2002 TOYOTA AVENSIS Repair Manual

700T1±01
B67031
Assist Grip
RH Visor Assy
LH Visor Assy
Map Lamp AssyRoof Headlining
Rain Sensor
Cover
Rain Sensor Cover Front Pillar Garnish RH
Front Door
Weatherstrip
RHWindshield Moulding
Outer Upper Visor Holder
Visor Holder
Inner Rear View Mirror Assy

Windshield Glass Stopper No. 1
Front Door Weatherstrip LHFront Pillar Garnish LH
Windshield Wiper Arm Cover
FR Wiper Arm LH
Cowl Top Ventilator
Louver RHWindshield Glass
FR Wiper Arm RH
Windshield Glass Stopper No. 2
Hood Cowl Top Seal
Cowl Top Ventilator Louver LHRain Sensor
w/ EC Mirror
Inner Rear Vice Mirror
Assy
: Specified torqueN
m (kgf
cm, ft
lbf)

Non±reusable part
20 (204, 15)
20 (204, 15)

Window Glass Adhesive Dam
Windshield Wiper
Arm Cover
70±14
± WINDSHIELD/WINDOWGLASS/MIRRORWINDSHIELD GLASS
AVENSIS REPAIR MANUAL (RM1018E)
WINDSHIELD GLASS
COMPONENTS

700T2±01
B50448
CutCut
Moulding
WindshieldBody
B67281
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD GLASS
70±15
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 ROOF HEADLINING ASSY ( See page 76±36 or 76±45 or 76±54 )
(a) Remove the front door weatherstrip LH.
(b) Remove the front door weatherstrip RH.
(c) Remove the front pillar garnish LH.
(d) Remove the front pillar garnish RH.
(e) Remove the LH visor.
(f) Remove the RH visor.
(g) Remove the assist grip.
(h) Remove the 2 visor holders.
(i) Remove the map lamp assy.
(j) Do not remove the roof headlining assy completely partially so that the \
windshield glass can be re- moved.
2 . REMOVE INNER REAR VIEW MIRROR ASSY ( See page 70±64)
3 . REMOVE RAIN SENSOR ( See page 66±26)
4 . REMOVE COWL T OP VENTIL ATOR LOUVER ( See page66±13 )
(a) Remove the 2 windshield wiper arm covers.
(b) Remove the FR wiper arm LH.
(c) Remove the FR wiper arm RH.
(d) Remove the hood to cowl top seal.
(e) Remove the cowl top ventilator louver LH.
(f) Remove the cowl top ventilator louver RH.
5. REMOVE WINDSHIELD MOULDING OUTER UPPER
(a) Using a knife, cut off the moulding, as shown in the il-lustration.
NOTICE:
Do not damage the body with the knife.
(b) Remove the remaining moulding.
HINT:
When removing, make a partial cut, then pull and remove it by
hand.
6. DISCONNECT CONNECTOR (W/ DEICER)
(a) Disconnect the deicer connector, as shown in the illustra- tion.

B62805
Stopper
Piano Wire
B63724Protective Tape Plastic Sheet
BO5231
70±16
± WINDSHIELD/WINDOWGLASS/MIRRORWINDSHIELD GLASS
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE WINDSHIELD GLASS
(a) Pass a piano wire between the vehicle body and glass
from the interior.
(b) Tie both wire ends to wooden blocks or similar objects.
HINT:
Apply protective tape to the outer surface to prevent the surface
from being scratched.
NOTICE:

When separating the glass, take care not to damage
the paint and the interior and exterior ornaments.

To prevent the safety pad from being scratched when
removing the glass, place a plastic sheet between the
piano wire and safety pad.
(c) Cut off the adhesive by pulling the piano wire around the
glass.
(d) Disengage the stoppers.
(e) Using a suction cup, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.
8. CLEAN WINDSHIELD GLASS
(a) Using a scraper, remove the damaged stoppers, dam and
adhesive sticking to the glass.
(b) Clean the outer circumference of the glass with white gas-
oline.
NOTICE:

Do not touch the glass surface after cleaning it.

Be careful not to damage the body.

Even if using new glass, clean the glass with white
gasoline.

B62806
B
A ACeramic Notch
Backside
B63758
± WINDSHIELD/WINDOWGLASS/MIRRORWINDSHIELD GLASS
70±17
AVENSIS REPAIR MANUAL (RM1018E)
9. INSTALL WINDSHIELD GLASS STOPPER NO.2
(a) Coat the installation part of the stopper with Primer G.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Do not keep any of the opened Primer G for later use.

Do not apply too much primer.
(b) Install 2 new stoppers onto the glass, as shown in the il-
lustration.
Standard dimension:
A40.0 mm (1.575 in.)
B7.7 mm (0.303 in.)
10. INSTALL WINDSHIELD GLASS STOPPER NO.1
(a) Install 2 new stoppers to the vehicle body, as shown in the
illustration.

B67032
A
A
B
A
AB
AA ± A
B ± B
Ceramic Notch
Stopper Dam
DamCeramic Notch a
C
C
C ± C
b
Ceramic End
Ceramic End
70±18
± WINDSHIELD/WINDOWGLASS/MIRRORWINDSHIELD GLASS
AVENSIS REPAIR MANUAL (RM1018E)
11. INSTALL WINDOW GLASS ADHESIVE DAM
(a) Coat the installation part of the window glass adhesive dam with Primer G.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Do not apply too much primer.
(b) Install a new dam, applying double±sided tape all the way around the glass except where the dam is
installed, as shown in the illustration.
Standard dimension:
a7.0 mm (0.276 in.)
b56.0 mm (2.205 in.)
12. INSTALL WINDSHIELD MOULDING OUTER UPPER
(a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Do not coat the adhesive with Primer G.

Do not keep any of the opened Primer G for later use.
(b) Install the moulding.

Adhesive
Adhesive
BO4420Body
BO2820
Mark
B67819
Primer M
Primer M
AdhesiveCORRECT
WRONG
Primer M
± WINDSHIELD/WINDOWGLASS/MIRRORWINDSHIELD GLASS
70±19
AVENSIS REPAIR MANUAL (RM1018E)
13. INSTALL WINDSHIELD GLASS
(a) Clean and shape the contact surface of the vehicle body.
(1) Using a knife, cut away any rough adhesive on the
contact surface of the vehicle body to ensure the
appropriate surface shape.
HINT:
Leave as much adhesive on the vehicle body as possible.
(2) Clean the contact surface of the vehicle body with
a piece of shop rag saturated with cleaner.
HINT:
Even if all the adhesive has been removed, clean the vehicle
body.
(b) Position the glass.
(1) Using a suction cup, place the glass in the correct
position.
(2) Check that the whole contact surface of the glass
rim is perfectly even.
(3) Place reference marks between the glass and ve-
hicle body.
NOTICE:
Check that the stoppers are attached to the vehicle body
correctly.
HINT:
When reusing the glass, check and correct the reference mark
positions.
(4) Remove the glass.
(c) Using a brush, coat the exposed part of the vehicle body
on the vehicle side with Primer M.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Do not coat the adhesive with Primer M.

Do not keep any of the opened Primer M for later use.

B67034
Primer Ga
a
b
a ± a
c ± c
c b
b ± bc Backside
Primer GPrimer G
B67035
A
B
a
a
b b A ± A
C ± C B ± B BA
C Backside
ba c
C
c
a
b
BO2821
70±20
± WINDSHIELD/WINDOWGLASS/MIRRORWINDSHIELD GLASS
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
HINT:
If an area other than that specified is coated by accident, wipe
off the primer with a clean shop rag before it dries.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Do not keep any of the opened Primer G for later use.
(e) Apply adhesive.
Adhesive: Part No. 08850±00801 or equivalent
(1) Cut off the tip of the cartridge nozzle, as shown in
the illustration.
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the table below.
Tackfree time:
TemperatureTackfree Time
35C (95F)15 minutes
20C (68F)1 hour 40 minutes
5C (41F)8 hours
(2) Load the sealer gun with the cartridge.
(3) Coat the glass with adhesive, as shown in the il-
lustration.
Standard dimension:
a12.5 mm (0.492 in.)
b8.0 mm (0.315 in.)
c3.0 mm (0.118 in.)
(f) Install the glass to the body.
(1) Using a suction cup, position the glass so that the
reference marks are aligned, and press it in gently
along the rim.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Check that the stoppers are attached to the vehicle
body correctly.

Check the clearance between the vehicle body and
glass.

BO3986
Adhesive
N08495
Adhesive
Windshield
Dam
± WINDSHIELD/WINDOWGLASS/MIRRORWINDSHIELD GLASS
70±21
AVENSIS REPAIR MANUAL (RM1018E)
(2) Lightly press the front surface of the glass to ensure
a close fit.
(3) Using a scraper, remove any excess or protruding
adhesive.
HINT:
Apply adhesive onto the glass rim.
NOTICE:
Take care not to drive the vehicle for the time described in
the table below.
Minimum time:
TemperatureMinimum time prior to driving vehicle
35
C (95
F)1 hour 30 minutes
20
C (68
F)5 hours
5
C (41
F)24 hours
14. INSPECT FOR LEAKS AND REPAIR
(a) Conduct a leak test after the adhesive has completely hardened.
(b) Seal any leaks with auto glass sealer.