Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001AJJE
Model Year Start: 2019 Model: Avalon HV Prod Date Range: [04/2018 - 08/2021]
Title: FRONT SUSPENSION: FRONT SUSPENSION MEMBER(for HV Model): REMOVAL; 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during front frame assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane departure alert system (w/ Steering Control)

2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM (for HV Model): INITIALIZATION

Pre-collision system

Intelligent clearance sonar system*

Lighting system (for HV Model with Cornering Light)

Memorize steering angle neutral point

Parking assist monitor system

2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM(for HV Model): INITIALIZATION

Panoramic view monitor system

2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

Replacement of ECM

Vehicle Identification Number (VIN) registration

MIL illuminates

2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: REGISTRATION

  • Replacement of engine assembly
  • Gas leak from exhaust system is repaired
  • Replacement of engine coolant temperature sensor

Inspection After Repair
  • Poor idle, etc.
  • Engine start function, etc.

2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

Replacement of inverter with converter assembly

Resolver learning
  • DTCs are stored
  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less
  • Shock or vibration during acceleration

2019 - 2020 MY Avalon HV [04/2018 - 08/2020]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for NICKEL METAL HYDRIDE BATTERY): UTILITY 2021 - 2022 MY Avalon HV [08/2020 -        ]; HYBRID / BATTERY CONTROL: MOTOR GENERATOR CONTROL SYSTEM (for LITHIUM-ION BATTERY): UTILITY

Replacement of hybrid vehicle transaxle assembly
  • Resolver learning
  • Initialize resolver

Front wheel alignment adjustment
  1. Clear zero point calibration data.
  2. Perform yaw rate and acceleration sensor zero point calibration.
  • DTCs are stored
  • ABS warning light illuminates
  • Brake warning light / yellow (minor malfunction) illuminates
  • Slip indicator light illuminates
  • VSC disabled or malfunctions

2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for HV Model): CALIBRATION

  • Suspension, tires, etc.

    (The vehicle height changes because of suspension or tire replacement)

  • Replacement of front bumper assembly
  • Measurement of ultrasonic sensor detection angle
  • Ultrasonic sensor detection angle registration
  • Intelligent clearance sonar system
  • Intuitive parking assist system

2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: INTELLIGENT CLEARANCE SONAR SYSTEM (for HV Model): CALIBRATION

Suspension, tires, etc.

(The vehicle height changes because of suspension or tire replacement)

Rear television camera assembly optical axis (Back camera position setting)

Parking assist monitor system

for Initialization: 2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM(for HV Model): INITIALIZATION

for Calibration: 2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM(for HV Model): CALIBRATION

Replacement of front bumper assembly

Front television camera view adjustment

Panoramic view monitor system

for Initialization: 2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): INITIALIZATION

for Calibration: 2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for HV Model): CALIBRATION

Suspension, tires, etc.

(The vehicle height changes because of suspension or tire replacement)
  • Parking assist ECU initialization
  • Adjust steering angle
  • Television camera assembly optical axis adjustment (Back camera position setting)
  • Replacement of headlight ECU sub-assembly LH
  • Replacement of headlight assembly LH

Synchronize the vehicle information

Lighting system (for HV Model with Cornering Light)

2019 - 2022 MY Avalon HV [04/2018 -        ]; LIGHTING (EXT): LIGHTING SYSTEM (for HV Model with Cornering Light): INITIALIZATION

Rack and pinion power steering gear assembly
  • Perform torque sensor zero point calibration
  • Assist map writing
  • DTCs are output
  • Steering effort different between turning steering wheel left and right
  • EPS warning light illuminates

2019 - 2022 MY Avalon HV [04/2018 -        ]; POWER ASSIST SYSTEMS: POWER STEERING SYSTEM(for HV Model): CALIBRATION

*: When performing learning using the Techstream.

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; PARK ASSIST / MONITORING: INTELLIGENT CLEARANCE SONAR SYSTEM (for HV Model): CALIBRATION

PROCEDURE

1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL

2. REMOVE FUEL DELIVERY GUARD

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

3. INSTALL ENGINE HANGERS

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

4. REMOVE STEERING GEAR HEAT INSULATOR

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; STEERING GEAR / LINKAGE: STEERING GEAR (for HV Model): REMOVAL+

5. DISCONNECT WIRE HARNESS

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; STEERING GEAR / LINKAGE: STEERING GEAR (for HV Model): REMOVAL+

6. REMOVE FRONT FRAME ASSEMBLY

(a) Remove the 3 nuts and separate the front engine mounting insulator from the front frame assembly.

(b) Remove the 4 nuts and separate the rear engine mounting insulator from the front frame assembly.

7. REMOVE FRONT STABILIZER BAR WITH BRACKET

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; STEERING GEAR / LINKAGE: STEERING GEAR (for HV Model): REMOVAL+

8. REMOVE RACK AND PINION POWER STEERING GEAR ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; STEERING GEAR / LINKAGE: STEERING GEAR (for HV Model): REMOVAL+

9. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

(a) Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly LH from the front frame assembly.

NOTICE:

Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut secured.

(b) Remove the front lower arm bushing stopper from the front lower No. 1 suspension arm sub-assembly.

10. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

11. REMOVE NO. 2 EXHAUST PIPE SUPPORT BRACKET

(a) Remove the 2 bolts and No. 2 exhaust pipe support bracket from the front frame assembly.

12. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER

(a) Remove the 2 front suspension member body mounting front stoppers from the front frame assembly.

13. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER

(a) Remove the 2 front suspension member body mounting rear stoppers from the front frame assembly.

14. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION (for LH Side)

(a) Using a chisel and hammer, kink the flange of the front suspension member body mounting front cushion as shown in the illustration.

*a

Flange

(b) Apply lubricant to the contact surfaces of the front suspension member body mounting front cushion.

(c) Install SST as shown in the illustration.

SST: 09830-10010

09830-01010

09830-01040

09830-01050

SST: 09950-40011

09951-04020

09952-04010

09954-04010

09955-04011

09958-04011

NOTICE:

Apply molybdenum grease to the threads and tip of the SST center bolt before use.

*1

Front Suspension Member Body Mounting Front Cushion

(d) Turn the SST center bolt as shown in the illustration to create a clearance between the front suspension member body mounting front cushion and the front frame assembly.

*a

Hold

Turn

(e) While applying lubricant to the front suspension member body mounting front cushion through the clearance, gradually remove the front suspension member body mounting front cushion.

NOTICE:

  • Tighten SST slowly and evenly.
  • Be careful as the mounting cushion may fly out.
  • The mounting cushion cannot be reused.

15. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION (for RH Side)

HINT:

Perform the same procedure as for the LH side.

16. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH

(a) Using a chisel and hammer, kink the flange of the front suspension member body mounting rear cushion LH as shown in the illustration.

*a

Flange

(b) Apply lubricant to the contact surfaces of the front suspension member body mounting rear cushion LH.

(c) Install SST as shown in the illustration.

SST: 09830-10010

09830-01010

09830-01040

09830-01050

SST: 09950-40011

09951-04020

09952-04010

09954-04010

09955-04011

09958-04011

NOTICE:

Apply molybdenum grease to the threads and tip of the SST center bolt before use.

*1

Front Suspension Member Body Mounting Rear Cushion LH

(d) Turn the SST center bolt as shown in the illustration to create a clearance between the front suspension member body mounting rear cushion LH and the front frame assembly.

*a

Hold

Turn

(e) While applying lubricant to the front suspension member body mounting rear cushion LH through the clearance, gradually remove the front suspension member body mounting rear cushion LH.

NOTICE:

  • Tighten SST slowly and evenly.
  • Be careful as the mounting cushion may fly out.
  • The mounting cushion cannot be reused.

17. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION

HINT:

Perform the same procedure as for the front suspension member body mounting rear cushion LH.

18. REMOVE HOLE PLUG

(a) Remove the 7 hole plugs from the front frame assembly.

HINT:

There are 2 different shapes of hole plug.

19. REMOVE BOLT

(a) Remove the 2 bolts from the front frame assembly.