TOYOTA AVENSIS 1999 Supplement

BO19D–01
V00005
Clip RemoverPliers
Screwdriver
Scraper Shape (Example) Removal/Installation
– BODYCLIP
BO–1
CLIP
REPLACEMENT
The removal and installation methods of typical clips used in body parts are shown in the table below.
HINT:
If the clip is damaged during the operation, always replace it with a new clip.

V00012
Removal Installation Shape (Example) Removal/Installation
Removal Installation BO–2
– BODYCLIP

BO0IO–04
I12751
Roof Headlining
Sun Visor Opening Trim
Holder Front Pillar Garnish

Windshield
Outside Moulding
Front Pillar Garnish Windshield Wiper Arm
N·m (kgf·cm, ft·lbf) : Specified torque

Non–reusable partWiper Arm
Sun Visor
20 (205, 15)
20 (205, 15)

Dam Inner Rear View Mirror
Cowl Louver Map Light Assembly
Cap
Hood to Cowl Top seal
Stopper
w/ Curtain shield air bag:
Front Pillar Garnish
w/ Curtain shield air bag:
Front Pillar Garnish
– BODYWINDSHIELD
BO–3
WINDSHIELD
COMPONENTS

BO2J0–01
H03507
: Clip
H11626
Pillar Garniush
Cover
2 Clips
I12491
H03502
BO–4
– BODYWINDSHIELD
REMOVAL
1. REMOVE THESE PARS
(a) Remove the front wiper arms.
(b) Remove the weatherstrip.
(c) Remove the cowl louver.
(d) Remove the sun visors and holders.
(e) Remove the map light assembly.
(f) Remove the assist grip.
(g) Remove the upper part of front door opening trims.
(h) w/ Curtain Shield Airbag:
(1) Using a screwdriver, raise the pillar garnish cover.
(2) Remove the bolt, pillar garnish cover and front pillar
garnish.
(3) Remove the 2 bolts.
(4) Pack the airbag with protection cover.
NOTICE:
Protection range is from instrument panel to ceiling.
(i) Remove the front pillar garnishes.
(j) Remove the inner rear view mirror.
(k) Remove the upper back panel hole No.1 cover.
2. REMOVE WINDSHIELD OUTSIDE UPPER MOULDING
Using a knife, cut off the moulding, as shown.
NOTICE:
Do not damage the body with the knife.

BO5232
BO1689
– BODYWINDSHIELD
BO–5
3. REMOVE WINDSHIELD GLASS
(a) Push piano wire through between the body and glass
from the interior.
(b) Tie both wire ends to a wooden block or similar object.
HINT:
Apply adhesive tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and exterior ornaments. To prevent scratching the
safety pad when removing the windshield, place a plastic
sheet between the piano wire and safety pad.
(c) Cut the adhesive by pulling the piano wire around it.
(d) Remove the glass.
NOTICE:
Leave as much of the adhesive on the body as possible
when cutting off the glass.

BO2J1–01
BO4420
Adhesive
H03504
9.7 mm
Stopper(0.38 in.)
BO5231
H03505
a
a – ab
ba
a
a
b – bAAlong Datam Line
BO–6
– BODYWINDSHIELD
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
(a) Using a knife, cut away any rough areas on the body.
HINT:
Leave as much of the adhesive on the body as possible.
(b) Clean the cutting surface of the adhesive with a shop rag
saturated in cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
2. REPLACE STOPPER
(a) Remove the damaged stopper.
(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 the stoppers to the glass with the ceramic notch on
the glass aligned with the stoppers, as shown in the il-
lustration.
3. CLEAN REMOVED GLASS
(a) Using a scraper, remove the adhesive sticking to the
glass.
(b) Clean the glass with cleaner.
NOTICE:
Do not touch the glass after cleaning it.
4. INSTALL DAMS
Install the dams with double – stick tape as shown in the illustra-
tion.
A: 7.0 mm (0.28 in.)
NOTICE:
Do not touch the glass surface after cleaning it.

BO2820
BO4421
H02865
Primer M
Adhesive
Primer M
N10230
Primer G
– BODYWINDSHIELD
BO–7
5. POSITION GLASS
(a) Place the glass in the correct position.
(b) Check that all contacting parts of the glass rim are perfect-
ly even.
(c) Place reference marks between the glass and body.
(d) Remove the glass.
6. 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.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER
”M”
Using a brush, coat Primer M to the exposed part of body on the
vehicle side.
NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not coat Primer M to the adhesive.
Do not keep any of the opened Primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER
”G”
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
(b) Before the primer dries, wipe it off with a clean shop rag.
NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use.

H03506
a – aa
a
B
BStopper
b – b
Dam c
c
b
b
A
DamA
A c – c
B
N08495
BO2821
BO–8
– BODYWINDSHIELD
9. 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.
A: 12.5 mm (0.472 in.)
B: 8.0 mm (0.315 in.)
10. INSTALL GLASS
HINT:
Check that the dam is attached the body panel as shown in the
illustration.
(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.
(b) Using a spatula, apply adhesive on the glass rim.

BO3986
BO3671AdhesiveAdhesive
H03503
H11626
Pillar Garnish
Cover
2 Clips
– BODYWINDSHIELD
BO–9
(c) Use a scraper to remove any excessive or protruding
adhesive.
(d) Hold the windshield glass in place securely with protec-
tive tape or equivalent until the adhesive hardenes.
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
11. INSPECT FOR LEAKAGE AND REPAIR
(a) Do a leak test after the hardening time has elapsed.
(b) Seal any leakage with sealant.
Part No. 08833–00030 or equivalent
12. APPLY ADHESIVE AT MOULDING INSTALLATION
AREA
Coat the glass with adhesive at the moulding installation area.
Part No. 08833–00030 or equivalent
13. INSTALL WINDSHIELD MOULDING
Place the moulding onto the body and tap it by hand.
14. INSTALL THESE PARTS:
(a) Install the front part of roof headlining.
(b) Install the inner rear view mirror
(c) w/ Curtain Shield Air Bag:
(1) Remove the protection cover.
(2) Install the 2 bolts.
Torque: 5 N·m (51 kgf·cm, 44 in.·lbf)
(3) Install the front pillar garnish.
(4) Install the pillar garnish cover and bolt.
NOTICE:
Be sure to tighten the bolt.
(5) Fell the pillar garnish cover.
(d) Install the front pillar garnishes.