Body Exterior TOYOTA AVENSIS 2003 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2003, Model line: AVENSIS, Model: TOYOTA AVENSIS 2003Pages: 2234, PDF Size: 56.95 MB
Page 30 of 2234
NEW MODEL OUTLINEMO-28
EQUIPMENT LIST
: Standard OP: Option
EuropeGeneral
ENTRYMID
TECHNICALMID
ELEGANTGeneral
Countries
Exterior
Rear SpoilerWagonÐ
Side Protection MouldingOPOPOPOP
WindshieldGreenÐ
Front SideGreen
GlassRear Side & BackGreenGlassRear Side & BackWagonPrivacyOPOPOPÐ
Rear QuarterWagonGreenÐRear QuarterWagonPrivacyOPOPOPÐ
Chassis
195/65 R153ZZ-FE & 1ZZ-FE & 1AZ-FE
205/55 R161AZ-FSE & 1CD-FTVÐ
Tire205/55 R163ZZ-FE & 1ZZ-FE & 1AZ-FEOPOPOPOP
215/45 R171AZ-FEÐOPOPÐ215/45 R171AZ-FSEÐOPOPÐ
15 x 6J Steel3ZZ-FE & 1ZZ-FE & 1AZ-FE
16x61/2J Steel1AZ-FSE & 1CD-FTVÐ16 x 6 1/2 J Steel3ZZ-FE & 1ZZ-FE & 1AZ-FEOPOPOPOP
Disc Wheel16 x 6 1 / 2 JJ AluminumOPOPOPOP
16 x 6 1 / 2 JJ Light Weight AluminumOPOPOPOP
17 x 7JJ Aluminum1AZ-FEÐOPOPÐ17 x 7JJ Aluminum1AZ-FSEÐOPOPÐ
ABS (Anti-lock Brake System) with EBD (Electronic Brake force Distrib\
ution)
VSC (Vehicle Stability Control) & Brake1AZ-FSEÐ(y)Assist & TRC (Traction Control)1CD-FTVOPOPOPÐ
Wheel4-Spoke UrethaneÐÐWheel4-Spoke LeatherÐÐ
SteeringColumnManual Tilt & TelescopicSteeringEPS*13ZZ-FE & 1ZZ-FEÐ
Hydraulic Type Power
Steering1AZ-FSE & 1CD-FTV & 1AZ-FE
Body
CoverFabricCoverLeather1AZ-FSE & 1CD-FTVÐOPOPÐ
FrontManual
SeatFrontPower1AZ-FSE & 1CD-FTVÐOPOPÐ
FixSedanÐÐÐ
Rear60:40 FoldingSedanÐ
60:40 Double FoldingLiftback & WagonÐ
SeatBelt
Front3-Point ELR*2 Electrical Sensing Type Pretensioner
& Force Limiter
BeltRear3-Point ELR*2 & ALR*3
CRS (Child Restraint System) Anchor System (Rear Outside Seat Only)
*1: Electoronic Power Steering
*2: Emergency Locking Retractor
*3: Automatic Locking Retractor
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Page 193 of 2234
031GY±01
±
SERVICE SPECIFICATIONS EXTERIOR/INTERIOR TRIM
03±75
AVENSIS REPAIR MANUAL (RM1018E)
EXTERIOR/INTERIOR TRIM
TORQUE SPECIFICATION
Part TightenedNmkgf cmft lbf
FUEL LID CONTROL ASSY
Fuel lid control assy x Body8.08271 in. lbf
REAR BUMPER COVER
Rear bumper cover x Body5.55649 in.lbf
Rear bumper reinforcement No. 1 x Body11.511 516
BACK DOOR GARNISH OUTSIDE
Back door garnish Body4.95043 in.lbf
REAR SPOILER (WAGON MODELS)
Rear spoiler Body9.89987 in.lbf
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Page 1589 of 2234
700T8±01
B68025
Piano Wire
Clip
B69235
Protective Tape
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
70±35
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 BACK DOOR TRIM BOARD ASSY (See page 75±40)
(a) Remove the back door trim panel assy upper.
(b) Remove the back door side garnish LH.
(c) Remove the back door side garnish RH.
(d) Remove the back door trim board.
2.REMOVE CENTER STOP LAMP ASSY (See page 65±26)
3.REMOVE REAR WIPER MOTOR ASSY (See page 66±17
)
(a) Remove the wiper arm head cap.
(b) Remove the rear wiper arm.
(c) Remove the wiper motor.
4. REMOVE BACK DOOR GLASS
(a) Pass a piano wire between the body and glass from theinterior.
(b) 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 interior and exterior ornaments.
(c) Cut off the adhesive by pulling the piano wire around the glass.
(d) 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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Page 1595 of 2234
700TA±01
B68025
Clip
Piano Wire
B69236
Protective Tape
BO4421
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (WAGON MODELS)
70±41
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 BACK DOOR TRIM BOARD ASSY (See page 75±45)
(a) Remove the back door trim panel upper.
(b) Remove the back door side garnish LH.
(c) Remove the back door side garnish RH.
(d) Remove the back door trim board.
2.REMOVE REAR SPOILER (See page 76±30)
3.REMOVE REAR WIPER MOTOR ASSY (See page 66±17)
(a) Remove the wiper arm head cap.
(b) Remove the rear wiper arm.
(c) Remove the wiper motor.
4. REMOVE BACK DOOR GLASS
(a) Pass a piano wire between the body and glass from theinterior.
(b) 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 interior and exterior ornaments.
(c) Cut off the adhesive by pulling the piano wire around it.
(d) Using a suction rubber, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.
5. CLEAN BACK DOOR GLASS
(a) Clean the outer circumference of the glass with white gas- oline.
NOTICE:
Do not touch the glass surface after cleaning it.
Be careful not to damage the body.
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Page 1602 of 2234
B64495Protective Tape
BO5231
B62806
B
AA Ceramic Notch
Backside
B63758
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK WINDOW GLASS (SEDAN MODELS)
70±29
AVENSIS REPAIR MANUAL (RM1018E)
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 interior and exterior ornaments.
(c) Cut off the adhesive by pulling the piano wire around the
glass.
(d) Disengage the stoppers.
(e) Using a suction cup, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.
8. CLEAN BACK WINDOW GLASS
(a) Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
(b) Clean the outer circumference of the glass with white gas- oline.
NOTICE:
Do not touch the glass surface after cleaning it.
Be careful not to damage the body.
Even if using new glass, clean the glass with white
gasoline.
9. INSTALL BACK WINDW GLASS STOPPER NO.2
(a) Coat the installation part of the stopper with Primer G.
NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use.
Do not apply too much primer.
(b) Install 2 new stoppers onto the glass, as shown in the il- lustration.
Standard dimension:
A40.0 mm (1.575 in.)
B11.3 mm (0.445 in.)
10. INSTALL BACK WINDOW GLASS STOPPER NO.1
(a) Install 2 new stoppers to the vehicle body, as shown in theillustration.
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Page 1632 of 2234
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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Page 1647 of 2234
B62805
Stopper
Piano Wire
B63724Protective Tape
Plastic Sheet
BO5231
70±16
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE WINDSHIELD GLASS
(a) Pass a piano wire between the vehicle body and glass from the interior.
(b) 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.
To prevent the safety pad from being scratched when
removing the glass, place a plastic sheet between the
piano wire and safety pad.
(c) Cut off the adhesive by pulling the piano wire around the
glass.
(d) Disengage the stoppers.
(e) Using a suction cup, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.
8. CLEAN WINDSHIELD GLASS
(a) Using a scraper, remove the damaged stoppers, dam and adhesive sticking to the glass.
(b) Clean the outer circumference of the glass with white gas-
oline.
NOTICE:
Do not touch the glass surface after cleaning it.
Be careful not to damage the body.
Even if using new glass, clean the glass with white
gasoline.
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Page 1807 of 2234
760W5±01
B50319
Protective
Tape
B67149
Double±sided Tape
±
EXTERIOR/INTERIOR TRIM OUTSIDE MOULDING LH
76±21
AVENSIS REPAIR MANUAL (RM1018E)
OUTSIDE MOULDING LH
REPLACEMENT
HINT:
On the RH side, use the same procedures as on the LH side.
1. REMOVE OUTSIDE MOULDING LH
(a) Using a heat light, heat the moulding.Heating temprature: 40 ± 60 C (104 ± 140 F)
NOTICE:
Do not heat the moulding excessively.
(b) Tie both the piano wire ends to a wooden block or a similar object.
(c) Scrape tape off by pulling the piano wire and remove the moulding with reference pins remaining on the moulding.
NOTICE:
If reusing the moulding, take care not to damage the
moulding.
Do not damage the body.
(d) Remove the moulding.
2. INSTALL OUTSIDE MOULDING LH
(a) Using a heat light, heat the body surface. Heating temprature: 40 ± 60 C (104 ± 140 F)
NOTICE:
Do not heat the body excessively.
(b) Remove the tape from the body.
(c) Wipe off the stains with cleaner.
(d) Clean the moulding (if reusing the moulding).
(1) Using a heat light, heat the moulding.
Heating temprature: 20 ± 30 C (68 ± 86 F)
NOTICE:
Do not heat the moulding excessively. (2) Remove the tape from the moulding.
(3) Wipe off the stains with cleaner.
(4) Apply new double±sided tape to the moulding as
shown in the illustration.
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Page 1808 of 2234
B67150mm (in.)
16.2 (0.638)
28 (1.102)
228.7 (9.004)243 (9.567) 243 (9.567)
2.3 (0.091)
3.8 (0.150)
252.7 (9.949)
119 (4.685)
16.4 (0.646)
76±22
±
EXTERIOR/INTERIOR TRIM OUTSIDE MOULDING LH
AVENSIS REPAIR MANUAL (RM1018E)
(e) Using a heat light, heat the body and moulding. Heating temperature:
Body40 ± 60 C (104 ± 140 F)
Moulding20 ± 30C (68 ± 86 F)
NOTICE:
Do not heat the body and moulding excessively.
(f) Remove the peeling paper from the face of the moulding
and attach the moulding securely to the vehicle body.
NOTICE:
Be careful that dirt or foreign objects do not stick to adhe-
sive part when removeing the peeling paper.
(g) Push the moulding to the body, as shown in the illustra- tion.
NOTICE:
Do not apply excessive force onto the moulding. Instead,
apply steady pressure with your thumbs.
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Page 1819 of 2234
760WE±01
B67742
B67741
Front SideRear Side
1.3 (0.051)
mm (in.)
A
A
A ± A
4.8 (0.189)
1.5 (0.059) A ± A A
A
4.6 (1.811)
76±26
±
EXTERIOR/INTERIOR TRIM ROOF DRIP SIDE FINISH MOULDING CENTER LH
AVENSIS REPAIR MANUAL (RM1018E)
ROOF DRIP SIDE FINISH MOULDING CENTER LH
REPLACEMENT
HINT:
Use the same procedures on the RH side as on the LH side. 1. REMOVE ROOF DRIP SIDE FINISH MOULDINGCENTER LH
(a) Put the protective tape around the circumference of the moulding.
(b) Using a remover for the roof moulding, release the disen-
gage the clips both in the front and rear ends of the mould-
ing, and then remove the moulding.
NOTICE:
Do not remove the clips.
If that the clips are damaged or removed accidentally,
exchange them for supplied ones.
2. INSTALL ROOF DRIP SIDE FINISH MOULDING CENTER LH
NOTICE:
Only when exchanging the clips.
(a) Remove the tape that remains on the mounting surface
of the body, and then clean the surface with white gaso-
line.
(b) Using a heat light, heat up the clip installation surfaces of the body and moulding.
Heating temperature:
Body40 ± 60 C (104 ± 140 F)
Moulding20 ± 30C (68 ± 86 F)
NOTICE:
Do not heat the moulding and body excessively.
(c) Set the supplied clips in the positions as shown in the il-
lustration and press±fit them by hand to install them.
NOTICE:
Install the moulding when 30 minutes or more have passed
after press±fitting the clips.
HINT:
Initial hardening time: 30 minutes
Perfect hardening time: 24 hours
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