roof rack TOYOTA RAV4 1996 Service Repair Manual

ADJUSTMENTS
SUN ROOF HEIGHT
Corolla, Celica (1999), RAV4 & 4Runner
Completely close sun roof. Measure sun roof height. Roof panel should be even with glass weatherstrip, within
0.06" (1.5 mm). If adjustment is required, pry out trim panels from left and right sides of sun roof opening.
Install or remove shims between bracket and sun roof as necessary. Recheck sun roof height.
Camry
Completely close sun roof. Measure sun roof height. On USA-built Camry, roof panel should be even with glass
weatherstrip, within 0.06" (1.5 mm). On Japan-built Camry and Camry Solara, roof panel should be even with
glass weatherstrip, within 0.06" (1.5 mm) at front, and +0.06" (1.5 mm) or -0.04" (1.0 mm) at rear. On all
models, if adjustment is required, pry out trim panels from left and right sides of sun roof opening. Install or
remove shims between bracket and sun roof as necessary. Recheck sun roof height.
Land Cruiser
Completely close sun roof. Measure sun roof height. Roof panel should be even with glass weatherstrip, within
0.06" (1.5 mm) at front, and +0.06" (1.5 mm) or -0.04" (1.0 mm) on all sides except rear. Roof panel should be
even with glass weatherstrip, within 0.06" (1.5 mm) at rear. If adjustment is required, pry out trim panels from
left and right sides of sun roof opening. Install or remove shims between bracket and sun roof as necessary.
Recheck sun roof height.
Avalon, Celica (2000) & Sienna
Completely close sun roof. Measure sun roof height. Roof panel should be even with glass weatherstrip, within
0.06" (1.5 mm) at front, and +0.06" (1.5 mm) or -0.04" (1.0 mm) at rear. If adjustment is required, pry out trim
panels from left and right sides of sun roof opening. Install or remove shims between bracket and sun roof as
necessary. Recheck sun roof height.
SUN ROOF CLOSING CLEARANCE
RAV4 (4-Door), Land Cruiser & 4Runner
If sun roof closing clearances are unequal between right and left sides, pry out trim panels from left and right
sides of sun roof opening. Loosen sun roof slider mount nuts (RAV4 4-door and 4Runner; screws on Land
Cruiser). Move either side forward or backward as necessary. Tighten sun roof slider mount nuts. Recheck sun
roof alignment and operation.
SUN ROOF FRONT-TO-REAR ALIGNMENT
Avalon (1999), Camry, Camry Solara & Sienna
If front-to-rear position of sun roof is incorrect, pry out trim panels from left and right sides of sun roof opening.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
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Sunday, November 22, 2009 10:58:29 AMPage 14 © 2005 Mitchell Repair Information Company, LLC.

sun roof control relay, and sun roof motor assembly. Disconnect 4 drain hoses from sun roof housing.
Remove 16 bolts, 4 brackets, 4 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 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. See Fig. 31 . Turn drive gear until
marks align, indicating a completely 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
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Sunday, November 22, 2009 10:58:30 AMPage 37 © 2005 Mitchell Repair Information Company, LLC.

Fig. 31: Aligning Sun Roof Drive Gear (1999 Avalon, 1999 Celica & RAV4 4-Door)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (2000 Avalon)
1. Close sun roof. Turn ignition off. Remove rear seat cushion. Remove 4 bolts. Raise up and remove
seatback assembly. Remove front door and rear door scuff plates. See Fig. 28
. Remove front and rear
door opening trim. Remove rear pillar trim panels. Remove rear map light lenses and rear map lights.
Remove front door scuff inside plate. Remove front door opening trim.
2. Remove front seat outer belt shoulder floor anchor bolt. Remove center pillar lower and upper trim.
Remove front pillar trim. Remove front map light cover. Remove 3 screws and roof console box. Remove
dome light cover and dome light. Remove sun roof trim. Remove sun visors and assist grips. Remove
roof headlining.
3. Remove sun roof glass mounting nuts. See Fig. 32
. Pull upward on sun roof glass to remove. Remove
sun roof motor assembly. Disconnect 4 drain hoses from sun roof housing. Remove 8 bolts, 4 brackets, 6
nuts and sun roof housing. To install, reverse removal procedure.
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. Remove screw from sliding
roof housing. Slightly lift sliding roof housing, slide drive cable rearward and remove it. Remove sun roo
f
wind deflector panel. Remove 2 screws and guide blocks. Disconnect sun roof housing from drive rail
and slide sun roof housing forward. Remove guide blocks. Remove sun roof housing and cable guide
casing.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
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Sunday, November 22, 2009 10:58:30 AMPage 41 © 2005 Mitchell Repair Information Company, LLC.

Fig. 33: Aligning Drive Cable (2000 Avalon)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Camry - USA Built)
1. Close sun roof. Turn ignition off. Remove rear seat cushion and seat backs. Remove front door scuff
plates. See Fig. 34
. Remove front seat belt shoulder anchor bolts. Remove sun visor and holders.
Remove assist grips. Remove clips, pull up and remove front pillar trim. Remove rear door scuff plates.
Remove center pillar lower and upper trim. Remove rear pillar trim.
2. Remove dome light cover and dome light. Remove map light assembly. Release 2 clips at rear of roof
headlining and remove roof headlining. Remove sun roof side trim. Remove 4 sun roof glass adjustment
screws. See Fig. 35
.
3. Pull upward on sun roof glass and remove. Disconnect 4 drain hoses. Remove 8 bolts and 4 brackets.
Remove 6 nuts and sun roof housing.
Disassembly
1. Pull drain cap backward and remove it. Remove rear sun roof drip channel. Remove sunshade trim. Using
screwdriver, remove left and ri
ght roof drip channel guides. Remove 3 bolt and sun roof motor assembly.
NOTE: The Camry may have been manufactured by Toyota Motor Mfg. U.S.A. (USA
built), or manufactured by Toyota Motor Corp. Japan (Japan built). Ensure
correct removal and installation procedure is being used.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
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Sunday, November 22, 2009 10:58:30 AMPage 43 © 2005 Mitchell Repair Information Company, LLC.

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 38: Checking Drive Cable Alignment (Camry
- USA Built)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Camry - Japan Built)
1. Close sun roof. Turn ignition off. Remove rear seat cushion and seat backs. Remove front door scuff
plates. See Fig. 34
. Remove front seat belt shoulder anchor bolts. Remove sun visor and holders.
Remove assist grips. Remove clips, pull up and remove front pillar trim. Remove rear door scuff plates.
Remove center pillar lower and upper trim. Remove rear pillar trim.
2. Remove dome light cover and dome light. Remove map light assembly. Release 2 clips at rear of roof
headlining and remove roof headlining. Remove sun roof side trim. Using a Torx wrench, remove 4 sun
roof glass mounting screws. See Fig. 39
.
3. Pull upward on sun roof glass and remove. Remove 3 bolt 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 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.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
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Sunday, November 22, 2009 10:58:30 AMPage 49 © 2005 Mitchell Repair Information Company, LLC.

Fig. 40: Aligning Sun Roof Drive Gear (Camry -Japan Built, Corolla, RAV4 2-Door & Sienna)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Camry Solara)
1. Close sun roof. Turn ignition off. Remove front door scuff plates. See Fig. 41 . Remove front door
opening covers. Remove clips, pull up and remove front pillar trim. Pull up and remove front of rear seat
cushion. Release and fold seatback. Remove 3 clips. Remove 2 bolts and seatback assembly. Remove rear
seatback side hinges. Remove rear assist grips and quarter trim panels. Remove front seat belt shoulder
anchor and coat hook. Remove clip and "C" pillar trim.
2. Remove map light assembly. Remove dome light cover and dome light. Remove sun roof side trim.
Remove front assist grips. Remove sun visors and holders. Remove roof headlining. Using a Torx
wrench, remove 4 sun roof glass mounting screws. See Fig. 39
.
3. Pull upward on sun roof glass and remove. Remove 2 bolt 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, turn drive gear until marks align, indicating a full closed position. See Fig. 42 .
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
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Sunday, November 22, 2009 10:58:30 AMPage 54 © 2005 Mitchell Repair Information Company, LLC.

upward on sun roof glass and remove. Remove sun roof control relay. Remove sun roof motor. Remove 4
drain hoses. Remove 4 bolts, 6 nuts and sun roof housing.
Disassembly & Reassembly
1. Remove 4 sun roof housing brackets. Remove sun roof wind deflector panel. Remove sun roof drip
channel. Remove 12 screw and drive rail assembly. Remove sun roof panel stoppers. Pull sun roof wind
deflector panel backwards and remove. Pull cable guide casing forward and remove. Remove 2 screws
and drive cables guide blocks. Remove drive cable from guide rail.
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. 45
. To complete reassembly, reverse disassembly
procedure.
Installation
Prior to installing drive motor, remove cam plate cover from drive motor. See Fig. 31 . Turn drive gear until
marks align, indicating a completely 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 57 © 2005 Mitchell Repair Information Company, LLC.

Fig. 45: Aligning Drive Cable (1999 Celica)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (2000 Celica)
1. Close sun roof. Turn ignition off. Remove door scuff plates. See Fig. 46 . Remove package tray trim.
Remove 4 bolts and rear seatback. Remove rear seat cushion. Remove side and center hinges. Remove
seatback lock striker. Remove luggage compartment tray. Remove luggage compartment mat. Remove 2
bolts, 2 hooks, 3 clips and rear deck trim cover.
2. Remove deck trim side panel. Remove rear seat outer belt floor anchors. Remove rear quarter trim panel.
Remove front seat outer belt shoulder anchor. Remove coat hook and rear pillar upper trim. Remove front
pillar trim. Remove kick panels. Remove front door opening trims. Remove map light cover and map
light assembly. Remove sun roof opening trim. Remove visors and holders. Remove 5 clips and
headlining.
3. Remove sun roof glass mounting nuts. See Fig. 47
. Pull upward on sun roof glass and remove. Remove
dome light bracket. Remove sun roof motor. Remove 4 drain hoses. Remove 12 bolts, 6 brackets, 4 nuts
and sun roof housing.
Disassembly & Reassembly
Remove sunshade stoppers. Remove sunshade trim. Remove 6 screws and front housing frame. Remove sun
roof drip channels. Pull drive cables rearward and remove. To reassemble, adjust drive cables to a completely
closed and tilted down position. Slide both cables forward or backward to align marks. See Fig. 49
. To
complete reassembly, reverse disassembly procedure.
Installation
Ensure rear seat outer belt floor anchors are installed as shown. See Fig. 48 . 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
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Sunday, November 22, 2009 10:58:30 AMPage 61 © 2005 Mitchell Repair Information Company, LLC.

Fig. 49: Aligning Drive Cable (2000 Celica)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Corolla)
1. Close sun roof. Turn ignition off. Pull rear seat center belt through seat cushion slit. Remove 2 lock
hooks. Remove rear seat cushion. Remove 3 bolts and rear seatback. Remove rear view mirror. Remove
front door scuff plates. See Fig. 50
. Remove front kick panels. Remove center lower pillar trim. Remove
rear door scuff plates. Remove front door opening trim. Remove rear door opening trim.
2. Pry front pillar trim off and pull up to remove. Remove front and rear shoulder belt anchor bolts. Remove
center upper pillar trim. Push on front corners and lift up on centrally mounted brakelight cover. Remove
centrally mounted brakelight. Remove rear pillar trim.
3. Remove package tray tether anchor covers and tether anchors. Remove dome light cover and dome light.
Remove map light. Remove sun roof opening trim. Remove sun visors and holders. Remove front assist
grips. Remove 3 clips and headlining.
4. Using a Torx wrench, remove 4 screws and carefully remove sun roof glass. See Fig. 51
. Unplug and
remove drive motor assembly. Disconnect 4 drain hoses from sun roof housing. Remove 8 Torx screws
and 4 brackets. Remove 6 nuts and sun roof housing assembly.
Disassembly & Reassembly

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Sun Roofs
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Sunday, November 22, 2009 10:58:30 AMPage 65 © 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.