2002 TOYOTA AVENSIS Repair Manual

B66545
B66544
Clip
B66543
B66542
Clip
76±56
± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
20. REMOVE DECK BOARD SUB±ASSY
21. REMOVE DECK FLOOR BOX REAR
(a) Remove the deck floor box.
22. REMOVE DECK FLOOR BOX FRONT
(a) Using a screwdriver, disengage the 2 clips and 2 screws,
and remove the deck floor box.
HINT:
Tape the screwdriver tip before use.
23. REMOVE DECK FLOOR BOX RH
(a) Remove the 2 screws and deck floor box.
24. REMOVE DECK FLOOR BOX LH
(a) Remove the 2 screws and deck floor box.
25. REMOVE REAR FLOOR FINISH PLATE
(a) Using a screwdriver, disengage the 4 clips and remove
the floor finish plate.
HINT:
Tape the screwdriver tip before use.

B66536
Clip
Claw
B66540
Clip
B66538
Clip
B66539
Clip
± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (WAGON MODELS)
76±57
AVENSIS REPAIR MANUAL (RM1018E)
26. REMOVE DECK TRIM SIDE BOARD RH
(a) Remove the bolt and screw.
(b) Using a screwdriver, disengage the 5 clips and 2 claws,
and remove the deck trim side board.
HINT:
Tape the screwdriver tip before use.
27. REMOVE DECK TRIM SIDE BOARD LH
HINT:
Use the same procedures described for the RH side.
28. REMOVE ROOF HEADLINING TRIM SUB±ASSY
REAR
(a) Using a screwdriver, disengage the 5 clips and remove
the roof headlining trim.
HINT:
Tape the screwdriver tip before use.
29. REMOVE ROOF SIDE GARNISH INNER RH
(a) Remove the bolt.
(b) Using a screwdriver, disengage the 2 clips and remove
the window side garnish.
HINT:
Tape the screwdriver tip before use.
30. REMOVE ROOF SIDE GARNISH INNER LH
HINT:
Use the same procedures described for the RH side.
31. REMOVE REAR WINDOW SIDE GARNISH RH
(a) Using a screwdriver, disengage the 3 clips and screw, and
remove the roof side garnish.
HINT:
Tape the screwdriver tip before use.

B66528
Clip
B65292
700 mm120 mm
Adhesive Tape
Adhesive Tape
Protective Cover
76±58
± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
32. REMOVE REAR WINDOW SIDE GARNISH LH
HINT:
Use the same procedures described for the RH side.
33. REMOVE FRONT PILLAR GARNISH RH
(a) Using a screwdriver, disengage the 2 clips and remove
the pillar garnish.
HINT:
Tape the screwdriver tip before use.
(b) Pull the garnish upward and remove if from the instrument
panel.
(c) w/ Curtain shield airbag:
Protect the curtain shield airbag LH.
(1) Thoroughly cover the airbag with cloth or nylon of
700 mm (27.56 in.) x 120 mm (4.72 in.) and fix the
ends of the cover in place with adhesive tape as
shown in the illustration.
NOTICE:
Cover the curtain shield airbag with a protective cover as
soon as the front pillar garnish is removed.
34. REMOVE FRONT PILLAR GARNISH LH
HINT:
Use the same procedures described for the RH side.
35. REMOVE RH VISOR ASSY
(a) Remove the 2 screws and visor.
36. REMOVE LH VISOR ASSY
(a) Remove the 2 screws and visor.

A79919
Claw
Claw
B66541Claw
Claw
B66529
ClawClaw
B50596
90

± EXTERIOR/INTERIOR TRIMROOF HEADLINING ASSY (WAGON MODELS)
76±59
AVENSIS REPAIR MANUAL (RM1018E)
37. REMOVE MAP LAMP ASSY
(a) Using a screwdriver, disengage the 6 claws and remove
the lens cover.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 screws.
(c) Using a moulding remover, disengage the claws.
(d) Disconnect the map lamp switch connector and sliding
roof switch connector, and remove the map lamp.
38. REMOVE ROOM LAMP ASSY NO.2
(a) Using a moulding remover, disengage the 8 claws and re-
move the lens cover.
HINT:
Tape the screwdriver tip before use.
(b) Using a moulding remover, disengage the claws.
(c) Disconnect the map lamp switch connector and remove
the map lamp.
39. REMOVE ASSIST GRIP SUB±ASSY
(a) Using a screwdriver, disengage the 2 claws and remove
the 2 assist grip covers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 bolts and assist grip.
40. REMOVE VISOR HOLDER
(a) Remove the holder of the sun visor by turning it counter-
clockwise.
41. REMOVE SUN ROOF OPENING TRIM MOULDING (W/ SLIDING ROOF)

B66558
Clip
w/ Sliding Roof
w/o Sliding RoofClip
B66555
Tape
w/ Sliding Roof
w/o Sliding Roof
Tape
76±60
±
EXTERIOR/INTERIOR TRIM ROOF HEADLINING ASSY(WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
42.REMOVE ROOF HEADLINING ASSY
(a)w/ Sliding roof: Using a clip remover, disengage the 2 clips and remove
the roof headling.
(b)w/o Sliding roof: Using a clip remover, disengage the 4 clips and remove
the roof headling.
43.INSTALL ROOF HEADLINING ASSY
(a)Align the markings, and then install the wire harness with tape.
NOTICE:
Attach the roof wire harness securely.
(b)w/ Sliding roof: Install the 4 clips.
(c)wo/ Sliding roof: Install the 2 clips.
44.INSTALL REAR SEAT ASSY (See page 72±21)

2600M±04
F13686
C80880
F13683
F44622
26±10
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SHOCK ABSORBER WITH COIL SPRING
OVERHAUL
HINT:

COMPONENTS: See page 26±2

This procedure is provided for the overhaul on the LH side. Overhaul the oth\
er side by the same proce-
dure as the LH side.
1. REMOVE FRONT WHEEL
2. SEPARATE FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the stabilizer bar link fromthe shock absorber.
HINT:
If the ball joint turns together with the nut, use a hexagon (6 mm)
wrench to hold the stud.
3. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Remove the bolt, disconnect the front flexible hose and speed sensor front LH.
(b) Remove the 2 nuts and bolts on the lower side of the shock absorber.
(c) Remove the 3 nuts on the upper side of the shock absorb- er.
(d) Remove the shock absorber with the coil spring.

28mm
F44963
F40270
SST
F08624
SST
± FRONT SUSPENSIONFRONT SHOCK ABSORBER WITH COIL SPRING
26±11
AVENSIS REPAIR MANUAL (RM1018E)
4. FIX FRONT SHOCK ABSORBER WITH COIL SPRING
(a) Install 2 nuts and a bolt to the bracket at the lower side of
the shock absorber and secure it in a vise.
5. REMOVE FRONT SUSPENSION SUPPORT DUST COVER LH
6. REMOVE FRONT SUPPORT TO FRONT SHOCK
ABSORBER LH NUT
(a) Using SST, compress the coil spring.
SST 09727±30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Remove the front suspension support dust cover from the
suspension support.
(c) Using SST to hold the spring seat, remove the nut.
SST 09729±22031
7. REMOVE FRONT SUSPENSION SUPPORT SUB±ASSY LH
8. REMOVE FRONT SUSPENSION SUPPORT LH DUST SEAL
9. REMOVE FRONT COIL SPRING SEAT UPPER LH
10. REMOVE FRONT COIL SPRING INSULATOR UPPER LH
11. REMOVE FRONT COIL SPRING LH
12. REMOVE FRONT SPRING BUMPER LH
13. REMOVE FRONT COIL SPRING INSULATOR LOWER LH

C80884
F40271
SST
F13692
OutsideOutside
F40272
Outside
26±12
±
FRONT SUSPENSION FRONT SHOCK ABSORBER WITH COIL SPRING
AVENSIS REPAIR MANUAL (RM1018E)
14. INSPECT SHOCK ABSORBER ASSY FRONT LH
(a) Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound
during operation.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When disposing of the shock absorber, see DISPOSAL on
page 26±15.
15. INSTALL FRONT COIL SPRING INSULATOR LOWER LH
HINT:
Fit the front coil spring insulator lower into the gap of the shock abso\
rber.
(a) Install the front coil spring insulator lower onto the shock absorber.
16. INSTALL FRONT SPRING BUMPER LH
(a) Install the spring bumper to the piston rod.
17. INSTALL FRONT COIL SPRING LH
(a) Using SST, compress the coil spring.SST 09727±30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of the front coil
spring insulator lower LH.
18. INSTALL FRONT COIL SPRING INSULATOR UPPER LH
(a) Install the upper insulator as shown in the illustration.
19. INSTALL FRONT COIL SPRING SEAT UPPER LH
(a) Install the spring seat to the shock absorber with the mark facing to the outside of the vehicle.