TOYOTA AVENSIS 2002 Repair Manual

80028±04
B68363
ACC
ON
START LOCK
55

35

35
80±2
± VEHICLE CONTROL SYSTEMIGNITION OR STARTER SWITCH ASSY
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT IGNITION OR STARTER SWITCH ASSY
(a) Inspect the switch resistance.
Standard:
Terminal No.Switch ConditionSpecified Condition
2 ± 3ACC
1 ± 3
2 ± 3ON
4 ± 6Below 1

1 ± 3
4 ± 5START
4 ± 6
If the result is not as specified, replace the switch.

700T7±01
B67059
Back Door Side Garnish RH
Center Stop Lamp Assy
Back Door Trim Board
Back Door Side Garnish LH Back Door Trim
Panel Assy Upper
Wiper Arm Head Cap
Rear Wiper Arm Assy
Wiper Motor Assy
Back Door Glass
: Specified torque
N
m (kgf
cm, ft
lbf)

Non±reusable part
5.5 (56, 49 in.
lbf)5.5 (56, 49 in.
lbf)
5.5 (56, 49 in.
lbf)
70±34
± WINDSHIELD/WINDOWGLASS/MIRRORBACK DOOR GLASS (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR GLASS (LIFTBACK MODELS)
COMPONENTS

700T8±01
B68025
Piano Wire
Clip
B69235
Protective Tape
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
70±35
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 BACK DOOR TRIM BOARD ASSY (See page 75±40)
(a) Remove the back door trim panel assy upper.
(b) Remove the back door side garnish LH.
(c) Remove the back door side garnish RH.
(d) Remove the back door trim board.
2.REMOVE CENTER STOP LAMP ASSY (See page 65±26)
3.REMOVE REAR WIPER MOTOR ASSY (
See page 66±17)

(a) Remove the wiper arm head cap.
(b) Remove the rear wiper arm.
(c) Remove the wiper motor.
4. REMOVE BACK DOOR GLASS
(a) Pass a piano wire between the body and glass from theinterior.
(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 interior and exterior ornaments.
(c) Cut off the adhesive by pulling the piano wire around the glass.
(d) Using a suction rubber, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.

BO4421
Adhesive
Adhesive
BO4420Body
B67821
Primer M
Primer M
AdhesiveCORRECT
WRONG
: Primer M 70±36
± WINDSHIELD/WINDOWGLASS/MIRRORBACK DOOR GLASS (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
5. CLEAN BACK DOOR GLASS
(a) 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.
6. INSTALL BACK DOOR 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 body to ensure the appropri-
ate surface shape.
HINT:
Leave as much adhesive on the body as possible.
(2) Clean the contact surface of the body with a piece
of shop rag saturated with cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
(b) Using a brush, coat the exposed part of the 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.

B67051
A ± A
C ± C B ± B
c Backside
f ed
A
CA
CB
B
b a
: Primer G
± WINDSHIELD/WINDOWGLASS/MIRRORBACK DOOR GLASS (LIFTBACK MODELS)
70±37
AVENSIS REPAIR MANUAL (RM1018E)
(c) 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.
Standard dimension:
a10.2 mm (0.402 in.)
b23.7 mm (0.933 in.)
c9.1 mm (0.358 in.)
d11.0 mm (0.433 in.)
e14.0 mm (0.551 in.)
f11.0 mm (0.433 in.)

B67053
a
a bbd c
e A ± A
B ± B A
B
CA
B Backside
CC ± C
: Adhesive 70±38
± WINDSHIELD/WINDOWGLASS/MIRRORBACK DOOR GLASS (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
(d) 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
35
C (95
F)15 minutes
20
C (68
F)1 hour 40 minutes
5
C (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:
a12.0 mm (0.472 in.)
b8.0 mm (0.315 in.)
c14.2 mm (0.559 in.)
d30.7 mm (1.209 in.)
e13.1 mm (0.516 in.)

BO3986
Adhesive
± WINDSHIELD/WINDOWGLASS/MIRRORBACK DOOR GLASS (LIFTBACK MODELS)
70±39
AVENSIS REPAIR MANUAL (RM1018E)
(e) Install the glass to the body.
(1) Hold the back window glass in place securely with
tape or equivalent to the body until the adhesive has
hardened.
NOTICE:

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

Check that the clips are attached to the body correct-
ly.

Check the clearance between the body and glass.
(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
7. INSPECT FOR LEAKS AND REPAIR
(a) Conduct a leak test after the adhesive has completely hardened.
(b) Seal any leaks with auto glass sealer.

700T9±01
B67062
Back Door Trim Panel Assy Upper
Back Door Side Garnish RH
Back Door Side Garnish LHBack Door Trim Board
Rear Spoiler

Back Door Glass
Wiper Motor AssyRear Wiper Arm Assy Wiper Arm Head Cap
: Specified torqueN
m (kgf
cm, ft
lbf)

Non±reusable part
5.5 (56, 49 in.
lbf)
5.5 (56, 49 in.
lbf)
70±40
± WINDSHIELD/WINDOWGLASS/MIRRORBACK DOOR GLASS (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR GLASS (WAGON MODELS)
COMPONENTS

700TA±01
B68025
Clip
Piano Wire
B69236
Protective Tape
BO4421
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (WAGON MODELS)
70±41
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 BACK DOOR TRIM BOARD ASSY (See page 75±45)
(a) Remove the back door trim panel upper.
(b) Remove the back door side garnish LH.
(c) Remove the back door side garnish RH.
(d) Remove the back door trim board.
2.REMOVE REAR SPOILER (See page 76±30)
3.REMOVE REAR WIPER MOTOR ASSY (See page 66±17)
(a) Remove the wiper arm head cap.
(b) Remove the rear wiper arm.
(c) Remove the wiper motor.
4. REMOVE BACK DOOR GLASS
(a) Pass a piano wire between the body and glass from theinterior.
(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 interior and exterior ornaments.
(c) Cut off the adhesive by pulling the piano wire around it.
(d) Using a suction rubber, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.
5. CLEAN BACK DOOR GLASS
(a) 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.

Adhesive
Adhesive
BO4420Body
B67835
Primer M
Primer M
AdhesiveCORRECT
WRONG
: Primer M 70±42
± WINDSHIELD/WINDOWGLASS/MIRRORBACK DOOR GLASS (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
6. INSTALL BACK DOOR 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 body to ensure the appropri-
ate surface shape.
HINT:
Leave as much adhesive on the body as possible.
(2) Clean the contact surface of the body with a piece
of shop rag saturated with cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
(b) Using a brush, coat the exposed part of the 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.