Mark R13897 Vane pump rotor and cam ring mark Vane plate part number Vane plate length mm (in.) None 44345-26010 14.999-15.001 (0.59051-0.59059) 1 44345-26020 14.997-14.999 (0.59043-0.59051) 2 44345-26030 14.995-14.997 (0.59035-0.59043) 3 44345-26040 14.993-14.995 (0.59027-0.59035) 4 44345-26050 14.991-14.993 (0.59020-0.59027) 3. (a) INSPECT FLOW CONTROL VALVE Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight. (b) Check the flow control valve for leakage. Close one of the holes and apply 392 - 490 kPa (4 - 5 kgf/cm2, 57 - 71 psi) of compressed air into the opposite side hole, and confirm that air does not come out from the end holes. R11288 Compressed Air R07591 If necessary, replace the flow control valve with the one having the same letter as inscribed on the front housing. Inscribed Mark: A, B, C, D, E or F Inscribed Mark R11563 2001 AVALON (RM808U) Author
: Date
: 1493 SR-31 STEERING - POWER STEERING VANE PUMP 4. INSPECT SPRING Using vernier calipers, measure the free length of the spring. Minimum free length: 32.3 mm (1.272 in.) If it is not within the specification, replace the spring. Vernier Calipers R08702 2001 AVALON (RM808U) Author
: Date
: 1494 SR-35 STEERING - POWER STEERING VANE PUMP SR0ES-07 Pressure Feed Tube Stopper F08856 INSTALLATION 1. INSTALL PRESSURE FEED TUBE Install the pressure feed tube and gasket to the PS vane pump assembly with union bolt. HINT: Make sure the stopper of the pressure feed tube touches the front bracket as shown in the illustration, then install the union bolt. Torque: 52 N·m (530 kgf·cm, 38 ft·lbf) 2. INSTALL OIL PRESSURE SWITCH Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) NOTICE: Be careful to prevent oil seal from being attached to the connector. 3. INSTALL PS VANE PUMP ASSEMBLY WITH PRESSER FEED TUBE Temporarily install the PS vane pump assembly with 2 (A and B) bolts. 4. INSTALL DRIVE BELT (a) Adjust drive belt tension (See page SR-3 ). A B F08855 (b) Using SST, torque the bolt A. SST 09249-63010 Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) HINT:

Clamp (c) Engine Wire (d) Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). Disconnect the clamp with engine wire. Torque the bolt B. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) Connect the connector to the oil pressure switch. Fulcrum Length SST Z19285 2001 AVALON (RM808U) Author
: Date
: 1498 SR-36 STEERING 5. (a) Pressure Feed Tube Fulcrum Length - POWER STEERING VANE PUMP CONNECT PRESSURE FEED TUBE Using a spanner, hold the pressure feed tube steadily and using SST, connect the pressure feed tube. SST 09023-12700 Torque: 23 N·m (230 kgf·cm, 17 ft·lbf) HINT:
SST F13585 Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
This torque value is effective in case that SST is parallel to a torque wrench. (b) Install the 2 holders and 2 clamp plates to the pressure feed tube with bolt. (c) Install the 2 clamp plate with 2 nuts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) 6. CONNECT RETURN HOSE Connect the return hose with the clip. 7. INSTALL FRONT FENDER APRON SEAL RH Install the front fender apron seal RH with 2 bolts. 8. BLEED POWER STEERING SYSTEM (See page SR-4 ) 2001 AVALON (RM808U) Author
: Date
: 1499 SR-33 STEERING - POWER STEERING VANE PUMP SR0ER-03 REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID (See page SR-25 ) 2. INSTALL 2 STRAIGHT PINS Using a plastic hammer, tap in 2 new straight pins. NOTICE: Be careful not to damage the straight pins. 3. INSTALL VANE PUMP SHAFT Inscribed Mark 4. INSTALL CAM RING Align the holes of the cam ring and 2 straight pins, and install the cam ring with the inscribed mark facing outward. 5. INSTALL VANE PUMP ROTOR (a) Install the vane pump rotor with the inscribed mark facing outward. (b) Install a new snap ring to the vane pump shaft. R13458 6. INSTALL 10 VANE PLATES Install the 10 vane plates with the round end facing outward. 7. INSTALL GASKET Install a new gasket. 8. INSTALL SIDE PLATE Align the holes of the side plate and 2 straight pins, and install the side plate. Round End R01149 9. INSTALL WAVE WASHER Install the wave washer so that its protrusions fit into the slots in the side plate. 10. INSTALL REAR HOUSING (a) Coat 2 new O-rings with power steering fluid and install them to the rear housing. (b) Install the rear housing with 4 bolts. Torque: 17 N·m (170 kgf·cm, 12 ft·lbf) R11292 2001 AVALON (RM808U) Author
: Date
: 1496 SR-34 STEERING - POWER STEERING VANE PUMP 11. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION (a) Install the spring. (b) Install the flow control valve facing in the correct direction (See page SR-25 ). (c) Coat a new O-ring with power steering fluid and install it to the pressure port union. (d) Install the pressure port union. Torque: 83 N·m (850 kgf·cm, 62 ft·lbf) 12. INSTALL SUCTION PORT UNION (a) Coat a new O-ring with power steering fluid and install it to the suction port union. (b) Install the suction port union with bolt. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 13. INSTALL FRONT AND REAR BRACKETS Install the front and rear brackets with 3 bolts and 2 nuts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 14. (a) SST (b) 15. INSTALL VANE PUMP PULLEY Install the vane pump pulley and nut to the vane pump shaft. Using SST, stop the pulley rotating and torque the nut. SST 09960-10010 (09962-01000, 09963-01000) Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) MEASURE PS VANE PUMP ROTATING TORQUE (See page SR-28 ) F08854 2001 AVALON (RM808U) Author
: Date
: 1497 SR-27 STEERING - POWER STEERING VANE PUMP SR0EO-06 REMOVAL 1. REMOVE FRONT FENDER APRON SEAL RH Remove the 2 bolts and front fender apron seal RH. 2. DISCONNECT RETURN HOSE Remove the clip and disconnect the return hose. NOTICE: Take care not to spill fluid on the drive belt. 3. (a) (b) SST (c) Pressure Feed Tube DISCONNECT PRESSURE FEED TUBE Remove the 2 clamp plate set nuts. Remove the bolt, 2 clamp plates and 2 holders from the pressure feed tube. Using a spanner, hold the pressure feed tube steadily and using SST, disconnect the pressure feed tube. SST 09023-12700 F13584 A B F08855 4. REMOVE DRIVE BELT Loosen the 2 (A and B) bolts and drive belt. 5. REMOVE PS VANE PUMP ASSEMBLY WITH PRESSURE FEED TUBE (a) Disconnect the connector from the oil pressure switch. (b) Loosen the bolt A sufficiently so that pump assembly can be removed. HINT: Bolt A cannot be removed. (c) Remove the bolt B and PS vane pump assembly. 6. REMOVE OIL PRESSURE SWITCH NOTICE: Be careful not to drop the switch. If the switch is dropped or strongly damaged, replace it with a new one. 7. REMOVE PRESSURE FEED TUBE (a) Remove the oil pressure switch from the union bolt. (b) Remove the union bolt, gasket and pressure feed tube. 2001 AVALON (RM808U) Author
: Date
: 1490 SR-32 STEERING - POWER STEERING VANE PUMP SR0RU-02 REPLACEMENT Vinyl Tape NOTICE: When using a vise, do not overtighten it. IF NECESSARY, REPLACE OIL SEAL (a) Using a screwdriver with vinyl tape wound around its tip, remove the oil seal. NOTICE: Be careful not to damage the front housing. R11290 (b) (c) Press SST Oil Seal Coat a new oil seal lip with power steering fluid. Using SST, press in the oil seal. SST 09950-60010 (09951-00330), 09950-70010 (09951-07100) NOTICE: Make sure that the oil seal is installed facing in the correct direction. W03541 2001 AVALON (RM808U) Author
: Date
: 1495 SR-1 STEERING - STEERING SYSTEM STEERING SYSTEM SR0EB-02 PRECAUTION

Care must be taken to replace parts properly because they could affect the performance of the steering system and result in a driving hazard. The AVALON is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 2001 AVALON (RM808U) Author
: Date
: 1464 SR-8 STEERING - STEERING WHEEL STEERING WHEEL SR0EG-05 INSPECTION 1. (a) (b) CHECK STEERING WHEEL FREEPLAY Stop the vehicle and face the tires straight ahead. Rock the steering wheel gently up and down with a finger lightly, check the steering wheel freeplay. Maximum freeplay: 30 mm (1.18 in.) 2. (a) (b) (c) (d) CHECK STEERING EFFORT Center the steering wheel. Remove the steering wheel pad (See page SR-12 ). Start the engine and run it at idle. Measure the steering effort in both directions. Steering effort (Reference) 5.9 N·m (60 kgf·cm, 52 in.·lbf) F08857 F08858 HINT: Take the tire type, pressure and contact surface into consideration before making your diagnosis. (e) Torque the steering wheel set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) (f) Install the steering wheel pad (See page SR-22 ). 2001 AVALON (RM808U) Author
: Date
: 1471 SR-2 STEERING - TROUBLESHOOTING TROUBLESHOOTING SR0EC-02 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, repair or replace these parts. Symptom Suspect Area See page Hard steering 1. Tires (Improperly inflated) 2. Power steering fluid level (Low) 3. Drive belt (Loose) 4. Front wheel alignment (Incorrect) 5. Steering system joints (Worn) 6. Suspension arm ball joints (Worn) 7. Steering column (Binding) 8. Power steering vane pump 9. Power steering gear SA-2 SR-5 SR-3 SA-4 SA-38 SR-25 SR-37 Poor return 1. Tires (Improperly inflated) 2. Front wheel alignment (Incorrect) 3. Steering column (Binding) 4. Power steering gear SA-2 SA-4 SR-37 Excessive play 1. Steering system joints (Worn) 2. Suspension arm ball joints (Worn) 3. Universal joint, Intermediate shaft, Sliding yoke (Worn) 4. Front wheel bearing (Worn) 5. Power steering gear SA-38 SA-9 SR-37 Abnormal noise 1. Power steering fluid level (Low) 2. Steering system joints (Worn) 3. Power steering vane pump 4. Power steering gear SR-5 SR-25 SR-37 2001 AVALON (RM808U) Author
: Date
: 1465 SR-9 STEERING - TILT STEERING COLUMN TILT STEERING COLUMN SR0EH-06 COMPONENTS Floor shift: Speed Control Main Switch Assembly Steering Wheel Pad Torx Screw 8.8 (90, 78 in.·lbf) 50 (510, 37) Steering Wheel Lower No. 2 Cover Steering Wheel Combination Switch (w/ Spiral cable) Steering Wheel Lower No. 2 Cover Torx Screw Column Upper Cover 8.8 (90, 78 in.·lbf) Steering Column Assembly w/ VSC: Steering Angle Sensor Adapter Air Cleaner Assembly with Air Cleaner Hose w/ VSC: Steering Angle Sensor Column Lower Cover 35 (360, 26) No. 2 Column Lower Cover 25 (260, 19) Return Spring Clamp Intermediate Shaft Sub-assembly Lower Instrument Finish Panel Assembly 35 (360, 26) Universal Joint Assembly No. 2 Column Hole Cover Sub-assembly Lower LH Instrument Panel Insert Sub-assembly 35 (360, 26) Lower No. 1 Instrument Panel Sub-assembly Hood Lock Release Lever No. 2 Heater to Register Duct N·m (kgf·cm, ft·lbf) : Specified torque F08837 2001 AVALON (RM808U) 1472 SR-10 STEERING - TILT STEERING COLUMN Column shift: Speed Control Main Switch Assembly Steering Wheel Pad Torx Screw 8.8 (90, 78 in.·lbf) Steering Wheel Lower No. 2 Cover 50 (510, 37) Steering Wheel Combination Switch (w/ Spiral cable) Steering Wheel Lower No. 2 Cover Torx Screw Column Upper Cover Steering Column Assembly 8.8 (90, 78 in.·lbf) Transmission Control Cable Air Cleaner Assembly with Air Cleaner Hose w/ VSC: Steering Angle Sensor Column Lower Cover 25 (260, 19) No. 2 Column Lower Cover 35 (360, 26) Clamp Intermediate Shaft Sub-assembly 35 (360, 26) Lower Instrument Finish Panel Assembly w/ VSC: Steering Angle Sensor Adapter Return Spring Universal Joint Assembly No. 2 Column Hole Cover Sub-assembly Lower LH Instrument Panel Insert Sub-assembly 35 (360, 26) Lower No. 1 Instrument Panel Sub-assembly Hood Lock Release Lever No. 2 Heater to Register Duct N·m (kgf·cm, ft·lbf) : Specified torque F08849 2001 AVALON (RM808U) Author
: Date
: 1473 SR-1 1 STEERING Column shift: Shift Lever

- TILT STEERING COLUMN
2.8 (29, 25 in.·lbf) 3.4 (35, 30 in.·lbf) Shift Lock Solenoid Bracket Shift Lock Switch Corrugate Tube 11 (110, 8)
10 (100, 7) Shift Lever Housing Shift Lock Control ECU Compression Spring w/ Engine immobiliser system: Transponder Key Coil Main Shaft Collar Key Cylinder Lamp Assembly Key Cylinder
No. 2 Steering Column Ring
7.5 (75, 65 in.·lbf) Spring Retainer Turn Signal Bracket Column Upper Key Unlock Warning Switch Bracket Main Shaft Bushing Tension Spring
Steering Column Upper Tube Spring Guide Tilt Spring Tilt Lever Key Interlock Solenoid Ignition Switch
No. 2 Tilt Steering Bolt
Tilt Lever Lock Shaft 9.0 (90, 78 in.·lbf) Main Shaft Assembly w/ Engine immobiliser system: Transponder Key Amplifier Column Tube Assembly
No. 2 Tilt Steering Bolt
Tapered-head Bolt N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Molybdenum disulfide lithium base grease F09909 2001 AVALON (RM808U) 1474 SR-16 STEERING - TILT STEERING COLUMN SR0Z5-01 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. w/ Engine immobiliser system: REMOVE TRANSPONDER KEY COIL 2. REMOVE KEY CYLINDER LAMP ASSEMBLY Remove the screw and key cylinder lamp assembly. 3. Column shift: REMOVE SHIFT LOCK CONTROL ECU Disconnect the 3 connectors and remove the shift lock control ECU. 4. (a) Screw Extractor (b) (c) REMOVE COLUMN UPPER BRACKET Using a centering punch, mark the center of the 2 tapered-head bolts. Using a 3 - 4 mm (0.12 - 0.16 in.) drill, drill into the 2 bolts. Using a screw extractor, remove the 2 bolts and column upper bracket. F08832 5. (a) (b) (c) Column shift: REMOVE SHIFT LEVER HOUSING Remove the torx screw and shift lock switch. Remove the 2 torx screws and shift lock solenoid bracket. Remove the torx screw and shift lever. (d) 6. (a) (b) Remove the 3 torx screws and shift lever housing. REMOVE TURN SIGNAL BRACKET Remove the tension spring. Remove the 2 torx screws and turn signal bracket. R11903 F09911 2001 AVALON (RM808U) Author
: Date
: 1479 SR-17 STEERING TILT STEERING COLUMN 7. Plate Washer A Screw - SST Plate Washer B F09912 REMOVE STEERING COLUMN UPPER TUBE WITH MAIN SHAFT ASSEMBLY (a) Set SST, plate washer (18 and 36 mm outer diameter) and screw (4.0 mm diameter, 0.7 mm pitch, 15.0 mm length), as shown in the illustration. And then remove the 2 No. 2 tilt steering bolts. SST 09910-00015 (09911-0001 1, 09912-00010) Reference: Plate washer A (18 mm): 90562-04012 Plate washer B (36 mm): 90201-10201 Screw: 90154-40015 (b) Remove the column upper tube with the main shaft assembly from the column tube assembly. NOTICE: Do not bend the universal joint of the main shaft assembly more than 20°. (c) Remove tilt spring and spring guide. 8. (a) SST No. 2 Steering Column Ring F09910 REMOVE MAIN SHAFT ASSEMBLY Install SST to the main shaft assembly, as shown in the illustration. SST 09612-07010 (b) Using SST, compress the compression spring. NOTICE: Do not bend the universal joint of the main shaft assembly more than 20°. HINT: Hold the main shaft assembly with your hand so that it does not rotate. (c) Using a screwdriver, remove the No. 2 steering column ring. (d) Remove the spring retainer, compression spring, main shaft bushing and main shaft collar. 9. REMOVE TILT LEVER Remove the tilt lever lock shaft and tilt lever. 2001 AVALON (RM808U) Author
: Date
: 1480 SR-18 STEERING - TILT STEERING COLUMN SR0Z6-01 INSPECTION 1. INSPECT STEERING LOCK OPERATION Check that the steering lock mechanism operates properly. F09913 2. (a) (b) F09914 IF NECESSARY, REPLACE KEY CYLINDER Place the ignition key at the ACC position. Push down the stop pin with a screwdriver, and pull out the key cylinder. Install a new key cylinder. (c) HINT: Make sure the ignition key is at the ACC position. 3. INSPECT IGNITION SWITCH (See page BE-16 ) 4. IF NECESSARY, REPLACE IGNITION SWITCH (a) Remove the 2 screws and ignition switch. (b) Install a new ignition switch with the 2 screws. 5. INSPECT KEY UNLOCK WARNING SWITCH (See page BE-16 ) 6. IF NECESSARY, REPLACE KEY UNLOCK WARNING SWITCH (a) Slide the key unlock warning switch out of the column upper bracket. (b) Slide a new key unlock warning switch in the column upper bracket. 7. INSPECT KEY INTERLOCK SOLENOID (See page AX-16 and AX-18 ) 8. IF NECESSARY, REPLACE KEY INTERLOCK SOLENOID (a) Remove the 2 screws and key interlock solenoid. (b) Install a new key interlock solenoid with the 2 screws. 9. Column shift: INSPECT SHIFT LOCK SOLENOID, SHIFT LOCK SWITCH AND SHIFT LOCK CONTROL ECU (See page AX-18 ) 10. Column shift: IF NECESSARY, REPLACE SHIFT LOCK SOLENOID, SHIFT LOCK SWITCH AND SHIFT LOCK CONTROL ECU 11. w/ Engine immobiliser system: INSPECT TRANSPONDER KEY COIL (See page BE-181 ) 12. w/ Engine immobiliser system: IF NECESSARY, REPLACE TRANSPONDER KEY COIL 2001 AVALON (RM808U) Author
: Date
: 1481 SR-19 STEERING 13. (a) (b) - TILT STEERING COLUMN w/ Engine immobiliser system: IF NECESSARY, REPLACE TRANSPONDER KEY AMPLIFIER Remove the 2 screws and transponder key amplifier. Install a new transponder key amplifier with the 2 screws. 14. INSPECT BEARING Check the bearing rotation condition and check for abnormal noise. If faulty, replace the steering column upper tube sub-assembly. F09915 15. INSPECT BUSHING Check the bushing rotation condition and check for abnormal noise. If faulty, replace the steering column assembly. F09916 2001 AVALON (RM808U) Author
: Date
: 1482 SR-22 STEERING - TILT STEERING COLUMN SR0Z8-02 INSTALLATION 1. INSTALL SPEED CONTROL MAIN SWITCH ASSEMBLY TO STEERING WHEEL Install the speed control main switch assembly with the 2 screws to the steering wheel. 2. Guide (a) Projection (b) w/ VSC: INSTALL STEERING ANGLE SENSOR ADAPTER AND STEERING ANGLE SENSOR Fit a projection of the steering angle sensor adapter into a hole in the steering column shaft. Set a projection of the steering angle sensor in the guide of the steering column and fix the steering angle sensor. F08848 3. (a) Matchmarks (b) 4. F08831 (a) (b) 5. (a) (b) (c) 6. (a) (b) INSTALL UNIVERSAL JOINT ASSEMBLY Align the matchmarks on the universal joint assembly and main shaft assembly. Install the bolt. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) INSTALL NO. 2 COLUMN HOLE COVER SUB- ASSEMBLY AND INTERMEDIATE SHAFT SUB- ASSEMBLY Install the No. 2 column hole cover sub-assembly. Temporarily install the intermediate shaft sub-assembly with the bolt A. INSTALL STEERING COLUMN ASSEMBLY Install the steering column assembly with the 4 nuts. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) Connect the connectors. Install the nut and return spring. Column shift: CONNECT TRANSMISSION CONTROL CABLE Connect the transmission control cable to the cable bracket of the column tube. Connect the transmission control cable to the shift lever housing. F08834 2001 AVALON (RM808U) Author
: Date
: 1485 SR-23 STEERING 7. (a) (b) (c) - TILT STEERING COLUMN CONNECT INTERMEDIATE SHAFT SUB-ASSEMBLY Align the matchmarks on the intermediate shaft sub-assembly and control valve shaft. Install the bolt B. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) Torque the bolt A. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) A B Matchmarks F09930 (d) F08830 Connect the No. 2 column hole cover sub-assembly and tighten the clamp. 8. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE (a) Install the air cleaner assembly with air cleaner hose with the 3 bolts. (b) Connect the connectors. (c) Tighten the hose clamps. 9. INSTALL LOWER INSTRUMENT FINISH PANEL ASSEMBLY 10. INSTALL SPIRAL CABLE (See page BE-18 ) 11. INSTALL COMBINATION SWITCH WITH SPIRAL CABLE (a) Install the combination switch with spiral cable with the 3 screws. (b) Connect the airbag connector. (c) Connect the connectors. 12. INSTALL NO. 2 COLUMN LOWER COVER, COLUMN UPPER AND LOWER COVERS (a) Install the column upper and lower covers with the 3 screws. (b) Install the No. 2 column lower cover. 13. INSTALL NO. 2 HEATER TO REGISTER DUCT Install the No. 2 heater to register duct with the clip. 14. INSTALL LOWER LH INSTRUMENT PANEL INSERT SUB-ASSEMBL Y (a) Install the lower LH instrument panel insert sub-assembly with the 4 bolts. (b) Connect the connectors. 2001 AVALON (RM808U) Author
: Date
: 1486 SR-24 STEERING 15. (a) (b) (c) 16. (a) (b) (c) Marks Torx Screw F03856 Screw Case TILT STEERING COLUMN INSTALL LOWER NO. 1 INSTRUMENT PANEL SUBASSEMBLY Connect the connectors and install the lower No. 1 instrument panel sub-assembly. Install the 2 screws. Connect the hood lock release lever with the 2 screws. CENTER SPIRAL CABLE Check that the front wheels are facing straight ahead. Turn the spiral cable counterclockwise by hand until it becomes harder to turn. Then rotate the spiral cable clockwise about 2.5 turns to align the marks. HINT: The spiral cable will rotate about 2.5 turns to either left or right of the center. 17. INSTALL STEERING WHEEL (a) Align the matchmarks on the steering wheel and main shaft assembly. (b) Install the steering wheel set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) (c) Connect the connector. 18. INSTALL STEERING WHEEL PAD NOTICE:
Never use airbag parts from another vehicle. When replacing parts, replace with new ones.
Make sure the wheel pad is installed to the specified torque.
If the wheel pad has been dropped, or there are cracks, dents or other defects on the case or connector, replace the wheel pad with a new one.
When installing the wheel pad, take care that the wirings do not interfere with other parts and are not pinched between other parts. (a) Connect the airbag connector. (b) (c) (d) 19. 20. F08828 - Install the steering wheel pad after confirming that the circumference groove of the torx screws is caught on the screw case. Using a torx socket wrench, install the 2 screws. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) Install the 2 steering wheel lower No. 2 covers. CHECK STEERING WHEEL CENTER POINT w/ VSC: PERFORM STEERING ANGLE SENSOR ZERO POINT CALIBRATION (See page DI-252 ) 2001 AVALON (RM808U) Author
: Date
: 1487 SR-20 STEERING - TILT STEERING COLUMN SR0Z7-01 REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT PARTS INDICATED BY ARROWS WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See page SR-9) 2. INSTALL TILT LEVER Install the tilt lever with a new tilt lever lock shaft. Torque: 9.0 N·m (90 kgf·cm, 78 in.·lbf) 3. INSTALL MAIN SHAFT ASSEMBLY (a) Install the main shaft collar, main shaft bushing, compression spring and spring retainer. (b) Install a new No. 2 steering column ring to the main shaft assembly. (c) SST No. 2 Steering Column Ring F09910 Install SST to the main shaft assembly, as shown in the illustration. SST 09612-07010 (d) Using SST, push down the No. 2 steering column ring until it fits into the shaft groove and install the main shaft assembly. NOTICE: Do not bend the universal joint of the shaft assembly more than 20°. HINT: Hold the main shaft assembly with your hand so that it does not rotate. 4. (a) (b) (c) (d) Tilt Spring and Spring Guide INSTALL STEERING COLUMN UPPER TUBE WITH MAIN SHAFT ASSEMBLY Install the steering column upper tube with the main shaft assembly into the column tube assembly. Install the tilt spring and spring guide. Using a vise to hold the steering column upper tube. Temporarily install 2 new No. 2 tilt steering bolts. F09917 2001 AVALON (RM808U) Author
: Date
: 1483 SR-21 STEERING (e) (f) Pin Punch - TILT STEERING COLUMN Using a punch and a hammer, tap in the No. 2 tilt steering bolt. Using a pin punch, stake on 3 places evenly around the hole as shown in the illustration. F09918 5. (a) F09919 INSTALL TURN SIGNAL BRACKET Install the turn signal bracket with 2 new torx screws. Torque: 7.5 N·m (75 kgf·cm, 65 in.·lbf) HINT: Set the hole of the turn signal bracket and projection of steering column upper tube. (b) Install the tension spring. 6. Column shift: INSTALL SHIFT LEVER HOUSING (a) Install the shift lever housing with 3 new torx screws. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) (b) Install the shift lever with a new torx screw. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) (c) Install the shift lock solenoid bracket with 2 new torx screws. Torque: 3.4 N·m (35 kgf·cm, 30 in.·lbf) (d) Install the shift lock switch with a new torx screw. Torque: 2.8 N·m (29 kgf·cm, 25 in.·lbf) 7. (a) F08833 INSTALL COLUMN UPPER BRACKET Install the column upper bracket with 2 new taperedhead bolts. (b) Tighten the tapered-head bolts until the bolt heads break off. 8. Column shift: INSTALL SHIFT LOCK CONTROL ECU Install the shift lock control ECU and connect the 3 connectors. 9. INSTALL KEY CYLINDER LAMP ASSEMBLY Install the key cylinder lamp assembly with screw. 10. w/ Engine immobiliser system: INSTALL TRANSPONDER KEY COIL 2001 AVALON (RM808U) Author
: Date
: 1484 SR-12 STEERING - TILT STEERING COLUMN SR0Z4-01 REMOVAL 1. REMOVE STEERING WHEEL PAD NOTICE: If the airbag connector is disconnected with the ignition switch at ON or ACC, DTCs will be recorded. Screw Case Torx Screw (a) Place the front wheels facing straight ahead. (b) Remove the 2 steering wheel lower No. 2 covers. (c) Using a torx socket wrench, loosen the 2 torx screws. HINT: Loosen the 2 screws until the groove along the screw circumference catches on the screw case. F08825 (d) Pull out the wheel pad from the steering wheel and disconnect the airbag connector. CAUTION:
When storing the wheel pad, keep the upper surface of the pad facing upward.
Never disassemble the wheel pad. NOTICE: When removing the wheel pad, take care not to pull the airbag wire harness. Airbag Connector Correct Wrong F08826 2. (a) (b) (c) Matchmarks (d) SST REMOVE STEERING WHEEL Disconnect the connector. Remove the steering wheel set nut. Place matchmarks on the steering wheel and main shaft assembly. Using SST, remove the steering wheel. SST 09950- 50012 (09951- 05010, 09952- 05010, 09953-05020, 09954-05020) F08827 2001 AVALON (RM808U) Author
: Date
: 1475 SR-13 STEERING - TILT STEERING COLUMN 3. REMOVE LOWER NO. 1 INSTRUMENT PANEL SUBASSEMBLY (a) Remove the 2 screws and disconnect the hood lock release lever. (b) Remove the 2 screws. (c) Disconnect the connectors and remove the lower No. 1 instrument panel sub-assembly. 4. REMOVE LOWER LH INSTRUMENT PANEL INSERT SUB-ASSEMBL Y (a) Disconnect the connectors. (b) Remove the 4 bolts and lower LH instrument panel insert sub-assembly . 5. REMOVE NO. 2 HEATER TO REGISTER DUCT Remove the clip and No. 2 heater to register duct. 6. REMOVE NO. 2 COLUMN LOWER COVER, COLUMN UPPER AND LOWER COVERS (a) Remove the No. 2 column lower cover. (b) Remove the 3 screws, column upper and lower covers. 7. REMOVE COMBINATION SWITCH WITH SPIRAL CABLE (a) Disconnect the connectors. (b) Disconnect the airbag connector. (c) Remove the 3 screws and combination switch with spiral cable. 8. REMOVE SPIRAL CABLE (See page BE-18 ) NOTICE: Do not disassemble the spiral cable or apply oil to it. 9. REMOVE LOWER INSTRUMENT FINISH PANEL ASSEMBLY 10. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE (a) Loosen the hose clamps. (b) Disconnect the connectors. (c) Remove the 3 bolts and air cleaner assembly with air cleaner hose. 11. (a) DISCONNECT INTERMEDIATE SHAFT SUB- ASSEMBLY Loosen the clamp and disconnect the No. 2 column hole cover sub-assembly. F08830 2001 AVALON (RM808U) Author
: Date
: 1476 SR-14 STEERING (b) (c) - TILT STEERING COLUMN Place matchmarks on the intermediate shaft sub-assembly and control valve shaft. Loosen the bolt A and remove the bolt B, then disconnect the intermediate shaft sub-assembly. A B Matchmarks F08829 12. Shift Lever Housing (a) (b) Cable Bracket Column shift: DISCONNECT TRANSMISSION CONTROL CABLE Using a screwdriver, disconnect the transmission control cable from the shift lever housing. Using a offset wrench (23mm), disconnect the transmission control cable from the cable bracket of the column tube. F08850 13. (a) (b) (c) 14. (a) F08834 (b) 15. (a) Matchmarks (b) 16. REMOVE STEERING COLUMN ASSEMBLY Remove the nut and return spring. Disconnect the connectors. Remove the 4 nuts and steering column assembly. REMOVE INTERMEDIATE SHAFT SUB-ASSEMBLY AND NO. 2 COLUMN HOLE COVER SUB-ASSEMBLY Remove the bolt A and remove the intermediate shaft sub-assembly . Remove the No. 2 column hole cover sub-assembly. REMOVE UNIVERSAL JOINT ASSEMBLY Place matchmarks on the universal joint assembly and main shaft assembly. Remove the bolt and universal joint assembly. w/ VSC: REMOVE STEERING ANGLE SENSOR AND STEERING ANGLE SENSOR ADAPTER F08831 2001 AVALON (RM808U) Author
: Date
: 1477 SR-15 STEERING - TILT STEERING COLUMN 17. REMOVE SPEED CONTROL MAIN SWITCH ASSEMBLY FROM STEERING WHEEL Remove the 2 screws and speed control main switch assembly from the steering wheel. 2001 AVALON (RM808U) Author
: Date
: 1478 SA-8 SUSPENSION AND AXLE - FRONT AXLE HUB FRONT AXLE HUB SA0VR-02 COMPONENTS Shock Absorber 211 (2,150, 156) Tie Rod End Drive Shaft 8.0 (82, 71 in.·lbf) 107 (1,090, 79) ABS Speed Sensor Hub Bolt
Cotter Pin 49 (500, 36) Brake Caliper
Cotter Pin Lock Cap Lower Suspension Arm 294 (3,000, 217)
Dust Deflector Disc
Snap Ring 127 (1,300, 94)
Bearing
Cotter Pin Steering Knuckle 123 (1,250, 90) Dust Cover 8.3 (85, 74 in.·lbf) Lower Ball Joint Axle Hub N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part F04047 2001 AVALON (RM808U) Author
: Date
: 1342 SA-1 1 SUSPENSION AND AXLE - FRONT AXLE HUB SA0VT-02 DISASSEMBLY 1. REMOVE DUST DEFLECTOR Using a screwdriver, remove the dust deflector. 2. REMOVE LOWER BALL JOINT (a) Remove the cotter pin and nut. SST (b) Using SST, remove the lower ball joint. SST 09628-6201 1 3. (a) REMOVE AXLE HUB Using SST, remove the axle hub. SST 09520-00031 R08859 SST R00789 (b) SST W02110 Using SST and a press, remove the inner race (outside) from the axle hub. SST 09950-00020, 09950-60010 (09951-00400), 09950-70010 (09951-07100) 4. REMOVE DUST COVER Using a torx wrench (T30), remove the 4 bolts and dust cover. 5. REMOVE BEARING FROM STEERING KNUCKLE (a) Using snap ring pliers, remove the snap ring. (b) Place the inner race on the outside of the bearing. (c) Using SST and a press, remove the bearing. SST 09310-35010, 09527-17011 SST SST R11486 2001 AVALON (RM808U) Author
: Date
: 1345 SA-13 SUSPENSION AND AXLE - FRONT AXLE HUB SA0VV-03 INSTALLATION Installation is in the reverse order of removal (See page SA-9 ). HINT: After installation, check the ABS speed sensor signal (See page DI-212 or DI-252 ) and front wheel alignment (See page SA-4 ). NOTICE: w/ VSC: After installation, perform the steering angle sensor zero point calibration (See page DI-252 ). 2001 AVALON (RM808U) Author
: Date
: 1347 SA-12 SUSPENSION AND AXLE - FRONT AXLE HUB SA0VU-02 REASSEMBLY SST 1. (a) R00792 SST SST R08860 SST INSTALL BEARING Using SST and a press, install a new bearing to the steering knuckle. SST 09608-32010 (b) Using snap ring pliers, install a new snap ring. 2. INSTALL DUST COVER Using a torx wrench (T30), install the dust cover with the 4 bolts. Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) 3. INSTALL FRONT AXLE HUB Using SST and a press, install the axle hub. SST 09310-35010, 09608-32010 4. INSTALL LOWER BALL JOINT (a) Install the lower ball joint and nut. Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf) (b) Install a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 5. INSTALL DUST DEFLECTOR Using SST and a hammer, install a new dust deflector. SST 09316-6001 1 (09316-00011, 09316-00041), 09608-32010 HINT: Align the hole for the ABS speed sensor in the dust deflector with the one in the steering knuckle. SST R08861 2001 AVALON (RM808U) Author
: Date
: 1346 SA-9 SUSPENSION AND AXLE - FRONT AXLE HUB SA0VS-02 REMOVAL 1. 2. (a) (b) REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) CHECK BEARING BACKLASH AND AXLE HUB DEVIATION Remove the 2 bolts, brake caliper and disc. Support the brake caliper securely. (c) W03084 W03093 Using a dial indicator, check the backlash near the center of the axle hub. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. (d) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm (0.0020 in.) If the deviation exceeds the maximum, replace the axle hub. (e) Install the disc, brake caliper and 2 bolts. Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf) 3. REMOVE DRIVE SHAFT LOCK NUT (a) Remove the cotter pin and lock cap. (b) While applying the brakes, remove the nut. Torque: 294 N·m (3,000 kgf·cm, 217 ft·lbf) (c) Remove the 2 bolts, brake caliper and disc. (d) Support the brake caliper securely. 4. DISCONNECT ABS SPEED SENSOR AND WIRE HARNESS CLAMP Remove the bolt and disconnect the ABS speed sensor and wire harness clamp. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) 5. LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK ABSORBER HINT: Do not remove the bolts. Torque: 211 N·m (2,150 kgf·cm, 156 ft·lbf) HINT: At the this time of installation, coat the nut’s thread with engine oil. W03139 2001 AVALON (RM808U) Author
: Date
: 1343 SA-10 SUSPENSION AND AXLE 6. (a) (b) - FRONT AXLE HUB DISCONNECT TIE ROD END FROM STEERING KNUCKLE Remove the cotter pin and nut. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Using SST, disconnect the tie rod end from the steering knuckle. SST 09610-20012 SST W03094 7. F02207 DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM Remove the 2 nuts and bolt. Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf) 8. REMOVE STEERING KNUCKLE WITH AXLE HUB (a) Remove the 2 nuts and bolts on the lower side of the shock absorber. (b) Remove the steering knuckle with the axle hub. NOTICE: Be careful not to damage the boot and ABS speed sensor rotor. 2001 AVALON (RM808U) Author
: Date
: 1344 SA-15 SUSPENSION AND AXLE - FRONT DRIVE SHAFT FRONT DRIVE SHAFT SA0VX-02 COMPONENTS Fender Apron Seal Drive Shaft (RH) Fender Apron Seal Lock Bolt
32 (330, 24) Drive Shaft (LH) Tie Rod End
Snap Ring 49 (500, 36)
Cotter pin Lower Suspension Arm
Boot Clamp Lock Cap
No. 2 Dust Deflector 294 (3,000, 217) 127 (1,300, 94) Outbord Joint Shaft RH:
Boot
Snap Ring
Boot LH: Tripod Inboard Joint Shaft Inboard Joint Shaft
Snap Ring
Snap Ring
Dust Cover
Dust Cover
Bearing N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part F07396 2001 AVALON (RM808U) Author
: Date
: 1349 SA-18 SUSPENSION AND AXLE - FRONT DRIVE SHAFT SA1EA-03 DISASSEMBLY 1. (a) (b) (c) N00191 (d) 2. (a) (b) (c) CHECK DRIVE SHAFT Check to see that there is no remarkable play in the outboard joint. Check to see that the inboard joint slides smoothly in the thrust direction. Check to see that there is no remarkable play in the radial direction of the inboard joint. Check the boots for damage. REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS Using pliers, pinch the claws to compress the large inboard joint boot clamp and remove it. Using a side cutter, cut the small inboard joint boot clamp and remove it. Using a side cutter, cut the 2 outboard joint boot clamps and remove them. F07391 3. (a) Matchmarks F07392 REMOVE INBOARD JOINT SHAFT Place matchmarks on the tripod, inboard and outboard joint shafts. NOTICE: Do not punch the marks. (b) Remove the inboard joint shaft from the outboard joint shaft. 4. REMOVE TRIPOD (a) Using a snap ring expander, remove the snap ring. (b) Place matchmarks on the outboard joint shaft and tripod. NOTICE: Do not punch the marks. (c) Using a brass bar and hammer, remove the tripod from the outboard joint shaft. NOTICE: Do not tap the roller. Matchmarks N00194 2001 AVALON (RM808U) Author
: Date
: 1352 SA-19 SUSPENSION AND AXLE - FRONT DRIVE SHAFT 5. REMOVE INBOARD AND OUTBOARD JOINT BOOTS Slide out the 2 boots. NOTICE: Do not disassemble the outboard joint. 6. LH drive shaft: REMOVE DUST COVER Using SST and a press, remove the dust cover from the inboard joint shaft. SST 09950-00020 SST F07394 7. (a) RH drive shaft: DISASSEMBLE INBOARD JOINT SHAFT Using a press, remove the transaxle side dust cover from the inboard joint shaft. SA1446 (b) SST (c) Using SST and a press, remove the bearing side dust cover. SST 09950-00020 Using a snap ring expander, remove the snap ring. R09717 (d) SST (e) Using SST and a press, remove the bearing. SST 09950-00020 Remove the snap ring. F07393 2001 AVALON (RM808U) Author
: Date
: 1353 SA-20 SUSPENSION AND AXLE - FRONT DRIVE SHAFT 8. (a) (b) REMOVE NO. 2 DUST DEFLECTOR Mount the outboard joint shaft in a soft jaw vise. Using a screwdriver and hammer, remove the No. 2 dust deflector. NOTICE: Be careful not to damage the ABS speed sensor rotor. F06452 2001 AVALON (RM808U) Author
: Date
: 1354 SA-24 SUSPENSION AND AXLE - FRONT DRIVE SHAFT SA0W1-03 INSTALLATION Installation is in the reverse order of removal (See page SA-16 ). HINT: After installation, check the ABS speed sensor signal (See page DI-212 or DI-252 ) and front wheel alignment (See page SA-4 ). NOTICE: w/ VSC: After installation, perform the steering angle sensor zero point calibration (See page DI-252 ). 2001 AVALON (RM808U) Author
: Date
: 1358 SA-21 SUSPENSION AND AXLE - FRONT DRIVE SHAFT SA1EB-03 REASSEMBLY 1. INSTALL NO. 2 DUST DEFLECTOR Using SST and a press, install a new No. 2 dust deflector. SST 09309-36010, 09316-20011 2. RH drive shaft: ASSEMBLE INBOARD JOINT SHAFT (a) Install a new snap ring to the inboard joint shaft. SST R15532 Steel Plate (b) (c) Using a steel plate and press, install a new bearing. Using a snap ring expander, install a new snap ring. (d) Using SST, an extension bar and press, install a new bearing side dust cover. SST 09506-35010 FA1888 1.0 mm (0.039 in.) HINT: The clearance between the dust cover and the bearing should be kept in the range shown in the illustration. SST → → FA1971 (e) Steel Plate Using a steel plate and press, install a new transaxle side dust cover until the distance from the tip of the inboard joint shaft to the dust cover falls within the specified value, as shown in the illustration. Distance: 109.5 - 110.5 mm (4.31 - 4.35 in.) F08682 3. LH drive shaft: INSTALL DUST COVER Using a press, install a new dust cover. F07395 2001 AVALON (RM808U) Author
: Date
: 1355 SA-22 SUSPENSION AND AXLE Inboard Joint Boot Outboard Joint Boot 4. - FRONT DRIVE SHAFT TEMPORARILY INSTALL OUTBOARD AND INBOARD JOINT BOOTS AND NEW BOOT CLAMPS HINT:
Vinyl tape F01747 Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent the boots from being damaged.
Before installing the boots, place 3 new clamps to the small boot ends and large boot end (outboard joint side). 5. INSTALL TRIPOD (a) Place the beveled side of the tripod axial spline toward the outboard joint. (b) Align the matchmarks placed before removal. (c) Using a brass bar and hammer, tap in the tripod to the outboard joint shaft. NOTICE: Do not tap the roller. (d) Using a snap ring expander, install a new snap ring. 6. INSTALL BOOT TO OUTBOARD JOINT Before assembling the boot, pack the outboard joint and boot with grease in the boot kit. Grease capacity (Color = Gray): 105 - 125 g (3.7 - 4.4 oz.) 7. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT (a) Pack the inboard joint and boot with grease in the boot kit. Grease capacity (Color = Yellow ocher): 170 - 190 g (6.0 - 6.7 oz.) (b) Align the matchmarks placed before removal, and install the inboard joint shaft to the outboard joint shaft. (c) Temporarily install the boot to the inboard joint shaft. 8. (a) (b) CHECK DRIVE SHAFT LENGTH Make sure that the 2 boots are on the shaft groove. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: LH 586.0 ± 2.0 mm (23.071 ± 0.079 in.) RH 881.6 ± 2.0 mm (34.709 ± 0.079 in.) R00764 2001 AVALON (RM808U) Author
: Date
: 1356 SA-23 SUSPENSION AND AXLE 9. (a) (b) 10. (a) - FRONT DRIVE SHAFT Large inboard joint boot clamp: INSTALL BOOT CLAMP TO INBOARD JOINT SHAFT BOOT Place the large inboard joint boot clamp. Using pliers, pinch the claws to compress the clamp and engage the other claws. Others: INSTALL BOOT CLAMPS TO BOTH BOOTS Secure the preplaced 3 clamps onto the boots. F07391 (b) Place SST onto the clamp. SST 09521-24010 (c) Tighten the SST so that the clamp is pinched. NOTICE: Do not overtighten the SST. SST R10353 (d) Clearance 11. Using SST, adjust the clearance of the clamp. SST 09240-00020 Clearance: A : 1.9 mm (0.075 in.) or less B : 1.5 - 2.5 mm (0.059 - 0.098 in.) C : 3.0 - 4.0 mm (0.118 - 0.157 in.) CHECK DRIVE SHAFT (See page SA-18 ) SST A B C F00616 2001 AVALON (RM808U) Author
: Date
: 1357 SA-16 SUSPENSION AND AXLE - FRONT DRIVE SHAFT SA0VY-02 REMOVAL SST FA1535 NOTICE:
The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with SST. SST 09608-16042 (09608-02021, 09608-02041)
After disconnecting the drive shaft from the axle hub, work carefully so as not to damage the ABS speed sensor rotor serration on the drive shaft. 1. REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. REMOVE FRONT FENDER APRON SEAL 3. DRAIN ATF 4. (a) (b) 5. 6. REMOVE DRIVE SHAFT LOCK NUT Remove the cotter pin and lock cap. While applying brakes, remove the nut. Torque: 294 N·m (3,000 kgf·cm, 217 ft·lbf) DISCONNECT TIE ROD END FROM STEERING KNUCKLE (See page SA-9 ) DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT (See page SA-9 ) W03093 7. DISCONNECT DRIVE SHAFT FROM AXLE HUB Using a plastic hammer, disconnect the drive shaft from the axle hub. NOTICE: Be careful not to damage the boot and ABS speed sensor rotor. W03142 8. LH drive shaft: REMOVE DRIVE SHAFT (a) Using a hub nut wrench and hammer handle or an equivalent, remove the drive shaft. NOTICE: Be careful not to damage the dust cover and oil seal. F07389 2001 AVALON (RM808U) Author
: Date
: 1350 SA-17 SUSPENSION AND AXLE - FRONT DRIVE SHAFT HINT: At the time of installation, please refer to the following items.
Coat gear oil to the inboard joint shaft and differential case sliding surface.
Before installing the drive shaft, set the snap ring opening side facing downward.
Whether or not the inboard joint shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in.
After installation, check that there is 2 - 3 mm (0.08 - 0.12 in.) of play in the axial direction.
After installation, check that the drive shaft cannot be removed by hand. (b) Using a screwdriver, remove the snap ring from the inboard joint shaft. 9. W03144 RH drive shaft: REMOVE DRIVE SHAFT (a) Remove the bearing lock bolt. Torque: 32 N·m (330 kgf·cm, 24 ft·lbf) (b) Using pliers, remove the snap ring and drive shaft. NOTICE: Be careful not to damage the dust cover and oil seal. HINT: At the time of installation, coat gear oil to the inboard joint shaft and differential case sliding surface. 2001 AVALON (RM808U) Author
: Date
: 1351 SA-36 SUSPENSION AND AXLE - FRONT LOWER BALL JOINT FRONT LOWER BALL JOINT SA0VA-02 COMPONENTS 211 (2,150, 156) Shock Absorber 107 (1,090, 79) 8.0 (82, 71 in.·lbf) ABS Speed Sensor Drive Shaft Tie Rod End Brake Caliper
Dust Deflector Lower Suspension Arm 49 (500, 36)
Cotter Pin Disc
Cotter Pin 123 (1,250, 90) Lower Ball Joint 294 (3,000, 217) 127 (1,300, 94) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part
Cotter Pin Steering Knuckle with Axle Hub Lock Cap F06451 2001 AVALON (RM808U) Author
: Date
: 1370 SA-38 SUSPENSION AND AXLE - FRONT LOWER BALL JOINT SA0VC-01 INSPECTION N00208 INSPECT LOWER BALL JOINT FOR ROTATION CONDITION (a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading on the 5th turn. Turning torque: 1.0 - 3.4 N·m (10 - 35 kgf·cm, 8.7 - 30 in.·lbf) 2001 AVALON (RM808U) Author
: Date
: 1372 SA-39 SUSPENSION AND AXLE - FRONT LOWER BALL JOINT SA0VD-03 INSTALLATION 1. (a) INSTALL LOWER BALL JOINT Install the lower ball joint and nut. Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf) (b) Install a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. R08850 SST SST R08861 2. INSTALL NEW DUST DEFLECTOR Using SST and a hammer, install a new dust deflector. SST 09316-6001 1 (09316-00011, 09316-00041), 09608-32010 HINT: Align the holes for the ABS speed sensor in the dust deflector and steering knuckle. 3. INSTALL FRONT AXLE HUB (See page SA-13 ) 4. CHECK ABS SPEED SENSOR SIGNAL (See page DI-212 or DI-252 ) AND FRONT WHEEL ALIGNMENT (See page SA-4 ) 5. w/ VSC: PERFORM STEERING ANGLE SENSOR ZERO POINT CALIBRATION (See page DI-252 ) 2001 AVALON (RM808U) Author
: Date
: 1373 SA-37 SUSPENSION AND AXLE - FRONT LOWER BALL JOINT SA0VB-01 REMOVAL SST 1. 2. (a) (b) REMOVE FRONT AXLE HUB (See page SA-9 ) REMOVE LOWER BALL JOINT Using a screwdriver, remove the dust deflector. Remove the cotter pin and nut. (c) Using SST, remove the lower ball joint. SST 09628-6201 1 R08859 2001 AVALON (RM808U) Author
: Date
: 1371 SA-32 SUSPENSION AND AXLE - FRONT LOWER SUSPENSION ARM FRONT LOWER SUSPENSION ARM SA0V6-02 COMPONENTS 206 (2,100, 152) Lower Suspension Arm Bushing Stopper
Bushing 206 (2,100, 152) Lower Ball Joint 206 (2,100, 152) 127 (1,300, 94) Lower Suspension Arm 127 (1,300, 94) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part F02228 2001 AVALON (RM808U) Author
: Date
: 1366 SA-35 SUSPENSION AND AXLE - FRONT LOWER SUSPENSION ARM SA0V9-02 INSTALLATION Installation is in the reverse order of removal (See page SA-33 ). HINT: After installation, check the front wheel alignment (See page SA-4 ). 2001 AVALON (RM808U) Author
: Date
: 1369 SA-33 SUSPENSION AND AXLE - FRONT LOWER SUSPENSION ARM SA0V7-02 REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT Remove the 2 nuts and bolt, and disconnect the lower suspension arm from the lower ball joint. Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf) F02225 3. (a) REMOVE LOWER SUSPENSION ARM Remove the 2 bolts on the front side of the lower suspension arm. Torque: 206 N·m (2,100 kgf·cm, 152 ft·lbf) (b) Remove the bolt and nut on the rear side of the lower suspension arm. Torque: 206 N·m (2,100 kgf·cm, 152 ft·lbf) Remove the lower suspension arm. Remove the lower suspension arm bushing stopper from the lower suspension arm. F02226 (c) (d) F02227 2001 AVALON (RM808U) Author
: Date
: 1367 SA-34 SUSPENSION AND AXLE - FRONT LOWER SUSPENSION ARM SA0V8-02 Steel Plate SST REPLACEMENT REPLACE BUSHING (a) Using SST, a steel plate and press, remove the bushing. SST 09649-17010, 09710-04081 W03205 (b) SST 20 ± 3° Using SST and a press, install a new bushing. SST 09238-47012, 09649-17010 HINT: Before installing the bushing, set it in the correct direction, as shown in the illustration. 2.5 ± 0.5 mm (0.098 ± 0.020 in.) W03206 2001 AVALON (RM808U) Author
: Date
: 1368 SA-25 SUSPENSION AND AXLE - FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER SA0UZ-02 COMPONENTS 80 (820, 59)
49 (500, 36) Suspension Support Bearing Shock Absorber with Coil Spring Spring Upper Seat Stabilizer Bar Link Spring Bumper Upper Insulator Lower Insulator 39 (400, 29) 211 (2,150, 156) 29 (300, 22) Flexible Hose ABS Speed Sensor Wire Harness Coil Spring Shock Absorber N·m (kgf·cm, ft·lbf) : Specified torque
Non- reusable part F07387 2001 AVALON (RM808U) Author
: Date
: 1359 SA-27 SUSPENSION AND AXLE - FRONT SHOCK ABSORBER SA0V1-02 DISASSEMBLY REMOVE COIL SPRING (a) Install 2 nuts and a bolt to the bracket at the lower side of the shock absorber and secure it in a vise. (b) Using 2 SST of the same type, compress the coil spring. SST 09727-30021 NOTICE: Do not use an impact wrench. It will damage the SST. SST SST W03198 (c) SST (d) Using SST to hold the suspension support, remove the nut. SST 09729-22031 Remove the suspension support, bearing, spring upper seat, upper insulator, coil spring, lower insulator and spring bumper. W03199 2001 AVALON (RM808U) Author
: Date
: 1361 SA-29 SUSPENSION AND AXLE - FRONT SHOCK ABSORBER SA0V3-02 DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION:
When drilling, chips may fly out, work carefully.
The gas is colorless, odorless and non-poisonous. W03648 2001 AVALON (RM808U) Author
: Date
: 1363 SA-28 SUSPENSION AND AXLE - FRONT SHOCK ABSORBER SA0V2-02 INSPECTION W03646 INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during operation. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL on page SA-29 . 2001 AVALON (RM808U) Author
: Date
: 1362 SA-31 SUSPENSION AND AXLE - FRONT SHOCK ABSORBER SA0V5-03 INSTALLATION Installation is in the reverse order of removal (See page SA-26 ). HINT: After installation, check the front wheel alignment (See page SA-4 ). NOTICE: w/ VSC: After installation, perform the steering angle sensor zero point calibration (See page DI-252 ). 2001 AVALON (RM808U) Author
: Date
: 1365 SA-30 SUSPENSION AND AXLE - FRONT SHOCK ABSORBER SA0V4-02 REASSEMBLY 1. 2. INSTALL LOWER INSULATOR ONTO SHOCK ABSORBER INSTALL SPRING BUMPER TO PISTON ROD 3. (a) INSTALL COIL SPRING Using 2 SST of the same type, compress the coil spring. SST 09727-30021 NOTICE: Do not use an impact wrench. It will damage the SST. SST W03200 W03201 (b) Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the spring lower seat. 4. INSTALL SPRING UPPER SEAT AND INSULATOR (a) Align the ’OUT’ mark of spring upper seat with the mark of the upper insulator. (b) Install the spring upper seat with upper insulator to the shock absorber with the mark facing to the outside of the vehicle. (c) Install the bearing and suspension support. (d) Using SST to hold the suspension support, install a new nut. SST 09729-22031 Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) (e) Remove the 2 SST from the coil spring. NOTICE: Check that the bearing fits into the recess in the suspension support. SST W03199 2001 AVALON (RM808U) Author
: Date
: 1364 SA-26 SUSPENSION AND AXLE - FRONT SHOCK ABSORBER SA0V0-02 REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. DISCONNECT FLEXIBLE HOSE AND ABS SPEED SENSOR WIRE HARNESS CLAMP Remove the bolt and disconnect the flexible hose and ABS speed sensor wire harness clamp from the shock absorber. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) 3. DISCONNECT STABILIZER BAR LINK FROM SHOCK ABSORBER (See page SA-41 ) 4. DISCONNECT SHOCK ABSORBER FROM STEERING KNUCKLE (a) Remove the 2 nuts and bolts on the lower side of the shock absorber. Torque: 211 N·m (2,150 kgf·cm, 156 ft·lbf) (b) Remove the shock absorber from the steering knuckle. HINT: At the time of installation, coat the nut’s threads with engine oil. 5. REMOVE SHOCK ABSORBER WITH COIL SPRING Remove the 3 nuts and shock absorber with the coil spring. Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) HINT: At the time of installation, rotate the suspension support and set it in the direction, as shown. To outside F07388 2001 AVALON (RM808U) Author
: Date
: 1360 SA-40 SUSPENSION AND AXLE - FRONT STABILIZER BAR FRONT STABILIZER BAR SA0W2-02 COMPONENTS 39 (400, 29) 19 (195, 14) 19 (195, 14) Bracket Stabilizer Bar Link Bushing Bracket Bushing 39 (400, 29) Stabilizer Bar Link 39 (400, 29) Stabilizer Bar 39 (400, 29) N·m (kgf·cm, ft·lbf) : Specified torque F06453 2001 AVALON (RM808U) Author
: Date
: 1374 SA-42 SUSPENSION AND AXLE - FRONT STABILIZER BAR SA0W4-01 INSPECTION Z00340 INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTATION CONDITION (a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading on the 5th turn. Turning torque: 0.05 - 1.0 N·m (0.5 - 10 kgf·cm, 0.4 - 8.7 in.·lbf) 2001 AVALON (RM808U) Author
: Date
: 1376 SA-43 SUSPENSION AND AXLE - FRONT STABILIZER BAR SA0W5-01 INSTALLATION Installation is in the reverse order of removal (See page SA-41 ). 2001 AVALON (RM808U) Author
: Date
: 1377 SA-41 SUSPENSION AND AXLE - FRONT STABILIZER BAR SA0W3-02 REMOVAL 1. REMOVE FRONT WHEELS Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. (a) REMOVE STABILIZER BAR LINKS Remove the 2 nuts and stabilizer bar link. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. (b) Employ the same manner described above to the other side. F06454 3. (a) F06456 REMOVE BRACKETS AND BUSHINGS Remove the 2 bolts, bracket and bushing. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) HINT: At the time of installation, install the bushing to the inside of the bushing stopper on the stabilizer bar. (b) Employ the same manner described above to the other side. 4. REMOVE STABILIZER BAR Remove the stabilizer bar from the left hand side. NOTICE: Be careful not to damage the pressure feed tube. 2001 AVALON (RM808U) Author
: Date
: 1375 SA-4 SUSPENSION AND AXLE - FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Front: SA1DP-04 INSPECTION NOTICE: w/ VSC: Be sure to perform the steering angle sensor zero point calibration after adjusting the front wheel alignment (See page DI-252 ). 1. MEASURE VEHICLE HEIGHT Vehicle height: Rear: Front*1 mm (in.) 213 (8.39) Rear*2 mm (in.) 266 (10.47) *1: F02090 Front measuring point Measure the distance from the ground to the center of the front side lower suspension arm mounting bolt. *2: Rear measuring point Measure the distance from the ground to the center of the front side strut rod mounting bolt. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. 2. Gauge Alignment Tester INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: Right-left error -0 °37’ ± 45’ (-0.62° ± 0.75°) 45’ (0.75°) or less Right-left error 2°10’ ± 45’ (2.17° ± 0.75°) 45’ (0.75°) or less Right-left error 13°04’ ± 45’ (13.07° ± 0.75°) 45’ (0.75°) or less Camber Z03382 Caster Steering axis inclination If the caster and steering axis inclination are not within the specified values, after the camber has been correctly adjusted, recheck the suspension parts for damaged and/or worn out parts. 2001 AVALON (RM808U) Author
: Date
: 1338 SA-5 SUSPENSION AND AXLE - FRONT WHEEL ALIGNMENT 4. ADJUST CAMBER NOTICE: After the camber has been adjusted, inspect the toe-in. (a) Remove the front wheel and ABS speed sensor clamp. (b) Remove the 2 nuts on the lower side of the shock absorber. (c) Coat the threads of the nuts with engine oil. (d) Temporarily install the 2 nuts. F04031 (e) (f) (g) (h) HINT: Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. Tighten the nuts. Torque: 211 N·m (2,150 kgf·cm, 156 ft·lbf) Install the ABS speed sensor clamp and front wheel. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) Check the camber.
Try to adjust the camber to the center of the specified value.
Adjusting value for the set bolts is 6’ - 30’ (0.1° - 0.5°). If the camber is not within the specified value, using the following table, estimate how much additional camber adjustment will be required, and select the camber adjusting bolt. 1 2 Adjusting Bolt Set Bolt Bolt 90105-17001 90105-17003 90105-17004 90105-17005 F04048 1 Dot Adjusting Value 1 2 1 2 2 Dots 1 2 3 Dots 1 2 15’ 30’ 45’ 1°00’ 1°15’ 1°30’ F01195 (i) Do the steps mentioned above again. Between step (b) and (c), replace 1 or 2 selected bolts. HINT: When replacing the 2 bolts, replace 1 bolt for each time. 2001 AVALON (RM808U) Author
: Date
: 1339 SA-6 SUSPENSION AND AXLE A - FRONT WHEEL ALIGNMENT 5. INSPECT TOE-IN Toe-in: B D Toe-in (total) Front A + B: 0° ± 12’ (0° ± 0.2°) C - D: 0 ± 2 mm (0 ± 0.08 in.) If the toe-in is not within the specified value, adjust it at the rack ends. 6. ADJUST TOE-IN (a) Remove the rack boot set clips. C SA3213 (b) (c) Loosen the tie rod end lock nuts. Turn the right and left rack ends by an equal amount to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified value. F02245 (d) (e) Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 in.) or less Torque the tie rod end lock nuts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) Place the boots on the seats and install the clips. (f) HINT: Make sure that the boots are not twisted. F02246 A B B 7. INSPECT WHEEL ANGLE Turn the steering wheel fully, and measure the turning angle. Wheel turning angle: A Front Inside wheel 35°45’ ± 1° (35.75° ± 1°) Outside wheel: Reference 31°23’ (31.38°) If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths. A: Inside B: Outside SA0028 2001 AVALON (RM808U) Author
: Date
: 1340 SA-14 SUSPENSION AND AXLE - FRONT WHEEL HUB BOLT FRONT WHEEL HUB BOLT SA0VW-02 REPLACEMENT 1. 2. (a) (b) SST REMOVE FRONT WHEEL REMOVE BRAKE CALIPER AND DISC Remove the 2 bolts, brake caliper and disc. Support the brake caliper securely. 3. REMOVE HUB BOLT Using SST and a hammer handle or an equivalent, remove the hub bolt. SST 09628-1001 1 W03096 4. (a) Nut Washer W03097 INSTALL HUB BOLT Install a washer and nut to a new hub bolt, as shown in the illustration. (b) Using a hammer handle or an equivalent to hold, install the hub bolt by torquing the nut. 5. INSTALL DISC AND BRAKE CALIPER Install the disc and brake caliper with the 2 bolts. Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf) 6. INSTALL FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1348 SA-44 SUSPENSION AND AXLE - REAR AXLE HUB REAR AXLE HUB SA0ER-03 COMPONENTS Reused Nut : 196 (2,000, 145) New Nut : 255 (2,600, 188) Rear Axle Carrier No.2 Lower Suspension Arm 181 (1,850, 134) 47 (475, 34) No.1 Lower Suspension Arm Brake Caliper ABS Speed Sensor 80 (820, 59)
O-Ring 8.0 (82, 71 in.·lbf) Disc 113 (1,150, 83) Hub Bolt Strut Rod Rear Axle Hub N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part F08681 2001 AVALON (RM808U) Author
: Date
: 1378 SA-47 SUSPENSION AND AXLE - REAR AXLE HUB SA0W7-03 INSTALLATION Installation is in the reverse order of removal (See page SA-45 ). HINT: After installation, check the ABS speed sensor signal (See page DI-212 or DI-252 ) and rear wheel alignment (See page SA-7 ). 2001 AVALON (RM808U) Author
: Date
: 1381 SA-45 SUSPENSION AND AXLE - REAR AXLE HUB SA0W6-02 REMOVAL 1. 2. (a) (b) REMOVE REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) REMOVE BRAKE CALIPER AND DISC Remove the brake caliper and disc. Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) Support the brake caliper securely. 3. R10948 CHECK BEARING BACKLASH AND AXLE HUB DEVIATION (a) Using a dial indicator, check the backlash near the center of the axle hub. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the axle hub. (b) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.07 mm (0.0028 in.) If the deviation exceeds the maximum, replace the axle hub. 4. DISCONNECT ABS SPEED SENSOR Remove the bolt and disconnect the ABS speed sensor. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) 5. (a) REMOVE REAR AXLE HUB Remove the 4 bolts and rear axle hub. Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) Remove the O-ring. (b) HINT: At the time of installation, coat a new O-ring with MP grease. (c) Support the backing plate securely. Z00206 6. (a) A A REMOVE REAR AXLE CARRIER Loosen the 3 nuts. Torque: Nut A (Reused nut): 196 N·m (2,000 kgf·cm, 145 ft·lbf) Nut A (New nut): 255 N·m (2,600 kgf·cm, 188 ft·lbf) Nut B: 181 N·m (1,850 kgf·cm, 134 ft·lbf) B W03211 2001 AVALON (RM808U) Author
: Date
: 1379 SA-46 SUSPENSION AND AXLE - REAR AXLE HUB HINT: At the time of installation, please refer to the following items.
After stabilizing the suspension, torque the nuts.
If reusing the 2 nuts A, coat the nut’s threads with engine oil. (b) R11165 Remove the bolt and nut, and disconnect the strut rod from the rear axle carrier. NOTICE: Do not turn the nut. Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf) (c) Remove the 2 nuts and bolts on the lower side of the shock absorber. (d) Remove the nut, washer and bolt and disconnect the No. 1 and No. 2 lower suspension arm from the rear axle carrier. (e) Remove the rear axle carrier. 2001 AVALON (RM808U) Author
: Date
: 1380 SA-56 SUSPENSION AND AXLE - REAR LOWER SUSPENSION ARM AND STRUT ROD REAR LOWER SUSPENSION ARM AND STRUT ROD SA0VF-02 COMPONENTS Suspension Member Lower Stopper Suspension Member Suspension Member Upper Stopper Suspension Member Lower Stopper 38 (390, 28) 56 (570, 41) 51 (520, 38) 51 (520, 38) Suspension Arm Washer Stabilizer Bar Bracket 19 (195, 14) Adjusting Tube 181 (1,850, 134) No. 2 Lower Suspension Arm 181 (1,850, 134) 113 (1,150, 83) 5.4 (55, 48 in.·lbf) No. 1 Lower Suspension Arm Tailpipe
Gasket Strut Rod Heated Oxygen Sensor 113 (1,150, 83) Parking Brake Cable 43 (440, 32) Center Exhaust Pipe 43 (440, 32)
Gasket N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part F07385 2001 AVALON (RM808U) Author
: Date
: 1390 SA-59 SUSPENSION AND AXLE - REAR LOWER SUSPENSION ARM AND STRUT ROD SA1F8-02 DISASSEMBLY DISASSEMBLE NO. 2 LOWER SUSPENSION ARM (a) Loosen the 2 lock nuts. F06459 (b) (c) Turn the adjusting tube and disassemble the No. 2 lower suspension arm. Remove the 2 lock nuts. F06461 2001 AVALON (RM808U) Author
: Date
: 1393 SA-61 SUSPENSION AND AXLE - REAR LOWER SUSPENSION ARM AND STRUT ROD SA0VJ-02 INSTALLATION Installation is in the reverse order of removal (See page SA-57 ). HINT: After installation, check the rear wheel alignment (See page SA-7 ). 2001 AVALON (RM808U) Author
: Date
: 1395 SA-60 SUSPENSION AND AXLE - REAR LOWER SUSPENSION ARM AND STRUT ROD SA1F9-02 REASSEMBLY ASSEMBLE NO. 2 LOWER SUSPENSION ARM (a) Install the 2 lock nuts. (b) Turn the adjusting tube and assemble the No. 2 lower suspension arm. F06460 HINT: When assembling the No. 2 lower suspension arm, try to make sure that the lengths of A and B shown in the illustration are the same. Maximum difference: 3.0 mm (0.118 in.) A B W03223 (c) Adjust the No. 2 lower suspension arm length by turning the adjusting tube. Arm length: 512.3 mm (20.169 in.) Temporarily tighten the 2 lock nuts. (d) HINT: After adjusting the rear wheel alignment, torque the lock nuts (See page SA-7 ). Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) F06462 2001 AVALON (RM808U) Author
: Date
: 1394 SA-57 SUSPENSION AND AXLE - REAR LOWER SUSPENSION ARM AND STRUT ROD SA0VG-02 REMOVAL 1. 2. 3. (a) REMOVE REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) REMOVE CENTER EXHAUST PIPE REMOVE STRUT ROD Remove the bolt and disconnect the parking brake cable. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (b) Remove the 2 bolts and nuts. Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf) NOTICE: Do not turn the nut. HINT: At the time of installation, after stabilizing the suspension, torque the bolts. (c) Remove the strut rod. W03216 4. (a) Rear W03217 REMOVE NO. 2 LOWER SUSPENSION ARM Remove the 3 nuts, suspension arm washer and washer. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) HINT: At the time of installation, after stabilizing the suspension, torque the nuts. (b) Remove the No. 2 lower suspension arm. HINT: At the time of installation, face the paint mark to the rearward. 5. REMOVE STABILIZER BAR BRACKETS (See page SA-63 ) 6. REMOVE NO. 1 LOWER SUSPENSION ARM (a) Support the suspension member with a jack. (b) (c) Remove the 4 nuts, 2 bolts and 8 suspension member stoppers. Torque: A: 51 N·m (520 kgf·cm, 38 ft·lbf) B: 38 N·m (390 kgf·cm, 28 ft·lbf) Lower the suspension member. B B A A F06465 2001 AVALON (RM808U) Author
: Date
: 1391 SA-58 SUSPENSION AND AXLE (d) - REAR LOWER SUSPENSION ARM AND STRUT ROD Remove the 2 bolts, washers and No. 1 lower suspension arm. HINT: At the time of installation, face the paint mark to the rearward. Rear W03220 2001 AVALON (RM808U) Author
: Date
: 1392 SA-49 SUSPENSION AND AXLE - REAR SHOCK ABSORBER REAR SHOCK ABSORBER SA0W9-02 COMPONENTS Rear Seatback 41 (420, 30) 18 (185, 13)
49 (500, 36) 18 (185, 13) Collar Suspension Support Rear Seat Cushion Spring Bumper Cap 39 (400, 29) Coil Spring Lower Insulator Shock Absorber with Coil Spring 39 (400, 29) Stabilizer Bar Link Shock Absorber Reused nut: 196 (2,000, 145) New nut: 255 (2,600, 188) ABS Speed Sensor Wire Harness 5.4 (55, 48 in.·lbf) Flexible Hose 29 (300, 22) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part F07384 2001 AVALON (RM808U) Author
: Date
: 1383 SA-51 SUSPENSION AND AXLE - REAR SHOCK ABSORBER SA0WB-02 DISASSEMBLY REMOVE COIL SPRING (a) Install 2 nuts and a bolt to the bracket at the lower side of the shock absorber and secure it in a vise. (b) Using SST, compress the coil spring. SST 09727-30021 NOTICE: Do not use an impact wrench. It will damage the SST. (c) Remove the nut. (d) Remove the collar, suspension support, coil spring, lower insulator and spring bumper. SST W03214 2001 AVALON (RM808U) Author
: Date
: 1385 SA-53 SUSPENSION AND AXLE - REAR SHOCK ABSORBER SA0WD-02 DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION:
When drilling, chips may fly out, work carefully.
The gas is colorless, odorless and non-poisonous. W03647 2001 AVALON (RM808U) Author
: Date
: 1387 SA-52 SUSPENSION AND AXLE - REAR SHOCK ABSORBER SA0WC-02 INSPECTION W03646 INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during operation. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL on page SA-53 . 2001 AVALON (RM808U) Author
: Date
: 1386 SA-55 SUSPENSION AND AXLE - REAR SHOCK ABSORBER SA0WF-02 INSTALLATION Installation is in the reverse order of removal (See page SA-50 ). HINT: After installation, check the rear wheel alignment (See page SA-7 ). 2001 AVALON (RM808U) Author
: Date
: 1389 SA-54 SUSPENSION AND AXLE - REAR SHOCK ABSORBER SA0WE-02 REASSEMBLY 1. 2. INSTALL LOWER INSULATOR INSTALL SPRING BUMPER TO PISTON ROD 3. (a) INSTALL COIL SPRING Using SST, compress the coil spring. SST 09727-30021 NOTICE: Do not use an impact wrench. It will damage the SST. SST R00911 (b) Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the lower insulator. 4. INSTALL SUSPENSION SUPPORT (a) Install the suspension support to the piston rod. (b) Install the collar. (c) Temporarily tighten a new nut. R00912 (d) Suspension Support (e) Outside Rotate the suspension support to set it in the correct direction shown in the illustration. Remove the SST. SST 09727-30021 HINT: After removing SST, recheck the direction of the suspension support. Lower Bracket F06469 2001 AVALON (RM808U) Author
: Date
: 1388 SA-50 SUSPENSION AND AXLE - REAR SHOCK ABSORBER SA0WA-02 REMOVAL 1. 2. REMOVE REAR SEAT (See page BO-1 19) REMOVE REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 3. R00749 DISCONNECT FLEXIBLE HOSE AND ABS SPEED SENSOR WIRE HARNESS CLAMP Remove the 2 bolts and disconnect the flexible hose and ABS speed sensor wire harness clamp. Torque: Flexible hose: 29 N·m (300 kgf·cm, 22 ft·lbf) ABS speed sensor wire harness: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 4. DISCONNECT STABILIZER BAR LINK FROM SHOCK ABSORBER (See page SA-63 ) 5. REMOVE SHOCK ABSORBER WITH COIL SPRING (a) Loosen the 2 nuts on the lower side of the shock absorber. Torque: Reused nut: 196 N·m (2,000 kgf·cm, 145 ft·lbf) New nut: 255 N·m (2,600 kgf·cm, 188 ft·lbf) HINT: At the time of installation, coat the nut’s threads with engine oil. (b) Support the rear axle carrier with a jack. F01924 F07383 (c) Remove the cap. (d) Loosen the nut in the center of the suspension support. NOTICE: Do not remove it. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) HINT: If not disassembling the shock absorber, it is not necessary to loosen the nut. (e) Remove the 3 nuts of the suspension support. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (f) Lower the rear axle carrier and remove the 2 bolts on the lower side of the shock absorber. (g) Remove the shock absorber with the coil spring. 2001 AVALON (RM808U) Author
: Date
: 1384 SA-62 SUSPENSION AND AXLE - REAR STABILIZER BAR REAR STABILIZER BAR SA0VK-02 COMPONENTS Stabilizer Bar Stabilizer Bar Link 39 (400, 29) 39 (400, 29) Bushing 19 (195, 14) 19 (195, 14) N·m (kgf·cm, ft·lbf) : Specified torque Stabilizer Bar Bracket F07397 2001 AVALON (RM808U) Author
: Date
: 1396 SA-64 SUSPENSION AND AXLE - REAR STABILIZER BAR SA0VM-01 INSPECTION Z00340 INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTATION CONDITION (a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. (b) Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading on the 5th turn. Turning torque: 0.05 - 1.0 N·m (0.5 - 10 kgf·cm, 0.4 - 8.7 in.·lbf) 2001 AVALON (RM808U) Author
: Date
: 1398 SA-65 SUSPENSION AND AXLE - REAR STABILIZER BAR SA0VN-01 INSTALLATION Installation is in the reverse order of removal (See page SA-63 ). 2001 AVALON (RM808U) Author
: Date
: 1399 SA-63 SUSPENSION AND AXLE - REAR STABILIZER BAR SA0VL-02 REMOVAL 1. REMOVE REAR WHEELS Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. REMOVE STABILIZER BAR LINKS (a) Remove the 2 nuts and stabilizer bar link. HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (b) Employ the same manner described above to the other side. F06464 3. (a) W03226 REMOVE BRACKETS AND BUSHINGS Remove the 2 bolts, bracket and bushing. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) HINT: At the time of installation, install the bushing to the outside of the bushing on the stabilizer bar. (b) Employ the same manner described above to the other side. 4. REMOVE STABILIZER BAR 2001 AVALON (RM808U) Author
: Date
: 1397 SA-7 SUSPENSION AND AXLE - REAR WHEEL ALIGNMENT REAR WHEEL ALIGNMENT SA1DQ-03 INSPECTION 1. 2. MEASURE VEHICLE HEIGHT (See page SA-4 ) INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER Camber: Camber Right-left error -0 °43’ ± 45’ (-0.72° ± 0.75°) 45’ (0.75°) or less If the measured value is not within the specified value, inspect the suspension parts for damage and/or wear and replace them if necessary because camber is not adjustable. A 4. INSPECT TOE-IN Toe-in: B D Toe-in (total) Front A + B: 0°24’ ± 12’ (0.4° ± 0.2°) C - D: 4 ± 2 mm (0.16 ± 0.08 in.) If the toe-in is not within the specified value, adjust it at the No. 2 lower suspension arm. C SA3213 5. (a) ADJUST TOE-IN Measure the lengths of the right and left No. 2 lower suspension arms. No. 2 lower suspension arm length difference: 1 mm (0.04 in.) or less If the right-left difference is greater than the specified value, adjust the length. F04051 (b) (c) Loosen the lock nuts. Turn the right and left adjusting tube by an equal amount to adjust toe-in. HINT:

(d) F04052 Try to adjust the toe-in to the center value. One turn of the each adjusting tube will adjust the toe-in by about 36’ (0.6°, 6.7 mm, 0.264 in.). Torque the lock nuts. Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1341 SA-48 SUSPENSION AND AXLE - REAR WHEEL HUB BOLT REAR WHEEL HUB BOLT SA0W8-02 REPLACEMENT 1. 2. (a) (b) SST REMOVE REAR WHEEL REMOVE BRAKE CALIPER AND DISC Remove the 2 bolts, brake caliper and disc. Support the brake caliper securely. 3. REMOVE HUB BOLT Using SST and a hammer handle or an equivalent, remove the hub bolt. SST 09628-1001 1 Z00212 4. (a) Nut Washer Z00213 INSTALL HUB BOLT Install a washer and nut to a new hub bolt as shown in the illustration. (b) Using a hammer handle or an equivalent to hold, install the hub bolt by torquing the nut. 5. INSTALL DISC AND BRAKE CALIPER Install the disc and brake caliper with the 2 bolts. Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) 6. INSTALL REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2001 AVALON (RM808U) Author
: Date
: 1382 SA-2 SUSPENSION AND AXLE - TIRE AND WHEEL TIRE AND WHEEL SA1DO-03 INSPECTION 1. INSPECT TIRE (a) Check the tires for wear and proper inflation pressure. Cold tire inflation pressure: (b) Tire size Front, rear kPa (kgf/cm2, psi) P205/65R15 92H 210 (2.1, 31) P205/60R16 91H 220 (2.2, 32) Check the tire runout. Tire runout: 1.0 mm (0.039 in.) or less R03031 2. ROTATING TIRES HINT: See the illustration for where to rotate each tire when you include the spare tire in the rotation and when you do not. Front W02620 3. (a) (b) INSPECT WHEEL BALANCE Check and adjust the Off-the-car balance. If necessary, check and adjust the On-the-car balance. Imbalance after adjustment: 8.0 g (0.018 lb) or less R07928 2001 AVALON (RM808U) Author
: Date
: 1336 SA-3 SUSPENSION AND AXLE 4. (a) (b) W03084 5. 6. 7. 8.


- TIRE AND WHEEL CHECK WHEEL BEARING LOOSENESS Check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) Check the axle hub deviation. Maximum: 0.05 mm (0.0020 in.) CHECK FRONT SUSPENSION FOR LOOSENESS CHECK STEERING LINKAGE FOR LOOSENESS CHECK BALL JOINT FOR LOOSENESS CHECK SHOCK ABSORBER WORKS PROPERLY Check that oil leaks Check mounting bushings for wear Bounce front and rear of the vehicle 2001 AVALON (RM808U) Author
: Date
: 1337 SA-1 SUSPENSION AND AXLE - TROUBLESHOOTING TROUBLESHOOTING SA0CB-02 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page 3. Tire (Worn or improperly inflated) 4. Wheel alignment (Incorrect) Wander/pulls 5. Steering linkage (Loosen or worn) 6. Hub bearing (Worn) 7. Steering gear (Out of adjustment or broken) 8. Suspension parts (Worn) 1. Vehicle (Overloaded) 2. Spring (Weak) SA-25 SA-49 SA-28 SA-52 Bottoming 3. Shock absorber (Worn) 1. Tire (Worn or improperly inflated) 2. Stabilizer bar (Bent or broken) SA-2 SA-40 SA-62 SA-28 SA-52 Sways/pitches 3. Shock absorber (Worn) Front wheel shimmy Abnormal tire wear 1. 2. 3. 4. 5. 6. 7. 8. SA-2 SA-4 SA-7 SA-9 SA-45 SR-37 - Tire (Worn or improperly inflated) Wheel (Out of balance) Shock absorber (Worn) Wheel alignment (Incorrect) Ball joint (Worn) Hub bearing (Worn) Steering linkage (Loosen or worn) Steering gear (Out of adjustment or broken) 1. Tire (Worn or improperly inflated) 2. Wheel alignment (Incorrect) 3. Shock absorber (Worn) SA-2 SA-2 SA-28 SA-4 SA-38 SA-9 SR-37 SA-2 SA-4 SA-28 SA-52 - 4. Suspension parts (Worn) 2001 AVALON (RM808U) Author
: Date
: 1335