TOYOTA AVENSIS 2005 Service Repair Manual

BO4421
Adhesive
Adhesive
BO4420Body
B67821
Primer M
Primer M
AdhesiveCORRECT
WRONG
: Primer M 70±36
± WINDSHIELD/WINDOWGLASS/MIRRORBACK DOOR GLASS (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
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.
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 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.

B67051
A ± A
C ± C B ± B
c Backside
f ed
A
CA
CB
B
b a
: Primer G
± WINDSHIELD/WINDOWGLASS/MIRRORBACK 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.)

B67053
a
a bbd c
e A ± A
B ± B A
B
CA
B Backside
CC ± C
: Adhesive 70±38
± WINDSHIELD/WINDOWGLASS/MIRRORBACK 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 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
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.)

BO3986
Adhesive
± WINDSHIELD/WINDOWGLASS/MIRRORBACK 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 with
tape 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.

700T7±01
B67059
Back Door Side Garnish RH
Center Stop Lamp Assy
Back Door Trim Board
Back Door Side Garnish LH Back Door Trim
Panel Assy Upper
Wiper Arm Head Cap
Rear Wiper Arm Assy
Wiper Motor Assy
Back Door Glass
: Specified torque
N
m (kgf
cm, ft
lbf)

Non±reusable part
5.5 (56, 49 in.
lbf)5.5 (56, 49 in.
lbf)
5.5 (56, 49 in.
lbf)
70±34
± WINDSHIELD/WINDOWGLASS/MIRRORBACK DOOR GLASS (LIFTBACK MODELS)
AVENSIS REPAIR MANUAL (RM1018E)
BACK DOOR GLASS (LIFTBACK MODELS)
COMPONENTS

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 SE AT CUSHION ASSY ( See page 72±27 or 72±32 )
2 . REMOVE REAR SE ATBACK 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 S TOP LAMP ASSY ( See page 65±26)
5 . REMOVE P ACKAGE TR AY TRIM P ANEL ASSY ( See page 61±15 )
6. REMOVE BACK WINDOW MOULDING OUTSIDE UPPER
(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.

B64495Protective Tape
BO5231
B62806
B
A ACeramic Notch
Backside
B63758
± WINDSHIELD/WINDOWGLASS/MIRRORBACK 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 the
illustration.

B67816
Backside
A ± A
A
Aa
Adhesive
Adhesive
BO4420Body
70±30
± WINDSHIELD/WINDOWGLASS/MIRRORBACK 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 surface 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 Primer 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 except 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.

B64130
Mark
B67820
Primer M
Primer M
AdhesiveCORRECT
WRONG
Primer M
± WINDSHIELD/WINDOWGLASS/MIRRORBACK WINDOW GLASS (SEDAN MODELS)
70±31
AVENSIS REPAIR MANUAL (RM1018E)
(b) Position the glass.
(1) Using a suction cup, place the glass in the correct
position.
(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.

B67039
Primer G
Primer Ga
a
b
a ± a
c ± c
c b
b ± bcb
b Backside
Primer G
B67040
B A
B
aa d
b
b
c A ± A
C ± C B ± B B
b bC Backside
B A
B
C
a
a d
B64131
70±32
± WINDSHIELD/WINDOWGLASS/MIRRORBACK 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 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.)
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 the
reference 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.