2005 Toyota Avalon Service & Repair Manual

FOREWORD This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA AVALON. Applicable models: GSX30 series This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fend- ers of the TOYOTA model is bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collision- damaged body components of the TOYOTA AVALON refer to the repair manuals. If you require the above manuals, please contact your TOYOTA Dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice.

VIEWS OF THIS TEXT Scope of the repair work explanation D This text explains the welding panel replacement instructions from the vehicle’s white body condition. We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel. Section categories D Each section has been divided as shown below. Section Title Contents Examples INTRODUCTION Explanation of general body repair. Views of weld panel replacement instructions. Cautionary items. Views of weld panel replacement instructions. BODY PANEL REPLACEMENT Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts. Front side member replacement. Quarter panel replacement. BODY DIMENSIONS Body aligning measurements. Dimension diagrams. PAINT D COATING Scope and type of anti-rust treatment, etc. together with weld panel replacement. Under coat. Body sealer. Abbreviation of contents in this text. D The following essential procedures have been abbreviated. When actually working, conduct this work properly. (1) Jack and lift operations. (2) Clean and wash removed parts, if necessary. (3) Visual inspection.

F10004A F10001A F10002A F10003A Glass Cover Seat Cover WRONG WRONG INTRODUCTION IN-1 GENERAL REPAIR INSTRUCTIONS 1. WORK PRECAUTIONS (a) VEHICLE PROTECTION (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fire-proof covers. (b) SAFETY (1) Never stand in direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable. (2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening totally. (3) If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line. (c) SAFETY WORK CLOTHES (1) In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands. Code Name A Dust-Prevention Mask B Face Protector C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves

INTRODUCTION IN-2 2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS (1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following table. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must be given to the property of the plastic. Code Material name Heat * resistant temperature limit _C (_F) Resistance to alcohol or gasoline Notes AAS Acrylonitrile Acrylic Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ABS Acrylonitrile Butadiene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. AES Acrylonitrile Ethylene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ASA Acrylonitrile Styrene Acrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. CAB Cellulose Acetate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. EPDM Ethylene Propylene 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. FRP Fiber Reinforced Plastics 180 (356) Alcohol and gasoline are harmless. Avoid alkali. EVA Ethylene Acetate 70 (158) Alcohol is harmless if applid only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. E / VAC Ethylene / Vinyl Acetate Copolymer Resin 70 (158) Alcohol is harmless if applid only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. PA Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless. Avoid battery acid. PBT Polybutylene Terephthalate 160 (320) Alcohol and gasoline are harmless. Most solvents are harmless. PC Polycarbonate 120 (248) Alcohol is harmless. Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali. *Temperatures higher than those listed here may result in material deformation during repair.

INTRODUCTION IN-3 Code Material name Heat * resistant temperature limit _C (_F) Resistance to alcohol or gasoline Notes PE Polyethylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PET Polyethylene Terephthalate 75 (167) Alcohol and gasoline are harmless. Avoid dipping in water. PMMA Polymethyl Methacrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. POM Polyoxymethylene (Polyacetal) 100 (212) Alcohol and gasoline are harmless. Most solvents are harmless. PP Polypropylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PPF Composite Reinforced Polypropylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PPO Modified Polyphenylene Oxide 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for quick wiping to remove grease. PS Polystyrene 60 (140) Alcohol and gasoline are harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PUR Polyurethane 80 (176) Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PVC Polyvinylchloride (Vinyl) 80 (176) Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. SAN Styrene Acrylonitrile 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents etc. TPO Thermoplastic Olefine 80 (176) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. TPU Thermoplastic Polyurethane 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. TSOP TOYOTA Super Olefine Polymer 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. UP Unsaturated Polyester 110 (233) Alcohol and gasoline are harmless. Avoid alkali. *Temperatures higher than those listed here may result in material deformation during repair.

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2005 Toyota Avalon Service & Repair Manual

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