2005 Toyota Camry Service & Repair Manual

0108G−07 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 CAMRY REPAIR MANUAL (RM1121U) HOW TO USE THIS MANUAL GENERAL INFORMATION 1. GENERAL DESCRIPTION (a) This manual is written in accordance with SAE J2008. (b) Repair operations can be separated into 3 main processes: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting 3. Final Inspection (c) This manual explains the ”Diagnosis” (found in the ”Diagnostics” section) and ”Removing and Instal- ling, Replacing, Disassembling, Installing and Checking, and Adjusting”. ”Final Inspection” is omitted. (d) The following essential operations are not written in this manual. However, these operations must be performed in actual situations. (1) Operations with a jack or lift (2) Cleaning of a removed part when necessary (3) 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 situation. 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) Component drawing is placed under the title where necessary. (b) Non−reusable parts, grease application areas, precoated parts and tightening torque are specified in the component drawings. Example:

Illustration: what to do and where Component part No. Detailed text: how to perform task Task heading: what you will be doing Set part No. INSTALL FRONT AXLE HUB BEARING <FRONT AXLE HUB BEARING OUTER LH> The ”< >” marks highlight the part’s name in the Parts Catalog D31332 01−2 − INTRODUCTION HOW TO USE THIS MANUAL 2 Author: Date: 2005 CAMRY REPAIR MANUAL (RM1121U) (c) Tightening torque, grease application areas, and non−reusable parts are described as important points 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) The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. (e) 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. (f) Illustrations of similar models are sometimes used. In those cases, specific details may be different from the actual vehicle. (g) 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 text where needed. 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 the components being repaired. HINT Provides additional information to help you perform repairs.

− INTRODUCTION HOW TO USE THIS MANUAL 01−3 3 Author: Date: 2005 CAMRY REPAIR MANUAL (RM1121U) 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)

0307K−02 4 5 6 7 8 9 10 11 B06431 Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt Class 4T 5T 6T 7T 8T 9T 10T 11T No Mark w/ Washer No Mark No Mark w/ Washer − SERVICE SPECIFICATIONS STANDARD BOLT 03−1 116 Author: Date: 2005 CAMRY REPAIR MANUAL (RM1121U) STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH

0307L−02 03−2 − SERVICE SPECIFICATIONS STANDARD BOLT 117 Author: Date: 2005 CAMRY REPAIR MANUAL (RM1121U) SPECIFIED TORQUE FOR STANDARD BOLTS Class Diameter mm Pitch mm Specified torque Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 4T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 5 12.5 26 47 74 115 55 130 260 480 760 1,150 48 in.·lbf 9 19 35 55 83 6 14 29 53 84 − 60 145 290 540 850 − 52 in.·lbf 10 21 39 61 − 5T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 6.5 15.5 32 59 91 140 65 160 330 600 930 1,400 56 in.·lbf 12 24 43 67 101 7.5 17.5 36 65 100 − 75 175 360 670 1,050 − 65 in.·lbf 13 26 48 76 − 6T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 8 19 39 71 110 170 80 195 400 730 1,100 1,750 69 in.·lbf 14 29 53 80 127 9 21 44 80 125 − 90 210 440 810 1,250 − 78 in.·lbf 15 32 59 90 − 7T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 10.5 25 52 95 145 230 110 260 530 970 1,500 2,300 8 19 38 70 108 166 12 28 58 105 165 − 120 290 590 1,050 1,700 − 9 21 43 76 123 − 8T 8 10 12 1.25 1.25 1.25 29 61 110 300 620 1,100 22 45 80 33 68 120 330 690 1,250 24 50 90 9T 8 10 12 1.25 1.25 1.25 34 70 125 340 710 1,300 25 51 94 37 78 140 380 790 1,450 27 57 105 10T 8 10 12 1.25 1.25 1.25 38 78 140 390 800 1,450 28 58 105 42 88 155 430 890 1,600 31 64 116 11T 8 10 12 1.25 1.25 1.25 42 87 155 430 890 1,600 31 64 116 47 97 175 480 990 1,800 35 72 130

030EM−04 03−6 − SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM 121 Author: Date: 2005 CAMRY REPAIR MANUAL (RM1121U) TORQUE SPECIFICATION 2AZ−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf Throttle body assy x Intake manifold 30 306 22 Knock sensor x Cylinder block sub−assy 20 199 14 Intake manifold x Cylinder head sub−assy 30 306 22 ECM x Instrument panel reinforcement 5.5 56 49 in.⋅lbf ECM x Blower assy 5.5 56 49 in.⋅lbf Accelerator pedal rod assy x Body 7.5 76 66 in.⋅lbf 1MZ−FE/3MZ−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf Front suspension upper brace center x Body (w/ Performance Rod) 80 815 59 V−bank cover sub−assy x Cylinder head cover sub−assy LH 7.9 81 70 in.⋅lbf Throttle body assy x Intake air connector 11 112 8 Air cleaner cap sub−assy x Air cleaner case sub−assy 5.0 51 44 in.⋅lbf Knock sensor x Cylinder block sub−assy 1MZ−FE 39 398 29 Knock sensor x Cylinder block sub−assy 3MZ−FE 20 199 14 Water outlet x Cylinder head sub−assy 15 153 11 Water outlet x Cylinder head LH 15 153 11 Intake manifold x Cylinder head sub−assy 15 153 11 Intake manifold x Cylinder head LH 15 153 11 Ground cable x Intake manifold 8.4 86 74 in.⋅lbf ECM x Instrument panel reinforcement 5.5 56 49 in.⋅lbf ECM x Blower assy 5.5 56 49 in.⋅lbf Accelerator pedal rod assy x Body 7.5 76 66 in.⋅lbf

030EN−04 − SERVICE SPECIFICATIONS FUEL 03−7 122 Author: Date: 2005 CAMRY REPAIR MANUAL (RM1121U) FUEL SERVICE DATA 2AZ−FE: Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm 2 , 44 to 50 psi) Fuel pressure 147 kPa (1.5 kgf/cm 2 , 21 psi) or more Fuel injector Resistance at 20_C (68_F) Injection volume Difference between each cylinder Fuel leakage 13.4 to 14.2Ω 76 to 91 cm 2 (4.6 to 5.5 cu in.) per 15 seconds 15 cm 3 (0.9 cu in.) or less 1 drop or less per 12 minutes Fuel pump Resistance at 20_C (68_F) 0.2 to 3.0 Ω 1MZ−FE/3MZ−FE: Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm 2 , 44 to 50 psi) Fuel pressure 147 kPa (1.5 kgf/cm 2 , 21 psi) or more Fuel injector Resistance at 20_C (68_F) Injection volume Difference between each cylinder Fuel leakage 13.4 to 14.2Ω 60 to 73 cm 2 (3.7 to 4.5 cu in.) per 15 seconds 13 cm 3 (0.8 cu in.) or less 1 drop or less per 12 minutes Fuel pump Resistance at 20_C (68_F) 0.2 to 3.0 Ω

030EO−03 03−8 − SERVICE SPECIFICATIONS FUEL 123 Author: Date: 2005 CAMRY REPAIR MANUAL (RM1121U) TORQUE SPECIFICATION 2AZ−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf Fuel delivery pipe x Cylinder head 20 204 15 Fuel tank bent tube set plate x Fuel tank assy 5.9 60 52 in.⋅lbf Fuel main tube support x Fuel tank assy 5.4 55 48 in.⋅lbf Fuel tank band sub−assy No. 1 RH x Body 39 400 29 Fuel tank band sub−assy No. 1 LH x Body 39 400 29 Fuel tank protector lower center x Fuel tank assy 5.4 55 48 in.⋅lbf Packing brake cable assy No. 2 x Body 5.4 55 48 in.⋅lbf Packing brake cable assy No. 3 x Body 5.4 55 48 in.⋅lbf Exhaust pipe assy center x Exhaust pipe assy front 56 571 41 Exhaust pipe assy center x Exhaust pipe assy tail 56 571 41 Floor panel brace rear x Body 20 199 14 1MZ−FE/3MZ−FE: Part Tightened N⋅m kgf⋅cm ft⋅lbf Fuel delivery pipe sub−assy x Intake manifold 10 102 7 Fuel delivery pipe No. 2 x Intake manifold 10 102 7 Fuel pipe No. 2 union bolt x Fuel delivery pipe No. 2 33 331 24 Fuel pressure pulsation damper assy x Fuel delivery pipe sub−assy 33 331 24 Fuel pipe sub−assy No. 1 x Intake manifold 20 199 14 Surge tank stay No. 2 x Intake air surge tank 20 199 14 Surge tank stay No. 2 x Cylinder head 20 199 14 Surge tank stay No. 1 x Intake air surge tank 20 199 14 Surge tank stay No. 1 x Cylinder head 20 199 14 Engine hunger No. 1 x Intake air surge tank 20 199 14 Engine hunger No. 1 x Cylinder head 20 199 14 Pressure feed tube assy x Engine hunger No. 1 7.8 80 69 in.⋅lbf Intake air surge tank x Intake manifold 28 286 21 Emission control valve set x Emission control valve bracket 8.0 80 71 in.⋅lbf Fuel tank bent tube set plate x Fuel tank assy 5.9 60 52 in.⋅lbf Fuel main tube support x Fuel tank assy 5.4 55 48 in.⋅lbf Fuel tank band sub−assy No. 1 RH x Body 39 400 29 Fuel tank band sub−assy No. 1 LH x Body 39 400 29 Fuel tank protector lower center x Fuel tank assy 5.4 55 48 in.⋅lbf Packing brake cable assy No. 2 x Body 5.4 55 48 in.⋅lbf Packing brake cable assy No. 3 x Body 5.4 55 48 in.⋅lbf Exhaust pipe assy center x Exhaust pipe assy front 56 571 41 Exhaust pipe assy center x Exhaust pipe assy tail 56 571 41 Floor panel brace rear x Body 20 199 14

030EP−04 − SERVICE SPECIFICATIONS EMISSION CONTROL 03−9 124 Author: Date: 2005 CAMRY REPAIR MANUAL (RM1121U) EMISSION CONTROL SERVICE DATA 2AZ−FE: VSV for CCV Resistance at 20 _C (68 _F) at 100 _C (212 _F) 25 to 30 Ω 32 to 40 Ω VSV for EVAP Resistance 1 − 2 1 − Body ground 2 − Body ground 26 to 30 Ω at 20 _C (68 _F) 10 kΩ or higher 10 kΩ or higher Air fuel ratio sensor Resistance 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 0.8 to 1.4 Ω at 20 _C (68 _F) 1.8 to 3.2 Ω at 800 _C (1,472 _F) Heated oxygen sensor (Bank 1 Sensor 2) Resistance 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 11 to 16 Ω at 20 _C (68 _F) 23 to 32 Ω at 800 _C (1,472 _F) 1MZ−FE/3MZ−FE: VSV for CCV Resistance at 20 _C (68 _F) at 100 _C (212 _F) 25 to 30 Ω 32 to 40 Ω VSV for EVAP Resistance 1 − 2 1 − Body ground 2 − Body ground 26 to 30 Ω at 20 _C (68 _F) 10 kΩ or higher 10 kΩ or higher Air fuel ratio sensor Resistance 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 0.8 to 1.4 Ω at 20 _C (68 _F) 1.8 to 3.2 Ω at 800 _C (1,472 _F) Heated oxygen sensor (Bank 1 Sensor 2) Resistance 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 11 to 16 Ω at 20 _C (68 _F) 23 to 32 Ω at 800 _C (1,472 _F) Heated oxygen sensor (Bank 2 Sensor 2) Resistance 1 (HT) − 2 (+B) 1 (HT) − 2 (+B) 11 to 16 Ω at 20 _C (68 _F) 23 to 32 Ω at 800 _C (1,472 _F)

030EN−04 − SERVICE SPECIFICATIONS FUEL 03−7 122 Author: Date: 2005 CAMRY REPAIR MANUAL (RM1121U) FUEL SERVICE DATA 2AZ−FE: Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm 2 , 44 to 50 psi) Fuel pressure 147 kPa (1.5 kgf/cm 2 , 21 psi) or more Fuel injector Resistance at 20_C (68_F) Injection volume Difference between each cylinder Fuel leakage 13.4 to 14.2Ω 76 to 91 cm 2 (4.6 to 5.5 cu in.) per 15 seconds 15 cm 3 (0.9 cu in.) or less 1 drop or less per 12 minutes Fuel pump Resistance at 20_C (68_F) 0.2 to 3.0 Ω 1MZ−FE/3MZ−FE: Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm 2 , 44 to 50 psi) Fuel pressure 147 kPa (1.5 kgf/cm 2 , 21 psi) or more Fuel injector Resistance at 20_C (68_F) Injection volume Difference between each cylinder Fuel leakage 13.4 to 14.2Ω 60 to 73 cm 2 (3.7 to 4.5 cu in.) per 15 seconds 13 cm 3 (0.8 cu in.) or less 1 drop or less per 12 minutes Fuel pump Resistance at 20_C (68_F) 0.2 to 3.0 Ω

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2005 Toyota Camry Service & Repair Manual

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