Toyota PZQ72-42080 User manual

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PLACE THESE INSTRUCTIONS IN VEHICLE GLOVEBOX AFTER INSTALLATION IS COMPLETE
Ensure appropriate PPE is worn
whilst installing this accessory.
!CAUTION Review the compliance plaque fitted to the cargo barrier
for correct maintenance of this accessory.
Periodically check the torque of all fasteners to values
listed in instructions.
CARE INSTRUCTIONS Approximately 90 minutes.
INSTALLATION TIME
RAV4
FITTING INSTRUCTIONS
PRODUCTION DATE: DECEMBER 2012 ONWARDS
ACCESSORY PART NUMBER: PZQ72-420 CARGO BARRIER

ISSUE 1:  PART NUMBER: PZQ72-4200PAGE 2 OF 13
KIT CONTENTS
TOOLS REQUIRED
1 2 3 4
Fitting Instructions Cargo Barrier Upper Straps Bolt Pack
CHECK THAT THE CONTENTS OF THE CARGO BAR-
RIER KITARE COMPLETE & UNDAMAGED PRIOR TO
FITMENT.
!IF ANY CONTENTS OF THE CARGO BARRIER KITARE INCOMPLETE OR
DAMAGED THEY MUST BE REPLACED USING SPECIFIED ACESSORY
COMPONENTS.
!
x1 x1 x2 x1
1 2 3 4
Trim Removal Tool Metric Sockets & Spanners Torque wrench Sharp knife
5 6
9
78
Hammer Right Angle Drill
19mm Vinyl Cutter
De-Burring Tool
Metric Drill Set
Centre Punch
Allen Key Set
10 11

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CARGO BARRIER ASSEMBLY
ITEM NO. DESCRIPTION QTY.
1
WELDED FRAME ASSEMBLY
1
12
LOWER WHEEL BRACE BRACKET PASSENGER
1
13
LOWER WHEEL BRACE BRACKET DRIVER
1
14
BOTTOM STRAP REAR
2
15
TOP STRAP REAR
2
16
ANCHOR PLATE
4
17
BUSH PLASTIC 16mm
4
18
CARGO BOLT 35 MM 4
19
M6 SPRING WASHER
8
20
WASHER M10 WAVE
10
21
SCREW BUTTON HD M6 X 16
8
22
SCREW BUTTON HD M10 X 16
2
23
BOLT COACH M10 X 35 4
24
WASHER FLAT M10
4
25
THUMB NUT 4
26 BUSH RUBBER 25 X 9.5 4
27
COVER PLATE
2
28
15G ANTI RUST SACHET
1
29
M10x1.5x40mm SPIKE
1
23 26 24 20 25
15
222016
12
14
1
4 PLACES
13
8 PLACES
2119
1820172716
2 PLACES
18 20 17
2 PLACES BOTH SIDES
BOTH SIDES
2 PLACES
28 29

PART NUMBER: PZQ72-420 0 PAGE 4 OF 13
1. Removing lower trim panel.
1.1.
1.1.
Open the luggage compartment door of the vehicle and fold the
Open the luggage compartment door of the vehicle and fold the
second row seats down.
second row seats down.
1.2.
1.2.
Remove the deck board to expose the wheel well.
Remove the deck board to expose the wheel well.
1.3.
1.3.
Remove the spare wheel from the vehicle.
Remove the spare wheel from the vehicle.
1.4.
1.4.
Remove the plastic storage compartment by removing the three
Remove the plastic storage compartment by removing the three
trim plugs with a trim plug removal tool.
trim plugs with a trim plug removal tool.
1.5.
1.5.
Use a No.2 philips head screwdriver to remove the four screws
Use a No.2 philips head screwdriver to remove the four screws
holding the centre storage compartment in place.
holding the centre storage compartment in place.
1.6.
1.6.
With the four screws removed, remove the centre floor storage
With the four screws removed, remove the centre floor storage
compartment.
compartment.
1.7.
1.7.
Passenger side screws shown. Repeat for for drivers side.
Passenger side screws shown. Repeat for for drivers side.
1.8.
1.8.
Using a No. 2 philips head screw driver remove the screw inside
Using a No. 2 philips head screw driver remove the screw inside
the cargo blind tether point.
the cargo blind tether point.
1.9.
1.9.
Passenger side screw shown. Repeat for for drivers side.
Passenger side screw shown. Repeat for for drivers side.
NOTICES
CAUTION :
Wear protective gloves during the removal of the trim as sharp edges on the parts may cause
injury.
RAV4 CARGO BARRIER
DECEMBER 2012 ONWARDS
ACCESSORY PART NUMBER: PZQ72-420 0
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PART NUMBER: PZQ72-420 0 PAGE 5 OF 13
RAV4 CARGO BARRIER
ACCESSORY PART NUMBER: PZQ72-4200
1.10. Using a 14mm socket and rachet remove the lower wheel
arch tie-down point .
1.11. Passenger side shown, repeat for drivers side.
1.12. Using a 10mm socket and rachet, remove both of the upper
trim screws shown.
1.13. Passenger side shown, repeat for drivers side.
1.14. Remove tie-down point using 10mm socket.
1.15. Using a small flat trim removal tool, remove the interior light
cover.
1.16. With the interior light detached from the trim, disconnect the
light at the connector .
1.17. Remove the rear scuff plate by carefully pulling the plate
upwards.
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PART NUMBER: PZQ72-4200
PAGE 6 OF 13
RAV4 CARGO BARRIER
ACCESSORY PART NUMBER: PZQ72-420 0
2. Removing upper trim panel.
1.18. Reach under the trim panel and pull towards the centre of the
vehicle.
1.19. With the trim levered from the car use both hands to DISLODGE
the trim from the upper trim panel and the vehicle shell.
NOTE : Ensure care is taken when levering the lower trim panel
from the vehicle. Slowly lever the trim panel to preserve the
functionality of the small trim clips.
2.1. Using a flat plastic trim removal tool, insert the tool between the
rear door seal and the upper trim panel as shown.
2.2. Lever the upper trim panel from the vehicle and DISLODGE.
2.3. Passenger side shown, repeat for drivers side.
3.1. Cut out TEMPLATE A with scissors and place the drilling
template on the drivers wheel brace support as shown.
3.2. Peel back the lower quarter trim and fix the template in place
with masking tape.
3.3. Repeat for passenger side using TEMPLATE B.
3.4. Using a centre punch, mark the three holes on the template.
3.5. Using a 7mm drill bit, drill all three holes using a cordless
drill as shown.
3.6. Using an 11mm drill bit, drill the centre hole using a cordless
drill.
3.7. Drivers side shown. Repeat for passenger side.
3. Installing lower mounting bracket.
DECEMBER 2012 ONWARDS
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PART NUMBER: PZQ72-420 0 PAGE 7 OF 13
RAV4 CARGO BARRIER
ACCESSORY PART NUMBER: PZQ72-420 0
3.8. Use a deburring tool to remove any burrs from the holes and
apply the anti-rust grease provided.
3.9. Drivers side shown. Repeat for passenger side.
3.10. Using an anchor plate , feed the plate into the wheel
brace support and align with the drilled holes.
3.11. Using the M6 x 16mm bolts and M6 spring washers ,
fasten the drivers lower wheel brace bracket to the
anchor plate.
TORQUE FASTENER TO 13Nm
3.12. Using the M10 x 16mm bolt and a wave washer ,
fasten the bolt in the centre hole.
TORQUE FASTENER TO 20Nm
3.13. Drivers side shown. Repeat for passenger side using the lower
wheel brace bracket passenger .
3.14. With the lower wheel brace bracket in place, screw the M10
spike provided into the captive nut in the bracket and
reinstall the lower trim panel by completing step 1.17. &
1.18. in reverse.
3.15. With the trim reinstalled apply pressure to the trim to identify a
witness mark in the lower trim panel created by the M10 spike.
3.16. With the witness mark identified, remove the spike and use a 19mm
vinyl cutter to cut a hole in the lower wheel arch panel as shown. Take
care to ensure the trim panels and brackets are not damaged.
3.17. Drivers side shown, repeat for passenger side.
NOTE: Leave the trim panel dislodged.
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PART NUMBER: PZQ72-4200 PAGE 8 OF 13
RAV4 CARGO BARRIER
DECEMBER 2012 ONWARDS
ACCESSORY PART NUMBER: PZQ72-420 0
4.1. Using a small flat trim removal tool, dislodge the centre
seatbelt trim cover from the headliner and remove.
4.2. Using a trim clip removal tool, remove the three trim
plugs from the headliner at the rear of the vehicle.
4.3. With the three trim plugs removed, cut out TEMPLATE C and
align the template with the centre trim plug hole and the edge
of the headliner.
4.4. Using a centre punch mark the centres of the two holes.
4.5. Lower the headliner and using a 7mm pilot hole drill bit fitted
with a 10mm depth stop and a 90 degree drill, drill the marked
centres of the holes, drilling through both the headliner and the
vehicle panel.
4.6. With a pilot hole drilled, use a 19mm vinyl cutter with a non
cutting pilot to cut the headliner holes.
DRILL THROUGH THE HEADLINER ONLY!
4.7. Using the cover plate provided, position the cover plate
over the drilled hole and align the plate so that it is parrellel to
the back door weather strip. Mark the two outer holes on the
panel using a marker.
4.8. Using a centre punch, mark the two outer holes.
4. Installing upper mounting anchors.
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PART NUMBER: PZQ72-4200 PAGE 9 OF 13
RAV4 CARGO BARRIER
ACCESSORY PART NUMBER: PZQ72-420 0
4.9. Using a 7mm drill bit and a 10mm drill stop, drill the holes
marked in 4.8 using a 90 degree drill. Use an 11mm drill bit
fitted with a 10mm depth stop to drill out the centre holes.
CAUTION: Take care when drilling through vehicle panel,
to ensure the drill piece does not pierce the outer roof skin.
4.10. Using a deburring tool, remove all burrs from the drilled holes
and apply anti rust grease to the drilled edges.
4.11. Passenger side shown, repeat for drivers side.
4.12. With the holes drilled, feed the anchor plate through the
panel cutout and align over the drilled holes.
4.13. Using four M6 x 16mm bolts and M6 spring washers
attach the cover plate to the anchor plate installed in 4.13.
TORQUE FASTENER TO 13Nm
4.14. With the mounting plates secured in place, use a vacuum
cleaner to extract all swarf and shavings from the headliner
and vehicle panel cavity.
4.15. Raise the headliner back up and secure in place with the trim
plugs removed in step 4.2.
4.16. Reinstall the interior trim of the car by following steps 1.1. to
2.2. in reverse.
5.1. With the frame outside of the car, insert the coach bolts
through the frame mounts and secure this bolt in place by
sliding the rubber bush over the bolt.
5.2. Fold the second row seats into the upright position.
5. Preparing the barrier for installation.
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PART NUMBER: PZQ72-4200
PAGE 10 OF 13
RAV4 CARGO BARRIER
DECEMBER 2012 ONWARDS
ACCESSORY PART NUMBER: PZQ72-4200
6.1. Insert the frame assembly though the rear door of the vehicle
and place the barrier in position behind the second row seats.
6.2. Fasten the two top rear straps to the coach bolt
on the frame using the thumb nuts , M10 flat washer
and M10 wave washers .
6.3. With the top straps fastened to the frame, fasten the free end
of the straps to the upper mounts previously installed in the
vehicle. Place the 16mm plastic bush into the 19mm hole
in the headliner and fasten the strap to the vehicle using the
35mm cargo bolt and M10 wave washer .
6.4. Installing the lower mounting brackets.
6.5. Fasten the rear bottom bracket to the cargo barrier by
placing the slotted hole in the bracket over the coach bolt in the
cargo barrier frame and secure in place using a thumb nut
and an M10 wave washer .
6.6. Fasten the free end of the lower rear bracket to the lower
wheel brace bracket ( & ) through the trim using a
16mm plastic bush , M10 wave washer and a 35mm
cargo bolt .
6.7. With all the brackets attached to the barrier and the vehicle,
ensure that the barrier is positioned centrally about the vehicle
and tighten all thumb nuts and cargo bolts to a firm hand
tightness.
6.8. After completion, store the fitting instructions
in the vehicles glove box for future reference.
6. Installing the barrier in the rear position.
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