A25A-FXS (ENGINE MECHANICAL): CYLINDER HEAD GASKET: REMOVAL; 2022 MY Avalon HV [08/2021

Last Modified: 08-21-2023	6.11:8.1.0	Doc ID: RM100000001XNHN
Model Year Start: 2022	Model: Avalon HV	Prod Date Range: [08/2021 - ]
Title: A25A-FXS (ENGINE MECHANICAL): CYLINDER HEAD GASKET: REMOVAL; 2022 MY Avalon HV [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 cylinder head gasket removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane Tracing Assist System
		Pre-collision System
		Intelligent clearance sonar system*
		Lighting System (for HV 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	Perform Vehicle Identification Number (VIN) registration	MIL illuminates
Gas leak from exhaust system is repaired Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body 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 spark plug Replacement of ignition coil assembly Replacement of EGR valve assembly Replacement of knock control sensor Replacement of fuel pressure sensor (fuel delivery pipe with sensor assembly) (for low pressure side) Replacement of engine coolant temperature sensor	Inspection After Repair	Poor idle, etc. Engine start function, etc.
Replacement of inverter with converter assembly	Resolver learning	DTCs are stored Slight vibration at a vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration
Replacement of hybrid vehicle transaxle assembly	Resolver learning Initialize resolver
Front wheel alignment adjustment	Clear zero point calibration data. Perform yaw rate and acceleration sensor zero point calibration.	DTCs are stored ABS warning light illuminates Brake warning light / yellow (minor malfunction) illuminates Slip indicator light illuminates VSC disabled or malfunctions
Suspension, tires, etc.*1 Replacement of front bumper assembly	Measurement of ultrasonic sensor detection angle Ultrasonic sensor detection angle registration	Intelligent clearance sonar system Intuitive parking assist system
Suspension, tires, etc.*1	Rear television camera assembly optical axis (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.*1	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 headlight ECU sub-assembly LH Replacement of headlight assembly LH	Synchronize the vehicle information	Lighting system (for HV Model with Cornering Light)

*: When performing learning using the Techstream.
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*1: If the vehicle height has changed due to suspension or tire replacement

NOTICE:

This procedure includes the removal 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 ENGINE ASSEMBLY TO ENGINE STAND

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2. REMOVE ENGINE HANGERS

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3. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

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4. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

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

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6. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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7. REMOVE MANIFOLD STAY

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8. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

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9. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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10. REMOVE THROTTLE BODY GASKET

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11. REMOVE EGR COOLER ASSEMBLY

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12. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

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13. REMOVE EGR VALVE ASSEMBLY

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14. REMOVE NO. 3 WATER BY-PASS PIPE

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15. REMOVE NO. 2 WATER BY-PASS PIPE

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16. REMOVE INTAKE MANIFOLD

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17. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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18. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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19. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

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

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21. REMOVE NO. 7 WATER BY-PASS HOSE

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22. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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23. REMOVE NO. 1 DELIVERY PIPE SPACER

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24. REMOVE INJECTOR VIBRATION INSULATOR

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25. REMOVE NO. 5 ENGINE WIRE

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26. REMOVE PORT FUEL INJECTOR ASSEMBLY

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27. REMOVE FUEL DELIVERY PIPE

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28. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

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29. REMOVE IGNITION COIL ASSEMBLY

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30. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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31. REMOVE OIL PRESSURE CONTROL VALVE ASSEMBLY

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32. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

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33. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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34. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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35. REMOVE O-RING

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36. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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37. REMOVE CAM TIMING CONTROL MOTOR O-RING

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38. REMOVE CRANKSHAFT PULLEY ASSEMBLY

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39. REMOVE WATER OUTLET

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40. REMOVE WATER BY-PASS OUTLET

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41. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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42. REMOVE SPARK PLUG TUBE GASKET

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43. REMOVE ENGINE MOUNTING BRACKET RH

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44. REMOVE NO. 2 TIMING CHAIN COVER ASSEMBLY

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45. REMOVE TIMING CHAIN COVER OIL SEAL

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46. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

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47. REMOVE OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

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48. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

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49. REMOVE CHAIN SUB-ASSEMBLY

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50. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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51. REMOVE CHAIN TENSIONER SLIPPER

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52. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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53. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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54. REMOVE TIMING CHAIN COVER ASSEMBLY

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55. REMOVE FUEL PUMP LIFTER GUIDE

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56. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

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57. REMOVE CAMSHAFT BEARING CAP

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58. REMOVE CAMSHAFT

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59. REMOVE NO. 2 CAMSHAFT

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60. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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61. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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62. REMOVE VALVE STEM CAP

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63. REMOVE CYLINDER HEAD SUB-ASSEMBLY

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64. REMOVE CYLINDER HEAD GASKET

(a) Remove the cylinder head gasket from the cylinder block sub-assembly.

65. INSPECT CYLINDER HEAD SET BOLT

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66. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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