Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001AOD2
Model Year Start: 2019 Model: Avalon HV Prod Date Range: [04/2018 - 08/2021]
Title: A25A-FXS (ENGINE MECHANICAL): ENGINE ASSEMBLY: 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 engine 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

Perform 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.*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

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

Suspension, tires, etc.*1

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

Parking assist monitor system

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

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

Replacement of front bumper assembly

Front television camera view adjustment

Panoramic view monitor system

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

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

Suspension, tires, etc.*1

  • 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

  • *: 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

  • *1: If the vehicle height has changed due to suspension or tire replacement

CAUTION:

  • The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

    *a

    An Object Exceeding Weight Limit of Engine Lifter

  • To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; HEATING / AIR CONDITIONING: REFRIGERANT: REPLACEMENT+

3. DISCHARGE FUEL SYSTEM PRESSURE

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

5. SECURE STEERING WHEEL

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

6. REMOVE FRONT WHEELS

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; MAINTENANCE: TIRE AND WHEEL: REMOVAL

7. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

(a) Remove the 3 screws and front wheel opening extension pad LH.

8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

(a) Remove the 3 screws and front wheel opening extension pad RH.

9. REMOVE NO. 1 ENGINE UNDER COVER

(a) Remove the bolt, 2 clips, 6 screws and No. 1 engine under cover.

10. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

(a) Remove the 4 screws, 6 clips and No. 2 engine under cover assembly.

11. REMOVE FRONT FENDER APRON SEAL LH

(a) Remove the 2 screws, clip and front fender apron seal LH.

12. REMOVE FRONT FENDER APRON SEAL RH

(a) Remove the 2 screws, clip and front fender apron seal RH.

13. REMOVE HEADLIGHT ASSEMBLY

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; LIGHTING (EXT): HEADLIGHT ASSEMBLY: REMOVAL

14. REMOVE FRONT LOWER BUMPER ABSORBER

(a) Remove the 4 bolts.

(b) Disengage the 2 claws to remove the front lower bumper absorber.

15. DRAIN ENGINE COOLANT

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; MAINTENANCE: A25A-FXS COOLANT (for Engine): REPLACEMENT+

16. DRAIN ENGINE OIL

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; MAINTENANCE: A25A-FXS OIL AND OIL FILTER: REPLACEMENT+

17. DRAIN HYBRID TRANSAXLE FLUID

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; P710 (HYBRID TRANSMISSION / TRANSAXLE): HYBRID TRANSAXLE FLUID: ADJUSTMENT+

18. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Lift the front of the No. 1 engine cover sub-assembly to disengage the 2 clips, and then lift the rear of the No. 1 engine cover sub-assembly to disengage the clip and remove the No. 1 engine cover sub-assembly.

NOTICE:

Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

19. REMOVE INVERTER WITH CONVERTER ASSEMBLY

Click here 2019 - 2020 MY Avalon HV [04/2018 - 08/2020]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL 2021 MY Avalon HV [08/2020 - 08/2021]; HYBRID / BATTERY CONTROL: INVERTER WITH CONVERTER: REMOVAL

20. REMOVE INVERTER RESERVE TANK ASSEMBLY

(a) Remove the bolt.

*1

No. 5 Inverter Cooling Hose

*2

No. 2 Inverter Cooling Hose

*a

Pin

*b

Grommet

(b) Disengage the pin and remove the inverter reserve tank assembly.

(c) Slide the clip and disconnect the No. 5 inverter cooling hose from the inverter reserve tank assembly.

(d) Slide the clip and disconnect the No. 2 inverter cooling hose from the inverter reserve tank assembly.

21. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Slide the clip and disconnect the No. 1 fuel vapor feed hose from the No. 1 vacuum switching valve assembly.

22. DISCONNECT OUTLET HEATER HOSE

(a) Pull out the retainer to disengage the lock claws and pull off the outlet heater hose from the No. 2 water by-pass pipe sub-assembly.

*a

Retainer

Pull out

Pull off

(b) Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.

(c) Cover the disconnected No. 2 water by-pass pipe sub-assembly and outlet heater hose connector with plastic bags to prevent damage and contamination.

23. DISCONNECT INLET HEATER HOSE

(a) Pull out the retainer to disengage the lock claws and pull off the inlet heater hose from the flow shutting valve (water by-pass hose assembly).

*a

Retainer

Pull out

Pull off

(b) Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.

(c) Cover the disconnected flow shutting valve (water by-pass hose assembly) and inlet heater hose connector with plastic bags to prevent damage and contamination.

24. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the No. 1 fuel pipe clamp from the fuel tube connector.

(b) Disconnect the fuel tube sub-assembly.

(1) Disconnect the fuel tube sub-assembly from the fuel pipe.

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (FUEL): FUEL SYSTEM: PRECAUTION

25. REMOVE NO. 2 ENGINE COOLANT TEMPERATURE SENSOR

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (ENGINE CONTROL): ENGINE COOLANT TEMPERATURE SENSOR: REMOVAL+

26. DISCONNECT NO. 1 RADIATOR HOSE

(a) Slide the clip and disconnect the No. 1 radiator hose from the water outlet.

(b) Remove the bolt to disconnect the No. 1 radiator hose from the front engine mounting bracket.

27. DISCONNECT NO. 2 RADIATOR HOSE

(a) Slide the clip and disconnect the No. 2 radiator hose from the water inlet.

28. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; HEATING / AIR CONDITIONING: COMPRESSOR (for A25A-FXS): REMOVAL+

29. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; HEATING / AIR CONDITIONING: COMPRESSOR (for A25A-FXS): REMOVAL+

30. DISCONNECT NO. 5 INVERTER COOLING HOSE

(a) Slide the clip and disconnect the No. 5 inverter cooling hose from the motor cooling cooler.

31. DISCONNECT WIRE HARNESS

HINT:

After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.

(a) Remove the No. 2 relay block cover from the engine room relay block and junction block assembly.

(b) Remove the nut from the engine room relay block and junction block assembly.

(c) Disconnect the 5 connectors from the engine room relay block and junction block assembly.

(d) Using a screwdriver, disengage the claw and disconnect the wire harness from the engine room relay block and junction block assembly.

(e) Remove the 2 bolts and disengage the earth wire.

32. DISCONNECT NO. 5 WATER BY-PASS HOSE

(a) Slide the clip and disconnect the No. 5 water by-pass hose from the No. 3 water by-pass pipe.

33. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

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

34. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (INTAKE / EXHAUST): EXHAUST MANIFOLD: REMOVAL

35. REMOVE FRONT DRIVE SHAFT ASSEMBLY

Click here 2019 - 2021 MY Avalon Avalon HV [04/2018 - 08/2021]; DRIVE SHAFT / PROPELLER SHAFT: FRONT DRIVE SHAFT ASSEMBLY (for 2WD): REMOVAL

36. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on an engine lifter.

NOTICE:

  • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
  • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
  • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.

(b) Remove the 6 bolts and body mounting plate.

(c) Remove the 3 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

(d) Remove the 3 bolts and remove the engine mounting stay LH from the engine mounting insulator LH.

(e) Remove the 4 bolts and separate the engine mounting insulator LH from the hybrid vehicle transaxle assembly.

Bolt

Nut

(f) Remove the 4 bolts (A), 2 bolts (B) and 2 bolts (C) and front bumper extension sub-assembly RH and front bumper extension sub-assembly LH from the front frame assembly and vehicle body.

(g) Remove the 2 bolts (D), 2 bolts (E) and 2 nuts and front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH from the front frame assembly and vehicle body.

(h) Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.

NOTICE:

  • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
  • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

37. REMOVE FUEL DELIVERY GUARD

(a) Remove the bolt and fuel delivery guard from the engine mounting bracket RH.

38. INSTALL ENGINE HANGERS

(a) Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

No. 1 Engine Hanger

12281-25030

No. 2 Engine Hanger

12282-25010

Bolt

90105-A0354

*1

No. 1 Engine Hanger

*2

No. 2 Engine Hanger

(b) Using an engine sling device and engine lift, secure the engine assembly with transaxle.

NOTICE:

  • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.
  • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

39. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the flywheel housing under cover from the cylinder block sub-assembly.

40. 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+

41. REMOVE ENGINE WIRE

(a) Disconnect all clamps and connectors and remove the engine wire from the engine assembly with transaxle.

42. REMOVE FRONT FRAME ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; FRONT SUSPENSION: FRONT SUSPENSION MEMBER(for HV Model): REMOVAL+

43. REMOVE FRONT ENGINE MOUNTING INSULATOR

HINT:

Perform this procedure only when replacement of the front engine mounting insulator is necessary.

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; P710 (HYBRID TRANSMISSION / TRANSAXLE): HYBRID VEHICLE TRANSAXLE: REMOVAL+

44. REMOVE REAR ENGINE MOUNTING INSULATOR

HINT:

Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

(a) Remove the bolt and rear engine mounting insulator from the rear engine mounting bracket.

45. REMOVE HV AIR CONDITIONING WIRE

(a) Disengage the 2 clamps.

(b) Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the connector.

*a

Green-colored Lock

Slide

CAUTION:

Make sure to wear insulated gloves.

NOTICE:

Insulate the disconnected terminals and connector with insulating tape.

(c) Remove the bolt.

(d) Disengage the guide to remove the HV air conditioning wire from the hybrid vehicle transaxle assembly.

46. REMOVE STARTER HOLE INSULATOR

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; P710 (HYBRID TRANSMISSION / TRANSAXLE): HYBRID VEHICLE TRANSAXLE: REMOVAL+

47. REMOVE FLYWHEEL HOUSING SIDE COVER

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; P710 (HYBRID TRANSMISSION / TRANSAXLE): HYBRID VEHICLE TRANSAXLE: REMOVAL+

48. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; P710 (HYBRID TRANSMISSION / TRANSAXLE): HYBRID VEHICLE TRANSAXLE: REMOVAL+

49. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

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

50. REMOVE FLYWHEEL SUB-ASSEMBLY

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

51. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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

52. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

(a) Install the engine assembly to an engine stand.

53. REMOVE ENGINE HANGERS

(a) Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and engine mounting bracket RH.

54. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

(a) Disengage the No. 6 water by-pass hose.

(b) Remove the bolt, nut and the radiator reserve tank assembly.

(c) Disengage the clamp.

(d) Remove the bolt and disconnect the cooler bracket from the engine mounting insulator sub-assembly RH.

(e) Remove the 2 bolts and nut and remove the engine mounting insulator sub-assembly RH.

55. REMOVE ENGINE MOUNTING SPACER

HINT:

Perform this procedure only when replacement of the engine mounting spacer is necessary.

(a) Remove the 2 bolts and engine mounting spacer from the vehicle body.

56. REMOVE ENGINE MOUNTING INSULATOR LH

HINT:

Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

(a) Remove the 2 bolts, nut and the engine mounting insulator LH.