TOYOTA AVENSIS 2002 Repair Manual

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.

660CS±01
E68351
I35261


E68352
±
WIPER & WASHER HEADLAMP WASHER ACTUATOR SUB±ASSY LH
66±25
AVENSIS REPAIR MANUAL (RM1018E)
HEADLAMP WASHER ACTUATOR SUB±ASSY LH
REPLACEMENT
1.REMOVE FRONT BUMPER COVER (See page 76±3)
2. R E M O V E H E A D L A M P WA S H E R A C T U ATO RSUB±ASSY LH
(a) Separate the headlamp cleaner hose from the headlamp washer actuator sub±assy.
(b) Pull out the headlamp cleaner washer nozzle.
(c) Disengage the 2 claws, remove the headlamp cleaner washer nozzle.
(d) Remove the 2 bolts.
(e) Deform the upper part of the headlamp washer actuator sub±assy LH, to remove it.

660CT±02
I357963 Claws
I357972 Claws
I357982 Claws
I35799
66±26
± WIPER & WASHERRAIN SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
RAIN SENSOR
REPLACEMENT
1. REMOVE INNER REAR VIEW MIRROR STAY HOLDER COVER
2. REMOVE RAIN SENSOR
(a) Disengage the 3 claws and remove the mirror stay holder
cover.
(b) Disengage the 2 claws and remove the rain sensor cover.
(c) Disconnect the connector.
(d) Disengage the 2 claws and remove the rain sensor spring
cover.
(e) Remove the rain sensor.
3. INSTALL RAIN SENSOR
(a) Install the rain sensor and rain sensor spring cover.
(b) Connect the connector and install the rain sensor cover and the mirror stay holder cover.

± WIPER & WASHERRAIN SENSOR
66±27
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:

Check if there is any SilGel, which of the rain sensor that has been removed, left on the wind-
shield glass and remove it if there is any.

Clean the dirt on the glass with a cloth etc.

When installing a new rain sensor, peel the transparent protective cap off the SilGel first.

Be careful not to let any air bubble in the rain sensor when installing it.

660CO±02

I35264
Wagon:
Liftback:
±
WIPER & WASHE R REAR WIPER MO TOR ASSY
66±17
A VENSIS RE PAIR MANUAL (RM1018E)
REA R WIPER MO TOR ASSY
REPLACEMENT
1 . REMOV E REAR WIPER ARM ASSY
(a ) Remove the nut and the rear wiper arm.
2 . REMOVE BACK DOOR TRIM BOARD ASSY ( See page LIFTBACK 75±40, W AGON 75±45 )
3. REMOVE REAR WIPER MOTOR ASSY
(a) Remove the 3 bolts.
(b) Disconnect the connector, and remove the rear wiper mo- tor assy.
4. INSTALL REAR WIPER MOTOR ASSY
(a) Install the rear wiper motor assy with the 3 bolts. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
(b) Connect the connector.