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

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001Q5AJ
Model Year Start: 2021	Model: Avalon	Prod Date Range: [08/2020 - ]
Title: A25A-FKS (ENGINE MECHANICAL): ENGINE UNIT: 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 unit 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 Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor 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	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

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)
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 V-RIBBED BELT

Click here

3. REMOVE GENERATOR ASSEMBLY

Click here

4. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

(a) Remove the 2 bolts and 2 nuts.

	Bolt
	Nut

(b) Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor assembly with pulley.

5. REMOVE NO. 2 ENGINE COVER

(a) Remove the 2 bolts and No. 2 engine cover from the No. 2 timing chain cover assembly.

6. REMOVE 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) Remove the 2 bolts and V-ribbed belt tensioner assembly from the No. 2 timing chain cover assembly.

7. REMOVE NO. 2 TIMING CHAIN COVER INSULATOR

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

8. REMOVE TIMING GEAR COVER INSULATOR

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

9. 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 outlet water by-pass sub-assembly.

(b) Remove the bolt and No. 2 water by-pass pipe sub-assembly.

10. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

(a) Remove the bolt to disconnect the flow shutting valve (water by-pass hose assembly).

(b) Remove the 2 bolts and the water hose clamp bracket.

(c) Slide the clip and remove the flow shutting valve (water by-pass hose assembly) from the outlet water by-pass sub-assembly.

HINT:

Use a container to catch any engine coolant which flows out of the flow shutting valve (water by-pass hose assembly) and outlet water by-pass sub-assembly.

11. SEPARATE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Click here

12. REMOVE MANIFOLD STAY

Click here

13. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

Click here

14. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here

15. REMOVE THROTTLE BODY GASKET

Click here

16. REMOVE EGR COOLER ASSEMBLY

Click here

17. REMOVE NO. 1 EGR COOLER BRACKET

(a) Remove the 2 bolts and No. 1 EGR cooler bracket from the EGR valve bracket and water outlet.

18. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

Click here

19. 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.

20. REMOVE EGR VALVE ASSEMBLY

(a) Disconnect the clamp.

(b) Slide the clip and disconnect the No. 8 water by-pass hose from the EGR valve assembly.

(d) Remove the EGR valve assembly vertically.

*a	Pin
*b	Hole

(e) Using an 8 mm socket wrench, remove the bolt and EGR valve bracket.

21. REMOVE NO. 3 WATER BY-PASS PIPE

(a) Using an 8 mm socket wrench, remove the bolt and disconnect the No. 3 water by-pass pipe from the intake manifold.

(b) Slide the clip and remove the No. 3 water by-pass pipe from the water outlet.

22. 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.

23. REMOVE INTAKE MANIFOLD

Click here

24. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Click here

25. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here

26. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

(b) Using an 8 mm socket wrench, remove the bolt.

27. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here

28. REMOVE NO. 7 WATER BY-PASS HOSE

(a) Slide the 2 clips and remove the No. 7 water by-pass hose.

29. REMOVE SENSOR WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 3 clamps.

30. REMOVE NO. 6 ENGINE WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 2 clamps.

31. 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.

32. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here

33. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here

34. REMOVE INJECTOR VIBRATION INSULATOR

Click here

35. REMOVE NO. 5 ENGINE WIRE

Click here

36. REMOVE PORT FUEL INJECTOR ASSEMBLY

Click here

37. REMOVE FUEL DELIVERY PIPE

Click here

38. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

Click here

39. REMOVE FUEL INJECTOR SEAL

Click here

40. REMOVE IGNITION COIL ASSEMBLY

Click here

41. 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.

42. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

Click here

43. REMOVE ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)

(a) Remove the 4 bolts, engine water pump assembly (water inlet housing) and gasket from the cylinder block sub-assembly.

44. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the bolt and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.

45. REMOVE PURGE VALVE (PURGE VSV)

Click here

46. REMOVE NO. 2 VACUUM SWITCHING VALVE BRACKET

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

47. REMOVE STUD BOLT

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