Toyota RAV4 2009 User manual

Upper Mesh Grille (includes):
12 Gage S.S. Polished Surround
Fine Mesh Section
Top Mounting Plate
Lower Retainer w/Pins
(10) #8-32 ESNA Half Nuts
Lower Grille Mesh Surround
Lower Grille Mesh Section
Hardware Kit (components listed below):
(8) #8-32 ESNA Half Nuts
(4) .156” x 1” Vinyl Caps
(1’) 3/4” x .045” Double Faced Tape
(8) 1.006” x .189” x .062” Black Plastic Washers
(1) Upper Grille Hole Location Template
(1) Emblem Plate
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Description Part No.
Quantity
************
1130-0038-09
1130-0020-09
1130-0210-09
1130-0049-09
1999-0065-00
1130-0022-09
1130-0021-09
1130-1902-09
1999-0065-00
1999-0241-00
3004-9247-92
1999-0264-00
1130-0039-09
1297-0158-08
Fine Mesh Part #1130-0102-09
1. Open the hood and remove the factory push
pins retaining the black radiator support panel
cover and remove the cover.
3. Pull up on the outer corners of the bumper
cover and use a 10mm deep socket to remove
the two (2) bolts securing the upper brace.
Shop Tip:
Use a magnet to remove the bolts once they
are loose.
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WARNING! PLEASE HANDLE WITH CARE!
THE EDGES OF THE STAINLESS STEEL MESH &
GRILLE MAY BE SHARP!
2. Remove the two (2) factory screws and five
(5) factory push pins retaining the sides of
the bumper cover.
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IMPORTANT: PLEASE RETAIN THIS INSTRUCTION MANUAL FOR FUTURE REFERENCE
2009 Toyota RAV-4
Stainless Steel
Mesh Grilles
L 30 G8P
Important information before you begin:
This E&G grille installation kit includes
grille hole location template(s) to drill
mounting holes in the vehicle. Before
marking or drilling any holes into the
vehicle, you MUST verify that the tem-
plate(s) provided in this kit match the
mounting pin locations on the grille(s).
Upper “Q” Grille (includes):
12 Gage S.S. Polished Upper “Q” Grille
Top Mounting Plate
Lower Retainer w/Pins
(10) #8-32 ESNA Half Nuts
12 Gage S.S. Polished Lower “Q” Grille
Hardware Kit (components listed below):
(8) #8-32 ESNA Half Nuts
(4) .156” x 1” Vinyl Caps
(1’) 3/4” x .045” Double Faced Tape
(8) 1.006” x .189” x .062” Black Plastic Washers
(1) Upper Grille Hole Location Template
(1) Emblem Plate
1
1
1
Description Part No.
Quantity
************
1130-0184-09
1130-0210-09
1130-0049-09
1999-0065-00
1130-0183-09
1130-1902-09
1999-0065-00
1999-0241-00
3004-9247-92
1999-0264-00
1130-0039-09
1297-0158-08
“Q” Part #1130-0185-09Q

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6.Remove the rubber weatherstrip from the clips
holding it to the top edges of the bumper cover.
8.Pull out on the sides of the factory bumper cover to
release it from the sides of the factory grille.
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5.Remove the upper grille support bar from behind the
factory grille. Save for reinstallation.
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7.Pull the top of the factory grille toward you and
remove the lower four (4) 10mm hex bolts and the
mounting clips they thread into. Shop Tip: Use a small
flat blade screw driver to carefully pry to clips off once
the bolts are removed. You will not be able to remove
the factory grille from the bumper cover if you do not
remove the clips first. Do not drop the clips behind
the bumper cover.
9.Push in on the factory grille while holding the sides
of the bumper cover to release it.
Shop Tip:
Place a piece of cardboard in front of the AC con-
denser to protect it while removing the factory grille.
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4.Disconnect the electrical connectors from the horns
mounted onto the top brace and remove the
10mm hex bolt from the center bracket (where
shown, pull the grille forward to expose the bolt).
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12.Remove the factory grille emblem by pushing in on
the clips and push the emblem off.
11.Remove the factory weatherstrip from across the
top of the factory grille and remove the clips that
retain the weatherstrip (to be reused on the mesh
grille).
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14.Peel off the double faced tape backing, align the
mounting tabs through the slots in the emblem
backing plate and press the emblem firmly in place
to set the tape.
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13.Clean the back of the emblem and install the sup-
plied double faced tape (where shown).
15.Trim the factory tabs protruding from the back of
the emblem plate prior to installation onto the
mesh grille to keep the tabs from contacting the
mesh.
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10. Carefully remove the factory grille from behind the
bumper cover. The factory grille fits around the
bumper cover so do not force the removal. Take
your time and do not damage the painted bumper
cover.
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20.
Prior to lower grille installation, peel back a corner of
the protective covering on the lower grille surround.
19.Trim the ends from the vinyl caps supplied in the
hardware kit and install one onto each of the
lower mounting studs.
18. Carefully trim paint anything inside the grille opening
with flat or semi-gloss black paint that would be visi-
ble through the mesh grille.
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17. Reinstall the upper grille support, reusing the facto-
ry hardware previously removed. Reconnect the
factory horns at this time.
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21.Align the mesh section and surround into the
lower grille opening and install a large black plastic
washer and a #8-32 ESNA lock nut onto the lower
studs and tighten. Do not overtighten or you will
indent the stainless grille surround at the stud loca-
tions!
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16.Carefully center the emblem assembly onto the
mesh grille and install a 1” O.D. by 1/8” I.D. black
plastic washer, stainless steel lock washer and a
#8-32 stainless steel nut onto each stud and tight-
en. It may be necessary to clip the mesh in order
to perfectly center the emblem.

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28.Reinstall the upper factory screws and push pins to
retain the top of the mesh grille, then reinstall the
rubber weatherstrip onto the mesh grille and the
top edges of the bumper cover.
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27.Reinstall the weatherstrip push pins back into the
weatherstrip prior to installation across the top of
the mesh grille.
26. Align the mesh grille lower mounting pins with the
slots drilled in the previous step and push the mount-
ing pins through the slots until the grille is tight
against the bumper cover.
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25. Carefully drill through the marks made in the previous
step with a .125” (1/8”) drill bit. Use the drill bit to
connect the holes making a mounting slot to allow
for slight left to right adjustment. Do not slip with the
drill bit while making the slots or you will damage the
bumper cover!
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23. Cut out and align the upper grille lower mounting
hole location template with the center line of the grille
opening and tape it into place.
24.Use an awl or similar pointed tool to mark the center
of the hole locations onto the bumper cover, them flip
the template over and mark the hole locations onto
the opposite side. Remove the template.
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22.Apply masking tape around the edges of the bumper
cover at the upper grille opening. Measure and mark
the exact center of the grille opening (as shown).
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30. Carefully close the hood to once again check for
proper grille to hood clearance to make sure the
radiator support panel cover did not push the
assembled grille forward. The bumper cover sur-
rounding the grille should also be flush with the
hood.
31. Finished installation.
29. Reinstall the radiator support panel cover back
onto the vehicle using the factory push fasteners.
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