TOYOTA AVENSIS 2003 Service Repair Manual

B69289
1.4 W
Test Bulb
Switch ON
5 (IG)
6 (DEF) 1 (E)
B67057
B67058
1.4 W Test Bulb
Switch ON 1 (IG)
6 (D)
3 (E)
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDOW DEFOGGER SYSTEM
70±51
AVENSIS REPAIR MANUAL (RM1018E)
(b) Inspect operation of the defogger timer.
(1) Connect the positive (+) lead from the battery to ter-minal 6 and the negative (±) lead to terminal 1.
(2) Connect the positive (+) lead from the battery to ter- minal 5 through a 1.4 W test bulb.
(3) Push the rear window defogger switch ON, check that the switch and the test bulb illuminate for 12 ±
18 minutes, and then they go off.
If the result is not as specified, replace the switch assy.
3. INSPECT FR WIPER DEICER SWITCH (W/ DEICER)
(a) check that the wiper deicer switch illuminates. Standard:
Measurement ConditionSpecified Condition
Battery positive (+)
1
Battery negative (±)
4Illuminates
If the result is not as specified, replace the switch or bulb.
(b) Inspect operation of the wiper deicer timer.
(1) Connect the positive (+) lead from the battery to ter-minal 6 and the negative (±) lead to terminal 3.
(2) Connect the positive (+) lead from the battery to ter-
minal 1 through a 1.4 W test bulb.
(3) Push the wiper deicer switch ON, check that the switch and the test bulb illuminate for 12 ± 18 min-
utes, and then they go off.
If the result is not as specified, replace the switch.
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B68230
12
3
4
5
6
7
4 (H+)
5 (H±)
B68231
12
3
4
5
6
7
4 (H+)
5 (H±)
B70597
70±52
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDOW DEFOGGER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
4. INSPECT OUTER REAR VIEW MIRROR ASSY LH (w/ OUTER MIRROR HEATER)
(a) Inspect operation of the mirror heater.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+)
H+ (4)
Battery negative (±)
H± (5)Mirror becomes warm
If the result is not as specified, replace the mirror assy.
5. INSPECT OUTER REAR VIEW MIRROR ASSY RH (w/
OUTER MIRROR HEATER)
(a) Inspect operation of the mirror heater. Standard:
Measurement ConditionSpecified Condition
Battery positive (+)
H+ (4)
Battery negative (±)
H± (5)Mirror becomes warm
If the result is not as specified, replace the mirror assy.
6. INSPECT FRONT WINDOW (DEICER WIRE) (W/
DEICER)
(a) Inspect the resistance of the deicer wire. Standard:
Terminal No.Specified Condition
1 ± 2Below 1

If the result is not as specified, replace the window.
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B66134
Tester ProbeTin FoilDefogger Wire
B63720
At Center
V
B63721
0 V
Broken
Wire Less than
10V
Battery
Side
Ground SideFoil Strip



±
WINDSHIELD/WINDOWGLASS/MIRROR WINDOW DEFOGGER SYSTEM
70±53
AVENSIS REPAIR MANUAL (RM1018E)
7. INSPECT BACK WINDOW (DEFOGGER WIRE)
NOTICE:

When cleaning the glass, wipe the glass along the
wire using a soft and dry cloth. Take care not to dam-
age the wires.

Do not use detergents or glass cleaners including
abrasive ingredients.

When measuring voltage, wrap a piece of tin foil
around the tip of the negative probe and press the foil
against the wire with your finger, as shown in the il-
lustration
(a) Turn the ignition switch ON.
(b) Turn the defogger switch ON.
(c) Inspect the voltage at the center of each defogger wire, as shown in the illustration.
Standard:
VoltageCriteria
Approx. 5 VOkay, wire is not broken
Approx. 10 or 0 VWire is broken
HINT:
If there is approximately 10 V, the wire may be broken between
the center of the wire and the end on the battery side. If there
is no voltage, the wire may be broken between the center of the
wire and the end on the ground side.
(d) Place the voltmeter positive (+) lead against the defoggerwire on the battery side.
(e) Place the voltmeter negative (±) lead with the foil strip against the wire on the ground side.
(f) Slide the positive (+) lead from the battery side to the
ground side.
(g) The point where the voltmeter deflects from approx. 10V to 0 V is the place where the defogger wire is broken.
HINT:
If the defogger wire is not broken, the voltmeter indicates 0 V
at the positive (+) end of the defogger wire but gradually in-
creases to about 12 V as the meter probe moves to the other
end.
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B63722
Repair PointBroken
Wire
Masking Tape
B63723
B68374
1
2
35
B68374
1
2
35
70±54
±
WINDSHIELD/WINDOWGLASS/MIRROR WINDOW DEFOGGER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(h) If necessary, repair the defogger wire. (1) Clean the broken wire tips with grease, wax and sili-cone remover.
(2) Place the masking tape along the both sides of the wire.
(3) Thoroughly mix the repair agent (Dupont paste No. 4817).
(4) Using a fine tip brush, apply a small amount of the agent to the wire.
(5) After a few minutes, remove the masking tape.
NOTICE:
Do not repair the defogger wire again for at least 24 hours.
8. INSPECT FR WIPER DEICER RELAY (W/ DEICER)
(a) Inspect the resistance. Standard:
Terminal Connection.Specified Condition
10 k
or higher10 k
or higher
3 ± 5Below 1

(When battery voltage is applied to terminals 1 and 2)
If the result is not as specified, replace the relay.
9. INSPECT DEFOGGER RELAY
(a) Inspect the resistance. Standard:
Terminal No.Specified Condition
10 k
or higher10 k
or higher
3 ± 5Below 1

(When battery voltage is applied to terminals 1 and 2)
If the result is not as specified, replace the relay.
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700T1±01
B67031
Assist GripRH Visor Assy
LH Visor Assy
Map Lamp Assy Roof Headlining
Rain Sensor
Cover Rain Sensor Cover
Front Pillar Garnish RH
Front Door
Weatherstrip
RH Windshield Moulding
Outer Upper
Visor Holder
Visor Holder Inner Rear View Mirror Assy

Windshield Glass Stopper No. 1
Front Door Weatherstrip LH Front Pillar Garnish LH
Windshield Wiper Arm Cover
FR Wiper Arm LH
Cowl Top Ventilator
Louver RH Windshield Glass
FR Wiper Arm RH

Windshield Glass Stopper No. 2
Hood Cowl Top Seal Cowl Top Ventilator Louver LH Rain 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/MIRROR WINDSHIELD GLASS
AVENSIS REPAIR MANUAL (RM1018E)
WINDSHIELD GLASS
COMPONENTS
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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 TOP VENTILATOR 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.
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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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