Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001BMOS
Model Year Start: 2019 Model: Avalon Prod Date Range: [04/2018 - 08/2021]
Title: 2GR-FKS (INTAKE / EXHAUST): INTAKE MANIFOLD: REMOVAL; 2019 - 2021 MY Avalon [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 intake manifold removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link
*: When performing learning using the Techstream.

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

Battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane departure alert system (w/ Steering Control)

2019 - 2021 MY Avalon [04/2018 - 08/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM (for Gasoline Model): INITIALIZATION

Pre-collision system

Intelligent clearance sonar system*

Lighting System (for Gasoline Model with Cornering Light)

Memorize steering angle neutral point

Parking assist monitor system

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

Panoramic view monitor system

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

  • Replacement of fuel injector assembly
  • Replacement of fuel pressure sensor (fuel delivery pipe with sensor assembly)
  • Replacement of throttle body with motor assembly
  • Cleaning the deposits from the throttle body with motor assembly

Inspection after repair
  • Poor idle, etc.
  • Engine start function, etc.

2019 MY Avalon [04/2018 - 08/2019]; 2GR-FKS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION 2020 - 2022 MY Avalon [08/2019 -        ]; 2GR-FKS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

PROCEDURE

1. PRECAUTION

NOTICE:

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

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

2. DISCHARGE FUEL SYSTEM PRESSURE

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; 2GR-FKS (FUEL): FUEL SYSTEM: PRECAUTION

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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

4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; WIPER / WASHER: FRONT WIPER MOTOR: REMOVAL

5. REMOVE FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

Click here 2019 - 2020 MY Avalon [04/2018 - 08/2020]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (for Gasoline Model): REMOVAL+ 2021 MY Avalon [08/2020 - 08/2021]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (for Gasoline Model): REMOVAL+

6. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; 2GR-FKS (ENGINE CONTROL): THROTTLE BODY: REMOVAL

7. REMOVE V-BANK COVER SUB-ASSEMBLY

Click here 2019 - 2021 MY Avalon [04/2018 - 08/2021]; 2GR-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL+

8. DISCONNECT VENTILATION HOSE

(a) Slide the clip and disconnect the ventilation hose from the intake air surge tank assembly.

9. DISCONNECT PURGE VALVE (PURGE VSV)

(a) Disconnect the No. 1 fuel vapor feed hose from the intake air surge tank assembly.

(b) Remove the bolt and disconnect the purge valve (purge VSV) from the intake air surge tank assembly.

10. REMOVE NO. 2 SURGE TANK STAY

(a) Remove the 2 bolts and No. 2 surge tank stay from the intake air surge tank assembly and camshaft housing RH.

11. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

(a) Disconnect the vacuum switching valve (for ACIS) connector.

(b) Disengage the 2 clamps to disconnect the vacuum hose sub-assembly from the intake air surge tank assembly.

(c) Disengage the 2 clamps to disconnect the vacuum hose sub-assembly from the intake air surge tank assembly.

*1

Vacuum Hose Sub-assembly

*2

Vacuum Hose

*3

No. 2 Air Tube

(d) Disengage the clamp to disconnect the vacuum hose from the intake air surge tank assembly.

(e) Disengage the clamp to disconnect the No. 2 air tube from the intake air surge tank assembly.

(f) Remove the 5 bolts, 2 nuts and intake air surge tank assembly from the intake manifold.

Bolt

Nut

(g) Remove the plug from the intake air surge tank assembly.

12. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET

(a) Remove the air surge tank to intake manifold gasket from the intake air surge tank assembly.

13. REMOVE NO. 1 V-BANK COVER BRACKET

HINT:

Perform this procedure only when replacement of the No. 1 V-bank cover bracket is necessary.

(a) Remove the 2 No. 1 V-bank cover brackets from the intake air surge tank assembly.

14. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the bolt and disconnect the wire harness clamp from the wire harness clamp bracket.

(b) Remove the bolt and separate the wire harness clamp bracket from the No. 2 engine mounting stay RH.

(c) Remove the bolt, 2 nuts and No. 2 engine mounting stay RH from the engine mounting insulator sub-assembly RH.

Bolt

Nut

(d) Remove the bolt and No. 2 engine mounting stay RH from the intake manifold and front No. 1 engine mounting bracket LH.

15. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here 2019 - 2021 MY Avalon [04/2018 - 08/2021]; 2GR-FKS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

16. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

Click here 2019 - 2021 MY Avalon [04/2018 - 08/2021]; 2GR-FKS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

17. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here 2019 - 2021 MY Avalon [04/2018 - 08/2021]; 2GR-FKS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

18. REMOVE INJECTOR VIBRATION INSULATOR

Click here 2019 - 2021 MY Avalon [04/2018 - 08/2021]; 2GR-FKS (FUEL): FUEL INJECTOR (for Port Injection): REMOVAL+

19. REMOVE INTAKE MANIFOLD

(a) Remove the 4 bolts, 4 nuts and intake manifold from the cylinder head sub-assembly.

Bolt

Nut

20. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

(a) Remove the 2 No. 1 intake manifold to head gaskets from each cylinder head sub-assembly.

21. REMOVE STUD BOLT

HINT:

If a stud bolt is deformed or the threads are damaged, replace it.

(a) Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.