Toyota Avalon Service & Repair Manual: Removal

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 hybrid vehicle transaxle 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

*: When performing learning using the Techstream.

Click here

*1: The vehicle height changes because of suspension or tire replacement

Auxiliary 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*

Lighting system (w/ AFS)(EXT)

Memorize steering angle neutral point

Parking assist monitor system

Panoramic view monitor system

Replacement of ECM

Perform Vehicle Identification Number (VIN) registration

MIL illuminates

  • Replacement of engine assembly
  • Replacement of air fuel ratio sensor (sensor 2)
  • Replacement of engine coolant temperature sensor
  • Gas leak from exhaust system is repaired

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

  1. Clear zero point calibration data.
  2. 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)
  • Replacement of headlight ECU sub-assembly LH
  • Replacement of headlight assembly LH

Synchronize the vehicle information

Lighting system (for HV Model with Cornering Light)

CAUTION:

  • Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

    Click here

  • To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
  • To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.
  • To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
  • 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

  • The hybrid vehicle transaxle assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the transmission jack may suddenly drop or a part may fall.

    *a

    Object Exceeding Weight Limit of Transmission Jack

NOTICE:

  • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here

  • If the ECM has been struck or dropped, replace it.
  • Perform Vehicle Identification Number (VIN) registration when replacing the ECM.

    Click here

PROCEDURE

1. PERFORM RESOLVER INITIALIZATION

NOTICE:

If it is necessary to replace the hybrid vehicle transaxle assembly, make sure to perform resolver initialization before starting work.

Click here

2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

Click here

3. REMOVE FUEL DELIVERY GUARD

Click here

4. INSTALL ENGINE HANGERS

Click here

5. REMOVE STEERING GEAR HEAT INSULATOR

Click here

6. DISCONNECT ENGINE WIRE

(a) Remove the 2 bolts.

(b) Disconnect the 5 clamps.

(c) Disconnect the wire harness connector from the rack and pinion power steering gear assembly.

HINT:

Release the lock before rotating the lock lever.

(d) Remove the 2 bolts and separate the wire harness from the rack and pinion power steering gear assembly.

7. DISCONNECT HV AIR CONDITIONING WIRE

(a) Remove the bolt.

(b) Disengage the guide to disconnect the HV air conditioning wire from the hybrid vehicle transaxle assembly.

8. REMOVE STARTER HOLE INSULATOR

(a) Remove the 2 bolts and starter hole insulator from the engine assembly.

9. REMOVE FLYWHEEL HOUSING SIDE COVER

(a) Remove the flywheel housing side cover from the engine assembly.

10. REMOVE FRONT FRAME ASSEMBLY

Click here

11. REMOVE FRONT ENGINE MOUNTING INSULATOR

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

12. REMOVE FRONT ENGINE MOUNTING BRACKET

(a) Remove the 3 bolts and front engine mounting bracket from the hybrid vehicle transaxle assembly.

13. REMOVE REAR ENGINE MOUNTING INSULATOR

Click here

14. REMOVE REAR ENGINE MOUNTING BRACKET

(a) Remove the 4 bolts and rear engine mounting bracket from the hybrid vehicle transaxle assembly.

15. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

(a) Remove the 8 bolts and hybrid vehicle transaxle assembly from the engine assembly.

NOTICE:

  • To avoid damaging the knock pins, do not pry between the hybrid vehicle transaxle assembly and engine assembly.
  • To prevent the splines of the transmission input damper assembly from becoming misaligned, do not allow the hybrid vehicle transaxle assembly to hit the transmission input damper assembly during hybrid vehicle transaxle assembly removal and installation.

16. REMOVE MOTOR CABLE

Click here

17. REMOVE MOTOR COOLING COOLER

Click here

18. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Remove the 2 bolts and No. 1 transmission control cable bracket from the hybrid vehicle transaxle assembly.

19. REMOVE HOSE BRACKET

(a) Remove the 2 bolts and hose bracket from the hybrid vehicle transaxle assembly.

20. REMOVE TRANSMISSION WIRE

(a) Disconnect the connector.

(b) Remove the bolt and transmission wire from the hybrid vehicle transaxle assembly.

21. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the 4 bolts and 4 wire harness clamp brackets from the hybrid vehicle transaxle assembly.

22. REMOVE TRANSAXLE HOUSING PLUG

(a) Remove the transaxle housing plug and gasket from the hybrid vehicle transaxle assembly.

23. REMOVE STUD BOLT

(a) Using a E8 "TORX" socket wrench, remove the 2 stud bolts from the hybrid vehicle transaxle assembly.

24. REMOVE TRANSAXLE CASE PROTECTOR

(a) Remove the 2 bolts.

*1

Clip

(b) Remove the clip and transaxle case protector from the hybrid vehicle transaxle assembly.

    Installation

    Input Shaft Oil Seal

    See More:

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