Toyota Avensis 2003, Avensis 2004, Avensis 2005 User Manual

BODY PANEL REPLACEMENT

RADIATOR UPPER SUPPORT (ASSY)

REMOVAL

BP-1

F14459-A

F14459

BP-2

BODY PANEL REPLACEMENT

INSTALLATION

! Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension

diagram. (See the body dimension diagram)

! Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the

finish.

! After welding, apply the polyurethane foam to the corresponding parts. ! After welding, apply body sealer and under-coating to the corresponding parts. ! After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

F14460

PAINT ! COATING

PC-19

BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS

HINT:

1) Anti-chipping paint should be applide to some areas before the second coat and to others after the top coat.

2) If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in grease, wax and silicone remover.

PVC Chipping Primer

Urethane Primer

Soft - Chip Primer (Poly Olefine)

F14419

PC-18

PAINT ! COATING

SILENCER SHEET INSTALLATION AREAS

Thickness of Asphalt Sheet

1.6mm (0.063in.)

1.8mm (0.071in.)

3.0mm (0.118in.)

F14418

PAINT ! COATING

PC-15

BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS

HINT:

1) Whenever adjusting the doors and hoods, apply anti-rust agent (wax) around the hinges.

2) Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part.

3) Wipe off the anti-rust agent immediately with a rag soaked in a grease, wax and silicone remover, if accidently applied to other areas.

[Sedan]

F14412

PC-16

[Liftback]

PAINT ! COATING

F14414

[Wagon]

PAINT ! COATING

PC-17

F14413

PC-12

PAINT ! COATING

FOAMED MATERIAL APPLICATION AREAS

The sections shown in the figure below are filled with foamed material to provide noise insullation. After repairing these sections or their peripheries, refill with foamed materials

HINT:

1) Use the service holes located on the reverse side of the body panel to refill with foamed materials.

2) When handling foamed material, follow the directions of the material’s manufacturer.

[Sedan]

F14415

[Liftback]

PAINT ! COATING

PC-13

F14417

PC-14

[Wagon]

PAINT ! COATING

F14416

PAINT ! COATING

PC-11

BODY PANEL UNDERCOATING AREAS

HINT:

1) First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover.

2) Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are accidently coated, wipe off the coating immediately.

3) Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the entire area.

4) Do not coat parts which become hot, such as the tailpipe, or moving parts, such as the propeller shaft.

5) Besides the locations described below, apply undercoating to all weld points under the body to insure corrosion prevention.

6) Be sure to seal the edge of the flange of the member and bracket with undercoating.

7) If undercoat is damaged by peeling, cracks, etc., be sure to repair as necessary.

8) Before the undercoat apply sealer allowing rust prevention to be attained.

REFERENCE

Referring to the notes above, undercoating should be applied according to the specifications for your country.

F14411

IN-18

INTRODUCTION

ABBREVIATIONS USED IN THIS MANUAL

For convenience, the following abbreviations are used in this manual.

ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g. Exempli Gratia (for Example) Ex. Except FWD Front Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in. inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without

IN-16

INTRODUCTION

PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS

1. HEAT REPAIR FOR BODY STRUCTURE PANELS

Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are being sought after. At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve the strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If a body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized.

2. STRUCTURE PANEL KINKS

A sharp deformation angle on the panel that cannot be returned to its original shape by pulling or hammering is called a kink. Since structure parts were designed to exhibit a 100% performance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are repaired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the part where the kink has occurred.

INTRODUCTION

3. IMPACT BEAM REPAIR

The impact beam and bracket are necessary and important parts in maintaining a survival space for passengers in a side collision. For impact beam, we use special high tensile strength steel. The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives. Since these parts were designed to exhibit a 100% performance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are repaired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the door assembly when impact beam or bracket is damaged.

IN-17

INTRODUCTION

HANDLING PRECAUTIONS ON RELATED COMPONENTS

1. BRAKE SYSTEM

The brake system is one of the most important safety components. Always follow the directions and notes given in section BR of the repair manual for the relevant model when handling brake system parts.

NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system.

2. DRIVE TRAIN AND CHASSIS

The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate repair of the body must also be done to ensure correct alignment.

HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model during alignment and section DI of this section.

IN-15

Component to be aligned

Front Wheels Front Suspension (26) section

Rear Wheels Rear Suspension (27) section

Section of repair manual

for relevant model

3. COMPONENTS ADJACENT TO THE BODY PANELS

Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.

! Before repairing the body panels, remove their components or apply protective covers over the com-

ponents.

! Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool

tip or blade to prevent damaging the components and the body paint.

! Before removing components from the outer surface of the body, attach protective tape to the body to

ensure no damage to painted areas.

HINT: Apply touch-up paint to any damaged paint surfaces.

! Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.

4. ECU (ELECTRONIC CONTROL UNIT)

Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs.

! Before starting electric welding operations, disconnect the negative (–) terminal cable from the bat-

tery. When the negative (–) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all equipped with memory function, it is not possible to make a record of the memory contents. So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory.

! Do not expose the ECUs to ambient temperatures above 80"C (176"F).

NOTICE: If it is possible the ambient temperature may reach 80"C (176"F) or more, remove the ECUs from the vehicle before starting work.

! Be careful not to drop the ECUs and not to apply physical shocks to them.

IN-10

Cutting Okay

Reinforcement

INTRODUCTION

PROPER AND EFFICIENT WORK PROCEDURES

1. REMOVAL

(a) PRE-REMOVAL MEASURING

(1) Before removal or cutting operations, take measure-

ments in accordance with the dimension diagram. Always use a puller to straighten a damaged body or frame.

F10007

(b) CUTTING AREA

(1) Always cut in a straight line and avoid reinforced area.

WRONG

Corners

F10008A

(1) Check behind any area to be drilled or cut to insure

that there are no hoses, wires, etc., that may be damaged.

HINT: See “Handling Precautions on Related Components” on page IN-15.

F10009A

(d) REMOVAL OF ADJACENT COMPONENTS

(1) When removing adjacent components, apply protec-

tive tape to the surrounding body and your tools to prevent damage.

HINT: See “Handling Precautions on Related Components” on page IN-15.

F10010

Less than 3mm

F10011A

F10012

INTRODUCTION

2. PREPARATION FOR INSTALLATION

(a) SPOT WELD POINTS

(1) When welding panels with a combined thickness of

over 3mm (0.12in.), use a MIG (Metal Inert Gas) welder for plug welding.

HINT: Spot welding will not provide sufficient durability for panels over 3mm (0.12in.) thick.

(b) APPLICATION OF WELD-THROUGH PRIMER

(SPOT SEALER) (1) Remove the paint from the portion of the new parts

and body to be welded, and apply weld-through primer.

IN-11

Air Saw

Puncher

20 ! 30mm

F10013A

F10014

Overlap

(1) For areas where a spot welder cannot be used, use a

puncher or drill to make holes for plug welding.

REFERENCE: mm (in.)

Thickness of welded portion Size of plug hole

1.0 (0.04) under 5 (0.20) ø over

1.0 (0.04) – 1.5 (0.06) 6.4 (0.26) ø over

1.5 (0.06) over 8 (0.31) ø over

(d) SAFETY PRECAUTIONS FOR ELECTRICAL COM-

PONENTS (1) When welding, there is a danger that electrical compo-

nents will be damaged by the electrical current flowing through the body.

(2) Before starting work, disconnect the negative terminal

of the battery and ground the welder near the welding location of the body.

(e) ROUGH CUTTING OF JOINTS

(1) For joint areas, rough cut the new parts, leaving 20 –

30mm (0.79 – 1.18in.) overlap.

F10015A

IN-12

Body Measurement Diagrams

INTRODUCTION

3. INSTALLATION

(a) PRE-WELDING MEASUREMENTS

(1) Always take measurements before installing under-

body or engine components to insure correct assembly. After installation, confirm proper fit.

F10016A

(b) WELDING PRECAUTIONS

(1) The number of welding spots should be as follows.

Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs.

(2) Plug welding should be done with a MIG (Metal Inert

Gas) welder. Do not gas weld or braze panels at areas other than specified.

WRONG

CORRECT WRONG

Tip Cutter

F10017A

(1) Always check the welded spots to insure they are se-

cure.

(2) When smoothing out the weld spots with a disc grind-

er, be careful not to grind off too much as this would weaken the weld.

F10018A

(d) SPOT WELD LOCATIONS

(1) Try to avoid welding over previous spots.

F10019A

Old Spot Locations

New Spot Locations

F10020A

(e) SPOT WELDING PRECAUTIONS

(1) The shape of the welding tip point has an effect on the

strength of the weld.

(2) Always insure that the seams and welding tip are free

of paint.

INTRODUCTION

IN-13

Sealer Gun

4. ANTI-RUST TREATMENT

(a) BODY SEALER APPLICATION

(1) For water-proofing and anti-corrosion measures, al-

ways apply the body sealer to the body panel seams and hems of the doors, hoods, etc.

F10021A

(b) UNDERCOAT APPLICATION

(1) To prevent corrosion and protect the body from dam-

age by flying stones, always apply sufficient undercoat to the bottom surface of the under body and inside of the wheel housings.

F10022

5. ANTI-RUST TREATMENT AFTER PAINTING PROCESS

(a) ANTI-RUST AGENT (WAX) APPLICATION

(1) To preserve impossible to paint areas from corrosion,

always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc.

F10023

IN-14

INTRODUCTION

6. ANTI-RUST TREATMENT BY PAINTING

REFERENCE:

Painting prevents corrosion and protect the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described.

(a) ANTI-CHIPPING PAINT

(1) To prevent corrosion and protect the body from dam-

age by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc.

HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat.

! Apply the anti-chipping paint after

the top coat.

Anti-Chipping Paint

Top Coat

Second Coat

Under Coat (ED Primer)

Steel Metal

! Apply the anti-chipping paint before

the second coat.

Top Coat

Second Coat

Anti-Chipping Paint

Under Coat (ED Primer)

Steel Metal

F10024A

INTRODUCTION

HOW TO USE THIS MANUAL

1. BODY PANEL REPLACEMENT THIS MANUAL

IN-5

BP-34

QUARTER PANEL (CUT)

REMOVAL

BODY PANEL REPLACEMENT

POINT

1 Remove the at the same time.

PART NAME

Fuel Filler Opening Lid

REPLACEMENT PART AND METHOD

QUARTER PANEL (CUT)

Replacement method (ASSY) ... Assembly replacement (CUT) ... Major cutting (less than 1/2 of part used) (CUT-H) ... Half cutting (about 1/ 2 of part used) (CUT-P) ... Partial cutting (most of part used)

Replacement part

REMOVAL CONDTIONS

PART LOCATION

REMOVAL DIAGRAM

Describes in detail removal of the damaged part involving repair by cutting.

REMOVAL GUIDE

Provides additional information to more efficiently help you perform the removal.

F13890A

IN-6

INTRODUCTION

BODY PANEL REPLACEMENT BP-35

INSTALLATION

! Temporaily install the new parts and measure each p art of the new parts in accordance with the body dimension

diagram. (See the body dimension dia gram)

! Inspec t the fi ting of the rela ted part s aroun d the new pa rts befo re w elding. Thi s aff ects the appear ance of the

finish.

5mm

POINT

1 Before temporarily installing the new parts, apply body sealer to the wheel arch.

HINT:

1) Apply body sealer about 5mm (0.20in.) front the flange, avoiding any oozing.

2) Apply sealer evenly, about 3 – 4mm (0.12 – 0.16in.) in diameter.

3) For other sealing points, refer to section PC.

PART NAME

A B

Fuel Filler Opening Lid Waterproof Rivet

INSTALLATION CONDITIONS

INSTALLATION DIAGRAM

Describes in detail installation to the new part involving repair by welding and/ or cutting, but excluding painting.

INSTALLATIOLN GUIDE

Provides additional information to more efficiently help you perform the installation.

SYMBOLS

(See page IN-7)

ILLUSTRATION OF WELD POINTS

Weld method and panel position symbols (See page IN-9)

PART NAME

F13891A

INTRODUCTION

IN-7

2. SYMBOLS

The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required.

SYMBOLS MEANING ILLUSTRATION

CUT AND JOIN LOCATION

(SAW CUT)

CUT AND JOIN LOCATION

(Cut Location for

Supply Parts)

CUT LOCATION

CUT WITH DISC

SANDER, ETC.

—

BRAZE

(Removal)

BRAZE

(Installation)

WELD POINTS

SPOT WELD OR

MIG PLUG WELD

(See Page IN-9)

CONTINUOUS

MIG WELD

(BUTT WELD)

CONTINUOUS

MIG WELD

(TACK WELD)

BODY SEALER

F13893A

IN-8

INTRODUCTION

SYMBOLS MEANING ILLUSTRATION

—

Assembly Mark

BODY SEALER

(Flat Finishing)

BODY SEALER

(No flat Finishing)

F13894A

INTRODUCTION

3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE:

REMOVAL INSTALLATION

IN-9

Weld points

Remove weld point and panel position

SYMBOLS

MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION

Remove Weld Points

(Outside)

(Middle)

Weld points

Weld method and panel position

Spot Weld

MIG Plug Weld

(Inside)

HINT: Panel position symbols are as seen from the working posture.

Spot MIG Weld

F13892A

Glass Cover

INTRODUCTION

GENERAL REPAIR INSTRUCTIONS

1. WORK PRECAUTIONS

(a) VEHICLE PROTECTION

(1) When welding, protect the painted surfaces, windows,

seats and carpet with heat resistant, fire-proof covers.

IN-1

WRONG

Seat Cover

F10001A

(b) SAFETY

(1) Never stand in direct line with the chain when using a

puller on the body or frame, and be sure to attach a safety cable.

F10002A

(2) Before performing repair work, check for fuel leaks.

If a leak is found, be sure to close the opening totally.

(3) If it is necessary to use a flame in the area of the fuel

tank, first remove the tank and plug the fuel line.

WRONG

F10003A

F10004

(1) In addition to the usual mechanic’s wear, cap and

safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands.

Code Name

A Dust-Prevention Mask

B Face Protector

C Eye Protector

D Safety Shoes

E Welder’s Glasses

F Ear Plugs

G Head Protector

H Welder’s Gloves

IN-2

INTRODUCTION

2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS

(1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following table. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint-

ing etc.), consideration must be given to the property of the plastic.

Heat

Code

Material

name

resistant temperature limit !C (!F)

Resistance to

alcohol or gasoline

Notes

AAS

ABS

AES

ASA

CAB

EPDM

FRP

Acrylonitrile Acrylic Styrene

Acrylonitrile Butadiene Styrene

Acrylonitrile Ethylene Styrene

Acrylonitrile Styrene Acrylate

Cellulose Acetate

Ethylene Propylene

Fiber Reinforced Plastics

(176)

100

(212)

180

(356)

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.

Alcohol and gasoline are harmless. Avoid alkali.

Avoid gasoline and organic or aromatic solvents.

Most solvents are harmless but avoid dipping in gasoline, solvents, etc.

EVA

PBT

PC Polycarbonate

*Temperatures higher than those listed here may result in material deformation during repair.

Ethylene Acetate

Polyamide (Nylon)

Polybutylene Terephthalate

(158)

(176)

160

(320)

120

(248)

Alcohol is harmless if applid only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol and gasoline are harmless. Avoid battery acid.

Alcohol and gasoline are harmless. Most solvents are harmless.

Alcohol is harmless.

Avoid gasoline and organic or aromatic solvents.

Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali.

Code

Material

name

Heat

resistant

temperature

limit !C (!F)

INTRODUCTION

Resistance to

alcohol or gasoline

IN-3

Notes

PE Polyethylene

PET

PMMA

POM

PP Polypropylene

PPO

PS Polystyrene

PUR Polyurethane

Polyethylene Terephthalate

Polymethyl Methacrylate

Polyoxymethylene (Polyacetal)

Modified Polyphenylene Oxide

(176)

(167)

(176)

100

(212)

(176)

100

(212)

(140)

(176)

Alcohol and gasoline are harmless. Most solvents are harmless.

Alcohol and gasoline are harmless. Avoid dipping in water.

Alcohol is harmless if applied only for short time in small amounts.

Alcohol and gasoline are harmless. Most solvents are harmless.

Alcohol is harmless.

Alcohol and gasoline are harmless if applied only for short time in small amounts.

Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease).

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

Gasoline is harmless if applied only for quick wiping to remove grease.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

Alcohol and gasoline are harmless if

PVC

SAN

TPO

TPU

TSOP

*Temperatures higher than those listed here may result in material deformation during repair.

Polyvinylchloride (Vinyl)

Styrene Acrylonitrile

Thermoplastic Olefine

Thermoplastic Polyurethane

TOYOTA Super Olefine Polymer

Unsaturated Polyester

(176)

110

(233)

applied only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.

Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).

Alcohol and gasoline are harmless. Most solvents are harmless.

Alcohol and gasoline are harmless. Avoid alkali.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

Avoid dipping or immersing in alcohol, gasoline, solvents etc.

Most solvents are harmless but avoid dipping in gasoline, solvents, etc.

Avoid dipping or immersing in alcohol, gasoline, solvents, etc.

IN-4

INTRODUCTION

3. LOCATION OF PLASTIC BODY PARTS

Parts Name Code

Radiator Grille ABS/ASA

Front Bumper Cover TSOP

Front Spoiler TSOP

Front Bumper Side Moulding TSOP

Headlight Washer Nozzle Cover PC/ABS

Headlight PC/PP

Fog light PP

Side Turn Signal Light PMMA/ABS

Outer Rear View Mirror ASA

Roof Rack Leg Cover (Wagon Only) ABS

Door Outside Handle PC/PBT/ PA

Door Outside Moulding PP /EPDM

Body Rocker Panel Moulding PP

Rear Combination Light PMMA/PC / ABS

Rear Spoiler (Wagon Only) ABS

Center Stop Light (Wagon Only) PMMA/ABS

Luggage Compartment Door Outside Garnish ABS

License Plate Light PMMA/ABS

Rear Bumper Cover TSOP

Rear Bumper Side Moulding TSOP

! Resin material differs with model.

/ Made up of 2 or more kinds of materials.

BODY DIMENSIONS

BODY DIMENSION DRAWINGS

ENGINE COMPARTMENT

(Three-Dimensional Distance)

DI-3

467

(18.39)

851

(33.50)

854

(33.62)

647

(25.47)

(29.92)

444

(17.48)

760

1,427

(56.18)

760

(29.92)

838

(32.99)

1,478

(58.19)

1,038

(40.87)

834

1,089

(42.87)

523

(20.59)

(6.27)

817

(32.17)

210

Engine

Model

ZZ, CD

1,410

(55.51)

1,323

(52.09)

874

(34.41)

422

(16.61)

1,378

(54.25)

(40.28)

768

(30.24)

537

(21.14)

1,023

(32.83)

Vehicle Dimensions

B-c C-n C-N C-O

or or or or G-g G-h g-H

b-C c-N c-n c-o

1,227 1,428 159 113 828 854 876

(48.31) (56.22) (6.26) (4.45) (32.60) (33.62) (34.49)

1,022 625

(40.24) (24.61)

1,010 606

(39.76) (23.86)

I-j I-J J-L j-l K-k or or

593 607 250 240 1,439 1,452 272

(23.35) (23.90) (9.84) (9.45) (56.65) (57.17) (10.71)

N-o N-O

n-O n-o

mm (in.)

Symbol Name Hole dia. Symbol Name Hole dia.

A, a

B, b

C, c

E, e

G, g

H, h

Front fender installation nut

Front spring support hole-inner

Front fender installation nut

Cowl top inner panel standard hole

Front side member standard hole

Engine mounting installation nut

Radiator support standard hole

Front crossmember side gusset standard hole

6 (0.24) nut

11 (0.43)

6 (0.24) nut

—

18 (0.71)

12 (0.47)

10 (0.39) nut

10 (0.39)

J, j

K, k

L, l

M, m

N, n

O, o

—

Hood lock brace installation bolt

Front side member rear plate standard hole

Front fender extention standard hole

Radiator upper support installation nut

Front apron to cowl side upper member standard hole

Hood hinge installation nut

—

6 (0.24) bolt

13 (0.51)

7 (0.28)

6 (0.24) nut

10 (0.39)

8 (0.31) nut

—

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Toyota Avensis 2003, Avensis 2004, Avensis 2005 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual