TOYOTA RAV4 1996 Service Repair Manual

Fig. 53: Removing Headlining (Land Cruiser)
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 71 © 2005 Mitchell Repair Information Company, LLC.

Fig. 54: Exploded View Of Sun Roof Assembly (Land Cruiser)
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 72 © 2005 Mitchell Repair Information Company, LLC.

Fig. 55: Aligning Drive Cable (Land Cruiser)
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 73 © 2005 Mitchell Repair Information Company, LLC.

Fig. 56: Aligning Sun Roof Drive Gear (Land Cruiser)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (RAV4 2-Door)
1. Close sun roof. Turn ignition off. Remove rear seat track covers. Remove 2 bolts. Pull seat cushion band,
release seat lock from body striker and remove rear seat. Remove rear floor finish plate. See Fig. 58
.
Remove dome light cover and light. Remove assist grips. Remove door scuff plates. Remove sun visors
and holders.
2. Remove rear view mirror. Remove map light cover and map light. Remove front and rear outer seat belt
floor anchor bolts. Remove 4 rear quarter trim panel bolts. Remove rear quarter trim panels. Remove
front and rear seat outer seat belt shoulder anchor bolts. Remove roof side trim panels. Remove roof
headlining rear trim. Remove front seat outer seat belt should anchor bolt.
3. Remove front center and rear upper trim panels. Remove roof headlining. Remove 4 Torx screws
securing sun roof glass. Pull upward on sun roof glass to remove. Remove 3 bolts and sun roof motor
assembly. See Fig. 57
. Remove 4 drain hoses. Remove 12 bolts and 6 brackets. Remove 4 nuts and sun
roof housing assembly.
Disassembly & Reassembly
1. Remove screws and sun roof panel stoppers. Remove sunshade trim. Remove rear sun roof drip channel.
Remove screws and
guide rail stoppers. Slide drive cable rearward and remove it. Remove sun roof wind

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 74 © 2005 Mitchell Repair Information Company, LLC.

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. 52
. To complete reassembly, reverse disassembly
procedure.
Installation
Apply adhesive to bolts securing gear side of sun roof motor assembly. Prior to installing drive motor, remove
cam plate cover from sun roof drive motor. See Fig. 40
. Turn drive gear until marks align, indicating a full
closed position. Reinstall cam plate cover. Ensure sun roof is properly aligned. See ADJUSTMENTS
. 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 75 © 2005 Mitchell Repair Information Company, LLC.

Fig. 57: Exploded View Of Sun Roof Assembly (RAV4 2-Door)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (RAV4 4-Door)
1. Close sun roof. Turn ignition off. Release seat lock from body striker by pulling seat cushion lock lever.
Remove 2 rear and front side bolts. Remove rear seat. Remove rear floor finish plate. See Fig. 58
.
Remove rear door scuff plates. Remove dome light cover and light. Remove assist grips. Remove front
door scuff plates. Remove sun visors and holders.
2. Remove rear view mirror. Remove map light cover and map light. Remove rear outer seat belt floor
anchor bolt. Remove rear quarter trim panels. Remove rear seat outer seat belt shoulder anchor bolt.
Remove roof side trim panels. Remove roof headlinin
g rear trim. Remove front seat outer seat belt

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 76 © 2005 Mitchell Repair Information Company, LLC.

shoulder anchor bolt.
3. Remove center pillar lower trim panels. Pull center pillar lower trim panels up to remove. Remove center
pillar upper trim panels. Remove front pillar trim panels. Remove 4 clips and roof headlining. Remove
sun roof side trim panels. Remove 6 nuts and 4 shims. See Fig. 59
. Pull upward on sun roof glass to
remove. Remove front and rear sun roof trim panels.
4. Remove control relay. Remove 3 bolts and sun roof motor assembly. Remove drip channel. Remove 2
screws from arms and 2 screws from panel and wind deflector. Remove wind deflector. Slide drive cables
back. Disconnect 4 hoses. Remove 10 bolts, 4 nuts and sun roof housing.
Disassembly & Reassembly
1. Remove 2 screws and sun roof panel stoppers. Pull sunshade trim back to remove. Remove 2 screws and
cable guide casings. Remove sun roof front stopper. Remove 2 screws and drive cable guide block. Pull
drive cables from guide rails.
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. 60
. Use butyl tape to cover cut in weatherstrip, between
cable guide casings and guide rails. To complete reassembly, reverse disassembly procedure.
Installation
Apply adhesive to bolts securing gear side of sun roof motor assembly. Prior to installing drive motor, remove
cam plate cover from sun roof drive motor. See Fig. 31
. Remove large screw, washers and shims. Turn drive
gear using screwdriver 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 77 © 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 78 © 2005 Mitchell Repair Information Company, LLC.

Fig. 58: Removing Headlining (RAV4 4-Door Shown; 2-Door Is Similar)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 59: Exploded View Of Sun Roof Assembly (RAV4 4Door)

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 79 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 60: Aligning Drive Cable (RAV4 4
-Door)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Sienna 4-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 rear speaker cover and rear quarter trim panel
cover. Remove seat belt bezel from rear quarter trim panel. Remove luggage room light. Carefully
remove left and right quarter trim panels by removing 4 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 quarter trim front panel. Disconnect power connectors and heater control cable. Remove slide
door scuff plate. 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. Release 4 clips and remove roof headlining.
4. Remove sun roof side trim. Usin
g a Torx wrench, remove 4 sun roof mounting bolts. See Fig. 62. Pull

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
Microsoft
Sunday, November 22, 2009 10:58:30 AMPage 80 © 2005 Mitchell Repair Information Company, LLC.