Front board TOYOTA AVENSIS 2003 Service User Guide

610EC±01
B66569
Protrusion Part
Front
Front
Mark
Protrusion Part
61±24
±
SEAT BELT REAR SEAT BELT (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
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 LH side as on the RH side.
1.REMOVE REAR DOOR SCUFF PLATE RH (See page 76±54)
2. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH
3.REMOVE REAR SEAT ASSY (See page 72±21)
4. REMOVE TONNEAU COVER ASSY
5. REMOVE BACK DOOR WEATHERSTRIP
6.REMOVE DECK BOARD SUB±ASSY (See page 76±54)
7.REMOVE DECK FLOOR BOX REAR (See page 76±54)
8.REMOVE DECK FLOOR BOX FRONT (See page 76±54)
9.REMOVE DECK FLOOR BOX RH (See page 76±54)
10.REMOVE REAR FLOOR FINISH PLATE (See page 76±54)
11.REMOVE DECK TRIM SIDE BOARD RH (See page 76±54)
12. REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER
(a) Remove the bolt and belt on the floor anchor side.
(b) Remove the 2 bolts and belt on the retractor side.
13. REMOVE REAR SEAT BELT ASSY OUTER CENTER
(a)Remove the rear seatback board RH (See page 72±21).
(b)Remove the rear seat shoulder belt cover (See page 72±21).
(c) Remove the bolt on the retractor side and remove the belt outer center c\
ompletely.
(d) Remove the bolt and belt outer center on the floor anchor side.
14. REMOVE REAR SEAT 3 POINT TYPE BELT ASSY INNER
(a) Remove the bolt and belt.
15. REMOVE REAR SEAT 3 POINT TYPE BELT ASSY INNER
(a) Remove the bolt and belt.
16. REMOVE CHILD RESTRAINT SEAT ANCHOR BRACKET SUB±ASSY RH
(a) Remove the 2 bolts and anchor bracket.
17. INSTALL CHILD RESTRAINT SEAT ANCHOR BRACKET SUB±ASSY RH
(a) Install the child restraint seat anchor bracket with the 2 bolts. Torque: 31 N
m (316 kgf
cm, 23 ft
lbf)
18. INSTALL REAR SEAT 3 POINT TYPE BELT ASSY INNER
(a) Install the belt with the bolt as shown in the illustration.
Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
NOTICE:

Makesure that the anchor part does not run onto the
protrusion part of the floor panel.

Do not disassemble the retractor.
19. INSTALL REAR SEAT BELT ASSY OUTER CENTER
(a) Install the belt with the bolt on the retractor side. Torque: 42 N
m (430 kgf
cm, 31 ft
lbf)
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670SC±03
67±16
±
AUDIO & VISUAL SYSTEM AMPLIFIER ANTENNA ASSY (SEDAN MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
AMPLIFIER ANTENNA ASSY (SEDAN MODELS)
REPLACEMENT
1.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
2.REMOVE INSTRUMENT CLUSTER FINISH PANEL 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 ASSEMBLY W/BRACKET (See page 67±5)
7.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
8.REMOVE HEATER TO REGISTER DUCT NO.2 (See page 71±11)
9.REMOVE FRONT SEAT ASSY RH (See page POWER SEAT 72±11, MANUAL SEAT72±16)
10.REMOVE FRONT DOOR SCUFF PLATE RH (See page 76±36)
11.REMOVE REAR DOOR SCUFF PLATE RH (See page 76±36)
12.REMOVE COWL SIDE TRIM BOARD RH (See page 76±36)
13.REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
14.REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
15.REMOVE REAR SEAT CUSHION ASSEMBLY (See page 72±32)
16.REMOVE REAR SEATBACK 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
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670SD±02
±
AUDIO & VISUAL SYSTEM AMPLIFIER ANTENNA ASSY (WAGON MODELS)
67±19
AVENSIS REPAIR MANUAL (RM1018E)
AMPLIFIER ANTENNA ASSY (WAGON MODELS)
REPLACEMENT
1.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
2.REMOVE INSTRUMENT CLUSTER FINISH PANEL 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 ASSEMBLY W/BRACKET (See page 67±5)
7.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
8.REMOVE HEATER TO REGISTER DUCT NO.2 (See page 71±11)
9.REMOVE FRONT SEAT ASSY RH (See page POWER SEAT 72±11, MANUAL SEAT 72±16)
10.REMOVE FRONT DOOR SCUFF PLATE RH (See page 76±36)
11.REMOVE REAR DOOR SCUFF PLATE RH (See page 76±36)
12.REMOVE COWL SIDE TRIM BOARD RH (See page 76±36)
13.REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
14.REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP 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 WEATHERSTRIP (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 PLATE (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
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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.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
2.REMOVE INSTRUMENT CLUSTER FINISH PANEL 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 ASSEMBLY W/BRACKET (See page 67±5)
7.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
8.REMOVE HEATER TO REGISTER DUCT NO.2 (See page 71±11)
9.REMOVE FRONT DOOR SCUFF PLATE RH (See page 76±36)
10.REMOVE REAR DOOR SCUFF PLATE RH (See page 76±36)
11.REMOVE COWL SIDE TRIM BOARD RH (See page 76±36)
12.REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 76±36)
13.REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP 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 PACKAGE TRAY TRIM PANEL ASSY (See page 76±45)
18.REMOVE REAR FLOOR FINISH PLATE (See page 76±45)
19.REMOVE DECK TRIM SIDE PANEL ASSY RH (See page 76±45)
20.REMOVE ROOF SIDE GARNISH INNER RH (See page 76±45)
21.REMOVE FRONT SEAT ASSY RH (See page POWER SEAT 72±11, MANUAL SEAT 72±16)
22. REMOVE FLOOR CARPET ASSY FRONT
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670S8±01

I35168

I35169
(2)
(1)
(3)
H02440
Riveter
Mandrel
67±10
±
AUDIO & VISUAL SYSTEM FRONT NO.1 SPEAKER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
FRONT NO.1 SPEAKER ASSY
REPLACEMENT
1. REMOVE REAR DOOR WINDOW REGULATOR HANDLE ASSY (W/O POWER WINDOW) (See page 75±8)
2.REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page 75±8)
3.REMOVE FRONT DOOR TRIM BASE LH (See page 75±8)
4.REMOVE FUEL LID OPENER SWITCH (See page 75±8)
5. REMOVE POWER WINDOW REGULATOR SWITCH ASSY (W/ POWER WINDOW) (See page 75±8)
6.REMOVE FRONT DOOR TRIM BOARD SUB±ASSY LH (See page 75±8)
7. REMOVE FRONT NO.1 SPEAKER ASSY
(a) Disconnect the connector.
(b) Using a drill of less then
4 mm (0.16 in.), drill out the 3
rivet heads and remove the front No.1 speaker assy from
the front door panel.
(c) Gently and vertically put the drill to the rivet, and cut the rivet flanges.
NOTICE:

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

Take care as the cut rivet is hot.
(d) Even if flange is taken off, continue drilling and push out remaining fragments with the drill.
(e) Using a vacuum cleaner, remove the drilled rivet and their
dust from the inside of the front door panel.
8. INSTALL FRONT NO.1 SPEAKER ASSY
(a) Using an air riveter or a hand riveter, install 3 new strike rivets to install the front No.1 speaker assy on the front
door panel.
NOTICE:

Install the new strike rivet in order shown in the il-
lustration to install the front No.1 speaker assy.

Do not prize a riveter, as the riveter could be dam-
aged, loosened and the mandrel could be bent.
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700TI±01
B68929
B68929
±
WINDSHIELD/WINDOWGLASS/MIRROR OUTER REAR VIEW MIRROR ASSY LH
70±65
AVENSIS REPAIR MANUAL (RM1018E)
OUTER REAR VIEW MIRROR ASSY LH
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.
1.REMOVE FRONT DOOR HOLE COVER SUB±ASSY NO.1 LH (See page 75±8)
(a) Remove the front door lower frame bracket garnish.
(b) Remove the front door trim base.
(c) Only driver side: Remove the fuel lid opener switch.
(d) w/ Power window: Remove the power window regulator switch.
(e) Remove the front door trim board sub.
(f) Remove the front door inside handle.
(g) remove the front service hole cover No. 1.
2. REMOVE OUTER REAR VIEW MIRROR ASSY LH
(a) Disconnect the connector.
(b) Remove the 3 screws and mirror .
3. INSTALL OUTER REAR VIEW MIRROR ASSY LH
(a) Install the mirror with the 3 screws.Torque: 10 N
m (102 kgf
cm, 7 ft
lbf)
(b) Connect the connector.
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700T3±01
B67165
Roof Side Garnish Inner LHDeck Trim Side Board LH


Quarter Window Assy LH
Rear Window
Side Garnish LH
Luggage Compartment
Trim Hook No. 2

Non±reusable part Tonneau Cover Assy
Deck Board Sub±assy
Deck Floor Box Front
Deck Floor Box LH
Rear Floor Finish Plate
Deck Floor Box Rear
Roof Headlining Retainer Front
Rear Door Opening Trim Weatherstrip LH
Rear Door Sucuff Plate LH
70±22
±
WINDSHIELD/WINDOWGLASS/MIRROR QUARTER WINDOW ASSY LH (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
QUARTER WINDOW ASSY LH (WAGON MODELS)
COMPONENTS
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700T4±01
B68022
Piano Wire
Clip
Clip
B68023
Protective Tape
±
WINDSHIELD/WINDOWGLASS/MIRROR QUARTER WINDOW ASSY LH (WAGON MODELS)
70±23
AVENSIS REPAIR MANUAL (RM1018E)
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.
1.REMOVE REAR WINDOW SIDE GARNISH LH (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.
(g) Remove the deck floor box front.
(h) Remove the rear floor finish plate.
(i) Remove the roof headlining retainer front.
(j) Remove the luggage compartment trim hook No. 2.
(k) Remove the deck trim side board.
(l) Remove the roof side garnish inner.
(m) Remove the rear window side garnish.
2. REMOVE QUARTER WINDOW ASSY LH
(a) Disconnect the connectors.
(b) Pass a piano wire between the vehicle body and glassfrom the interior.
(c) Tie both wire ends to wooden blocks or similar objects.
HINT:
Apply protective tape to the outer surface to prevent the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and the interior and exterior ornaments.
(d) Cut off the adhesive by pulling the piano wire around the glass.
(e) Using a suction rubber, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.
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B66038
Heater to Register Duct No.2Instrument Panel Lower AssyCowl Side Trim
Board RHFront Door
Scuff Plate
RH
Floor Shift
Shift Lever
Knob Sub±assy
Console Panel
Sub±assy Upper
Console Panel Sub±assy LowerConsole Box Assy RR
Front Door
Scuff Plate LH Cowl Side Trim
Board LH
Instrument Panel Airbag Assy Console Rear End
Panel
Radio Receiver
Assembly w/ Bracket
Windshield
Wiper Switch Assy
Instrument Panel
Hole Cover Head lamp
Dimmer Switch Assy
Instrument Panel Under
Cover Sub±assy No.2
Horn Button Assy
Steering Wheel Assy
Instrument Panel Under Cover
Sub±assy No.1
H
N´m (kgf´cm, ft´lbf) : Specified torque M/T Transaxle:
A/T Transaxle:
A/T Only:
M/T Only:
50 (510, 37)
8.8 (90, 78 in.´lbf)
orEF
D
B
B or
EF
I
or
EF
or
EF
H
HH
H
H
HH
H
H
CC
CC
H
H Console Panel
Sub±assy Upper
18 (184, 13)
18 (184, 13)
71±8
±
INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER
AVENSIS REPAIR MANUAL (RM1018E)
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B65611
Clamp
B50126
Hog Ring Pliers
72±14
±
SEATFRONT SEAT ASSEMBLY LH (POWER SEAT TYPE)
AVENSIS REPAIR MANUAL (RM1018E)
(g)w/ Side airbag: Install the wire harness and clamp of the side airbag
through the seat cushion cover end.
NOTICE:
Be careful not to damage the cover.
(h)Install the seatback board with the 2 screws.
21.INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER
(a)Install the seat cushion pad to the seat cushion cover.
(b)Using hog ring pliers, install the seat cushion cover with new hog rings to the seat cushion pad.
NOTICE:

Be careful not to damage the cover.

When installing the hog rings, take care to prevent
wrinkles as much as possible.
22.INSTALL FRONT SEAT INNER BELT ASSY LH
(a)Install the inner belt with the nut. Torque: 42 N
m (428 kgf
cm, 31 ft
lbf)
(b)Connect the connectors.
(c)Check that the inner seat belt moves smoothly.
23.INSTALL FRONT SEAT ASSY LH
(a)Place the seat in the cabin.
(b)Connect the connectors under the seat.
(c)Install the seat with the 4 bolts. Torque: 37 N
m (375 kgf
cm, 27 ft
lbf)
(d)Install the 4 seat track covers.
(e)Install the headrest.
24.INSPECT POWER SEAT OPERATION (See page 72±4)
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