A25A-FXS (ENGINE MECHANICAL): CYLINDER HEAD GASKET: REMOVAL; 2019 - 2021 MY Avalon HV [04/2018

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001AOCU
Model Year Start: 2019	Model: Avalon HV	Prod Date Range: [04/2018 - 08/2021]
Title: A25A-FXS (ENGINE MECHANICAL): CYLINDER HEAD GASKET: 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 cylinder head gasket 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)
		Pre-collision system
		Intelligent clearance sonar system*
		Lighting System (for HV Model with Cornering Light)
	Memorize steering angle neutral point	Parking assist monitor system
	Memorize steering angle neutral point	Panoramic view monitor system
Replacement of ECM	Perform Vehicle Identification Number (VIN) registration	MIL illuminates
Gas leak from exhaust system is repaired Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body assembly Replacement of cam timing control motor with EDU assembly Removal and installation of a cam timing control motor with EDU assembly Replacement of camshaft timing gear assembly Removal and installation of a camshaft timing gear assembly Replacement of cylinder head sub-assembly Replacement of camshaft (for intake or exhaust camshaft) Replacement of camshaft timing exhaust gear assembly Replacement of port fuel injector assembly Replacement of direct fuel injector assembly Replacement of fuel pump assembly (for high pressure side) Replacement of spark plug Replacement of ignition coil assembly Replacement of EGR valve assembly Replacement of knock control sensor Replacement of fuel pressure sensor (fuel delivery pipe with sensor assembly) (for low pressure side) Replacement of engine coolant temperature sensor	Inspection After Repair	Poor idle, etc. Engine start function, etc.
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
Replacement of hybrid vehicle transaxle assembly	Resolver learning Initialize resolver
Front wheel alignment adjustment	Clear zero point calibration data. 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
Suspension, tires, etc.*1 Replacement of front bumper assembly	Measurement of ultrasonic sensor detection angle Ultrasonic sensor detection angle registration	Intelligent clearance sonar system Intuitive parking assist system
Suspension, tires, etc.*1	Rear television camera assembly optical axis (Back camera position setting)	Parking assist monitor system	for Initialization for Calibration
Replacement of front bumper assembly	Front television camera view adjustment	Panoramic view monitor system	for Initialization for Calibration
Suspension, tires, etc.*1	Parking assist ECU initialization Adjust steering angle Television camera assembly optical axis adjustment (Back camera position setting)	Panoramic view monitor system	for Initialization for Calibration
Replacement of headlight ECU sub-assembly LH Replacement of headlight assembly LH	Synchronize the vehicle information	Lighting system (for HV Model with Cornering Light)

*: When performing learning using the Techstream.
Click here
*1: If the vehicle height has changed due to suspension or tire replacement

NOTICE:

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

Click here

PROCEDURE

1. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

Click here

2. REMOVE ENGINE HANGERS

Click here

3. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

Click here

4. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

Click here

5. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

Click here

6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Click here

7. REMOVE MANIFOLD STAY

Click here

8. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

Click here

9. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here

10. REMOVE THROTTLE BODY GASKET

Click here

11. REMOVE EGR COOLER ASSEMBLY

Click here

12. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

Click here

13. REMOVE NO. 4 WATER BY-PASS HOSE

Click here

14. REMOVE EGR VALVE ASSEMBLY

Click here

15. REMOVE NO. 3 WATER BY-PASS PIPE

Click here

16. REMOVE NO. 2 WATER BY-PASS PIPE

Click here

17. REMOVE INTAKE MANIFOLD

Click here

18. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Click here

19. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here

20. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

Click here

21. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here

22. REMOVE NO. 7 WATER BY-PASS HOSE

Click here

23. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here

24. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here

25. REMOVE INJECTOR VIBRATION INSULATOR

Click here

26. REMOVE NO. 5 ENGINE WIRE

Click here

27. REMOVE PORT FUEL INJECTOR ASSEMBLY

Click here

28. REMOVE FUEL DELIVERY PIPE

Click here

29. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

Click here

30. REMOVE IGNITION COIL ASSEMBLY

Click here

31. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

Click here

32. REMOVE OIL PRESSURE CONTROL VALVE ASSEMBLY

Click here

33. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

Click here

34. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

Click here

35. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

Click here

36. REMOVE O-RING

Click here

37. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

Click here

38. REMOVE CAM TIMING CONTROL MOTOR O-RING

Click here

39. REMOVE CRANKSHAFT PULLEY ASSEMBLY

Click here

40. REMOVE WATER OUTLET

Click here

41. REMOVE WATER BY-PASS OUTLET

Click here

42. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

Click here

43. REMOVE SPARK PLUG TUBE GASKET

Click here

44. REMOVE ENGINE MOUNTING BRACKET RH

Click here

45. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY

Click here

46. REMOVE TIMING CHAIN COVER OIL SEAL

Click here

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

Click here

48. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

Click here

49. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

Click here

50. REMOVE CHAIN SUB-ASSEMBLY

Click here

51. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

Click here

52. REMOVE CHAIN TENSIONER SLIPPER

Click here

53. REMOVE NO. 1 CHAIN VIBRATION DAMPER

Click here

54. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Click here

55. REMOVE TIMING CHAIN COVER ASSEMBLY

Click here

56. REMOVE FUEL PUMP LIFTER GUIDE

Click here

57. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

Click here

58. REMOVE CAMSHAFT BEARING CAP

Click here

59. REMOVE CAMSHAFT

Click here

60. REMOVE NO. 2 CAMSHAFT

Click here

61. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Click here

62. REMOVE VALVE LASH ADJUSTER ASSEMBLY

Click here

63. REMOVE VALVE STEM CAP

Click here

64. REMOVE CYLINDER HEAD SUB-ASSEMBLY

Click here

65. REMOVE CYLINDER HEAD GASKET

(a) Remove the cylinder head gasket from the cylinder block sub-assembly.

66. INSPECT CYLINDER HEAD SET BOLT

Click here

67. INSPECT CYLINDER HEAD SUB-ASSEMBLY

Click here