2002 TOYOTA AVENSIS Repair Manual

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)

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

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)

750N9±01
B66997: Clip
H19055Clip
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 removethe 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.REMOVE REAR SPOILER (See page 76±30)
7.REMOVE REAR WIPER MOTOR ASSY (See page 66±17)
8.REMOVE BACK DOOR GARNISH SUB±ASSY OUTSIDE RH (See page 76±29)

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 (See page 65±26)
11.BACK DOOR STAY ASSY RH (See page 65±26) 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/DOORBACK 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
AB ab 75±48
± ENGINE HOOD/DOORBACK 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:
a80 mm (3.15 in.)
b20 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.