TOYOTA AVENSIS 2003 Service Repair Manual

B66999
B67001
75±44
±
ENGINE HOOD/DOORBACK DOOR(WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
(c)Horizontally and vertically adjust the door by loosening the door side hinge bolts.
(d)Tighten the door side hinge bolts after the adjustment.
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
(e)Remove the floor finish plate (See page 76±54)
(f) Adjust the striker position by slightly loosening the striker mounting 2 screws and hitting the striker with a plastic±
faced hammer.
(g) Tighten the striker mounting screws after the adjustment. Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)
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750N9±01
B66997: Clip
H19055Clip
B66998: Clip

B68469: Clip
±
ENGINE HOOD/DOORBACK 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)
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B66315
B66315
75±46
±
ENGINE HOOD/DOORBACK 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.
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750NA±01
H19020
±
ENGINE HOOD/DOOR BACK 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
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750NB±01
B65104
AB
ab
75±48
±
ENGINE HOOD/DOOR BACK 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 pulledout.
(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.
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750MV±01
B67988
Front Door Glass
Sub±assy LH
Front Door Glass Run LH
Front Door Frame Sub±assy Rear Lower LH
8.0 (82, 71 in.´lbf)
Front Door Glass Weatherstrip Inner LH
Front Door Trim Board Sub±assy LH
Front Door Armrest
Base Panel Upper
Courtesy Lamp : Specified torque
N´m (kgf´cm, ft´lbf) Front No. 1 Speaker Assy
Front Door Inside Handle Sub±assy LH
Fuel Lid Opener Switch
Front Door Trim Base LHClip
Power Window Regulator
Switch Assy
Front Door Armrest Base Panel Upper
w/o Rear Power Window
Front Door Window Regulator
Sub±assy LH
8.0 (82, 71 in.´lbf)
Power Window Regulator
Master Switch Assy
Rivet
Non±reusable part



5.5 (56, 49 in.´lbf)
75±4
±
ENGINE HOOD/DOOR FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DOOR
COMPONENTS
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B67989
Front Door Outside Handle Frame Sub±assy LHw/ Key:
Front Door Outside Handle Cover LH
Front Door Handle
Assy Outside LH
Front Door Outside Handle Pad Rear
Front Door Outside
Handle Pad Front
Hole Plug
Front Door Lock Open Rod
Front Door w/ Motor Lock Assy LH
Door Lock Wire Harness Packing
5.0 (51, 44 in.´lbf)
Front Door Belt Moulding LH
Front Door Hinge
Assy Upper LH
Front Door Check Assy
30 (306, 22)

5.5 (56, 49 in.´lbf)
Front Door Hinge
Assy Lower LH26 (265, 19)
Front Door Weatherstrip LH
Cushion Rubber Front Door Lower Frame
Bracket Garnish LH
Outer Rear View Mirror Assy LH
Front Door Speaker No. 2
Front Door Service Hole Cover

: Specified torqueN´m (kgf´cm, ft´lbf)

Precoated Part Non±reusable part
 Clip
26 (265, 19)
Front Door Lower
Frame Seal


Butyl Tape

10 (102, 7)
Front Door Stiffener
Cushion No. 1
Side Trim
Spacer LH
Key Cylinder
w/o Key:
Front Door Outside
Handle Cover LHw/ SpeakerFront Door Lower Frame
Bracket Garnish LH
±
ENGINE HOOD/DOOR FRONT DOOR
75±5
AVENSIS REPAIR MANUAL (RM1018E)
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750MW±01
B57104
Centering BoltStandard Bolt
B66965
A
B
C
E D
B66966
75±6
±
ENGINE HOOD/DOOR FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:

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

Because a centering bolt is used as a door hinge mount-
ing 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 FRONT DOOR PANEL SUB±ASSY LH
(a) Check that the clearance is within the standard range.
Standard range:
A4.6
1.5 mm (0.181
0.059 in.)
B5.5
1.5 mm (0.220
0.059 in.)
C4.6
1.5 mm (0.181
0.059 in.)
D160 mm (6.30 in.)
E4.8
1.5 mm (0.189
0.059 in.)
2. ADJUST FRONT DOOR PANEL SUB±ASSY LH
(a) Using SST, adjust the door horizontally and vertically by
loosening the body side hinge bolts.
SST 09812±00010, 09812±00020
(b) Tighten the body side hinge bolts after the adjustment. SST 09812±00010, 09812±00020
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
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B66967
B62411
±
ENGINE HOOD/DOOR FRONT DOOR
75±7
AVENSIS REPAIR MANUAL (RM1018E)
(c) Adjust the door forward/rearward and vertically by loos-
ening the door side hinge bolts.
(d) Tighten the door side hinge bolts after the adjustment.
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
(e) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic±
faced hammer.
(f) Tighten the striker mounting screws after the adjustment. Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)
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750MX±01
B66969: Clip
B66970
: Clip
: Claw
B67801
Claw
75±8
±
ENGINE HOOD/DOORFRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
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. 1.REMOVE FRONT DOOR LOWER FRAME BRACKETGARNISH LH
(a)Using a screwdriver, disengage the 2 clip and remove the garnish.
HINT:
Tape the screwdriver tip before use.
(b)w/ Speaker: Remove the front door speaker No. 2 (See page
67±12).
2. REMOVE FRONT DOOR TRIM BASE LH
(a) Using a screwdriver, disengage the 5 claws and clip, and remove the trim base.
HINT:
Tape the screwdriver tip before use.
3. REMOVE FUEL LID OPENER SWITCH
(a) Using a screwdriver, disengage the 2 claws and remove the switch.
HINT:
Tape the screwdriver tip before use.
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