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7537

ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)

BACK DOOR (LIFTBACK MODELS)


750N401

COMPONENTS

Rear Wiper Arm and Blade Assy 7.0 (71, 62 in.lbf)


Rear Wiper
w/ Packing Washer 22 (264, 19)
Wiper Arm Head Cap
Back Door Stay Assy RH

Nut 5.5 (56, 49 in.lbf) Female


Stopper RH
Rear Wiper Motor Assy
Center Stop Lamp Assy
Back Door Damper Assy 4.9 (49, 43 in.lbf)
5.5 (56, 49 in.lbf)
5.5 (56, 49 in.lbf)
5.5 (56, 49 in.lbf)

7.0 (71, 62 in.lbf) 22 (264, 19)

Back Door
Stay Assy LH
Hook
Back Door Trim Back Door Garnish Subassy
Female Panel Assy Upper Outside RH
Stopper LH Hook Back Door Side
Garnish RH
Back Door Side
Garnish LH
5.5 (56, 49 in.lbf)
Back Door Service
Hole Cover

19.5 (200, 14)


Cushion Rubber
Back Door Trim Board Assy
Cushion Rubber

8.0 (82, 71 in.lbf) Back Door Lock Assy

Rope Hook Assy

Floor Finish Plate


11.5 (120, 8)

Back Door Lock Striker

Nm (kgfcm, ftlbf) : Specified torque B66986

AVENSIS REPAIR MANUAL (RM1018E)


7538
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)
750N501

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.

Centering Bolt Standard Bolt

B57104

1. INSPECT BACK DOOR PANEL SUBASSY


(a) Check that the clearance is within the standard range.

A C

B67535

Standard range:
A 6.3  1.5 mm (0.248  0.059 in.)
B 4.9  1.5 mm (0.193  0.059 in.)
C 5.0  1.5 mm (0.197  0.059 in.)
D 8.0  1.5 mm (0.315  0.059 in.)

2. ADJUST BACK DOOR PANEL SUBASSY


(a) Adjust the door vertically and forward/rearward by loos-
ening the body side hinge bolts.
(b) Tighten the body side hinge bolts after the adjustment.
Torque: 19.5 Nm (200 kgfcm, 14 ftlbf)

B66993
AVENSIS REPAIR MANUAL (RM1018E)
7539
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)

(c) Horizontally and vertically adjust the door by loosening


the 8 door side hinge bolts.
(d) Tighten the door side hinge bolts after the adjustment.
Torque: 19.5 Nm (200 kgfcm, 14 ftlbf)

B66992

(e) Remove the floor finish plate (See page 7645)


(f) Adjust the striker position by slightly loosening the striker
mounting screws and hitting the striker with a plastic
faced hammer.
(g) Tighten the striker mounting screws after the adjustment.
Torque: 11.5 Nm (120 kgfcm, 8 ftlbf)

B66994

(h) Adjust the side female stopper so that the door can be
opened/closed smoothly, as shown in the illustration.
(i) Tighten the side female stopper after the adjustment.
Torque: 5.5 Nm (56 kgfcm, 49 in.lbf)

B66995

AVENSIS REPAIR MANUAL (RM1018E)


7540
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)
750N601

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 remove
the trim.
HINT:
Tape the screwdriver tip before use.

: Clip B66988

2. REMOVE BACK DOOR SIDE GARNISH LH


(a) Using a clip remover, remove the hook.
(b) Using a screwdriver, disengage the 2 clips and remove
Hook the side garnish.
HINT:
Tape the screwdriver tip before use.
3. REMOVE BACK DOOR SIDE GARNISH RH
HINT:
: Clip B66989 Use the same procedures described for the LH side.

4. REMOVE BACK DOOR TRIM BOARD ASSY


(a) Remove the 2 screws.
(b) Using a screwdriver, disengage the 12 clips and remove
the trim board.
HINT:
Tape the screwdriver tip before use.
(c) Remove the 4 service hole covers.

: Clip B66990

5. REMOVE BACK DOOR DAMPER ASSY


(a) Remove the 4 bolts and damper.

B66991

6. REMOVE BACK DOOR GARNISH SUBASSY OUTSIDE RH (See page 7627)


7. REMOVE REAR WIPER MOTOR ASSY (See page 6617)
8. REMOVE CENTER STOP LAMP ASSY (See page 6526)

AVENSIS REPAIR MANUAL (RM1018E)


7541
ENGINE HOOD/DOOR BACK DOOR (LIFTBACK MODELS)

9. REMOVE BACK DOOR LOCK ASSY


(a) Disconnect the connector.
(b) Remove the 3 bolts and door lock.

B66996

10. REMOVE BACK DOOR STAY ASSY LH (See page 7547)


11. REMOVE BACK DOOR STAY ASSY RH (See page 7547)

12. INSTALL BACK DOOR LOCK ASSY


(a) Install the door lock with the 3 bolts.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
(b) Connect the door lock connector

B66996

13. INSTALL BACK DOOR DAMPER ASSY


(a) Install the damper with the 4 bolts.
Torque: 5.5 Nm (56 kgfcm, 49 in.lbf)

B66991

AVENSIS REPAIR MANUAL (RM1018E)


7542
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)

BACK DOOR (WAGON MODELS)


750N701

COMPONENTS

Back Door Stay Assy RH


Rear Wiper Arm and Blade Assy Rear Spoiler
Rear Wiper w/ Packing
Washer 7.0 (71, 62 in.lbf)

Wiper Arm Head Cap


5.5 (56, 49 in.lbf)

Wiper Motor Assy

4.9 (49, 43 in.lbf) 4.9 (49, 43 in.lbf)

Back Door Trim Panel Assy Upper

Back Door Side Garnish RH


Back Door Side Garnish LH

Back Door Garnish Subassy Outside RH

Back Door Trim Board Assy


Back Door Service Hole Cover

19.5 (200, 14)

Back Door Lock Assy


8.0 (82, 71 in.lbf)
Door Pull Handle
22 (264, 19)

Door Pull Handle

Floor Finish Plate

Back Door 11.5 (120, 8)


Stay Assy LH 7.0 (71, 62 in.lbf)

Nm (kgfcm, ftlbf) : Specified torque Back Door Lock Striker


B66987

AVENSIS REPAIR MANUAL (RM1018E)


7543
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)
750N801

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.

Centering Bolt Standard Bolt

B57104

1. INSPECT BACK DOOR PANEL SUBASSY


(a) Check that the clearance is within the standard range.

B D

B67534

Standard range:
A 7.5  1.5 mm (0.295  0.059 in.)
B 4.9  1.5 mm (0.193  0.059 in.)
C 5.4  1.5 mm (0.213  0.059 in.)
D 6.0  1.5 mm (0.236  0.059 in.)

2. ADJUST BACK DOOR PANEL SUBASSY


(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 Nm (265 kgfcm, 19 ftlbf)

B67000
AVENSIS REPAIR MANUAL (RM1018E)
7544
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)

(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 Nm (265 kgfcm, 19 ftlbf)

B66999

(e) Remove the floor finish plate (See page 7654)


(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 Nm (235 kgfcm, 17 ftlbf)

B67001

AVENSIS REPAIR MANUAL (RM1018E)


7545
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)
750N901

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 remove
the trim panel.
HINT:
Tape the screwdriver tip before use.

: Clip B66997

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.
Clip H19055

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.

: Clip B66998

5. REMOVE DOOR PULL HANDLE


(a) Using a screwdriver, disengage the 4 claws and remove
the pull handle.

: Clip
 B68469

6. REMOVE REAR SPOILER (See page 7630)


7. REMOVE REAR WIPER MOTOR ASSY (See page 6617)
8. REMOVE BACK DOOR GARNISH SUBASSY OUTSIDE RH (See page 7629)

AVENSIS REPAIR MANUAL (RM1018E)


7546
ENGINE HOOD/DOOR BACK DOOR (WAGON MODELS)

9. REMOVE BACK DOOR LOCK ASSY


(a) Disconnect the door lock connector.
(b) Remove the 3 bolts and door lock.

B66315

10. BACK DOOR STAY ASSY LH (See page 6526)


11. BACK DOOR STAY ASSY RH (See page 6526)

12. INSTALL BACK DOOR LOCK ASSY


(a) Install the door lock with the 3 bolts.
Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
(b) Connect the door lock connector.

B66315

AVENSIS REPAIR MANUAL (RM1018E)


7547
ENGINE HOOD/DOOR BACK DOOR STAY

BACK DOOR STAY


750NA01

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.

H19020

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

AVENSIS REPAIR MANUAL (RM1018E)


7548
ENGINE HOOD/DOOR BACK DOOR STAY
750NB01

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 pistonrod 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.
a b Standard dimension:
A B a 80 mm (3.15 in.)
B65104 b 20 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.

AVENSIS REPAIR MANUAL (RM1018E)


754
ENGINE HOOD/DOOR FRONT DOOR

FRONT DOOR
750MV01

COMPONENTS

Front Door Glass Run LH

Front Door Frame Subassy Rear Lower LH

8.0 (82, 71 in.lbf)

w/o Rear Power Window

Front Door Armrest Front Door Glass


Base Panel Upper Subassy LH
Power Window Regulator
Master Switch Assy

Front Door Armrest Base Panel Upper 5.5 (56, 49 in.lbf)

Front Door Window Regulator


Subassy LH

8.0 (82, 71 in.lbf)

Front Door Glass Weatherstrip Inner LH

Power Window Regulator


Front Door Inside Handle Subassy LH
Switch Assy

Front No. 1 Speaker Assy

 Rivet
Fuel Lid Opener Switch
Front Door Trim Board Subassy LH
Courtesy Lamp Clip
Front Door Trim Base LH
Nm (kgfcm, ftlbf) : Specified torque
 Nonreusable part B67988

AVENSIS REPAIR MANUAL (RM1018E)


755
ENGINE HOOD/DOOR FRONT DOOR

w/ Key:
w/ Speaker
w/o Key: Front Door Outside Handle Cover LH
Front Door Outside Front Door Speaker No. 2
Key Cylinder
Handle Cover LH Front Door Lower Frame
Bracket Garnish LH
Front Door Outside
Front Door Handle Outer Rear View Mirror Assy LH
Handle Pad Front
Assy Outside LH

Hole Plug Front Door Outside Handle Pad Rear


10 (102, 7)
Front Door Lock Open Rod

Front Door Outside Handle Frame Subassy LH


Front Door Lower Frame
Bracket Garnish LH

z Front Door Service Hole Cover


Front Door w/ Motor Lock Assy LH
L 5.0 (51, 44 in.lbf)

z Door Lock Wire Harness Packing

z Butyl Tape

Front Door Weatherstrip LH


Front Door Belt Moulding LH
Front Door Lower
Clip Frame Seal

Front Door Stiffener


Cushion No. 1 26 (265, 19)

Front Door Hinge


Side Trim 5.5 (56, 49 in.lbf)
Assy Upper LH
Spacer LH

Cushion Rubber L 30 (306, 22)

Front Door Check Assy

Front Door Hinge 26 (265, 19)


Nm (kgfcm, ftlbf) : Specified torque Assy Lower LH
z Nonreusable part
L Precoated Part
B67989

AVENSIS REPAIR MANUAL (RM1018E)


756
ENGINE HOOD/DOOR FRONT DOOR
750MW01

ADJUSTMENT
HINT:
 Use the same procedures on the RH side as on the LH side.

 Because a centering bolt is used as a door hinge mount-


ing bolt on the body side and the door side, the door can
not be adjusted with them on. Substitute a bolt with a
washer for the centering bolt.

Centering Bolt Standard Bolt

B57104

1. INSPECT FRONT DOOR PANEL SUBASSY LH


(a) Check that the clearance is within the standard range.

D
A
B

B66965

Standard range:
A 4.6  1.5 mm (0.181  0.059 in.)
B 5.5  1.5 mm (0.220  0.059 in.)
C 4.6  1.5 mm (0.181  0.059 in.)
D 160 mm (6.30 in.)
E 4.8  1.5 mm (0.189  0.059 in.)

2. ADJUST FRONT DOOR PANEL SUBASSY LH


(a) Using SST, adjust the door horizontally and vertically by
loosening the body side hinge bolts.
SST 0981200010, 0981200020
(b) Tighten the body side hinge bolts after the adjustment.
SST 0981200010, 0981200020
Torque: 26 Nm (265 kgfcm, 19 ftlbf)

B66966

AVENSIS REPAIR MANUAL (RM1018E)


757
ENGINE HOOD/DOOR FRONT DOOR

(c) Adjust the door forward/rearward and vertically by loos-


ening the door side hinge bolts.
(d) Tighten the door side hinge bolts after the adjustment.
Torque: 26 Nm (265 kgfcm, 19 ftlbf)

B66967

(e) Adjust the striker position by slightly loosening the striker


mounting screws and hitting the striker with a plastic
faced hammer.
(f) Tighten the striker mounting screws after the adjustment.
Torque: 23 Nm (235 kgfcm, 17 ftlbf)

B62411

AVENSIS REPAIR MANUAL (RM1018E)


758
ENGINE HOOD/DOOR FRONT DOOR
750MX01

OVERHAUL
HINT:
 The installation is in the reverse order of the removal. However, when there is a special point concern-
ing the installation, it is indicated.
 Use the same procedures on the RH side as on the LH side.

1. REMOVE FRONT DOOR LOWER FRAME BRACKET


GARNISH LH
(a) Using a screwdriver, disengage the 2 clip and remove the
garnish.
HINT:
Tape the screwdriver tip before use.
(b) w/ Speaker:
Remove the front door speaker No. 2 (See page
: Clip
B66969 6712).

2. REMOVE FRONT DOOR TRIM BASE LH


(a) Using a screwdriver, disengage the 5 claws and clip, and
remove the trim base.
HINT:
Tape the screwdriver tip before use.

: Clip
: Claw B66970

3. REMOVE FUEL LID OPENER SWITCH


(a) Using a screwdriver, disengage the 2 claws and remove
the switch.
HINT:
Tape the screwdriver tip before use.

Claw
B67801

AVENSIS REPAIR MANUAL (RM1018E)


759
ENGINE HOOD/DOOR FRONT DOOR

4. REMOVE POWER WINDOW REGULATOR MASTER


SWITCH ASSY
(a) Using a screwdriver, disengage the 4 claws and clip, and
remove the armrest base panel upper together with the
switch.
HINT:
Tape the screwdriver tip before use.
(b) Disconnect the switch connector.
(c) Remove the 3 screws and switch from the armrest base
panel upper.

B70388

Protective Protective
5. REMOVE FRONT DOOR TRIM BOARD SUBASSY LH
Tape Tape (a) Disconnect the courtesy lamp connector.
(b) Remove the 3 cushion rubbers.
Screw (c) Remove the 2 screws and bolt as indicated.
(d) Using a clip remover, disengage 9 clips.
(e) Remove the trim board upward.
HINT:
In order to prevent the door panel from being damaged, cover
the areas indicated by the arrow marks in the illustration with
protective tape.
(f) Disengage the 2 claws and remove the courtesy lamp.
Bolt
Cushion Rubber
: Clip B66971

6. REMOVE FRONT DOOR GLASS WEATHERSTRIP


INNER LH
(a) Remove the weatherstrip inner upward in the direction in-
dicated by the arrow mark in the illustration.

B70121

7. REMOVE FRONT DOOR INSIDE HANDLE SUBASSY


Claw A
LH
1
(a) Using a screwdriver, disengage the claw A indicated.
HINT:
2 Tape the screwdriver tip before use.
(b) Move the inside handle in the direction indicated the by
arrow mark in the illustration.
(c) Disconnect the 2 cables from the inside handle.
: Claw B68930

AVENSIS REPAIR MANUAL (RM1018E)


7510
ENGINE HOOD/DOOR FRONT DOOR

8. REMOVE FRONT DOOR SERVICE HOLE COVER


Butyl Tape (a) Remove the service hole cover.
NOTICE:
Remove the tape remaining on the door side.

B69067

(b) Remove the lower frame seal.

B66981

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.

B68929

10.
REMOVE FRONT NO.1 SPEAKER ASSY (W/
SPEAKER)
(a) Using a drill of less than 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.
B61431 (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 7623)
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.

AVENSIS REPAIR MANUAL (RM1018E)


7511
ENGINE HOOD/DOOR FRONT DOOR

14. REMOVE FRONT DOOR GLASS SUBASSY 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.
B62422

(c) Remove the door glass in the direction indicated by the


2 arrows in the illustration.
1 NOTICE:
 Do not damage the glass.
 When the bolts are removed, the glass may fall and
become deformed.
(d) Remove the glass run.

B62423

15. REMOVE FRONT DOOR WINDOW REGULATOR


SUBASSY 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:
B66968 Remove the window regulator through the service hole.

16. REMOVE FRONT DOOR FRAME SUBASSY REAR


LOWER LH
(a) Remove the bolt and frame.
HINT:
Remove the frame through the service hole.

B61434

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.

Hole Plug
 B68932

AVENSIS REPAIR MANUAL (RM1018E)


7512
ENGINE HOOD/DOOR FRONT DOOR

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:
B66894 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.

2
B56613

20. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME


SUBASSY LH
(a) Using a torx socket wrench (T30), loosen the screw of the
frame.

Screw

B70122

(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.
B57102

21. REMOVE FRONT DOOR CHECK ASSY LH


(a) Remove the 2 nuts, bolt and check.
HINT:
Remove the check through the service hole.

B68928

AVENSIS REPAIR MANUAL (RM1018E)


7513
ENGINE HOOD/DOOR FRONT DOOR

22. REMOVE FRONT DOOR WEATHERSTRIP LH


(a) Using a clip remover, disengage the clips and remove the weatherstrip.
HINT:
If the clips are damaged, replace them with new clips.

23. INSTALL FRONT DOOR CHECK ASSY LH


(a) Apply MP grease to the sliding areas of the check.
(b) Install the check to the door panel with the 2 nuts.
Torque: 5.5 Nm (56 kgfcm, 49 in.lbf)
(c) Apply adhesive to the threads of the bolt.
Adhesive:
Part No. 0883300070, THREE BOND 1324 or equiva-
Adhesive
lent
B68928 (d) Install the door check to the body panel with the bolt.
Torque: 30 Nm (306 kgfcm, 22 in.lbf)
24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME
SUBASSY LH
(a) Install the outside handle link.
(b) Apply MP grease to the sliding areas of the frame.
(c) Using a torx socket wrench (T30), install the frame with
the screw.
Torque: 4.0 Nm (41 kgfcm, 35 in.lbf)
Screw

B70122

25. INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH


(a) Install the outside handle pads front and rear.
(b) Install the handle pushing it in the direction of the arrow
mark in the illustration.
NOTICE:
2 If the release plate is not pulled and held when installing the
handle, the release plate will interfere with the handle and
1
become damaged.
B64044 26. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
door lock.
(b) Install a new door lock wire harness packing.
NOTICE:
 When reusing a door lock that has been removed, re-
place the packing in the connecting part with a new
one.
 Be careful that no grease or dirt does not sticks to the
packing surface in the connecting part.
 Reusing removed packing or using damaged packing
will allow water to penetrate through to the connect-
ing part resulting in a door lock malfunction.

AVENSIS REPAIR MANUAL (RM1018E)


7514
ENGINE HOOD/DOOR FRONT DOOR

(c) Insert the control rod into the door lock, and then set it to
the door panel.
NOTICE:
Make sure that the handle link is securely engaged with the
lock.

Rod

B65961

(d) Apply adhesive to the threads of the 3 screws.


Adhesive:
Adhesive
Part No. 0883300070, THREE BOND 1324 or equiva-
lent
(e) Using a torx socket wrench (T30), install the door lock with
the 3 screws.
Torque: 5.0 Nm (51 kgfcm, 44 in.lbf)
Adhesive (f) Connect the door lock connector.
B66894

27. INSTALL FRONT DOOR OUTSIDE HANDLE COVER


(a) Using a torx socket wrench (T30), install the cover with the
door lock key cylinder installed with the screw.
Torque: 7.0 Nm (71 kgfcm, 62 in.lbf)
(b) Install the hole plug.

Hole Plug B68932




28. INSTALL FRONT DOOR FRAME SUBASSY REAR


LOWER LH
(a) Install the frame with the bolt.
Torque: 5.5 Nm (56 kgfcm, 49 in.lbf)

B62425

29. INSTALL FRONT DOOR WINDOW REGULATOR


SUBASSY LH
(a) Apply MP grease to the sliding and rotating areas of the
window regulator.
NOTICE:
Do not apply grease to the spring of the window regulator.

B66972

AVENSIS REPAIR MANUAL (RM1018E)


7515
ENGINE HOOD/DOOR FRONT DOOR

(b) Install the window regulator with the 6 bolts.


Torque: 8.0 Nm (82 kgfcm, 71 in.lbf)
(c) Connect the window regulator connector.
NOTICE:
Be careful not to drop and deform the door window regula-
tor as this may cause deformation.

B66968

30. INSTALL FRONT DOOR GLASS SUBASSY LH


1
(a) Install the glass run.
2 NOTICE:
Do not damage the door glass.
(b) Insert the door glass into the door panel along the glass
run in the direction indicated by arrows in the illustration.

B62423

(c) Install the door glass to the window regulator with the 2
bolts.
Torque: 5.0 Nm (51 kgfcm, 44 in.lbf)
(d) Reset the power window motor (See page 7013).
(e) Inspect operation of the power window.
HINT:
When the installation point of the door glass does not match,
adjust the regulator position in manual operation.
B62422 (1) Connect the power window switch to the wire har-
ness and turn the ignition switch ON.
(2) Repeat UP and DOWN operation several times in
manual operation.

31. INSTALL FRONT NO.1 SPEAKER ASSY


(a) Using an air riveter or hand riveter, install the speaker to
the door with the 3 rivets.

B61441

AVENSIS REPAIR MANUAL (RM1018E)


7516
ENGINE HOOD/DOOR FRONT DOOR

WRONG NOTICE:
 Do not operate the riveter an angle as this will damage
Riveter
it bend the mandrel.

Mandrel
H02440

 Do not tilt the riveter when removing the rivet as the


WRONG
Riveter speaker will not be tightened firmly.

WRONG
Riveter

H02441

 Install the rivet while attaching the speaker to ensure


WRONG
that it is tightened firmly.
Riveter (b) Connect the speaker connector.

H02442

32. INSTALL OUTER REAR VIEW MIRROR ASSY LH


(a) Install the mirror with the 3 screws.
Torque: 10 Nm (102 kgfcm, 7 ftlbf)
(b) Connect the mirror connector.

B68929

33. INSTALL FRONT DOOR SERVICE HOLE COVER


Butyl Tape (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.
B69067  After attaching the service hole cover, check the sealing
quality.
AVENSIS REPAIR MANUAL (RM1018E)
7517
ENGINE HOOD/DOOR FRONT DOOR

(c) Install the lower frame seal front.

B66981

AVENSIS REPAIR MANUAL (RM1018E)


751
ENGINE HOOD/DOOR HOOD

HOOD
750MT01

COMPONENTS

Hood Subassy

Hood Insulator

Engine Room Side Cover RH

x8
Battery Service Hole Cover Clip

13 (133, 10)

Hood Hinge Assy RH


Radiator Cover
Hood to Front End Panel Seal
13 (133, 10)
Hood Lock Assy
Hood to Front Fender Seal RH

Cushion Rubber
8.0 (82, 71 in.lbf) Hood Hinge Assy LH

Cushion Rubber
Hood to Front Fender Seal LH

Front Bumper Assy

Nm (kgfcm, ftlbf) : Specified torque


B67533

AVENSIS REPAIR MANUAL (RM1018E)


752
ENGINE HOOD/DOOR HOOD
750MU01

ADJUSTMENT

HINT:
Because a centering bolt is used as a hood hinge mounting bolt
and hood lock mounting bolt, the hood and hood lock can not
be adjusted with them on. Substitute a bolt with a washer for the
centering bolt.

Centering Bolt Standard Bolt

B57104

1. INSPECT HOOD SUBASSY


(a) Check that the clearance is within the standard range.

B66962

Standard range:
A 3.5  1.5 mm (0.138  0.059 in.)
3.5 1.5 or +2.5 mm
B
(0.138 0.059 or + 0.098 in.)

2. ADJUST HOOD SUBASSY


(a) Horizontally and vertically adjust the hood.
(1) Loosen the 4 hood hinge bolts on the hood side.

B61420

AVENSIS REPAIR MANUAL (RM1018E)


753
ENGINE HOOD/DOOR HOOD

(2) Adjust the clearance by moving the hood, so that it


will be in the standard range.
A 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 Nm (133 kgfcm, 10 ftlbf)

Aligned
B66963

(b) Adjust the height of the hood front end using the cushion
rubber.
(1) Adjust the cushion rubber so that the hood and the
fender 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 front
B66964 end 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 763).

(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 Nm (82 kgfcm, 71 in.lbf)

B62401

AVENSIS REPAIR MANUAL (RM1018E)


7532
ENGINE HOOD/DOOR LUGGAGE COMPARTMENT DOOR

LUGGAGE COMPARTMENT DOOR


750N101

COMPONENTS

Luggage Compartment Door Lock Cylinder Assy


4.9 (49, 43 in.lbf)

Luggage Compartment
Door Panel Subassy Luggage Compartment
Outside Garnish

5.0 (51, 44 in.lbf)

Licence Plate Lamp Assy

Luggage Lock Assy


7.0 (71, 62 in.lbf)

Back Door Trim Cover

Clip
Hinge Cover

Luggage Compartment Floor Carpet Luggage Compartment


Trim Inner RH

Luggage Compartment
Trim Inner LH
Luggage Compartment Trim Hook No. 2

Rear Floor Finish Plate

11.5 (120, 8)

Luggage Striker Assy


5.0 (51, 44 in.lbf)

Rope Hook Assy


Nm (kgfcm, ftlbf) : Specified torque B66985

AVENSIS REPAIR MANUAL (RM1018E)


7533
ENGINE HOOD/DOOR LUGGAGE COMPARTMENT DOOR
750N201

ADJUSTMENT

HINT:
Because a centering bolt is used as a luggage compartment
door mounting bolt, the luggage compartment door can not be
adjusted with it on. Substitute a bolt with a washer for the cen-
tering bolt.

Centering Bolt Standard Bolt

B57104

1. INSPECT LUGGAGE COMPARTMENT DOOR PANEL SUBASSY


(a) Check that the clearance is within the standard range.

A
B

B66984

Standard range:
A 4.0  1.5 mm (0.157  0.059 in.)
B 5.3  1.5 mm (0.209  0.059 in.)
7.1 1.5 or + 2.5 mm
C
(0.280 0.059 or + 0.098 in.)

2. ADJUST LUGGAGE COMPARTMENT DOOR PANEL


SUBASSY
(a) Using a clip remover, remove the clips and hinge cover.
(b) Using a clip remover, remove the 11 clips and trim cover.
(c) Adjust the door horizontally and vertically by Loosening
the door bolts.
(d) Tighten the door mounting bolts after the adjustment.
Torque: 7.0 Nm (71 kgfcm, 62 in.lbf)
B61457

AVENSIS REPAIR MANUAL (RM1018E)


7534
ENGINE HOOD/DOOR LUGGAGE COMPARTMENT DOOR

(e) Adjust the striker.


HINT:
Adjust the door lock position by moving the striker so that the
door striker can enter smoothly.
(1) Using a hammer and a brass bar, tap the striker to
adjust it.
(2) Tighten the 2 bolts after the adjustment.
Torque: 11.5 Nm (120 kgfcm, 8 ftlbf)
B66994

AVENSIS REPAIR MANUAL (RM1018E)


7535
ENGINE HOOD/DOOR LUGGAGE DOOR HINGE TORSION BAR

LUGGAGE DOOR HINGE TORSION BAR


750N301

REPLACEMENT
HINT:
 The installation is in the reverse order of the removal. However, when there is a special point concern-
ing the installation, it is indicated.
 Use the same procedures on the RH side as on the LH side.
 After removing the torsion bar, opening and closing door operation should be carried out while holding
the door with your hand in order to perform an accurate test by providing sliding resistance.
 The RH side torsion bar is on the upper side and the LH side torsion bar is on the lower side, thus the
installation should be performed in the order of RH to LH and removal should be performed in the order
of LH to RH.
1. REMOVE LUGGAGE DOOR HINGE TORSION BAR LH
(a) Remove the floor carpet.
(b) Remove the floor finish plate.
(1) Remove the 2 screws and 2 No. 2 trim hooks.
(2) Remove the 2 bolts and rope hook assy
(3) Using a clip remover, remove the 2 clips and floor
finish plate.
(c) Remove the clips and trim cover inner LH and RH.
(d) Remove the torsion bar RH from the clip placed in the cen-
ter of the upper back panel.

(e) Remove the tip of the torsion bar from the roof side inner
panel by hand.

B55944

(f) Take out the hinge arm from the torsion bar in the rear
direction.
(g) Pull the torsion bar to your side in order to remove the U
shaped part from the hinge support.

B55945

2. REMOVE LUGGAGE DOOR HINGE TORSION BAR RH

AVENSIS REPAIR MANUAL (RM1018E)


7536
ENGINE HOOD/DOOR LUGGAGE DOOR HINGE TORSION BAR

3. INSTALL LUGGAGE DOOR HINGE TORSION BAR LH


(a) Set the tip of the torsion bar in the installation hole placed
Installation Hole
in the center part. The holes placed in the upper and lower
parts are used for adjustment.

Installation Hole
(For Adjustment)
B56621

4. INSTALL LUGGAGE DOOR HINGE TORSION BAR RH

AVENSIS REPAIR MANUAL (RM1018E)