TOYOTA RAV4 1996 Service Repair Manual

BO4421
H02865
Primer M
Primer M
Adhesive
Primer M
N08473
Primer G
H02984
A
B BO−54
− BODYBACK DOOR GLASS
1996 RAV4 (RM447U)
5. 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.
6. COAT CONTACT SURFACE OF BODY WITH PRIMER
”M”
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.
7. COAT CONTACT SURFACE OF GLASS WITH PRIMER
”G”
(a) Using a brush or sponge, coat the edge of the glass and
the contact surface with Primer G.
(b) Before the Primer dries, wipe it off with a clean shop rag.
NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use.
8. INSTALL BACK DOOR MOULDING
Place the moulding onto the body and tap it by hand.
9. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
Part No. 08850−00801 or equivalent.
HINT:
After cutting off the rip, use all adhesive within the time de-
scribed in the chart 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 grass with adhesive, as shown.
A: 10 mm (0.39 in.)
B: 10.5 mm (0.41 in.)

H03898
BO3986
− BODYBACK DOOR GLASS
BO−55
1996 RAV4 (RM447U)
10. INSTALL GLASS
(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.
(b) Using a spatula, apply adhesive on the glass rim.
(c) Use a scraper to remove any excess or protruding adhe-
sive.
(d) Hold the windshield glass in place securely with a protec-
tive tape or equivalent until the adhesive hardenes.
NOTICE:
Take care not to drive the vehicle during the time described
in the chart 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 LEAKS AND REPAIR
(a) Do a leak test after the hardening time has elapsed.
(b) Seal any leak with auto glass sealer.
Part No. 08833−00030 or equivalent.
12. INSTALL WIPER ARM
13. INSTALL STOP LIGHT
14. INSTALL UPPER SIDE GARNISHES
15. INSTALL UPPER GARNISHES
16. INSTALL STOP LIGHT COVER

N11736
BO3D5−01
N11465
BO−56
− BODYREMOVABLE ROOF
1996 RAV4 (RM447U)
REMOVABLE ROOF
ON−VEHICLE INSPECTION
INSPECT REMOVABLE ROOF ALIGNMENT
(a) With the removable roof closed, check for water leakage.
(b) Check for a difference in level between the removable
roof and the roof panel.
Level: 0.75 − 2.75 mm (0.02 − 0.11 in.)

BO3D6−01
− BODYREMOVABLE ROOF
BO−57
1996 RAV4 (RM447U)
COMPONENTS

N17929
BO−58
− BODYREMOVABLE ROOF
1996 RAV4 (RM447U)

BO3D7−01
N11414
− BODYREMOVABLE ROOF
BO−59
1996 RAV4 (RM447U)
REMOVAL
HINT:
Tape a screwdriver tip before using to pry parts.
1. REMOVE REAR SEAT
2. REMOVE FRONT DOOR SCUFF PLATE
3. REMOVE REAR FLOOR FINISH PLATE
4. REMOVE FRONT SEAT BELT SHOULDER ANCHOR
BOLT
5. REMOVE QUARTER TRIM LH AND RH
(a) Quarter trim LH and RH.
(b) Rear seat belt shoulder anchor bolt.
6. REMOVE ROOF SIDE INNER GARNISH
(a) Roof side inner garnish.
(b) Front pillar garnish.
7. REMOVE FRONT AND REAR REMOVABLE ROOF
(a) Disconnect the lock handle from the lock base.
(b) Pull the removable roof rearward to remove it.
8. REMOVE LOCK HANDLE
Remove the 2 screws and lock handle from the removable roof.
9. REMOVE AUXILIARY CATCH

N11417
N11415
BO−60
− BODYREMOVABLE ROOF
1996 RAV4 (RM447U)
10. REMOVE WIND DEFLECTOR PANEL
Remove the 2 deflector panel clips, while prying them with a
screwdriver.
11. REMOVE LOCK BASE
Remove the 2 screws and lock garnish.
12. REMOVE LOCK GARNISH
Remove the 2 nuts, lock base and spacer.
13. REMOVE OPENING TRIM
14. REMOVE INNER WEATHERSTRIP
15. REMOVE HINGE CASE
Remove the 2 nuts and hinge case.
16. REMOVE ROOM LIGHT
17. REMOVE PERSONAL LIGHT
18. REMOVE INNER REAR VIEW MIRROR
19. REMOVE SUN VISORS
20. REMOVE ROOF HEADLINING

BO3D8−01
N11414
N11446
Spacer
− BODYREMOVABLE ROOF
BO−61
1996 RAV4 (RM447U)
ADJUSTMENT
1. DISCONNECT LOCK HANDLE FROM LOCK BASE
2. REMOVE LOCK GARNISH
Remove the 2 screws and lock garnish.
3. CONNECT LOCK HANDLE TO LOCK BASE
4. ADJUST REMOVABLE ROOF
(a) Remove the 2 nuts and lock base.
(b) Adjust it by increasing or decreasing the number of
spacers.
(c) Install the lock base with 2 nuts.
5. INSTALL LOCK GARNISH
Install the lock garnish with 2 screws.

BO3D9−01
BO−62
− BODYREMOVABLE ROOF
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal (See page BO−59).

BR02F−04
− BRAKEBRAKE SYSTEM
BR−1
1996 RAV4 (RM447U)
BRAKE SYSTEM
PRECAUTION
Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts having the same part number
or equivalent.
It is very important to keep parts and the area clean when repairing the brake system.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.