TOYOTA AVENSIS 2003 Service Repair Manual

700T6±01
B50453
CutCut
B62805
Stopper
Piano Wire
70±28
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK WINDOW GLASS (SEDAN MODELS)
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 REAR SEAT CUSHION ASSY (See page 72±27 or 72±32)
2.REMOVE REAR SEATBACK ASSY (See page 72±27 or 72±32)
3.REMOVE ROOF HEADLINING ASSY (See page 76±36)
(a) Remove the rear door weatherstrip LH.
(b) Remove the rear door weatherstrip RH.
(c) Remove the roof side garnish inner LH.
(d) Remove the roof side garnish inner RH.
(e) Remove the 2 assist grips.
(f) Remove the rear map lamp.
(g) Remove the roof headlining assy.
4.REMOVE CENTER STOP LAMP ASSY (See page 65±26)
5.REMOVE PACKAGE TRAY TRIM PANEL ASSY (See page 61±15) 6. REMOVE BACK WINDOW MOULDING OUTSIDEUPPER
(a) Using a knife, cut off the moulding, as shown in the il- lustration.
NOTICE:
Do not damage the vehicle body with the knife.
(b) Remove the remaining moulding.
HINT:
When removing, make a partial cut, then pull and remove it by
hand.
7. REMOVE BACK WINDOW 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.
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B64495Protective Tape
BO5231
B62806
B
AA Ceramic Notch
Backside
B63758
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK WINDOW GLASS (SEDAN MODELS)
70±29
AVENSIS REPAIR MANUAL (RM1018E)
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 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 BACK WINDOW 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.
9. INSTALL BACK WINDW 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.)
B11.3 mm (0.445 in.)
10. INSTALL BACK WINDOW GLASS STOPPER NO.1
(a) Install 2 new stoppers to the vehicle body, as shown in theillustration.
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B67816
Backside
A ± A
A A a
Adhesive
Adhesive
BO4420Body
70±30
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK WINDOW GLASS (SEDAN MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
11. INSTALL BACK WINDOW MOULDING OUTSIDE UPPER
(a) Using a brush or sponge, coat the edge of the glass and the contact surf\
ace with Primer G.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Do not coat the adhesive with Primer G.

Do not keep any of the opened Primer G for later use.
(b) Install the moulding.
12. INSTALL BACK WINDOW GLASS ADHESIVE DAM
(a) Coat the installation part of the back window glass adhesive dam with Pr\
imer G.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Do not apply too much primer.
(b) Install a new dam, applying double±sided tape all the way around the glass e\
xcept where the dam is installed, as shown in the illustration
Standard dimension (a) : 14.0 mm (0.551 in.)
13. INSTALL BACK WINDOW 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 vehicle body to ensure the
appropriate surface shape.
HINT:
Leave as much adhesive on the vehicle body as possible. (2) Clean the contact surface of the vehicle body with
a piece of shop rag saturated with cleaner.
HINT:
Even if all the adhesive has been removed, clean the vehicle
body.
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B64130
Mark
B67820
Primer M
Primer M
AdhesiveCORRECT
WRONG
Primer M
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK WINDOW GLASS (SEDAN MODELS)
70±31
AVENSIS REPAIR MANUAL (RM1018E)
(b) Position the glass.
(1) Using a suction cup, place the glass in the correctposition.
(2) Check that the whole contact surface of the glass rim is perfectly even.
(3) Place reference marks between the glass and ve- hicle body.
NOTICE:
Check that the stoppers are attached to the vehicle body
correctly.
HINT:
When reusing the glass, check and correct the reference mark
positions. (4) Remove the glass.
(c) Using a brush, coat the exposed part of the vehicle body 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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B67039
Primer G
Primer G a
a
b
a ± a
c ± c
c
b
b ± b c
b
b
Backside
Primer G
B67040
B
A
B
a a
d
b
b c
A ± A
C ± C
B ± B
B
b
b C
Backside
B
A
B
Ca
a
d
B64131
70±32
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK WINDOW GLASS (SEDAN MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
(d) 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.
(e) 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
35C (95 F)15 minutes
20C (68 F)1 hour 40 minutes
5C (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:
a12.5 mm (0.492 in.)
b8.0 mm (0.315 in.)
c21.0 mm (0.827 in.)
d6.5 mm (0.226 in.)
(f) Install the glass. (1) Using a suction cup, position the glass so that thereference marks are aligned, and press it in gently
along the rim.
NOTICE:

Allow the primer coating to dry for 3 minutes or more.

Check that the stoppers are attached to the vehicle
body correctly.
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BO3986
Adhesive
N08495
Adhesive
WindshieldDam
±
WINDSHIELD/WINDOWGLASS/MIRROR BACK 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.
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700TJ±01
B56435
Slide
B61414
Slide
B66957
Butyl TapeMirror Base
a
b
c
d
70±64
±
WINDSHIELD/WINDOWGLASS/MIRROR INNER REAR VIEW MIRROR ASSY
AVENSIS REPAIR MANUAL (RM1018E)
INNER REAR VIEW MIRROR ASSY
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 INNER REAR VIEW MIRROR ASSY(EC MIRROR)
(a) Remove the inner rear view mirror cover.
(b) Remove the rain sensor covers (See page XX±XXX).
(c) Remove the screw.
(d) Disconnect the connector.
(e) Remove the rear view inner mirror.
2. REMOVE INNER REAR VIEW MIRROR ASSY (NORMAL MIRROR)
(a) Remove the inner rear view mirror, as shown in the il- lustration.
3. INSTALL INNER REAR VIEW MIRROR ASSY (NORMAL MIRROR)
(a) Prepare 2 pieces of butyl tape having the dimensions, as
shown in the illustration.
(b) While extending them until they fit the length of the mirror base (24 mm, (0.944 in.)), apply them to both side of the
mirror base respectively.
(c) Install inner rear view mirror.
NOTICE:
If butyl tape spreads out of the inside groove when applied,
remove the excessive amount of tape so that it will not stick
to the glass. Dimension:
a10 mm (0.393 in.)
b4 mm (0.157 in.)
c6 mm (0.236 in.)
d24 mm (0.944 in.)
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700TI±01
B68929
B68929
±
WINDSHIELD/WINDOWGLASS/MIRROR OUTER REAR VIEW MIRROR ASSY LH
70±65
AVENSIS REPAIR MANUAL (RM1018E)
OUTER REAR VIEW MIRROR ASSY LH
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 FRONT DOOR HOLE COVER SUB±ASSY NO.1 LH (See page 75±8)
(a) Remove the front door lower frame bracket garnish.
(b) Remove the front door trim base.
(c) Only driver side: Remove the fuel lid opener switch.
(d) w/ Power window: Remove the power window regulator switch.
(e) Remove the front door trim board sub.
(f) Remove the front door inside handle.
(g) remove the front service hole cover No. 1.
2. REMOVE OUTER REAR VIEW MIRROR ASSY LH
(a) Disconnect the connector.
(b) Remove the 3 screws and mirror .
3. INSTALL OUTER REAR VIEW MIRROR ASSY LH
(a) Install the mirror with the 3 screws.Torque: 10 N
m (102 kgf
cm, 7 ft
lbf)
(b) Connect the connector.
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700TE±01
B54715
Switch
Position(A) (B)
Retract ed
Position Driving
Position
B54716
Switch
Position
(A) (B)
Forward
Position
Retract ed
Position
(3)
Retracted
PositionDriving
Position
(4)
B54717
Switch
Position
(A) (B)
Retract ed
Position Driving
Position
Retract ed
Position
(1)
(3)
±
WINDSHIELD/WINDOWGLASS/MIRROR POWER MIRROR CONTROL SYSTEM
70±55
AVENSIS REPAIR MANUAL (RM1018E)
POWER MIRROR CONTROL SYSTEM
ON±VEHICLE INSPECTION
1. OPERATIONAL INSPECTION ELECTRICALLY±RE-
TRACT DOOR MIRROR OPERATION
(a) Turn the ignition switch to the ACC position.
(b) At each position of the outer mirror body, check the opera- tion when operating the retract switch of the outer mirror.
(c) Check the outer mirror operation, as shown in the illustra- tion.
(1) Push the retract switch from the (A) position to the
(B) position.
(2) Check that the right and left mirrors move from the driving position to the retracted position.
(d) Check the outer mirror operation, as shown in the illustra- tion.
(1) Move one of the mirrors to the forward position byhand.
(2) Push the retract switch from the (A) position to the
(B) position.
(3) Check that the mirror moves from the forward posi- tion to the retract position.
(4) Check that the other mirror moves from the driving position to the retracted position.
(e) Check the outer mirror operation, as shown in the illustra- tion.
(1) Move one of the mirrors to the retracted position byhand.
(2) Push the retract switch from the (A) position to the (B) position.
(3) Check that the other mirror moves from the driving position to the retracted position.
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B54718
Switch
Position(A)
(B)
Retract ed
Position
Driving
Position
B54719
Switch
Position
(A)
(B)
Retracted
Position Driving
Position
Driving
Position
(3)
(1)
70±56
±
WINDSHIELD/WINDOWGLASS/MIRROR POWER MIRROR CONTROL SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(f) Check the outer mirror operation, as shown in the illustra- tion.
(1) Push the retract switch from the (B) position to the(A) position.
(2) Check that the right and left mirrors move from the retracted position to the driving position.
(g) Check the outer mirror operation, as shown in the illustra- tion.
(1) Move one of mirrors to the driving position by hand.
(2) Push the retract switch From the (A) position to the
(B) position.
(3) Check that the other mirror moves from the re-
tracted position to the driving position.
(h) Check operation of the outer mirror body when the igni- tion switch is turned OFF during operation.
(1) When turning the ignition switch OFF during opera-tion of the mirror body, check that the mirror body
operation stops.
(2) Check that the mirror body continues to operate when the ignition switch is turned to ACC again.
HINT:
If the retract switch is switched while the ignition switch is OFF
and the ignition switch is turned to ACC again, the mirror body
will operate in the opposite direction.
(i) Check operation of the outer mirror body when it is re-
strained by an obstacle.
(1) Check that operation stops when restraining themirror body movement by hand while the mirror
body is moving to the retraced position or the driving
position.
(2) Switch the retract switch under the above condition, and check that the mirror body starts operation
again to the opposite direction.
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