TOYOTA AVENSIS 2002 Repair Manual

B67146
59.3 (2.335)20.5 (0.807)
131.2 (5.165)88.6 (3.488)
89 (3.504)
161.1 (6.342)
14.7 (0.579)
47.1 (1.854)
61.3 (2.41)
97.3 (3.831)
27 (1.063)
48.2 (1.898)2
3
2
3
Liftback Models
1
1
mm (in.)
± EXTERIOR/INTERIOR TRIMNAME PLATE
76±19
AVENSIS REPAIR MANUAL (RM1018E)

B67147
129.7 (5.106)52.5 (2.067)
162 (6.378)144.5 (5.689)
115.4 (4.543)
109.6 (4.315)38.1 (1.500)95.5 (3.760)
115.4 (4.543)
40 (1.575)
109.6 (4.315)
97 (3.819)2
3
1
12
3
Wagon Models
mm (in.)
76±20
± EXTERIOR/INTERIOR TRIMNAME PLATE
AVENSIS REPAIR MANUAL (RM1018E)

760W5±01
B50319
Protective
Tape
B67149
Double±sided Tape
± EXTERIOR/INTERIOR TRIMOUTSIDE MOULDING LH
76±21
AVENSIS REPAIR MANUAL (RM1018E)
OUTSIDE MOULDING LH
REPLACEMENT
HINT:
On the RH side, use the same procedures as on the LH side.
1. REMOVE OUTSIDE MOULDING LH
(a) Using a heat light, heat the moulding.
Heating temprature: 40 ± 60C (104 ± 140F)
NOTICE:
Do not heat the moulding excessively.
(b) Tie both the piano wire ends to a wooden block or a similar
object.
(c) Scrape tape off by pulling the piano wire and remove the
moulding with reference pins remaining on the moulding.
NOTICE:

If reusing the moulding, take care not to damage the
moulding.

Do not damage the body.
(d) Remove the moulding.
2. INSTALL OUTSIDE MOULDING LH
(a) Using a heat light, heat the body surface.
Heating temprature: 40 ± 60C (104 ± 140F)
NOTICE:
Do not heat the body excessively.
(b) Remove the tape from the body.
(c) Wipe off the stains with cleaner.
(d) Clean the moulding (if reusing the moulding).
(1) Using a heat light, heat the moulding.
Heating temprature: 20 ± 30C (68 ± 86F)
NOTICE:
Do not heat the moulding excessively.
(2) Remove the tape from the moulding.
(3) Wipe off the stains with cleaner.
(4) Apply new double±sided tape to the moulding as
shown in the illustration.

B67150mm (in.) 16.2 (0.638)
28 (1.102)
228.7 (9.004)243 (9.567)
243 (9.567) 2.3 (0.091)
3.8 (0.150)
252.7 (9.949)119 (4.685)
16.4 (0.646)
76±22
± EXTERIOR/INTERIOR TRIMOUTSIDE MOULDING LH
AVENSIS REPAIR MANUAL (RM1018E)
(e) Using a heat light, heat the body and moulding.
Heating temperature:
Body40 ± 60
C (104 ± 140
F)
Moulding20 ± 30
C (68 ± 86
F)
NOTICE:
Do not heat the body and moulding excessively.
(f) Remove the peeling paper from the face of the moulding
and attach the moulding securely to the vehicle body.
NOTICE:
Be careful that dirt or foreign objects do not stick to adhe-
sive part when removeing the peeling paper.
(g) Push the moulding to the body, as shown in the illustra-
tion.
NOTICE:
Do not apply excessive force onto the moulding. Instead,
apply steady pressure with your thumbs.

760X1±01
B67428
Rear Floor
Finish Plate
Rear Floor Finish Plate
Rear Bumper CoverRear Bumper
Reinforcement No. 1
Rear Bumper Side
Retainer LHRear Bumper Side
Retainer RH
Rear Bumper
Retainer Upper LHRear Bumper
Retainer Upper RH
Rear Bumper Side
Moulding LHRear Bumper Side
Moulding RH Liftback ModelsLuggage Compartment
Trim Hook
Rope Hook AssyRope Hook
Assy
Rear Bumper Pad RH
Rear Bumper Pad LH
N
m (kgf
cm, ft
lbf) : Specified torque
5.5 (55, 49 in.
lbf)
11.5 (115, 16)
± EXTERIOR/INTERIOR TRIMREAR BUMPER (SEDAN/LIFTBACK)
76±5
AVENSIS REPAIR MANUAL (RM1018E)
REAR BUMPER (SEDAN/LIFTBACK)
COMPONENTS

760X2±01
B67426
B67427Protective Tape
Claw
76±6
± EXTERIOR/INTERIOR TRIMREAR BUMPER (SEDAN/LIFTBACK)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated.
1. REMOVE REAR FLOOR FINISH PLATE (SEDAN
MODELS)
(a) Remove the 2 hooks and 2 rope hooks.
(b) Using a moulding remover, remove the 2 clips and finish
plate.
(c) Using a screwdriver, disengage the 4 claws and finish
plate.
HINT:
Tape the screwdriver tip before use.
2. REMOVE REAR FLOOR FINISH PLATE (LIFTBACK MODELS)
(a) Remove the 2 bolts and 2 rope hooks.
(b) Using a screwdriver, disengage the 4 claws and finish plate.
HINT:
Tape the screwdriver tip before use.
3. REMOVE REAR BUMPER COVER
(a) Put protective tape under the quarter panel.
(b) Remove the 2 screws, 4 nuts and 3 clips.
(c) Using a screwdriver, disengage the 14 claws and remove
the bumper.
HINT:
Tape the screwdriver tip before use.
4. REMOVE REAR BUMPER REINFORCEMENT NO.1
(a) Remove the 8 bolts and reinforcement.
5. REMOVE REAR BUMPER SIDE RETAINER LH
(a) Remove the 2 screws.
(b) Using a screwdriver, remove the retainer.
HINT:
Tape the screwdriver tip before use.
6. REMOVE REAR BUMPER SIDE RETAINER RH
HINT:
Use the same procedures described for the LH side.
7. REMOVE REAR BUMPER RETAINER UPPER LH
(a) Remove the 2 screws.
(b) Using a screwdriver, remove the retainer.

B67427
± EXTERIOR/INTERIOR TRIMREAR BUMPER (SEDAN/LIFTBACK)
76±7
AVENSIS REPAIR MANUAL (RM1018E)
HINT:
Tape the screwdriver tip before use.
8. REMOVE REAR BUMPER RETAINER UPPER RH
HINT:
Use the same procedures described for the LH side.
9. REMOVE REAR BUMPER SIDE MOULDING LH
(a) Using a screwdriver, disengage the 10 claws and remove the moulding.
HINT:
Tape the screwdriver tip before use.
10. REMOVE REAR BUMPER SIDE MOULDING RH
HINT:
Use the same procedures described for the LH side.
11. INSTALL REAR BUMPER REINFORCEMENT NO.1
(a) Install the reinforcement with the 8 bolts.
Torque: 11.5 N
m (115 kgf
cm, 16 ft
lbf)
12. INSTALL REAR BUMPER COVER
(a) Install the bumper cover with the 4 nuts, 2 screws and 3
clips.
Torque: 5.5 N
m (55 kgf
cm, 49 in.
lbf) for screw

760X3±01
B67423
Rear Floor
Finish Plate
Rear Bumper Cover Rear Bumper Side
Retainer LHRear Bumper Side
Retainer RH
Rear Bumper
Retainer Upper LHRear Bumper
Retainer Upper RH
Rear Bumper Side
Moulding LHRear Bumper Side
Moulding RH Rear Bumper
Reinforcement No. 1
Rear Bumper Pad RH
Rear Bumper
Pad LH
N
m (kgf
cm, ft
lbf) : Specified torque
Deck Floor Box Rear
Deck Floor
Box LH
Deck Floor Box RH
11.5 (115, 16)
11.5 (115, 16)
5.5 (55,49 in.
lbf)
76±8
± EXTERIOR/INTERIOR TRIMREAR BUMPER (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
REAR BUMPER (WAGON MODELS)
COMPONENTS

760X4±01
B67429
Clip
B67430
Claw
±
EXTERIOR/INTERIOR TRIM REAR BUMPER(WAGON MODELS)
76±9
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
The installation is in the reverse order of the removal. However, when there is a special point concerning
the installation, it is indicated.
1.REMOVE REAR FLOOR FINISH PLATE
(a)Using a screwdriver, remove the 4 clips and finish plate.
HINT:
Tape the screwdriver tip before use.
2.REMOVE DECK FLOOR BOX REAR (See page 76±54)
3.REMOVE DECK FLOOR BOX LH (See page 76±54)
4.REMOVE DECK FLOOR BOX RH (See page 76±54) 5. REMOVE REAR BUMPER COVER
(a) Put protective tape under the quarter panel.
(b) Remove the 2 screws, 3 clips and 4 nuts.
(c) Using a screwdriver, disengage the 16 claws and removethe bumper cover.
HINT:
Tape the screwdriver tip before use.
6. REMOVE REAR BUMPER REINFORCEMENT NO.1
(a) Remove the 8 bolts and reinforcement.
7. REMOVE REAR BUMPER SIDE RETAINER LH
(a) Remove the 2 screws.
(b) Using a screwdriver, disengage the 3 claws and remove the side retainer.
HINT:
Tape the screwdriver tip before use.
8. REMOVE REAR BUMPER SIDE RETAINER RH
HINT:
Use the same procedures described for the LH side.
9. REMOVE REAR BUMPER RETAINER UPPER LH
(a) Remove the 2 screws.
(b) Using a screwdriver, disengage the claw and remove the retainer upper.
HINT:
Tape the screwdriver tip before use.
10. REMOVE REAR BUMPER RETAINER UPPER RH
HINT:
Use the same procedures described for the LH side.
11. REMOVE REAR BUMPER SIDE MOULDING LH
(a) Using screwdriver, remove the moulding.

B67430
76±10
± EXTERIOR/INTERIOR TRIMREAR BUMPER (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
HINT:
Tape the screwdriver tip before use.
12. REMOVE REAR BUMPER SIDE MOULDING RH
HINT:
Use the same procedures described for the LH side.
13. INSTALL REAR BUMPER REINFORCEMENT NO.1
(a) Install the reinforcement with the 8 bolts.
Torque: 11.5 N
m (115 kgf
cm, 16 ft
lbf)
14. INSTALL REAR BUMPER COVER
(a) Install the bumper cover with the 2 screws, 3 clips and 4
nuts.
Torque: 5.5 N
m (55 kgf
cm, 49 in.
lbf) for screw