TOYOTA AVALON 2001 Service Repair Manual

BO0Y6-03
H12136
Front Door Outside MouldingRear Door Outside Moulding
- BODYBODY OUTSIDE MOULDING
BO-43
1828 Author
: Date
:
2001 AVALON (RM808U)
BODY OUTSIDE MOULDING
COMPONENTS

BO0Y8-03
H12138
Adhesive Tape
Adhesive TapeAdhesive Tape
Adhesive Tape
- BODYBODY OUTSIDE MOULDING
BO-45
1830 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
1. CLEAN BODY MOUNTING SURFACE
(a) Using a heat light, heat the body mounting surface to 40
- 60 °C (104 - 140 °F).
NOTICE:
Do not heat the body excessively.
(b) Remove the adhesive tape from the body.
(c) Wipe off stains with cleaner.
2. CLEAN MOULDING
If reusing moulding:
(a) Using a heat light, heat the moulding to 20 - 30 °C (68 -
86 °F).
NOTICE:
Do not heat the moulding excessively.
(b) Remove the adhesive tape from the moulding.
(c) Wipe off stains with cleaner.
(d) Apply a new adhesive tape to the moulding as shown in
the illustration.
3. INSTALL MOULDING
(a) Using a heat light, heat the body and moulding.
Body: 40 - 60 °C (104 - 140 °F)
Moulding: 20 - 30 °C (68 - 86 °F)
NOTICE:
Do not heat the moulding excessively.
(b) Lift the moulding release sheet from the face of moulding.
NOTICE:
When the moulding release sheet is removed, make sure
that no dirt or dust can get onto the coated area.

BO5229
BO-46
- BODYBODY OUTSIDE MOULDING
1831 Author
: Date
:
2001 AVALON (RM808U)
(c) Align the bosess with their corresponding holes in the
body, and press firmly on the moulding.
NOTICE:
Do not apply excessive force onto the moulding, but steady
pressure with your thumbs.

BO0Y7-03
H00792Protective Tape
BO-44
- BODYBODY OUTSIDE MOULDING
1829 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. HEAT MOULDING
Using a heat light, heat the moulding to 40 - 60 °C (104 - 140
°F).
NOTICE:
Do not heat moulding excessively.
2. REMOVE OUTSIDE MOULDING
(a) Tie both piano wire ends to wooden blocks or similar ob-
jects.
(b) Cut the adhesive tape by pulling the piano wire as shown.
NOTICE:

If reusing the moulding, take care not to damage the
moulding.

Do not damage the body.
(c) Remove the moulding.

BO2PK-01
H12166
w/ Rear personal light:
Rear Personal Light
RH Roof Side
Inner Garnish

Back Window
Moulding
Back Window Glass
w/ Speaker:
High-mounted
Stop Light
LH Roof Side Inner Garnish
Package Tray Trim
Upper Back Silencer
Rear Seatback
Rear Seat
Outer Belt RH
Rear Seat Inner
with Center Belt Rear Seat Cushion Roof Headlining
Rear Door
Opening Trim
No. 1 Stopper

No. 2 Stopper

No. 1 Stopper

No. 2 Stopper
: Specified torque
N´m (kgf´cm, ft´lbf)

Non-reusable partw/o Speaker:
High-mounted Stop Light
Rear Seat Inner Belt
41 (420, 30)
41 (420, 30)41 (420, 30)
18 (185, 13)
18 (185, 13)
Rear Seat Outer Belt LH
- BODYBACK WINDOW GLASS
BO-69
1854 Author
: Date
:
2001 AVALON (RM808U)
BACK WINDOW GLASS
COMPONENTS

BO2PM-01
BO4420
Adhesive
BO5231
H10503
H12165
Stopper A
- BODYBACK WINDOW GLASS
BO-73
1858 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 shop rag sat-
urated 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.
(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 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.
A: 12 mm (0.47 in.)

H07649Connected Portion
H10504
BO4421
H02865
Primer M
Adhesive
Primer M
BO-74
- BODYBACK WINDOW GLASS
1859 Author
: Date
:
2001 AVALON (RM808U)
5. INSTALL NEW BACK WINDOW OUTSIDE MOULDING
Install new back window outside moulding to the back window
glass as shown in the illustration.
HINT:

Install the back window outside moulding from the center
of the glass at the lower side of the vehicle.

When installing the back window outside moulding, do
not stretch it.
6. 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.
7. 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.
8. 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 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.

H10507
Primer G a - aa
a
b
b
b
b
b - b
H07651
Adhesive a - aa
a
b
b
b
b
b - b
AA
BB
H10505
- BODYBACK WINDOW GLASS
BO-75
1860 Author
: Date
:
2001 AVALON (RM808U)
9. 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 dry the primer coated sur-
face.

Do not keep any of the opened Primer G for later use.
10. 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.)
11. INSTALL GLASS
(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.

H08966
BO-76
- BODYBACK WINDOW GLASS
1861 Author
: Date
:
2001 AVALON (RM808U)
HINT:
Confirm that the moulding is attached to the body panel as
shown in the illustration.
(b) Hold the back window glass 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
12. INSPECT FOR LEAK AND REPAIR
NOTICE:
Conduct a leak test after hardening time has elapsed.
13. CONNECT DEFOGGER WIRE CONNECTOR
14. INSTALL ROOF HEADLINING
15. w/ Rear personal light:
INSTALL REAR PERSONAL LIGHT
16. INSTALL UPPER BACK SILENCER
17. INSTALL PACKAGE TRAY TRIM
18. INSTALL HIGH-MOUNTED STOP LIGHT
19. INSTALL ROOF SIDE INNER GARNISH
20. INSTALL REAR SEAT (See page BO-123)

BO2PL-01
H12128
:7 Clips
H03125H12122H12806
2 Clips w/o Speaker:
w/ Speaker:
H07599
BO-70
- BODYBACK WINDOW GLASS
1855 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE REAR SEAT (See page BO-120)
2. REMOVE ROOF SIDE INNER GARNISH
(a) Using a screwdriver, remove the roof side inner garnish.
HINT:
Tape the screwdriver tip before use.
(b) Employ the same manner described above to the other
side.
3. REMOVE HIGH-MOUNTED STOP LIGHT
Remove the high-mounted stop light as shown in the illustra-
tion, then disconnect the connector.
4. REMOVE PACKAGE TRAY TRIM
(a) Using a screwdriver, remove the 3 rear seat belt bezel.
HINT:
Tape the screwdriver tip before use.