roof TOYOTA AVENSIS 2002 Repair Manual

670SE±01
I35216: Clamps
67±22
±
AUDIO & VISUAL SYSTEM AMPLIFIER ANTENNA ASSY(LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
AMPLIFIER ANTENNA ASSY(LIFTBACK MODELS)
REPLACEMENT
1.REMOVE ROOF HEADLINING ASSY (See page 76±45)
2.REMOVE AMPLIFIER ANTENNA ASSY
(a)Disconnect the connectors.
(b)Remove the bolt.
(c)Remove the 3 clamps and the amplifier antenna assy.
3.INSTALL AMPLIFIER ANTENNA ASSY
(a)Install the bolt. Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
(b)Install the 3 clamps and the amplifier antenna assy.
(c)Disconnect the connectors.
4.INSTALL ROOF HEADLINING ASSY (See page 76±45)

670SC±03
67±16
±
AUDIO & VISUAL SYSTEM AMPLIFIER ANTENNA ASSY (SEDAN MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
AMPLIFIER ANTENNA ASSY (SEDAN MODELS)
REPLACEMENT
1 . DISCONNEC T B ATTE RY NEG ATIVE TERMINAL ( See page 60±1)
2 . REMOVE INSTRUMENT CLUSTER FINISH P ANEL GARNISH NO.2 ( See page 71±11 )
3. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (W/ NAVIGATION SYSTEM) (See page 67±6 )
4 . REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) ( See page 41±11 )
5 . REMOVE CONSOLE PANEL SUB±ASSY UPPER ( See page 71±11 )
6 . REMOVE RADIO RECEIVER ASSEMB LY W/BRACKET ( See page 67±5)
7 . REMOVE CONSOLE BOX ASSY RR ( See page 71±11 )
8 . REMOVE HE ATER T O REGISTER DUCT NO.2 ( See page 71±11 )
9 . REMOVE FRONT SE AT ASSY RH ( See page POWER SE AT 72± 11 , MANUAL SE AT 72±16 )
10 . REMOV E FRONT DOOR SCUFF PL ATE RH ( See page 76±36 )
1 1 . REMOVE REAR DOOR SCUFF PL ATE RH ( See page 76±36 )
12 . REMOVE COWL SIDE TRIM BOARD RH ( See page 76±36)
13 . REMOVE FRONT DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
14 . REMOVE REAR DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
15 . REMOVE REAR SE AT CUSHION ASSEMB LY ( See page 72±32 )
16 . REMOVE REAR SE ATBACK ASSY ( See page 40/60 FOLDING 72±27 , UNITED FIXED 72±32 )
17 . REMOVE ROOF SIDE GARNISH INNER RH ( See page 76±36)
18. REMOVE FLOOR CARPET ASSY FRONT

670SD±02
±
AUDIO & VISUAL SYSTEM AMPLIFIER ANTENNA ASSY (WAGON MODELS)
67±19
AVENSIS REPAIR MANUAL (RM1018E)
AMPLIFIER ANTENNA ASSY (WAGON MODELS)
REPLACEMENT
1. DISCONNEC T B ATTE RY NEG ATIVE TERMINAL ( See page 60±1)
2 . REMOVE INSTRUMENT CLUSTER FINISH P ANEL GARNISH NO.2 ( See page 71±11 )
3. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (W/ NAVIGATION SYSTEM) (See page 67±6 )
4 . REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) ( See page 41±11 )
5 . REMOVE CONSOLE PANEL SUB±ASSY UPPER ( See page 71±11 )
6 . REMOVE RADIO RECEIVER ASSEMB LY W/BRACKET ( See page 67±5)
7 . REMOVE CONSOLE BOX ASSY RR ( See page 71±11 )
8 . REMOVE HE ATER T O REGISTER DUCT NO.2 ( See page 71±11 )
9 . REMOVE FRONT SE AT ASSY RH ( See page POWER SE AT 72± 11 , MANUAL SE AT 72±16 )
10 . REMOVE FRONT DOOR SCUFF PL ATE RH ( See page 76±36 )
1 1 . REMOVE REAR DOOR SCUFF PL ATE RH ( See page 76±36 )
12 . REMOVE COWL SIDE TRIM BOARD RH ( See page 76±36)
13 . REMOVE FRONT DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
14 . REMOVE REAR DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
15. REMOVE REAR SEAT CUSHION ASSEMBLY (See page 40/60 FOLDING FLIP±UP CUSHION72±21 , 40/60 FOLDING 72±27 )
16. REMOVE REAR SEATBACK ASSY
(See page 40/60 FOLDING FLIP±UP CUSHION72±21 , 40/60 FOLDING 72±27 )
17. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 40/60 FOLDING FLIP±UP CUSHION72±21 , 40/60 FOLDING 72±27 )
18. REMOVE TONNEAU COVER ASSY
19 . REMOVE BACK DOOR WE ATHERSTRIP ( See page 76±54 )
20 . REMOVE DECK BOARD SUB±ASSY ( See page 76±54)
21 . REMOVE DECK FLOOR BOX REAR ( See page 76±54)
22 . REMOVE DECK FLOOR BOX FRONT ( See page 76±54)
23 . REMOVE DECK FLOOR BOX RH ( See page 76±54)
24 . REMOVE REAR FLOOR FINISH PL ATE ( See page 76±54 )
25 . REMOVE DECK TRIM SIDE BOARD RH ( See page 76±54)
26 . REMOVE ROOF SIDE GARNISH INNER RH ( See page 76±54)
27. REMOVE FLOOR CARPET ASSY FRONT

670SF±01
I35218: Clamp
I36708
±
AUDIO & VISUAL SYSTEM ANTENNA CORD SUB±ASSY
67±23
AVENSIS REPAIR MANUAL (RM1018E)
ANTENNA CORD SUB±ASSY
REPLACEMENT
1.REMOVE ROOF HEADLINING ASSY (See page 76±45)
2.REMOVE BACK DOOR TRIM PANEL ASSY UPPER (See page 75±40)
3.REMOVE ANTENNA CORD SUB±ASSY
(a)Disconnect the connectors.
(b)Remove the bolt.
(c)Remove the clamp and draw out the antenna cord sub±assy from the inte\
rior and the back door.
4.INSTALL ANTENNA CORD SUB±ASSY
(a)Press the 4 points of the grommet shown in the illustra-tion, and install the antenna cord sub±assy.
(b)Install the bolt. Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
(c)Connect the connectors.
5.INSTALL ROOF HEADLINING ASSY (See page 76±45)

670SG±02
67±24
±
AUDIO & VISUAL SYSTEM ANTENNA CORD SUB±ASSY NO.3
AVENSIS REPAIR MANUAL (RM1018E)
ANTENNA CORD SUB±ASSY NO.3
REPLACEMENT
1 . DISCONNEC T B ATTE RY NEG ATIVE TERMINAL ( See page 60±1)
2 . REMOVE INSTRUMENT CLUSTER FINISH P ANEL GARNISH NO.2 ( See page 71±11 )
3. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (W/ NAVIGATION SYSTEM) (See page 67±6 )
4 . REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE) ( See page 41±11 )
5 . REMOVE CONSOLE PANEL SUB±ASSY UPPER ( See page 71±11 )
6 . REMOVE RADIO RECEIVER ASSEMB LY W/BRACKET ( See page 67±5)
7 . REMOVE CONSOLE BOX ASSY RR ( See page 71±11 )
8 . REMOVE HE ATER T O REGISTER DUCT NO.2 ( See page 71±11 )
9 . REMOVE FRONT DOOR SCUFF PL ATE RH ( See page 76±36 )
10 . REMOVE REAR DOOR SCUFF PL ATE RH ( See page 76±36 )
1 1 . REMOVE COWL SIDE TRIM BOARD RH ( See page 76±36)
12 . REMOVE FRONT DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
13 . REMOVE REAR DOOR OPENING TRIM WE ATHERSTRIP RH ( See page 76±36 )
14. REMOVE REAR SEAT CUSHION ASSEMBLY (See page 40/60 FOLDING FLIP±UP CUSHION 72±21 , 40/60 FOLDING 72±27 )
15. REMOVE REAR SEATBACK ASSY (See page 40/60 FOLDING FLIP±UP CUSHION 72±21 , 40/60 FOLDING 72±27 )
16. REMOVE REAR SIDE SEAT BACK ASSY RH (See page 40/60 FOLDING FLIP±UP CUSHION 72±21 , 40/60 FOLDING 72±27 )
17 . REMOVE P ACKAGE TR AY TRIM P ANEL ASSY ( See page 76±45 )
18 . REMOVE REAR FLOOR FINISH PL ATE ( See page 76±45 )
19 . REMOVE DECK TRIM SIDE P ANEL ASSY RH ( See page 76±45)
20 . REMOVE ROOF SIDE GARNISH INNER RH ( See page 76±45)
21 . REMOVE FRONT SE AT ASSY RH ( See page POWER SE AT 72± 11 , MANUAL SE AT 72±16 )
22. REMOVE FLOOR CARPET ASSY FRONT

750N3±01
B55944
B55945
± ENGINE HOOD/DOORLUGGAGE DOOR HINGE TORSION BAR
75±35
AVENSIS REPAIR MANUAL (RM1018E)
LUGGAGE DOOR HINGE TORSION BAR
REPLACEMENT
HINT:

The installation is in the reverse order of the removal. However, when there is a special point concern-
ing the installation, it is indicated.

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

After removing the torsion bar, opening and closing door operation should be carried out while holding
the door with your hand in order to perform an accurate test by providing sliding resistance.

The RH side torsion bar is on the upper side and the LH side torsion bar is on the lower side, thus the
installation should be performed in the order of RH to LH and removal should be performed in the order
of LH to RH.
1. REMOVE LUGGAGE DOOR HINGE TORSION BAR LH
(a) Remove the floor carpet.
(b) Remove the floor finish plate.
(1) Remove the 2 screws and 2 No. 2 trim hooks.
(2) Remove the 2 bolts and rope hook assy
(3) Using a clip remover, remove the 2 clips and floor
finish plate.
(c) Remove the clips and trim cover inner LH and RH.
(d) Remove the torsion bar RH from the clip placed in the cen-
ter of the upper back panel.
(e) Remove the tip of the torsion bar from the roof side inner
panel by hand.
(f) Take out the hinge arm from the torsion bar in the rear
direction.
(g) Pull the torsion bar to your side in order to remove the U±
shaped part from the hinge support.
2. REMOVE LUGGAGE DOOR HINGE TORSION BAR RH

760WE±01
B67742
B67741
Front Side
Rear Side 1.3 (0.051)
mm (in.) A
A A ± A
4.8 (0.189)
1.5 (0.059)
A ± AA
A
4.6 (1.811)
76±26
± EXTERIOR/INTERIOR TRIMROOF DRIP SIDE FINISH MOULDING CENTER LH
AVENSIS REPAIR MANUAL (RM1018E)
ROOF DRIP SIDE FINISH MOULDING CENTER LH
REPLACEMENT
HINT:
Use the same procedures on the RH side as on the LH side.
1. REMOVE ROOF DRIP SIDE FINISH MOULDING
CENTER LH
(a) Put the protective tape around the circumference of the
moulding.
(b) Using a remover for the roof moulding, release the disen-
gage the clips both in the front and rear ends of the mould-
ing, and then remove the moulding.
NOTICE:

Do not remove the clips.

If that the clips are damaged or removed accidentally,
exchange them for supplied ones.
2. INSTALL ROOF DRIP SIDE FINISH MOULDING
CENTER LH
NOTICE:
Only when exchanging the clips.
(a) Remove the tape that remains on the mounting surface
of the body, and then clean the surface with white gaso-
line.
(b) Using a heat light, heat up the clip installation surfaces of
the body and moulding.
Heating temperature:
Body40 ± 60C (104 ± 140F)
Moulding20 ± 30C (68 ± 86F)
NOTICE:
Do not heat the moulding and body excessively.
(c) Set the supplied clips in the positions as shown in the il-
lustration and press±fit them by hand to install them.
NOTICE:
Install the moulding when 30 minutes or more have passed
after press±fitting the clips.
HINT:

Initial hardening time: 30 minutes

Perfect hardening time: 24 hours

760WV±01
B70682
Roof Side Garnish Inner RH
Front Pillar Garnish RH
Front Door Opening Trim Weatherstrip RH
Center Pillar Garnish RHRear Door Opening Trim Weatherstrip RH
Front Door
Scuff Plate RH
Rear Door Scuff
Plate RH
Cowl Side Trim Board RH
41.2 (420, 30)Center Pillar Garnish
Lower RH
Front Pillar Garnish LH
Front Door Opening Trim
Weatherstrip LH
Cowl Side Trim Board LH
Front Door Scuff Plate LH
Center Pillar Garnish Lower LH
Rear Door Scuff Plate LH
Center Pillar Garnish LH
Rear Door Opening Trim
Weatherstrip LH
Roof Side Garnish Inner LH
Package Tray
Trim Panel Assy
N
m (kgf
cm ft
lbf): Specified torque
41.2 (420, 30)
Rear Floor Finish Plate
Deck Trim Side
Panel Assy RH
Deck Trim Side
Board LH
Rear Headlining Sub±assy 76±42
± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
ROOF HEADLINING ASSY (LIFTBACK MODELS)
COMPONENTS

B70683
LH Visor Assy Visor Holder w/ Sliding Roof
Roof Headlining Assy
RH Visor Assy
Map Lamp AssyRoom Lamp Assy No. 2
Lens Cover
Assist Grip
Sub±assy
Lens CoverAssist Grip Sub±assy
Assist Grip Sub±assy
Assist Grip Sub±assy
Sun Roof Opening
Trim Moulding
± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (LIFTBACK MODELS)
76±43
AVENSIS REPAIR MANUAL (RM1018E)

B66566
w/o Sliding Roof
LH Visor Assy Visor HolderRoof Headlining Assy
RH Visor Assy
Map Lamp AssyRoom Lamp Assy No. 2
Lens Cover
Assist Grip Sub±assy
Lens CoverAssist Grip Sub±assy
Assist Grip Sub±assy
Assist Grip Sub±assy
76±44
± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)