Toyota PT278-42130 User manual

TOYOTA RAV4 2013 - CROSSBAR KIT
Preparation
Page 1 of 4 pages
Issue: C 1/25/2013
Part Number: PT278-42130
Kit Contents
Item # Quantity Reqd. Description
1 1 Crossbar Assembly Front (long)
2 1 Crossbar Assembly Rear (short)
3 1 User’s Manual
Hardware Bag Contents
Item # Quantity Reqd. Description
1 1 Front LH Side Lower Clamp
2 1 Front RH Side Lower Clamp
3 1 Rear LH Side Lower Clamp
4 1 Rear RH Side Lower Clamp
5 1 Lever Key
6 4 Lever Assembly with t-bolt
7 2 Forward Limit Label
Additional Items Required For Installation
Item # Quantity Reqd. Description
1
2
3
Conflicts
Recommended Tools
Personal & Vehicle
Protection Notes
Safety Glasses
Safety Gloves
Vehicle Protection Cloth
Wrist & Belt Buckle
Protection
Special Tools Notes
Installation Tools Notes
Tape Measure (Metric)
Non-Intrusive Infrared Temp
Probe/Gun
Heat Gun
Special Chemicals Notes
Cleaner Approved Cleaner
General Applicability
Recommended Sequence of Application
Item # Accessory
1
2
3
*Mandatory
Vehicle Service Parts (may be required for reassembly)
Item # Quantity Reqd. Description
1
2
3
Legend
STOP: Damage to the vehicle may occur. Do not
proceed until process has been complied with.
OPERATOR SAFETY: Use caution to avoid risk of
injury.
CAUTION: A process that must be carefully observed
in order to reduce the risk of damage to the
accessory/vehicle and to ensure a quality installation.
TOOLS & EQUIPMENT: Used in Figures calls out the
specific tools and equipment recommended for this
process.
REVISION MARK: This mark highlights a change in
installation with respect to previous issue.
SAFETY TORQUE: This mark indicates that torque is
related to safety.

TOYOTA RAV4 2013 - CROSSBAR KIT
Procedure
Page 2 of 4 pages
Issue: C 1/25/2013
Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this
accessory should follow approved guidelines to ensure a quality installation.
These guidelines can be found in the "Accessory Installation Practices" document.
This document covers such items as:-
Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.).
Safety (eye protection, rechecking torque procedure, etc.).
Vehicle Disassembly/Reassembly (panel removal, part storage, etc.).
Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.).
Please see your Toyota dealer for a copy of this document. 1. Affix front crossbar “Forward Limit”
warning labels to side rails.
(a) The side rail surface temperature must be
between 60˚F and 110˚F.
(a) Clean the area on the front LH side rail.
(b) Using a ruler, measure 83mm (3.25 in.) back
from front of side rail.
(c) Remove adhesive backing from label and
position so that the triangle on the label is
pointing to the rear of the vehicle. Label
should be 83mm back from back of the front
rail cover. (Fig. 1-1)
(d) Repeat for RH side rail.
2. Install Crossbars (Fig. 2-1)
(a) Make sure FORWARD arrows on crossbar
end supports are pointing toward the front of
the vehicle. (Fig. 2-1)
(b) Load front crossbar (longer) so that the front
of the crossbar touches the line on “forward
limit” warning label. (2 places) (Fig. 2-1)
(c) Load rear crossbar (shorter) so that the rear
of the crossbar is ~50mm (~2 in.) from the
front of the rear rail cover. (2 places)
(Fig. 2-1)
NOTE: DO NOT POSITION FRONT
CROSSBAR ON OR FORWARD OF
WARNING LABEL.
(d) If necessary, adjust the width of the crossbar
by sliding the R.H. end support so that there
is a secure fit on the side rail. (Fig. 2-2c)
Fig. 1-1 83mm
(3.25in.) Front of
Vehicle
Front of
Vehicle
Fig. 2-1
~50mm
(~2 in.)
Fig. 2-2
Front of
Vehicle

TOYOTA RAV4 2013 - CROSSBAR KIT
Procedure
Page 3 of 4 pages
Issue: C 1/25/2013
3. Install Lower Clamps
(a) Verify proper clamps prior to installation by
looking for position markings on top of
clamp. (4 places) (Fig. 3-1)
(b) Carefully position clamp underneath side rail
under cross bar support. Use vehicle
protection to avoid contact with surface.
While positioning the clamp, insert the lever
through the hole on the support and into the
clamp. Make sure lever screw engages and
bottom support is flush with upper support.
Tighten lever handle until handle bottoms out
on support. (4 places) (Fig. 3-1)
(c) After lever is tight, back off one turn, line the
lever up with the opening in the support and
close lever. (4 places) (Fig. 3-2)
Be careful to avoid pinching.
NOTE: ENSURE THE CROSSBAR IS
SECURELY FASTENED TO THE SIDE
RAILS.
(d) Using the supplied key, turn lock in lever to
lock the crossbar in position. (4 places)
(Fig. 3-3)
4. Install User’s Manual
(a) Place Crossbar User’s Manual and lever key
in the vehicle’s glove box.
Fig. 3-1 Tighten
Fig. 3-2
Fig. 3-3
UNLOCKED
LOCKED
Position Marking
Front of
Vehicle

TOYOTA RAV4 2013 - CROSSBAR KIT
Checklist - these points MUST be checked to ensure a quality installation.
Check: Look For:
Page 4 of 4 pages
Issue: C 1/25/2013
Accessory Function Checks
Ensure crossbars are secure and in correct
position
Crossbar User’s Manual/ Lever Key
Crossbar Gaps
Crossbar Orientation
Vehicle Function Checks
Front crossbar should not be forward of
warning label.
User’s Manual, Installation Instructions and
Lever Key inside vehicle glove box.
Ensure crossbars are fully clamped with no
gaps around the end supports.
Ensure the crossbars FORWARD arrow is
facing the front of the vehicle.
Vehicle Appearance Check
After accessory installation and removal of
protective cover(s), perform a visual
inspection.
Ensure no damage (including scuffs and
scratches) was caused during the
installation process.
(For PPO installations, refer to TMS
Accessory Quality Shipping Standard.)