Engine Mechanical: Removal & Installation Toyota Avalon XX20 рестайлинг

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal

1. Release fuel system pressure. See «FUEL PRESSURE RELEASE»(ref-162868-S26135821232004061400000) . Remove battery and battery tray. Remove hood. Remove engine under cover. Remove fender apron seals. Drain cooling system and engine oil. Disconnect accelerator cable. Remove air cleaner cap and air cleaner case.
2. Remove cruise control actuator and bracket. Remove radiator and coolant reservoir tank. Remove front exhaust pipe. Disconnect electrical connections at ignitor and noise filter near left strut tower.
3. Disconnect generator and starter wiring, ground straps from left and right fender aprons and 2 wiring harness connectors from left fender apron. Disconnect ground cable and engine wire protector clamp from battery bracket. Remove engine wire clamp from bracket on right fender apron. Remove wire clamp from bracket on fuel filter and brake booster vacuum hose from air intake chamber. Disconnect coolant reservoir hose from water outlet, heater hoses and fuel inlet hose from fuel filter. Remove purge hose from pipe on emission control valve set and from charcoal canister. Remove 2 vacuum hoses from ACIS vacuum tank.
4. From inside passenger compartment, remove lower instrument panel. Disconnect 3 ECM connectors. Disconnect 3 cowl wiring connectors from connectors on bracket. Disconnect grommet from cowl panel and pull engine wiring harness into engine compartment.
5. Remove drive shafts. See appropriate article in DRIVE AXLES. Remove starter assembly.
6. Disconnect wiring from A/C compressor. Remove compressor drive belt. Remove 4 bolts, nut and adjusting bar bracket from compressor. Remove compressor. Disconnect control cables from transaxle.
7. Remove 2 nuts and disconnect power steering pressure line from engine hanger. Loosen 2 bolts and remove power steering belt. Remove 2 mounting bolts and remove power steering pump.
8. Remove bolts holding transaxle to mounting insulator. Remove 4 nuts holding front frame to mounting bracket (2 nuts are hidden under rubber plugs in frame). Remove engine mounting absorber. Remove 3 bolts and remove engine mounting insulator from front frame.
9. Install approved engine sling to engine hangers only. Remove 3 bolts and remove right engine mounting stay. Remove 3 bolts and remove engine moving control rod and No. 2 right engine mounting bracket. Lift engine and transaxle from vehicle, using care not to damage any components.
10. Engine should be mounted on engine stand. Front and rear mounting insulators can be removed. Transaxle can be separated from engine, if needed.

Installation

1. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000) . When installing transaxle to engine, use threadlock sealant on ends of drive plate mounting bolts. When installing exhaust pipe, install NEW gaskets and mounting nuts. Refill fluids. Start engine and check for leaks. Road test vehicle.

1. Install NEW cylinder head gaskets on cylinder block. Ensure identification mark is facing upward at lower corner of cylinder block. (Scheme 24) Ensure all holes in cylinder head gaskets align with cylinder block. Install cylinder heads.
2. Apply engine oil on cylinder head bolt threads and cylinder head bolt-to-cylinder head contact surfaces. Install and tighten 12-point cylinder head bolts to specification in sequence using several passes. see scheme 8 See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000). Replace any bolt that cannot be tightened to specification. To reach final torque, put paint on front-facing part of bolt head, then tighten an additional 90 degrees as indicated.
3. Apply light coat of oil to threads of recessed head bolts. Install recessed cylinder head bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000). Install camshafts using proper procedure. See «CAMSHAFT»(ref-162868-S03594388962004061400000).
4. To install remaining components, reverse removal procedure. If camshaft or cylinder head components are serviced, adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-162868-S03109661792004061400000) under ADJUSTMENTS. Install NEW gaskets on rear timing belt cover. (Scheme 25)
5. When installing intake manifold assembly, tighten bolts and nuts in sequence, using several passes to reach final specification. (Scheme 26)
6. Use NEW gaskets and "O" rings as removed. Ensure all bolts and nuts are tightened to specifications. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000). Adjust fluid levels and control cables.

Scheme 24

Scheme 25

Scheme 26

Remove camshaft. See CAMSHAFT . Note location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and valve lifters from cylinder head.

To install, reverse removal procedure. Ensure components are installed in original location. If camshaft, adjusting shim or valve lifter are replaced, check valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

Remove transaxle and drive plate. Using a knife, cut off oil seal lip. Pry oil seal from crankshaft rear oil seal housing. Use care not to damage sealing surfaces.

1. Ensure all sealing surfaces are clean. Apply grease to seal lip of oil seal. Install oil seal in crankshaft rear oil seal housing until oil seal is even with housing surface.
2. Apply Loctite to drive plate bolts. Install and tighten bolts to specification in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000) . To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Drain cooling system. Remove timing belt, camshaft sprockets and No. 2 idler pulley. See «TIMING BELT»(ref-162868-S19871717312004061400000) .
2. Remove inner timing belt cover. Remove bolts/nuts, water pump and gasket.

To install, reverse removal procedure. Use NEW gaskets. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Ensure proper procedure is followed when installing timing belt. Fill cooling system.

1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove front exhaust pipe that fits between exhaust manifolds and catalytic converter.
2. Remove dipstick. Remove lower oil pan bolts and nuts. Install a cutter blade between upper and lower oil pans. Carefully tap seal cutter around lower oil pan to cut and loosen seal. Remove lower oil pan.
3. Remove oil strainer and gasket. Remove exhaust pipe support stay and drive plate cover. Remove upper oil pan-to-transaxle bolts. Remove upper oil pan. Remove baffle plate, if necessary.

1. Ensure all pan and block sealing surfaces are clean. Apply a.16-.20" (4.0-5.0 mm) diameter bead of sealant on upper oil pan. (Scheme 27) Install upper oil pan. Install bolts and nuts and tighten, uniformly and in several passes, to specifications. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000).
2. Install drive plate cover and exhaust pipe support stay. Tighten bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000).
3. Using NEW gasket, install pick-up tube. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000).
4. Apply a.16-.20" (4.0-5.0 mm) diameter bead of sealant on lower oil pan. (Scheme 27) Install lower oil pan. Install bolts and nuts and tighten, uniformly and in several passes, to specification. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000).

Scheme 27

Removal & Disassembly

1. Remove right front wheel and fender apron seal. Drain oil. Remove front exhaust pipe and pipe bracket from upper oil pan.
2. Remove accessory drive belts and power steering pump bracket. Remove A/C compressor from engine mounting and position aside.
3. Remove timing belt. Remove camshaft timing sprockets and crankshaft timing sprocket. See «TIMING BELT»(ref-162868-S19871717312004061400000) under REMOVAL & INSTALLATION.
4. Remove inner timing belt cover from front of cylinder heads. Remove A/C compressor bracket.
5. Remove lower oil pan and strainer. Remove upper oil pan. See «OIL PAN»(ref-162868-S25648453492004061400000) under REMOVAL & INSTALLATION.
6. Remove baffle plate from upper oil pan. Remove crankshaft position sensor. Remove 9 bolts and remove oil pump, using a screwdriver to pry between oil pump and main bearing cap. Remove and discard "O" ring.
7. Remove relief valve plug, gasket, spring and relief valve from side of oil pump housing. Remove 9 screws and remove pump body cover, and drive and driven rotors.

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure both rotors are installed in oil pump body with identification mark (triangle mark) facing oil pump body cover. Install oil pump body cover.
2. Using NEW gasket, install and tighten relief valve plug to specification. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000) . Using seal installer tool, install crankshaft front seal (if removed) until seal surface is even with oil pump body. Coat seal lip with grease.
3. To install, apply sealant on mating surface of oil pump. DO NOT apply excess sealant or allow sealant into bolt holes.
4. Install NEW "O" ring on cylinder block. Install oil pump. Ensure splined teeth on drive rotor of oil pump engage with splines on crankshaft. Install and tighten bolts, in several passes, to specification. See «TORQUE SPECIFICATIONS»(ref-162868-S41817469462004061400000) .
5. Install crankshaft position sensor, upper oil pan with baffle plate, oil strainer, and lower oil pan. See «OIL PAN»(ref-162868-S25648453492004061400000) under REMOVAL & INSTALLATION. Install remaining components in reverse order of removal procedure. Start engine and check pump for leaks.