TOYOTA AVENSIS 2003 Service Repair Manual

7408U±01
±
SLIDING ROOF/CONVERTIBLE SLIDING ROOF SYSTEM
74±5
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
SymptomSuspected AreaSee Page
AUTO function does not operate1. Sliding roof motor assy74±3
Sliding roof system does not operate
1. S/ROOF fuse
2. GAUGE1 fuse
3. IG1 relay
4. Integration relay
5. Sliding roof housing assy
6. Sliding roof motor switch assy
7. Sliding roof motor assy
8. Wire harness±
±
±
±
74±15 74±6
74±3
74±3
Sliding roof system stops operation halfway
1. Sliding roof motor assy
2. Wire harness
3. Sliding roof housing assy74±3
74±3
74±15
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7408V±01
B67892
1
4 3
2
B67891
10
9876 54321


A05115
74±6
±
SLIDING ROOF/CONVERTIBLESLIDING ROOF SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1.INSPECT SLIDING ROOF MOTOR SWITCH ASSY
(a)Remove the sliding roof motor switch (See pages 76±36, 76±45 and 76±54).
(b)Check the resistance between the terminals when oper- ating the switch.
Standard:
Terminals No.Switch OperationSpecified Condition
1 ± 2TILT UP is pressedBelow 1

2 ± 3SLIDE OPEN is pressedBelow 1

1, 3 ± 2OFF10 k
or higher
If the result is not as specified, replace the switch assy.
2.INSPECT SLIDING ROOF MOTOR ASSY
(a)Disconnect the sliding roof motor connector
(See pages 76±36, 76±45 and 76±54).
(b) Check the resistance and voltage between the terminals of the wire harness side connector.
Standard:
Terminals No.ConditionSpecified Condition
5  Body groundConstantBelow 1

3 ± 5Ignition switch ON10 to 14 V
10 ± 5Constant10 to 14 V
6 ± 5TILT UP is pressedBelow 1

1 ± 5SLIDE OPEN is pressedBelow 1

8 ± 5Ignition switch OFF

ON, Engine idle speedPulse generation *
Reference (*): Using an oscilloscope
ItemContents
Tool Setting10 V/DIV., 20 ms/DV.
Vehicle ConditionEngine idle speed
If the result is not as specified, there may be a malfunction on
the wire harness side.
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7408W±01
±
SLIDING ROOF/CONVERTIBLE SLIDING ROOF SYSTEM
74±7
AVENSIS REPAIR MANUAL (RM1018E)
RESET
1. RESET SLIDING ROOF MOTOR
(a) If the AUTO operation function does not operate, reset the sliding roof motor as f\
ollows:
(1) Press the sliding roof switch on the TILT UP side and hold it until the sliding roof motor stops.Then release the switch and leave it untouched for 10 seconds or more.
(2) Press the sliding roof switch on the TILT UP side again for 10 seconds or more and hold it until the sliding roof glass stops at the fully open and up position.
(3) Release the switch, press it again within 5 seconds and hold it until a series \
of movements indi- cated below have been completed:
Fully closing
Fully opening
Fully closing
HINT:
When the battery terminal is disconnected or after the jam protection functi\
on has operated, the sliding roof
motor ECU may not detect the position of the roof glass. If the AUTO operation function is still disabled even
after the sliding roof motor is reset, the Hall IC (built in the sliding roo\
f motor) for detecting the roof glass
position may be malfunctioning.
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750N4±01
B66986
Back Door Trim
Panel Assy UpperBack Door Trim Board Assy
Back Door Side
Garnish LH
Back Door Garnish Sub±assy
Outside RH
Floor Finish Plate
Center Stop Lamp Assy
Back Door Lock Striker
Hook
Back Door Side
Garnish RH Back Door Stay Assy RH
Back Door Lock Assy
Rear Wiper Motor Assy
Back Door
Stay Assy LHBack Door Service
Hole Cover
: Specified torqueN´m (kgf´cm, ft´lbf)
19.5 (200, 14)
5.5 (56, 49 in.´lbf)
Hook
Rear Wiper Arm and Blade Assy
Rear Wiper
w/ Packing Washer
Wiper Arm Head Cap
Nut5.5 (56, 49 in.´lbf)
5.5 (56, 49 in.´lbf)
Cushion Rubber
Cushion Rubber
Rope Hook Assy
11.5 (120, 8)
22 (264, 19)
7.0 (71, 62 in.´lbf)
5.5 (56, 49 in.´lbf)
8.0 (82, 71 in.´lbf)
7.0 (71, 62 in.´lbf)22 (264, 19)
Female
Stopper RH
Female
Stopper LH
4.9 (49, 43 in.´lbf)Back Door Damper Assy
5.5 (56, 49 in.´lbf)
±
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)
75±37
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR (LIFTBACK MODELS)
COMPONENTS
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750N5±01
B57104
Centering BoltStandard Bolt
B67535
A
B C
D
B66993
75±38
±
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Because a centering bolt is used as a door hinge mounting bolt
on the body side and door side, the door can not be adjusted
with them on. Substitute a bolt with a washer for the centering
bolt.
1. INSPECT BACK DOOR PANEL SUB±ASSY
(a) Check that the clearance is within the standard range.
Standard range:
A6.3
1.5 mm (0.248
0.059 in.)
B4.9
1.5 mm (0.193
0.059 in.)
C5.0
1.5 mm (0.197
0.059 in.)
D8.0
1.5 mm (0.315
0.059 in.)
2. ADJUST BACK DOOR PANEL SUB±ASSY
(a) Adjust the door vertically and forward/rearward by loos-
ening the body side hinge bolts.
(b) Tighten the body side hinge bolts after the adjustment. Torque: 19.5 N
m (200 kgf
cm, 14 ft
lbf)
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B66992
B66994
B66995
±
ENGINE HOOD/DOORBACK DOOR(LIFTBACK MODELS)
75±39
AVENSIS REPAIR MANUAL (RM1018E)
(c)Horizontally and vertically adjust the door by loosening
the 8 door side hinge bolts.
(d)Tighten the door side hinge bolts after the adjustment.
Torque: 19.5 N
m (200 kgf
cm, 14 ft
lbf)
(e)Remove the floor finish plate (See page 76±45)
(f) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic±
faced hammer.
(g) Tighten the striker mounting screws after the adjustment. Torque: 11.5 N
m (120 kgf
cm, 8 ft
lbf)
(h) Adjust the side female stopper so that the door can be opened/closed smoothly, as shown in the illustration.
(i) Tighten the side female stopper after the adjustment. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
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750N6±01
B66988: Clip
B66989: Clip
Hook
B66990: Clip
B66991
75±40
±
ENGINE HOOD/DOORBACK DOOR(LIFTBACK MODELS)
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.
HINT:
Tape the screwdriver tip before use.
2.REMOVE BACK DOOR SIDE GARNISH LH
(a)Using a clip remover, remove the hook.
(b)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)Remove the 2 screws.
(b)Using a screwdriver, disengage the 12 clips and remove the trim board.
HINT:
Tape the screwdriver tip before use.
(c)Remove the 4 service hole covers.
5.REMOVE BACK DOOR DAMPER ASSY
(a)Remove the 4 bolts and damper.
6.REMOVE BACK DOOR GARNISH SUB±ASSY OUTSIDE RH (See page 76±27)
7.REMOVE REAR WIPER MOTOR ASSY (See page 66±17)
8.REMOVE CENTER STOP LAMP ASSY (See page 65±26)
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B66996
B66996
B66991
±
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)
75±41
AVENSIS REPAIR MANUAL (RM1018E)
9. REMOVE BACK DOOR LOCK ASSY
(a) Disconnect the connector.
(b) Remove the 3 bolts and door lock.
10.REMOVE BACK DOOR STAY ASSY LH (See page 75±47)
11.REMOVE BACK DOOR STAY ASSY RH (See page 75±47) 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
13. INSTALL BACK DOOR DAMPER ASSY
(a) Install the damper with the 4 bolts. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
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750N7±01
B66987
Back Door Trim Panel Assy UpperBack Door Side Garnish LH
Wiper Motor Assy
Rear Spoiler
Back Door Garnish Sub±assy Outside RH Back Door Trim Board Assy
Door Pull Handle
Back Door Lock Striker
Back Door Side Garnish RH
Door Pull Handle
: Specified torque
N´m (kgf´cm, ft´lbf)
Floor Finish Plate
Rear Wiper Arm and Blade Assy
Wiper Arm Head Cap
5.5 (56, 49 in.´lbf)
Rear Wiper w/ Packing
Washer
Back Door
Stay Assy LH
7.0 (71, 62 in.´lbf)
22 (264, 19)
11.5 (120, 8)
Back Door Stay Assy RH
7.0 (71, 62 in.´lbf)
8.0 (82, 71 in.´lbf)
19.5 (200, 14)
Back Door Service Hole Cover
Back Door Lock Assy
4.9 (49, 43 in.´lbf)4.9 (49, 43 in.´lbf)
75±42
±
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR (WAGON MODELS)
COMPONENTS
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750N8±01
B57104
Centering BoltStandard Bolt
B67534
A
B C
D
B67000
±
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)
75±43
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Because a centering bolt is used as a door hinge mounting bolt
on the body side and door side, the door can not be adjusted
with them on. Substitute a bolt with a washer for the centering
bolt.
1. INSPECT BACK DOOR PANEL SUB±ASSY
(a) Check that the clearance is within the standard range.
Standard range:
A7.5
1.5 mm (0.295
0.059 in.)
B4.9
1.5 mm (0.193
0.059 in.)
C5.4
1.5 mm (0.213
0.059 in.)
D6.0
1.5 mm (0.236
0.059 in.)
2. ADJUST BACK DOOR PANEL SUB±ASSY
(a) Adjust the door horizontally and forward/rearward by
loosening 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)
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