1996 TOYOTA RAV4 Service Repair Manual

Thickness of
welded portionSize of plug hole
1.0 (0.04) under 5 (0.20) f over
1.0 (0.04) - 1.5 (0.06) 6.5 (0.26) f over
1.5 (0.06) over 8 (0.31) f over
REFERENCE:mm (in.)
PREPARATION FOR INSTALLATION
SPOT WELD POINTS
APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER)
When welding panels with a
combined-thickness of over
3 mm (0.12in.), use a MIG
(Metal Inert Gas) welder for
plug welding.
HINT: Spot welding will not
provide sufficient durability
for panels over 3 mm
(0.12in.) thick.
Less than
3 mm
Remove the paint from
the portion of the new
parts and body to be
welded, and apply
weld-through primer.
HINT: See ºANTI-
RUST TREATMENTº
on page AR-2.
Air Saw
WRONG
Puncher
20 - 30 mm
Overlap
ROUGH CUTTING OF JOINTS
For joint areas, rough cut the
new parts, leaving 20 - 30 mm
(0.79 - 1.18in.) overlap.MAKING HOLES FOR PLUG WELDING
For areas where a spot welder cannot be
used, use a puncher or drill to make holes
for plug welding.
INTRODUCTIONINœ11

New Spot
Locations
POST-WELDING
REFINISHING
1. Always check the welded
spots to insure they are
secure.
2. When smoothing out the
weld spots with a disc
grinder, be careful not to
grind off too much as this
would weaken the weld.
INSTALLATION
PRE-WELDING MEASUREMENTS
Always take measurements
before installing underbody or
engine components to insure
correct assembly. After installation,
confirm proper fit.WELDING PRECAUTIONS
1. The number of welding spots
should be as follows.
Spot weld: 1.3 y No. of
manufacturer`s spots.
Plug weld: More than No.
of manufacturer's plugs.
WRONG
WRONG OKAY
2. Plug welding should be done
with a MIG (Metal Inert Gas)
welder. Do not gas weld or
braze panels at areas other
than specified.
Safety Glass
Body
Measurement
Diagrams
SPOT WELDING PRECAUTIONS
1. The shape of the welding tip
point has an effect on the
strength of the weld.
2. Always insure that the
seams and welding tip are
free of paint. SPOT WELD LOCATIONS
Try to avoid welding over
previous spots.
Old
Spot
Locations
Tip Cutter
INTRODUCTIONINœ12

ANTI-RUST TREATMENT
When replacing body panels, always apply body sealer, anti-rust agent or undercoat according to the reœ
quirements of your country.
HINT: For further details, see the description given in Section AR of this manual.
BODY SEALER
Apply body sealer to the
required areas.ANTI-RUST AGENT (WAX)
Apply anti-rust agent to
following sections.

Inside of the hems of the
doors and hood.

Around the hinges of the
doors and hood.

Inside of the welded parts
with boxed cross-section.
Cartridge Type Tube Type
UNDERCOAT
Apply undercoat to the underbody and
wheel housings.
Spray Gun
Undercoating
(Oil base)Undercoating
(Water base)
INTRODUCTIONINœ13

SUPPORT POSITIONPANTOGRAPH JACK POSITION
CAUTION: Before jacking-up the rear and front, make sure the car is
not carrying any extra weight.
Front Front crossmember. . . . . . . .
Rear Rear axle beam. . . . . . . .
JACK POSITION
Front
VEHICLE LIFT AND SUPPORT LOCATIONS
Safety stand and swing arm type lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTIONINœ14

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
w/ with
w/o without
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONINœ15

GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.
(Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.
(Two-dimensional distance)

Horizontal distance in forward/rearward between
the centers of two measuring points.

The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left
and right are symmetrical.
(c) The dimensions in the following drawing indicate
actual distance. Therefore, please use the dimenœ
sions as a reference.
2. MEASURING
(a) Basically, all measurements are to be done with a
tracking gauge. For portions where it is not possible
to use a tracking gauge, a tape measure should be
used.
(b) Use only a tracking gauge that has no looseness in
the body, measuring plate, or pointers.
HINT:
1. The height of the left and right pointers must be equal.
2. Always calibrate the tracking gauge before measuring or
after adjusting the pointer height.
3. Take care not to drop the tracking gauge or otherwise
shock it.
4. Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and
bends in the tape.
(d) When tracking a diagonal measurement from the
front spring support inner hole to the suspension
member upper rear installation hole, measure
along the front spring support panel surface.
Center-to-center
straight-line
distance Three-dimensional
distance
Front Spring Support Inner Hole
Tape Measure
Along Body
Surface
Front Suspension Member Rear Side
Upper Installation HoleMaster Gauge PointerPointer LoosenessBody LoosenessPlate Looseness Two-dimensional
distanceCenter-to-center
Horizontal distance in
forward/rearward
Vertical distance
in lower surface Vertical distance
in center
Imaginary Standard Line
WrongCorrect
Pointer
BODY DIMENSIONSDIœ2

HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (Seen from rear).
K-k
1386
(54.57)552
(21.73)C-K
or
c-k
1494
(58.82)C-k
or
c-K
(Three-Dimensional Distance)
mm (in.)
Hole dia.
6 (0.24) nut
10 (0.39)
10 (0.39)
6 (0.24) nut
10 (0.39) Name
Cooler condenser installation nut
Radiator support extension standard hole
Radiator support standard hole
Front bumper support installation nut
Front apron to cowl side member standard hole Symbol
G, g
H, h
I, i
J
K, k Hole dia.
6 (0.24) nut
11 (0.43)
6 (0.24) nut
13 (0.51)
18 (0.71) Name
Front fender installation nut
Front spring support hole - inner
Front fender installation nut
Cowl top panel center mark
Front side member standard hole
Front side member standard hole Symbol
A, a
B, b
C, c
D, d
E, e
F, f
BODY DIMENSION DRAWINGS
ENGINE COMPARTMENT
BODY DIMENSIONSDIœ3

1,140
(44.88)E-e
1,302
(51.26)F-fVehicle Dimensions Left e Right
1,388
(54.65)G-g H-h
1,388
(54.65)I-i
1,388
(54.65)1,044
(41.10)J-j
1,188
(46.77)K-k
1,403
(55.24)L-l
1,541
(60.67)E-g
or
e-G
1,586
(62.44)E-i
or
e-IE-k
or
e-K
1,289
(50.75)1,754
(69.06)G-k
or
g-K
1,585
(62.40)G-l
or
g-LH-q
or
h-Q
1,628
(64.09)I-j
or
i-J
1,626
(64.02)J-r
or
j-R
1,169
(46.02)1,497
(58.94)
HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (Seen from rear.)
K-l
or
k-L
(Three-Dimensional Distance)
mm (in.)
Hole dia.
13 (0.51)
13 (0.51) Name
Rocker panel assembly mark
Rocker panel assembly mark
Roof side rail assembly mark
Center body pillar assembly mark
Center body pillar assembly mark
Rear door hinge installation hole
Rear door hinge installation hole Symbol
H, h
I, i
J, j
K, k
L, l
M, m
N, n Hole dia.
8 (0.31) nut
8 (0.31) nut Name
Roof panel / front body pillar adjoining portion
Cowl top outer panel outside radius corner
Front door hinge installation nut
Front door hinge installation nut
Front body pillar assembly mark
Front body pillar assembly mark
Front body pillar assembly mark Symbol
A, a
B, b
C, c
D, d
E, e
F, f
G, g
BODY OPENING AREAS (Side View-Front)
BODY DIMENSIONSDIœ4