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Home >> Toyota >> 2015 >> Avalon Hybrid Limited >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (Service Information) (Hybrid) >> Engine Assembly & Engine Under Cover >> Removal [10/2014 - ] >> Procedure

Removal [10/2014 - ]: Procedure

  1. PRECAUTION 
    WARNING:
    • The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the appropriate repair information, or the engine lifter may suddenly drop.
    • The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in the appropriate repair information to handle the system correctly. Failure to do so may result in serious injury or electrocution (Refer to PRECAUTION [10/2014 - ] ).
    NOTE:

    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 (Refer to PRECAUTION [10/2014 - ] ).

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISCHARGE FUEL SYSTEM PRESSURE 

    (Refer to PRECAUTION [10/2014 - ] )

  4. REMOVE SERVICE PLUG GRIP 

    (Refer to REMOVAL [10/2014 - ] )

  5. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  6. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 3

  7. REMOVE FRONT WHEELS 
  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 
  9. REMOVE ENGINE UNDER COVER RH 
  10. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 
  11. REMOVE ENGINE UNDER COVER LH 
  12. REMOVE FRONT FENDER APRON SEAL LH 
  13. REMOVE FRONT FENDER APRON SEAL RH 
  14. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 1

  15. DRAIN COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  16. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 1

  17. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 1

  18. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Lift the rear of the No. 1 engine cover sub-assembly to detach it from the 2 pins.
      GTY373455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lift the front of the No. 1 engine cover sub-assembly to detach it from the pin and remove it.
      NOTE:

      Attempting to disengage both front and rear pins at the same time may cause the No. 1 engine cover sub-assembly to break.

  19. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 1 and PROCEDURE - Step 1

  20. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 4

  21. CHECK TERMINAL VOLTAGE 

    Refer to PROCEDURE - Step 5

  22. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 6

  23. REMOVE INLET AIR CLEANER ASSEMBLY 
    1. Remove the 2 bolts and inlet air cleaner assembly.
      GTY315521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  25. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
  26. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Remove the 2 bolts and air cleaner case sub-assembly.
      GTY605670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Projection
  27. REMOVE NO. 5 INVERTER BRACKET 

    Refer to PROCEDURE - Step 12

  28. REMOVE NO. 4 INVERTER BRACKET 

    Refer to PROCEDURE - Step 13

  29. REMOVE UPPER INVERTER COVER 

    Refer to PROCEDURE - Step 14

  30. DISCONNECT GENERATOR CABLE 

    Refer to PROCEDURE - Step 15

  31. REMOVE UPPER INVERTER COVER 

    Refer to PROCEDURE - Step 16

  32. DISCONNECT MOTOR CABLE 

    Refer to PROCEDURE - Step 17

  33. REMOVE NO. 3 MOTOR CABLE BRACKET 

    Refer to PROCEDURE - Step 18

  34. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 19

  35. DISCONNECT NO. 4 ENGINE WIRE 

    Refer to PROCEDURE - Step 20

  36. DISCONNECT NO. 4 FLOOR WIRE 

    Refer to PROCEDURE - Step 21

  37. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 22

  38. DISCONNECT LOW VOLTAGE CONNECTOR 

    Refer to PROCEDURE - Step 23

  39. DISCONNECT NO. 3 ENGINE ROOM WIRE 

    Refer to PROCEDURE - Step 24

  40. REMOVE NO. 4 INVERTER COOLING HOSE 

    Refer to PROCEDURE - Step 25

  41. REMOVE NO. 1 INVERTER COOLING HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 26

  42. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to PROCEDURE - Step 27

  43. DISCONNECT NO. 4 ENGINE WIRE 
    1. Disengage the 2 wire harness clamps to disconnect the No. 4 engine wire from the fan shroud.
      GTY380086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. DISCONNECT ENGINE WIRE 
    1. Remove the No. 1 relay block cover.
    2. Disconnect the 4 connectors and disengage the wire harness clamp.
      GTY380090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and disconnect the wire harness and wire harness bracket from the body.
      GTY380092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Pull up the lever to disconnect the ECM connector.
      GTY315515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the wire clamp.
  45. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.
      GTY365486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with clip from the No. 1 transmission control cable bracket.
    3. Remove the clip from the transmission control cable assembly.
    4. Disconnect the transmission control cable assembly from the 2 transmission control brackets.
      GTY365091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Remove the hose clamp to disconnect the air fuel ratio sensor wire from the No. 1 radiator hose.
      GTY322043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clamp and disconnect the No. 1 radiator hose.
  47. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clamp and disconnect the No. 2 radiator hose.
      GTY319433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. DISCONNECT NO. 5 INVERTER COOLING HOSE 
    1. Slide the clamp and disconnect the No. 5 inverter cooling hose from the hybrid vehicle transaxle assembly.
      GTY322042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. DISCONNECT INLET HEATER WATER HOSE 
    1. Slide the clamp and disconnect the inlet heater water hose.
      GTY319434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Slide the clamp and disconnect the outlet heater water hose.
      GTY319432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  52. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the 2 bolts and No. 2 engine mounting stay RH.
      GTY321995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. DISCONNECT EARTH WIRE 
    1. Remove the bolt to disconnect the earth wire from the engine moving control rod bracket.
      GTY315310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE ENGINE MOVING CONTROL ROD BRACKET 
    1. Remove the 4 bolts and engine moving control rod bracket.
      GTY541123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE ENGINE MOVING CONTROL ROD 
    1. Remove the bolt and engine moving control rod and No. 3 engine mounting stay RH from the engine moving control rod bracket.
      GTY319901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Perform this procedure only when replacement of the engine moving control rod is necessary.

  56. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 5

  57. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  58. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to PROCEDURE - Step 5

  59. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 4

  60. REMOVE FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 9

  61. REMOVE FRONT AXLE SHAFT NUT RH 

    HINT: 

    Use the same procedure described for the LH side.

  62. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 4 and PROCEDURE - Step 4

  63. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  64. SEPARATE FRONT SPEED SENSOR LH 

    Refer to PROCEDURE - Step 5

  65. SEPARATE FRONT SPEED SENSOR RH 

    HINT: 

    Use the same procedure described for the LH side.

  66. SEPARATE TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 5

  67. SEPARATE TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  68. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 10

  69. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  70. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  71. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  72. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 15

  73. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH 

    Refer to PROCEDURE - Step 17

  74. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 16

  75. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover.
      GTY315306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transaxle.
      GTY319412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Attachment Installation Position
      NOTE:
      • Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.
      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed or removed from an engine stand.
      • To prevent coolant leaks, do not position the height adjustment attachments or plate lift attachments under the No. 2 motor water jacket cover assembly.
        GTY587654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 No. 2 Motor Water Jacket Cover Assembly
    2. Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH.
      GTY559175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
    3. Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH.
    4. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.
      NOTE:
      • Make sure that the engine is clear of all wiring and hoses.
      • While lowering the engine from the vehicle, do not allow it to contact the vehicle.
    5. Install the engine hangers (See step  20).
    6. Using an engine sling device and engine lift, secure the engine assembly.
  77. DISCONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 2

  78. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine assembly.
  79. REMOVE FRONT FRAME ASSEMBLY 
    1. Remove the bolt to disconnect the wire harness clamp bracket from the front frame assembly.
      GTY380085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to disconnect the No. 4 engine wire from the front engine mounting insulator.
    3. Remove the nut and separate the engine mounting insulator LH.
      GTY318528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and separate the front engine mounting insulator.
      GTY319431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the nut and separate the engine mounting insulator RH.
      GTY318530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the front frame assembly.
    7. Using a height adjustable attachment and plate lift attachment, place the engine assembly on a flat level surface.
      NOTE:
      • Using a height adjustable attachment and plate lift attachment, place the engine assembly with transaxle horizontally.
      • To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.
      • Using an engine sling device and engine lift, secure the engine assembly before service.
  80. REMOVE FRONT ENGINE MOUNTING INSULATOR 
    1. Remove the 3 nuts and front engine mounting insulator.
      GTY315307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Perform this procedure only when replacement of the front engine mounting insulator is necessary.

  81. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the 2 hole plugs from the front frame assembly.
      GTY318527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and engine mounting insulator LH.

      HINT: 

      Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

  82. REMOVE ENGINE MOUNTING INSULATOR RH 
    1. Remove the 2 hole plugs from the front frame assembly.
      GTY318521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and engine mounting insulator RH.

      HINT: 

      Perform this procedure only when replacement of the engine mounting insulator RH is necessary.

  83. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH.
      GTY304895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
      GTY251253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 7

  86. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 4

  87. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 

    See step  2

  88. REMOVE FLYWHEEL SUB-ASSEMBLY 

    See step  3

  89. INSTALL ENGINE STAND 
    1. Install the engine assembly to an engine stand.
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