TOYOTA AVENSIS 2005 Service Repair Manual

B66975
B62439
± ENGINE HOOD/DOORREAR DOOR
75±21
AVENSIS REPAIR MANUAL (RM1018E)
(c) Horizontally and vertically adjust the door by loosening
the door side hinge bolts.
(d) Tighten the body 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)

750MY±01
B67990
Rear Door Quarter
Window Glass LH Rear Door Quarter
Window Weatherstrip LH
Wagon Models
Rear Door Quarter
Window Glass LH Sedan and
Liftback Models
Rear Door Window Division Bar Sub±assy
Rear Door Glass
Sub±assy LH Rear Door Glass Run LH
5.5 (56, 49 in.´lbf)
Rear Door Armrest Base Panel Upper
Rear Door Glass Weatherstrip Inner LH
Rear Speaker Assy Power Window Regulator Switch AssyRear Door Window Regulator Sub±assy LH
8.0 (82, 71 in.´lbf)
Rear Door Inside Handle Sub±assy LH
w/ Power Window
8.0 (82, 71 in.´lbf)
Rear Door Armrest Base Panel Upper
Rear Door Base LH
Door Trim Retainer Cap
Window Regulator Inside Handle
Rear Door Window Regulator Handle Shaft Snap Ring
: Specified torqueN´m (kgf´cm, ft´lbf)Rear Door Quarter
Window Weatherstrip LH
5.5 (56, 49 in.´lbf)
5.5 (56, 49 in.´lbf)
Rear Door Window Regulator Sub±assy LH
Non±reusable part
Rivet

Clip
Rear Door Trim board Sub±assy LH
75±18
± ENGINE HOOD/DOORREAR DOOR
AVENSIS REPAIR MANUAL (RM1018E)
REAR DOOR
COMPONENTS

B67991
Rear Door Lock w/ Motor Assy LH
26 (265, 19)
26 (265, 19)
5.5 (56, 49 in.´lbf)
30 (306, 22)
Rear Door Check Assy
Rear Door Weatherstrip LHRear Door Belt Moulding LH Rear Door Outside Handle Frame Sub±assy LHRear Door Outside Handle Cover LH
Rear Door Outside Handle Assy LH
Rear Door Outside Handle Pad Rear Rear Door Outside Handle Pad Front
Child Protector
Lock Hole PlugDoor Lock Wire Harness Packing

5.0 (51, 44 in.´lbf)

Clip
Cushion Rubber
Cushion Rubber
Rear Door Hinge Assy Lower LH Rear Door Hinge Assy Upper LH
Rear Door Speaker Assy No. 2Door Lock Link Silencer
: Specified torqueN´m (kgf´cm, ft´lbf)


Precoated Part Non±reusable part 
Front Door Service Hole Cover 
Butyl Tape
± ENGINE HOOD/DOORREAR DOOR
75±19
AVENSIS REPAIR MANUAL (RM1018E)

750MX±01
B66969: Clip
B66970
: Clip
: Claw
B67801
Claw
75±8
±
ENGINE HOOD/DOOR FRONT 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.

B70388
B66971: Clip
Protective
TapeProtective
Tape
Screw
BoltCushion Rubber
B70121
B68930
Claw A
: Claw 1
2
± ENGINE HOOD/DOORFRONT DOOR
75±9
AVENSIS REPAIR MANUAL (RM1018E)
4. REMOVE POWER WINDOW REGULATOR MASTER
SWITCH ASSY
(a) Using a screwdriver, disengage the 4 claws and clip, and
remove the armrest base panel upper together with the
switch.
HINT:
Tape the screwdriver tip before use.
(b) Disconnect the switch connector.
(c) Remove the 3 screws and switch from the armrest base
panel upper.
5. REMOVE FRONT DOOR TRIM BOARD SUB±ASSY LH
(a) Disconnect the courtesy lamp connector.
(b) Remove the 3 cushion rubbers.
(c) Remove the 2 screws and bolt as indicated.
(d) Using a clip remover, disengage 9 clips.
(e) Remove the trim board upward.
HINT:
In order to prevent the door panel from being damaged, cover
the areas indicated by the arrow marks in the illustration with
protective tape.
(f) Disengage the 2 claws and remove the courtesy lamp.
6. REMOVE FRONT DOOR GLASS WEATHERSTRIP
INNER LH
(a) Remove the weatherstrip inner upward in the direction in-
dicated by the arrow mark in the illustration.
7. REMOVE FRONT DOOR INSIDE HANDLE SUB±ASSY
LH
(a) Using a screwdriver, disengage the claw A indicated.
HINT:
Tape the screwdriver tip before use.
(b) Move the inside handle in the direction indicated the by
arrow mark in the illustration.
(c) Disconnect the 2 cables from the inside handle.

B69067
Butyl Tape
B66981
B68929
B61431
75±10
±
ENGINE HOOD/DOOR FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
8.REMOVE FRONT DOOR SERVICE HOLE COVER
(a)Remove the service hole cover.
NOTICE:
Remove the tape remaining on the door side.
(b)Remove the lower frame seal.
9.REMOVE OUTER REAR VIEW MIRROR ASSY LH
(a)Disconnect the mirror connector.
(b)Remove the 3 screws and mirror.
NOTICE:
When the screws are removed, the mirror may fall and be-
come deformed.
10.REMOVE FRONT NO.1 SPEAKER ASSY (W/ SPEAKER)
(a)Using a drill of less than ù 4 mm (0.16 in.), drill out the 3 rivets heads and remove the speaker.
NOTICE:

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

Be careful with the cut rivet, because it is hot.
(b)Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
(c)Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door.
11.REMOVE FRONT DOOR BELT MOULDING ASSY LH (See page 76±23)
12. REMOVE FRONT DOOR STIFFENER CUSHION NO.1
(a) Using a screwdriver, disengage the 2 claws and remove the cushion.
13. REMOVE FRONT DOOR SPACER LH
(a) Using a screwdriver, disengage the 2 claws and remove the spacer.

B62422
B62423
12
B66968
B61434

B68932Hole Plug
± ENGINE HOOD/DOORFRONT DOOR
75±11
AVENSIS REPAIR MANUAL (RM1018E)
14. REMOVE FRONT DOOR GLASS SUB±ASSY LH
HINT:
Insert a shop rag inside the door panel to prevent the glass from
being scratched.
(a) Move the door glass until the bolts appear in the service
holes.
(b) Remove the 2 bolts holding the door glass to the window
regulator.
(c) Remove the door glass in the direction indicated by the
arrows in the illustration.
NOTICE:

Do not damage the glass.

When the bolts are removed, the glass may fall and
become deformed.
(d) Remove the glass run.
15. REMOVE FRONT DOOR WINDOW REGULATOR
SUB±ASSY LH
(a) Disconnect the window regulator connector.
(b) Remove the 6 bolts and window regulator.
NOTICE:
When the bolts are removed, the window regulator may fall
and become deformed.
HINT:
Remove the window regulator through the service hole.
16. REMOVE FRONT DOOR FRAME SUB±ASSY REAR
LOWER LH
(a) Remove the bolt and frame.
HINT:
Remove the frame through the service hole.
17. REMOVE FRONT DOOR OUTSIDE HANDLE COVER
(a) Remove the hole plug.
(b) Using a torx socket wrench (T30), loosen the screw and
remove the cover with the door lock key cylinder installed.

B66894
B56613
1
2
B70122
Screw
B57102
B68928
75±12
± ENGINE HOOD/DOORFRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
18. REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH
(a) Disconnect the door lock connector.
(b) Using a torx socket wrench (T30), remove the 3 screws
and door lock.
NOTICE:
When the bolts are removed, the window regulator may fall
and become deformed.
HINT:
Remove the door lock through the service hole.
19. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH
(a) Remove the handle pushing and pulling it in the direction
indicated by the arrow mark in the illustration.
(b) Remove the outside handle pads front and rear.
20. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME
SUB±ASSY LH
(a) Using a torx socket wrench (T30), loosen the screw of the
frame.
(b) Using pliers, disengage the clips and remove the frame,
as shown in the illustration.
NOTICE:
Be sure to remove the outside handle together with the
clips, as the clips will be damaged if they remain attached
to the door panel.
HINT:
Remove the frame through the service hole.
21. REMOVE FRONT DOOR CHECK ASSY LH
(a) Remove the 2 nuts, bolt and check.
HINT:
Remove the check through the service hole.

B68928
Adhesive
B70122
Screw
B64044
1 2
± ENGINE HOOD/DOORFRONT DOOR
75±13
AVENSIS REPAIR MANUAL (RM1018E)
22. REMOVE FRONT DOOR WEATHERSTRIP LH
(a) Using a clip remover, disengage the clips and remove the weatherstrip.
HINT:
If the clips are damaged, replace them with new clips.
23. INSTALL FRONT DOOR CHECK ASSY LH
(a) Apply MP grease to the sliding areas of the check.
(b) Install the check to the door panel with the 2 nuts.
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
(c) Apply adhesive to the threads of the bolt.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(d) Install the door check to the body panel with the bolt.
Torque: 30 N
m (306 kgf
cm, 22 in.
lbf)
24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME
SUB±ASSY LH
(a) Install the outside handle link.
(b) Apply MP grease to the sliding areas of the frame.
(c) Using a torx socket wrench (T30), install the frame with
the screw.
Torque: 4.0 N
m (41 kgf
cm, 35 in.
lbf)
25. INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH
(a) Install the outside handle pads front and rear.
(b) Install the handle pushing it in the direction of the arrow
mark in the illustration.
NOTICE:
If the release plate is not pulled and held when installing the
handle, the release plate will interfere with the handle and
become damaged.
26. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
door lock.
(b) Install a new door lock wire harness packing.
NOTICE:

When reusing a door lock that has been removed, re-
place the packing in the connecting part with a new
one.

Be careful that no grease or dirt does not sticks to the
packing surface in the connecting part.

Reusing removed packing or using damaged packing
will allow water to penetrate through to the connect-
ing part resulting in a door lock malfunction.

B65961
Rod
B66894
Adhesive
Adhesive

B68932Hole Plug
B62425
B66972
75±14
± ENGINE HOOD/DOORFRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(c) Insert the control rod into the door lock, and then set it to
the door panel.
NOTICE:
Make sure that the handle link is securely engaged with the
lock.
(d) Apply adhesive to the threads of the 3 screws.
Adhesive:
Part No. 08833±00070, THREE BOND 1324 or equiva-
lent
(e) Using a torx socket wrench (T30), install the door lock with
the 3 screws.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(f) Connect the door lock connector.
27. INSTALL FRONT DOOR OUTSIDE HANDLE COVER
(a) Using a torx socket wrench (T30), install the cover with the
door lock key cylinder installed with the screw.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
(b) Install the hole plug.
28. INSTALL FRONT DOOR FRAME SUB±ASSY REAR
LOWER LH
(a) Install the frame with the bolt.
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
29. I N S TA L L F R O N T D O O R W I N D O W R E G U L ATO R
SUB±ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
window regulator.
NOTICE:
Do not apply grease to the spring of the window regulator.