Toyota Camry, Avalon, Solara, Lexus ES300 Repair Manual 1997-2001

CLEANING
(Refer to illustrations 16.1a, 16.1b, 16.1c, 16.8 and 16.10)

CAUTION! The core plugs (also known as freeze or soft plugs) may be difficult or impossible to retrieve if they're driven completely into the block coolant passages.

1. Using the blunt end of a punch, tap in on the outer edge of the core plug to turn the plug sideways in the bore. Then using pliers pull the core plug from the engine block (see illustrations).


NOTE: The V6 engine does not have conventional core plugs in its aluminum block, but rather bolted-on plates with RTV sealant (see illustration).


2. Using a gasket scraper, remove all traces of gasket material from the engine block. Be very careful not to nick or gouge the gasket sealant surfaces.



3. Remove the main bearing caps or cap assembly and separate the bearing inserts from the caps and the engine block. Tag the bearings, indicating which cylinder they were removed from and whether they were in the cap or the block, then set them aside.



4. Remove all of the threaded oil gallery plugs from the block. The plugs are usually very tight - they may have to be drilled out and the holes retapped. Use new plugs when the engine is reassembled.



5. If the engine is extremely dirty, it should be taken to an automotive machine shop for cleaning.



6. After the block is returned, clean all oil holes and oil galleries one more time. Brushes specifically designed for this purpose are available at most auto parts stores.
   
   Flush the passages with warm water until the water runs clear, dry the block thoroughly and wipe all machined surfaces with a light rust preventive oil.
   
   If you have access to compressed air, use it to speed the drying process and to blow out all the oil holes and galleries.

DRIVEAXLE BOOT REPLACEMENT

NOTE: Complete rebuilt driveaxles are available on an exchange basis, which eliminates much time and work. Check on the cost and availability of parts before disassembling the vehicle.

1. Remove the driveaxle (see Section 10).



2. Mount the driveaxle in a vise with wood lined jaws (to prevent damage to the axleshaft). Check the CV joint for excessive play in the radial direction, which indicates worn parts.
   
   Check for smooth operation throughout the full range of motion for each CV joint. If a boot is torn, the recommended procedure is to disassemble the joint, clean the components and inspect for damage due to loss of lubrication and possible contamination by foreign matter.


DISASSEMBLY
(Refer to illustrations 11.3, 11.4, 11.6 and 11.7)


3. Using diagonal cutters, cut the boot clamps (see illustration), remove the clamps and discard them.



4. Using a screwdriver, carefully pry up on the edge of the outer boot and push it away from the CV joint. Old and worn boots can be cut off. Pull the inner CV joint boot back from the housing and slide the housing from the tripod (see illustration).



5. Mark the tripod and axle shaft to ensure that they are reassembled properly.



6. Remove the tripod joint snap-ring with a pair of snap-ring pliers (see illustration).

Introduction: About this manual | Introduction | Vehicle identification numbers | Maintenance techniques, tools and working facilities | Buying parts | Jacking and towing | Booster battery (jump) starting | Conversion factors | Automotive chemicals and lubricants | Safety first! | Troubleshooting

• Tune-up and routine maintenance
• 2.2L four-cylinder engine
• 3.0L DOHC V6 engine
• General engine overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions and engine control systems
• 5-speed manual transmission
• 4-speed automatic transmission
• Driveline
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams