Maintenance - 4.2

[Hoovie]

Difficulty - Medium

Time – 45 Minutes

Tools - 12mm Sockets, PZ2 Pozidrive Screwdriver, Flat blade Screwdriver, Pliers, Trim removal tool or thin blade (scraper, etc) wrapped with tape to protect, Protective blanket (to rest bumper on)

Frequency – As required.

Introduction

To access a number of components, it is necessary to remove the bumper. This is a description of how that can be done on a RAV 4.2 2003-2006 Model (Round Fog light version).

The RAV4.2 2000-2003 Model (Square Fog lights) looks to be identical but I cannot guarantee that.

Procedure

This diagram shows the various components of the front assembly – the items that must be removed are numbered 1,2 & 3

1. The Grill must be removed first.

The screws circled in Red hold the grill in place and are removed with the PZ2 driver. The grill is also secured by three clips that are accessible – just – by moving the top of the grill forward. These are plastic clips are separated by a sharp pull forwards if you are feeling brave or the clips can be persuaded to come out by careful pressure of the securing lugs to release. NOTE: be VERY careful how any tools are used when working near the rad – the fins of the rad are easily damaged by knife blades, screwdriver tips, etc. so make sure no tools slip and hit it.

2. Once the Grill is removed, the "Front End Panel" must be removed. This is taken off by removing the two screws circled in Green in the picture in 1. above; the four plastic clips visible once the grill is off (position is shown circled in green below);

And then another bit of bravery is required…The End Panel is kept in place at each end by two plastic fittings – the holes for these fittings are circled in red above. These just pull off, but require firm persuasion to come out. Again take great care with any tools as you are separating painted metal parts and do not want any tools to slip, so this is where a trim removal tool could help.

3. Once the end panel is removed, the Front Bumper itself can be removed. This is done by removing the 7 hex screws (using a mix of spanner and screwdriver) in the positions circled below in green. The 2 areas circled in red keep the bumper in position via a simple tongue and groove style clip and no tools are needed there.

Before the screws are removed, it is best to position the blanket or cloth underneath for the bumper to rest on to avoid any scratches.

4. There is not a lot of free play on the cabling to the foglights, so it is best to unplug those as the bumper is freed so they are not strained supporting the bumper in mid air.

When the car is in this disassembled mode, work such as replacing horns, washer bottle, fitting nudge bars, etc can be carried out.

Reassembly is in the exact reverse order, taking care to ensure the bumper is aligned correctly on the clips that are shown within the red circles and the screws that go into the front wing areas before fully tightening the screws underneath.

[Helirazor]

Thanks for a great run down of how to do this.

I'm looking like I will have to do this as I fear my washer motors have had it with this icey weather despite a near concentrated mix.

Just one point, could you tell me what the 2 x clips on the End Panel are like? I'm thinking of may be getting some in before attempting, then if they break I'm not left with a Rav in bits and no clips to fix them?

If anyone else is thinking the same here's the place I have found who sell all kinds of clips etc:-

http://www.tools-supplies.co.uk/automotive-trim-clipsbody-clipsbody-fixings-156-c.asp

[Mike JD]

If anyone else is thinking the same here's the place I have found who sell all kinds of clips etc:-

http://www.tools-supplies.co.uk/automotive-trim-clipsbody-clipsbody-fixings-156-c.asp

Now that is one useful link, chap. Very gratefully bookmarked. Been looking for that sort of supplier for a while

Mike D

[Davrav]

Thanks for a great run down of how to do this.

I'm looking like I will have to do this as I fear my washer motors have had it with this icey weather despite a near concentrated mix.

Just one point, could you tell me what the 2 x clips on the End Panel are like? I'm thinking of may be getting some in before attempting, then if they break I'm not left with a Rav in bits and no clips to fix them?

If anyone else is thinking the same here's the place I have found who sell all kinds of clips etc:-

http://www.tools-supplies.co.uk/automotive-trim-clipsbody-clipsbody-fixings-156-c.asp

That's an excellent find - less than 10 miles from home and hadn't a clue they were there

[crofter]

Great post,hoovie,THANKS.

As it covers the Mk2 it is now stored.

[Ravi Shankar]

Excellent article have bookmarked that link may replace my fiddley Battery cover clips with the screw type ones.

[Ady-Rav4]

Hey thanks Hoovie for posting this. It's a great guide for me as I want to replace the standard horns with twin air horns. It was easy to do when we had our 4.1, as there was room without no dimantling. But when we got our 4.2, the first view under the bonnet, I thought, god, 2 fans, thats buggered it! Need to change the horns soon, don't like the beep beep!

[sniper9652]

Hi all, I intend on removing my bumper tomorrow so that I can put it into a body repair on Monday to have some 'plastic welding' done to a split/crack that extends from underneath the round fog light and around it slightly, it is a complete split/crack from the bottom of the bumper upwards!

Q.1. Do I have to remove the neg lead (-) off the Battery so that the airbags will be safe?

Q.2. I have the Toyota Rav 4 moulded bull bar fitted to the bumper...is this easy to remove once the bumper is off?

Sorry if I have missed this in 'Hoovies' excellent description of bumper removal!

TIA, Steve

[Hoovie]

Hey Steve, thanks for the comment :)

Q1 - airbag .... I didn't, but doesn't mean I did it right!

Q2 - Nudge Bar ... From memory, the bolts are exposed once bumper off and just needs right sized spanner to undo (a spray of WD40 first may be a good idea)

How much you being charged for the bumper repair, BTW?

Cheers,

David.

[Big Kev]

Hey Steve, thanks for the comment :)

Q1 - airbag .... I didn't, but doesn't mean I did it right!

Q2 - Nudge Bar ... From memory, the bolts are exposed once bumper off and just needs right sized spanner to undo (a spray of WD40 first may be a good idea)

How much you being charged for the bumper repair, BTW?

Cheers,

David.

OoPS....HOOVIE'S NEW BUSINESS HEID JUST CLICKED IN THERE....!!!!!

[sniper9652]

Hey Steve, thanks for the comment :)

Q1 - airbag .... I didn't, but doesn't mean I did it right!

Q2 - Nudge Bar ... From memory, the bolts are exposed once bumper off and just needs right sized spanner to undo (a spray of WD40 first may be a good idea)

How much you being charged for the bumper repair, BTW?

Cheers,

David.

Hi David, they have quoted me £120 all in inc re-paint (of mended area) as long as I take the bumper off to save on labour charges! They are in Warrington and have a very professional set-up so I think this is a fair price?

Steve

[Hoovie]

£120 is pretty ballpark for a hot weld and repaint on a bumper I think, but it does sound like your crack is pretty extensive, so not bad a deal (offset by you adding in your own labour, but the bumper removal is a quick job )

Have fun :)