TOYOTA AVENSIS 2002 Repair Manual

B58558
Up
Down
12 3
456
B690245
21
35
3
2 1
70±10
± WINDSHIELD/WINDOWGLASS/MIRRORPOWER WINDOW CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(4) Check that the door glass goes down when the
power window regulator switch is pushed DOWN.
If the result is not as specified, replace the regulator sub±assy.
6. INSPECT REAR DOOR WINDOW REGULATOR
SUB±ASSY RH
(a) Inspect operation of the power window regulator.
(1) Apply battery voltage to the connector terminals.
(2) Check that the regulator smoothly operates.
Standard:
Measurement ConditionSpecified Condition
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
2Regulator moves upward
Battery positive (+)
6
Battery negative (±)
4Battery positive (+)
1Regulator moves
downward
(b) Inspect operation of the PTC inside the power window
regulator motor.
NOTICE:
The work must be performed with the power window regu-
lator and door glass installed in the vehicle.
(1) Set a electrical tester DC 400 A probe to the wire
harness of terminal 4 or 6.
NOTICE:
Match the arrow mark of the probe with the current direc-
tion.
(2) Fully close the door glass by operating the power
window switch and keep the door glass there for
approximately 60 seconds.
(3) Try to operate the power window past the fully
closed position using the power window switch and
measure the time until the electrical current
changes into 1 A from 16 to 34 A (Inspection of cur-
rent shut±off).
Standard: Less than 1 second
(4) Check that the door glass goes down when the
power window regulator switch is pushed DOWN.
If the result is not as specified, replace the regulator sub±assy.
7. INSPECT IG1 RELAY
(a) Check resistance of the relay.
Standard:
Tester ConnectionSpecified Condition
10 kor higher
3 ± 5Below 1 
(When battery voltage is applied to terminals 1 and 2)
If the result is not as specified, replace the relay.

B66773
DADBDN
Vehicle Front Side Vehicle Rear Side
DB
DA
DHDC
DN
DC
DH
Integration Relay
± WINDSHIELD/WINDOWGLASS/MIRRORPOWER WINDOW CONTROL SYSTEM
70±11
AVENSIS REPAIR MANUAL (RM1018E)
8. INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSY (INTEGRATION RELAY)

B58556
Front Door
Courtesy Lamp
Switch
Pushed Free
Body Ground
70±12
± WINDSHIELD/WINDOWGLASS/MIRRORPOWER WINDOW CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(a) Disconnect the DA, DB, DC, DH and DN J/B connectors.
(b) Check the voltage and resistance between each terminal of the wire harness side connectors and the
body ground.
Standard:
Tester ConnectionConditionSpecified Condition
DA±8 ± Body groundNo key inserted in ignition key cylinder
Ye s10 k
or higher
Below 1

DA±9 ± Body groundConstantBelow 1

B±13 ± Body groundDriver side door CLOSED
OPEN10 k
or higher
Below 1

DC±9 ± Body groundPassenger side door CLOSED
OPEN10 k
or higher
Below 1

DH±5 ± Body groundIgnition switch ON
Others10 to 14 V
0 V
DN±1 ± Body groundConstant10 to 14 V
If the result is not as specified, there may be a malfunction on the wire harness side or the J/B assy (integra-
tion relay) may have a malfunction.
(c) Reconnect the DA, DB, DC, DH and DN J/B connectors.
(d) Check the voltage of terminal 5 of the DH connector.
Standard:
Tester ConnectionConditionSpecified Condition
DH±5 ± Body groundIgnition switch ON
Others10 to 14 V
0 V
If the result is not as specified, there may be a malfunction on the wire harness side or the J/B assy (integra-
tion relay) may have a malfunction.
9. INSPECT FRONT DOOR COURTESY LAMP SWITCH
ASSY
(a) Remove the courtesy lamp switch.
(b) Check the switch resistance.
Standard:
Tester ConnectionSwitch PositionSpecified Condition
1 Body groundSwitch pushed10 k
or higher1 ± Body groundSwitch freeBelow 1

If the result is not as specified, replace the switch assy.

700SB±01
± WINDSHIELD/WINDOWGLASS/MIRRORPOWER WINDOW CONTROL SYSTEM
70±13
AVENSIS REPAIR MANUAL (RM1018E)
RESET
NOTICE:

The power window regulator motor must be reset when the fitting of the door glass is adjusted
or when the door glass run is replaced.

Whenever disconnecting the battery terminal, reset all the other systems besides the power
window control system.
1. RESET WINDOW REGULATOR SUB±ASSY (REGULATOR MOTOR)
(a) Turn the ignition switch ON.
(b) Operate the power window using the master (regulator) switch.
(c) Disconnect the battery, fuse or motor connector while the power window is operating, so that the power
window motor is forced to stop.
(d) Reconnect the battery, fuse or motor connector.
(e) Pull up the power window switch until the power window is fully closed and hold the switch at least 1
second.
(f) Check that the AUTO UP/DOWN function operates completely.

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

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.

700TB±01
B67064
LHD Models
Defogger Wire
Liftback
Wagon
Defogger Wire
Defogger Wire
Hazard Warning Signal Switch Assy w/ Deicer:
FR DEICER Relay
Fuse Block Assy
w/ Deicer:
FR DIC Fuse
w/ Mirror Heater:
MIR HTR Fuse
Passenger Side R/B Assy
w/ Mirror Heater:
Outer Rear View Mirror Assy RH
w/ Mirror Heater:
Outer Rear View
Mirror Assy LH
Rear Window
Defogger Relay
70±46
± WINDSHIELD/WINDOWGLASS/MIRRORWINDOW DEFOGGER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
WINDOW DEFOGGER SYSTEM
LOCATION