Following are photos of the cowl rattle fix on my RAV. The plastic
screw/clips on the battery cowl cover were removed and replaced #8 body panel
screws anchored to a combination of Nylon Nuts and U Type Speed Nuts. The
nylon nuts press into the support members and body panels in the slots made for
the the screw/clips (locations marked A).. The Speed Nuts slide over
the slot in the large cowl cover and the top left mounting bracket (locations
marked B). Either use 5/16" flat washers under the body panel screws
or trim the back off of the old plastic screw/clips and use the remaining
portion as washers for the body panel screws. Note that 3/4" self adhesive foam
insulation tape has been applied to all locations on cross members and body panels
contacted by cowl. Also, the red plastic cover from the
positive battery terminal has been removed. I did not remove the rubber
edge from the cowl panel, but instead applied a strip of 3/8" black foam to
the windshield under the edge of the rubber strip to keep it from contacting the
windshield. On the larger cowl panel I slid a strip of felt between the
rubber strip and the windshield. Using the felt allowed me to just loosen
the top cowl fasteners to slide it in rather than having to remove it completely
as would have been the case to use the adhesive foam.
Locations of new fasteners for battery cover cowl section
A = Nylon Nut B = U Type Speed Nut
Fastener specs
All made by Body-Tite Corp. and purchased at Pep Boys
Arrows show location of 3/8"
foam tape installed on body and support members
Arrow shows 3/8" black foam tape
installed on windshield.
Rubber strip on cowl edge is centered
on this foam tape when
cowl is installed.
Nylon Nut installed in support member
U Type Speed Nut installed (on large cowl panel)
This is the infamous screw/clip -
back view and with the
screw part removed from the clip/washer
Back
of the clip/washer with the clip portion trimmed off and a
front view with the
new body panel screw
Here's
the cowl re-installed using 5/16" zinc washers under the body panel
screws. Looks tacky...
Here's
one of the finished screws using the
trimmed screw/clip in place of the
washer.
Much improved!
Here's
a close up of the cowl edge showing the
rubber strip (A) that presses on the
windshield
and the application of foam tape to the plastic
edge inside the cowl
(B)
Here's
a full view of the cowl back showing the foam tape installed over the plastic
edge.
Some
owners have removed the rubber edge on the cowl panel that contacts the
windshield and say that this has solved their rattle. This has let to
concern from others
about the lack of a seal against the windshield and
where water running down the
windshield is going to go when it runs under the
cowl. This is not an issue to be
concerned about since there is a drain in
the cowl panel that drains water into the engine
compartment behind the battery
anyway. This
is the drain hole in the battery cover cowl.