7537

ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)

BACK DOOR (LIFTBACK MODELS)

750N401

COMPONENTS
Rear Wiper w/ Packing Washer Rear Wiper Arm and Blade Assy
22 (264, 19) 7.0 (71, 62 in.lbf)

Wiper Arm Head Cap Nut Rear Wiper Motor Assy Center Stop Lamp Assy Back Door Damper Assy
5.5 (56, 49 in.lbf) 5.5 (56, 49 in.lbf)

Back Door Stay Assy RH Female Stopper RH

4.9 (49, 43 in.lbf) 5.5 (56, 49 in.lbf)

5.5 (56, 49 in.lbf)

7.0 (71, 62 in.lbf)

22 (264, 19)

Back Door Stay Assy LH Hook Female Stopper LH Back Door Trim Panel Assy Upper Hook Back Door Side Garnish LH Back Door Service Hole Cover Back Door Garnish Subassy Outside RH Back Door Side Garnish RH

5.5 (56, 49 in.lbf)

19.5 (200, 14)

Cushion Rubber Back Door Trim Board Assy Cushion Rubber

8.0 (82, 71 in.lbf)

Back Door Lock Assy

Rope Hook Assy Floor Finish Plate

11.5 (120, 8)

Back Door Lock Striker Nm (kgfcm, ftlbf) : Specified torque

B66986

AVENSIS REPAIR MANUAL (RM1018E)

7538
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)
750N501

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.
Centering Bolt Standard Bolt
B57104

1. (a)

INSPECT BACK DOOR PANEL SUBASSY Check that the clearance is within the standard range.
A

B D

B67535

Standard range:
A B C D 6.3 " 1.5 mm (0.248 " 0.059 in.) 4.9 " 1.5 mm (0.193 " 0.059 in.) 5.0 " 1.5 mm (0.197 " 0.059 in.) 8.0 " 1.5 mm (0.315 " 0.059 in.)

2. (a) (b)

ADJUST BACK DOOR PANEL SUBASSY Adjust the door vertically and forward/rearward by loosening the body side hinge bolts. Tighten the body side hinge bolts after the adjustment. Torque: 19.5 NVm (200 kgfVcm, 14 ftVlbf)

B66993

AVENSIS REPAIR MANUAL (RM1018E)

7539
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)

(c) (d)

Horizontally and vertically adjust the door by loosening the 8 door side hinge bolts. Tighten the door side hinge bolts after the adjustment. Torque: 19.5 NVm (200 kgfVcm, 14 ftVlbf)

B66992

(e) (f)

(g)

Remove the floor finish plate (See page 7645) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic faced hammer. Tighten the striker mounting screws after the adjustment. Torque: 11.5 NVm (120 kgfVcm, 8 ftVlbf)

B66994

(h) (i)

Adjust the side female stopper so that the door can be opened/closed smoothly, as shown in the illustration. Tighten the side female stopper after the adjustment. Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf)

B66995

AVENSIS REPAIR MANUAL (RM1018E)

7540
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)
750N601

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. (a) REMOVE BACK DOOR TRIM PANEL ASSY UPPER Using a screwdriver, disengage the 4 clips and remove the trim.

HINT: Tape the screwdriver tip before use.

: Clip

B66988

2. (a) (b)
Hook

REMOVE BACK DOOR SIDE GARNISH LH Using a clip remover, remove the hook. Using a screwdriver, disengage the 2 clips and remove the side garnish.

: Clip B66989

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. (a) (b) REMOVE BACK DOOR TRIM BOARD ASSY Remove the 2 screws. 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.
: Clip
B66990

5. (a)

REMOVE BACK DOOR DAMPER ASSY Remove the 4 bolts and damper.

B66991

6. 7. 8.

REMOVE BACK DOOR GARNISH SUBASSY OUTSIDE RH (See page 7627) REMOVE REAR WIPER MOTOR ASSY (See page 6617) REMOVE CENTER STOP LAMP ASSY (See page 6526)

AVENSIS REPAIR MANUAL (RM1018E)

7541
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)

9. (a) (b)

REMOVE BACK DOOR LOCK ASSY Disconnect the connector. Remove the 3 bolts and door lock.

B66996

10. 11.

REMOVE BACK DOOR STAY ASSY LH (See page 7547) REMOVE BACK DOOR STAY ASSY RH (See page 7547)

12. (a) (b)

INSTALL BACK DOOR LOCK ASSY Install the door lock with the 3 bolts. Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) Connect the door lock connector

B66996

13. (a)

INSTALL BACK DOOR DAMPER ASSY Install the damper with the 4 bolts. Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf)

B66991

AVENSIS REPAIR MANUAL (RM1018E)

7542
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)

BACK DOOR (WAGON MODELS)

750N701

COMPONENTS
Back Door Stay Assy RH Rear Wiper Arm and Blade Assy Rear Wiper w/ Packing Washer Wiper Arm Head Cap
5.5 (56, 49 in.lbf)

Rear Spoiler
7.0 (71, 62 in.lbf)

Wiper Motor Assy

4.9 (49, 43 in.lbf) 4.9 (49, 43 in.lbf)

Back Door Trim Panel Assy Upper Back Door Side Garnish RH Back Door Side Garnish LH Back Door Garnish Subassy Outside RH Back Door Trim Board Assy Back Door Service Hole Cover

19.5 (200, 14)

Back Door Lock Assy

8.0 (82, 71 in.lbf) 22 (264, 19)

Door Pull Handle

Door Pull Handle Floor Finish Plate Back Door Stay Assy LH Nm (kgfcm, ftlbf) : Specified torque

11.5 (120, 8) 7.0 (71, 62 in.lbf)

Back Door Lock Striker

B66987

AVENSIS REPAIR MANUAL (RM1018E)

7543
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)
750N801

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.
Centering Bolt Standard Bolt
B57104

1. (a)

INSPECT BACK DOOR PANEL SUBASSY Check that the clearance is within the standard range.

B67534

Standard range:
A B C D 7.5 " 1.5 mm (0.295 " 0.059 in.) 4.9 " 1.5 mm (0.193 " 0.059 in.) 5.4 " 1.5 mm (0.213 " 0.059 in.) 6.0 " 1.5 mm (0.236 " 0.059 in.)

2. (a) (b)

ADJUST BACK DOOR PANEL SUBASSY Adjust the door horizontally and forward/rearward by loosening the body side hinge bolts. Tighten the body side hinge bolts after the adjustment. Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)

B67000

AVENSIS REPAIR MANUAL (RM1018E)

7544
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)

(c) (d)

Horizontally and vertically adjust the door by loosening the door side hinge bolts. Tighten the door side hinge bolts after the adjustment. Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)

B66999

(e) (f)

(g)

Remove the floor finish plate (See page 7654) Adjust the striker position by slightly loosening the striker mounting 2 screws and hitting the striker with a plastic faced hammer. Tighten the striker mounting screws after the adjustment. Torque: 23 NVm (235 kgfVcm, 17 ftVlbf)

B67001

AVENSIS REPAIR MANUAL (RM1018E)

7545
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)
750N901

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. (a) REMOVE BACK DOOR TRIM PANEL ASSY UPPER Using a screwdriver, disengage the 4 clips and remove the trim panel.

HINT: Tape the screwdriver tip before use.

: Clip

B66997

2. (a)

REMOVE BACK DOOR SIDE GARNISH LH 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.
Clip
H19055

4. (a)

REMOVE BACK DOOR TRIM BOARD ASSY 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.

: Clip

B66998

5. (a)

REMOVE DOOR PULL HANDLE Using a screwdriver, disengage the 4 claws and remove the pull handle.

: Clip
B60469 B68469

6. 7. 8.

REMOVE REAR SPOILER (See page 7630) REMOVE REAR WIPER MOTOR ASSY (See page 6617) REMOVE BACK DOOR GARNISH SUBASSY OUTSIDE RH (See page 7629)

AVENSIS REPAIR MANUAL (RM1018E)

7546
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)

9. (a) (b)

REMOVE BACK DOOR LOCK ASSY Disconnect the door lock connector. Remove the 3 bolts and door lock.

B66315

10. 11.

BACK DOOR STAY ASSY LH (See page 6526) BACK DOOR STAY ASSY RH (See page 6526)

12. (a) (b)

INSTALL BACK DOOR LOCK ASSY Install the door lock with the 3 bolts. Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) Connect the door lock connector.

B66315

AVENSIS REPAIR MANUAL (RM1018E)

7547
ENGINE HOOD/DOOR BACK DOOR STAY

BACK DOOR STAY

750NA01

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: S Remove the door stay while supporting the back door with your hands. S Tape the screwdriver tip before use. (b) Remove the 2 bolts and stay from the body.
H19020

2. (a)

INSTALL BACK DOOR STAY ASSY LH Install the stay with the bolts. Torque: 22 NVm (264 kgfVcm, 19 ftVlbf) on door side 7.0 NVm (71 kgfVcm, 63 in.Vlbf) on body side

AVENSIS REPAIR MANUAL (RM1018E)

7548
ENGINE HOOD/DOOR BACK DOOR STAY
750NB01

DISPOSAL
HINT: Use the same procedures on the RH side as on the LH side.

1. (a) (b)

a A

b B
B65104

DISPOSE OF BACK DOOR STAY ASSY LH Horizontally fix the stay in a vise with the pistonrod pulled out. 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 b 80 mm (3.15 in.) 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 cutting could be blown out. Therefore, cover it with clothes or thr like.

AVENSIS REPAIR MANUAL (RM1018E)

754
ENGINE HOOD/DOOR FRONT DOOR

FRONT DOOR
750MV01

COMPONENTS
Front Door Glass Run LH

Front Door Frame Subassy Rear Lower LH

8.0 (82, 71 in.lbf)

w/o Rear Power Window Front Door Armrest Base Panel Upper Power Window Regulator Master Switch Assy Front Door Glass Subassy LH

Front Door Armrest Base Panel Upper

5.5 (56, 49 in.lbf)

Front Door Window Regulator Subassy LH

8.0 (82, 71 in.lbf)

Front Door Glass Weatherstrip Inner LH

Power Window Regulator Switch Assy

Front Door Inside Handle Subassy LH

Front No. 1 Speaker Assy

z Rivet Fuel Lid Opener Switch Front Door Trim Board Subassy LH Courtesy Lamp Clip Front Door Trim Base LH Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

B67988

AVENSIS REPAIR MANUAL (RM1018E)

755
ENGINE HOOD/DOOR FRONT DOOR

w/ Key: Front Door Outside Handle Cover LH w/o Key: Front Door Outside Key Cylinder Handle Cover LH Front Door Outside Handle Pad Front Hole Plug

w/ Speaker Front Door Speaker No. 2 Front Door Lower Frame Bracket Garnish LH Outer Rear View Mirror Assy LH

Front Door Handle Assy Outside LH Front Door Outside Handle Pad Rear Front Door Lock Open Rod

10 (102, 7)

Front Door Outside Handle Frame Subassy LH

Front Door Lower Frame Bracket Garnish LH z Front Door Service Hole Cover

Front Door w/ Motor Lock Assy LH

5.0 (51, 44 in.lbf)

z Door Lock Wire Harness Packing z Butyl Tape Front Door Weatherstrip LH Front Door Belt Moulding LH Clip Front Door Lower Frame Seal

Front Door Stiffener Cushion No. 1

26 (265, 19)

Side Trim Spacer LH

Front Door Hinge Assy Upper LH

5.5 (56, 49 in.lbf)

Cushion Rubber

30 (306, 22)

Front Door Check Assy Front Door Hinge Assy Lower LH

26 (265, 19)

Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part L Precoated Part

AVENSIS REPAIR MANUAL (RM1018E)

B67989

756
ENGINE HOOD/DOOR FRONT DOOR
750MW01

ADJUSTMENT
HINT:
S

Use the same procedures on the RH side as on the LH side.

S

Because a centering bolt is used as a door hinge mounting 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.

Centering Bolt

Standard Bolt
B57104

1. (a)

INSPECT FRONT DOOR PANEL SUBASSY LH Check that the clearance is within the standard range.
D B

B66965

Standard range:
A B C D E 4.6 " 1.5 mm (0.181 " 0.059 in.) 5.5 " 1.5 mm (0.220 " 0.059 in.) 4.6 " 1.5 mm (0.181 " 0.059 in.) 160 mm (6.30 in.) 4.8 " 1.5 mm (0.189 " 0.059 in.)

2. (a)

(b)

ADJUST FRONT DOOR PANEL SUBASSY LH Using SST, adjust the door horizontally and vertically by loosening the body side hinge bolts. SST 0981200010, 0981200020 Tighten the body side hinge bolts after the adjustment. SST 0981200010, 0981200020 Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)

B66966

AVENSIS REPAIR MANUAL (RM1018E)

757
ENGINE HOOD/DOOR FRONT DOOR

(c) (d)

Adjust the door forward/rearward and vertically by loosening the door side hinge bolts. Tighten the door side hinge bolts after the adjustment. Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)

B66967

(e)

(f)

Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic faced hammer. Tighten the striker mounting screws after the adjustment. Torque: 23 NVm (235 kgfVcm, 17 ftVlbf)

B62411

AVENSIS REPAIR MANUAL (RM1018E)

758
ENGINE HOOD/DOOR FRONT DOOR
750MX01

OVERHAUL
HINT:
S S

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. Use the same procedures on the RH side as on the LH side.

1. (a)

REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH Using a screwdriver, disengage the 2 clip and remove the garnish.

: Clip
B66969

HINT: Tape the screwdriver tip before use. (b) w/ Speaker: Remove the front door speaker No. 2 (See page 6712). 2. (a) REMOVE FRONT DOOR TRIM BASE LH Using a screwdriver, disengage the 5 claws and clip, and remove the trim base.

HINT: Tape the screwdriver tip before use.

: Clip : Claw

B66970

3. (a)

REMOVE FUEL LID OPENER SWITCH Using a screwdriver, disengage the 2 claws and remove the switch.

HINT: Tape the screwdriver tip before use.

Claw
B67801

AVENSIS REPAIR MANUAL (RM1018E)

759
ENGINE HOOD/DOOR FRONT DOOR

4. (a)

REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY 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.

B70388

Protective Tape

Protective Tape Screw

5. REMOVE FRONT DOOR TRIM BOARD SUBASSY 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.

Cushion Rubber

Bolt
B66971

: Clip

6. (a)

REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER LH Remove the weatherstrip inner upward in the direction indicated by the arrow mark in the illustration.

B70121

Claw A 1 2

7.

(a) 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.
: Claw
B68930

REMOVE FRONT DOOR INSIDE HANDLE SUBASSY LH Using a screwdriver, disengage the claw A indicated.

AVENSIS REPAIR MANUAL (RM1018E)

7510
ENGINE HOOD/DOOR FRONT DOOR

Butyl Tape

8. REMOVE FRONT DOOR SERVICE HOLE COVER (a) Remove the service hole cover. NOTICE: Remove the tape remaining on the door side.

B69067

(b)

Remove the lower frame seal.

B66981

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 become deformed.

B68929

11. 12. (a) 13. (a)

REMOVE FRONT NO.1 SPEAKER ASSY (W/ SPEAKER) (a) Using a drill of less than 4 mm (0.16 in.), drill out the 3 rivets heads and remove the speaker. NOTICE: S Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill. S Be careful with the cut rivet, because it is hot. (b) Even if the flange is taken off, continue drilling and push B61431 out the remaining fragments using the drill. (c) Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door. REMOVE FRONT DOOR BELT MOULDING ASSY LH (See page 7623) REMOVE FRONT DOOR STIFFENER CUSHION NO.1 Using a screwdriver, disengage the 2 claws and remove the cushion. REMOVE FRONT DOOR SPACER LH Using a screwdriver, disengage the 2 claws and remove the spacer.

10.

AVENSIS REPAIR MANUAL (RM1018E)

7511
ENGINE HOOD/DOOR FRONT DOOR

14. REMOVE FRONT DOOR GLASS SUBASSY 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.
B62422

(c)
2 1

Remove the door glass in the direction indicated by the arrows in the illustration. NOTICE: S Do not damage the glass. S When the bolts are removed, the glass may fall and become deformed. (d) Remove the glass run.
B62423

15.

B66968

REMOVE FRONT DOOR WINDOW REGULATOR SUBASSY 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 SUBASSY REAR LOWER LH Remove the bolt and frame.

(a) HINT: Remove the frame through the service hole.

B61434

17. (a) (b)

REMOVE FRONT DOOR OUTSIDE HANDLE COVER Remove the hole plug. Using a torx socket wrench (T30), loosen the screw and remove the cover with the door lock key cylinder installed.

Hole Plug
B61438 B68932

AVENSIS REPAIR MANUAL (RM1018E)

7512
ENGINE HOOD/DOOR FRONT DOOR

18. (a) (b)

B66894

REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH Disconnect the door lock connector. 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. (a) (b) REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH Remove the handle pushing and pulling it in the direction indicated by the arrow mark in the illustration. Remove the outside handle pads front and rear.

1 2
B56613

20. (a)

REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUBASSY LH Using a torx socket wrench (T30), loosen the screw of the frame.

Screw
B70122

(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.
B57102

21. REMOVE FRONT DOOR CHECK ASSY LH (a) Remove the 2 nuts, bolt and check. HINT: Remove the check through the service hole.

B68928

AVENSIS REPAIR MANUAL (RM1018E)

7513
ENGINE HOOD/DOOR FRONT DOOR

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. (a) (b) (c) INSTALL FRONT DOOR CHECK ASSY LH Apply MP grease to the sliding areas of the check. Install the check to the door panel with the 2 nuts. Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf) Apply adhesive to the threads of the bolt. Adhesive: Part No. 0883300070, THREE BOND 1324 or equivalent Install the door check to the body panel with the bolt. Torque: 30 NVm (306 kgfVcm, 22 in.Vlbf) INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUBASSY LH Install the outside handle link. Apply MP grease to the sliding areas of the frame. Using a torx socket wrench (T30), install the frame with the screw. Torque: 4.0 NVm (41 kgfVcm, 35 in.Vlbf)

Adhesive
B68928

(d) 24. (a) (b) (c)

Screw
B70122

25. (a) (b)

2 1
B64044

INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH Install the outside handle pads front and rear. 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: S When reusing a door lock that has been removed, replace the packing in the connecting part with a new one. S Be careful that no grease or dirt does not sticks to the packing surface in the connecting part. S Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part resulting in a door lock malfunction.

AVENSIS REPAIR MANUAL (RM1018E)

7514
ENGINE HOOD/DOOR FRONT DOOR

(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.
Rod

B65961

(d)
Adhesive

(e)

Adhesive
B66894

(f)

Apply adhesive to the threads of the 3 screws. Adhesive: Part No. 0883300070, THREE BOND 1324 or equivalent Using a torx socket wrench (T30), install the door lock with the 3 screws. Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) Connect the door lock connector.

27. (a)

(b)

INSTALL FRONT DOOR OUTSIDE HANDLE COVER Using a torx socket wrench (T30), install the cover with the door lock key cylinder installed with the screw. Torque: 7.0 NVm (71 kgfVcm, 62 in.Vlbf) Install the hole plug.

B61438

Hole Plug

B68932

28. (a)

INSTALL FRONT DOOR FRAME SUBASSY REAR LOWER LH Install the frame with the bolt. Torque: 5.5 NVm (56 kgfVcm, 49 in.Vlbf)

B62425

29.

INSTALL FRONT DOOR WINDOW REGULATOR SUBASSY 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.

B66972

AVENSIS REPAIR MANUAL (RM1018E)

7515
ENGINE HOOD/DOOR FRONT DOOR

(b)

Install the window regulator with the 6 bolts. Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf) (c) Connect the window regulator connector. NOTICE: Be careful not to drop and deform the door window regulator as this may cause deformation.

B66968

1 2

30. INSTALL FRONT DOOR GLASS SUBASSY 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.

B62423

(c)

B62422

(d) (e) 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 harness and turn the ignition switch ON. (2) Repeat UP and DOWN operation several times in manual operation.

Install the door glass to the window regulator with the 2 bolts. Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf) Reset the power window motor (See page 7013). Inspect operation of the power window.

31. (a)

INSTALL FRONT NO.1 SPEAKER ASSY Using an air riveter or hand riveter, install the speaker to the door with the 3 rivets.

B61441

AVENSIS REPAIR MANUAL (RM1018E)

7516
ENGINE HOOD/DOOR FRONT DOOR

WRONG Riveter

NOTICE: S Do not operate the riveter an angle as this will damage it bend the mandrel.

Mandrel
H02440

WRONG Riveter

Do not tilt the riveter when removing the rivet as the speaker will not be tightened firmly.

WRONG Riveter

H02441

WRONG Riveter

(b)

Install the rivet while attaching the speaker to ensure that it is tightened firmly. Connect the speaker connector.

H02442

32. (a) (b)

INSTALL OUTER REAR VIEW MIRROR ASSY LH Install the mirror with the 3 screws. Torque: 10 NVm (102 kgfVcm, 7 ftVlbf) Connect the mirror connector.

B68929

Butyl Tape

B69067

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: S When installing the service hole cover, pull out the links and connectors through the service hole cover. S There should be no wrinkles or folds after attaching the service hole cover. S After attaching the service hole cover, check the sealing quality.

AVENSIS REPAIR MANUAL (RM1018E)

7517
ENGINE HOOD/DOOR FRONT DOOR

(c)

Install the lower frame seal front.

B66981

AVENSIS REPAIR MANUAL (RM1018E)

751
ENGINE HOOD/DOOR HOOD

HOOD
750MT01

COMPONENTS
Hood Subassy

Hood Insulator

Engine Room Side Cover RH x8 Battery Service Hole Cover Clip

13 (133, 10)

Hood Hinge Assy RH Radiator Cover Hood to Front End Panel Seal
13 (133, 10)

Hood Lock Assy Hood to Front Fender Seal RH

8.0 (82, 71 in.lbf)

Cushion Rubber Cushion Rubber

Hood Hinge Assy LH

Hood to Front Fender Seal LH

Front Bumper Assy

Nm (kgfcm, ftlbf) : Specified torque

B67533

AVENSIS REPAIR MANUAL (RM1018E)

752
ENGINE HOOD/DOOR HOOD
750MU01

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.
Centering Bolt Standard Bolt
B57104

1. (a)

INSPECT HOOD SUBASSY Check that the clearance is within the standard range.

B A

B66962

Standard range:
A B 3.5 " 1.5 mm (0.138 " 0.059 in.) 3.5 1.5 or +2.5 mm (0.138 0.059 or + 0.098 in.)

2. (a)

ADJUST HOOD SUBASSY Horizontally and vertically adjust the hood. (1) Loosen the 4 hood hinge bolts on the hood side.

B61420

AVENSIS REPAIR MANUAL (RM1018E)

753
ENGINE HOOD/DOOR HOOD

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 adjustment. Torque: 13 NVm (133 kgfVcm, 10 ftVlbf)

(2)

Aligned
B66963

(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.

B66964

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 radiator cover. (4) Using a clip remover, remove the 3 clips and engine room side cover RH. (5) Remove the front bumper (See page 763).

(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 NVm (82 kgfVcm, 71 in.Vlbf)

B62401

AVENSIS REPAIR MANUAL (RM1018E)

7532
ENGINE HOOD/DOOR LUGGAGE COMPARTMENT DOOR

LUGGAGE COMPARTMENT DOOR

750N101

COMPONENTS

4.9 (49, 43 in.lbf)

Luggage Compartment Door Lock Cylinder Assy

Luggage Compartment Door Panel Subassy

Luggage Compartment Outside Garnish

5.0 (51, 44 in.lbf)

Licence Plate Lamp Assy Luggage Lock Assy

7.0 (71, 62 in.lbf)

Back Door Trim Cover Clip Hinge Cover Luggage Compartment Floor Carpet Luggage Compartment Trim Inner RH

Luggage Compartment Trim Inner LH Luggage Compartment Trim Hook No. 2 Rear Floor Finish Plate

11.5 (120, 8)

Luggage Striker Assy

5.0 (51, 44 in.lbf)

Nm (kgfcm, ftlbf) : Specified torque

Rope Hook Assy

B66985

AVENSIS REPAIR MANUAL (RM1018E)

7533
ENGINE HOOD/DOOR LUGGAGE COMPARTMENT DOOR
750N201

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 centering bolt.
Centering Bolt Standard Bolt
B57104

1. (a)

INSPECT LUGGAGE COMPARTMENT DOOR PANEL SUBASSY Check that the clearance is within the standard range.

A B

B66984

Standard range:
A B C 4.0 " 1.5 mm (0.157 " 0.059 in.) 5.3 " 1.5 mm (0.209 " 0.059 in.) 7.1 1.5 or + 2.5 mm (0.280 0.059 or + 0.098 in.)

2. (a) (b) (c) (d)

B61457

ADJUST LUGGAGE COMPARTMENT DOOR PANEL SUBASSY Using a clip remover, remove the clips and hinge cover. Using a clip remover, remove the 11 clips and trim cover. Adjust the door horizontally and vertically by Loosening the door bolts. Tighten the door mounting bolts after the adjustment. Torque: 7.0 NVm (71 kgfVcm, 62 in.Vlbf)

AVENSIS REPAIR MANUAL (RM1018E)

7534
ENGINE HOOD/DOOR LUGGAGE COMPARTMENT DOOR

(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 NVm (120 kgfVcm, 8 ftVlbf)
B66994

AVENSIS REPAIR MANUAL (RM1018E)

7535
ENGINE HOOD/DOOR LUGGAGE DOOR HINGE TORSION BAR

LUGGAGE DOOR HINGE TORSION BAR

750N301

REPLACEMENT
HINT:
S S S S

The installation is in the reverse order of the removal. However, when there is a special point concerning 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 center of the upper back panel.

(e)

Remove the tip of the torsion bar from the roof side inner panel by hand.

B55944

(f) (g)

Take out the hinge arm from the torsion bar in the rear direction. Pull the torsion bar to your side in order to remove the U shaped part from the hinge support.

B55945

2.

REMOVE LUGGAGE DOOR HINGE TORSION BAR RH

AVENSIS REPAIR MANUAL (RM1018E)

7536
ENGINE HOOD/DOOR LUGGAGE DOOR HINGE TORSION BAR

Installation Hole

3. (a)

INSTALL LUGGAGE DOOR HINGE TORSION BAR LH 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.

Installation Hole (For Adjustment)

B56621

4.

INSTALL LUGGAGE DOOR HINGE TORSION BAR RH

AVENSIS REPAIR MANUAL (RM1018E)