Toyota PT278-42130 User manual

TOYOTA RAV4/HV 2013 - CROSSBAR KIT
Preparation
Page 1 of 6 pages
Issue: G 12/13/2016
Part Number: PT278-42130
Kit Contents
Item # Quantity Reqd. Description
1 1 Crossbar Assembly Front (long)
2 1 Crossbar Assembly Rear (short)
3 1 Hardware Bag
Hardware Bag Contents
Item # Quantity Reqd. Description
1 1 Key
2 2 Forward Limit Label
3 1 Installation Instructions
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/HV 2013 - CROSSBAR KIT
Procedure
Page 2 of 6 pages
Issue: G 12/13/2016
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 the Front Crossbar “Forward Limit”
Warning Labels to the Side Rails.
(a) The side rail surface temperature must be
between 60˚F and 110˚F.
(b) Clean the area on the front LH side rail.
(c) Use a ruler to measure 83mm (3.25 in.)
back from the front of the side rail.
(d) Remove the adhesive backing from the
label and position it so that the triangle on
the label is pointing to the rear of the
vehicle. The label should be 83mm to the
rear of the vehicle from the back of the
front rail cover (2 places) (Fig. 1-1).
(e) Repeat Step 1 for the RH side.
2. Prepare the Front and Rear Crossbars.
(a) Open the crossbar levers (Fig. 2-1).
(b) Loosen the levers 2 turns
counterclockwise, lowering the clamp. DO
NOT DISENGAGE THE CLAMPS
FROM THE SUPPORTS (Fig. 2-1).
Front of
Vehicle
83mm
(3.25 in)
Fig. 1-1
Open
Lever
Loosen
Lever
2 Turns
Fig. 2-1

TOYOTA RAV4/HV 2013 - CROSSBAR KIT
Procedure
Page 3 of 6 pages
Issue: G 12/13/2016
3. Install the Front Crossbar.
(a) The front crossbar has a “FRONT” sticker
on the center of the bar (Fig. 3-1).
(b) Install the front crossbar at an angle
parallel with the roof surface (Fig. 3-1).
(1) Slide the 1
st
support over the side rail.
(2) Rotate the 2
nd
support forward over the
side rail.
NOTE: Make sure thje clamp is open
enough to clear the side rail. DO NOT
FORCE IT ONTO THE SIDE RAIL.
(c) Straighten the crossbar so that the front of
the support is 100mm (4 in.) rearward of
the “forward limit” warning label (2 places)
(Fig. 3-2).
(d) Make sure the FORWARD arrows on the
crossbar supports are pointing toward the
front of the vehicle (Fig. 3-2).
4. Secure the Front Crossbar.
(a) Turn the lever clockwise to tighten the
clamp to the crossbar (2 places) (Fig. 4-1).
(b) After the lever is tight, back off until the
lever lines up with the opening in the
support, and close the lever (2 places) (Fig.
4-1).
(c) Use the supplied key to turn the lock in the
lever to lock the crossbar in position (2
places) (Fig. 4-1).
1s
t
2n
d
Front of
Vehicle
Fig. 3-1
Lock Crossbar
Front of
Vehicle
100mm
(4in.)
Fig. 3-2
Tighten
Lever
Fig. 4-1

TOYOTA RAV4/HV 2013 - CROSSBAR KIT
Procedure
Page 4 of 6 pages
Issue: G 12/13/2016
5. Install the Rear Crossbar.
(a) Install the rear crossbar at an angle parallel
with the roof surface (Fig. 5-1).
(1) Slide the 1st support over the side rail.
(2) Rotate the 2nd support rearward over the
side rail.
NOTE: Make sure the clamp is open
enough to clear the side rail. DO NOT
FORCE IT ONTO THE SIDE RAIL.
(b) Straighten the rear crossbar so that the rear
of the crossbar is 51mm (2.0 in.) from the
front of the rear rail cover (2 places) (Fig.
5-2).
(c) Make sure the FORWARD arrows on the
crossbar supports are pointing toward the
front of the vehicle (Fig. 5-2).
6. Secure the Rear Crossbars.
(a) Turn the lever clockwise to tighten the
clamp to the crossbar (2 places) (Fig. 6-1).
(b) After the lever is tight, back off until the
lever lines up with the opening in the
support, and close the lever (2 places) (Fig.
6-1).
(c) Use the supplied key to turn the lock in the
lever to lock the crossbar in position (2
places) (Fig. 6-1).
1s
t
2n
d
Front of
Vehicle
Fig. 5-1
51mm (2 in.)
Fig. 5-2
Tighten
Lever
Lower Lever Lock Crossbar
Fig. 6-1

TOYOTA RAV4/HV 2013 - CROSSBAR KIT
Procedure
Page 5 of 6 pages
Issue: G 12/13/2016
7. Place the Installation Instructions.
(a) Place the Crossbar Installation Instructions
and the lever key in the supplied bag and
store it in the vehicle’s glove box.

TOYOTA RAV4/HV 2013 - CROSSBAR KIT
Checklist - these points MUST be checked to ensure a quality installation.
Check: Look For:
Page 6 of 6 pages
Issue: G 12/13/2016
Accessory Function Checks
Ensure crossbars are secure and in correct
position
Crossbar Installation Instructions/Key
Crossbar Gaps
Crossbar Orientation
Vehicle Function Checks
Front crossbar should not be forward of
warning label.
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.)