1996 TOYOTA RAV4 Service Repair Manual

Vehicle Dimensions Left e Right
O-o
1,188
(46.77)P-p
1,388
(54.66)1,388
(54.66)Q-q
R-r
1,049
(41.30)S-s
1,202
(47.32)1,404
(55.28)T-t
1,374
(54.09)O-s
or
o-SO-t
or
o-T
1,541
(60.67)1,463
(57.60)P-t
or
p-T
1,639
(64.53)Q-r
or
q-R
1,525
(60.04)S-t
or
s-T
HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (Seen from rear.)
mm (in.)
(Three-Dimensional Distance)
Hole dia. Name
Roof side rail assembly mark
Quarter panel assembly mark
Quarter panel assembly mark Symbol
R, r
S, s
T, t Hole dia. Name
Center body pillar assembly mark
Center body pillar assembly mark
Rocker panel assembly mark Symbol
O, o
P, p
Q, q
BODY OPENING AREAS (Side View-Rear)
BODY DIMENSIONSDIœ5

HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (Seen from rear).
mm (in.)
(Three-Dimensional Distance)
Hole dia.
6 (0.24) nut
7.5y7.5 (0.295y0.295)
16 (0.63) Name
Back door stopper installation nut-lower
Rear floor finish plate installation hole
Shock absorber installation hole
Roof side rail assembly mark Symbol
c
D, d
E, e
F, f Hole dia.
13 (0.51)
8 (0.31) nut
13 (0.51) Name
Back door opening frame / Roof panel adjoining
portion
Back door hinge installation hole-upper
B
Back door lock striker installation nut-upper
C
Back door hinge installation hole-lower Symbol
A, a
b
BODY OPENING AREAS (REAR View)
BODY DIMENSIONSDIœ6

HINT: For symbols, capital letters indicate right side of vehicle,
small letters indicate left side of vehicle (Seen from rear).
(Two-Dimensional Distance)
mm (in.)
Hole dia.
18 (0.71)
18 (0.71)
34y17.5 (1.34y0.689)12.5 (0.492)
12.5 (4.492)
10 (0.39)
18 (0.71) Name
Front floor under reinforcement standard hole
Rear floor side member standard hole
Strut bar installation hole-inner
Rear suspension member installation nut
Rear floor crossmember working hole No. 3
Rear floor crossmember standard hole
Rear side member standard hole Symbol
G, g
H, h
I, i
J, j
K, k
L, l
M, m Hole dia.
8 (0.31) nut
18 (0.71)
10 (0.39) nut
12 (0.47) nut
14 (0.55) nut
12 (0.47) nut
18 (0.71) Name
Engine mounting member installation nut
Front side member standard hole
Engine mount installation nut-front
Engine mount installation nut
Front suspension crossmember installation nut
Front suspension crossmember installation nut-outer
Front floor under reinforcement standard hole Symbol
A, a
B, b
C
c
D, d
E, e
F, f
UNDER BODY
BODY DIMENSIONSDIœ7

Wheel Base2,410 (94.88)
Imaginary
Standard
Line
mm (in.)
(Two-Dimensional Distance)
Hole dia.
10 (0.39) nut
18 (0.71)
18 (0.71)
39y17.5 (1.34y0.689)12.5 (0.492)
12.5 (0.492)
10 (0.39)
18 (0.71) Name
Propeller shaft center support bearing installation nut
Front floor under reinforcement standard hole
Rear floor side member standard hole
Strut bar installation hole-inner
Rear suspension member installation nut
Rear floor crossmember working hole No. 3
Rear floor crossmember standard hole
Rear side member standard hole Symbol
H, h
I, i
J, j
K, k
L, l
M, rn
N, n
O, o Hole dia.
8 (0.31) nut
18 (0.71)
10 (0.39) nut
12 (0.47) nut
11 (0.43)
14 (0.55) nut
12 (0.47) nut
18 (0.71) Name
Engine mounting member installation nut
Front side member standard hole
Engine mount installation nut-front
Engine mount installation nut
Front spring support hole-outer
Front suspension crossmember installation nut
Front suspension crossmember installation nut-outer
Front floor under reinforcement standard hole Symbol
A, a
B, b
C
c
D, d
E, e
F, f
UNDER BODY (Cont'd)
G, g
BODY DIMENSIONSDIœ8

GENERAL INFORMATION
Anti-rust treatment is necessary before welding and before and after the painting process.
ANTI-RUST TREATMENT BEFORE WELDING
Weld-Through Primer
(Spot Sealer)1. WELD-THROUGH PRIMER (SPOT SEALER) APPLICATION
For anti-corrosion measures, always apply the
weld-through primer (spot sealer) to welding
surfaces where the paint film has been removed.
HINT: Apply the weld-through primer (spot sealer)
so that it does not ooze out from the joining surfaces.
WELD-THROUGH PRIMER (SPOT SEALER)
APPLICATION
ANTI-RUST TREATMENT BEFORE PAINTING PROCESS
Sealer Gum1. BODY SEALER APPLICATION
For water-proofing and anti-corrosion measures,
always apply the body sealer to the body panel
seams and hems of the doors, hoods, etc.
BODY SEALER APPLICATION
2. UNDERCOAT APPLICATION
To prevent corrosion and protect the body from
damage by flying stones, always apply sufficient
undercoat to the bottom surface of the under body
and inside of the wheel housings.
UNDERCOAT APPLICATION ANTI-RUST TREATMENT
ARœ2

Steel Metal Undercoat (ED Primer)Anti-Chipping Paint Second Coat
Steel Metal Undercoat (ED Primer) Second Coat Top Coat
ANTI-RUST TREATMENT AFTER PAINTING PROCESS
1. ANTI-RUST AGENT (WAX) APPLICATION
To preserve impossible to paint areas from corrosion,
always apply sufficient anti-rust agent (wax) to the inside
of the hemming areas of the doors and hoods, and
around the hinges, or the welded surfaces inside the
boxed cross-section structure of the side member, body
pillar, etc.
ANTI-RUST AGENT (WAX) APPLICATION
REFERENCE: ANTI-RUST TREATMENT BY PAINTING
Painting prevents corrosion and protects the sheet metal from damage. In this section, anti-chipping paint
only for anti-corrosion purpose is described.
1. ANTI-CHIPPING PAINT
To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint
to the rocker panel, wheel arch areas, valance panel, etc.
HINT:
Depending on the model or the application area, there are cases where the application of anti-chipping
paint is necessary before the second coat or after the top coat.

Apply the anti-chipping paint
before the second coat.
Apply the anti-chipping paint
after the top coat.
Anti-Chipping PaintTop Coat
ANTI-RUST TREATMENTARœ3

BODY PANEL SEALING AREAS
HINT:
1. Prior to applying body sealer, clean the area with a rag soaked in a grease, wax and silicone remover.
2. If weld-through primer was used, first wipe off any excess and coat with anti-corrosion primer before
applying body sealer.
3. Wipe off excess body sealer with a rag soaked in a grease, wax and silicone remover.
4. If body sealer is damaged by peeling, cracks, etc., be sure to repair as necessary.
Flat Surfacing
Flat Surfacing
ANTI-RUST TREATMENTARœ4

Flat Surfacing
Flat Surfacing
Flat Surfacing
ANTI-RUST TREATMENTARœ5