TOYOTA AVALON 2001 Service Repair Manual

H12124
2 Clips
H12161
Claw
Claw
H121623 Clips
H08965
H10479
Protective
Tape
- BODYBACK WINDOW GLASS
BO-71
1856 Author
: Date
:
2001 AVALON (RM808U)
(b) Remove the package tray trim as shown in the illustration.
5. REMOVE UPPER BLACK SILENCER
6. w/ Rear personal light:
REMOVE REAR PERSONAL LIGHT
(a) Using a screwdriver, remove the rear personal light, then
disconnect the connector.
HINT:
Tape the screwdriver tip before use.
(b) Employ the same manner described above to the other
side.
7. REMOVE ROOF HEADLINING
Disengage the 3 clips and remove the rear side of roof headlin-
ing.
8. DISCONNECT DEFOGGER WIRE CONNECTOR
9. REMOVE BACK WINDOW MOULDING
(a) Using a knife, cut off the moulding as shown.
NOTICE:
Do not damage the body with the knife.
(b) Remove the remaining moulding.
10. REMOVE BACK WINDOW GLASS
(a) Insert a piano wire between body and glass and let it pass
through.
(b) Tie both wire ends to wooden blocks or similar objects.
HINT:
Apply protective tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and exterior.

H10480
Protective
Tape
H07610
H10413
BO-72
- BODYBACK WINDOW GLASS
1857 Author
: Date
:
2001 AVALON (RM808U)
(c) Cut the adhesive by pulling the piano wire around it.
HINT:
Cut the adhesive areas as shown in the illustration, leaving the
adhesive where the stoppers are.
(d) Let the piano wire pass as shown in the illustration, cut off
the adhesive sticking to the stoppers.
NOTICE:
Do not damage the glass stoppers.
(e) Disengage the stoppers, then remove the glass.
NOTICE:
Leave of the adhesive on the body as much as possible
when cutting off the glass.

BO0XH-02
V00005
Shape (Example)
Removal/Installation
Clip RemoverPliers
Screwdriver
Scraper
- BODYCLIP
BO-1
1786 Author
: Date
:
2001 AVALON (RM808U)
CLIP
REPLACEMENT
The removal and installation methods of typical clips used in body parts are shown in the table below.
HINT:
If the clip is damaged during the operation, always replace it with a new clip.

V00012
Shape (Example)
Removal/Installation
Removal
Installation
Removal
Installation BO-2
- BODYCLIP
1787 Author
: Date
:
2001 AVALON (RM808U)

BO0XJ-04
H12099: Specified torqueN´m (kgf´cm, ft´lbf)
Oil Cooler
11 (115, 8)
5.4 (55, 48 in.´lbf)
11 (115, 8)
Front Bumper
Upper Reinforcement
RH Side Support
RH No. 2 Extension
Insert
LH Side Support
13 (130, 9)
Front Bumper Reinforcement
LH No. 2 Extension
Insert
13 (130, 9)
Front Bumper Energy Absorber
5.4 (55, 48 in.´lbf)
5.4 (55, 48 in.´lbf)
Front Bumper Cover
w/o Fog light:
RH Hole Cover
w/ Fog light:
RH Fog Light Assembly
8.3 (85, 74 in.´lbf)
w/ Fog light:
LH Fog Light Assembly
w/o Fog light:
LH Hole Cover
11 (115, 8)
BO-4
- BODYFRONT BUMPER
1789 Author
: Date
:
2001 AVALON (RM808U)
FRONT BUMPER
COMPONENTS

BO2OQ-01
N01363
SST
N01364
BO2556
BO-14
- BODYFRONT DOOR
1799 Author
: Date
:
2001 AVALON (RM808U)
ADJUSTMENT
1. ADJUST DOOR IN FORWARD/REARWARD AND VER-
TICAL DIRECTIONS
Using SST, loosen the body side hinge bolts to adjust.
SST 09812-00010
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL
DIRECTIONS
Loosen the door side hinge bolts to adjust.
HINT:
Substitute the bolt with washer for the centering bolt.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
3. ADJUST DOOR LOCK STRIKER
(a) Check that the door fit and door lock linkages are adjusted
correctly.
(b) Loosen the striker mounting screws.
Torque: 23 N´m (230 kgf´cm, 17 ft´lbf)
(c) Using a plastic hammer, tap the striker to adjust it.

BO2OO-01
H12112
Rear Lower FrameDoor Lock Striker23 (230, 17)
Front Door Weatherstrip
Door Glass Run
Outside Rear View
Mirror
Door Glass
Lower Frame
Bracket Garnish
7.8 (80, 69 in.´lbf)25 (260, 19)
5.4 (55, 48 in.´lbf)
Outside Handle
Key Cylinder
5.4 (55, 48 in.´lbf)
Door
Hinge
7.8 (80, 69 in.´lbf)
Door Check
25 (260, 19)
Door Speaker BoardFront Lower
Frame
25 (260, 19)
Door Hinge
Front Door Outside Lower Moulding
Door Lock Protector
Service Hole Cover
5.4 (55, 48 in.´lbf)

Precoated part
Door LockInside Handle
4.9 (50, 43 in.´lbf)
Inside Handle
Bezel
Cover
Door TrimUpper Armrest
Base Panel
Power Window Switch
Front Door Armrest
Courtesy Light
Front Door
Belt Moulding Front Door
Inner Weatherstrip
x10
5.4 (55, 48 in.´lbf)
Window Regulator
Guide Assembly
5.4 (55, 48 in.´lbf)
x8
x4
Window Regulator Motor
No. 2 Service Hole Cover
Front Door Trim Pocket : Specified torqueN´m (kgf´cm, ft´lbf)
BO-8
- BODYFRONT DOOR
1793 Author
: Date
:
2001 AVALON (RM808U)
FRONT DOOR
COMPONENTS

BO2OP-01
H04751
H12102
H12103
H12137
x10
x8
- BODYFRONT DOOR
BO-9
1794 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE INSIDE HANDLE BEZEL
(a) Using a screwdriver, remove the cover.
HINT:
Tape the screwdriver tip before use.
(b) Remove the screw.
(c) Using a screwdriver, remove the inside handle bezel as
shown in the illustration.
HINT:
Tape the screwdriver tip before use.
2. REMOVE COURTESY LIGHT
3. REMOVE UPPER ARMREST BASE PANEL WITH
POWER WINDOW SWITCH
(a) Using a screwdriver, remove the upper armrest base pan-
el with power window switch.
HINT:
Tape the screwdriver tip before use.
(b) Disconnect the connector.
(c) Remove the 3 screws and power window switch from the
upper armrest base panel.
4. REMOVE DOOR TRIM
(a) Using a screwdriver, remove the 2 caps.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 6 screws and clip.
(c) Pull the trim upward to remove it.
(d) Using a screwdriver, remove the front door inner weather-
strip from the front door trim.
(e) Remove the 10 screws and front door armrest from the
front door trim.
(f) Remove the 8 screws and front door trim pocket from the
front door trim.

H12104Clip
H06127
H12105
H12106
BO-10
- BODYFRONT DOOR
1795 Author
: Date
:
2001 AVALON (RM808U)
5. REMOVE LOWER FRAME BRACKET GARNISH
Using a screwdriver, remove the lower frame bracket as shown
in the illustration.
HINT:
Tape the screwdriver tip before use.
6. REMOVE OUTSIDE REAR VIEW MIRROR
Torque: 7.8 N´m (80 kgf´cm, 69 ft´lbf)
7. REMOVE DOOR SPEAKER BOARD
8. REMOVE INSIDE HANDLE
(a) Remove the screw.
(b) Slide the inside handle backward to remove it.
(c) Disconnect the 2 cables from the inside handle as shown
in the illustration.
9. REMOVE SERVICE HOLE COVER
(a) Using a clip remover, remove the grommets.
(b) Remove the service hole cover.
NOTICE:
Do not tear the cover.
HINT:
At the time of reassembly, please refer to the following item.
Bring out the 2 control cables and wire harness through the ser-
vice hole cover.
10. REMOVE FRONT DOOR WEATHERSTRIP
(a) Using a clip remover, remove the clip.
(b) Remove the screw from the door check.
(c) Using a clip remover, remove the front door weatherstrip.
(d) Reinstall the screw to the door check.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)

H12107
Protective Tape
H12108
H02440
- BODYFRONT DOOR
BO-1 1
1796 Author
: Date
:
2001 AVALON (RM808U)
11. REMOVE FRONT DOOR BELT MOULDING
(a) Apply protective tape to the outer surface as shown in the
illustration, to keep the surface from being scratched.
(b) Using a moulding remover, remove the front door belt
moulding.
12. REMOVE FRONT DOOR OUTSIDE LOWER MOULD-
ING
(a) Using a drill of less than ù3.2 mm (0.126 in.), drill out the
3 rivet heads.
HINT:
Gently and vertically put the drill to the rivets, and cut the rivet
flanges.
CAUTION:
Take care as the cut rivets are hot.
NOTICE:
Prizing the hole with a drill can lead to damage to the rivet
hole or the drill itself.
(b) Using a clip remover, remove the clip.
(c) Remove the front door outside lower moulding.
(d) Using a vacuum cleaner, remove the drilled rivets and
accociated metallic dust from the inside of door panel.
HINT:
At the time of reassembly, please refer to the following item.
Using an air riveter with nose piece No. 1 or a hand riveter with
nose piece No. 1 to install new 3 rivets to the front door outside
lower moulding.
NOTICE:

At the time of reassembly, please refer to the follow-
ing items.

Do not prize a riveter, as riveter is damaged, it is not
tightened and the mandrel is bent.