1996 TOYOTA RAV4 Service Repair Manual

INSTALLATION
BODY PANEL REPLACEMENTREœ27

REAR FLOOR SIDE REAR MEMBER (ASSY)
REMOVAL (With the rear floor pan extension and rear
floor inner crossmember removed.)
Rear Floor Inner Crossmember
1. After removing the rear floor inner crossœ
member, remove the rear floor side rear
member.
BODY PANEL REPLACEMENTREœ28

INSTALLATION
Butt Weld
1. Temporarily install the new parts and meaœ
sure each part in accordance with the body
dimension diagram.2. Install the new parts of rear floor inner crossœ
member shown above.
BODY PANEL REPLACEMENTREœ29

ROOF PANEL (ASSY): Normal Roof
REMOVAL
BODY PANEL REPLACEMENTREœ30

INSTALLATION
Body Sealer
1. Before temporarily installing the new parts,
apply body sealer to the windshield header
panel, roof panel reinforcement and back
door opening frame.HINT:
1) Apply just enough sealer for the new parts to
make contact.
2) For other sealing points, refer to Section AR.
BODY PANEL REPLACEMENTREœ31

ROOF PANEL (ASSY): Moon Roof
REMOVAL
BODY PANEL REPLACEMENTREœ32

INSTALLATION
Body Sealer
1. Before temporarily installing the new parts,
apply body sealer to the windshield header
panel, roof panel reinforcement and back
door opening frame.HINT:
1) Apply just enough sealer for the new parts to
make contact.
2) For other sealing points, refer to Section AR.
BODY PANEL REPLACEMENTREœ33

CodeMaterial
nameHeat*
resistant
temperature
limit °C (°F)Resistance to
alcohol or gasolineNotes
AASAcrylonitrile
Acrylic Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid gasoline and
organic or aromatic
solvents.
ABSAcrylonitrile
Butadiene Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease.)Avoid gasoline and
organic or aromatic
solvents.
AESAcrylonitrile
Ethylene Styrene80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
BMCBulk
Moulding
Compound150
(302)Alcohol and gasoline are
harmless.Most solvents are
harmless.
CABCellulose
Acetate80
(176)Alcohol is harmless if applied
only for short time in small
amounts (e.g., quick wiping to
remove grease).Avoid gasoline and
organic or aromatic
solvents.
EPDM100
(212) Ethylene
PropyleneAlcohol is harmless.
Gasoline is harmless if applied
only for short time in small
amounts.Most solvents are
harmless but avoid
dipping in gasoline,
solvents, etc.
PAPolyamide
(Nylon)80
(176)Alcohol and gasoline are
harmless.Avoid battery acid.
PBTPolybutylene
Terephthalate160
(320)Alcohol and gasoline are
harmless.Most solvents are
harmless.
PC
Polycarbonate120
(248)Alcohol is harmless.Avoid gasoline brake
fluid, wax, wax removers
and organic solvents.
Avoid alkali.
PE
Polyethylene80
(176)Alcohol and gasoline are harmless.Most solvents are
harmless.
PETPolyethylene
Terephthalate75
(167)Alcohol and gasoline are
harmless.Avoid dipping in water.
HANDLING PRECAUTIONS
1. The repair procedure for plastic body parts must conform with the type of plastic material.
2. Plastic body parts are identified by the codes in the following chart.
3. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding,
painting etc.), consideration must given to the property of the plastic.
*Temperatures higher than those listed here may result in material deformation during repair.
PLASTIC BODY PARTSPPœ2