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

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001Q5AF
Model Year Start: 2021	Model: Avalon	Prod Date Range: [08/2020 - ]
Title: A25A-FKS (ENGINE MECHANICAL): ENGINE ASSEMBLY: REMOVAL; 2021 - 2022 MY Avalon [08/2020 - ]

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 Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
1: When performing learning using the Techstream. Click here 2: Not necessary when ECM replaced with new one
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*1
		Lighting System (for Gasoline 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	Vehicle Identification Number (VIN) registration	MIL comes on
Replacement of ECM	ECU communication ID registration (Immobiliser system)	Engine start function
Replacement of engine assembly Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.
Replacement of automatic transaxle assembly	Perform reset memory Input transaxle compensation code into ECM Perform road test to allow ECM to learn	Large shift shock Deterioration of fuel efficiency	for UB80F Initialization for UB80F Registration
Replacement of ECM (If transaxle compensation code read from ECM)	Perform reset memory*2 Transfer transaxle compensation code Perform road test to allow ECM to learn
Replacement of ECM (If transaxle compensation code not read from ECM)	Perform reset memory*2 Reset transaxle compensation code Perform road test to allow ECM to learn
Replacement of automatic transaxle fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly
Suspension, tires, etc. (The vehicle height changes because of suspension or tire replacement.) Replacement of front bumper assembly	Measure ultrasonic sensor detection angle Ultrasonic sensor detection angle registration	Intelligent Clearance Sonar System Intuitive Parking Assist System
Suspension, tires, etc. (The vehicle height changes because of suspension or tire replacement.)	Rear television camera assembly optical axis adjustment (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. (The vehicle height changes because of suspension or tire replacement.)	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 ECM	Code registration (Smart Key System (for Start Function, Gasoline Model))	Wireless Door Lock Control System Smart Key System (for Entry Function, Gasoline Model) Smart Key System (for Start Function, Gasoline Model) Steering lock function
Front wheel alignment adjustment	Perform system variant learning and acceleration sensor zero point calibration.	VSC is disabled or malfunctions DTCs are output Slip indicator light illuminates ABS warning light illuminates

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.

NOTICE:

After the engine switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Audio and Visual System)
After the engine switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Navigation System)

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.

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click here

3. DISCHARGE FUEL SYSTEM PRESSURE

Click here

4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Click here

5. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

6. SECURE STEERING WHEEL

Click here

7. REMOVE FRONT WHEELS

Click here

8. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

(a) Remove the 3 screws and front wheel opening extension pad LH.

9. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

(a) Remove the 3 screws and front wheel opening extension pad RH.

10. REMOVE NO. 1 ENGINE UNDER COVER

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

11. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY

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

12. REMOVE FRONT FENDER APRON SEAL LH

(a) Remove the 2 screws, clip and front fender apron seal LH.

13. REMOVE FRONT FENDER APRON SEAL RH

(a) Remove the 2 screws, clip and front fender apron seal RH.

14. REMOVE FRONT BUMPER COVER

Click here

15. REMOVE FRONT LOWER BUMPER ABSORBER

(a) Remove the 4 bolts.

(b) Disengage the 2 claws to remove the front lower bumper absorber.

16. DRAIN ENGINE COOLANT

Click here

17. DRAIN ENGINE OIL

Click here

18. DRAIN AUTOMATIC TRANSAXLE FLUID

Click here

19. DRAIN TRANSFER OIL

20. 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.

21. REMOVE INLET AIR CLEANER ASSEMBLY

(a) Remove the 2 bolts and inlet air cleaner assembly.

22. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

(a) Disconnect the mass air flow meter sub-assembly connector.

(b) Disengage the 3 wire harness clamps.

(d) Disengage the vacuum hose from the air cleaner hose.

(e) Loosen the hose clip.

NOTICE:

Make sure the air cleaner support remains attached to the vehicle body.

(f) Disengage the 3 pins and remove the air cleaner assembly with air cleaner hose.

23. REMOVE ECM

Click here

24. REMOVE BATTERY

Click here

25. REMOVE BATTERY CLAMP SUB-ASSEMBLY

(a) Disengage the 4 clamps.

(b) Remove the 3 bolts and battery clamp sub-assembly.

26. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) While disengaging the clip as shown in the illustration, disconnect the transmission control cable assembly from the transmission control shaft lever together with the clip.

*a	Clip
*b	45° to 60°

(b) Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.

27. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV).

28. DISCONNECT UNION TO CHECK VALVE HOSE

(a) Slide the clip and disconnect the union to check valve hose from the vacuum pump assembly.

29. DISCONNECT OUTLET HEATER WATER HOSE

(a) Pull out the retainer to disengage the lock claws and pull off the outlet heater water hose connector.

*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 water hose connector with plastic bags to prevent damage and contamination.

30. DISCONNECT INLET HEATER WATER HOSE

(a) Pull out the retainer to disengage the lock claws and pull off the inlet heater water hose connector.

*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.

31. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the EFI 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

32. DISCONNECT NO. 1 RADIATOR HOSE

(a) Disengage the clamp to disconnect the No. 1 radiator hose from the No. 1 radiator bracket.

(b) Slide the clip and disconnect the No. 1 radiator hose from the water outlet.

33. DISCONNECT NO. 2 RADIATOR HOSE

(a) Slide the clip and disconnect the No. 2 radiator hose from the water inlet with thermostat sub-assembly.

34. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

Click here

35. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

Click here

36. 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 relay block cover from the engine room relay block and junction block assembly.

(b) Remove the nut.

(d) Using a screwdriver, disengage the claw and separate the wire harness from the engine room relay block and junction block assembly.

(e) Disengage the 3 clamps.

(f) Remove the nut and disconnect the wire harness from the positive (+) battery terminal.

(g) Remove the bolt and disconnect earth wire from the automatic transaxle assembly.

(h) Remove the bolt and disconnect the wire harness from the vehicle body.

37. 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.

(b) Disengage the clamp.

38. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

39. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

Click here

40. REMOVE FRONT DRIVE SHAFT ASSEMBLY

Click here

41. 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) Disengage the clamp.

(d) Remove the 3 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

(e) Remove the bolt and nut and separate the rear No. 2 engine mounting insulator from the engine mounting bracket sub-assembly LH.

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

	Bolt
	Nut

(g) Remove the 2 bolts (D), 2 bolts (E), 2 nuts, 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.

42. REMOVE FUEL DELIVERY GUARD

(a) Remove the bolt and fuel delivery guard from the engine mounting bracket RH.

43. REMOVE FUEL PUMP PROTECTOR

(a) Remove the 2 bolts and fuel pump protector from the cylinder head sub-assembly.

44. 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.

45. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the flywheel housing under cover from the cylinder block sub-assembly.

46. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

Click here

47. DISCONNECT VACUUM HOSE

Click here

48. REMOVE FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE)

Click here

49. DISCONNECT WATER BY-PASS HOSE ASSEMBLY

Click here

50. REMOVE BREATHER PLUG HOSE

Click here

51. REMOVE STEERING GEAR HEAT INSULATOR

Click here

52. DISCONNECT WIRE HARNESS

Click here

53. REMOVE FRONT FRAME ASSEMBLY

(a) Remove the bolt and separate the front engine mounting insulator from the front engine mounting bracket.

(b) Remove the bolt and separate the rear engine mounting insulator from the rear engine mounting bracket sub-assembly.

54. REMOVE FRONT ENGINE MOUNTING INSULATOR

HINT:

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

(a) Remove the 3 nuts and front engine mounting insulator from the front frame assembly.

55. REMOVE PROPELLER SHAFT HEAT INSULATOR

Click here

56. 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 wiring harness clamp bracket.

*1	Wiring Harness Clamp Bracket
*2	Exhaust Sensor Clamp Bracket

(b) Remove the bolt and exhaust sensor clamp bracket.

57. REMOVE FRONT ENGINE MOUNTING BRACKET

Click here

58. REMOVE FLYWHEEL HOUSING SIDE COVER

Click here

59. REMOVE STARTER ASSEMBLY

Click here

60. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

Click here

61. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click here

62. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Click here

63. REMOVE ENGINE WIRE

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

64. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

(a) Install the engine assembly to an engine stand.

65. 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.

66. 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) Disconnect the No. 6 water by-pass hose.

(b) Disengage the clamp.

(d) Remove the bolt and disconnect the bracket from the engine mounting insulator sub-assembly RH.

(e) Disengage the clamp.

(f) Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH.

67. 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.

68. REMOVE ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

HINT:

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

(a) Remove the 4 bolts and engine mounting bracket sub-assembly LH from the vehicle body.

69. REMOVE 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