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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Body & Frame >> Exterior/Interior Trim >> Exterior Panels / Trim - Service Information (1 Of 3) (PHEV) >> Front Bumper >> Reassembly [06/2020 - 12/2021] >> Procedure

Reassembly [06/2020 - 12/2021]: Procedure

  1. INSTALL FRONT BUMPER EXTENSION SUB-ASSEMBLY LH 
    1. Install the front bumper extension sub-assembly LH with the 2 nuts and 2 bolts.
      GTY886157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt A
      Bolt B
      Nut

      for Bolt A 

      Torque: 135 N.m (1377 kgf/cm, 100 ft.lbf) 

      for Bolt B 

      Torque: 9.5 N.m (97 kgf/cm, 84 in.lbf) 

      for Nut 

      Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

  2. INSTALL FRONT BUMPER EXTENSION SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  3. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Attach the guide and install the No. 1 engine under cover as shown in the illustration.
      GTY881124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the 2 bolts.

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

      GTY1013785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT BUMPER NO. 2 REINFORCEMENT 
    1. Install the front bumper No. 2 reinforcement with the 4 nuts.
      GTY937273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 18 N.m (184 kgf/cm, 13 ft.lbf) 

  5. INSTALL FRONT BUMPER LOWER ABSORBER 
    1. Attach the claw and install the front bumper lower absorber.
      GTY1008264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the clip.
  6. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY 
    1. Install the front bumper reinforcement sub-assembly with the 8 bolts.
      GTY1009287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

    2. Attach the wire harness clamp.
      GTY882617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT BUMPER NO. 2 ENERGY ABSORBER 
    1. Attach the guide and install the front bumper No. 2 energy absorber.
      GTY1010133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT BUMPER SIDE RETAINER LH 
    1. Attach the clip and claw to install the front bumper side retainer LH as shown in the illustration.
      GTY1014629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the bolt.
  9. INSTALL FRONT BUMPER SIDE RETAINER RH 

    HINT: 

    Use the same procedure described for the LH side.

  10. INSTALL LOWER NO. 1 RADIATOR GRILLE 
    1. Attach the claw and guide to install the lower No. 1 radiator grille as shown in the illustration.
      GTY1009305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  11. INSTALL RADIATOR GRILLE PROTECTOR 

    HINT: 

    When installing a new radiator grille protector, heat the lower No. 2 radiator grille using a heat light.

    Standard

    Item Temperature
    Lower No. 2 Radiator Grille 20 to 30°C (68 to 86°F)
    WARNING:
    • Do not touch the heat light and heated parts.
    • Touching the heat light may result in burns.
    • Touching heated parts for a long time may result in burns.
    GTY749838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Heated Part
    *b Heat Light
    NOTE:

    Do not heat the lower No. 2 radiator grille excessively.

    1. When reusing the lower No. 2 radiator grille:
      1. Using a heat light, heat the lower No. 2 radiator grille surface.
      2. Remove any remaining double-sided tape from the lower No. 2 radiator grille.
      3. Wipe off any tape adhesive residue with cleaner.
        NOTE:
        • Installing the radiator grille protector with some double-sided tape remaining may cause poor adhesion. Perform this procedure until the tape is sufficiently removed.
        • Make sure to use a cloth when removing. Using a screwdriver, etc., may cause damage and poor adhesion.
        • Clean a new lower No. 2 radiator grille surface.
    2. Apply primer to the lower No. 2 radiator grille on the installation area of the radiator grille protector using a brush or felt.
      GTY1114815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark-off Line
      Primer
      NOTE:
      • Replace the brush or felt if it is dirty or has become hardened.
      • Keep any painted surface free from primer.
      • If the primer contacts a painted surface, it may leave light primer marks. Therefore, use protective tape when using liquid primer.
      • Do not touch surfaces to which primer has been applied until the radiator grille protector has been attached.
    3. Let the primer dry sufficiently.
      NOTE:

      Do not touch applied surfaces until the primer is dry.

      Recommended drying time

      10 minutes or more (at 23°C (73°F))

    4. Remove the release paper of a new radiator grille protector trying not to touch the adhesional surface.

      HINT: 

      After removing the release paper, keep the exposed adhesive free from foreign matter.

    5. Align the radiator grille protector with the mark-off line on the lower No. 2 radiator grille and install it.

      HINT: 

      Press the radiator grille protector firmly to install it.

      GTY1116625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark-off Line
  12. INSTALL LOWER NO. 2 RADIATOR GRILLE 
    1. Attach the claw and install the lower No. 2 radiator grille as shown in the illustration.
      GTY1009259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the 2 screws.
      GTY1009024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT BUMPER MOULDING 
    1. Attach the claw and guide to install the front bumper moulding as shown in the illustration.
      GTY1009105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
    2. Install the 4 screws.
  14. INSTALL FRONT BUMPER SIDE MOULDING LH 
    1. Attach the claw and install the front bumper side moulding LH as shown in the illustration.
      GTY1008968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the 3 screws.
  15. INSTALL FRONT BUMPER SIDE MOULDING RH 

    HINT: 

    Use the same procedure described for the LH side.

  16. INSTALL FRONT BUMPER GUARD 
    1. Attach the claw and guide to install the front bumper guard as shown in the illustration.
      GTY1009893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
    2. Install the 6 outside moulding retainers.
      GTY1009905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 screws.
  17. INSTALL FRONT BUMPER GUARD COVER LH 
    1. Attach the fall prevention hook to the guide.
      GTY1008129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fall Prevention Hook
    2. Attach the claw and install the front bumper guard cover LH as shown in the illustration.
      GTY1009172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  18. INSTALL FRONT BUMPER GUARD COVER RH 

    HINT: 

    Use the same procedure described for the LH side.

  19. INSTALL FRONT BUMPER ARM HOLE COVER LH 
    1. Attach the fall prevention hook to the guide.
      GTY1007615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fall Prevention Hook
    2. Attach the claw and install the front bumper arm hole cover LH as shown in the illustration.
      GTY1009588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  20. INSTALL FRONT BUMPER ARM HOLE COVER RH 

    HINT: 

    Use the same procedure described for the LH side.

  21. INSTALL RADIATOR GRILLE EMBLEM 
    1. Attach the claw and guide to install the radiator grille emblem as shown in the illustration.
      GTY1009859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the 2 screws.
  22. INSTALL FRONT BUMPER HOLE COVER LH 
    1. w/o Daytime Running Light:
      GTY1006009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
      1. Attach the claw and install the front bumper hole cover LH as shown in the illustration.
      2. Install the clip.
    2. w/ Daytime Running Light:
      GTY1009667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
      1. Attach the claw and install the front bumper hole cover LH as shown in the illustration.
      2. Install the clip.
  23. INSTALL FRONT BUMPER HOLE COVER RH 

    HINT: 

    Use the same procedure described for the LH side.

  24. INSTALL SIDE RADIATOR GRILLE MOULDING LH 
    1. Attach the claw and install the side radiator grille moulding LH as shown in the illustration.
      GTY1009462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  25. INSTALL SIDE RADIATOR GRILLE MOULDING RH 

    HINT: 

    Use the same procedure described for the LH side.

  26. INSTALL RADIATOR GRILLE BRACKET 
    1. Attach the claw and guide to install the radiator grille bracket as shown in the illustration.
      GTY1009880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the 8 screws.
    3. Attach the guide and install the 2 clips (B).
      GTY907958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Screw
      Clip (A)
      Clip (B)
    4. Install the 4 clips (A).
    5. Install the 2 screws.
  27. INSTALL FRONT HOOD TO END PANEL SEAL 
    1. Attach the clip and install the front hood to end panel seal as shown in the illustration.
      GTY1010139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  28. INSTALL FRONT BUMPER EXTENSION MOUNTING BRACKET 
    1. Install the front bumper extension mounting bracket with the 2 screws.
      GTY1007081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL NUT 
    1. Install the 2 nuts.
      GTY944804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  30. INSTALL NO. 4 ENGINE ROOM WIRE 
    1. w/o Daytime Running Light:
      1. Attach the clamp and install the No. 4 engine room wire.
        GTY1014424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *A w/ Intuitive Parking Assist System - -
    2. w/ Daytime Running Light:
      1. Attach the clamp and install the No. 4 engine room wire.
        GTY1007079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL DAYTIME RUNNING LIGHT ASSEMBLY LH (w/ Daytime Running Light) 

    Refer to PROCEDURE - Step 1

  32. INSTALL DAYTIME RUNNING LIGHT ASSEMBLY RH (w/ Daytime Running Light) 

    HINT: 

    Use the same procedure as for the LH side.

  33. INSTALL FRONT TELEVISION CAMERA ASSEMBLY (w/ Panoramic View Monitor System) 

    Refer to PROCEDURE - Step 1

  34. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  35. INSTALL FRONT CENTER ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) 

    Refer to PROCEDURE - Step 2

  36. INSTALL FRONT CORNER ULTRASONIC SENSOR RETAINER (w/ Intuitive Parking Assist System) 

    Refer to PROCEDURE - Step 3

  37. INSTALL FRONT CENTER ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) 

    Refer to PROCEDURE - Step 4

  38. INSTALL FRONT CORNER ULTRASONIC SENSOR (w/ Intuitive Parking Assist System) 

    Refer to PROCEDURE - Step 5

  39. INSTALL FRONT ULTRASONIC SENSOR CLIP (w/ Intuitive Parking Assist System) 

    Refer to PROCEDURE - Step 6

  40. INSTALL FOG LIGHT SEAL (w/o Intuitive Parking Assist System) 

    HINT: 

    • Use the same procedure for both fog light seals.
    • When installing the fog light seal, heat the front bumper cover and fog light seal using a heat light.

    Standard

    Item Temperature
    Front Bumper Cover 20 to 30°C (68 to 86°F)
    Fog Light Seal
    WARNING:
    • Do not touch the heat light and heated parts.
    • Touching the heat light may result in burns.
    • Touching heated parts for a long time may result in burns.
    GTY749838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Heated Part
    *b Heat Light
    NOTE:

    Do not heat the front bumper cover and fog light seal excessively.

    1. When reusing the front bumper cover:
      1. Using a heat light, heat the front bumper cover surface.
      2. Remove any remaining double-sided tape from the front bumper cover.
      3. Wipe off any tape adhesive residue with cleaner.
        NOTE:
        • Installing the fog light seal with some double-sided tape remaining may cause poor adhesion. Perform this procedure until the tape is sufficiently removed.
        • Make sure to use a cloth when removing. Using a screwdriver, etc., may cause damage and poor adhesion.
        • Also, clean a new front bumper cover surface.
    2. Apply primer to the front bumper cover on the installation area of the fog light seal using a brush or felt.
      GTY883188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Mark-off Line
      Primer
      NOTE:
      • Replace the brush or felt if it is dirty or has become hardened.
      • Keep any painted surface free from primer.
      • If the primer contacts a painted surface, it may leave light primer marks. Therefore, use protective tape when using liquid primer.
      • Do not touch surfaces to which primer has been applied until the fog light seal has been attached.
    3. Let the primer dry sufficiently.
      NOTE:

      Do not touch applied surfaces until the primer is dry.

      Recommended drying time

      10 minutes or more (at 23°C (73°F))

    4. Using a heat light, heat the front bumper cover and a new fog light seal.
      NOTE:

      Do not heat the front bumper cover and fog light seal excessively.

    5. Remove the release paper from the fog light seal.
      NOTE:

      After removing the peeling paper, do not touch the surface of the tape with your fingers or cotton work gloves.

    6. Install the No. 4 engine room wire in the position shown in the illustration.
      GTY884031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 4 Engine Room Wire
      *a Mark-off Line
    7. Install the fog light seal in the position shown in the illustration.
      NOTE:

      The application strength of the fog light seal will weaken if reapplied. If reapplication is necessary, be sure to replace it with a new one.

      HINT: 

      Apply pressure so that it does not lift up from the front bumper cover.

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