Body - Tick/Creak/Squeak From Windshield Base
NVHNV001-04
REVISED
Title:
COWL NOISE
Models:
'01 - '05 RAV4
January 14, 2004
TSB REVISION NOTICE:
March 4, 2005: 2004 - 2005 model years have been added to Applicable Vehicles, Production Change Information removed, some graphics clarified, Required Tools & Material section added, and measurements updated to include American standards.
Previous versions of this TSB should be discarded.
TSB UPDATE NOTICE:
This TSB updates NV004-01, "Tick Noise at Base of Windshield." Please review all of the information as there are many changes incorporated into this TSB.
TSB No. NV004-01 is now obsolete and should be discarded.
Introduction
Some customers may experience a tick, creak, squeak, or rattle noise coming from the front of the passenger compartment when hitting sharp bumps in the road. A field fix has been developed to reduce this noise.
Applicable Vehicles
2001 - 2005 model year RAV4 vehicles.
Parts Information
Warranty Information
Applicable Warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Required Tools & Material
Repair Procedure:
Determining Location of Noise
In order to determine the root cause of the noise (cowl louver or cowl panel), remove the cowl louver and reconfirm the customer's complaint with a test drive. If the noise is gone, perform the repair instructions pertaining to the cowl louver in this TSB. If the noise is still present, perform the repair procedure for the cowl panel in this TSB.
1. Remove both windshield wiper arms.
2. Remove RH cowl top ventilator louver/battery cover.
3. Remove driver's side (center) cowl top ventilator louver.
Repair Procedure: Cowl Louver
1. Apply 3M Squeak Reduction tape (P/N: 3M 06356) along the bottom edge of the windshield as shown.
2. Remove the four original pieces of felt from the driver's side center cowl top ventilator louver retainers as shown in Figure 1.
3. Cut four new pieces of felt to the dimensions shown and apply them to the four retainers as shown in Figure 2.
Felt Size:
Length: 20 mm (0.79 in.)
Width: 20 mm (0.79 in.)
Thickness: 2 mm (0.08 in.)
4. Add to the caulking sponge sealant (EPT sealer) originally applied to the center cowl top ventilator louver in the area shown in Figure 3.
5. Prepare eight new pieces of EPT sealer in the sizes shown in table.
6. Apply the new strips of EPT sealer to the front of the cowl louver as shown in Figure 4.
7. Prepare a piece of felt in the dimensions shown below and apply to the 7 x 12 mm (0.28 x 0.47 in.) oval hole in the dash panel as shown below. The hole is located behind the wiper motor assembly.
Felt Size:
Length: 15 mm (0.59 in.)
Width: 20 mm (0.79 in.)
Thickness: 0.5 mm (0.02 in.)
Hole diameter: 7 x 12 mm (0.28 x 0.47 in.)
8. Prepare three more pieces of EPT sealer and apply to the passenger side cowl top ventilator louver/battery cover as shown below in Figure 6.
9. Trim the EPT sealer to match the shape of the cowl louver.
10. Reinstall passenger's side (center) cowl top ventilator louver.
11. Reinstall passenger's side cowl top ventilator louver/battery cover.
12. Reinstall both windshield wipers.
Repair Procedure: Cowl Panel
1. If you have confirmed that the tick sound continues with the cowl louver removed, proceed with the following field fix.
2. Once the cowl louver is removed, remove the wiper motor and link assembly. Unclip the wiper motor's wire harness from the cowl panel.
3. Remove the cowl panel and remove the original two pieces EPT sealer from the cowl panel.
4. Prepare the three new pieces of EPT sealer as listed below.
5. Make sure that the mating surfaces are clean and apply the new EPT sealer in the locations shown below. Make sure that the EPT sealer hangs off of the edge of the panel by 1 mm (0.04 in.) when applying it to section "A."
6. Before reinstalling the cowl panel, add four pieces of felt to the front suspension upper center brace as shown below.
Felt size:
Length: 30 mm (1.18 in.)
Width: 22 mm (0.87 in.)
Thickness: 0.5 mm (0.02 in.)
7. Before reinstalling the cowl panel, apply the butyl tape (P/N: 3M 08610) or equivalent between the dash panel and the two dash panel insulator seals (yellow resin part), which are located behind the two center holes on the cowl panel outer.
8. When applying the butyl tape, apply the tape to both right and left sides and the bottom area of the dash panel insulator seal.
9. Reinstall the cowl panel and the wiper motor and link assembly.
10. Reinstall the driver's side (center) cowl top ventilator louver.
11. Reinstall passenger's side cowl top ventilator louver/battery cover.
12. Reinstall both windshield wiper arms.