A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2021 - 2022 MY Avalon [08/2020

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001Q5AE
Model Year Start: 2021	Model: Avalon	Prod Date Range: [08/2020 - ]
Title: A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: INSTALLATION; 2021 - 2022 MY Avalon [08/2020 - ]

INSTALLATION

CAUTION / NOTICE / HINT

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

PROCEDURE

1. INSTALL REAR NO. 2 ENGINE MOUNTING INSULATOR

HINT:

Perform this procedure only when replacement of the rear No. 2 engine mounting insulator is necessary.

Click here

2. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

HINT:

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

(a) Install the engine mounting bracket sub-assembly LH to the vehicle body with the 4 bolts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C), (D) and (A).
Make sure that there is no gap between the engine mounting bracket sub-assembly LH and vehicle body before tightening the bolts.

3. INSTALL ENGINE MOUNTING SPACER

HINT:

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

(a) Install the engine mounting spacer to the vehicle body with the 2 bolts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

4. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

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

(a) Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

(b) Engage the clamp.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(d) Install the radiator reserve tank assembly with the bolt and nut.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(e) Engage the clamp.

(f) Connect the No. 6 water by-pass hose.

5. INSTALL ENGINE HANGERS

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6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

(a) Remove the engine assembly from the engine stand.

7. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine assembly.

8. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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9. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click here

10. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

Click here

11. INSTALL STARTER ASSEMBLY

Click here

12. INSTALL FLYWHEEL HOUSING SIDE COVER

Click here

13. INSTALL FRONT ENGINE MOUNTING BRACKET

Click here

14. INSTALL REAR ENGINE MOUNTING INSULATOR

HINT:

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

(a) Install the rear engine mounting insulator to the front frame assembly with the 4 nuts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

(b) Install the exhaust sensor clamp bracket with the bolt.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

15. INSTALL PROPELLER SHAFT HEAT INSULATOR

Click here

16. INSTALL FRONT ENGINE MOUNTING INSULATOR

HINT:

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

(a) Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

17. INSTALL FRONT FRAME ASSEMBLY

(a) Install the rear engine mounting insulator to the rear engine mounting bracket sub-assembly with the bolt.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

(b) Install the front engine mounting insulator to the front engine mounting bracket with the bolt.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

18. CONNECT WIRE HARNESS

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19. INSTALL STEERING GEAR HEAT INSULATOR

Click here

20. INSTALL BREATHER PLUG HOSE

Click here

21. CONNECT WATER BY-PASS HOSE ASSEMBLY

Click here

22. INSTALL FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE)

Click here

23. CONNECT VACUUM HOSE

Click here

24. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

Click here

25. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover to the cylinder block sub-assembly.

26. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

HINT:

Perform "Inspection After Repair" after replacing the engine assembly.

Click here

(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.

(b) Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(d) Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

(e) Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

CAUTION:

Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

NOTICE:

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

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

	Bolt
	Nut

Torque:

Bolt (A) :

9.0 N·m {92 kgf·cm, 80 in·lbf}

Bolt (B) :

12.5 N·m {127 kgf·cm, 9 ft·lbf}

Bolt (C) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

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

Torque:

Bolt (D) :

17.5 N·m {178 kgf·cm, 13 ft·lbf}

Bolt (E) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

Nut :

17.5 N·m {178 kgf·cm, 13 ft·lbf}

(h) Install the rear No. 2 engine mounting insulator to the engine mounting bracket sub-assembly LH with the bolt and nut.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

NOTICE:

While holding the bolt in place, tighten the nut.

(i) Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 3 bolts and nut.

Torque:

Bolt :

72 N·m {734 kgf·cm, 53 ft·lbf}

Nut :

42 N·m {428 kgf·cm, 31 ft·lbf}

(j) Install the body mounting plate with the 6 bolts.

Torque:

17.5 N·m {178 kgf·cm, 13 ft·lbf}

(k) Engage the clamp.

27. INSTALL FRONT DRIVE SHAFT ASSEMBLY

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28. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

Click here

29. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

30. CONNECT NO. 5 WATER BY-PASS HOSE

(a) Engage the clamp.

(b) Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.

31. CONNECT WIRE HARNESS

(a) Connect the wire harness to the vehicle body with the bolt.

Torque:

Bolt (A) :

8.0 N·m {82 kgf·cm, 71 in·lbf}

(b) Connect the earth wire to the automatic transaxle assembly with the bolt.

Torque:

Bolt (B) :

20 N·m {204 kgf·cm, 15 ft·lbf}

Torque:

Nut (C) :

7.6 N·m {77 kgf·cm, 67 in·lbf}

(d) Engage the 3 clamps.

(e) Engage the claw to install the wire harness to the engine room relay block and junction block assembly.

(f) Connect the 4 connectors.

(g) Install the nut.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(h) Install the relay block cover to the engine room relay block and junction block assembly.

32. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

Click here

33. CONNECT SUCTION HOSE SUB-ASSEMBLY

Click here

34. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the clip to secure it.

35. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

(b) Engage the clamp to connect the No. 1 radiator hose to the No. 1 radiator bracket with the clamp.

36. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly.

(1) Connect the fuel tube sub-assembly to the fuel pipe.

Click here

(b) Install the EFI fuel pipe clamp to the fuel tube connector.

37. CONNECT INLET HEATER WATER HOSE

(a) Align the protrusions of the inlet heater water hose connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and push them together until the inlet heater water hose connector makes a "click" sound.

*a	Protrusion
*b	Cutout

(b) Push in the retainer.

*a	Retainer
	Push
	Push in

(c) Check that the flow shutting valve (water by-pass hose assembly) and inlet heater water hose connector are securely connected by pulling on them.

38. CONNECT OUTLET HEATER WATER HOSE

(a) Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater water hose connector and push them together until the outlet heater water hose connector makes a "click" sound.

*a	Protrusion
*b	Cutout

(b) Push in the retainer.

*a	Retainer
	Push
	Push in

(c) Check that the No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector are securely connected by pulling on them.

39. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the union to check valve hose to the vacuum pump assembly and slide the clip to secure it.

40. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.

41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

(b) Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.

NOTICE:

Before installing the transmission control cable assembly, check that the park/neutral position switch assembly and shift lever are in N.

*a	Correct
*b	Incorrect

42. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the battery clamp sub-assembly with the 3 bolts.

Torque:

18.5 N·m {189 kgf·cm, 14 ft·lbf}

(b) Engage the 4 clamps.

43. INSTALL BATTERY

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44. INSTALL ECM

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45. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

(a) Install the air cleaner assembly with air cleaner hose to the throttle body with motor assembly and unlock the hose clip to secure it as shown in the illustration.

NOTICE:

Align the cutout of the air cleaner hose with the protrusion of the throttle body with motor assembly.

*a	Protrusion
*b	Cutout
*c	Top
*d	Front of Vehicle
*e	Locked
*f	Unlocked

(b) Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

NOTICE:

Make sure to position the clip as shown in the illustration.

*a	Top
*b	Front of Vehicle
*c	45°(Claw of Clip Location)
*d	Paint Mark

NOTICE:

Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports at the same time.
Check that the pins are securely inserted into air cleaner supports.

*a	Air Cleaner Support

(d) Engage the vacuum hose to the air cleaner hose.

(e) Engage the 3 wire harness clamps.

(f) Connect the mass air flow meter sub-assembly connector.

46. INSTALL INLET AIR CLEANER ASSEMBLY

(a) Install the inlet air cleaner assembly with the 2 bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

47. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Engage the 3 clips to install the No. 1 engine cover sub-assembly.

NOTICE:

Make sure that the clips are engaged securely.
If the clips are forcibly engaged or struck with an object, they may be damaged.

48. INSPECT VACUUM HOSES

(a) Inspect the vacuum hoses.

49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Click here

50. ADD ENGINE OIL

Click here

51. ADD ENGINE COOLANT

Click here

52. ADD AUTOMATIC TRANSAXLE FLUID

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53. ADD TRANSFER OIL

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54. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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55. WARM UP ENGINE

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56. INSPECT SHIFT LEVER POSITION

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57. ADJUST SHIFT LEVER POSITION

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58. INSPECT FOR ENGINE OIL LEAK

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59. INSPECT FOR COOLANT LEAK

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60. INSPECT FOR REFRIGERANT LEAK

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61. INSPECT FOR FUEL LEAK

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62. INSPECT FOR EXHAUST GAS LEAK

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63. CHECK ENGINE OIL LEVEL

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64. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

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65. INSPECT FOR TRANSFER OIL LEAK

66. INSTALL FRONT LOWER BUMPER ABSORBER

(a) Engage the 2 claws to install the front lower bumper absorber.

(b) Install the 4 bolts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

67. INSTALL FRONT BUMPER COVER

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68. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the 2 screws and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

69. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 screws and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

70. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

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

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

71. INSTALL NO. 1 ENGINE UNDER COVER

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

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

72. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

(a) Install the front wheel opening extension pad LH with the 3 screws.

73. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

(a) Install the front wheel opening extension pad RH with the 3 screws.

74. INSTALL FRONT WHEELS

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75. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

76. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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77. PERFORM INITIALIZATION

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78. INSPECT IGNITION TIMING

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79. INSPECT ENGINE IDLE SPEED

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80. INSPECT CO/HC

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81. CHECK SPEED SENSOR SIGNAL

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