TOYOTA AVENSIS 2005 Service Repair Manual

BO3986
Adhesive
N08495
Adhesive
Windshield
Dam
± WINDSHIELD/WINDOWGLASS/MIRRORBACK WINDOW GLASS (SEDAN MODELS)
70±33
AVENSIS REPAIR MANUAL (RM1018E)

Check the clearance between the vehicle 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
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.

700T5±01
B67036
Assist Grip
Roof Headlining Assy

Back Window Glass Stopper No. 2
Back Window Moulding Outside Upper
Center Stop Lamp AssyRoof Side Garnish Inner RH
Rear Door Weatherstrip RH
Package Tray Trim Panel Assy Rear Door Weatherstrip LH
Back Window Glass Stopper No. 1

Back Window Glass Adhesive Dam
Roof Side Garnish Inner LH

Non±reusable partBack Window Glass
Assist Grip
Rear Map Lamp
± WINDSHIELD/WINDOWGLASS/MIRRORBACK WINDOW GLASS (SEDAN MODELS)
70±27
AVENSIS REPAIR MANUAL (RM1018E)
BACK WINDOW GLASS (SEDAN MODELS)
COMPONENTS

700T4±01
B68022
Piano Wire
Clip
Clip
B68023
Protective Tape
±
WINDSHIELD/WINDOWGLASS/MIRROR QUARTER WINDOW ASSY LH (WAGON MODELS)
70±23
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:

The installation is in the reverse order of the removal. However, when there is a special point concern-
ing the installation, it is indicated.

Use the same procedures on the RH side as on the LH side.
1.REMOVE REAR WINDOW SIDE GARNISH LH (See page 76±54)
(a) Remove the rear door opening trim weatherstrip LH
(b) Remove the rear door scuff plate.
(c) Remove the tonneau cover.
(d) Remove the deck board.
(e) Remove the deck floor box rear.
(f) Remove the deck floor box.
(g) Remove the deck floor box front.
(h) Remove the rear floor finish plate.
(i) Remove the roof headlining retainer front.
(j) Remove the luggage compartment trim hook No. 2.
(k) Remove the deck trim side board.
(l) Remove the roof side garnish inner.
(m) Remove the rear window side garnish.
2. REMOVE QUARTER WINDOW ASSY LH
(a) Disconnect the connectors.
(b) Pass a piano wire between the vehicle body and glassfrom the interior.
(c) 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.
(d) Cut off the adhesive by pulling the piano wire around the glass.
(e) 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
B67869
Primer M
Primer M
Adhesive
CORRECT
WRONG
: Primer M 70±24
± WINDSHIELD/WINDOWGLASS/MIRRORQUARTER WINDOW ASSY LH (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
3. CLEAN QUARTER WINDOW ASSY LH
(a) Clean the outer circumference of the glass with white gas-
oline.
NOTICE:

Do not touch the glass surface after cleaning it.
4. INSTALL QUARTER WINDOW ASSY LH
(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.

B67044
a
d
ec b A ± AB ± B
C ± C
: Primer G Backside
AB
A
CB
C
B67870
Backside
: Adhesive a
d
e c
bB ± B
C ± C AB
A
CB
C
a
bA ± A
± WINDSHIELD/WINDOWGLASS/MIRRORQUARTER WINDOW ASSY LH (WAGON MODELS)
70±25
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
Standard dimension:
a5.5 mm (0.217 in.)
b19.0 mm (0.748 in.)
c11.0 mm (0.433 in.)
d11.0 mm (0.433 in.)
e7.5 mm (0.295 in.)
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.
(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
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.)
c9.5 mm (0.374 in.)
d11.0 mm (0.433 in.)
e11.5 mm (0.453 in.)
(e) Install the glass to the body.
(1) Hold the quarter window in place securely with pro-
tective tape or equivalent until the adhesive hard-
ens.
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.

BO3986
Adhesive
70±26
± WINDSHIELD/WINDOWGLASS/MIRRORQUARTER WINDOW ASSY LH (WAGON MODELS)
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 the vehicle
35
C (95
F)1 hour 30 minutes
20
C (68
F)5 hours
5
C (41
F)24 hours
5. INSPECT FOR LEAKS AND REPAIR
(a) Conduct a leak test after the adhesive has completely hardened.
(b) Seal any leaks with auto glass sealer.

700T3±01
B67165
Roof Side Garnish Inner LH
Deck Trim Side Board LH
Quarter Window Assy LH Rear Window
Side Garnish LH
Luggage Compartment
Trim Hook No. 2

Non±reusable partTonneau Cover Assy
Deck Board Sub±assy
Deck Floor Box Front
Deck Floor Box LH
Rear Floor Finish Plate
Deck Floor Box Rear
Roof Headlining Retainer Front
Rear Door Opening Trim Weatherstrip LH
Rear Door Sucuff Plate LH
70±22
± WINDSHIELD/WINDOWGLASS/MIRRORQUARTER WINDOW ASSY LH (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
QUARTER WINDOW ASSY LH (WAGON MODELS)
COMPONENTS

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 T OP VENTIL ATOR 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.

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.