1996 TOYOTA RAV4 Service Repair Manual

BO48F−01
N14560
BO−48
− BODYQUARTER WINDOW GLASS (5−Door)
1996 RAV4 (RM447U)
QUARTER WINDOW GLASS (5−Door)
COMPONENTS

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.

BO48H−01
BO−50
− BODYQUARTER WINDOW GLASS (5−Door)
1996 RAV4 (RM447U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page BO−49).

BO10W−01
H03772
Back Door Glass Back Door Moulding
Wiper Arm
Stop Light
Stop Light
Cover
Upper GarnishUpper Side
Garnish
Back Door Upper Cover
Upper Side Garnish
5.4 (55, 48 in.·lbf)
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part
− BODYBACK DOOR GLASS
BO−51
1996 RAV4 (RM447U)
BACK DOOR GLASS
COMPONENTS

BO10X−08
H04707
BO5232
H03789
BO−52
− BODYBACK DOOR GLASS
1996 RAV4 (RM447U)
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.
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.
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:
Leave as much of the adhesive on the body as possible
when cutting off the glass.

BO48I−01
BO4420
Adhesive
Adhesive
BO5231
H02982
H03788
− BODYBACK DOOR GLASS
BO−53
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. 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.
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.

BO4421
H02865
Primer M
Primer M
Adhesive
Primer M
N08473
Primer G
H02984
A
B BO−54
− BODYBACK DOOR GLASS
1996 RAV4 (RM447U)
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.
6. 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.
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:
Let the primer coating dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use.
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-
scribed 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 grass with adhesive, as shown.
A: 10 mm (0.39 in.)
B: 10.5 mm (0.41 in.)

H03898
BO3986
− BODYBACK DOOR GLASS
BO−55
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.
(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.
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. 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