Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001AOCS
Model Year Start: 2019 Model: Avalon HV Prod Date Range: [04/2018 - 08/2021]
Title: A25A-FXS (ENGINE MECHANICAL): CYLINDER HEAD GASKET: INSTALLATION; 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

PROCEDURE

1. INSTALL CYLINDER HEAD GASKET

(a) Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

(b) Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.

*a

Lot No.

Front of Engine

NOTICE:

  • Make sure that the cylinder head gasket is installed in the correct orientation.
  • Remove any oil from the contact surfaces.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

3. INSTALL NO. 2 CAMSHAFT

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

4. INSTALL CAMSHAFT

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

5. INSTALL CAMSHAFT BEARING CAP

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

6. INSTALL VALVE STEM CAP

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

7. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

10. INSTALL FUEL PUMP LIFTER GUIDE

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

11. INSTALL TIMING CHAIN COVER ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

12. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

13. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

14. INSTALL NO. 1 CHAIN VIBRATION DAMPER

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

15. INSTALL CHAIN TENSIONER SLIPPER

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

17. INSTALL CHAIN SUB-ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

18. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

19. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

20. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+ 2020 - 2022 MY Avalon HV [08/2019 -        ]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: DISASSEMBLY+

21. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY

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22. INSTALL TIMING CHAIN COVER OIL SEAL

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (ENGINE MECHANICAL): FRONT CRANKSHAFT OIL SEAL: INSTALLATION+

23. INSTALL SPARK PLUG TUBE GASKET

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24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

25. INSTALL WATER BY-PASS OUTLET

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26. INSTALL WATER OUTLET

Click here 2019 MY Avalon HV [04/2018 - 08/2019]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+ 2020 - 2021 MY Avalon HV [08/2019 - 08/2021]; A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: REASSEMBLY+

27. INSTALL CRANKSHAFT PULLEY ASSEMBLY

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28. INSTALL CAM TIMING CONTROL MOTOR O-RING

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (ENGINE CONTROL): CAMSHAFT TIMING CONTROL MOTOR: INSTALLATION+

29. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (ENGINE CONTROL): CAMSHAFT TIMING CONTROL MOTOR: INSTALLATION+

30. INSTALL O-RING

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (ENGINE CONTROL): CAMSHAFT OIL CONTROL SOLENOID: INSTALLATION+

31. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (ENGINE CONTROL): CAMSHAFT OIL CONTROL SOLENOID: INSTALLATION+

32. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (LUBRICATION): OIL PRESSURE SWITCHING VALVE: INSTALLATION+

33. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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34. INSTALL IGNITION COIL ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (ENGINE CONTROL): IGNITION COIL AND SPARK PLUG: INSTALLATION+

35. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): INSTALLATION+

36. INSTALL FUEL DELIVERY PIPE

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): INSTALLATION+

37. INSTALL PORT FUEL INJECTOR ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

38. INSTALL NO. 5 ENGINE WIRE

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

39. INSTALL INJECTOR VIBRATION INSULATOR

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

40. INSTALL NO. 1 DELIVERY PIPE SPACER

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

41. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

42. INSTALL NO. 7 WATER BY-PASS HOSE

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

43. TEMPORARILY INSTALL FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

44. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

45. INSTALL FUEL(ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): INSTALLATION+

46. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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47. CONNECT FUEL TUBE SUB-ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): INSTALLATION+

48. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (INTAKE / EXHAUST): INTAKE MANIFOLD: INSTALLATION+

49. INSTALL INTAKE MANIFOLD

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50. INSTALL NO. 2 WATER BY-PASS PIPE

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51. INSTALL NO. 3 WATER BY-PASS PIPE

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52. INSTALL EGR VALVE ASSEMBLY

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53. INSTALL NO. 4 WATER BY-PASS HOSE

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54. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (EMISSION CONTROL): EGR VALVE: INSTALLATION+

55. INSTALL EGR COOLER ASSEMBLY

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56. INSTALL THROTTLE BODY GASKET

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57. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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58. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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59. INSTALL MANIFOLD STAY

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60. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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61. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

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62. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

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63. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

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64. INSTALL ENGINE HANGERS

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65. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

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