BO−1

BODY − CLIP

CLIP
BO0ZO−01

REPLACEMENT
The removal and installation methods of typical clips used in body parts are shown in the table below.
HINT:
If the clip is damaged during the operation, always replace it with a new clip.

Shape (Example) Removal / Installation

Pliers

Clip Remover

Screwdriver

Scraper

V00005

1996 RAV4 (RM447U)

BO−2
BODY − CLIP

Shape (Example) Removal / Installation

Removal Installation

Removal
Installation

V00012

1996 RAV4 (RM447U)

BO−4
BODY − FRONT BUMPER

FRONT BUMPER
BO0ZQ−15

COMPONENTS

Z17567

1996 RAV4 (RM447U)

 BO−5
BODY − FRONT BUMPER
BO481−01

REMOVAL
1. REMOVE FRONT FENDER MOULDING
2. REMOVE FENDER LINER
3. REMOVE FRONT BUMPER COVER
Remove the 4 bolts, 3 clips, 2 screws and the bumper cover.
4. REMOVE HEADLIGHT UNDER COVER
5. REMOVE HEADLIGHT

N11455

6. REMOVE UPPER REINFORCEMENT

Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
7. REMOVE BUMPER STAY
Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)

N11456

1996 RAV4 (RM447U)

BO−6
BODY − FRONT BUMPER
BO482−01

INSTALLATION
Installation is in the reverse order of removal procedure (See page BO−5).

1996 RAV4 (RM447U)

 BO−7
BODY − REAR BUMPER

REAR BUMPER
BO3D3−02

COMPONENTS

N17305

1996 RAV4 (RM447U)

BO−8
BODY − HOOD

HOOD BO0ZS−01

ADJUSTMENT
HINT:
Since the centering bolt is used as the hood hinge and lock set
bolt, the hood and lock cannot be adjusted with it on. Substitute
the bolt with washer for the centering bolt.
Centering Bolt Standard Bolt
H01976

1. ADJUST HOOD IN FORWARD/REARWARD AND

LEFT/RIGHT DIRECTIONS
Adjust the hood by loosening the hood side hinge bolts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

N11408

2. ADJUST FRONT EDGE OF HOOD IN VERTICAL

DIRECTIONS
Adjust the hood by turning the cushions.

N11409

3. ADJUST HOOD LOCK

Adjust the lock by loosening the 2 bolts and nut.
Torque:
7.5 N·m (75 kgf·cm, 65 in.·lbf) for bolt
8.5 N·m (85 kgf·cm, 74 in.·lbf) for nut

N11458

1996 RAV4 (RM447U)

 BO−9
BODY − FRONT DOOR

FRONT DOOR
BO0ZT−14

COMPONENTS

N17928

1996 RAV4 (RM447U)

BO−10
BODY − FRONT DOOR
BO483−01

DISASSEMBLY
HINT:
Tape the screwdriver tip before using to pry parts.
1. w/o Power Window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a shop rag and remove the regulator
handle and plate.

BO0020

2. REMOVE INSIDE HANDLE BEZEL

(a) Remove the screw.
(b) Using a screwdriver, pry out the bezel.
3. REMOVE OUTSIDE REAR VIEW MIRROR COVER
4. REMOVE DOOR PULL HANDLE
5. w/ Power window:
REMOVE POWER WINDOW SWITCH

N11412

6. REMOVE DOOR TRIM

(a) Remove the 3 screws.
(b) Insert a screwdriver between the door and door trim to pry
out the door trim.
(c) Pull the trim upwards to remove it.

N11473

7. REMOVE DOOR INSIDE HANDLE

(a) Disconnect the link and door lock cable.
(b) Remove the 2 screws and inside handle.
8. REMOVE SERVICE HOLE COVER
HINT:
At the time of reassembly, bring out the links through the service
hole cover.
9. REMOVE OUTSIDE REAR VIEW MIRROR
N17924 10. REMOVE DOOR GLASS RUN
11. REMOVE DOOR BELT MOULDING
12. REMOVE DOOR SPEAKER

1996 RAV4 (RM447U)

 BO−11
BODY − FRONT DOOR

13. REMOVE DOOR GLASS

(a) Open the door glass until the bolts appear in the service
hole.
(b) Remove the 2 bolts.
NOTICE:
Be careful not to drop the door glass.
(c) Pull up the door glass upwards to remove it.

N11460

14. REMOVE WINDOW REGULATOR

(a) Remove the door lock cable from the window regulator.
(b) Remove the 6 nuts.
(c) Disconnect the connector.
(d) Remove the regulator through the service hole.

N17925

HINT:
At the time of reassembly, apply MP grease to the window regu-
lator rollers.

N11568

15. REMOVE DOOR LOCK

(a) Remove the clip.
(b) Disconnect the link from the door lock.
(c) Remove the 3 screws.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
HINT:
At the time of reassembly, apply adhesive to the 3 screws.
Part No. 08833−00070, THREE BOND 1324 or equiva-
N17926 lent
(d) w/ Power door lock:
Disconnect the connector.
(e) Remove the door lock through the service hole.

1996 RAV4 (RM447U)

BO−12
BODY − FRONT DOOR

HINT:
At the time of reassembly, apply MP grease to the sliding sur-
face of the door lock.
16. REMOVE OUTSIDE HANDLE
17. REMOVE DOOR LOCK CYLINDER
Remove the snap ring and door lock cylinder from the outside
handle.

N17927

1996 RAV4 (RM447U)

 BO−13
BODY − FRONT DOOR
BO0ZV−01

ADJUSTMENT
1. ADJUST DOOR IN FORWARD/REARWARD AND VER-
TICAL DIRECTIONS
Using SST, adjust the door by loosening the body side hinge
bolts.
SST 09812−00010
Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)

N11553

2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL

DIRECTIONS
Loosen the door side hinge bolts to adjust.
HINT:
Substitute the standard bolt for the centering bolt (See page
BO−8).
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

N11554

3. ADJUST DOOR LOCK STRIKER

(a) Check that the door fits and door lock linkages are ad-
justed correctly.
(b) Loosen the striker mounting screws to adjust.
(c) Using a plastic hammer, tap the striker to adjust it.

BO2556

1996 RAV4 (RM447U)

BO−14
BODY − FRONT DOOR
BO484−01

REASSEMBLY
Reassembly is in the reverse order of disassembly procedure (See page BO−10).

1996 RAV4 (RM447U)

 BO−15
BODY − REAR DOOR

REAR DOOR
BO0ZX−14

COMPONENTS

Z17568

1996 RAV4 (RM447U)

BO−16
BODY − REAR DOOR
BO485−01

DISASSEMBLY
HINT:
Tape the screwdriver tip before using to pry the parts.
1. w/o Power Window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a shop rag and remove the regulator
handle and plate.

BO0020

2. REMOVE DOOR INSIDE HANDLE BEZEL

(a) Remove the screw.
(b) Using a screwdriver, pry out the bezel.

H03781

3. REMOVE DOOR TRIM

(a) Remove the 2 screws from the armrest.
(b) Insert a screwdriver between the retainer and door trim
board to pry the door trim loose.
(c) Remove the door trim.

: 7 Clips H03807

4. REMOVE ARMREST
Remove the 2 screws and armrest from the door trim.
5. REMOVE POWER WINDOW SWITCH
(a) Disconnect the connector.
(b) Using a screwdriver, remove the switch.
6. REMOVE DOOR INSIDE HANDLE
(a) Remove the 2 bolts.
(b) Disconnect the control link and remove door inside han-
H03783 dle.

7. REMOVE SERVICE HOLE COVER

Remove the 2 grommets and service hole cover.
HINT:
Panel
At the time of reassembly, bring out the connector though the
Cotton Tape service hole cover.
Cover

BO2455

1996 RAV4 (RM447U)

 BO−17
BODY − REAR DOOR

8. REMOVE DOOR BELT MOULDING

9. REMOVE DOOR GLASS RUN
10. REMOVE DIVISION BAR
11. REMOVE REAR DOOR QUARTER WINDOW WEATH-
ERSTRIP
12. REMOVE REAR DOOR QUARTER WINDOW GLASS

: 5 Clips
H03784

13. REMOVE DOOR GLASS AND WINDOW REGULATOR

ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 3 bolts and nut from the window regulator.
(c) w/o Power Window:
Remove the 3 bolts from the window regulator.
(d) Remove the 2 nuts and glass channel from the window
regulator lift arm bracket, then remove the door glass.
H03785 (e) Remove the window regulator through the service hole.
HINT:
At the time of reassembly, apply MP grease to the window regu-
lator rollers.

N14554

14. REMOVE DOOR LOCK ASSEMBLY

(a) w/ Power door Lock:
Disconnect the connector.
(b) Disconnect the 2 links from the outside handle.
(c) Remove the 3 screws and door lock assembly.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
HINT:
At the time of reassembly, refer to following procedure.
S Apply adhesive to the 3 screws.

1996 RAV4 (RM447U)

BO−18
BODY − REAR DOOR

Part No. 08833−00070, THREE BOND 1324 or equiva-

lent.

S Apply MP grease to the sliding and rotating parts of the

door lock assembly.
15. REMOVE DOOR OUTSIDE HANDLE
Remove the 2 bolts and door outside handle.

N14555

1996 RAV4 (RM447U)

 BO−19
BODY − REAR DOOR
BO0ZZ−01

ADJUSTMENT
1. ADJUST DOOR IN FORWARD/REARWARD AND VER-
TICAL DIRECTIONS
Using SST, adjust the door by loosening the body side hinge
bolts.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)

H03786

2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL

DIRECTIONS
Loosen the door side hinge bolts to adjust.
HINT:
Substitute the standard bolt for the centering bolt (See page
BO−8).
Torque: 12N·m (122 kgf·cm, 9 ft·lbf)

H03787

3. ADJUST DOOR LOCK STRIKER

(a) Check that the door fits and door lock linkages are ad-
justed correctly.
(b) Loosen the striker mounting screws to adjust.
(c) Using a plastic hammer, tap the striker to adjust it.

BO2556

1996 RAV4 (RM447U)

BO−20
BODY − REAR DOOR
BO486−01

REASSEMBLY
Reassembly is in the reverse order of disassembly procedure (See page BO−16).

1996 RAV4 (RM447U)

 BO−21
BODY − BACK DOOR

BACK DOOR
BO101−09

COMPONENTS

Z17570

1996 RAV4 (RM447U)

BO−22
BODY − BACK DOOR
BO487−01

DISASSEMBLY
HINT:
Tape the screwdriver tip before using to pry parts.
1. REMOVE BACK DOOR UPPER COVER
2. REMOVE BACK DOOR TRIM BOARD

N11413

3. REMOVE SERVICE HOLE COVER

HINT:
Panel At the time of reassembly, bring out the links through the service
hole cover.
Cotton Tape 4. REMOVE BACK SPARE TIRE BRACKET
5. REMOVE REAR WIPER ARM
Cover
6. REMOVE WIPER MOTOR

BO2455

7. REMOVE DOOR LOCK ASSEMBLY

(a) Remove the 4 plug hole covers and 3 screws.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
HINT:
S Apply adhesive to the 3 screws.
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent.

N11427

S Apply MP grease to the sliding surface of the door lock

control.
(b) Disconnect the connector.
(c) Disconnect the 2 links.

N11556

8. REMOVE BACK DOOR OUTSIDE HANDLE

(a) Remove the 4 plug hole covers.
(b) Remove the 4 screws, door lock and back door outside
handle.

N11463

1996 RAV4 (RM447U)

 BO−23
BODY − BACK DOOR

9. REMOVE DOOR OUTSIDE GARNISH

(a) Remove the 4 plug hole covers.
(b) Insert a screwdriver between the door outside garnish
and back door to remove the door outside garnish.
(c) Disconnect the license plate light connector.

: 12 Clips
H04262

10. REMOVE STOP LIGHT COVER

11. REMOVE UPPER GARNISHES
12. REMOVE UPPER SIDE GARNISHES
13. REMOVE STOP LIGHT

N11440

1996 RAV4 (RM447U)

BO−24
BODY − BACK DOOR
BO103−02

ADJUSTMENT
1. ADJUST DOOR IN FORWARD / REARWARD AND
VERTICAL DIRECTIONS
Adjust the door by slightly loosening the hinge nuts on the body
side.
Torque: 27 N·m (270 kgf·cm, 19 ft·lbf)

N11422

2. ADJUST DOOR LOCK STRIKER

(a) Loosen the striker mounting screws.
(b) Using a plastic hammer, tap the striker to adjust it.

N11428

1996 RAV4 (RM447U)

 BO−25
BODY − BACK DOOR
BO488−01

REASSEMBLY
Reassembly is in the reverse order of disassembly procedure (See page BO−22).

1996 RAV4 (RM447U)

BO−26
BODY − FRONT WIPER AND WASHER

FRONT WIPER AND WASHER

BO105−01

COMPONENTS

Cowl Top Ventilator Louver

Wiper Arm

Wiper Arm
Cover
Wiper Arm Cover
20 (200, 15) 20 (200, 15)

Wiper Arm

5.4 (55, 48 in.·lbf)

Wiper Motor Link

5.4 (55, 48 in.·lbf)

Wiper Motor

N·m (kgf·cm, ft·lbf) : Specified torque

H03762

1996 RAV4 (RM447U)

 BO−27
BODY − FRONT WIPER AND WASHER
BO106−01

REMOVAL
1. REMOVE FRONT WIPER ARMS
2. REMOVE COWL TOP VENTILATOR LOUVER
3. REMOVE FRONT WIPER MOTOR
(a) Disconnect the connector, then remove the 4 bolts.
(b) Disconnect the motor from the wiper link and remove it.
4. REMOVE WIPER LINK
(a) Remove the 6 bolts.
(b) Remove the wiper link through the service hole.

1996 RAV4 (RM447U)

BO−28
BODY − FRONT WIPER AND WASHER
BO3D4−01

INSPECTION
INSPECT FRONT WASHER NOZZLE
While operating the washer, check that the distance between
the point where the washer fluid from the upper nozzles hits the
windshield and the upsurge area are within the range indicated
by the hatched line.
A Approx. 250 mm (9.84 in.)
B Approx. 270 mm (10.6 in.)
C Approx. 370 mm (14.5 in.)
D Approx. 155 mm (6.10 in.)
E Approx. 240 mm (9.44 in.)
F Approx. 200 mm (7.87 in.)
G Approx. 370 mm (14.5 in.)

1996 RAV4 (RM447U)

 BO−29
BODY − FRONT WIPER AND WASHER
BO108−01

2 ∼ 2.5 mm ADJUSTMENT
(0.079 ∼ 0.098 in.) ADJUST FRONT WASHER NOZZLE
Using a tool like the one shown in the illustration, change the
direction of the nozzle hole to adjust the point where washer
fluid hits the windshield.

0.7 ∼ 0.75 mm
(0.028 ∼ 0.030 in.) BE3367

1996 RAV4 (RM447U)

BO−30
BODY − FRONT WIPER AND WASHER
BO109−01

INSTALLATION
1. INSTALL WIPER LINK
Install the wiper link through the service hole, then torque the
6 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
2. INSTALL WIPER MOTOR
(a) Connect the wiper motor to the wiper link.
(b) Torque the 4 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(c) Connect the connector.
3. INSTALL COWL TOP VENTILATOR LOUVER
4. INSTALL WIPER ARMS
(a) Install the wiper arms and operate the wipers once and
turn the wiper switch OFF.

(b) Adjust the installation positions of the wiper arms to the

positions, as shown.
A Approx. 25 mm (0.98 in.)
A
B Approx. 25 mm (0.98 in.)
(c) Tighten the nut.
Torque: 20 N·m (200 kgf·cm, 15 ft·lbf)
B

N11511

1996 RAV4 (RM447U)

 BO−31
BODY − REAR WIPER AND WASHER

REAR WIPER AND WASHER

BO10A−01

COMPONENTS

Back Door
Upper Cover

Back Door Trim Board

Service Hole Cover

Wiper Arm

Wiper Motor
5.4 (55, 48 in.·lbf)

Grommet

N·m (kgf·cm, ft·lbf) : Specified torque

H03763

1996 RAV4 (RM447U)

BO−32
BODY − REAR WIPER AND WASHER
BO10B−01

REMOVAL
1. REMOVE REAR WIPER ARM
2. REMOVE BACK DOOR UPPER COVER
3. REMOVE BACK DOOR TRIM BOARD
4. REMOVE SERVICE HOLE COVER
5. REMOVE REAR WIPER MOTOR ASSEMBLY
(a) Disconnect the connector, then loosen the 3 bolts.
(b) Remove the motor assembly.
N11413

1996 RAV4 (RM447U)

 BO−33
BODY − REAR WIPER AND WASHER
BO10C−01

ADJUSTMENT
B INSPECT REAR WASHER NOZZLE
While operating the washer, check that the point where the
washer fluid hits the back door glass and the upsurge area are
within the range indicated by the circle.
A Approx. 174 mm (6.85 in.)
B Approx. 167 mm (6.57 in.)
A
H02952

1996 RAV4 (RM447U)

BO−34
BODY − REAR WIPER AND WASHER
BO10D−01

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
A B
the wiper switch OFF.
(c) Adjust the installation position of the wiper arm to the posi-
tion, as shown.
A Approx. 6.2 mm (0.24 in.)
N11513
B Approx. 184 mm (7.24 in.)

1996 RAV4 (RM447U)

 BO−35
BODY − BODY OUTSIDE MOULDING

BODY OUTSIDE MOULDING

BO489−01

COMPONENTS

N17307

1996 RAV4 (RM447U)

BO−36
BODY − BODY OUTSIDE MOULDING
BO48A−01

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.

N11441

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.

N11442

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.
N11443

(b) Using a screwdriver, pry out the clips and remove the
moulding.

N17309

1996 RAV4 (RM447U)

 BO−37
BODY − BODY OUTSIDE MOULDING

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.

N17310

1996 RAV4 (RM447U)

BO−38
BODY − BODY OUTSIDE MOULDING
BO48B−01

INSTALLATION
Installation is in the reverse order of removal procedure (See page BO−36).

1996 RAV4 (RM447U)

 BO−39
BODY − WINDSHIELD

WINDSHIELD
BO10N−01

COMPONENTS

z Dam
z Stopper
Windshield
Sun Visor
Holder
Inner Rear
View Mirror Cover
Holder
Sun Visor
Inner Rear
View Mirror

z Windshield Moulding Personal Light

Personal Light Cover
Front Pillar Garnish

Hood to Cowl Top Seal

Wiper Arm

Arm Cover Front Pillar Garnish

20 (200, 15)

Arm Cover Wiper Arm

20 (200, 15)

Cowl Top Ventilator

Louver

N·m (kgf·cm, ft·lbf) : Specified torque

z Non−reusable part
H03769

1996 RAV4 (RM447U)

BO−40
BODY − WINDSHIELD
BO10O−12

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.

N11424

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.

BO5232

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.
BO1689 NOTICE:
Leave as much of the adhesive on the body as possible
when cutting off the glass.

1996 RAV4 (RM447U)

 BO−41
BODY − WINDSHIELD
BO10P−08

INSTALLATION
Adhesive 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
(a) Using a knife, cut away any rough areas on the body.
HINT:
Adhesive
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:
BO4420
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.

BO5231

3. INSTALL STOPPERS
Install the stoppers onto the glass as shown in the illustration.

14.8 mm
(0.58 in.)

H02972

4. INSTALL DAM
25 mm 7 mm Install the dam with double−stick tape all the way around of
(0.98 in.) (0.27 in.) glass except where the stoppers are installed as shown on the
illustration.
NOTICE:
Do not touch the glass face after cleaning it.

Under Upper / Side

H02973

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.

H03791

1996 RAV4 (RM447U)

BO−42
BODY − WINDSHIELD

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.

BO4421

7. COAT CONTACT SURFACE OF BODY WITH PRIMER

Primer M Primer M
”M”
Using a brush, coat Primer M to the exposed part of body on the
vehicle side.
NOTICE:
S Let the primer coating dry for 3 minutes or more.
S Do not coat Primer M to the adhesive.
Primer M
S Do not keep any of the opened primer M for later use.
Adhesive H02865

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:
S Let the primer coating dry for 3 minutes or more.
Primer G S Do not keep any of the opened Primer G for later use.
N08473

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.
Temperature Tackfree time
A
35°C (95°F) 15 minutes
H03970
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.)

1996 RAV4 (RM447U)

 BO−43
BODY − WINDSHIELD

10. INSTALL GLASS

(a) Position the glass so that the reference marks are lined
up, and press in gently along the rim.

H03790

(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.

N08495

(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.
Temperature Minimum time prior to driving the vehicle
BO3986
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
1996 RAV4 (RM447U)
BO−44
BODY − WINDSHIELD

17. INSTALL PERSONAL LIGHT

18. INSTALL INNER REAR VIEW MIRROR

1996 RAV4 (RM447U)

 BO−45
BODY − QUARTER WINDOW GLASS (3−Door)

QUARTER WINDOW GLASS (3−Door)

BO48C−01

COMPONENTS

N18296

1996 RAV4 (RM447U)

BO−46
BODY − QUARTER WINDOW GLASS (3−Door)
BO48D−01

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.

: 4 Clips H02975

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 Clips
9. REMOVE QUARTER WINDOW LOCK
H02976 Remove the bolt, 2 screws and quarter window glass.
10. REMOVE HINGE

1996 RAV4 (RM447U)

 BO−47
BODY − QUARTER WINDOW GLASS (3−Door)
BO48E−01

INSTALLATION
Installation is in the reverse of removal procedure (See page BO−46).

1996 RAV4 (RM447U)

BO−48
BODY − QUARTER WINDOW GLASS (5−Door)

QUARTER WINDOW GLASS (5−Door)

BO48F−01

COMPONENTS

N14560

1996 RAV4 (RM447U)

 BO−49
BODY − QUARTER WINDOW GLASS (5−Door)
BO48G−01

REMOVAL
HINT:
Tape the screwdriver tip before using to pry parts.
1. REMOVE REAR DOOR SCUFF PLATE
2. REMOVE REAR FLOOR FINISH PLATE

N14553

3. REMOVE REAR SIDE TRIM

4 Clips (a) Remove the rear seat outer belt floor anchor bolt.
(b) Using a screwdriver, pull the garnish upwards to remove
it.

H02978

4. REMOVE DECK SIDE TRIM

(a) Remove the side trim tool bag cover.
: Clip (b) Remove the 8 screws.
(c) Using a screwdriver, remove the deck side trim.

H02979

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.
: 4 Clips

H02980

6. REMOVE QUARTER WINDOW GLASS

Remove the 3 clips and glass.

H02981

1996 RAV4 (RM447U)

BO−50
BODY − QUARTER WINDOW GLASS (5−Door)
BO48H−01

INSTALLATION
Installation is in the reverse order of removal procedure (See page BO−49).

1996 RAV4 (RM447U)

 BO−51
BODY − BACK DOOR GLASS

BACK DOOR GLASS

BO10W−01

COMPONENTS

z Back Door Moulding

Back Door Glass

Wiper Arm

5.4 (55, 48 in.·lbf)

Stop Light
Upper Side
Stop Light Garnish
Cover

Upper Garnish

Back Door Upper Cover

Upper Side Garnish

N·m (kgf·cm, ft·lbf) : Specified torque

z Non−reusable part
H03772

1996 RAV4 (RM447U)

BO−52
BODY − BACK DOOR GLASS
BO10X−08

REMOVAL
1. REMOVE STOP LIGHT COVER
2. REMOVE UPPER GARNISHES
3. REMOVE UPPER SIDE GARNISHES
4. REMOVE STOP LIGHT
5. REMOVE WIPER ARM

6. REMOVE BACK DOOR MOULDING

Using a knife, cut off the moulding as shown in the illustration.
NOTICE:
Do not damage the body with the knife.

H04707

7. REMOVE BACK DOOR GLASS

(a) Push piano wire through 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.

BO5232

NOTICE:
When scraping 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 plas-
tic sheet between the piano wire and safety pad.
(c) Cut the adhesive by pulling the piano wire around it.
(d) Remove the glass.
NOTICE:
H03789 Leave as much of the adhesive on the body as possible
when cutting off the glass.

1996 RAV4 (RM447U)

 BO−53
BODY − BACK DOOR GLASS
BO48I−01

Adhesive
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
(a) Using a knife, cut away any rough areas on the body.
Adhesive 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:
BO4420
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.

BO5231

3. REPLACE SPACER
(a) Remove the damaged stopper.
(b) Cut off the old adhesive around the stopper installation
area.
NOTICE:
Be careful not to damage the body.
(c) Clean the installation area.
(d) Position the spacers on the edge of the glass, as shown.
H02982

4. 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.

H03788

1996 RAV4 (RM447U)

BO−54
BODY − BACK DOOR GLASS

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.

BO4421

6. COAT CONTACT SURFACE OF BODY WITH PRIMER

Primer M Primer M ”M”
Using a brush, coat Primer M to the exposed part of body on the
vehicle side.
NOTICE:
S Let the primer coating dry for 3 minutes or more.
S Do not coat Primer M to the adhesive.
Primer M
S Do not keep any of the opened primer M for later use.
Adhesive H02865

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:
S Let the primer coating dry for 3 minutes or more.
Primer G S Do not keep any of the opened Primer G for later use.
N08473 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-
A scribed in the chart below.
Temperature Tackfree time

B 35°C (95°F) 15 minutes

H02984
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.)

1996 RAV4 (RM447U)

 BO−55
BODY − BACK DOOR GLASS

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.

H03898

(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.
Temperature Minimum time prior to driving the vehicle
BO3986
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

1996 RAV4 (RM447U)

BO−56
BODY − REMOVABLE ROOF

REMOVABLE ROOF BO3D5−01

ON−VEHICLE INSPECTION
INSPECT REMOVABLE ROOF ALIGNMENT
(a) With the removable roof closed, check for water leakage.

N11736

(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.)

N11465

1996 RAV4 (RM447U)

 BO−57
BODY − REMOVABLE ROOF
BO3D6−01

COMPONENTS

1996 RAV4 (RM447U)

BO−58
BODY − REMOVABLE ROOF

N17929

1996 RAV4 (RM447U)

 BO−59
BODY − REMOVABLE ROOF
BO3D7−01

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.

N11414

8. REMOVE LOCK HANDLE

Remove the 2 screws and lock handle from the removable roof.
9. REMOVE AUXILIARY CATCH

1996 RAV4 (RM447U)

BO−60
BODY − REMOVABLE ROOF

10. REMOVE WIND DEFLECTOR PANEL

Remove the 2 deflector panel clips, while prying them with a
screwdriver.

N11417

11. REMOVE LOCK BASE

Remove the 2 screws and lock garnish.
12. REMOVE LOCK GARNISH
Remove the 2 nuts, lock base and spacer.

N11415

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

1996 RAV4 (RM447U)

 BO−61
BODY − REMOVABLE ROOF
BO3D8−01

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

N11414

4. ADJUST REMOVABLE ROOF

(a) Remove the 2 nuts and lock base.
(b) Adjust it by increasing or decreasing the number of
Spacer spacers.
(c) Install the lock base with 2 nuts.
5. INSTALL LOCK GARNISH
Install the lock garnish with 2 screws.

N11446

1996 RAV4 (RM447U)

BO−62
BODY − REMOVABLE ROOF
BO3D9−01

INSTALLATION
Installation is in the reverse order of removal (See page BO−59).

1996 RAV4 (RM447U)