TOYOTA RAV4 1996 Service Repair Manual

upward on sun roof glass and remove. Remove 3 bolts and sun roof motor assembly. Disconnect 4 drain
hoses. Remove 8 bolts and 4 brackets. Remove 6 nuts and sun roof housing.
Removal (Sienna 5-Door)
1. Close sun roof. Turn ignition off. Remove second row seats. Remove third row seats (if equipped).
Remove liftback door scuff plate. See Fig. 61
. Remove slide door scuff plate. Remove rear speaker
cover. On left side remove rear quarter trim panel cover. On right side remove air inlet grille. On both
sides, remove seat belt bezel from rear quarter trim panel. Remove luggage room light. Remove slide
door courtesy lights. Carefully remove left and right quarter trim panels by removing 2 screws, and
releasing clips along outer edges. Remove "D" pillar trim. Remove second row seat shoulder belt outer
anchor bolt and "C" pillar trim.
2. Remove roof side rail trim. Remove front door scuff plates. Remove kick panels. Remove front door
opening trim. Remove front pillar trim. Disconnect tweeter speaker (if equipped).
3. Remove front seat shoulder belt outer floor anchor bolt. Remove center pillar lower trim. Remove front
seat shoulder belt seat shoulder belt outer anchor bolt. Remove coat hooks. Remove assist grips. Remove
sun visors and holders. Remove sun roof opening trim moldings. Remove overhead console. Remove
dome light cover and dome lights. Remove heater control panel. Release 4 clips and remove roof
headlining.
4. Remove sun roof side trim. Using a Torx wrench, remove 4 sun roof mounting bolts. See Fig. 62
. Pull
upward on sun roof glass and remove. Remove 3 bolts and sun roof motor assembly. Disconnect 4 drain
hoses. Remove 8 bolts and 4 brackets. Remove 6 nuts and sun roof housing.
Disassembly & Reassembly
1. Remove screws and sun roof panel stoppers. Remove sunshade trim. Remove rear sun roof drip channel.
Remove 4 screws and rear frame. Remove screws and guide rail stoppers. Slide drive cable rearward and
remove it. Remove sun roof wind deflector panel. Remove 2 screws and guide blocks. Remove 6 screws
and sun roof housing.
2. To reassemble, adjust drive cables to a completely closed and tilted down position. Slide both cables
forward or backward to align marks. See Fig. 30
. To complete reassembly, reverse disassembly
procedure.
Installation
Prior to installing drive motor, remove cam plate cover from drive motor. Turn drive gear until marks align,
indicating a full closed position. See Fig. 40
. Reinstall cam plate cover. Tighten nuts and bolt to specification.
See TORQUE SPECIFICATIONS
. To complete installation, reverse removal procedure.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 81 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 82 © 2005 Mitchell Repair Information Company, LLC.

Fig. 61: Removing Headlining (Sienna)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 62: Exploded View Of Sun Roof Assembly (Sienna)

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 83 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (4Runner)
1. Close sun roof. Turn ignition off. Remove dome lights, rear header trim panel and liftback door scuff
plate. See Fig. 63
. Remove rear door scuff plate and rear seat side trim. On right side, remove electrical
outlet. Remove luggage compartment cover, holder and hook (if equipped). Remove front seat belt
shoulder floor anchor bolt.
2. Remove deck side trim. Disconnect connector and pass seat belts through deck side trim. Remove front
door scuff plates. Remove center pillar lower trim. Remove front seat belt shoulder anchor bolt. Remove
center pillar upper trim panel. Remove assist grips, and front pillar trim panel. Remove map light lens and
map light assembly. Remove rear view mirror and sun visors. Release 6 clips, and remove roof
headlining.
3. Disconnect 4 drain hoses, and connectors from sun roof housing. See Fig. 64
. Remove 2 nuts, 8 bolts and
housing assembly.
Disassembly & Reassembly
1. Remove sun shade trim. Remove side trim panel. Remove sun roof mounting nuts and glass. Remove drip
channel. Remove control relay, and sun roof motor assembly. Remove wind deflector. Remove sun roof
housing. Remove drive rail.
2. Remove screws and sun roof panel stoppers. Remove sunshade trim. Remove side trim. Remove 4 nuts
and sun roof glass. Remove rear sun roof drip channel. Remove control relay.
3. Remove 3 bolts and sun roof motor. Remove sun roof wind deflector panel. Remove screws and guide
rail stoppers. Remove 6 screws and sun roof housing. Slide drive cable forward and remove it. To
reassemble, adjust drive cables to a completely closed and tilted down position. Slide both cables forward
or backwards to align marks. See Fig. 65
. To complete reassembly, reverse disassembly procedure.
Installation
Prior to installing drive motor, remove cam plate cover from drive motor. See Fig. 66 . Using screwdriver, turn
drive gear until marks align, indicating a full closed position. Reinstall cam plate cover. Tighten nuts and bolt to
specification. See TORQUE SPECIFICATIONS
. To complete installation, reverse removal procedure.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 84 © 2005 Mitchell Repair Information Company, LLC.

Fig. 63: Removing Headlining (4Runner)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 85 © 2005 Mitchell Repair Information Company, LLC.

Fig. 64: Exploded View Of Sun Roof Assembly (4Runner)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 86 © 2005 Mitchell Repair Information Company, LLC.

Fig. 65: Aligning Drive Cable (4Runner)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 87 © 2005 Mitchell Repair Information Company, LLC.

Fig. 66: Aligning Sun Roof Drive Gear (4Runner)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
Application (1) Ft. Lbs. (N.m)
Seat Belt Anchor Bolts32 (43)
INCH Lbs. (N.m)
Sun Roof Glass Screws36 (4)
Sun Roof Motor Assembly Bolts48 (5)
Sun Roof Mounting Bolts49 (6)
(1)Use Loctite on all bolts.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 88 © 2005 Mitchell Repair Information Company, LLC.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 89 © 2005 Mitchell Repair Information Company, LLC.

Fig. 67: Power Sun Roof System Wiring Diagram (1999 Avalon)

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 90 © 2005 Mitchell Repair Information Company, LLC.