Installation

SLIDING ROOF / CONVERTIBLE: ROOF DRIVE MOTOR: INSTALLATION

1. APPLY NON-SILICONE GREASE

(a) Apply non-silicone grease to the moving parts of the sliding roof drive gear assembly LH.

2. INSTALL SLIDING ROOF DRIVE GEAR ASSEMBLY LH

(a) Remove the bolts and clean the bolt holes with non-residue solvent.

(b) Apply Toyota genuine adhesive 1324, Three Bond 1324, or equivalent to the threads of the bolts.

(c) Using socket hexagon wrench 6, install the sliding roof drive gear assembly LH with the 3 bolts.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

(d) Connect the connector.

3. TEMPORARILY TIGHTEN NO. 2 ROOF PANEL STRENGTH SUB-ASSEMBLY Installation

4. SET ROOF PANEL STRENGTH SUB-ASSEMBLY

(a) Manually move the roof panel strength sub-assembly to the position shown in the illustration.

5. INSTALL REAR SLIDE ROOF PANEL SUB-ASSEMBLY Installation

6. TEMPORARILY TIGHTEN FRONT SLIDE ROOF PANEL SUB-ASSEMBLY Installation

7. INSPECT FITTING OF FRONT SLIDE ROOF PANEL SUB-ASSEMBLY

(a) Check that the removable roof locks are released.

(b) If necessary, use a 5 mm hexagon wrench to turn the sliding roof drive gear sub-assembly counterclockwise to release the locks.

NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will release when the wrench is turned approximately 360 degrees.

(c) Fully close the front slide roof panel sub-assembly manually.

NOTICE:
* Perform this operation using 2 persons.
* Synchronize the movement of the left and right sides of the roof panels when moving them.

HINT
Slowly close the roof panels while checking that the guide pins on the roof panel and the sockets on the pillars are aligned.

(d) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly clockwise to engage the lock of the rear slide roof panel sub-assembly.

(f) Check that the eccentric bolt lightly contacts the bottom edges of the engaged U-hooks at location *b shown in the illustration.

Text in Illustration

HINT
If the contact is not as indicated, loosen the lock bolt, adjust the eccentric bolt, and then tighten the lock bolt.

Torque : 15.5 Nm (158 kgf-cm, 11 ft-lbf)

(g) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly clockwise to engage the locks of the front slide roof panel sub-assembly.

NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will engage when the wrench is turned approximately 360 degrees.

(h) Unlock the locks and check the fit of the guide pins.

HINT
The fit can be adjusted using the removable roof auxiliary catch assembly Installation.

(i) Measure the clearance between the front header and front slide roof panel sub-assembly (A), and then make the adjustment for the lengthwise direction.

(j) Remove the 4 centering bolts from the roof. Using a T40 "TORX" socket wrench, tighten the front slide roof panel assembly and rear slide roof panel assembly with the 4 screws.

Torque : 40 Nm (408 kgf-cm, 29 ft-lbf)

(k) Tighten the adjustment screw so that the clearance between the roof panel strength assembly and adjustment screw is the standard value of 0 mm (0 in.), then turn the adjustment screw a further 90° and tighten the lock bolt to lock the adjustment screw.

Standard Clearance:

0 mm (0 in.)

Text in Illustration

(l) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly counterclockwise to release the locks of the front slide roof panel sub-assembly.

NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will release when the wrench is turned approximately 360 degrees.

(m) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly clockwise to close the lock while measuring the roof lock stroke (C). C (Roof lock stroke) = A - B

Standard:

1.5 mm (0.059 in.)

HINT
* If the roof lock stroke (C) is not within the specified range, adjust it by turning the adjustment screw of the roof panel strength sub-assembly. Loosen the lock screw before turning the adjustment screw.
* When tightening the adjustment screw of the roof panel strength sub-assembly, the distance (A) between the front header and the front slide roof panel sub-assembly will become larger, and when loosening it, the distance (A) will become smaller.
* After the adjustment, tighten the lock screw.

(n) Check the metal top movement.

(1) Apply approximately 200 N (20 kgf, 45 f) of force to part A in the direction shown in the illustration, and measure the amount of roof panel movement at location B.

Standard:

Less than 1.0 mm (0.039 in.)

HINT
* If the roof panel movement is not within the specified range, turn the adjustment screw on the roof panel strength sub-assembly to adjust the amount of movement. Loosen the lock screw before turning the adjustment screw.
* When tightening the adjustment screw of the roof panel strength sub-assembly, the distance (A) between the front header and the front slide roof panel sub-assembly will become larger, and when loosening it, the distance (A) will become smaller.
* After the adjustment, tighten the lock screw.

(o) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly counterclockwise to release the lock of the rear slide roof panel sub-assembly.

NOTICE:
* Perform this operation using 2 persons.
* Synchronize the movement of the left and right sides of the upper back window frame sub-assembly when moving it.

(q) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly clockwise to engage the lock of the rear slide roof panel sub-assembly.

(s) Measure and record the clearances at measurement locations 1, 2 and 3 shown in the illustration and adjust it to the standard.

Standard 1:

Clearance (a)

Difference (b)

Standard 2:

Clearance (a)

Difference (b)

Standard 3:

Clearance (a)

Difference (b)

HINT
If any result is out of the standard, adjust it by moving the No. 2 roof panel strength sub-assembly.

8. FULLY TIGHTEN NO. 2 ROOF PANEL STRENGTH SUB-ASSEMBLY

(a) Fully tighten the No. 2 roof panel strength sub-assembly with the 4 bolts.

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

(1) Using a T40 "TORX" socket wrench, install the slide roof motor assembly to the No. 2 roof panel strength sub-assembly with the 2 bolts.

Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)

(2) Engage the clamp.

(3) Connect the 2 connectors.

9. SET METALTOP ROOF

(a) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly counterclockwise to release the lock of the rear slide roof panel sub-assembly.

NOTICE:
* Insert the hexagon wrench all the way in and turn it with both hands.
* Do not apply excessive force after the drive gear stops turning.

HINT
The locks will release when the wrench is turned approximately 360 degrees.

(b) Stow the upper back window frame sub-assembly in the luggage compartment.

NOTICE:
* Perform this operation using 2 persons.
* Synchronize the movement of the left and right sides of the upper back window frame sub-assembly when moving it.
* Make sure that the luggage compartment door hinge assemblies are not stowed.

(c) Using a 5 mm hexagon wrench, turn the sliding roof drive gear sub-assembly counterclockwise to release the lock of the front slide roof panel sub-assembly.

NOTICE:
* Perform this operation using 2 persons.
* Synchronize the movement of the left and right sides of the roof when moving it.

10. INSTALL ROOF SIDE INNER GARNISH LH Installation

11. INSTALL ROOF SIDE INNER GARNISH RH Installation

12. INSTALL REAR SIDE RAIL SPACER LH Installation

13. INSTALL REAR SIDE RAIL SPACER RH Installation

14. INSTALL ROOF HEADLINING ASSEMBLY (for Rear Side) Installation

15. INSTALL NO. 3 ROOF SIDE RAIL GARNISH LH Installation

16. INSTALL NO. 3 ROOF SIDE RAIL GARNISH RH Installation

17. INSTALL FRONT SIDE RAIL SPACER RH Installation

18. INSTALL ROOF HEADLINING ASSEMBLY (for Center) Installation

19. INSTALL NO. 1 ROOF SIDE RAIL GARNISH LH Installation

20. INSTALL NO. 1 ROOF SIDE RAIL GARNISH RH Installation

21. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH Installation

22. INSTALL REAR FLOOR FINISH SIDE PLATE LH Installation

23. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH Installation

24. INSTALL ROPE HOOK ASSEMBLY (for Front LH) Installation

25. INSTALL ROPE HOOK (for LH Side) Installation

26. INSTALL LUGGAGE COMPARTMENT DOOR SIDE CUSHION RH (for LH Side) Installation

27. INSTALL PACKAGE TRAY TRIM SIDE COVER LH Installation

28. INSTALL PACKAGE TRAY TRIM SIDE COVER RH Installation

29. INSTALL TONNEAU COVER STOPPER SUB-ASSEMBLY LH Installation

30. INSTALL NO. 2 LUGGAGE COMPARTMENT DOOR CUSHION (for LH Side) Installation

31. INSTALL LOWER INNER LUGGAGE COMPARTMENT TRIM COVER Installation

32. INSTALL FRONT LUGGAGE COMPARTMENT TRIM COVER Installation

33. INSTALL SLIDING ROOF GUIDE RAIL STOPPER Installation

34. INSTALL TONNEAU COVER HOOK HOLDER Installation

35. INSTALL TONNEAU COVER ASSEMBLY Installation

36. INSTALL REAR LUGGAGE COMPARTMENT TRIM COVER Installation

37. INSTALL ROPE HOOK ASSEMBLY (for Rear Side) Installation

38. INSTALL LUGGAGE DOOR LOCK PROTECTOR Installation

39. INSTALL DECK SIDE TRIM BOX LH Installation

40. INSTALL DECK SIDE TRIM BOX RH Installation

41. INSTALL SPARE WHEEL COVER TRAY ASSEMBLY (w/o Spare Tire) Installation

42. INSTALL SPARE TIRE (w/ Spare Tire)

43. INSTALL SPARE WHEEL CUSHION (w/ Spare Tire) Installation

44. INSTALL LUGGAGE COMPARTMENT FLOOR MAT (w/o Spare Tire) Installation

45. INSTALL LUGGAGE COMPARTMENT FLOOR MAT (w/ Spare Tire) Installation

46. SET TONNEAU COVER

(a) Move the tonneau cover to the position shown in the illustration.

47. SET METALTOP ROOF Installation

48. SET LUGGAGE COMPARTMENT DOOR PANEL SUB-ASSEMBLY Installation

49. SET PACKAGE TRAY TRIM BRACKET Installation

50. TEMPORARILY TIGHTEN PACKAGE TRAY PANEL (for Rear Side) Installation

51. TEMPORARILY TIGHTEN PACKAGE TRAY PANEL (for Front Side) Installation

52. INSPECT FITTING OF PACKAGE TRAY PANEL Installation

53. FULLY TIGHTEN PACKAGE TRAY PANEL (for Rear Side) Installation

54. FULLY TIGHTEN PACKAGE TRAY PANEL (for Front Side) Installation

55. SET LUGGAGE COMPARTMENT DOOR Installation

56. INSTALL PACKAGE TRAY TRIM COVER Installation

57. INSTALL UNDER PACKAGE TRAY TRIM COVER Installation

58. INSTALL ROOM PARTITION TRIM (for LH Side) Installation

59. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH Installation

60. CONNECT FRONT SEAT OUTER BELT ASSEMBLY LH Installation

61. INSTALL LAP BELT OUTER ANCHOR COVER LH Installation

62. INSTALL DOOR SCUFF PLATE ASSEMBLY LH Installation

63. INSTALL REAR SEATBACK ASSEMBLY WITH REAR CONSOLE BOX ASSEMBLY Installation

64. INSTALL REAR SEAT CUSHION ASSEMBLY LH Installation

65. INSTALL REAR SEAT CUSHION ASSEMBLY RH Installation

66. INSTALL PACKAGE TRAY TRIM GARNISH LH Installation

67. INSTALL PACKAGE TRAY TRIM GARNISH RH Installation

68. INSTALL NO. 2 PACKAGE TRAY TRIM PANEL ASSEMBLY Installation

69. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY Installation

70. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

71. INSPECT SRS WARNING LIGHT

Diagnosis System

72. SET LUGGAGE COMPARTMENT DOOR Installation

73. INSPECT FITTING OF PACKAGE TRAY TRIM COVER Installation

74. INSPECT RETRACTABLE HARDTOP SYSTEM Installation

75. INSPECT FOR WATER LEAKS Installation