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

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001Q5AI
Model Year Start: 2021	Model: Avalon	Prod Date Range: [08/2020 - ]
Title: A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: INSTALLATION; 2021 - 2022 MY Avalon [08/2020 - ]

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL STUD BOLT

(a) Using an E8 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

2. INSTALL NO. 2 VACUUM SWITCHING VALVE BRACKET

(a) Using an 8 mm socket wrench, install the No. 2 vacuum switching valve bracket to the cylinder head sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

3. INSTALL PURGE VALVE (PURGE VSV)

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4. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the bolt.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

5. INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)

(a) Install the engine water pump assembly (water inlet housing) and a new gasket to the cylinder block sub-assembly with the 4 bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

6. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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7. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring.

(b) Install the O-ring to the engine oil level dipstick guide.

(c) Using an 8 mm socket wrench, install the engine oil level dipstick guide to the camshaft housing sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Install the engine oil level dipstick.

8. INSTALL IGNITION COIL ASSEMBLY

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9. INSTALL FUEL INJECTOR SEAL

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10. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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11. INSTALL FUEL DELIVERY PIPE

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12. INSTALL PORT FUEL INJECTOR ASSEMBLY

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13. INSTALL NO. 5 ENGINE WIRE

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14. INSTALL INJECTOR VIBRATION INSULATOR

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15. INSTALL NO. 1 DELIVERY PIPE SPACER

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16. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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17. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

18. INSTALL NO. 6 ENGINE WIRE

(a) Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Engage the 2 clamps.

19. INSTALL SENSOR WIRE

(a) Using an 8 mm socket wrench, install the sensor wire to the water inlet with thermostat sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Engage the 3 clamps.

20. INSTALL NO. 7 WATER BY-PASS HOSE

(a) Install the No. 7 water by-pass hose and slide the 2 clips to secure it.

21. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

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22. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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23. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

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24. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

*a	17 mm Union Nut Wrench
*b	Torque Wrench Fulcrum Length

(b) Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

Torque:

Specified tightening torque :

35 N·m {357 kgf·cm, 26 ft·lbf}

NOTICE:

Do not adjust the torque in the loosening direction.

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

25. CONNECT FUEL TUBE SUB-ASSEMBLY

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26. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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27. INSTALL INTAKE MANIFOLD

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28. INSTALL NO. 2 WATER BY-PASS PIPE

(a) Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (A).

(b) Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (B).

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Using an 8 mm socket wrench, tighten the 2 bolts (B).

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

29. INSTALL NO. 3 WATER BY-PASS PIPE

(a) Install the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.

(b) Using an 8 mm socket wrench, connect the No. 3 water by-pass pipe to the intake manifold with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

30. INSTALL EGR VALVE ASSEMBLY

(a) Using an 8 mm socket wrench, install the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing sub-assembly.

*a	Pin
*b	Hole

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Connect the No. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

(e) Connect the clamp.

31. INSTALL NO. 4 WATER BY-PASS HOSE

(a) Install the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

32. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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33. INSTALL NO. 1 EGR COOLER BRACKET

(a) Install the No. 1 EGR cooler bracket to the EGR valve bracket and water outlet with the 2 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

34. INSTALL EGR COOLER ASSEMBLY

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35. INSTALL THROTTLE BODY GASKET

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36. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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37. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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38. INSTALL MANIFOLD STAY

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39. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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40. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

(a) Connect the flow shutting valve (water by-pass hose assembly) to the outlet water by-pass sub-assembly and slide the clip to secure it.

NOTICE:

Make sure to slide the flow shutting valve (water by-pass hose assembly) until it contacts the hose stopper of the outlet water by-pass sub-assembly.
Make sure that the claws of the clip are within the location shown in the illustration.

*a	Paint Mark
*b	45° (Claw of Clip Location)

(b) Install the water hose clamp bracket with the 2 bolts.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

41. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

(a) Install the No. 2 water by-pass pipe sub-assembly with the bolt.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

(b) Connect the No. 2 water by-pass pipe sub-assembly to the outlet water by-pass sub-assembly and slide the clip to secure it.

42. INSTALL TIMING GEAR COVER INSULATOR

(a) Using an 8 mm socket wrench, install the timing gear cover insulator and plate washer to the No. 2 timing chain cover assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

43. INSTALL NO. 2 TIMING CHAIN COVER INSULATOR

(a) Install the No. 2 timing chain cover insulator to the V-ribbed belt tensioner assembly.

44. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

NOTICE:

Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.
Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.

(a) Install the V-ribbed belt tensioner assembly to the No. 2 timing chain cover assembly with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

45. INSTALL NO. 2 ENGINE COVER

(a) Install the No. 2 engine cover to the No. 2 timing chain cover assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

46. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

(a) Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.

	Bolt
	Nut

Torque:

For reusable stiffening crankcase assembly :

5.0 N·m {51 kgf·cm, 44 in·lbf}

For new stiffening crankcase assembly :

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

HINT:

Tighten the bolts and nuts in the order shown in the illustration.

47. INSTALL GENERATOR ASSEMBLY

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48. INSTALL V-RIBBED BELT

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49. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the drive shaft bearing bracket with the 3 bolts.

Torque:

63.7 N·m {650 kgf·cm, 47 ft·lbf}