UPTOP BRAVO Roof Rack Installation Guide

up TOP BRAVO
Rav4 5G 2019-Up

BRAVO Roof Rack

Thank you for selecting upTOP™ as the choice for your vehicle. The roof rack designed for your platform requires competency with basic handle tools and assembly procedures. Proper Installation of this product requires modification to factory holes and the installation of threaded inserts into factory locations to anchor the roof rack in place. If you are not comfortable or you feel it is above your pay grade you are encouraged to seek professional installation of this product.

TOOLS REQUIRED

• 5/32 Allen wrench
• 5mm Allen wrench
• 3/16 Allen wrench
• 1/2” wrench (2X)
• 10mm wrench (2X)
• Cordless Drill
• Silicone Sealant
• Vibra TITE VC-3 Thread locker (Included)

The dynamic (moving) weight capacity of your roof rack far exceeds the specifications set forth by Toyota. Please follow manufacturer recommendations for the safe roof load capacity for the Toyota RAV4 5G. upTOP recommends keeping evenly distributed cargo loads of 250 pounds on the Toyota RAV4 5G. Static (parked) weight restrictions are limited to 850 pounds.
You will need adequate floor space to assemble your roof rack prior to installing it to your vehicle. An area 80×80” is recommended for this assembly.
You are encouraged to inspect the contents of your package prior to completing assembly and installation. For any missing/damaged parts email pictures and descriptions to [email protected] with your order number as reference in the subject line. A specialist will assist you with the process for field repair or component replacement.
It is important to plan for any wiring that needs to be completed during the course of rack installation. Incorporate these steps into the steps in this guide at points that reduce additional disassembly of the rack while it is installed on the vehicle.

NOTE
Factory roof rack/roof rails require additional tools not listed above. Please refer to page 10 for detailed information on the required tools and procedure for removing the factory rack/rails.

Toyota RAV4 5G Major Components

Toyota RAV4 5G Torque Specifications

Figure 1
1362 Front/Middle Foot
The Ambidextrous 1361 foot will be used as the FRONT and MIDDLE foot on both the DRIVER and PASSENGER side.
The INNER Slots (Shown here in ORANGE) will align with the FRONT mounting locations.
The OUTER Slots (Shown here in PINK) will align with the MIDDLE mounting locations.
The elongated slots are designed to facilitate left/right alignment of the rack on the vehicle.
Apply VC3 Thread locking compound to the threads of all twelve (12) feet to rack bolts and allow to dry. 15-20 minutes. Compound will remain gummy.

Figure 2
1363 Rear Foot
The Ambidextrous 1362 foot will be used as the REAR foot on both the DRIVER and PASSENGER side.
The kidney slots (Shown here in BLUE) allow the feet to articulate to the slope of the roof at the rear of the vehicle.
The 1363 feet will align with one of the grab handle (Not included) provisional holes on each side. If you are installing grab handles to the RAV4 5G rack the hardware included with the grab handles will supersede the original roof rack hardware. Just simply attach the foot along with the rest of the hardware and tighten to specification.
Apply VC3 Thread locking compound to the threads of all twelve (12) feet to rack bolts and allow to dry. 15-20 minutes. Compound will remain gummy.

Figure 3
Foot Alignment
Driver Side (2041) Shown Gather the following:

• 5mm Allen wrench
• 13mm wrench
• Foot to Rack Hardware
• 2041 Driver Side
• 2042 Passenger Side
• 1362 Front/Middle Feet
• 1363 Rear Feet
• Align the feet as shown above and insert the hardware. The bolt heads pass through the 2041 side into the feet.
• Install the two (2) 1362 Feet and the 1361 feet as shown.

Figure 4
1361 Shown
Hardware Orientation.

Figure 5
Foot Alignment
Passenger Side (2042) Shown

Gather the following:

• 5mm Allen wrench
• 13mm wrench
• Foot to Rack Hardware
• 2041 Driver Side
• 1362 Front/Middle Feet
• 1363 Rear Feet
• Align the feet as shown above and insert the hardware. The bolt heads pass through the 2042 side into the feet.
• Install the two (2) 1362 Feet and the 1361 feet as shown.
• As with the driver side the kidney slot in the 1363 is used at the rear of the roof rack. (See Alignment marks in Figure 3.)

PROGRESS CHECK
• Tighten all of the hardware for the feet by hand. Leave loose enough that you can adjust the angle to match the contour of the roof of the vehicle to aide in attaching the rack to the roof.

Figure 6
Load Bars
Driver Side (2041) Shown

Gather the following:

• 5/32 Allen wrench
• Load Bars (7 Total)
• Load Bar Hardware

The load bars shipped with your kit are all the same physical size and can be used in any load bar location in the roof rack assembly.
The REAR load bar will mount VERTICALLY (Shown here in PINK) in order to adequately clear the shark fan antenna mounted at the rear of your vehicle. We’ve also provided a horizontal slot in that location in the event that you choose to modify or remove your shark fin antenna and wish to run the rear load bar in the same orientation as the other six (6) load bars shown here in ORANGE.
Each load bar has two (2) thread tapped holes on each end and those 1/4-20 threaded holes are the mounting provisions for the load bars.
The load bar will install into the rack assembly as shown with the following hardware:

• (4) 1/4-20×1 Button Head Bolt
• (4) 1/4 Lock Washer
• Align and install the load bars into the rack.
• Repeat the process on the passenger side.
• Torque to specifications found on page 2.

NOTE
Although the load bars can be installed at any location within the horizontal slot it is important to ensure that the load bars are even with one another with respect to the DRIVER and PASSENGER side to ensure that the rack assembly is square.
Failure to install the load bars parallel from side to side can skew the rack body and cause alignment issues with the rack on the vehicle.
Load bars can be adjusted at any time after installation to facilitate better alignment with various pieces of kit.

WINDSCREEN

NOTE!!
Fairings cut for specific light bars as well as universal 40 cuts will experience significant wind noise when installed into the rack assembly and driven at speed with the light bar absent from the assembly. Wind passes through the open holes and/or slot and is intercepted by the front slot on the load bars.
The fairings are designed with this in mind and the angles/openings are engineered to work in unison with the light bars to limit or eliminate noise/vibration.

The windscreen for your roof rack utilizes a splitter design that cuts through the air at speed and splits the wind. This patent pending design is the result of hundreds of hours of design, engineering and testing. The end result is a design that cuts through the air forcing air under the rack taking advantage of the aerodynamic signature of your vehicle as well as pushing air up and over the rack giving the roof rack a smaller aerodynamic profile that results in the least amount of wind noise possible with an aftermarket roof rack. The large upper face serves to cut air up and over any gear that you might have attached to it.
If your fairing is cut for lighting you are encouraged to install the light bar(s) prior to installing the roof rack on the vehicle. This will add some weight during the process of lifting the roof rack onto the vehicle but it is far easier to install the light bars into the fairing whilst it is off the vehicle and at a good working height. Please access our lighting installation guide on our website under the instructions tab for comprehensive information about light installation.

Gather the following:

• Fairing specified in your order*
• Wind Screen Hardware
• 3/16 Allen wrench
• 1/2” wrench

*If your fairing is cut for a specific light bar you will also been delivered a kit of hardware for that task that is NOT listed in the parts for this step. Refer to rear of guide for lighting installation.

Figure 7
Wind Screen
Driver Side (2041) Shown

• Align the flange on your wind screen to the holes at the front of the rack and insert the bolts.
• Repeat the process on the passenger side (2042).

Figure 8
Wind Screen
Inside Shown

• Install a flange nut onto the exposed studs of each bolt.
• Torque to specifications found on page 2.

VEHICLE PREPERATION

If your RAV4 5G is equipped with a factory roof rack/roof rails you will need to remove it prior to proceeding with the installation of your upTOP roof rack. The factory roof rack attaches to cast aluminum cleats installed by Toyota.
In addition to the factory roof rack you will also be required to remove the factory installed cleats that the roof rack mounts to inside your drip rails. These cleats are anchored via bolts from underneath the roof of the vehicle and will require minor disassembly of the headliner area of your vehicle.

GATHER THE FOLLOWING:

• 13mm wrench
• 13mm socket and ratchet
• Plastic trim removal tool (Available for cheap on amazon if you do not have one)

TOYOTA RAV4 Factory Roof Rack Removal

• If equipped follow Toyota procedures for removing cross bars. This requires key provided with vehicle to complete.
• With the rails removed using a plastic trim tool work under the edge of the black trim over your drip rails to pop the front leading edge of the trim up to gain leverage.
• Pull up to the sky releasing the plastic trim clips (Located about 8” apart throughout the length of the drip rail to unsnap and remove from the roof.
• Repeat the process on both sides of the car to gain access to the cast aluminum cleats that are bolted into place in the drip rails.
• Using a 13mm Socket/Ratchet GENTLY unbolt the cleats from the roof of the vehicle. The cleats are through bolted to the roof of the car and might SLIP making removal impossible without gaining access to the underside of the headliner.
• Should the factory nuts slip you will have to pull down the rubber edge trim door gaskets and work around the side curtain air bags to access the nuts. Once you can access the nuts use a 13mm wrench to hold the nuts in place and finish removing the fasteners.
• You will have exposed holes in the drip rails, ten (10) per side.
• Six (6) of these will be used per side with the remaining four (4) per side being plugged/ sealed with the included push clips in your hardware kit. (Discussed later).
  There are numerous videos available online that cover the removal of the factory roof rack. For copyright reasons we do not provide links to content not originated by upTOP overland.
  A simple Google search with the make and model of your vehicle will yield sources with good information about the removal process.
  Once you have the rails and trim removed clean the drip rail areas with a mild detergent to remove any debris that might affect the adhesion of the sealant required for the roof rack installation.

WARNING
Vehicles produced in 2022 could have factory roof configuration that will differ from the notes derived from our prototype car.
• Additional alignment and drilling may be required. Align roof rack as indicated in guide and complete modifications as necessary.

Figure 9
Drip Rail Interface Key

• YELLOW Holes receive M6x1.00 PlusNUT into factory location. No Drilling required. 1362 Feet.
• RED Holes receive Push In Clips with sealant to close unused holes. 1362 Feet.
• BLUE Holes receive M6x1.00 PlusNUT into factory location however holes need to be enlarged with provided 9mm Drill Bit w/Stop Collar. 1363 Feet.

The factory drip rails shown here in PINK have factory produced holes for the OEM roof rack trim that will be repurposed for the mounting locations for your upTOP roof rack. Each side has ten (10) holes running from back to front. Use the illustration below as a guide for the conversion of open holes to threaded inserts with the provided drill kit.

plusNUT Installation
GATHER THE FOLLOWING:

• 10mm wrench (2X)
• Hammer
• Cordless Drill
• 9mm Drill Bit (Provided)
• Hardware containing plusNUTS

Figure 10
plusNUT Installation Hardware
To properly install a plusNUT with a pair of wrenches you will need to sandwich one of your 10mm wrenches between the two washers provided in your drill kit. Slide the included bolt through the washers/wrench head and thread the plusNUT onto the bolt until it is tight.
The included bolt/washers are reusable and you can use them to install all of the plusNUTS required for mounting your roof rack.

Figure 11
plusNUT Insertion
The procedure outlined in Figure 10-12 covers the installation process for all of the plusNUTS included with your kit HOWEVER the plusNUTS to be installed into the BLUE locations in Figure 9 must be enlarged to allow the plusNUTS to fit. This process is covered in Figure 13.

• Assemble the hardware as pictured in Figure 10.
• Align the base of the plusNUT into any of the YELLOW holes in Figure 9.
• Use a hammer/mallet against the head of the bolt to tamp the assembly down into the hole until the ring lip of the plusNUT is flush with the surface of your drip rail.

Figure 12
plusNUT Installation

• As you operate wrench B counter clock wise hold wrench A stationary.
• This motion will “draw” up the plusNUT into an “X” beneath the surface of your drip rail and bite into the metal underneath creating a very sturdy anchor point for the mounting hardware of your roof rack.
• This motion will NOT be visible as it is taking place beneath the roof of your vehicle.
• Continue to tighten the plusNUT until it gets noticeably tougher to continue turning.
• Reverse wrench A to remove the threading bolt completely.
• Collect the bolt, washers, and wrench B and continue the process until all eight (8) locations indexed in YELLOW have plusNUTS installed into location.
• Hand thread your roof rack mounting hardware into the plusNUTS ONE AT A TIME BY HAND to ensure that the threads are set and undamaged for installation.
• If you over torque the plusNUT it can twist causing thread misalignment.
• If you under torque the plusNUT it could spin during hardware installation causing the bolt to become stuck in perpetual free spin.
• If you encounter resistance when installing the hardware by hand visually inspect the threaded portion inside the plusNUT and verify that the threaded channel is in line (centered) with the original installation angle of the plusNUT.
• If you need to repair the threads of the provided plusNUTS you will need to source a thread tap (Not Included) that is: M6x1.00 Metric

Figure 13
BLUE Hole Enlargement
The two (2) rear most holes at the back of the drip rail on the DRIVER and PASSENGER side will be used for the plusNUTS intended to secure the rear feet (1363) of your roof rack.
The holes need to be enlarged to accept the plusNUT. The factory size was adequate for the clips that secured your trim panels in place but DO NOT try to force the assembled plusNUT into the smaller rear factory holes. You will damage the wings on the plusNUTS and they WILL BREAK when you attempt to install them with the wrenches.

• Position and secure the supplied drill stop collar to the 9mm drill bit in your kit. Leave approximately 1/2” (12mm) exposed at the business end.
• The collar is intended to allow you to blind drill the rear holes to enlarge them just enough to get the plusNUT the clearance it needs for installation without penetrating the interior cabin of the vehicle and causing damage.
• The included collar eliminates the need to disassemble the rear of the car to move things out of the way to complete this process.
• The rear holes don’t have much material to remove to get the plusNUT to fit inside and drilling them out is much easier than attempting this in a location where there is no existing hole.
• Drill out all four (4) holes indicated in BLUE in Figure 9.
• Clean the metal shavings out of the way using a damp cloth to help them stick. A microfibre towel works great for this task.
• Repeat the process outlined in Figure 10-12 to install the last four (4) plusNUTS into the drip rails of your vehicle.

REMAINING HOLES

The remaining holes in figure 9 shown in RED need to be adequately sealed in order to prevent elements from penetrating the cabin of your vehicle.
Your kit includes some push in plastic clips to install into the holes.

Figure 14
Push Clips*
Appearance may vary based on supply chain.

You should have four (4) exposed smaller holes in each drip rail on the DRIVER and PASSENGER side of the vehicle shown in RED in Figure 9.

• Apply a small amount of sealant to the area around each exposed hole.
• Press a push clip into each hole until the upper portion sits into the sealant and bottoms out against the surface of the drip rail.
• Repeat the process until any hole in your drip rail WITHOUT a plusNUT has a push clip installed with sealant.

As with all applications of sealant you are encouraged not to wash the vehicle or leave in the elements for up to 48 hours to allow the sealant to fully cure.

SEALANT/SPACERS

Choosing the right sealant is as easy as selecting a silicone based product engineered for outdoor use. The product will NOT be visible after installation so color is not as critical as quality. We typically use an exterior grade RTV sealant that is readily available at most hardware/auto parts stores. If you have specific questions about sealant please email [email protected] and reference your order number in the subject line of the email.
Your kit includes aluminum spacers intended to level the roof rack against the contour of the vehicle and provide a sturdy, stable platform to help distribute cargo along the entirety of the rack without causing pressure points or over stressing the structure of the vehicle.

Figure 15
Sealant
Apply the same type of sealant (Shown here in PINK) used for the push clips to the area surrounding each plusNUT you installed to the vehicle drip rail. Be sure to squeeze sealant into the threaded area as well as around the lip of the plusNUT to form a small puddle to allow the spacer to seat into the sealant.
The following page indicates the spacer length/position for the Toyota RAV4.

Figure 16
Spacers
Your kit includes two (2) different length of aluminum spacers and they need to be placed according to the illustration above.
The FRONT and REAR spacers are 1.250” in length, shown here in PINK.
The MIDDLE spacers are 1.00” in length, shown here in BLUE.
• Align the spacers over the plusNUT locations and seat them into the sealant puddles completed on page 17.

RACK TO ROOF
GATHER THE FOLLOWING

• Hardware Kit “Rack to Roof”
• 5mm Allen wrench
• A friend that will help you lift this exceptionally awkward piece of roof rack art onto the roof of your future adventure vehicle.

NOTE
We recommend that you take the roof rack onto the vehicle from the FRONT as it is easier to clear the hood first and then gently sit the rack into position over the spacers you previously installed.
This is a TWO PERSON task. DO NOT ATTEMPT to lift this roof rack onto your vehicle alone. Damage to the vehicle, injury to yourself or both will likely occur.

• Lift the roof rack into the air with a person on both the DRIVER AND PASSENGER SIDE of the rack.
• Slowly raise the rack up over your head and walk it onto the vehicle.
• GENTLY sit the rack down into position aligning the feet with the spacers.
• Have your lift buddy hold the rack in position while you gather the hardware/Allen wrench.

The hardware provided for this rack uses two (2) different length bolts.
The FRONT and REAR locations use 65mm bolts while the MIDDLE locations use a slightly shorter 55mm bolt. If you try to install a 65mm bolt into the middle location it will bottom out in the plusNUT and cause it to spin. Ask me how I know.

BY HAND…….
Start each hardware set into the plusNUTS.

Figure 17
Front Foot Hardware
Align the hardware to the INNER slots over to lineup with the plusNUTS.
Each location gets the following:

• (2) 65mm M6x1.00 Socket Head Bolts
• (2) 6mm Lock Washers
• (2) 6x25mm Fender Washers

Start the fasteners by hand but DO NOT FULLY TIGHTEN THEM. You will want them loose enough to center the rack on the vehicle during final checks.

Figure 18
Middle Foot Hardware
Align the hardware to the OUTER slots over to lineup with the plusNUTS.
Each location gets the following:

• (2) 55mm M6x1.00 Socket Head Bolts
• (2) 6mm Lock Washers
• (2) 6x25mm Fender Washers

Start the fasteners by hand but DO NOT FULLY TIGHTEN THEM. You will want them loose enough to center the rack on the vehicle during final checks.

Figure 19
Rear Foot Hardware
Align the hardware to the OUTER slots over to lineup with the plusNUTS.
Each location gets the following:

• (2) 65mm M6x1.00 Socket Head Bolts
• (2) 6mm Lock Washers
• (2) 6x25mm Fender Washers

Start the fasteners by hand but DO NOT FULLY TIGHTEN THEM. You will want them loose enough to center the rack on the vehicle during final checks.

Figure 20
Centering
Use a tape measure and visual queues to align the rack on the vehicle and center it. You should have a visibly even gap in the slots of the feet with respect to the driver and passenger side.
With the rack centered use the 5mm Allen wrench to fully tighten the mounting feet bolts.
Reference the torque specs on page 2 and fully tighten all of the hardware used in the assembly and installation of the roof rack.
Complete any wiring as needed and the installation is completed.

up TOP fine PRINT

• It is recommended to inspect the rack hardware at regular intervals to ensure fasteners are tight. If the rack ever needs to be removed and reinstalled you will need to repeat the silicone sealant steps before reinstallation of the rack to roof hardware.
• The powder coated finish on your rack uses a chemical compound to maintain UV stability for years to come. Wash the roof rack at regular intervals to keep the load bar channels, drip rails and mounting components free of dirt and debris. Foreign objects (mud) can dry and cause noise and vibration.
• If your color matched components are painted care for them in the same manner as you care for the exterior finish of your vehicle.
• Repair or replace worn parts with expediency. All hardware is available for purchase by calling our technical support line at 720.730.6381 Monday-Friday 8am to 4pm MDT or by email 24/7 364 (we don’t answer email on Christmas-get over it) [email protected]
• It is the responsibility of the end user to ensure all electrical connections are secured and fused properly for the circuit load they are carrying.
• up TOP Roof Rack dynamic (moving) weight capacity can often exceed the OEM vehicle manufacturers specification. In all cases the OEM specifications supersede the up TOP dynamic rated load capacity.
• DO NOT use the up TOP product in a manner inconsistent with its design intention. This will void your warranty.
• DO NOT modify or alter structural components of up TOP roof rack assemblies. This will void your warranty.
• Excessive speeds over rough terrain can exceed dynamic weight loads causing structural fatigue or failure of aluminum and steel components. Use your best judgement and common sense before committing to full send with an overloaded rack product.
• Component damage or failure due to negligence will result in voided warranty claims. Any failed component must be returned to up TOP with a properly submitted RMA request. Any product received without authorized RMA request will be returned to sender at their expense.
• Leave. No. Trace. Our planet is fragile. Some parts of it have been undisturbed for generations. Stay on trails and designated routes. DO NOT LITTER. Pack it in Pack it out. Basically be a decent human and protect our culture, wild lands and ecosystems.

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