Page 335 of 1897
BO2PK-01
H12166
w/ Rear personal light:
Rear Personal Light
RH Roof Side
Inner Garnish
Back Window
Moulding
Back Window Glass
w/ Speaker:
High-mounted
Stop Light
LH Roof Side Inner Garnish
Package Tray Trim
Upper Back Silencer
Rear Seatback
Rear Seat
Outer Belt RH
Rear Seat Inner
with Center Belt Rear Seat Cushion Roof Headlining
Rear Door
Opening Trim No. 1 Stopper
No. 2 Stopper
No. 1 Stopper
No. 2 Stopper
: Specified torque
N´m (kgf´cm, ft´lbf)
Non-reusable partw/o Speaker:
High-mounted Stop Light
Rear Seat Inner Belt
41 (420, 30)
41 (420, 30)41 (420, 30)
18 (185, 13)
18 (185, 13)
Rear Seat Outer Belt LH
- BODYBACK WINDOW GLASS
BO-69
1854 Author: Date:
2001 AVALON (RM808U)
BACK WINDOW GLASS
COMPONENTS
Page 336 of 1897
BO2PM-01
BO4420
Adhesive
BO5231
H10503
H12165
Stopper A
- BODYBACK WINDOW GLASS
BO-73
1858 Author: Date:
2001 AVALON (RM808U)
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
(a) Using a knife, cut away any rough areas on the body.
HINT:
Leave of the adhesive on the body as much as possible.
(b) Clean the cut surface of the adhesive with a shop rag sat-
urated in cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
2. CLEAN REMOVED GLASS
(a) Remove the damaged No. 2 stoppers.
(b) Using a scraper, remove the adhesive sticking to the
glass.
(c) Clean the glass with cleaner.
NOTICE:
Be careful not to damage the glass.
Do not touch the glass face after cleaning it.
3. REPLACE NO. 1 STOPPERS
(a) Remove the damaged stoppers.
(b) Cut off the old adhesive around the stopper installation
area.
NOTICE:
Be careful not to damage the body.
(c) Clean the installation area.
(d) Attach new stoppers to the body so that the notches on
the body will align with the stoppers as shown in the il-
lustration.
HINT:
Make sure that the stoppers are installed facing the correct
direction.
4. INSTALL NEW NO. 2 STOPPERS
Attach new stoppers to the glass so that the ceramic notches
on the glass will align with the stoppers as shown in the illustra-
tion.
A: 12 mm (0.47 in.)
Page 337 of 1897
H07649Connected Portion
H10504
BO4421
H02865
Primer M
Adhesive
Primer M
BO-74
- BODYBACK WINDOW GLASS
1859 Author: Date:
2001 AVALON (RM808U)
5. INSTALL NEW BACK WINDOW OUTSIDE MOULDING
Install new back window outside moulding to the back window
glass as shown in the illustration.
HINT:
Install the back window outside moulding from the center
of the glass at the lower side of the vehicle.
When installing the back window outside moulding, do
not stretch it.
6. POSITION GLASS
(a) Place the glass in the correct position.
(b) Check that all contacting parts of the glass rim are set per-
fectly even.
(c) Place reference marks on the glass and body.
(d) Remove the glass.
7. CLEAN CONTACT SURFACE OF GLASS
Using a cleaner, clean the contact surface which is black-col-
ored area around the entire glass rim.
NOTICE:
Do not touch the glass face after cleaning it.
8. COAT CONTACT SURFACE OF BODY WITH PRIMER
ºMº
Using a brush, coat Primer M to the exposed part of body on the
vehicle side.
NOTICE:
Allow 3 minutes or more dry the primer coated sur-
face.
Do not coat Primer M to the adhesive.
Do not keep any of the opened Primer M for later use.
Page 338 of 1897
H10507
Primer G a - aa
a
b
b
b
b
b - b
H07651
Adhesive a - aa
a
b
b
b
b
b - b
AA
BB
H10505
- BODYBACK WINDOW GLASS
BO-75
1860 Author: Date:
2001 AVALON (RM808U)
9. COAT CONTACT SURFACE OF GLASS WITH PRIMER
ºGº
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G as shown in the illustra-
tion.
(b) When the primer is applied by mistake to the area other
than the specified, wipe it off with a clean shop rag before
the primer dries.
NOTICE:
Allow 3 minutes or more dry the primer coated sur-
face.
Do not keep any of the opened Primer G for later use.
10. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
Part No. 08850-00801 or equivalent
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the table below.
TemperatureTackfree time
35 °C (95 °F)15 minutes
20 °C (68 °F)100 minutes
5 °C (41 °F)8 hours
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive as shown in the illustration.
A: 13.5 mm (0.531 in.)
B: 8.0 mm (0.315 in.)
11. INSTALL GLASS
(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.
Page 339 of 1897
H08966
BO-76
- BODYBACK WINDOW GLASS
1861 Author: Date:
2001 AVALON (RM808U)
HINT:
Confirm that the moulding is attached to the body panel as
shown in the illustration.
(b) Hold the back window glass in place securely with a pro-
tective tape or equivalent until the adhesive hardens.
NOTICE:
Take care not to drive the vehicle during the time described
in the table below.
TemperatureMinimum time prior to driving the vehicle
35 °C (95 °F)1.5 hours
20 °C (68 °F)5 hours
5 °C (41 °F)24 hours
12. INSPECT FOR LEAK AND REPAIR
NOTICE:
Conduct a leak test after hardening time has elapsed.
13. CONNECT DEFOGGER WIRE CONNECTOR
14. INSTALL ROOF HEADLINING
15. w/ Rear personal light:
INSTALL REAR PERSONAL LIGHT
16. INSTALL UPPER BACK SILENCER
17. INSTALL PACKAGE TRAY TRIM
18. INSTALL HIGH-MOUNTED STOP LIGHT
19. INSTALL ROOF SIDE INNER GARNISH
20. INSTALL REAR SEAT (See page BO-123)
Page 340 of 1897
BO2PL-01
H12128
:7 Clips
H03125H12122H12806
2 Clips w/o Speaker:
w/ Speaker:
H07599
BO-70
- BODYBACK WINDOW GLASS
1855 Author: Date:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE REAR SEAT (See page BO-120)
2. REMOVE ROOF SIDE INNER GARNISH
(a) Using a screwdriver, remove the roof side inner garnish.
HINT:
Tape the screwdriver tip before use.
(b) Employ the same manner described above to the other
side.
3. REMOVE HIGH-MOUNTED STOP LIGHT
Remove the high-mounted stop light as shown in the illustra-
tion, then disconnect the connector.
4. REMOVE PACKAGE TRAY TRIM
(a) Using a screwdriver, remove the 3 rear seat belt bezel.
HINT:
Tape the screwdriver tip before use.
Page 341 of 1897
H12124
2 Clips
H12161
Claw
Claw
H121623 Clips
H08965
H10479
Protective
Tape
- BODYBACK WINDOW GLASS
BO-71
1856 Author: Date:
2001 AVALON (RM808U)
(b) Remove the package tray trim as shown in the illustration.
5. REMOVE UPPER BLACK SILENCER
6. w/ Rear personal light:
REMOVE REAR PERSONAL LIGHT
(a) Using a screwdriver, remove the rear personal light, then
disconnect the connector.
HINT:
Tape the screwdriver tip before use.
(b) Employ the same manner described above to the other
side.
7. REMOVE ROOF HEADLINING
Disengage the 3 clips and remove the rear side of roof headlin-
ing.
8. DISCONNECT DEFOGGER WIRE CONNECTOR
9. REMOVE BACK WINDOW MOULDING
(a) Using a knife, cut off the moulding as shown.
NOTICE:
Do not damage the body with the knife.
(b) Remove the remaining moulding.
10. REMOVE BACK WINDOW GLASS
(a) Insert a piano wire between body and glass and let it pass
through.
(b) Tie both wire ends to wooden blocks or similar objects.
HINT:
Apply protective tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and exterior.
Page 342 of 1897
H10480
Protective
Tape
H07610
H10413
BO-72
- BODYBACK WINDOW GLASS
1857 Author: Date:
2001 AVALON (RM808U)
(c) Cut the adhesive by pulling the piano wire around it.
HINT:
Cut the adhesive areas as shown in the illustration, leaving the
adhesive where the stoppers are.
(d) Let the piano wire pass as shown in the illustration, cut off
the adhesive sticking to the stoppers.
NOTICE:
Do not damage the glass stoppers.
(e) Disengage the stoppers, then remove the glass.
NOTICE:
Leave of the adhesive on the body as much as possible
when cutting off the glass.
