Page 3393 of 5135
760WY±01
B67425
Claw
B67431
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
76±3
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
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 FRONT BUMPER COVER
(a) Put protective tape under the front fender.
HINT:
Because the spoiler covers LH and RH are assembled, remove
them together.
(b) Remove the spoiler.
(1) Remove the 9 screws and 6 claws.
(2) Remove the 6 retainers.
(3) Remove the spoiler covers LH and RH together.
(4) Remove the bolt and separate the spoiler cover RH
from the LH.
(c) Remove the 3 bolts and 2 clips.
(d) Using a screwdriver, disengage the 6 claws and remove
the bumper cover.
HINT:
Tape the screwdriver tip before use.
(e) w/ Fog lamp:
Disconnect the fog lamp connectors.
2. R E M O V E H E A D L A M P WA S H E R A C T U ATO R
SUB±ASSY LH (W/ HEADLAMP CLEANER)
(a) Remove the washer hose clip.
(b) Using a screwdriver, pry out the front washer nozzle.
HINT:
Tape the screwdriver tip before use.
(c) Remove the 2 screws and actuator.
3. REMOVE HEADLAMP WASHER ACTUATOR SUB±ASSY RH (W/ HEADLAMP CLEANER)
HINT:
Use the same procedures described for the LH side.
4. REMOVE INTERCOOLER COOLING AIR DUCT SUB±ASSY (W/ CAC 1CD±FTV ENGINE TYPE)
(a) Remove the 3 screws and air duct.
5. REMOVE FRONT BUMPER REINFORCEMENT SUB±ASSY
(a) Using a screwdriver, remove the wire harness.
(b) Remove the 8 bolts and reinforcement.
6. REMOVE FRONT BUMPER SIDE RETAINER LH
(a) Using a screwdriver, remove the 2 screws and retainer.
HINT:
Tape the screwdriver tip before use.
Page 3394 of 5135
B67425
76±4
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE FRONT BUMPER SIDE RETAINER RH
HINT:
Use the same procedures described for the LH side.
8. REMOVE FRONT BUMPER STAY SUB±ASSY LH
(a) Remove the 2 bolts and stay.
9. REMOVE FRONT BUMPER STAY SUB±ASSY RH
(a) Remove the 2 bolts and stay.
10. REMOVE FOG LAMP ASSY LH (W/ FOG LAMP)
(a) Remove the 2 screws and fog lamp.
11. REMOVE FOG LAMP ASSY RH (W/ FOG LAMP)
(a) Remove the 2 screws and fog lamp.
12. REMOVE FRONT BUMPER HOLE COVER LH
13. REMOVE FRONT BUMPER HOLE COVER RH
14. REMOVE FRONT BUMPER SIDE MOULDING LH
(a) Using a screwdriver, disengage the 9 claws and remove the retainer.
HINT:
Tape the screwdriver tip before use.
15. REMOVE FRONT BUMPER SIDE MOULDING RH
HINT:
Use the same procedures described for the LH side.
16. REMOVE HOOD TO FRONT END PANEL SEAL
(a) Using a screwdriver, remove the 10 clips and panel seal.
HINT:
Tape the screwdriver tip before use.
17. REMOVE RADIATOR GRILLE
(a) Using a screwdriver, disengage the 13 claws and remove the 2 screws and radiator grille.
HINT:
Tape the screwdriver tip before use.
18. REMOVE RADIATOR GRILLE LOWER
(a) Using a screwdriver, disengage the 10 claws and remove the grille lower.
HINT:
Tape the screwdriver tip before use.
19. INSTALL FRONT BUMPER REINFORCEMENT SUB±ASSY
(a) Install the reinforcement with the 8 bolts.
(b) Install the wire harness.
20. INSTALL FRONT BUMPER COVER
(a) w/ Fog lamp:
Connect the fog lamp connector.
(b) Engage the 6 claws and install the bumper cover.
(c) Install the 3 bolts and 2 clips.
(d) Install the spoiler.
(1) Install the spoiler covers LH and RH together.
(2) Install the 6 retainers.
(3) Install the 9 screws and 10 claws.
Page 3395 of 5135
760WX±01
B67422
Front Bumper CoverCAC Cooling
Air Duct Sub±assy Front Bumper
Reinforcement Sub±assy
Front Bumper Side
Retainer LH Front Bumper Side
Retainer RH
w/ Fog Lamp
Fog Lamp
Assy RH
Front Bumper Hole
Cover LH Front Bumper Hole
Cover RH
Front Spoiler
Cover LH Front Spoiler
Cover RHFront Bumper Side
Moulding LH Front Bumper Side
Moulding RHHood to Front
End Panel Seal Radiator GrilleRadiator Grille Lower
w/ CAC
Front Bumper
Stay Sub±assy LH Front Bumper
Stay Sub±assy RH
w/ Fog Lamp
Fog Lamp Assy LH
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
76±1
AVENSIS REPAIR MANUAL (RM1018E)
FRONT BUMPER
COMPONENTS
Page 3396 of 5135
B68229
w/ Headlamp Cleaner
Headlamp Washer
Actuator Sub±assy RH
Headlamp Washer
Actuator Sub±assy LH
Radiator Grille Lower
Front Bumper Cover Headlamp Washer
Nozzle Sub±assy LH Headlamp Washer
Nozzle Sub±assy RH
Front Spoiler
Cover LH Front Spoiler
Cover RH
76±2
± EXTERIOR/INTERIOR TRIMFRONT BUMPER
AVENSIS REPAIR MANUAL (RM1018E)
Page 3397 of 5135
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.
Page 3398 of 5135
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 Nm (264 kgfcm, 19 ftlbf) on door side
7.0 Nm (71 kgfcm, 63 in.lbf) on body side
Page 3399 of 5135
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)
Page 3400 of 5135
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.