TOYOTA AVENSIS 2005 Service Repair Manual

B66977: ClipScrew
Protective
TapeProtective
Tape
Bolt
Cushion Rubber
B70121
B68930
Claw A
: Claw 1
2
B66979
Butyl Tape
± ENGINE HOOD/DOORREAR DOOR
75±23
AVENSIS REPAIR MANUAL (RM1018E)
4. REMOVE REAR DOOR TRIM BOARD SUB±ASSY LH
(a) Remove the cushion rubber.
(b) Remove the bolt and 2 screws.
(c) Using a clip remover, remove the 10 clips and 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.
5. REMOVE REAR DOOR GLASS WEATHERSTRIP
INNER LH
(a) Remove the weatherstrip inner, as shown in the illustra-
tion.
6. REMOVE REAR DOOR INSIDE HANDLE SUB±ASSY
LH
(a) Using a screwdriver, disengage the claw A as indicated.
HINT:
Tape the screwdriver tip before use.
(b) Move the inside handle in the direction indicated by the
arrow mark in the illustration.
(c) Disconnect the 2 cables from the inside handle.
7. REMOVE REAR DOOR SERVICE HOLE COVER
(a) Remove the service hole cover.
NOTICE:
Remove the remaining tape on the door side.

B61431
B61450
B65138
12
3
B69209
75±24
±
ENGINE HOOD/DOOR REAR DOOR
AVENSIS REPAIR MANUAL (RM1018E)
8.REMOVE REAR SPEAKER ASSY (W/ SPEAKER)
(a)Using a drill of less than ù 4 mm (0.16 in.), drill out the 3 rivet heads and remove the speaker.
NOTICE:

Be sure to gently place the drill perpendicularly to the
rivet to prevent the rivet hole and the drill itself from
being damaged.

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.
9.REMOVE REAR SPEAKER ASSY NO.2 (W/ SPEAKER) (See page 67±15)
10.REMOVE REAR DOOR BELT MOULDING ASSY LH (See page 76±24)
11. REMOVE REAR DOOR WINDOW DIVISION BARSUB±ASSY LH
(a) Remove the glass run.
(b) Remove the screw and 2 bolts.
(c) Rotate the division bar by 45  and pull it upwards in the
direction indicated by the arrow marks in the illustration.
Then remove the division bar.
12. REMOVE REAR DOOR QUARTER WINDOW GLASS LH
(a) Remove the quarter glass together with the quarter win-
dow glass weatherstrip in the direction indicated by arrow
marks in the illustration.
(b) Remove the quarter window glass weatherstrip.

B66980
B66983
B62438
B57767
± ENGINE HOOD/DOORREAR DOOR
75±25
AVENSIS REPAIR MANUAL (RM1018E)
(c) Remove the door lock link silencer.
13. REMOVE REAR DOOR GLASS SUB±ASSY LH
(a) Carefully pull up the door glass out of the door panel.
HINT:
Insert a shop rag inside the door panel to prevent the glass from being scratched.
14. REMOVE REAR DOOR WINDOW REGULATOR
SUB±ASSY LH
(a) w/ Power window:
Disconnect the window regulator connector.
(b) Remove the 4 bolts and window regulator.
NOTICE:
When the bolts are removed, the window regulator may fall
and become deformed.
HINT:
Remove the door window regulator through the service hole.
15. REMOVE REAR 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.
HINT:
Remove the door lock through the service hole.
(c) Remove the door lock wire harness packing.
16. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH
(a) Using a torx socket wrench (T30), loosen the screw.
(b) Remove the cover.
HINT:
Remove the cover through the service hole.
17. REMOVE REAR DOOR OUTSIDE HANDLE ASSY LH
(a) Pull and hold the release plate of the handle frame as
shown in the illustration.

B56613
(1)
(2)
B68931
Screw
B68928
B68928
Adhesive
75±26
± ENGINE HOOD/DOORREAR DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the handle pushing and pulling it in the direction
indicated by the arrow mark in the illustration.
NOTICE:
If the release plate is not pulled and held when removing
the handle, the release plate will interfere with the handle
and become damaged .
(c) Remove the outside handle pads front and rear.
18. REMOVE REAR DOOR OUTSIDE HANDLE FRAME
SUB±ASSY LH
(a) Using a torx socket wrench (T30), loosen the screw and
remove the frame.
19. REMOVE REAR DOOR CHECK ASSY LH
(a) Remove the 2 nuts, bolt and check.
HINT:
Remove the check through the service hole.
20. REMOVE REAR DOOR WEATHERSTRIP LH
(a) Using a clip remover, disengage the clip and remove the weatherstrip.
HINT:
If the clip is damaged, replace it with a new clip.
21. INSTALL REAR 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 check to the body panel with the bolt.
Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)

B68931
Screw
B57767
B64044
1 2
± ENGINE HOOD/DOORREAR DOOR
75±27
AVENSIS REPAIR MANUAL (RM1018E)
22. INSTALL REAR DOOR OUTSIDE HANDLE FRAME
SUB±ASSY LH
(a) Apply MP grease to the sliding areas of the frame.
(b) Using a torx socket wrench (T30), install the handle frame
with the screw.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
NOTICE:
A cover should be inserted between the nut and the door
panel.
23. INSTALL REAR DOOR OUTSIDE HANDLE ASSY LH
(a) Install the outside handle pads front and rear.
(b) Pull and hold the release plate of the frame, as shown in
the illustration.
(c) Install the handle pushing it in the direction indicated by
arrow marks 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 be-
come damaged .
24. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH
(a) Using a torx socket wrench (T30), install the outside handle cover with the screw.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
25. INSTALL REAR 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 lock that has been removed, replace
the packing in the connecting part with a new one.

Be careful that grease or dirt does not stick 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.

B62438
Adhesive
Adhesive
B66982
w/ Power Window
w/o Power Window
B66983
75±28
± ENGINE HOOD/DOORREAR DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(c) Engage the door lock with the release plate of the handle,
and then set it to the door panel.
NOTICE:
Make sure that the release plate of the frame is securely en-
gaged with the door 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.
26. INSTALL REAR DOOR WINDOW REGULATOR
SUB±ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
window regulator.
(b) Install the window regulator with the 4 bolts.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
NOTICE:
Be careful not to drop the window regulator as this may
cause deformation.
(c) Connect the window regulator connector.

B66980
B69209
B65138
1
2
3
B61450
±
ENGINE HOOD/DOOR REAR DOOR
75±29
AVENSIS REPAIR MANUAL (RM1018E)
27.INSTALL REAR DOOR GLASS SUB±ASSY LH
NOTICE:
Be careful not to drop the glass as this may cause deformation.
(a)Install the door glass into the door panel.
HINT:
Insert a shop rag inside the door panel to prevent the door glass from b\
eing scratched.
28.INSTALL REAR DOOR QUARTER WINDOW GLASSLH
(a)Install the quarter window weatherstrip on the glass.
NOTICE:
Do not damage the glass.
(b)Install the door lock link silencer.
(c)Install the quarter window glass with the weatherstrip installed in the direction indicated by the arrow in the il-
lustration.
29.INSTALL REAR DOOR WINDOW DIVISION BAR SUB±ASSY LH
(a)Insert the division bar to the door panel and then rotate it by 90 
as shown in the illustration.
(b)Mount the door glass to the window regulator.
(c)Install the division bar with the 2 bolts and screw. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
(d)Install the glass run.
(e)Reset the power window motor (See page 70±13).
(f) Inspect operation of the power window.
HINT:
When the installation point of the door glass does not match,
adjust the window regulator position in manual operation.
(1) Connect the power window switch to the wire har-ness and turn the ignition switch ON.

B61441
H02440Mandrel
RiveterWRONG
H02441
Riveter
Riveter
WRONG
WRONG
H02442
Riveter
WRONG 75±30
± ENGINE HOOD/DOORREAR DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(2) Repeat UP and DOWN operation several times in
manual operation.
30. INSTALL REAR SPEAKER ASSY
(a) Using an air riveter or hand riveter, install the speaker to
the door with the 3 rivets.
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.

B66979
Butyl Tape

B70387
30
12
Front
Snap Ring
± ENGINE HOOD/DOORREAR DOOR
75±31
AVENSIS REPAIR MANUAL (RM1018E)
31. INSTALL REAR DOOR SERVICE HOLE COVER
(a) Apply butyl tape to the door panel, as shown in the illustra-
tion.
(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.
32. INSTALL REAR DOOR WINDOW REGULATOR
HANDLE ASSY (W/O POWER WINDOW)
(a) Fully close the window.
(b) Install the snap ring to the regulator handle.
(c) Install the regulator handle.
HINT:
With the window fully closed, install the plate and regulator han-
dle with the snap ring as shown in the illustration.

750MZ±01
B57104
Centering BoltStandard Bolt
B66973
AB
C
D
E
AE
B66974
75±20
± ENGINE HOOD/DOORREAR DOOR
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:

Use the same procedures on the RH side as on the LH side.

Because centering bolt is used as a door hinge mounting
bolt on the body side and the door side, the door can not
be adjusted with them on. Substitute a bolt with a washer
for the centering bolt.
1. INSPECT REAR DOOR PANEL SUB±ASSY LH
(a) Check that the clearance is within the standard range.
Standard range:
A4.8
1.5 mm (0.189
0.059 in.)
D160 mm (6.30 in.)
B5.5
1.5 mm (0.220
0.059 in.)
E4.3
1.5 mm (0.169
0.059 in.)
C4.8
1.5 mm (0189
0.059 in.)
2. ADJUST REAR DOOR PANEL SUB±ASSY LH
(a) Adjust the door forward/rearward and vertically by loos-
ening the body side hinge bolts.
(b) Tighten the body side hinge bolts after the adjustment.
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)