TOYOTA AVENSIS 2003 Service Repair Manual

B68229
w/ Headlamp CleanerHeadlamp 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 TRIM FRONT BUMPER
AVENSIS REPAIR MANUAL (RM1018E)
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760WY±01
B67425
Claw
B67431
±
EXTERIOR/INTERIOR TRIM FRONT 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 RHfrom 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 ENGI\
NE 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.
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B67425
76±4
±
EXTERIOR/INTERIOR TRIM FRONT 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.
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760WC±01
B67619
Clip
76±32
±
EXTERIOR/INTERIOR TRIM FRONT 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 removethe footrest.
HINT:
Tape the screwdriver tip before use.
(b) Disengage the clips and then remove the 2 clips from the footrest.
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760WC±01
B67619
Clip
76±32
±
EXTERIOR/INTERIOR TRIM FRONT 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 removethe footrest.
HINT:
Tape the screwdriver tip before use.
(b) Disengage the clips and then remove the 2 clips from the footrest.
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760X5±01
B68948
Sedan ModelsLuggage Compartment Trim Hook No. 2Rope Hook Assy
Luggage Compartment Floor Carpet
Luggage Compartment Trim Inner LH
5.0 (51, 44 in.´lbf)
: Specified torqueN´m (kgf´cm, ft´lbf)
Rear Floor Finish Plate
Fuel Lid Lock Control Assy
Fuel Filler Opening Lid Lock Retainer
5.5 (56, 49 in.´lbf)
±
EXTERIOR/INTERIOR TRIM FUEL LID LOCK CONTROL ASSY
76±11
AVENSIS REPAIR MANUAL (RM1018E)
FUEL LID LOCK CONTROL ASSY
COMPONENTS
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B68947
Liftback ModelsFuel Lid Lock Control Assy
Fuel Filler Opening Lid Lock Retainer
Rear Floor Finish Plate
Rear Door Opening Trim Weatherstrip LH
Rear Door Scuff Plate LH Deck Trim Side Board LH
Rope Hook Assy
Rope Hook Assy
: Specified torqueN

m (kgf
cm, ft
lbf)
5.5 (56, 49 in.´lbf)
76±12
±
EXTERIOR/INTERIOR TRIM FUEL LID LOCK CONTROL ASSY
AVENSIS REPAIR MANUAL (RM1018E)
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B68946
Wagon ModelsFuel Lid Lock Control Assy
Fuel Filler Opening Lid Lock Retainer
Deck Trim Side Board LH Luggage Compartment
Trim Hook No. 2
Tonneau Cover Assy
Deck Board Sub±assy
Deck Floor Box Front
Deck Floor Box LHRear Floor Finish Plate
Deck Floor Box Rear
Rear Door Opening Trim Weatherstrip LH
Rear Door Scuff Plate LH
: Specified torqueN
m (kgf
cm, ft
lbf)
5.5 (56, 49 in.´lbf)
±
EXTERIOR/INTERIOR TRIM FUEL LID LOCK CONTROL ASSY
76±13
AVENSIS REPAIR MANUAL (RM1018E)
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760X6±01
B68949
B69147
76±14
±
EXTERIOR/INTERIOR TRIMFUEL LID LOCK CONTROL ASSY
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 LUGGAGE COMPARTMENT TRIM COVER INNER LH (SEDAN MODELS) (See page 76±36)
(a) Remove the luggage compartment floor carpet.
(b) Remove the 2 rope hooks.
(c) Remove the rear floor finish plate.
(d) Remove the 2 luggage compartment trim hooks.
(e) Remove the luggage compartment trim inner.
2.REMOVE DECK TRIM SIDE BOARD LH (LIFTBACK MODELS) (See page 76±45)
(a) Remove the 2 rope hooks.
(b) Remove the rear floor finish plate.
(c) Remove the rear door opening trim weatherstrip LH.
(d) Remove the rear door scuff plate LH.
(e) Remove the deck trim side board.
3.REMOVE DECK TRIM SIDE PANEL ASSY LH (WAGON MODELS) (See page 76±54)
(a) Remove the rear door opening trim weatherstrip LH
(b) Remove the rear door scuff plate.
(c) Remove the tonneau cover.
(d) Remove the deck board.
(e) Remove the deck floor box rear.
(f) Remove the deck floor box LH.
(g) Remove the deck floor box front.
(h) Remove the rear floor finish plate.
(i) Remove the luggage compartment trim hook No. 2.
(j) Remove the deck trim side board.
4. REMOVE FUEL LID LOCK CONTROL ASSY
(a) Disconnect the connector.
(b) Remove the nut and fuel lid lock control.
5. REMOVE FUEL FILLER OPENING LID LOCKRETAINER
(a) Remove the fuel filler opening lid lock retainer, as shown
in the illustration.
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B68950
A
Check Hole
B68951
Male Part
Female Part
±
EXTERIOR/INTERIOR TRIM FUEL LID LOCK CONTROL ASSY
76±15
AVENSIS REPAIR MANUAL (RM1018E)
6. INSTALL FUEL LID LOCK CONTROL ASSY
(a) Install the fuel lid lock control with the the nut.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
HINT:
Check to see that the tip of the lock is securely insearted into
hole A, looking inside through the check hole.
7. INSTALL FUEL FILLER OPENING LID LOCK RETAINER
(a) Install the fuel filler opening lid lock retainer as shown in the illustration.
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