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 proce-
dures.
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 illustra-
tions 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 spec-
ifications 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)
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Description
The Toyota Avalon 2005 Service & Repair Manual provides a comprehensive technical guide for maintaining and repairing your vehicle. This manual is designed to assist both professional mechanics and DIY enthusiasts, offering detailed instructions and illustrations for performing various tasks.
- Schedule maintenance and perform routine tasks, such as oil changes and tire rotations.
- Diagnose and troubleshoot common issues and problems.
- Conduct detailed repairs, from brake jobs to engine overhauls.
- Reference specifications, diagrams, and technical data for a deeper understanding of your vehicle's inner workings.
This manual serves as a valuable resource for anyone looking to understand and maintain their Toyota Avalon 2005 at a professional level. Whether you're a seasoned mechanic or a DIY enthusiast, this manual provides the information and guidance you need to get the job done safely and effectively.
