750N4–01
B66986
Back Door Trim
Panel Assy Upper
Back Door Trim Board Assy
Back Door Side
Garnish LH
Back Door Garnish Sub–assy
Outside RH
Floor Finish Plate
Center Stop Lamp Assy
Back Door Lock Striker
Hook
Back Door Side
Garnish RH
Back Door Stay Assy RH
Back Door Lock Assy
Rear Wiper Motor Assy
Back Door
Stay Assy LH
Back Door Service
Hole Cover
: Specified torque
N·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
Nut
5.5 (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/DOOR
BACK DOOR (LIFTBACK MODELS)
75–37
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR (LIFTBACK MODELS)
COMPONENTS
750N5–01
B57104
Centering Bolt
Standard Bolt
B67535
A
B
C
D
B66993
75–38
–
ENGINE HOOD/DOOR
BACK 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:
A
6.3
1.5 mm (0.248
0.059 in.)
B
4.9
1.5 mm (0.193
0.059 in.)
C
5.0
1.5 mm (0.197
0.059 in.)
D
8.0
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 (
(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)
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 remove
the 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 (
7.
REMOVE REAR WIPER MOTOR ASSY (
8.
REMOVE CENTER STOP LAMP ASSY (
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 (
11.
REMOVE BACK DOOR STAY ASSY RH (
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)
750N7–01
B66987
Back Door Trim Panel Assy Upper
Back Door Side Garnish LH
Wiper Motor Assy
Rear 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/DOOR
BACK DOOR (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR (WAGON MODELS)
COMPONENTS
750N8–01
B57104
Centering Bolt
Standard Bolt
B67534
A
B
C
D
B67000
–
ENGINE HOOD/DOOR
BACK 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:
A
7.5
1.5 mm (0.295
0.059 in.)
B
4.9
1.5 mm (0.193
0.059 in.)
C
5.4
1.5 mm (0.213
0.059 in.)
D
6.0
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 (
(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)
750N9–01
B66997
: Clip
H19055
Clip
B66998
: Clip
B68469
: Clip
–
ENGINE HOOD/DOOR
BACK DOOR (WAGON MODELS)
75–45
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 remove
the trim panel.
HINT:
Tape the screwdriver tip before use.
2.
REMOVE BACK DOOR SIDE GARNISH LH
(a)
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)
Using a screwdriver, disengage the 13 clips and remove
the trim board.
HINT:
Tape the screwdriver tip before use.
(b)
Remove the 3 service hole covers.
5.
REMOVE DOOR PULL HANDLE
(a)
Using a screwdriver, disengage the 4 claws and remove
the pull handle.
6.
7.
REMOVE REAR WIPER MOTOR ASSY (
8.
B66315
B66315
75–46
–
ENGINE HOOD/DOOR
BACK DOOR (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
9.
REMOVE BACK DOOR LOCK ASSY
(a)
Disconnect the door lock connector.
(b)
Remove the 3 bolts and door lock.
10.
BACK DOOR STAY ASSY LH (
11.
BACK DOOR STAY ASSY RH (
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.
750NA–01
H19020
–
ENGINE HOOD/DOOR
BACK DOOR STAY
75–47
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR STAY
REPLACEMENT
HINT:
Use the same procedures on the RH side as on the LH side.
1.
REMOVE BACK DOOR STAY ASSY LH
(a)
Using a screwdriver, remove the stay from the door panel.
HINT:
Remove the door stay while supporting the back door with
your hands.
Tape the screwdriver tip before use.
(b)
Remove the 2 bolts and stay from the body.
2.
INSTALL BACK DOOR STAY ASSY LH
(a)
Install the stay with the bolts.
Torque:
22 N
m (264 kgf
cm, 19 ft
lbf) on door side
7.0 N
m (71 kgf
cm, 63 in.
lbf) on body side
750NB–01
B65104
A
B
a
b
75–48
–
ENGINE HOOD/DOOR
BACK DOOR STAY
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
Use the same procedures on the RH side as on the LH side.
1.
DISPOSE OF BACK DOOR STAY ASSY LH
(a)
Horizontally fix the stay in a vise with the piston–rod pulled
out.
(b)
Wearing safety glasses, gradually cut a part between A
and B as shown in the illustration using a metal saw to
gradually release the gas.
Standard dimension:
a
80 mm (3.15 in.)
b
20 mm (0.80 in.)
NOTICE:
Although the gas inside the stay is colorless, odorless and
harmless, there is a possibility that metal debris from cut-
ting could be blown out. Therefore, cover it with clothes or
thr like.
750MV–01
B67988
Front Door Glass
Sub–assy LH
Front Door Glass Run LH
Front Door Frame Sub–assy Rear Lower LH
8.0 (82, 71 in.·lbf)
Front Door Glass Weatherstrip Inner LH
Front Door Trim Board Sub–assy LH
Front Door Armrest
Base Panel Upper
Courtesy Lamp
: Specified torque
N·m (kgf·cm, ft·lbf)
Front No. 1 Speaker Assy
Front Door Inside Handle Sub–assy LH
Fuel Lid Opener Switch
Front Door Trim Base LH
Clip
Power Window Regulator
Switch Assy
Front Door Armrest Base Panel Upper
w/o Rear Power Window
Front Door Window Regulator
Sub–assy LH
8.0 (82, 71 in.·lbf)
Power Window Regulator
Master Switch Assy
Rivet
Non–reusable part
5.5 (56, 49 in.·lbf)
75–4
–
ENGINE HOOD/DOOR
FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
FRONT DOOR
COMPONENTS
B67989
Front Door Outside Handle Frame Sub–assy LH
w/ Key:
Front Door Outside Handle Cover LH
Front Door Handle
Assy Outside LH
Front Door Outside Handle Pad Rear
Front Door Outside
Handle Pad Front
Hole Plug
Front Door Lock Open Rod
Front Door w/ Motor Lock Assy LH
Door Lock Wire Harness Packing
z
5.0 (51, 44 in.·lbf)
Front Door Belt Moulding LH
Front Door Hinge
Assy Upper LH
Front Door Check Assy
30 (306, 22)
L
5.5 (56, 49 in.·lbf)
Front Door Hinge
Assy Lower LH
26 (265, 19)
Front Door Weatherstrip LH
Cushion Rubber
Front Door Lower Frame
Bracket Garnish LH
Outer Rear View Mirror Assy LH
Front Door Speaker No. 2
Front Door Service Hole Cover
z
: Specified torque
N·m (kgf·cm, ft·lbf)
L
Precoated Part
Non–reusable part
z
Clip
26 (265, 19)
Front Door Lower
Frame Seal
L
Butyl Tape
z
10 (102, 7)
Front Door Stiffener
Cushion No. 1
Side Trim
Spacer LH
Key Cylinder
w/o Key:
Front Door Outside
Handle Cover LH
w/ Speaker
Front Door Lower Frame
Bracket Garnish LH
–
ENGINE HOOD/DOOR
FRONT DOOR
75–5
AVENSIS REPAIR MANUAL (RM1018E)
750MW–01
B57104
Centering Bolt
Standard Bolt
B66965
A
B
C
E
D
B66966
75–6
–
ENGINE HOOD/DOOR
FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Use the same procedures on the RH side as on the LH side.
Because a centering bolt is used as a door hinge mount-
ing bolt on the body side and the door side, the door can
not be adjusted with them on. Substitute a bolt with a
washer for the centering bolt.
1.
INSPECT FRONT DOOR PANEL SUB–ASSY LH
(a)
Check that the clearance is within the standard range.
Standard range:
A
4.6
1.5 mm (0.181
0.059 in.)
B
5.5
1.5 mm (0.220
0.059 in.)
C
4.6
1.5 mm (0.181
0.059 in.)
D
160 mm (6.30 in.)
E
4.8
1.5 mm (0.189
0.059 in.)
2.
ADJUST FRONT DOOR PANEL SUB–ASSY LH
(a)
Using SST, adjust the door horizontally and vertically by
loosening the body side hinge bolts.
SST
09812–00010, 09812–00020
(b)
Tighten the body side hinge bolts after the adjustment.
SST
09812–00010, 09812–00020
Torque: 26 N
m (265 kgf
cm, 19 ft
lbf)
B66967
B62411
–
ENGINE HOOD/DOOR
FRONT DOOR
75–7
AVENSIS REPAIR MANUAL (RM1018E)
(c)
Adjust the door forward/rearward and vertically by loos-
ening 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)
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)
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 BRACKET
GARNISH 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 (
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
Tape
Protective
Tape
Screw
Bolt
Cushion Rubber
B70121
B68930
Claw A
: Claw
1
2
–
ENGINE HOOD/DOOR
FRONT 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 ø 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 (
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
1
2
B66968
B61434
B68932
Hole Plug
–
ENGINE HOOD/DOOR
FRONT 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/DOOR
FRONT 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/DOOR
FRONT 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
B68932
Hole Plug
B62425
B66972
75–14
–
ENGINE HOOD/DOOR
FRONT 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.
INSTALL FRONT DOOR WINDOW REGULATOR
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.
B66968
B62423
1
2
B62422
B61441
–
ENGINE HOOD/DOOR
FRONT DOOR
75–15
AVENSIS REPAIR MANUAL (RM1018E)
(b)
Install the window regulator with the 6 bolts.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
(c)
Connect the window regulator connector.
NOTICE:
Be careful not to drop and deform the door window regula-
tor as this may cause deformation.
30.
INSTALL FRONT DOOR GLASS SUB–ASSY LH
(a)
Install the glass run.
NOTICE:
Do not damage the door glass.
(b)
Insert the door glass into the door panel along the glass
run in the direction indicated by arrows in the illustration.
(c)
Install the door glass to the window regulator with the 2
bolts.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(d)
Reset the power window motor (
(e)
Inspect operation of the power window.
HINT:
When the installation point of the door glass does not match,
adjust the regulator position in manual operation.
(1)
Connect the power window switch to the wire har-
ness and turn the ignition switch ON.
(2)
Repeat UP and DOWN operation several times in
manual operation.
31.
INSTALL FRONT NO.1 SPEAKER ASSY
(a)
Using an air riveter or hand riveter, install the speaker to
the door with the 3 rivets.
H02440
Mandrel
Riveter
WRONG
H02441
Riveter
Riveter
WRONG
WRONG
H02442
Riveter
WRONG
B68929
B69067
Butyl Tape
75–16
–
ENGINE HOOD/DOOR
FRONT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:
Do not operate the riveter an angle as this will damage
it bend the mandrel.
Do not tilt the riveter when removing the rivet as the
speaker will not be tightened firmly.
Install the rivet while attaching the speaker to ensure
that it is tightened firmly.
(b)
Connect the speaker connector.
32.
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 mirror connector.
33.
INSTALL FRONT DOOR SERVICE HOLE COVER
(a)
Apply butyl tape to the door as shown in the illustration.
(b)
Install the service hole cover.
HINT:
When installing the service hole cover, pull out the links
and connectors through the service hole cover.
There should be no wrinkles or folds after attaching the
service hole cover.
After attaching the service hole cover, check the sealing
quality.
B66981
–
ENGINE HOOD/DOOR
FRONT DOOR
75–17
AVENSIS REPAIR MANUAL (RM1018E)
(c)
Install the lower frame seal front.
750MT–01
B67533
Hood Sub–assy
Hood Insulator
Engine Room Side Cover RH
Radiator Cover
Battery Service Hole Cover
Hood Hinge Assy RH
Hood to Front Fender Seal RH
Hood Lock Assy
Front Bumper Assy
Hood to Front Fender Seal LH
Hood Hinge Assy LH
x 8
Hood to Front End Panel Seal
8.0 (82, 71 in.·lbf)
13 (133, 10)
13 (133, 10)
: Specified torque
N·m (kgf·cm, ft·lbf)
Cushion Rubber
Cushion Rubber
Clip
–
ENGINE HOOD/DOOR
HOOD
75–1
AVENSIS REPAIR MANUAL (RM1018E)
HOOD
COMPONENTS
750MU–01
B57104
Centering Bolt
Standard Bolt
B66962
A
B
B61420
75–2
–
ENGINE HOOD/DOOR
HOOD
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Because a centering bolt is used as a hood hinge mounting bolt
and hood lock mounting bolt, the hood and hood lock can not
be adjusted with them on. Substitute a bolt with a washer for the
centering bolt.
1.
INSPECT HOOD SUB–ASSY
(a)
Check that the clearance is within the standard range.
Standard range:
A
3.5
1.5 mm (0.138
0.059 in.)
B
3.5 – 1.5 or +2.5 mm
(0.138 – 0.059 or + 0.098 in.)
2.
ADJUST HOOD SUB–ASSY
(a)
Horizontally and vertically adjust the hood.
(1)
Loosen the 4 hood hinge bolts on the hood side.
B66963
A
Aligned
B66964
B62401
–
ENGINE HOOD/DOOR
HOOD
75–3
AVENSIS REPAIR MANUAL (RM1018E)
(2)
Adjust the clearance by moving the hood, so that it
will be in the standard range.
Standard range (A): 3.5
1.5 mm (0.138
0.059 in.)
(3)
Tighten the hood side hinge bolts after the adjust-
ment.
Torque: 13 N
m (133 kgf
cm, 10 ft
lbf)
(b)
Adjust the height of the hood front end using the cushion
rubber.
(1)
Adjust the cushion rubber so that the hood and the
fender will be aligned.
HINT:
The cushion rubber goes up and down by turning it.
(c)
Adjust the hood lock.
(1)
Using a clip remover, remove the 6 clips and front
end seal.
(2)
Remove the retainer and battery service hole cover.
(3)
Using a clip remover, remove the 3 clips and radia-
tor cover.
(4)
Using a clip remover, remove the 3 clips and engine
room side cover RH.
(5)
(6)
Adjust the hood lock position by moving the striker,
so that the striker can enter smoothly.
(7)
Tighten the hood lock bolts after the adjustment.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
750N1–01
B66985
Luggage Compartment
Door Panel Sub–assy
Luggage Compartment
Outside Garnish
Licence Plate Lamp Assy
Luggage Compartment Door Lock Cylinder Assy
Luggage Compartment Trim Hook No. 2
Rear Floor Finish Plate
Luggage Striker Assy
Rope Hook Assy
Back Door Trim Cover
Luggage Compartment Floor Carpet
Luggage Compartment
Trim Inner RH
Luggage Compartment
Trim Inner LH
Luggage Lock Assy
Clip
4.9 (49, 43 in.·lbf)
5.0 (51, 44 in.·lbf)
5.0 (51, 44 in.·lbf)
Hinge Cover
: Specified torque
N·m (kgf·cm, ft·lbf)
7.0 (71, 62 in.·lbf)
11.5 (120, 8)
75–32
–
ENGINE HOOD/DOOR
LUGGAGE COMPARTMENT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
LUGGAGE COMPARTMENT DOOR
COMPONENTS
750N2–01
B57104
Centering Bolt
Standard Bolt
B66984
A
B
C
B61457
–
ENGINE HOOD/DOOR
LUGGAGE COMPARTMENT DOOR
75–33
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
HINT:
Because a centering bolt is used as a luggage compartment
door mounting bolt, the luggage compartment door can not be
adjusted with it on. Substitute a bolt with a washer for the cen-
tering bolt.
1.
INSPECT LUGGAGE COMPARTMENT DOOR PANEL SUB–ASSY
(a)
Check that the clearance is within the standard range.
Standard range:
A
4.0
1.5 mm (0.157
0.059 in.)
B
5.3
1.5 mm (0.209
0.059 in.)
C
7.1 – 1.5 or + 2.5 mm
(0.280 – 0.059 or + 0.098 in.)
2.
ADJUST LUGGAGE COMPARTMENT DOOR PANEL
SUB–ASSY
(a)
Using a clip remover, remove the clips and hinge cover.
(b)
Using a clip remover, remove the 11 clips and trim cover.
(c)
Adjust the door horizontally and vertically by Loosening
the door bolts.
(d)
Tighten the door mounting bolts after the adjustment.
Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
B66994
75–34
–
ENGINE HOOD/DOOR
LUGGAGE COMPARTMENT DOOR
AVENSIS REPAIR MANUAL (RM1018E)
(e)
Adjust the striker.
HINT:
Adjust the door lock position by moving the striker so that the
door striker can enter smoothly.
(1)
Using a hammer and a brass bar, tap the striker to
adjust it.
(2)
Tighten the 2 bolts after the adjustment.
Torque: 11.5 N
m (120 kgf
cm, 8 ft
lbf)
750N3–01
B55944
B55945
–
ENGINE HOOD/DOOR
LUGGAGE 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/DOOR
LUGGAGE 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
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