TOYOTA RAV4 1996 Service Repair Manual

BO10D−01
N11513
A
B BO−34
− BODYREAR WIPER AND WASHER
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL REAR WIPER MOTOR ASSEMBLY
(a) Install the wiper motor assembly.
(b) Torque the 3 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(c) Connect the connector.
2. INSTALL SERVICE HOLE COVER
3. INSTALL BACK DOOR TRIM BOARD
4. INSTALL BACK DOOR UPPER COVER
5. INSTALL REAR WIPER ARM
(a) Install the nut.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(b) Install the wiper arm and operate the wiper once and turn
the wiper switch OFF.
(c) Adjust the installation position of the wiper arm to the posi-
tion, as shown.
AApprox. 6.2 mm (0.24 in.)
BApprox. 184 mm (7.24 in.)

BO489−01
N17307
− BODYBODY OUTSIDE MOULDING
BO−35
1996 RAV4 (RM447U)
BODY OUTSIDE MOULDING
COMPONENTS

BO48A−01
N11441
N11442
N11443
N17309
BO−36
− BODYBODY OUTSIDE MOULDING
1996 RAV4 (RM447U)
REMOVAL
HINT:
Tape the screwdriver tip before using to pry parts.
1. REMOVE FRONT FENDER MOULDING
(a) Remove the fender liner.
(b) Remove the 3 screws.
(c) Using a screwdriver, pry out the clips and remove the
moulding.
2. REMOVE FRONT DOOR MOULDING
(a) Remove the 2 plug hole covers and 2 nuts.
(b) Using a moulding remover, pry loose the clips.
(c) Pull off the moulding by cutting the adhesive with a knife.
(d) Scrape off adhesive from the body with a cutter or sand-
paper.
If the clip remains on the body, turn the clip, then pull it out.
3. 3 Door models:
REMOVE REAR FENDER MOULDING
(a) Remove the 3 clips and 3 screws.
(b) Using a screwdriver, pry out the clips and remove the
moulding.
4. 5 Door models:
REMOVE REAR DOOR MOULDING
(a) Remove the 2 plug hole covers and 2 nuts.
(b) Using a screwdriver, pry out the clips and remove the
moulding.

N17310
− BODYBODY OUTSIDE MOULDING
BO−37
1996 RAV4 (RM447U)
5. 5 Door models:
REMOVE QUARTER OUTSIDE MOULDING
(a) Remove the 4 screws.
(b) Using a screwdriver, pry out the clips and remove the
moulding.

BO48B−01
BO−38
− BODYBODY OUTSIDE MOULDING
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page BO−36).

BO10N−01
H03769
Windshield Dam
 Stopper
Sun Visor
Holder
Inner Rear
View Mirror Cover
Sun Visor
Inner Rear
View Mirror
Personal Light
Personal Light Cover
Front Pillar Garnish
Hood to Cowl Top Seal
Wiper Arm
Cowl Top Vent ilat or
Louver Arm Cover
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part  Windshield Moulding
20 (200, 15)
20 (200, 15)
Arm Cover
Wiper Arm
Holder
Front Pillar Garnish
− BODYWINDSHIELD
BO−39
1996 RAV4 (RM447U)
WINDSHIELD
COMPONENTS

BO10O−12
N11424
BO5232
BO1689
BO−40
− BODYWINDSHIELD
1996 RAV4 (RM447U)
REMOVAL
1. REMOVE INNER REAR VIEW MIRROR
2. REMOVE PERSONAL LIGHT
3. REMOVE SUN VISORS AND HOLDERS
4. REMOVE FRONT PILLAR GARNISHES
5. REMOVE WIPER ARMS
6. REMOVE COWL TOP VENTILATOR LOUVER
7. REMOVE WINDSHIELD MOULDING
Using a knife, cut off the moulding, as shown.
NOTICE:
Do not damage the body with the knife.
8. REMOVE WINDSHIELD GLASS
(a) Push piano wire through between the body and glass
from the interior.
(b) Tie both wire ends to a wooden block or similar object.
HINT:
Apply adhesive tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and interior and exterior ornaments. To prevent
scratching the safety pad when removing the windshield,
place a plastic sheet between the piano wire and safety
pad.
(c) Cut the adhesive by pulling the piano wire around it.
(d) Remove the glass.
NOTICE:
Leave as much of the adhesive on the body as possible
when cutting off the glass.

BO10P−08
BO4420
Adhesive Adhesive
BO5231
H02972
14.8 mm
(0.58 in.)
H02973UnderUpper / Side 25 mm
(0.98 in.)7 mm
(0.27 in.)
H03791
− BODYWINDSHIELD
BO−41
1996 RAV4 (RM447U)
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
(a) Using a knife, cut away any rough areas on the body.
HINT:
Leave as much of the adhesive on the body as possible.
(b) Clean the cutting surface of the adhesive with a piece of
shop rag saturated in cleaner.
HINT:
Even if all the adhesive has been removed, clean the body.
2. CLEAN REMOVED GLASS
(a) Using a scraper, remove the adhesive sticking to the
glass.
(b) Clean the glass with cleaner.
NOTICE:
Do not touch the glass after cleaning it.
3. INSTALL STOPPERS
Install the stoppers onto the glass as shown in the illustration.
4. INSTALL DAM
Install the dam with double−stick tape all the way around of
glass except where the stoppers are installed as shown on the
illustration.
NOTICE:
Do not touch the glass face after cleaning it.
5. POSITION GLASS
(a) Place the glass in correct position.
(b) Check that all contacting parts of the glass rim are perfect-
ly even and do not make contact with the fasteners.
(c) Place the reference marks between the glass and body.
(d) Remove the glass.

BO4421
H02865
Primer MPrimer M
Adhesive
Primer M
N08473
Primer G
H03970
A BO−42
− BODYWINDSHIELD
1996 RAV4 (RM447U)
6. 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.
7. 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.
8. 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.
9. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle.
Part No. 08850−00801 or equivalent.
HINT:
After cutting off the tip, use all adhesive within the described
time 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 glass with adhesive as shown.
Adhesive height:
A: 10 mm (0.39 in.)

H03790
N08495
BO3986
− BODYWINDSHIELD
BO−43
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.
HINT:
Confirm that the dam is attached to the body panel, as shown
in the illustration.
(c) Use a scraper to remove any excessive or protruding
adhesive.
(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. INSTALL WINDSHIELD MOULDING
Place the moulding onto the body and install it by hand.
12. 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.
13. INSTALL COWL TOP VENTILATOR LOUVER
14. INSTALL WIPER ARMS
15. INSTALL FRONT PILLAR GARNISHES
16. INSTALL SUN VISORS AND HOLDERS