2005 Toyota Avalon Service & Repair Manual

010Q8−05 N17080 Filler Cap Float Reservoir Tank z Grommet Clip Slotted Spring Pin : Specified torque z Non−reusable part Cylinder Piston Push Rod Washer Snap Ring Boot z Gasket Lock Nut Clevis Pin Clevis N·m (kgf·cm, ft·lbf) 12 (120, 9) 15 (155, 11) − INTRODUCTION HOW TO USE THIS MANUAL 01−1 1 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) HOW TO USE THIS MANUAL GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (1) Diagnosis (2) Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting (3) Final Inspection (b) This manual explains (1) (see ”Diagnostics” section) and (2). (3) is omitted. (c) The following procedures are omitted from this manual. However, these procedures are essential and must be performed when applicable. (1) Using a jack or lift to perform operations (2) Cleaning a removed part (3) Performing a visual check 2. INDEX (a) An alphabetical INDEX section is provided at the end of the book as a reference to help you find the item to be repaired. 3. PREPARATION (a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the ”Preparation” section of this manual. 4. REPAIR PROCEDURES (a) A component illustration is placed under the title where necessary. (b) Non−reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. Example:

Illustration: what to do and where Component part No. Explanation text: how to perform task Task heading: what you will be doing Set part No. INSTALL FRONT AXLE HUB BEARING D32545 01−2 − INTRODUCTION HOW TO USE THIS MANUAL 2 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) (c) Torque specifications, grease application areas and non−reusable parts are emphasized in the procedures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc. are described in the illustration. (d) Only items with key points are described in the text. What to do and other details are placed in illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. (e) Illustrations of similar vehicle models are sometimes used. In those cases, specific details may be dif- ferent from the actual vehicle. (f) Procedures are presented in a step−by−step format: (1) The illustration shows what to do and where to do it. (2) The task heading tells what to do. (3) The explanation text tells how to perform the task. It also has information such as specifications and warnings. Example: HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task headings are easy to read and the text below the task heading provides detailed information. Important specifications and warnings are always written in bold type. 5. SERVICE SPECIFICATIONS (a) SPECIFICATIONS are presented in bold−faced text throughout the manual. The specifications are also found in the ”Service Specifications” section for quick reference. 6. TERMS DEFINITION CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs. 7. SI UNIT (a) The units used in this manual comply with the SI UNIT (International System of Units) standard. Units from the metric system and the English system are also provided. Example: Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf)

024QE−01 − PREPARATION ENGINE MECHANICAL 02−7 58 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) ENGINE MECHANICAL PREPARATION SST 09011−38121 12 mm Socket Wrench for 12 Pointed Head CYLINDER BLOCK ASSY(2GR−FE) 09032−00100 Oil Pan Seal Cutter CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 09201−10000 Valve Guide Bushing Remover & Replacer Set CYLINDER HEAD ASSY(2GR−FE) (09201−01050) Valve Guide Bushing Remover & Replacer 5 CYLINDER HEAD ASSY(2GR−FE) 09201−41020 Valve Stem Oil Seal Replacer CYLINDER HEAD ASSY(2GR−FE) 09202−00020 Attachment CYLINDER HEAD ASSY(2GR−FE) 09202−70020 Valve Spring Compressor CYLINDER HEAD ASSY(2GR−FE) (09202−00010) Attachment CYLINDER HEAD ASSY(2GR−FE) 09213−70011 Crankshaft Pully Holding Tool PARTIAL ENGINE ASSY(2GR−FE) CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) ENGINE REAR OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) (09213−70020) Bolt PARTIAL ENGINE ASSY(2GR−FE) CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) ENGINE REAR OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 09222−30010 Connecting Rod Bushing Remover & Replacer CYLINDER BLOCK ASSY(2GR−FE)

02−8 − PREPARATION ENGINE MECHANICAL 59 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) 09223−15030 Oil Seal & Bearing Replacer ENGINE REAR OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 09228−06501 Oil Filter Wrench PARTIAL ENGINE ASSY(2GR−FE) 09249−63010 Torque Wrench Adaptor DRIVE BELT(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) 09276−75010 Valve Lifter Tool CYLINDER HEAD GASKET(2GR−FE) CYLINDER HEAD GASKET NO.2(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 09316−60011 Transmission & Transfer Bearing Replacer CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) (09316−00011) Replacer Pipe CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 09330−00021 Companion Flange Holding Tool PARTIAL ENGINE ASSY(2GR−FE) CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) ENGINE REAR OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 09628−62011 Ball Joint Puller PARTIAL ENGINE ASSY(2GR−FE) 09843−18030 Tacho−pulse Pickup Wire No. 2 ENGINE(2GR−FE) 09843−18040 Diagnosis Check Wire No. 2 ENGINE(2GR−FE) 09930−00010 Drive Shaft Nut Chisel PARTIAL ENGINE ASSY(2GR−FE)

− PREPARATION ENGINE MECHANICAL 02−9 60 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) 09950−50013 Puller C Set CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) (09951−05010) Hanger 150 CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) (09952−05010) Slide Arm CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) (09953−05020) Center Bolt 150 CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) (09954−05021) Claw No. 2 CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 09950−60010 Replacer Set CYLINDER BLOCK ASSY(2GR−FE) (09951−00340) Replacer 34 CYLINDER BLOCK ASSY(2GR−FE) 09950−70010 Handle Set ENGINE REAR OIL SEAL(2GR−FE) CYLINDER HEAD ASSY(2GR−FE) CYLINDER BLOCK ASSY(2GR−FE) (09951−07100) Handle 100 CYLINDER HEAD ASSY(2GR−FE) CYLINDER BLOCK ASSY(2GR−FE) (09951−07150) Handle 150 ENGINE REAR OIL SEAL(2GR−FE) 09992−00500 Compression Gauge Attachment ENGINE(2GR−FE)

02−10 − PREPARATION ENGINE MECHANICAL 61 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) Recommended Tools 09011−12301 Socket Wrench 30 mm PARTIAL ENGINE ASSY(2GR−FE) 09040−00011 Hexagon Wrench Set PARTIAL ENGINE ASSY(2GR−FE) CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) CYLINDER HEAD ASSY(2GR−FE) CYLINDER BLOCK ASSY(2GR−FE) (09043−20060) Socket Hexagon Wrench 6 PARTIAL ENGINE ASSY(2GR−FE) (09043−20080) Socket Hexagon Wrench 8 PARTIAL ENGINE ASSY(2GR−FE) CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) (09043−20050) Socket Hexagon Wrench 5 CYLINDER BLOCK ASSY(2GR−FE) (09043−20100) Socket Hexagon Wrench 10 PARTIAL ENGINE ASSY(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) CYLINDER HEAD ASSY(2GR−FE) (09043−30140) Straight Hexagon Wrench 14 CYLINDER HEAD ASSY(2GR−FE) 09043−30190 Straight Hexagon Wrench 19 CYLINDER HEAD ASSY(2GR−FE) 09043−50100 Bi−hexagon Wrench 10 mm CYLINDER HEAD GASKET(2GR−FE) CYLINDER HEAD GASKET NO.2(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 09090−04020 Engine Sling Device PARTIAL ENGINE ASSY(2GR−FE) CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) CYLINDER HEAD GASKET(2GR−FE) CYLINDER HEAD GASKET NO.2(2GR−FE) 09200−00010 Engine Adjust Kit PARTIAL ENGINE ASSY(2GR−FE) (09857−00031) Spark Plug Gap Gauge ENGINE(2GR−FE)

− PREPARATION ENGINE MECHANICAL 02−11 62 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) SSM 08826−00080 Seal Packing Black or equivalent (FIPG) CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) CYLINDER HEAD GASKET(2GR−FE) CYLINDER HEAD GASKET NO.2(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 08826−00100 ”Seal Packing 1282B” THREE BOND 1282B or equivalent (FIPG) CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) 08833−00070 ”Adhesive 1324” THREE BOND 1324 or equivalent PARTIAL ENGINE ASSY(2GR−FE) CHAIN SUB−ASSY(2GR−FE) CAMSHAFT (RH BANK)(2GR−FE) CAMSHAFT (LH BANK)(2GR−FE) ENGINE REAR OIL SEAL(2GR−FE) PARTIAL ENGINE ASSY(2GR−FE) CYLINDER BLOCK ASSY(2GR−FE) 08833−00080 ”Adhesive 1344” THREE BOND 1344 LOCTITE 242 or equivalent PARTIAL ENGINE ASSY(2GR−FE) Equipment Abrasive compound Brush Caliper gauge Carbide cutter (30_) Carbide cutter (45_) Carbide cutter (60_) Carbide cutter (75_) Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune−up tester Groove cleaning tool Heater Micrometer Pin hole grinder Piston ring compressor Piston ring expander Plastigage Precision straight edge Press Reamer (5.5 mm) Ridge reamer Soft brush Solvent Spring tester

02−12 − PREPARATION ENGINE MECHANICAL 63 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) Steel square Thermometer Torque wrench Torx ® socket wrench Valve seat cutter Valve guide bushing brush V−block Vernier caliper Wire brush Bar Chain Block CO/HC meter Compression gauge Dial indicator with magnetic base Engine Sling Device Feeler gauge Radiator cap tester Slide calipers Tachometer Timing light Wooden block Deep socket wrench 24 mm

024Q5−01 − PREPARATION EXHAUST 02−13 64 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) EXHAUST PREPARATION Equipment Torque wrench Exhaust pipe assy

024Q4−01 02−14 − PREPARATION COOLING 65 Author: Date: 2005 AVALON REPAIR MANUAL (RM1169U) COOLING PREPARATION SST 09213−70011 Crankshaft Pully Holding Tool WATER PUMP ASSY(2GR−FE) (09213−70020) Bolt WATER PUMP ASSY(2GR−FE) 09230−01010 Radiator Service Tool Set RADIATOR ASSY(2GR−FE) (09231−01010) Overhaul Handle RADIATOR ASSY(2GR−FE) (09231−01030) Claw RADIATOR ASSY(2GR−FE) 09231−14010 Punch RADIATOR ASSY(2GR−FE) 09330−00021 Companion Flange Holding Tool WATER PUMP ASSY(2GR−FE) 09950−50013 Puller C Set WATER PUMP ASSY(2GR−FE) (09951−05010) Hanger 150 WATER PUMP ASSY(2GR−FE) (09952−05010) Slide Arm WATER PUMP ASSY(2GR−FE) (09953−05020) Center Bolt 150 WATER PUMP ASSY(2GR−FE) (09954−05021) Claw No. 2 WATER PUMP ASSY(2GR−FE)

2005 Toyota Avalon Service & Repair Manual

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