TOYOTA AVENSIS 2003 Service Repair Manual

750MU±01
B57104
Centering BoltStandard Bolt
B66962
A B
B61420
75±2
±
ENGINE HOOD/DOOR HOOD
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Because a centering bolt is used as a hood hinge mounting bolt
and hood lock mounting bolt, the hood and hood lock can not
be adjusted with them on. Substitute a bolt with a washer for the
centering bolt.
1. INSPECT HOOD SUB±ASSY
(a) Check that the clearance is within the standard range.
Standard range:
A3.5
1.5 mm (0.138
0.059 in.)
B3.5 ± 1.5 or +2.5 mm
(0.138 ± 0.059 or + 0.098 in.)
2. ADJUST HOOD SUB±ASSY
(a) Horizontally and vertically adjust the hood. (1) Loosen the 4 hood hinge bolts on the hood side.
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B66963
A
Aligned
B66964
B62401
±
ENGINE HOOD/DOORHOOD
75±3
AVENSIS REPAIR MANUAL (RM1018E)
(2)Adjust the clearance by moving the hood, so that it
will be in the standard range.
Standard range (A): 3.5
1.5 mm (0.138
0.059 in.)
(3)Tighten the hood side hinge bolts after the adjust-
ment.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(b)Adjust the height of the hood front end using the cushion rubber.
(1)Adjust the cushion rubber so that the hood and thefender will be aligned.
HINT:
The cushion rubber goes up and down by turning it.
(c)Adjust the hood lock.
(1)Using a clip remover, remove the 6 clips and frontend seal.
(2)Remove the retainer and battery service hole cover.
(3)Using a clip remover, remove the 3 clips and radia-
tor cover.
(4)Using a clip remover, remove the 3 clips and engine room side cover RH.
(5)Remove the front bumper (See page 76±3).
(6) Adjust the hood lock position by moving the striker, so that the striker can enter smoothly.
(7) Tighten the hood lock bolts after the adjustment.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
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750N1±01
B66985
Luggage Compartment
Door Panel Sub±assyLuggage Compartment
Outside Garnish
Licence Plate Lamp Assy
Luggage Compartment Door Lock Cylinder Assy
Luggage Compartment Trim Hook No. 2 Rear Floor Finish Plate
Luggage Striker Assy
Rope Hook Assy Back Door Trim Cover
Luggage Compartment Floor Carpet Luggage Compartment
Trim Inner RH
Luggage Compartment
Trim Inner LH Luggage Lock Assy
Clip
4.9 (49, 43 in.´lbf)
5.0 (51, 44 in.´lbf)
5.0 (51, 44 in.´lbf)
Hinge Cover
: Specified torqueN´m (kgf´cm, ft´lbf)
7.0 (71, 62 in.´lbf)
11.5 (120, 8)
75±32
±
ENGINE HOOD/DOOR LUGGAGE COMPARTMENT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
LUGGAGE COMPARTMENT DOOR
COMPONENTS
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750N2±01
B57104
Centering BoltStandard Bolt
B66984
A
B
C
B61457
±
ENGINE HOOD/DOOR LUGGAGE COMPARTMENT DOOR
75±33
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Because a centering bolt is used as a luggage compartment
door mounting bolt, the luggage compartment door can not be
adjusted with it on. Substitute a bolt with a washer for the cen-
tering bolt.
1. INSPECT LUGGAGE COMPARTMENT DOOR PANEL SUB±ASSY
(a) Check that the clearance is within the standard range.
Standard range:
A4.0
1.5 mm (0.157
0.059 in.)
B5.3
1.5 mm (0.209
0.059 in.)
C7.1 ± 1.5 or + 2.5 mm
(0.280 ± 0.059 or + 0.098 in.)
2. ADJUST LUGGAGE COMPARTMENT DOOR PANEL SUB±ASSY
(a) Using a clip remover, remove the clips and hinge cover.
(b) Using a clip remover, remove the 11 clips and trim cover.
(c) Adjust the door horizontally and vertically by Loosening
the door bolts.
(d) Tighten the door mounting bolts after the adjustment.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
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B66994
75±34
±
ENGINE HOOD/DOOR LUGGAGE COMPARTMENT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(e) Adjust the striker.
HINT:
Adjust the door lock position by moving the striker so that the
door striker can enter smoothly. (1) Using a hammer and a brass bar, tap the striker toadjust it.
(2) Tighten the 2 bolts after the adjustment.
Torque: 11.5 N
m (120 kgf
cm, 8 ft
lbf)
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750N3±01
B55944
B55945
±
ENGINE HOOD/DOOR LUGGAGE 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 s\
liding 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 perf\
ormed 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 floorfinish 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
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B56621
Installation Hole
Installation Hole
(For Adjustment)
75±36
±
ENGINE HOOD/DOOR LUGGAGE DOOR HINGE TORSION BAR
AVENSIS REPAIR MANUAL (RM1018E)
3. INSTALL LUGGAGE DOOR HINGE TORSION BAR LH
(a) Set the tip of the torsion bar in the installation hole placed in the center part. The holes placed in the upper and lower
parts are used for adjustment.
4. INSTALL LUGGAGE DOOR HINGE TORSION BAR RH
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760WA±01
B67627
ClipNut
76±28±
EXTERIOR/INTERIOR TRIMBACK 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)
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760WB±01
B67627
ClipNut
±
EXTERIOR/INTERIOR TRIMBACK 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)
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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 RH Front Bumper Side
Moulding LH
Front Bumper Side
Moulding RH
Hood to Front
End Panel Seal
Radiator Grille
Radiator 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 TRIM FRONT BUMPER
76±1
AVENSIS REPAIR MANUAL (RM1018E)
FRONT BUMPER
COMPONENTS
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