TOYOTA AVENSIS 2003 Service Repair Manual

B67051
A ± AC ± C
B ± B
c
Backside
f
e
d
A
C A
C B
B
b
a
: Primer G
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
70±37
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
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.
Standard dimension:
a10.2 mm (0.402 in.)
b23.7 mm (0.933 in.)
c9.1 mm (0.358 in.)
d11.0 mm (0.433 in.)
e14.0 mm (0.551 in.)
f11.0 mm (0.433 in.)
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B67053
aa
bb d
c
e
A ± A
B ± B
A
B
C A
B
Backside
C C ± C
: Adhesive
70±38
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Apply adhesive. Adhesive: Part No. 08850±00801 or equivalent
(1) Cut off the tip of the cartridge nozzle, as shown inthe illustration.
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the table below. Tackfree time:
TemperatureTackfree Time
35
C (95
F)15 minutes
20
C (68
F)1 hour 40 minutes
5
C (41
F)8 hours
(2) Load the sealer gun with the cartridge.
(3) Coat the glass with adhesive, as shown in the il-
lustration.
Standard dimension:
a12.0 mm (0.472 in.)
b8.0 mm (0.315 in.)
c14.2 mm (0.559 in.)
d30.7 mm (1.209 in.)
e13.1 mm (0.516 in.)
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BO3986
Adhesive
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (LIFTBACK MODELS)
70±39
AVENSIS REPAIR MANUAL (RM1018E)
(e) Install the glass to the body.
(1) Hold the back window glass in place securely withtape or equivalent to the body until the adhesive has
hardened.
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.
(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
7. INSPECT FOR LEAKS AND REPAIR
(a) Conduct a leak test after the adhesive has completely hardened.
(b) Seal any leaks with auto glass sealer.
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700T9±01
B67062
Back Door Trim Panel Assy Upper
Back Door Side Garnish RH Back Door Side Garnish LH Back Door Trim Board
Rear Spoiler

Back Door Glass
Wiper Motor Assy Rear Wiper Arm Assy
Wiper Arm Head Cap
: Specified torqueN

m (kgf
cm, ft
lbf)

Non±reusable part
5.5 (56, 49 in.
lbf)
5.5 (56, 49 in.
lbf)
70±40
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR GLASS (WAGON MODELS)
COMPONENTS
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700TA±01
B68025
Clip
Piano Wire
B69236
Protective Tape
BO4421
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (WAGON MODELS)
70±41
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 BACK DOOR TRIM BOARD ASSY (See page 75±45)
(a) Remove the back door trim panel upper.
(b) Remove the back door side garnish LH.
(c) Remove the back door side garnish RH.
(d) Remove the back door trim board.
2.REMOVE REAR SPOILER (See page 76±30)
3.REMOVE REAR WIPER MOTOR ASSY (See page 66±17)
(a) Remove the wiper arm head cap.
(b) Remove the rear wiper arm.
(c) Remove the wiper motor.
4. REMOVE BACK DOOR GLASS
(a) Pass a piano wire between the body and glass from theinterior.
(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 interior and exterior ornaments.
(c) Cut off the adhesive by pulling the piano wire around it.
(d) Using a suction rubber, remove the glass.
NOTICE:
Leave as much adhesive on the body as possible when re-
moving the glass.
5. CLEAN BACK DOOR GLASS
(a) 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.
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Adhesive
Adhesive
BO4420Body
B67835
Primer M
Primer M
AdhesiveCORRECT
WRONG
: Primer M
70±42
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
6. INSTALL BACK DOOR 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 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 pieceof 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.
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B67050
ab
A ± A
C ± C
B ± B
Backside
d
e
A
c
C
B
f
A
C B
: Primer G
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (WAGON MODELS)
70±43
AVENSIS REPAIR MANUAL (RM1018E)
(c) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
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.
Standard dimension:
a5.1 mm (0.201 in.)
b20.4 mm (0.512 in.)
c6.4 mm (0.252 in.)
d11.0 mm (0.433 in.)
e14.0 mm (0.551 in.)
f11.0 mm (0.433 in.)
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B67052
Backside: Adhesive a
b A ± A
C ± C
B ± B
d
e
A
c
C B
A
C B
b
a
70±44
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (WAGON MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
(d) Apply adhesive. Adhesive: Part No. 08850±00801 or equivalent
(1) Cut off the tip of the cartridge nozzle, as shown inthe illustration.
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the table below. Tackfree time:
TemperatureTackfree Time
35
C (95
F)15 minutes
20
C (68
F)1 hour 40 minutes
5
C (41
F)8 hours
(2) Load the sealer gun with the cartridge.
(3) Coat the glass with adhesive, as shown in the il-
lustration.
Standard dimension:
a12.0 mm (0.472 in.)
b8.0 mm (0.315 in.)
c12.1 mm (0.476 in.)
d27.4 mm (1.079 in.)
e13.4 mm (0.528 in.)
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BO3986
Adhesive
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK DOOR GLASS (WAGON MODELS)
70±45
AVENSIS REPAIR MANUAL (RM1018E)
(e) Install the glass to the body.
(1) Hold the back window glass in place securely withtape or equivalent to the body until the adhesive has
hardened.
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.
(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
7. INSPECT FOR LEAKS AND REPAIR
(a) Conduct a leak test after the adhesive has completely hardened.
(b) Seal any leaks with auto glass sealer.
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700T5±01
B67036
Assist Grip
Roof Headlining Assy
Back Window Glass Stopper No. 2
Back Window Moulding Outside Upper
Center Stop Lamp Assy Roof 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/MIRROR BACK WINDOW GLASS (SEDAN MODELS)
70±27
AVENSIS REPAIR MANUAL (RM1018E)
BACK WINDOW GLASS (SEDAN MODELS)
COMPONENTS
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