roof TOYOTA RAV4 1996 Service Repair Manual

BO48D−01
H02975: 4 Clips
H02976
: 9 Clips BO−46
− BODYQUARTER WINDOW GLASS (3−Door)
1996 RAV4 (RM447U)
REMOVAL
HINT:
Tape the 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 OUTER BELT SHOULDER AN-
CHOR BOLT
5. REMOVE QUARTER TRIM
(a) Remove the rear seat outer belt floor anchor bolt.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
(b) Remove the 4 screws.
(c) Using a screwdriver, remove the quarter trim.
6. REMOVE ROOF SIDE INNER GARNISH
(a) Remove the rear seat belt shoulder anchor bolt.
(b) Remove the 3 clips and roof side inner garnish.
7. REMOVE FRONT PILLAR GARNISH
Using a screwdriver, remove the front pillar garnish.
8. REMOVE QUARTER WINDOW GLASS
Remove the 2 nuts and quarter window glass.
9. REMOVE QUARTER WINDOW LOCK
Remove the bolt, 2 screws and quarter window glass.
10. REMOVE HINGE

N14553
BO48G−01
H02978
4 Clips
H02979
: Clip
H02980
: 4 Clips
H02981
− BODYQUARTER WINDOW GLASS (5−Door)
BO−49
1996 RAV4 (RM447U)
REMOVAL
HINT:
Tape the screwdriver tip before using to pry parts.
1. REMOVE REAR DOOR SCUFF PLATE
2. REMOVE REAR FLOOR FINISH PLATE
3. REMOVE REAR SIDE TRIM
(a) Remove the rear seat outer belt floor anchor bolt.
(b) Using a screwdriver, pull the garnish upwards to remove
it.
4. REMOVE DECK SIDE TRIM
(a) Remove the side trim tool bag cover.
(b) Remove the 8 screws.
(c) Using a screwdriver, remove the deck side trim.
5. REMOVE ROOF SIDE INNER GARNISH
(a) Remove the rear seat outer belt shoulder anchor bolt.
(b) Remove the screw and 3 clips.
(c) Using a screwdriver, remove the roof side inner garnish.
6. REMOVE QUARTER WINDOW GLASS
Remove the 3 clips and glass.

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).

GENERAL REPAIR INSTRUCTIONS
Work Precautions
VEHICLE PROTECTION
When welding, protect the
painted surfaces, windows,
seats and carpet with heat-
resistant, fire-proof covers. SAFETY
Never stand in direct line
with the chain when using
a puller on the body or
frame, and be sure to
attach a safety cable.SAFETY
1. Before performing repair work, check
for fuel leaks. If a leak is found, be sure
to close the opening totally.
2. If it is necessary to use a frame in the
area of the fuel tank, first remove the
tank and plug the fuel line.
WRONG
Glass Cover
Safety Cable
Seat Cover
WRONG
HAND TOOLS
Keeping your hand tools
in neat order improve
your work efficiency. SAFETY WORK CLOTHES
In addition to the usual mechanic's wear, cap and safety shoes,
the appropriate gloves, head protector, glasses, ear plugs, face
protector, dust-prevention mask, etc. should be worn as the
situation demands.
Dust-
Prevention
MaskWelder's
Glasses
Ear
Plugs
Face
ProtectorBody
Tools
Stand
Head
Protector Eye
Protector
Welder's
Gloves Safety
Shoes
INTRODUCTIONINœ9