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

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)
		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 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.
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. 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.

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

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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

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9. REMOVE THROTTLE BODY GASKET

Click here

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.

11. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

Click here

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

(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

17. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Click here

18. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here

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

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.

23. REMOVE NO. 6 ENGINE WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 2 clamps.

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

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26. REMOVE NO. 1 DELIVERY PIPE SPACER

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27. REMOVE INJECTOR VIBRATION INSULATOR

Click here

28. REMOVE NO. 5 ENGINE WIRE

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29. REMOVE PORT FUEL INJECTOR ASSEMBLY

Click here

30. REMOVE FUEL DELIVERY PIPE

Click here

31. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

Click here

32. REMOVE IGNITION COIL ASSEMBLY

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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.

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.