TOYOTA AVENSIS 2002 Repair Manual

A77865
A77866
(a)(a)
(b)(b)
(b)
± EXHAUSTEXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
15±3
AVENSIS REPAIR MANUAL (RM1018E)
4. REMOVE FLOOR PANEL BRACE FRONT
(a) Remove the 2 nuts, and then remove the floor panel
brace front.
5. REMOVE EXHAUST PIPE ASSY TAIL
(a) Remove the 2 bolts and 2 compression springs.
(b) Remove the exhaust pipe tail from the 3 exhaust pipe
supports.
(c) Remove the gasket from the exhaust pipe front.

A78492
(a)(a)
(b)
(b)
A77857
A78440
New Gasket
15±4
± EXHAUSTEXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs.
(b) Remove the exhaust pipe front from the 2 exhaust pipe
supports.
(c) Remove the gasket from the exhaust manifold.
7. INSTALL EXHAUST PIPE ASSY FRONT
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 41.5 mm (1.634 in.)
If the free length is less than minimum, replace the compression
spring.
(b) Install a new gasket to the exhaust manifold as shown in
the illustration.
(c) Install the exhaust pipe front to the 2 exhaust pipe sup-
ports.
(d) Tighten the 2 compression springs and 2 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)

A77857
A78440
New Gasket
± EXHAUSTEXHAUST PIPE ASSY (1ZZ±FE/3ZZ±FE)
15±5
AVENSIS REPAIR MANUAL (RM1018E)
8. INSTALL EXHAUST PIPE ASSY TAIL
(a) Compression spring inspection
(1) Using vernier calipers, measure the free length of
the compression spring.
Minimum length: 38.5 mm (1.516 in.)
If the free length is less than minimum, replace the compression
spring.
(b) Install a new gasket to the exhaust pipe front as shown in
the illustration.
(c) Install the exhaust pipe tail to the 3 exhaust pipe supports.
(d) Tighten the 2 compression springs and 2 bolts.
Torque: 43 N
m (440 kgf
cm, 32 ft
lbf)
9. INSTALL HEATED OXYGEN SENSOR (W/O HID SENSOR)
Torque: 44 N
m (449 kgf
cm, 33 ft
lbf)
10. INSTALL HEATED OXYGEN SENSOR (W/ HID SENSOR)
Torque: 44 N
m (449 kgf
cm, 33 ft
lbf)
11. CHECK FOR EXHAUST GAS LEAKS
12. INSTALL FLOOR PANEL BRACE FRONT
Torque: 30 N
m (302 kgf
cm, 22 ft
lbf)
13. INSTALL FRONT FLOOR FOOTREST (W/O HID SENSOR)

760WA±01
B67627
ClipNut
76±28±
EXTERIOR/INTERIOR TRIM BACK DOOR GARNISH SUB±ASSY
OUTSIDE(LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR GARNISH SUB±ASSY OUTSIDE(LIFTBACK
MODELS)
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 BACK DOOR TRIM PANEL ASSY UPPER (See page 75±40)
2.REMOVE BACK DOOR SIDE GARNISH LH (See page 75±40)
3.REMOVE BACK DOOR SIDE GARNISH RH (See page 75±40)
4.REMOVE BACK DOOR SIDE GARNISH CLIP (See page 75±40)
5.REMOVE BACK DOOR TRIM BOARD ASSY (See page 75±40)
6.REMOVE BACK DOOR GARNISH SUB±ASSY OUTSIDE (See page 75±40)
(a) Remove the 5 nuts, clip and garnish.
7. INSTALL BACK DOOR GARNISH SUB±ASSY OUTSIDE
(a) Install the garnish with the 5 nuts and clip. Torque: 4.9 N
m (50 kgf
cm, 43 in.
lbf)

760WB±01
B67627
ClipNut
±
EXTERIOR/INTERIOR TRIM BACK DOOR GARNISH SUB±ASSY
OUTSIDE(WAGON MODELS)76±29
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR GARNISH SUB±ASSY OUTSIDE(WAGON
MODELS)
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 BACK DOOR TRIM PANEL ASSY UPPER (See page 75±45)
2.REMOVE BACK DOOR SIDE GARNISH LH (See page 75±45)
3.REMOVE BACK DOOR SIDE GARNISH RH (See page 75±45)
4.REMOVE BACK DOOR TRIM BOARD ASSY (See page 75±45)
5.REMOVE DOOR PULL HANDLE (See page 75±45)
6. REMOVE BACK DOOR GARNISH SUB±ASSY OUTSIDE
(a) Remove the 5 nuts, clip and back door garnish.
7. INSTALL BACK DOOR GARNISH SUB±ASSY OUTSIDE
(a) Install the garnish with the 5 nuts and clip.
Torque: 4.9 N
m (50 kgf
cm, 43 in.
lbf)

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)

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.

760WC±01
B67619
Clip
76±32
± EXTERIOR/INTERIOR TRIMFRONT FLOOR FOOTREST
AVENSIS REPAIR MANUAL (RM1018E)
FRONT FLOOR FOOTREST
REPLACEMENT
HINT:
The installation is in the reverse order of the removal.
1. REMOVE FR FLOOR FOOTREST LH
(a) Using a screwdriver, disengage the 2 clips and remove
the footrest.
HINT:
Tape the screwdriver tip before use.
(b) Disengage the clips and then remove the 2 clips from the
footrest.