SOLAR ROOF INSTALLATION

PROCEDURE


  1. CLEAN ROOF WINDOW GLASS


    1. When reusing the roof window glass:


      1. B006ICM

        Using a scraper, remove any remaining double-sided tape and adhesive residue from the roof window glass.

        Note

        Be careful not to damage the roof window glass.

  2. INSTALL UPPER ROOF WINDOW MOULDING


    1. Clean the installation area of the upper roof window moulding on the roof window glass with a non-residue solvent.

    2. Apply primer G to the installation area of the upper roof window moulding on the roof window glass.

    3. Apply new double-sided tape to the installation area of the upper roof window moulding on the roof window glass.

      Note

      Make sure to apply the double-sided tape only after the primer G has dried.

    4. Without touching the contact surface of the double-sided tape, remove the release paper and install a new upper roof window moulding to the roof window glass at the position shown in the illustration.

      A003KECC02
      *A Back Side - -

  3. INSTALL LOWER ROOF WINDOW MOULDING PROTECTOR


    1. Clean the installation area of the lower roof window moulding protector on the roof window glass with a non-residue solvent.

    2. Apply primer G to the installation area of the lower roof window moulding protector on the roof window glass.

    3. A003NIMC01
      *A Back Side
      B006IOI Lower Roof Window Moulding Protector

      Without touching the contact surface of the double-sided tape, remove the release paper and install 2 new lower roof window moulding protectors to the roof window glass at the position shown in the illustration.

      Standard Dimension
      Area Dimension
      a 2.0 mm (0.0787 in.)

      Note

      Make sure to install the lower roof window moulding protector only after the primer G has dried.

  4. INSTALL ROOF WINDOW CLIP


    1. When reusing the roof window glass:


      1. A003N4SC01
        *a Release Paper
        B006IOI Adhesive Application Area

        Clean the adhesive application area of the roof window clip with a non-residue solvent.

      2. Apply an appropriate primer to the adhesive application area of roof window clip.

      3. Apply adhesive to the position shown in the illustration.

        Note

        Make sure to apply adhesive only after the primer has dried.

      4. Clean the installation area of the roof window clip on the roof window glass with a non-residue solvent.

      5. Apply primer G to the installation area of the roof window clip on the roof window glass.

      6. A003OEDC02
        *A Back Side
        *a Matchmark

        Without touching the contact surface of the double-sided tape, remove the release paper and install the roof window clip to the roof window glass at the positions shown in the illustration.

        Note

        Make sure to install the roof window clip only after the primer G has dried.

  5. INSTALL SIDE ROOF WINDOW CLIP

    Tech Tips

    Use the same procedure as for the roof window clip.

  6. INSTALL NO. 1 ROOF WINDOW GLASS SUB-ASSEMBLY


    1. Clean and shape the contact surface of the vehicle body.


      1. A003OZJC02
        *a Vehicle Body
        B006IOI Adhesive

        If the adhesive remaining on the vehicle is considerably uneven, smooth it using a knife.

        Standard Dimension
        Area Dimension
        a 1.0 mm (0.0394 in.) or more

        Note

        Make sure to leave a small amount of adhesive on the vehicle body to protect the vehicle from damage and for reference when applying adhesive again.

      2. Clean the contact surface of the vehicle body with a piece of cloth saturated with non-residue solvent.

    2. Apply Primer M to the exposed parts of the vehicle body (where there is no remaining adhesive).

      Note


      • Do not apply primer M to the adhesive.

      • Be careful when applying primer M to the panel joints and spot welds.

    3. When reusing the roof window glass:


      1. Apply primer G to the to the position shown in the illustration on the roof window glass using the remaining adhesive as a guide.

        A003KCOC01
        *A Back Side - -
        B006IOI Primer G - -
        Standard Dimension
        Area Dimension
        a 15.0 mm (0.591 in.) or more

    4. When using a new roof window glass:


      1. Apply primer G to the No. 1 roof window glass sub-assembly at the position shown in the illustration.

        A003O24C02
        *A Back Side - -
        *a Adhesive Positioning Center *b Ceramic Notch
        B006IOI Primer G - -
        Standard Dimension
        Area Dimension
        a 15.0 mm (0.591 in.) or more
    5. A003MB2C84
      *a Sealer Gun
      *b Nozzle

      Cut off the tip of the cartridge nozzle as shown in the illustration.

      Standard Dimension
      Area Dimension
      a 12.0 to 15.0 mm (0.472 to 0.591 in.)
      b 8.0 to 11.0 mm (0.315 to 0.433 in.)

    6. Load the sealer gun with the cartridge.

    7. Apply a bead of adhesive to the position shown in the illustration using the remaining adhesive as a guide.

      A003OIAC01
      *A Vehicle Body Upper Side - -
      B006IOI Adhesive - -
      Adhesive
      Toyota Genuine Windshield Glass Adhesive or equivalent

      Note

      Make sure to apply adhesive only after the primer M has dried.

    8. When reusing the roof window glass:


      1. Apply a bead of adhesive to the position shown in the illustration on the roof window glass using the remaining adhesive as a guide.

        A003NHOC01
        *A Back Side - -
        B006IOI Adhesive - -
        Adhesive
        Toyota Genuine Windshield Glass Adhesive or equivalent

        Note

        Make sure to apply adhesive only after the primer G has dried.

    9. When using a new roof window glass:


      1. Apply a bead of adhesive to the No. 1 roof window glass sub-assembly at the position shown in the illustration.

        A003P13C02
        *A Back Side - -
        *a Adhesive Positioning Center *b Ceramic Notch
        B006IOI Adhesive - -
        Adhesive
        Toyota Genuine Windshield Glass Adhesive or equivalent
        Standard Dimension
        Area Dimension
        a 8.4 mm (0.331 in.)
        b 8.0 mm (0.315 in.)
        c 8.0 mm (0.315 in.)

        Note

        Make sure to apply adhesive only after the primer G has dried.

    10. Install the No. 1 roof window glass sub-assembly.


      1. A003O6BE02

        Install 2 SST to the 2 roof window clips of the No. 1 roof window glass sub-assembly by hand as shown in the illustration.

        SST
        09802-47010

      2. Using suction cups, align the end of SST with the insertion hole of the roof window clip and SST as shown in the illustration and engage the 2 roof window clip to install the No. 1 roof window glass sub-assembly.

        A003MGPC02
        *a Insertion Hole of Roof Window Clip and SST - -
        B006IFV Install in this Direction - -

        Note

        Make sure to install the No. 1 roof window glass sub-assembly only after the primer M on the vehicle body has dried.

      3. A003LW4C01
        B006J86 Push here

        Lightly push the No. 1 roof window glass sub-assembly at the position shown in the illustration from the outside of the vehicle so that it is in full contact with the vehicle body.

      4. A003KQ1E02

        Remove 2 SST.

      5. Using a scraper, remove any excess or protruding adhesive.

        Note

        Remove any excess or protruding adhesive before it becomes hard.

        Minimum Time
        Temperature Minimum Time Prior to Driving Vehicle
        35°C (95°F) 7 hours
        20°C (68°F) 12 hours
        5°C (41°F) 54 hours

    11. Install the 4 nuts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    12. Turn back the curtain shield airbag assembly LH and install the earth wire with the bolt.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    13. Connect the connector.

  7. INSPECT FOR LEAK


    1. After the adhesive has hardened, apply water from the outside of the vehicle and check that no water leaks into the cabin.

    2. If water leaks into the cabin, allow the water to dry and add adhesive.

    3. Remove the protective tape and adhesive tape.

  8. INSTALL ROOF PANEL SUPPORT LH


    1. Install the roof panel support LH with the bolt and nut.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  9. INSTALL ROOF PANEL SUPPORT RH

    Tech Tips

    Use the same procedure as for the LH side.

  10. INSTALL CENTER ROOF DRIP SIDE FINISH MOULDING LH

    Click here

  11. INSTALL CENTER ROOF DRIP SIDE FINISH MOULDING RH

    Tech Tips

    Use the same procedure as for the LH side.

  12. INSTALL WINDSHIELD OUTSIDE MOULDING LH

    Click here

  13. INSTALL WINDSHIELD OUTSIDE MOULDING RH

    Tech Tips

    Use the same procedure as for the LH side.

  14. INSTALL ROOF HEADLINING ASSEMBLY

    Click here

  15. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here