TOYOTA AVENSIS 2005 Service Repair Manual

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

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

760WY±01
B67425
Claw
B67431
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
76±3
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 FRONT BUMPER COVER
(a) Put protective tape under the front fender.
HINT:
Because the spoiler covers LH and RH are assembled, remove
them together.
(b) Remove the spoiler.
(1) Remove the 9 screws and 6 claws.
(2) Remove the 6 retainers.
(3) Remove the spoiler covers LH and RH together.
(4) Remove the bolt and separate the spoiler cover RH
from the LH.
(c) Remove the 3 bolts and 2 clips.
(d) Using a screwdriver, disengage the 6 claws and remove
the bumper cover.
HINT:
Tape the screwdriver tip before use.
(e) w/ Fog lamp:
Disconnect the fog lamp connectors.
2. R E M O V E H E A D L A M P WA S H E R A C T U ATO R
SUB±ASSY LH (W/ HEADLAMP CLEANER)
(a) Remove the washer hose clip.
(b) Using a screwdriver, pry out the front washer nozzle.
HINT:
Tape the screwdriver tip before use.
(c) Remove the 2 screws and actuator.
3. REMOVE HEADLAMP WASHER ACTUATOR SUB±ASSY RH (W/ HEADLAMP CLEANER)
HINT:
Use the same procedures described for the LH side.
4. REMOVE INTERCOOLER COOLING AIR DUCT SUB±ASSY (W/ CAC 1CD±FTV ENGINE TYPE)
(a) Remove the 3 screws and air duct.
5. REMOVE FRONT BUMPER REINFORCEMENT SUB±ASSY
(a) Using a screwdriver, remove the wire harness.
(b) Remove the 8 bolts and reinforcement.
6. REMOVE FRONT BUMPER SIDE RETAINER LH
(a) Using a screwdriver, remove the 2 screws and retainer.
HINT:
Tape the screwdriver tip before use.

B67425
76±4
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE FRONT BUMPER SIDE RETAINER RH
HINT:
Use the same procedures described for the LH side.
8. REMOVE FRONT BUMPER STAY SUB±ASSY LH
(a) Remove the 2 bolts and stay.
9. REMOVE FRONT BUMPER STAY SUB±ASSY RH
(a) Remove the 2 bolts and stay.
10. REMOVE FOG LAMP ASSY LH (W/ FOG LAMP)
(a) Remove the 2 screws and fog lamp.
11. REMOVE FOG LAMP ASSY RH (W/ FOG LAMP)
(a) Remove the 2 screws and fog lamp.
12. REMOVE FRONT BUMPER HOLE COVER LH
13. REMOVE FRONT BUMPER HOLE COVER RH
14. REMOVE FRONT BUMPER SIDE MOULDING LH
(a) Using a screwdriver, disengage the 9 claws and remove the retainer.
HINT:
Tape the screwdriver tip before use.
15. REMOVE FRONT BUMPER SIDE MOULDING RH
HINT:
Use the same procedures described for the LH side.
16. REMOVE HOOD TO FRONT END PANEL SEAL
(a) Using a screwdriver, remove the 10 clips and panel seal.
HINT:
Tape the screwdriver tip before use.
17. REMOVE RADIATOR GRILLE
(a) Using a screwdriver, disengage the 13 claws and remove the 2 screws and radiator grille.
HINT:
Tape the screwdriver tip before use.
18. REMOVE RADIATOR GRILLE LOWER
(a) Using a screwdriver, disengage the 10 claws and remove the grille lower.
HINT:
Tape the screwdriver tip before use.
19. INSTALL FRONT BUMPER REINFORCEMENT SUB±ASSY
(a) Install the reinforcement with the 8 bolts.
(b) Install the wire harness.
20. INSTALL FRONT BUMPER COVER
(a) w/ Fog lamp:
Connect the fog lamp connector.
(b) Engage the 6 claws and install the bumper cover.
(c) Install the 3 bolts and 2 clips.
(d) Install the spoiler.
(1) Install the spoiler covers LH and RH together.
(2) Install the 6 retainers.
(3) Install the 9 screws and 10 claws.

760WX±01
B67422
Front Bumper CoverCAC Cooling
Air Duct Sub±assy Front Bumper
Reinforcement Sub±assy
Front Bumper Side
Retainer LH Front Bumper Side
Retainer RH
w/ Fog Lamp
Fog Lamp
Assy RH
Front Bumper Hole
Cover LH Front Bumper Hole
Cover RH
Front Spoiler
Cover LH Front Spoiler
Cover RHFront Bumper Side
Moulding LH Front Bumper Side
Moulding RHHood to Front
End Panel Seal Radiator GrilleRadiator Grille Lower
w/ CAC
Front Bumper
Stay Sub±assy LH Front Bumper
Stay Sub±assy RH
w/ Fog Lamp
Fog Lamp Assy LH
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
76±1
AVENSIS REPAIR MANUAL (RM1018E)
FRONT BUMPER
COMPONENTS

B68229
w/ Headlamp Cleaner
Headlamp Washer
Actuator Sub±assy RH
Headlamp Washer
Actuator Sub±assy LH
Radiator Grille Lower
Front Bumper Cover Headlamp Washer
Nozzle Sub±assy LH Headlamp Washer
Nozzle Sub±assy RH
Front Spoiler
Cover LH Front Spoiler
Cover RH
76±2
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
AVENSIS REPAIR MANUAL (RM1018E)

750NB±01
B65104
AB ab 75±48
± ENGINE HOOD/DOORBACK DOOR STAY
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
Use the same procedures on the RH side as on the LH side.
1. DISPOSE OF BACK DOOR STAY ASSY LH
(a) Horizontally fix the stay in a vise with the piston±rod pulled
out.
(b) Wearing safety glasses, gradually cut a part between A
and B as shown in the illustration using a metal saw to
gradually release the gas.
Standard dimension:
a80 mm (3.15 in.)
b20 mm (0.80 in.)
NOTICE:
Although the gas inside the stay is colorless, odorless and
harmless, there is a possibility that metal debris from cut-
ting could be blown out. Therefore, cover it with clothes or
thr like.

750NA±01
H19020
± ENGINE HOOD/DOORBACK DOOR STAY
75±47
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR STAY
REPLACEMENT
HINT:
Use the same procedures on the RH side as on the LH side.
1. REMOVE BACK DOOR STAY ASSY LH
(a) Using a screwdriver, remove the stay from the door panel.
HINT:

Remove the door stay while supporting the back door with
your hands.

Tape the screwdriver tip before use.
(b) Remove the 2 bolts and stay from the body.
2. INSTALL BACK DOOR STAY ASSY LH
(a) Install the stay with the bolts.
Torque:
22 N
m (264 kgf
cm, 19 ft
lbf) on door side
7.0 N
m (71 kgf
cm, 63 in.
lbf) on body side

750N9±01
B66997: Clip
H19055Clip
B66998: Clip

B68469: Clip
±
ENGINE HOOD/DOOR BACK DOOR(WAGON MODELS)
75±45
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
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 BACK DOOR TRIM PANEL ASSY UPPER
(a)Using a screwdriver, disengage the 4 clips and removethe trim panel.
HINT:
Tape the screwdriver tip before use.
2.REMOVE BACK DOOR SIDE GARNISH LH
(a)Using a screwdriver, disengage the 2 clips and remove the side garnish.
HINT:
Tape the screwdriver tip before use.
3.REMOVE BACK DOOR SIDE GARNISH RH
HINT:
Use the same procedures described for the LH side.
4.REMOVE BACK DOOR TRIM BOARD ASSY
(a)Using a screwdriver, disengage the 13 clips and remove the trim board.
HINT:
Tape the screwdriver tip before use.
(b)Remove the 3 service hole covers.
5.REMOVE DOOR PULL HANDLE
(a)Using a screwdriver, disengage the 4 claws and remove the pull handle.
6.REMOVE REAR SPOILER (See page 76±30)
7.REMOVE REAR WIPER MOTOR ASSY (See page 66±17)
8.REMOVE BACK DOOR GARNISH SUB±ASSY OUTSIDE RH (See page 76±29)

B66315
B66315
75±46
±
ENGINE HOOD/DOOR BACK DOOR(WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
9.REMOVE BACK DOOR LOCK ASSY
(a)Disconnect the door lock connector.
(b)Remove the 3 bolts and door lock.
10.BACK DOOR STAY ASSY LH (See page 65±26)
11.BACK DOOR STAY ASSY RH (See page 65±26) 12. INSTALL BACK DOOR LOCK ASSY
(a) Install the door lock with the 3 bolts.Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(b) Connect the door lock connector.