TOYOTA AVENSIS 2005 Service Repair Manual

750N8±01
B57104
Centering BoltStandard Bolt
B67534
A
BC
D
B67000
± ENGINE HOOD/DOORBACK DOOR (WAGON MODELS)
75±43
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Because a centering bolt is used as a door hinge mounting bolt
on the body side and door side, the door can not be adjusted
with them on. Substitute a bolt with a washer for the centering
bolt.
1. INSPECT BACK DOOR PANEL SUB±ASSY
(a) Check that the clearance is within the standard range.
Standard range:
A7.5
1.5 mm (0.295
0.059 in.)
B4.9
1.5 mm (0.193
0.059 in.)
C5.4
1.5 mm (0.213
0.059 in.)
D6.0
1.5 mm (0.236
0.059 in.)
2. ADJUST BACK DOOR PANEL SUB±ASSY
(a) Adjust the door horizontally and forward/rearward by
loosening the body side hinge bolts.
(b) Tighten the body side hinge bolts after the adjustment.
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)

B66999
B67001
75±44
±
ENGINE HOOD/DOOR BACK DOOR(WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
(c)Horizontally and vertically adjust the door by loosening the door side hinge bolts.
(d)Tighten the door side hinge bolts after the adjustment.
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
(e)Remove the floor finish plate (See page 76±54)
(f) Adjust the striker position by slightly loosening the striker mounting 2 screws and hitting the striker with a plastic±
faced hammer.
(g) Tighten the striker mounting screws after the adjustment. Torque: 23 N
m (235 kgf
cm, 17 ft
lbf)

750N7±01
B66987
Back Door Trim Panel Assy Upper
Back Door Side Garnish LH Wiper Motor AssyRear Spoiler
Back Door Garnish Sub±assy Outside RH
Back Door Trim Board Assy
Door Pull Handle
Back Door Lock Striker Back Door Side Garnish RH
Door Pull Handle
: Specified torque
N´m (kgf´cm, ft´lbf)
Floor Finish Plate Rear Wiper Arm and Blade Assy
Wiper Arm Head Cap
5.5 (56, 49 in.´lbf)
Rear Wiper w/ Packing
Washer
Back Door
Stay Assy LH
7.0 (71, 62 in.´lbf)
22 (264, 19)
11.5 (120, 8)
Back Door Stay Assy RH
7.0 (71, 62 in.´lbf)
8.0 (82, 71 in.´lbf)
19.5 (200, 14)
Back Door Service Hole Cover
Back Door Lock Assy
4.9 (49, 43 in.´lbf)4.9 (49, 43 in.´lbf)
75±42
± ENGINE HOOD/DOORBACK DOOR (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR (WAGON MODELS)
COMPONENTS

750N6±01
B66988: Clip
B66989: Clip
Hook
B66990: Clip
B66991
75±40
±
ENGINE HOOD/DOOR BACK DOOR(LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
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
(a)Using a screwdriver, disengage the 4 clips and removethe trim.
HINT:
Tape the screwdriver tip before use.
2.REMOVE BACK DOOR SIDE GARNISH LH
(a)Using a clip remover, remove the hook.
(b)Using a screwdriver, disengage the 2 clips and remove the side garnish.
HINT:
Tape the screwdriver tip before use.
3.REMOVE BACK DOOR SIDE GARNISH RH
HINT:
Use the same procedures described for the LH side.
4.REMOVE BACK DOOR TRIM BOARD ASSY
(a)Remove the 2 screws.
(b)Using a screwdriver, disengage the 12 clips and remove the trim board.
HINT:
Tape the screwdriver tip before use.
(c)Remove the 4 service hole covers.
5.REMOVE BACK DOOR DAMPER ASSY
(a)Remove the 4 bolts and damper.
6.REMOVE BACK DOOR GARNISH SUB±ASSY OUTSIDE RH (See page 76±27)
7.REMOVE REAR WIPER MOTOR ASSY (See page 66±17)
8.REMOVE CENTER STOP LAMP ASSY (See page 65±26)

B66996
B66996
B66991
±
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)
75±41
AVENSIS REPAIR MANUAL (RM1018E)
9. REMOVE BACK DOOR LOCK ASSY
(a) Disconnect the connector.
(b) Remove the 3 bolts and door lock.
10.REMOVE BACK DOOR STAY ASSY LH (See page 75±47)
11.REMOVE BACK DOOR STAY ASSY RH (See page 75±47) 12. INSTALL BACK DOOR LOCK ASSY
(a) Install the door lock with the 3 bolts.Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(b) Connect the door lock connector
13. INSTALL BACK DOOR DAMPER ASSY
(a) Install the damper with the 4 bolts. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)

750N5±01
B57104
Centering BoltStandard Bolt
B67535
A
BC
D
B66993
75±38
± ENGINE HOOD/DOORBACK DOOR (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Because a centering bolt is used as a door hinge mounting bolt
on the body side and door side, the door can not be adjusted
with them on. Substitute a bolt with a washer for the centering
bolt.
1. INSPECT BACK DOOR PANEL SUB±ASSY
(a) Check that the clearance is within the standard range.
Standard range:
A6.3
1.5 mm (0.248
0.059 in.)
B4.9
1.5 mm (0.193
0.059 in.)
C5.0
1.5 mm (0.197
0.059 in.)
D8.0
1.5 mm (0.315
0.059 in.)
2. ADJUST BACK DOOR PANEL SUB±ASSY
(a) Adjust the door vertically and forward/rearward by loos-
ening the body side hinge bolts.
(b) Tighten the body side hinge bolts after the adjustment.
Torque: 19.5 N
m (200 kgf
cm, 14 ft
lbf)

B66992
B66994
B66995
±
ENGINE HOOD/DOOR BACK DOOR(LIFTBACK MODELS)
75±39
AVENSIS REPAIR MANUAL (RM1018E)
(c)Horizontally and vertically adjust the door by loosening
the 8 door side hinge bolts.
(d)Tighten the door side hinge bolts after the adjustment.
Torque: 19.5 N
m (200 kgf
cm, 14 ft
lbf)
(e)Remove the floor finish plate (See page 76±45)
(f) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic±
faced hammer.
(g) Tighten the striker mounting screws after the adjustment. Torque: 11.5 N
m (120 kgf
cm, 8 ft
lbf)
(h) Adjust the side female stopper so that the door can be opened/closed smoothly, as shown in the illustration.
(i) Tighten the side female stopper after the adjustment. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)

750N4±01
B66986
Back Door Trim
Panel Assy Upper
Back Door Trim Board Assy Back Door Side
Garnish LHBack Door Garnish Sub±assy
Outside RH
Floor Finish Plate Center Stop Lamp Assy
Back Door Lock Striker Hook
Back Door Side
Garnish RHBack Door Stay Assy RH
Back Door Lock Assy Rear Wiper Motor Assy
Back Door
Stay Assy LH
Back Door Service
Hole Cover
: Specified torqueN´m (kgf´cm, ft´lbf)
19.5 (200, 14)
5.5 (56, 49 in.´lbf)
Hook Rear Wiper Arm and Blade Assy
Rear Wiper
w/ Packing Washer
Wiper Arm Head Cap
Nut5.5 (56, 49 in.´lbf)
5.5 (56, 49 in.´lbf)
Cushion Rubber
Cushion Rubber
Rope Hook Assy
11.5 (120, 8)
22 (264, 19)
7.0 (71, 62 in.´lbf)
5.5 (56, 49 in.´lbf)
8.0 (82, 71 in.´lbf)
7.0 (71, 62 in.´lbf)22 (264, 19)
Female
Stopper RH
Female
Stopper LH
4.9 (49, 43 in.´lbf)Back Door Damper Assy
5.5 (56, 49 in.´lbf)
± ENGINE HOOD/DOORBACK DOOR (LIFTBACK MODELS)
75±37
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR (LIFTBACK MODELS)
COMPONENTS

750N3±01
B55944
B55945
± ENGINE HOOD/DOORLUGGAGE 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 sliding 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 performed 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 floor
finish 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

B56621
Installation Hole
Installation Hole
(For Adjustment)
75±36
± ENGINE HOOD/DOORLUGGAGE 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