TOYOTA AVALON 2001 Service Repair Manual

BO2PS-01
- BODYSLIDING ROOF
BO-85
1870 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BO-81).

BO2PP-01
H12168
- BODYSLIDING ROOF
BO-79
1864 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE ROOF HEADLINING (See page BO-99)
2. REMOVE SIDE GARNISH
(a) Using a screwdriver, remove the garnish.
HINT:
Tape the screwdriver tip before use.
(b) Employ the same manner described above to the other
side.
3. REMOVE SLIDING ROOF GLASS ASSEMBLY
(a) Using a torx wrench, remove the 4 nuts.
Torque: 4.0 N´m (41 kgf´cm, 35 in.´lbf)
(b) Pull the glass upward to remove it.
4. REMOVE DRIVE GEAR
NOTICE:
Remove the drive gear with the sliding roof fully closed.
(a) Disconnect the connector.
(b) Remove the 2 bolts an drive gear.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(c) Remove the 2 screws and map light bracket from the drive
gear.

H12169
BO-80
- BODYSLIDING ROOF
1865 Author
: Date
:
2001 AVALON (RM808U)
5. REMOVE SLIDING ROOF HOUSING
(a) Disconnect the 4 drain hoses from the housing.
(b) Remove the 8 bolts and 4 brackets.
Torque: 5.4 (55 kgf´cm, 48 in.´lbf)
(c) Remove the 6 nuts, then remove the sliding roof housing.
Torque: 5.4 (55 kgf´cm, 48 in.´lbf)

BO0XI-03
- BODYSRS AIRBAG
BO-3
1788 Author
: Date
:
2001 AVALON (RM808U)
SRS AIRBAG
PRECAUTION
The AVALON is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front pas-
senger airbag and side airbag. Failure to carry out service operation in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing
(including removal or installation of parts, inspection or replacement), be sure to read the precautionary no-
tices in the RS section.

BO0XI-03
- BODYSRS AIRBAG
BO-3
1788 Author
: Date
:
2001 AVALON (RM808U)
SRS AIRBAG
PRECAUTION
The AVALON is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front pas-
senger airbag and side airbag. Failure to carry out service operation in the correct sequence could cause
the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing
(including removal or installation of parts, inspection or replacement), be sure to read the precautionary no-
tices in the RS section.

BO2PE-01
H12155
: Specified torqueN´m (kgf´cm, ft´lbf)

Non-reusable partHood To Cowl Top Seal Cowl Top Ventilator LouverWiper Arm Windshield Upper Moulding
Windshield GlassFront Door
Opening Trim Front Pillar Garnish
24 (248, 18)
Roof Headlining
Assist Grip
DamInner Rear View Mirror
Sun Visor
Holder Sun Visor
Inner Rear View
Mirror Cover
Holder
Roof Console Box Front Pillar Garnish
Front Door
Opening Trim
Retainer
24 (248, 18)

No. 1 Stopper

No. 2 Stopper

No. 2
Stopper
w/ Sliding roof:
Sliding Roof
Opening Trim




Dam

Lens

No. 1 Stopper
- BODYWINDSHIELD
BO-55
1840 Author
: Date
:
2001 AVALON (RM808U)
WINDSHIELD
COMPONENTS

BO2PG-01
BO4420
Adhesive
BO5231
H10503
H12148
A
- BODYWINDSHIELD
BO-59
1844 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 piece of shop
rag saturated 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 and dams.
(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 in 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.
HINT:
Make sure that the stoppers are installed facing the correct
direction.
A: 7.2 ± 0.5 mm (0.283 ± 0.020 in.)

H12149
H12150
Dam
H04300
BO4421
BO-60
- BODYWINDSHIELD
1845 Author
: Date
:
2001 AVALON (RM808U)
5. INSTALL NEW RETAINERS
Attach new retainers to the glass with the ceramic notch on the
glass aligned with the retainers as shown in the illustration.
6. INSTALL NEW DAMS
Attach new dams to the glass as shown in the illustration.
7. 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.
8. 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.

H02865
Primer M
Adhesive
Primer M
H12151
a
b
c
b - b a - a
c - c
Primer G a
b
c
H12152
a
b
c
b - b a - a
c - c
Adhesive a
b
c
A
B B
BAA
- BODYWINDSHIELD
BO-61
1846 Author
: Date
:
2001 AVALON (RM808U)
9. 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 to 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.
10. 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 to dry the primer coated sur-
face.

Do not keep any of the opened Primer G for later use.
11. 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.)

BO2821
H00679
H12153
w/o Rain gutter:
H12154
a
b
b - b a - aa
b w/ Rain gutter: BO-62
- BODYWINDSHIELD
1847 Author
: Date
:
2001 AVALON (RM808U)
12. INSTALL WINDSHIELD GLASS AND MOULDING
(a) Install the glass, aligning the reference marks using a suc-
tion rubber.
HINT:
Check to see that the stoppers are attached to the body correct-
ly.
(b) Lightly press the glass front surface for close contact.
(c) Correct insufficient or protruded adhesive agent using a
spatula.
HINT:
Apply adhesive agent up to the windshield glass edge.
(d) Install a new windshield moulding to the windshield glass
before the adhesive agent hardens.
HINT:
Install the moulding, aligning the center of moulding with the
center of body.
(e) Remove any excessive adhesive agent before it hardens.
(f) Hold the glass and moulding 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
13. INSPECT FOR LEAK AND REPAIR
NOTICE:
Conduct a leak test after the hardening time has elapsed.
14. w/ Sliding roof:
INSTALL SLIDING ROOF OPENING TRIM
15. INSTALL ASSIST GRIP
16. INSTALL COWL TOP VENTILATOR LOUVER
17. INSTALL HOOD TO COWL TOP SEAL
18. INSTALL WIPER ARMS
(a) Operate the wiper motor once and turn the wiper switch
OFF.
(b) Install the wiper arms and tighten nuts by hand.