TOYOTA AVALON 2001 Service Repair Manual

BO2556
- BODYREAR DOOR
BO-23
1808 Author
: Date
:
2001 AVALON (RM808U)
3. ADJUST DOOR LOCK STRIKER
(a) Check that the door fit and door lock linkages are adjusted
correctly.
(b) Loosen the striker mounting screws to adjust.
Torque: 23 N´m (230 kgf´cm, 17 ft´lbf)
(c) Using a plastic hammer, tap the striker to adjust it.

BO2OS-01
H12120
Door Lock Striker
Rear Guide Bracket
Garnish
23 (230, 17)
Rear Door
Window Guide
Rear Door Weatherstrip
Rear Door Glass Run
Rear Door Glass
Outside Handle
5.4 (55, 48 in.´lbf)
5.4 (55, 48 in.´lbf)


Door Lock
Door Lock ProtectorRear Door Outside
Lower Moulding
Door Speaker Board
25 (260, 19)
25 (260, 19)25 (260, 19)
7.8 (80, 69 in.´lbf)
Door Check
25 (260, 19)
Door Hinge
Inside Handle
Inside Handle Bezel
Service Hole Cover
Rear Door Belt Moulding
Cover
Upper Armrest Base Panel
Power Window
Switch
Rear Door ArmrestRear Door
Inner Weatherstrip
Door Trimx13
x7
Window Regulator
Guide Assembly
Window Regulator Motor
5.4 (55, 48 in.´lbf)
Rear Door Trim Pocket
: Specified torqueN´m (kgf´cm, ft´lbf)

Precoated Part
5.4 (55, 48 in.´lbf)
4.9 (50, 43 in.´lbf)
Guide Piece Plate
BO-16
- BODYREAR DOOR
1801 Author
: Date
:
2001 AVALON (RM808U)
REAR DOOR
COMPONENTS

BO2OT-01
H04751
H12111
H12113
Clip
H12114
- BODYREAR DOOR
BO-17
1802 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 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 power window switch from the upper armrest
base panel.
3. REMOVE REAR GUIDE BRACKET GARNISH
Using a screwdriver, remove the rear guide bracket garnish.
HINT:
Tape the screwdriver tip before use.
4. REMOVE DOOR TRIM
(a) Remove the 3 screws and 2 clips.
(b) Pull the trim upward to remove it.

H12163
x13
x7
H06127
H12115
H12116
Protective Tape BO-18
- BODYREAR DOOR
1803 Author
: Date
:
2001 AVALON (RM808U)
(c) Using a screwdriver, remove the rear door inner weather-
strip.
(d) Remove the 13 screws and rear door armrest.
(e) Remove the 7 screws and rear door trim pocket.
5. 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.
6. REMOVE DOOR SPEAKER BOARD
7. REMOVE SERVICE HOLE COVER
(a) Disconnect the 2 control cables from the link clamp.
(b) Using a clip remover, remove the grommets and link
clamp.
(c) 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.
8. REMOVE REAR DOOR WEATHERSTRIP
(a) Remove the screw from the door check.
(b) Using a clip remover, remove the rear door weatherstrip.
(c) Reinstall the screw to the door check.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
9. REMOVE REAR 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 rear door belt
moulding.

H12117
H02440
H02441
H02442
- BODYREAR DOOR
BO-19
1804 Author
: Date
:
2001 AVALON (RM808U)
10. REMOVE REAR DOOR OUTSIDE LOWER MOULDING
(a) Using a drill of less than ù3.2 mm (0.126 in.), drill out the
2 rivet heads.
HINT:
Gently and vertically put the drill to the rivet, and cut the rivet
flanges.
CAUTION:
Take care as the cut rivet is hot.
NOTICE:
Prizing the hole with a drill can lead to damage to the rivet
hole or breaking the drill.
(b) Using a clip remover, remove the clip.
(c) Remove the rear door outside lower moulding.
(d) Using a vacuum cleaner, remove the drilled rivets and
their 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 hand riveter with
nose piece No. 1, install the 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.

Do not tilt the riveter and disconnect the rivet from the
material while handling a riveter, as the materials are
not tightened firmly.

Install the rivet while attaching materials, as they are
not tightened firmly.
11. REMOVE DOOR GLASS RUN
12. REMOVE REAR DOOR WINDOW GUIDE WITH GUIDE
PIECE PLATE
(a) Remove the bolt, nut, 3 screws and rear door window
guide with guide piece plate.
(b) Remove the guide piece plate from the rear door window
guide.

H12118
BO-20
- BODYREAR DOOR
1805 Author
: Date
:
2001 AVALON (RM808U)
13. REMOVE REAR DOOR GLASS
(a) Open the door glass until the bolts appear in the service
hole.
(b) Remove the 2 bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
NOTICE:
Be careful not to drop the door glass.
(c) Pull the door glass upward to remove it.
14. REMOVE WINDOW REGULATOR ASSEMBLY
(a) Disconnect the connector, then remove the 4 nuts and
window regulator assembly.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Remove the window regulator assembly through the service
hole.
(b) Using a torx driver, remove the 3 torx screws and window
regulator motor from the window regulator guide assem-
bly.
HINT:

At the time of reassembly, please refer to the following
items.

Apply MP grease to the glass guide and rollers of window
regulator assembly.

After installing the window regulator assembly, window
regulator assembly need to be re-initialized.
Refer to BE-80.
15. REMOVE DOOR LOCK
(a) Disconnect the control link from the outside handle.
(b) Disconnect the connector.
(c) Remove the 3 torx screws and door lock.
Torque:
Bolt: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
Screw: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
HINT:
Remove the door lock through the service hole.
HINT:
At the time of reassembly, please refer to the following item.
Apply adhesive to 3 screws.
Part No. 08833-00070, THREE BOND 1324 or equiva-
lent
(d) Remove the 2 screws and door lock protector from the
door lock.

H12119
- BODYREAR DOOR
BO-21
1806 Author
: Date
:
2001 AVALON (RM808U)
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the sliding and rotating parts of the door
lock.
16. REMOVE OUTSIDE HANDLE
Remove the 2 bolts and outside handle.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)

BO2OV-01
BO-24
- BODYREAR DOOR
1809 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-17).

BO2QD-01
H12219
Center Armrest
Seat Cushion Pad
with Frame Seat Cushion Cover
Center Armrest Bracket
Center Armrest Hinge

Hog Ring
Shoulder Belt Guide
Headrest
Headrest Support
Headrest Support
Seatback Pad with Frame

Hog Ring
N´m (kgf´cm, ft´lbf): Specified torque

Non-reusable partSeatback Cover
5.9 (60, 52 in.´lbf)
18 (185, 13)
41 (420, 30)
18 (185, 13)
- BODYREAR SEAT
BO-1 19
1904 Author
: Date
:
2001 AVALON (RM808U)
REAR SEAT
COMPONENTS

BO2QF-01
H03147
- BODYREAR SEAT
BO-121
1906 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE HEADRESTS
2. REMOVE CENTER ARMREST
Remove the 2 nuts and center armrest.
Torque: 5.9 N´m (60 kgf´cm, 52 in.´lbf)
3. REMOVE SHOULDER BELT GUIDES
Remove the 4 screws and 2 shoulder belt guides.
4. REMOVE HEADREST SUPPORTS
5. REMOVE SEATBACK COVER
Remove the hog rings and seatback cover from the seatback
pad with frame.
6. REMOVE SEAT CUSHION COVER
Remove the hog rings and seat cushion cover from the seat
cushion pad.