2005 TOYOTA AVENSIS service

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 ù 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 (See page 76±23)
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
12
B66968
B61434

B68932Hole Plug
± ENGINE HOOD/DOORFRONT 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/DOORFRONT 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.

H02440Mandrel
RiveterWRONG
H02441
Riveter
Riveter
WRONG
WRONG
H02442
Riveter
WRONG
B68929
B69067
Butyl Tape
75±16
± ENGINE HOOD/DOORFRONT 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.

B67989
Front Door Outside Handle Frame Sub±assy LHw/ 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 5.0 (51, 44 in.´lbf)
Front Door Belt Moulding LH
Front Door Hinge
Assy Upper LH
Front Door Check Assy
30 (306, 22)

5.5 (56, 49 in.´lbf)
Front Door Hinge
Assy Lower LH26 (265, 19)
Front Door Weatherstrip LH
Cushion RubberFront Door Lower Frame
Bracket Garnish LH Outer Rear View Mirror Assy LH
Front Door Speaker No. 2
Front Door Service Hole Cover 
: Specified torqueN´m (kgf´cm, ft´lbf)


Precoated Part Non±reusable part Clip
26 (265, 19)
Front Door Lower
Frame Seal


Butyl Tape

10 (102, 7)
Front Door Stiffener
Cushion No. 1
Side Trim
Spacer LH
Key Cylinder
w/o Key:
Front Door Outside
Handle Cover LHw/ Speaker
Front Door Lower Frame
Bracket Garnish LH
± ENGINE HOOD/DOORFRONT DOOR
75±5
AVENSIS REPAIR MANUAL (RM1018E)

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 thefender 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 frontend 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)Remove the front bumper (See page 76±3).
(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)

750MT±01
B67533
Hood Sub±assy
Hood Insulator
Engine Room Side Cover RH
Radiator CoverBattery 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 torqueN´m (kgf´cm, ft´lbf)Cushion Rubber
Cushion Rubber
Clip
± ENGINE HOOD/DOORHOOD
75±1
AVENSIS REPAIR MANUAL (RM1018E)
HOOD
COMPONENTS

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)