1996 TOYOTA RAV4 Service Repair Manual

BO485−01
BO0020
H03781
H03807: 7 Clips
H03783
BO2455
Panel
Cover Cotton Tape
BO−16
− BODYREAR DOOR
1996 RAV4 (RM447U)
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.
2. REMOVE DOOR INSIDE HANDLE BEZEL
(a) Remove the screw.
(b) Using a screwdriver, pry out the bezel.
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.
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-
dle.
7. REMOVE SERVICE HOLE COVER
Remove the 2 grommets and service hole cover.
HINT:
At the time of reassembly, bring out the connector though the
service hole cover.

H03784: 5 Clips
H03785
N14554
− BODYREAR DOOR
BO−17
1996 RAV4 (RM447U)
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
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.
(e) Remove the window regulator through the service hole.
HINT:
At the time of reassembly, apply MP grease to the window regu-
lator rollers.
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.
Apply adhesive to the 3 screws.

N14555
BO−18
− BODYREAR DOOR
1996 RAV4 (RM447U)
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent.
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.

BO0ZZ−01
H03786
H03787
BO2556
− BODYREAR DOOR
BO−19
1996 RAV4 (RM447U)
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)
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)
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.

BO486−01
BO−20
− BODYREAR DOOR
1996 RAV4 (RM447U)
REASSEMBLY
Reassembly is in the reverse order of disassembly procedure (See page BO−16).

BO101−09
Z17570
− BODYBACK DOOR
BO−21
1996 RAV4 (RM447U)
BACK DOOR
COMPONENTS

BO487−01
N11413
BO2455
Panel
Cover Cotton Tape
N11427
N11556
N11463
BO−22
− BODYBACK DOOR
1996 RAV4 (RM447U)
DISASSEMBLY
HINT:
Tape the screwdriver tip before using to pry parts.
1. REMOVE BACK DOOR UPPER COVER
2. REMOVE BACK DOOR TRIM BOARD
3. REMOVE SERVICE HOLE COVER
HINT:
At the time of reassembly, bring out the links through the service
hole cover.
4. REMOVE BACK SPARE TIRE BRACKET
5. REMOVE REAR WIPER ARM
6. REMOVE WIPER MOTOR
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:
Apply adhesive to the 3 screws.
Part No. 08833−00070, THREE BOND 1324 or equiva-
lent.
Apply MP grease to the sliding surface of the door lock
control.
(b) Disconnect the connector.
(c) Disconnect the 2 links.
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.

H04262: 12 Clips
N11440
− BODYBACK DOOR
BO−23
1996 RAV4 (RM447U)
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.
10. REMOVE STOP LIGHT COVER
11. REMOVE UPPER GARNISHES
12. REMOVE UPPER SIDE GARNISHES
13. REMOVE STOP LIGHT