TOYOTA PRIUS 2001 Service Repair Manual

BO2821Reference Marks
BO4421
H02865
Primer M
AdhesivePrimer M
Primer M
H00471
Primer G
Dam Primer G
BO±48
± BODYWINDSHIELD
2001 PRIUS (RM778U)
5. POSITION GLASS
(a) Using a suction rubber, place the glass in the correct posi-
tion.
(b) Check that all contacting parts of the glass rim are perfect-
ly even.
(c) Place reference marks between the glass and body.
(d) Remove the glass.
6. CLEAN CONTACT SURFACE OF GLASS
Using a cleaner, clean the contact surface which is black±col-
ored area around the entire glass rim.
NOTICE:
Do not touch the glass face after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER
ºMº
Using a brush, coat Primer M to the exposed part of body on the
vehicle side.
NOTICE:

Let the primer coating dry for 3 minutes or more.

Do not coat Primer M to the adhesive.

Do not keep any of the opened Primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER
ºGº
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
(b) When the primer is coated wrongly to the area other than
the specified, wipe it off with a clean shop rag before the
primer dries.
NOTICE:

Let the primer coating dry for 3 minutes or more.

Do not keep any of the opened Primer G for later use.
9. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
Part No. 08850±00801 or equivalent

H00464
Adhesive
Dam
B
A
BO2821Reference Marks
H00679
Windshield Glass
Adhesive
± BODYWINDSHIELD
BO±49
2001 PRIUS (RM778U)
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the table below.
TemperatureTackfree time
35 °C (95 °F)15 minutes
20 °C (68 °F)100 minutes
5 °C (41 °F)8 hours
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive as shown.
A: 12 mm (0.47 in.)
B: 8 mm (0.31 in.)
10. INSTALL WINDSHIELD GLASS AND MOULDING
(a) Install the glass, aligning the reference marks using a suc-
tion rubber.
HINT:
Check to see that the stoppers are attached to the body correct-
ly.
(b) Lightly press the glass front surface for close contact.
(c) Correct insufficient or protruded adhesive agent using a
spatula.
HINT:
Apply the adhesive agent up to the windshield glass edge.

H15405
w/o Rain garter:
Windshield Glass
Body
w/ Rain garter:Windshield Moulding
Windshield Moulding
Windshield Glass
Body
H15399Point Marks
BO±50
± BODYWINDSHIELD
2001 PRIUS (RM778U)
(d) Install a new windshield moulding to the windshield glass
before the adhesive agent hardens.
HINT:
Install the moulding, aligning the center of moulding with the
center of body.
(e) Remove any excessive adhesive agent before it hardens.
(f) Hold the glass and moulding in place securely with a pro-
tective tape or equivalent until the adhesive hardenes.
NOTICE:
Take care not to drive the vehicle during the time described
in the table below.
TemperatureMinimum time prior to driving the vehicle
35 °C (95 °F)1.5 hours
20 °C (68 °F)5 hours
5 °C (41 °F)24 hours
11. INSPECT FOR LEAK AND REPAIR
NOTICE:
Conduct a leak test after the hardening time has elapsed.
12. INSTALL COWL TOP VENTILATOR LOUVERS
Install the cowl top ventilator louver LH and RH, then install the
2 screws.
13. INSTALL HOOD TO COWL TOP SEAL
14. INSTALL WIPER ARMS
(a) Operate the wiper motor once and turn the wiper switch
OFF.
(b) Install the wiper arms and tighten nuts by hand.
(c) Adjust the installation positions of the wiper arms to the
positions as shown in the illustration.
(d) Torque the 3 nuts.
Torque: 26 N´m (270 kgf´cm, 20 ft´lbf)
(e) Install the wiper arm head cap.
15. INSTALL FRONT SIDE OF ROOF HEADLINING
16. INSTALL ASSIST GRIP
(a) Install the assist grip with the 2 screws.
(b) Install the caps.
17. INSTALL SUN VISOR HOLDERS
Install the 2 sun visor holders with the 2 screws.
18. INSTALL SUN VISORS
Install the 2 sun visors with the 4 screws.
19. INSTALL MAP LAMP
(a) Connect the connector.
(b) Install the map lamp.

H15357
H13603
2 Clips
± BODYWINDSHIELD
BO±51
2001 PRIUS (RM778U)
20. INSTALL INNER REAR VIEW MIRROR
(a) Install the inner rear view mirror with the 2 screws.
Torque: 2.9 N´m (30 kgf´cm, 26 in.´lbf)
(b) Install the cover.
21. INSTALL FRONT PILLAR GARNISH AND NO. 1 FRONT
PILLAR SPACERS
(a) Install the 2 No. 1 front pillar spacers and 4 screws.
(b) Install the front pillar garnish to the body.
(c) Employ the same manner described above to the other
side.

BO3Q1±01
H13694
5 Clips
H15383
H15384
4 Clips
± BODYBACK WINDOW GLASS
BO±53
2001 PRIUS (RM778U)
REMOVAL
1. REMOVE REAR SEAT CUSHION (See page BO±83)
2. REMOVE REAR SEATBACK (See page BO±83)
3. REMOVE UPPER PART OF REAR DOOR OPENING
TRIMS
4. REMOVE ROOF SIDE INNER GARNISH
(a) Using a screwdriver, disengage the clips.
HINT:
Tape the screwdriver tip before use.
(b) Pull the garnish upward to remove it.
(c) Employ the same manner described above to the other
side.
5. REMOVE HIGH±MOUNTED STOP LIGHT
(a) Remove the clip, then pull the high±mounted stop light
cover.
(b) Disconnect the connector.
(c) Remove the 2 screws and high±mounted stop light.
6. REMOVE CRS TETHER ANCHORS
Remove the 3 CRS tether anchor covers and 3 CRS tether an-
chor brackets.
7. REMOVE PACKAGE TRAY TRIM PANEL
(a) Pull the package tray trim panel upward to disengage the
clips.
(b) Remove the rear seat outer belts through the cutout on
the package tray trim.
(c) Pull the package tray trim panel forward to remove it.
8. REMOVE SILENCER PAD
9. REMOVE REAR ASSIST GRIPS
(a) Using a screwdriver, remove the caps.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 4 screws and 2 rear assist grips.
10. PULL DOWN REAR PART OF ROOF HEADLINING
Remove the 2 clips.

H15378
H15379
Protective Tape
H15380
Protective Tape
H07610
BO±54
± BODYBACK WINDOW GLASS
2001 PRIUS (RM778U)
11. REMOVE BACK WINDOW OUTSIDE MOULDING
(a) Using a knife, cut off the moulding as shown in the illustra-
tion.
NOTICE:
Do not damage the body with the knife.
(b) Remove the remaining moulding.
12. REMOVE BACK WINDOW GLASS
(a) Disconnect the connector.
(b) Push piano wire through from the interior.
(c) Tie both wire ends to wooden blocks or similar objects
HINT:
Apply protective tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and exterior.
(d) Cut the adhesive by pulling the piano wire around it.
HINT:
Cut the adhesive areas as shown in the illustration, leaving the
adhesive where the stoppers are.
(e) Let the piano wire pass as shown in the illustration, cut off
the adhesive sticking to the stoppers.
NOTICE:

Do not damage the glass stoppers.

Leave as much of the adhesive on the body as pos-
sible when cutting off the glass.

BO3Q2±01
BO4420
Adhesive
BO5231
H15381
Stopper AA
H15382Connected Portion
± BODYBACK WINDOW GLASS
BO±55
2001 PRIUS (RM778U)
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
(a) Using a knife, cut away any rough areas on the body.
HINT:
Leave as much of the adhesive on the body as possible.
(b) Clean the cutting surface of the adhesive with a piece of
shop rag saturated in cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
2. CLEAN REMOVED GLASS
(a) Using a scraper, remove the adhesive sticking to the
glass.
(b) Clean the glass with cleaner.
NOTICE:

Be careful not to damage the glass.

Do not touch the glass face after cleaning it.
3. INSTALL NEW STOPPERS
Install new stoppers onto the glass.
A: 7.0 mm (0.276 in.)
4. INSTALL NEW BACK WINDOW OUTSIDE MOULDING
Install new back window outside moulding to the back window
glass as shown in the illustration.
HINT:

Install the back window outside moulding from the center
of the glass at the lower side of the vehicle.

When installing the back window outside moulding, do
not stretch it.

H10504Reference Marks
BO4421
H02865
Primer M
Primer M
Adhesive
H15385
a
a
bb
b
b
a ± a b ± b
Primer G BO±56
± BODYBACK WINDOW GLASS
2001 PRIUS (RM778U)
5. POSITION GLASS
(a) Place the glass in the correct position.
(b) Check that all contacting parts of the glass rim are perfect-
ly even.
(c) Place reference marks between the glass and body.
(d) Remove the glass.
6. CLEAN CONTACT SURFACE OF GLASS
Using a cleaner, clean the contact surface which is black±col-
ored area around the entire glass rim.
NOTICE:
Do not touch the glass face after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER
ºMº
Using a brush, coat Primer M to the exposed part of body on the
vehicle side.
NOTICE:

Let the primer coating dry for 3 minutes or more.

Do not coat Primer M to the adhesive.

Do not keep any of the opened Primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER
ºGº
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G as shown in the illustra-
tion.
(b) When the primer is coated wrongly to the area other than
the specified, wipe it off with a clean shop rag before the
primer dries.
NOTICE:

Let the primer coating dry for 3 minutes or more.

Do not keep any of the opened Primer G for later use.

H15386
a
a
b
b
b
b
a ± a b ± b
AA
BB
Adhesive
H10505Reference Marks
H15387
± BODYBACK WINDOW GLASS
BO±57
2001 PRIUS (RM778U)
9. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
Part No. 08850±00801 or equivalent
HINT:
After cutting off the tip, use all adhesive within the time de-
scribed in the table below.
TemperatureTackfree time
35°C (95°F)15 minutes
20°C (68°F)100 minutes
5°C (41°F)8 hours
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive as shown in the illustration.
A: 12 mm (0.47 in.)
B: 8 mm (0.31 in.)
10. INSTALL GLASS
(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.
HINT:
Confirm that the moulding is attached to the body panel as
shown in the illustration.
(b) Hold the back window glass in place securely with a pro-
tective tape or equivalent until the adhesive hardens.
NOTICE:
Take care not to drive the vehicle during the time described
in the table below.
TemperatureMinimum time prior to driving the vehicle
35°C (95°F)1.5 hours
20°C (68°F)5 hours
5°C (41°F)24 hours
11. INSPECT FOR LEAK AND REPAIR
(a) Conduct a leak test after the hardening time has elapsed.
(b) Seal any leak with sealant.
Part No. 08833±00030 or equivalent

H15384
4 Clips
H15383
H13694
5 Clips BO±58
± BODYBACK WINDOW GLASS
2001 PRIUS (RM778U)
12. INSTALL REAR PART OF ROOF HEADLINING
Install the 2 clips.
13. INSTALL REAR ASSIST GRIPS
(a) Install the 2 rear assist grips with the 4 screws.
(b) Install the caps.
14. INSTALL SILENCER PAD
15. INSTALL PACKAGE TRAY TRIM PANEL
(a) Install the seat belt through the cutout of the package tray
trim.
(b) Install the package tray trim as shown in the illustration.
16. INSTALL CRS TETHER ANCHORS
(a) Install the 3 CRS tether anchor brackets.
Torque: 20 N´m (200 kgf´cm, 14 ft´lbf)
(b) Install the CRS tether anchor covers.
17. INSTALL HIGH±MOUNTED STOP LIGHT
(a) Install the high±mounted stop light with the 2 screws.
(b) Connect the connector.
(c) Install the high±mounted stop light cover, then install the
clip.
18. INSTALL ROOF SIDE INNER GARNISH
(a) Install the roof side inner garnish as shown in the illustra-
tion.
(b) Employ the same manner described above to the other
side.
19. INSTALL UPPER PART OF REAR DOOR OPENING
TRIMS
20. INSTALL REAR SEATBACK (See page BO±86)
21. INSTALL REAR SEAT CUSHION (See page BO±86)