TOYOTA AVENSIS 2003 Service Repair Manual

B70388
B66971: Clip
Protective
TapeProtective
Tape
Screw
BoltCushion Rubber
B70121
B68930
Claw A
: Claw
1
2
±
ENGINE HOOD/DOOR FRONT DOOR
75±9
AVENSIS REPAIR MANUAL (RM1018E)
4. REMOVE POWER WINDOW REGULATOR MASTER
SWITCH ASSY
(a) Using a screwdriver, disengage the 4 claws and clip, and
remove the armrest base panel upper together with the
switch.
HINT:
Tape the screwdriver tip before use.
(b) Disconnect the switch connector.
(c) Remove the 3 screws and switch from the armrest base panel upper.
5. REMOVE FRONT DOOR TRIM BOARD SUB±ASSY LH
(a) Disconnect the courtesy lamp connector.
(b) Remove the 3 cushion rubbers.
(c) Remove the 2 screws and bolt as indicated.
(d) Using a clip remover, disengage 9 clips.
(e) Remove the trim board upward.
HINT:
In order to prevent the door panel from being damaged, cover
the areas indicated by the arrow marks in the illustration with
protective tape.
(f) Disengage the 2 claws and remove the courtesy lamp.
6. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER LH
(a) Remove the weatherstrip inner upward in the direction in- dicated by the arrow mark in the illustration.
7. REMOVE FRONT DOOR INSIDE HANDLE SUB±ASSY LH
(a) Using a screwdriver, disengage the claw A indicated.
HINT:
Tape the screwdriver tip before use.
(b) Move the inside handle in the direction indicated the by arrow mark in the illustration.
(c) Disconnect the 2 cables from the inside handle.
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B69067
Butyl Tape
B66981
B68929
B61431
75±10
±
ENGINE HOOD/DOORFRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
8.REMOVE FRONT DOOR SERVICE HOLE COVER
(a)Remove the service hole cover.
NOTICE:
Remove the tape remaining on the door side.
(b)Remove the lower frame seal.
9.REMOVE OUTER REAR VIEW MIRROR ASSY LH
(a)Disconnect the mirror connector.
(b)Remove the 3 screws and mirror.
NOTICE:
When the screws are removed, the mirror may fall and be-
come deformed.
10.REMOVE FRONT NO.1 SPEAKER ASSY (W/ SPEAKER)
(a)Using a drill of less than ù 4 mm (0.16 in.), drill out the 3 rivets heads and remove the speaker.
NOTICE:

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

Be careful with the cut rivet, because it is hot.
(b)Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
(c)Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door.
11.REMOVE FRONT DOOR BELT MOULDING ASSY LH (See page 76±23)
12. REMOVE FRONT DOOR STIFFENER CUSHION NO.1
(a) Using a screwdriver, disengage the 2 claws and remove the cushion.
13. REMOVE FRONT DOOR SPACER LH
(a) Using a screwdriver, disengage the 2 claws and remove the spacer.
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B62422
B62423
12
B66968
B61434

B68932Hole Plug
±
ENGINE HOOD/DOOR FRONT DOOR
75±11
AVENSIS REPAIR MANUAL (RM1018E)
14. REMOVE FRONT DOOR GLASS SUB±ASSY LH
HINT:
Insert a shop rag inside the door panel to prevent the glass from
being scratched.
(a) Move the door glass until the bolts appear in the service
holes.
(b) Remove the 2 bolts holding the door glass to the window
regulator.
(c) Remove the door glass in the direction indicated by the arrows in the illustration.
NOTICE:

Do not damage the glass.

When the bolts are removed, the glass may fall and
become deformed.
(d) Remove the glass run.
15. REMOVE FRONT DOOR WINDOW REGULATOR SUB±ASSY LH
(a) Disconnect the window regulator connector.
(b) Remove the 6 bolts and window regulator.
NOTICE:
When the bolts are removed, the window regulator may fall
and become deformed.
HINT:
Remove the window regulator through the service hole.
16. REMOVE FRONT DOOR FRAME SUB±ASSY REAR LOWER LH
(a) Remove the bolt and frame.
HINT:
Remove the frame through the service hole.
17. REMOVE FRONT DOOR OUTSIDE HANDLE COVER
(a) Remove the hole plug.
(b) Using a torx socket wrench (T30), loosen the screw and remove the cover with the door lock key cylinder installed.
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B66894
B56613
12
B70122
Screw
B57102
B68928
75±12
±
ENGINE HOOD/DOOR FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
18. REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH
(a) Disconnect the door lock connector.
(b) Using a torx socket wrench (T30), remove the 3 screws and door lock.
NOTICE:
When the bolts are removed, the window regulator may fall
and become deformed.
HINT:
Remove the door lock through the service hole.
19. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH
(a) Remove the handle pushing and pulling it in the direction indicated by the arrow mark in the illustration.
(b) Remove the outside handle pads front and rear.
20. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB±ASSY LH
(a) Using a torx socket wrench (T30), loosen the screw of the frame.
(b) Using pliers, disengage the clips and remove the frame, as shown in the illustration.
NOTICE:
Be sure to remove the outside handle together with the
clips, as the clips will be damaged if they remain attached
to the door panel.
HINT:
Remove the frame through the service hole.
21. REMOVE FRONT DOOR CHECK ASSY LH
(a) Remove the 2 nuts, bolt and check.
HINT:
Remove the check through the service hole.
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B68928
Adhesive
B70122
Screw
B64044
1
2
±
ENGINE HOOD/DOOR FRONT DOOR
75±13
AVENSIS REPAIR MANUAL (RM1018E)
22. REMOVE FRONT DOOR WEATHERSTRIP LH
(a) Using a clip remover, disengage the clips and remove the weatherstrip.
HINT:
If the clips are damaged, replace them with new clips.
23. INSTALL FRONT DOOR CHECK ASSY LH
(a) Apply MP grease to the sliding areas of the check.
(b) Install the check to the door panel with the 2 nuts.Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
(c) Apply adhesive to the threads of the bolt. Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(d) Install the door check to the body panel with the bolt. Torque: 30 N
m (306 kgf
cm, 22 in.
lbf)
24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME
SUB±ASSY LH
(a) Install the outside handle link.
(b) Apply MP grease to the sliding areas of the frame.
(c) Using a torx socket wrench (T30), install the frame with the screw.
Torque: 4.0 N
m (41 kgf
cm, 35 in.
lbf)
25. INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH
(a) Install the outside handle pads front and rear.
(b) Install the handle pushing it in the direction of the arrow mark in the illustration.
NOTICE:
If the release plate is not pulled and held when installing the
handle, the release plate will interfere with the handle and
become damaged.
26. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the door lock.
(b) Install a new door lock wire harness packing.
NOTICE:

When reusing a door lock that has been removed, re-
place the packing in the connecting part with a new
one.

Be careful that no grease or dirt does not sticks to the
packing surface in the connecting part.

Reusing removed packing or using damaged packing
will allow water to penetrate through to the connect-
ing part resulting in a door lock malfunction.
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B65961
Rod
B66894
Adhesive
Adhesive

B68932Hole Plug
B62425
B66972
75±14
±
ENGINE HOOD/DOOR FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(c) Insert the control rod into the door lock, and then set it to the door panel.
NOTICE:
Make sure that the handle link is securely engaged with the
lock.
(d) Apply adhesive to the threads of the 3 screws. Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(e) Using a torx socket wrench (T30), install the door lock with the 3 screws.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(f) Connect the door lock connector.
27. INSTALL FRONT DOOR OUTSIDE HANDLE COVER
(a) Using a torx socket wrench (T30), install the cover with the door lock key cylinder installed with the screw.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
(b) Install the hole plug.
28. INSTALL FRONT DOOR FRAME SUB±ASSY REAR
LOWER LH
(a) Install the frame with the bolt. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
29. I N S TA L L F R O N T D O O R W I N D O W R E G U L ATO R SUB±ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
window regulator.
NOTICE:
Do not apply grease to the spring of the window regulator.
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B66968
B62423
1
2
B62422
B61441
±
ENGINE HOOD/DOORFRONT DOOR
75±15
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the window regulator with the 6 bolts.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c)Connect the window regulator connector.
NOTICE:
Be careful not to drop and deform the door window regula-
tor as this may cause deformation.
30.INSTALL FRONT DOOR GLASS SUB±ASSY LH
(a)Install the glass run.
NOTICE:
Do not damage the door glass.
(b)Insert the door glass into the door panel along the glass run in the direction indicated by arrows in the illustration.
(c)Install the door glass to the window regulator with the 2 bolts.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(d)Reset the power window motor (See page 70±13).
(e) Inspect operation of the power window.
HINT:
When the installation point of the door glass does not match,
adjust the regulator position in manual operation. (1) Connect the power window switch to the wire har-
ness and turn the ignition switch ON.
(2) Repeat UP and DOWN operation several times in manual operation.
31. INSTALL FRONT NO.1 SPEAKER ASSY
(a) Using an air riveter or hand riveter, install the speaker to the door with the 3 rivets.
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H02440Mandrel
RiveterWRONG
H02441
Riveter
Riveter
WRONG
WRONG
H02442
Riveter
WRONG
B68929
B69067
Butyl Tape
75±16
±
ENGINE HOOD/DOOR FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

Do not operate the riveter an angle as this will damage
it bend the mandrel.

Do not tilt the riveter when removing the rivet as the
speaker will not be tightened firmly.

Install the rivet while attaching the speaker to ensure
that it is tightened firmly.
(b) Connect the speaker connector.
32. INSTALL OUTER REAR VIEW MIRROR ASSY LH
(a) Install the mirror with the 3 screws. Torque: 10 N
m (102 kgf
cm, 7 ft
lbf)
(b) Connect the mirror connector.
33. INSTALL FRONT DOOR SERVICE HOLE COVER
(a) Apply butyl tape to the door as shown in the illustration.
(b) Install the service hole cover.
HINT:

When installing the service hole cover, pull out the links
and connectors through the service hole cover.

There should be no wrinkles or folds after attaching the
service hole cover.

After attaching the service hole cover, check the sealing
quality.
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B66981
±
ENGINE HOOD/DOOR FRONT DOOR
75±17
AVENSIS REPAIR MANUAL (RM1018E)
(c) Install the lower frame seal front.
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750MT±01
B67533
Hood Sub±assyHood Insulator
Engine Room Side Cover RH
Radiator CoverBattery Service Hole Cover
Hood Hinge Assy RH
Hood to Front Fender Seal RH
Hood Lock Assy
Front Bumper Assy
Hood to Front Fender Seal LH
Hood Hinge Assy LH x 8
Hood to Front End Panel Seal
8.0 (82, 71 in.´lbf)
13 (133, 10)
13 (133, 10)
: Specified torqueN´m (kgf´cm, ft´lbf) Cushion Rubber
Cushion Rubber
Clip
±
ENGINE HOOD/DOOR HOOD
75±1
AVENSIS REPAIR MANUAL (RM1018E)
HOOD
COMPONENTS
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