2003 TOYOTA AVENSIS mirror

B62805
Stopper
Piano Wire
B63724Protective Tape
Plastic Sheet
BO5231
70±16
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD 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.
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B62806
B
AA Ceramic Notch
Backside
B63758
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD 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 theillustration.
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B67032
AA
B
A A B
AA ± A
B ± B
Ceramic Notch Stopper
Dam
DamCeramic Notch
a
C C
C ± C b
Ceramic End
Ceramic End
70±18
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD 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 e\
xcept 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 surf\
ace 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.
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Adhesive
Adhesive
BO4420Body
BO2820
Mark
B67819
Primer M
Primer M
AdhesiveCORRECT
WRONG
Primer M
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD 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 witha 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 correctposition.
(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.
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B67034
Primer Ga
a
b
a ± a
c ± c
c
b
b ± b c
Backside
Primer GPrimer G
B67035
A
B aa
b
b
A ± A
C ± C
B ± B
B
A
C
Backside
ba
c
C
c
a b
BO2821
70±20
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD 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 inthe illustration.
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the table below.
Tackfree time:
TemperatureTackfree Time
35C (95 F)15 minutes
20C (68 F)1 hour 40 minutes
5C (41 F)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 thereference 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.
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BO3986
Adhesive
N08495
Adhesive
WindshieldDam
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD 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.
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B66039
Instrument Panel Bracket
Sub±assy CenterInstrument Panel
Sub±assy Lower
Glove Box Lamp Assy
Outer Mirror Switch Assy w/ Bezel
Fuse Box Opening Cover
H
±
INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER
71±9
AVENSIS REPAIR MANUAL (RM1018E)
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B67989
Front Door Outside Handle Frame Sub±assy LHw/ Key:
Front Door Outside Handle Cover LH
Front Door Handle
Assy Outside LH
Front Door Outside Handle Pad Rear
Front Door Outside
Handle Pad Front
Hole Plug
Front Door Lock Open Rod
Front Door w/ Motor Lock Assy LH
Door Lock Wire Harness Packing
5.0 (51, 44 in.´lbf)
Front Door Belt Moulding LH
Front Door Hinge
Assy Upper LH
Front Door Check Assy
30 (306, 22)

5.5 (56, 49 in.´lbf)
Front Door Hinge
Assy Lower LH26 (265, 19)
Front Door Weatherstrip LH
Cushion Rubber Front Door Lower Frame
Bracket Garnish LH
Outer Rear View Mirror Assy LH
Front Door Speaker No. 2
Front Door Service Hole Cover

: Specified torqueN´m (kgf´cm, ft´lbf)

Precoated Part Non±reusable part
 Clip
26 (265, 19)
Front Door Lower
Frame Seal


Butyl Tape

10 (102, 7)
Front Door Stiffener
Cushion No. 1
Side Trim
Spacer LH
Key Cylinder
w/o Key:
Front Door Outside
Handle Cover LHw/ SpeakerFront Door Lower Frame
Bracket Garnish LH
±
ENGINE HOOD/DOOR FRONT DOOR
75±5
AVENSIS REPAIR MANUAL (RM1018E)
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