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

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)
		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
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.
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

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.

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2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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3. DISCHARGE FUEL SYSTEM PRESSURE

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4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

5. SECURE STEERING WHEEL

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6. REMOVE FRONT WHEELS

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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

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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

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16. DRAIN ENGINE OIL

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17. DRAIN HYBRID TRANSAXLE FLUID

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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

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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.

(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

25. REMOVE NO. 2 ENGINE COOLANT TEMPERATURE SENSOR

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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

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29. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

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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.

(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

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

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35. REMOVE FRONT DRIVE SHAFT ASSEMBLY

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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

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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

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43. REMOVE FRONT ENGINE MOUNTING INSULATOR

HINT:

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

Click here

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.

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

46. REMOVE STARTER HOLE INSULATOR

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47. REMOVE FLYWHEEL HOUSING SIDE COVER

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48. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

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49. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

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50. REMOVE FLYWHEEL SUB-ASSEMBLY

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51. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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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.

(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.