2001 TOYOTA AVALON Service Repair Manual

BO0XJ-04
H12099: Specified torqueN´m (kgf´cm, ft´lbf)
Oil Cooler
11 (115, 8)
5.4 (55, 48 in.´lbf)
11 (115, 8)
Front Bumper
Upper Reinforcement
RH Side Support
RH No. 2 Extension
Insert
LH Side Support
13 (130, 9)
Front Bumper Reinforcement
LH No. 2 Extension
Insert
13 (130, 9)
Front Bumper Energy Absorber
5.4 (55, 48 in.´lbf)
5.4 (55, 48 in.´lbf)
Front Bumper Cover
w/o Fog light:
RH Hole Cover
w/ Fog light:
RH Fog Light Assembly
8.3 (85, 74 in.´lbf)
w/ Fog light:
LH Fog Light Assembly
w/o Fog light:
LH Hole Cover
11 (115, 8)
BO-4
- BODYFRONT BUMPER
1789 Author
: Date
:
2001 AVALON (RM808U)
FRONT BUMPER
COMPONENTS

BO2OQ-01
N01363
SST
N01364
BO2556
BO-14
- BODYFRONT DOOR
1799 Author
: Date
:
2001 AVALON (RM808U)
ADJUSTMENT
1. ADJUST DOOR IN FORWARD/REARWARD AND VER-
TICAL DIRECTIONS
Using SST, loosen the body side hinge bolts to adjust.
SST 09812-00010
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL
DIRECTIONS
Loosen the door side hinge bolts to adjust.
HINT:
Substitute the bolt with washer for the centering bolt.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
3. ADJUST DOOR LOCK STRIKER
(a) Check that the door fit and door lock linkages are adjusted
correctly.
(b) Loosen the striker mounting screws.
Torque: 23 N´m (230 kgf´cm, 17 ft´lbf)
(c) Using a plastic hammer, tap the striker to adjust it.

BO2OO-01
H12112
Rear Lower FrameDoor Lock Striker23 (230, 17)
Front Door Weatherstrip
Door Glass Run
Outside Rear View
Mirror
Door Glass
Lower Frame
Bracket Garnish
7.8 (80, 69 in.´lbf)25 (260, 19)
5.4 (55, 48 in.´lbf)
Outside Handle
Key Cylinder
5.4 (55, 48 in.´lbf)
Door
Hinge
7.8 (80, 69 in.´lbf)
Door Check
25 (260, 19)
Door Speaker BoardFront Lower
Frame
25 (260, 19)
Door Hinge
Front Door Outside Lower Moulding
Door Lock Protector
Service Hole Cover
5.4 (55, 48 in.´lbf)

Precoated part
Door LockInside Handle
4.9 (50, 43 in.´lbf)
Inside Handle
Bezel
Cover
Door TrimUpper Armrest
Base Panel
Power Window Switch
Front Door Armrest
Courtesy Light
Front Door
Belt Moulding Front Door
Inner Weatherstrip
x10
5.4 (55, 48 in.´lbf)
Window Regulator
Guide Assembly
5.4 (55, 48 in.´lbf)
x8
x4
Window Regulator Motor
No. 2 Service Hole Cover
Front Door Trim Pocket : Specified torqueN´m (kgf´cm, ft´lbf)
BO-8
- BODYFRONT DOOR
1793 Author
: Date
:
2001 AVALON (RM808U)
FRONT DOOR
COMPONENTS

BO2OP-01
H04751
H12102
H12103
H12137
x10
x8
- BODYFRONT DOOR
BO-9
1794 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE INSIDE HANDLE BEZEL
(a) Using a screwdriver, remove the cover.
HINT:
Tape the screwdriver tip before use.
(b) Remove the screw.
(c) Using a screwdriver, remove the inside handle bezel as
shown in the illustration.
HINT:
Tape the screwdriver tip before use.
2. REMOVE COURTESY LIGHT
3. REMOVE UPPER ARMREST BASE PANEL WITH
POWER WINDOW SWITCH
(a) Using a screwdriver, remove the upper armrest base pan-
el with power window switch.
HINT:
Tape the screwdriver tip before use.
(b) Disconnect the connector.
(c) Remove the 3 screws and power window switch from the
upper armrest base panel.
4. REMOVE DOOR TRIM
(a) Using a screwdriver, remove the 2 caps.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 6 screws and clip.
(c) Pull the trim upward to remove it.
(d) Using a screwdriver, remove the front door inner weather-
strip from the front door trim.
(e) Remove the 10 screws and front door armrest from the
front door trim.
(f) Remove the 8 screws and front door trim pocket from the
front door trim.

H12104Clip
H06127
H12105
H12106
BO-10
- BODYFRONT DOOR
1795 Author
: Date
:
2001 AVALON (RM808U)
5. REMOVE LOWER FRAME BRACKET GARNISH
Using a screwdriver, remove the lower frame bracket as shown
in the illustration.
HINT:
Tape the screwdriver tip before use.
6. REMOVE OUTSIDE REAR VIEW MIRROR
Torque: 7.8 N´m (80 kgf´cm, 69 ft´lbf)
7. REMOVE DOOR SPEAKER BOARD
8. REMOVE INSIDE HANDLE
(a) Remove the screw.
(b) Slide the inside handle backward to remove it.
(c) Disconnect the 2 cables from the inside handle as shown
in the illustration.
9. REMOVE SERVICE HOLE COVER
(a) Using a clip remover, remove the grommets.
(b) Remove the service hole cover.
NOTICE:
Do not tear the cover.
HINT:
At the time of reassembly, please refer to the following item.
Bring out the 2 control cables and wire harness through the ser-
vice hole cover.
10. REMOVE FRONT DOOR WEATHERSTRIP
(a) Using a clip remover, remove the clip.
(b) Remove the screw from the door check.
(c) Using a clip remover, remove the front door weatherstrip.
(d) Reinstall the screw to the door check.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)

H12107
Protective Tape
H12108
H02440
- BODYFRONT DOOR
BO-1 1
1796 Author
: Date
:
2001 AVALON (RM808U)
11. REMOVE FRONT DOOR BELT MOULDING
(a) Apply protective tape to the outer surface as shown in the
illustration, to keep the surface from being scratched.
(b) Using a moulding remover, remove the front door belt
moulding.
12. REMOVE FRONT DOOR OUTSIDE LOWER MOULD-
ING
(a) Using a drill of less than ù3.2 mm (0.126 in.), drill out the
3 rivet heads.
HINT:
Gently and vertically put the drill to the rivets, and cut the rivet
flanges.
CAUTION:
Take care as the cut rivets are hot.
NOTICE:
Prizing the hole with a drill can lead to damage to the rivet
hole or the drill itself.
(b) Using a clip remover, remove the clip.
(c) Remove the front door outside lower moulding.
(d) Using a vacuum cleaner, remove the drilled rivets and
accociated metallic dust from the inside of door panel.
HINT:
At the time of reassembly, please refer to the following item.
Using an air riveter with nose piece No. 1 or a hand riveter with
nose piece No. 1 to install new 3 rivets to the front door outside
lower moulding.
NOTICE:

At the time of reassembly, please refer to the follow-
ing items.

Do not prize a riveter, as riveter is damaged, it is not
tightened and the mandrel is bent.

H02441
H02442
H12109
BO-12
- BODYFRONT DOOR
1797 Author
: Date
:
2001 AVALON (RM808U)

Do not tilt the riveter disconnect the rivet from the ma-
terial while handling a riveter, as the materials are not
tightened firmly.

Install the rivet while attaching materials, as they are
not tightened firmly.
13. REMOVE NO. 2 SERVICE HOLE COVER
Remove the window regulator connector clamp, 3 screws and
No. 2 service hole cover.
14. REMOVE DOOR GLASS
(a) Open the door glass until the bolts appear in the service
hole.
(b) Remove the 2 bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
NOTICE:
Be careful not to drop the door glass.
(c) Pull the door glass upward to remove it.
15. REMOVE DOOR GLASS RUN
16. REMOVE WINDOW REGULATOR ASSEMBLY
(a) Disconnect the connector, then remove the bolt, 3 nuts
and window regulator assembly.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Remove the window regulator assembly through the service
hole.
(b) Using a torx driver, remove the 3 torx screws and window
regulator motor from the window regulator guide assem-
bly.
HINT:
At the time of reassembly, please refer to the following items.

Apply MP grease to the glass guide and rollers of window
regulator assembly.

After installing the window regulator assembly, window
regulator assembly need to be re-initialized.
Refer to BE-80.
17. REMOVE FRONT LOWER FRAME
18. REMOVE REAR LOWER FRAME

H12110
- BODYFRONT DOOR
BO-13
1798 Author
: Date
:
2001 AVALON (RM808U)
19. REMOVE DOOR LOCK
(a) Disconnect the 2 control links from the outside handle and
door lock cylinder.
(b) Disconnect the connector.
(c) Remove the 3 torx screws, bolt and door lock.
Torque:
Bolt: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
Screw: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
HINT:
Remove the door lock through the service hole.
HINT:
At the time of reassembly, please refer to the following item.
Apply adhesive to 3 screws.
Part No. 08833-00070, THREE BOND 1324 or equiva-
lent
(d) Remove the 2 screws and door lock protector from the
door lock.
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the sliding and rotating parts of the door
lock.
20. REMOVE OUTSIDE HANDLE
(a) Remove the 2 bolts and outside handle with key cylinder.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(b) Remove the bolt and key cylinder from the outside han-
dle.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)