Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001AOD6
Model Year Start: 2019 Model: Avalon HV Prod Date Range: [04/2018 - 08/2021]
Title: A25A-FXS (ENGINE MECHANICAL): ENGINE UNIT: 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 unit 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 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 engine coolant temperature sensor
  • 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)

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

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

PROCEDURE

1. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket.

2. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

(a) Remove the bolt and 2 nuts.

Bolt

Nut

(b) Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor with motor assembly.

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

(a) Slide the clip and disconnect the No. 2 water by-pass pipe sub-assembly from the water by-pass outlet.

(b) Remove the bolt and the No. 2 water by-pass pipe sub-assembly.

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

(a) Remove the bolt.

(b) Slide the clip and remove the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet sub-assembly.

(c) Remove the 2 bolts and water hose clamp bracket.

5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 5 bolts and the No. 1 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).

6. REMOVE MANIFOLD STAY

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

7. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

(a) Using a 12 mm deep socket wrench, remove the 7 nuts and remove the exhaust manifold (TWC: Front Catalyst) from the cylinder head sub-assembly.

(b) Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

8. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

9. REMOVE THROTTLE BODY GASKET

Click here 2019 - 2022 MY Avalon HV [04/2018 -        ]; A25A-FXS (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

10. REMOVE EGR COOLER ASSEMBLY

(a) Slide the clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

*1

No. 3 Water By-pass Hose

*2

No. 4 Water By-pass Hose

(b) Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.

(c) Remove the 5 bolts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.

11. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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

12. REMOVE NO. 4 WATER BY-PASS HOSE

(a) Slide the clip and remove the No. 4 water by-pass hose from the EGR valve assembly.

13. REMOVE EGR VALVE ASSEMBLY

(a) Slide the clip and disconnect the No. 8 water by-pass hose from the EGR valve assembly.

(b) for EGR Valve Bracket Connection Type:

(1) Using an 8 mm socket wrench, remove the bolt and disconnect the No. 1 fuel pipe sub-assembly from the EGR valve bracket.

(2) Using an 8 mm socket wrench, remove the bolt.

(3) Remove the EGR valve assembly vertically.

*a

Pin

*b

Hole

(c) for Cylinder Head Cover Sub-assembly Connection Type:

(1) Using an 8 mm socket wrench, remove the bolt.

(2) Remove the EGR valve assembly vertically.

*a

Pin

*b

Hole

(d) Using an 8 mm socket wrench, remove the bolt and EGR valve bracket.

14. REMOVE NO. 3 WATER BY-PASS PIPE

(a) Using an 8 mm socket wrench, remove the bolt and No. 3 water by-pass pipe from the intake manifold.

(b) Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet.

15. REMOVE NO. 2 WATER BY-PASS PIPE

(a) Remove the bolt (A).

(b) Using an 8 mm socket wrench, remove the 2 bolts (B) and No. 2 water by-pass pipe.

16. REMOVE INTAKE MANIFOLD

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

17. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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

18. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): REMOVAL+

19. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) for EGR Valve Bracket Connection Type:

(1) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

(b) for Cylinder Head Cover Sub-assembly Connection Type:

(1) Using an 8 mm socket wrench, remove the bolt.

(2) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

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

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (FUEL): FUEL PUMP (for High Pressure): REMOVAL+

21. REMOVE NO. 7 WATER BY-PASS HOSE

(a) Slide the 2 clips and remove the No. 7 water by-pass hose.

22. REMOVE SENSOR WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 3 clamps.

(c) Using an 8 mm socket wrench, remove the bolt and sensor wire from the water inlet with thermostat sub-assembly.

23. REMOVE NO. 6 ENGINE WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 2 clamps.

(c) Remove the 2 nuts and No. 6 engine wire from the wire harness clamp bracket.

24. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.

25. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

26. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

27. REMOVE INJECTOR VIBRATION INSULATOR

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

28. REMOVE NO. 5 ENGINE WIRE

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

29. REMOVE PORT FUEL INJECTOR ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

30. REMOVE FUEL DELIVERY PIPE

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL+

31. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

Click here 2019 - 2021 MY Avalon HV [04/2018 - 08/2021]; A25A-FXS (FUEL): FUEL INJECTOR (for Direct Injection): REMOVAL+

32. REMOVE IGNITION COIL ASSEMBLY

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

33. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the engine oil level dipstick.

(b) Using an 8 mm socket wrench, remove the bolt and engine oil level dipstick guide from the camshaft housing sub-assembly.

(c) Remove the O-ring from the engine oil level dipstick guide.

34. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Type A:

(1) Remove the bolt and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.

(b) Type B:

(1) Remove the 2 bolts and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.