Toyota Avalon (XX50) 2019-2022 Service & Repair Manual: Disassembly

DISASSEMBLY

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 Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

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

Panoramic View Monitor System

Replacement of ECM

Vehicle Identification Number (VIN) registration

MIL comes on

ECU communication ID registration (Immobiliser system)

Engine start function

  • Replacement of throttle body with motor assembly
  • Cleaning the deposits from the throttle body with motor assembly
  • Replacement of cylinder head sub-assembly
  • Replacement of camshaft (for intake or exhaust camshaft)
  • Replacement of camshaft timing gear assembly
  • Replacement of camshaft timing exhaust gear assembly
  • Replacement of piston or piston ring
  • Replacement of fuel injector assembly (for port injection)
  • Replacement of fuel injector assembly (for direct injection)
  • Replacement of fuel pump assembly (for high pressure side)
  • Replacement of engine coolant temperature sensor
  • Replacement of spark plug
  • Replacement of ignition coil assembly
  • Air leaks from intake system
  • Gas leak from exhaust system is repaired
  • 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 Initialization

for 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

Replacement of ECM

Code registration (Smart Key System (for Start Function))

  • Wireless Door Lock Control System
  • Smart Key System (for Entry Function)
  • Smart Key System (for Start Function)
  • Steering lock function

Suspension, tires, etc.

  • Measure ultrasonic sensor detection angle
  • Ultrasonic sensor detection angle registration
  • Intelligent Clearance Sonar System
  • Intuitive Parking Assist System

Rear television camera assembly optical axis adjustment (Back camera position setting)

Parking Assist Monitor System

for Initialization

for Calibration

  • 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

Perform headlight ECU sub-assembly LH initialization

Lighting system (for Gasoline Model with Cornering Light)

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

  • *1: When performing learning using the Techstream.

    Click here

  • *2: Not necessary when ECM replaced with new one.

PROCEDURE

1. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD

(a) Check that the matchmarks on the connecting rod sub-assembly and connecting rod cap are aligned.

HINT:

The matchmarks on the connecting rod sub-assembly and connecting rod cap are guides for correct reassembly.

(b) Remove the 2 connecting rod bolts.

Front of Engine

(c) Using the 2 removed connecting rod bolts, remove the connecting rod cap and lower connecting rod bearing by wiggling the connecting rod cap right and left.

HINT:

Keep the lower connecting rod bearing installed to the connecting rod cap.

(d) Using a ridge reamer, remove all of the carbon from the top of the cylinder.

*a

Ridge Reamer

(e) Push the piston, connecting rod sub-assembly and upper connecting rod bearing through the top of the cylinder block sub-assembly.

HINT:

  • Keep the connecting rod bearing, connecting rod sub-assembly and connecting rod cap together.
  • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

2. REMOVE CONNECTING ROD BEARING

(a) Remove the connecting rod bearings from the connecting rod sub-assembly and connecting rod cap.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

3. REMOVE PISTON RING SET

(a) Using a piston ring expander, remove the No. 1 compression ring and No. 2 compression ring.

*a

Piston Ring Expander

(b) Remove the oil ring expander and 2 side rails by hand.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

4. REMOVE PISTON

(a) Check the fitting condition between the piston and piston pin.

(1) Try to move the piston back and forth on the piston pin.

HINT:

If abnormal movement is felt, replace the piston and piston pin as a set.

(b) Remove the connecting rod sub-assembly from the piston.

(1) Using a screwdriver, pry out the piston pin hole snap ring (front side).

NOTICE:

  • Do not remove the piston pin hole snap ring (rear side) unless it has to be replaced.
  • Be careful not to damage the piston when removing the piston pin hole snap ring (rear side).

(2) Gradually heat the piston to approximately 80°C (176°F).

CAUTION:

Be sure to wear protective gloves.

(3) Using a brass bar and a hammer, lightly tap out the piston pin and remove the connecting rod sub-assembly.

HINT:

  • The piston and piston pin are a matched set.
  • Arrange the removed parts in such a way that they can be reinstalled to their original locations.

(c) Using a gasket scraper, remove any carbon from the piston top.

NOTICE:

Be careful not to scratch the piston.

(d) Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

(e) Using solvent and a brush, thoroughly clean the piston.

NOTICE:

Do not use a wire brush.

5. REMOVE CRANKSHAFT

(a) Uniformly loosen and remove the 8 crankshaft bearing cap set bolts and 8 seal washers in several steps in the order shown in the illustration.

(b) Uniformly loosen the 16 crankshaft bearing cap set bolts in several steps in the order shown in the illustration.

(c) Using a screwdriver with its tip wrapped with protective tape, pry out the crankshaft bearing caps. Remove the 4 crankshaft bearing caps and 4 lower crankshaft bearings as a set.

NOTICE:

  • Push up the crankshaft bearing cap slowly and evenly, alternating between the right and left side so that the crankshaft bearing cap can be removed.
  • Be careful not to damage the contact surfaces of the cylinder block sub-assembly and the crankshaft bearing cap.

*1

Cylinder Block Sub-assembly

*2

Crankshaft Bearing Cap

*a

Protective Tape

*b

Contact Surface

(d) Remove the crankshaft.

6. REMOVE CRANKSHAFT BEARING

(a) Remove the upper crankshaft bearings and lower crankshaft bearings.

HINT:

Arrange the removed parts in such a way that they can be reinstalled to their original locations.

7. REMOVE CRANKSHAFT THRUST WASHER SET

(a) Remove the crankshaft thrust washer set from the cylinder block sub-assembly.

8. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY

(a) Using a 5 mm hexagon socket wrench, remove the 3 bolts and 3 No. 1 oil nozzle sub-assemblies.

(b) Check the 3 No. 1 oil nozzle sub-assemblies for damage or clogging.

HINT:

If there is damage or clogs, replace the No. 1 oil nozzle sub-assembly.

    Components

    Inspection

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