steering TOYOTA RAV4 1996 Service Repair Manual

1. Disconnect front speed sensor connector. Measure resistance between speed sensor connector terminals.
Resistance should be 1.4-1.8 k/ohms. Measure resistance between ground and each speed sensor
connector terminal. Resistance should be one megohm or more. If resistance is as specified, go to step 3 .
If resistance is not as specified, replace speed sensor.
2. Disconnect rear speed sensor connector. Measure resistance between speed sensor connector terminals.
Resistance should be 1.28-1.48 k/ohms. Measure resistance between ground and each speed sensor
connector terminal. Resistance should be one megohm or more. If resistance is as specified, go to next
step. If resistance is not as specified, replace speed sensor.
3. Check for open or short circuit in wiring harness between affected speed sensor and ABS ECU. See
WIRING DIAGRAMS
. Repair as necessary. If wiring harness is okay, go to next step.
4. Check speed sensor installation. Ensure mounting bolt is tightened to specification. See TORQUE
SPECIFICATIONS . Ensure zero clearance exists between sensor and front steering knuckle or rear axle
carrier. Replace speed sensor if necessary. If speed sensor installation is okay, check speed sensor signal.
See SPEED SENSOR DIAGNOSTICS
under DIAGNOSIS & TESTING. If signal is normal, go to next
step.
5. If oscilloscope is available, check speed sensor signal wave form. Remove ABS ECU. Do not disconnect
electrical connectors. Connect oscilloscope between GND terminal and terminals FR+, FL+, RR+ and
RL+ at ABS ECU connector. See Fig. 3
. Drive vehicle at 19 MPH and observe signal wave form. Signal
should be smooth and consistent without any irregular wave forms. If wave form is smooth and
consistent, replace ABS ECU. If wave form is not smooth and consistent, go to next step.
6. Check speed sensor rotor for missing teeth or damage. Check sensor tip for scratches, damage or foreign
objects. Replace components as necessary. If rotor and sensor are okay, replace ABS ECU.
DTC 37: TIRES OF DIFFERENT SIZE (2WD MODELS ONLY)
DTC Detecting Condition
Detection of the following condition may set DTC 37:
Driving vehicle at speed of more than 12 MPH for more than 20 seconds with one or 2 tires of different
sizes, 3 different times continuously will set DTC 37.
Diagnostic Procedure
Ensure vehicle tires are all the same size and correct size for vehicle. Replace tires as necessary. If tire size is
okay, replace ABS ECU.
DTC 41: LOW BATTERY VOLTAGE
Circuit Description
Circuit is power source for ABS ECU, which includes actuator. If malfunction occurs in power source circuit,
ABS ECU cuts off current to ABS control relay and prohibits ABS control. DEFINITIONS
under DIAGNOSIS & TESTING. For front speed sensor diagnosis,
start at step 1 . For rear speed sensor, start at step 2 .

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1999-2000 BRAKES Anti-Lock - RAV4
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1. Check charging system voltage. Ensure 10-14 volts is present. If charging system voltage is okay, go to
next step. If charging system voltage is not okay, check and repair charging system.
2. Turn ignition switch to ON position. Ensure ABS warning light comes on, then goes out after 3 seconds.
If ABS warning light does not illuminate, check fuse, bulb, and wiring harness. See ABS WARNING
LIGHT under DIAGNOSIS & TESTING. Turn ignition off.
3. Using a jumper wire, jumper terminals Ts and E
1 of DLC1. DLC1 is located in engine compartment on
left side of engine. See Fig. 2
. Ensure ABS warning light blinks 4 times per second. If ABS light does
not blink, go to ABS WARNING LIGHT
under DIAGNOSIS & TESTING. If ABS warning light
blinks, go to next step.
4. Using a floor jack, slowly jack up rear of vehicle. On vehicles with 215/70R16 tires, raise vehicle to a
height of 25.59-27.95" (650-710 mm). On vehicles with 235/60R16 tires, raise vehicle to a height of
26.38-28.74" (670-730 mm). If ABS warning light illuminates at specified height, check deceleration
sensor installation. If installation is okay, replace deceleration sensor. Lower vehicle.
5. Using a floor jack, slowly jack up front of vehicle. On vehicles with 215/70R16 tires, raise vehicle to a
height of 21.20-23.56" (550-610 mm). On vehicles with 235/60R16 tires, raise vehicle to a height of
22.44-24.80" (570-630 mm). If ABS warning light illuminates at specified height, check deceleration
sensor installation. If installation is okay, replace deceleration sensor. Lower vehicle.
6. Drive vehicle straight ahead at speed of 13 MPH or more. Lightly depress brake pedal. Ensure ABS
warning light pattern is normal (light blinks 4 times per second).
7. While driving vehicle straight ahead at speed of 13 MPH or more, moderately depress brake pedal.
Ensure ABS warning light illuminates in a solid pattern (light does not blink) while braking.
8. While driving vehicle straight ahead at speed of 13 MPH or more, firmly depress brake pedal. Ensure
ABS warning light illumination pattern changes from a solid pattern (light does not blink) to a normal
pattern (light blinks 4 times per second), then back to a solid pattern while braking.
9. If ABS warning light does not illuminate as described in steps 6 -8 , check deceleration sensor
installation. If installation is okay, replace deceleration sensor. Stop vehicle and turn ignition off. Remove
jumper wire from DLC1.
REMOVAL & INSTALLATION
ACTUATOR
Removal & Installation
Turn ignition off. Disconnect brakelines attached to actuator. Remove power steering hose retaining bracket
bolt and power steering reservoir. Disconnect actuator electrical connectors. Remove bolts, nuts and washers.
Remove actuator assembly. Remove actuator from actuator bracket. Remove cushions and holders from NOTE: When measuring vehicle height in following steps, measure at center of
lower body of vehicle.
WARNING:Hydraulic system may be under high pressure. Use caution when opening
hydraulic system.

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1999-2000 BRAKES Anti-Lock - RAV4
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Fig. 11: Exploded View of ABS Actuator
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
ABS ECU
Removal & Installation
Ensure ignition is off. Disconnect negative battery cable. Access ABS ECU, located at right side of passenger
compartment. See Fig. 1
. Disconnect ABS ECU connectors. Remove ABS ECU from vehicle. To install,
reverse removal procedure.
FRONT SENSOR ROTOR
Removal & Installation
Front sensor is part of front hub. For removal and installation of front hub, see AXLE SHAFTS - RAV4 article
in DRIVE AXLES.
REAR SENSOR ROTOR
Removal & Installation
Rear sensor rotor is pressed onto axle shaft. For axle shaft removal and installation procedure, see AXLE
SHAFTS - RAV4 article in DRIVE AXLES.
FRONT WHEEL SPEED SENSORS
Removal & Installation
1. Raise and support front of vehicle. Remove front wheel. Remove inner fender panel. Disconnect wheel
speed sensor connector. Remove clamp bolts holding sensor harness to body, strut assembly and steering
knuckle.
2. Remove wheel speed sensor mounting bolt. Remove wheel speed sensor from steering knuckle. To
install, reverse removal procedure. Ensure wheel speed sensor is flat against knuckle when bolt is
tightened. Tighten wheel speed sensor mounting bolt to specification. See TORQUE
SPECIFICATIONS .
REAR WHEEL SPEED SENSORS
Removal & Installation
1. Remove rear seat cushion and side trim panel. Raise and support vehicle. Remove wheel. Unplug wheel
speed sensor connector and remove wire harness from grommet. Disconnect parking brake cable from
suspension arm. Remove clamp bolts holding sensor wiring harness to body and suspension arm.
2. Remove wheel speed sensor. To install, reverse removal procedure. Ensure wheel speed sensor is flat NOTE: Front hub must be removed to service sensor rotor.

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1999-2000 BRAKES Anti-Lock - RAV4
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AIR BAG RESTRAINT SYSTEM
1996 ACCESSORIES/SAFETY EQUIPMENT Toyota Air Bag Restraint System
DESCRIPTION & OPERATION
Supplemental Restraint System (SRS) deploys a steering wheel pad (driver-side air bag) and passenger-side air
bag during a frontal impact of sufficient force. See Fig. 1. WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all WARNINGS and SERVICE PRECAUTIONS.

1996 Toyota 4Runner
AIR BAG RESTRAINT SYSTEM 1996 ACCESSORIES/SAFETY EQUIPMENT Toyota Air Bag Restraint System

1996 Toyota 4Runner
AIR BAG RESTRAINT SYSTEM 1996 ACCESSORIES/SAFETY EQUIPMENT Toyota Air Bag Restraint System
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The air bag sensor, which deploys air bags, contains a back-up power supply, safing sensor and diagnostic code
memory. Spiral cable (clockspring) maintains a complete circuit to the steering wheel pad.
SYSTEM OPERATION CHECK
Turn ignition switch to ACC or ON position. Air bag warning light in instrument cluster should come on for
about 6 seconds and then go out. If light does not respond as specified, SRS is malfunctioning and needs repair.
See DIAGNOSIS
.
SERVICE PRECAUTIONS
Observe the following precautions when working on SRS:
Before servicing any SRS or steering column component, disable SRS. See DISABLING &
ACTIVATING AIR BAG SYSTEM . Failure to disable system could result in accidental air bag
deployment and personal injury.
When diagnosing SRS, always check for diagnostic codes before disconnecting battery.
After ignition switch is turned to LOCK position and negative battery cable is disconnected, wait at least
90 seconds before working on SRS. SRS is equipped with a back-up power source that may allow air bag
to deploy within 90 seconds of disconnecting negative battery cable.
In a minor collision in which air bags do not deploy, steering wheel pad must be inspected.
NEVER use air bag parts from another vehicle. Replace air bag parts with new parts.
Air bag sensor assembly contains mercury. After replacement, DO NOT destroy the old part. When
scrapping vehicle or replacing air bag sensor assembly, remove air bag sensor assembly and dispose of as
toxic waste.
Never disassemble or repair system components. Replace cracked, dented or otherwise damaged system
components.
Remove air bag sensor if shocks are likely to be applied to the sensor during repairs.
When diagnosing electrical circuits, use a Digital Volt/Ohmmeter (DVOM) with high impedance (10,000
ohms minimum).
Information labels are attached to air bag components. Follow all notices on labels.
After servicing SRS, check air bag warning light to ensure system is functioning properly. See SYSTEM
OPERATION CHECK .
Always wear safety glasses when servicing or handling an air bag.
When placing a live air bag on a bench or other surface, always face air bag and trim cover up, away from
surface. This will reduce motion of module if accidentally deployed.
After deployment, air bag surface may contain deposits of sodium hydroxide which irritates skin. During
clean-up, always wear safety glasses, rubber gloves and long-sleeved shirt. After clean-up, wash hands
using mild soap and water.
When carrying a live air bag module, trim cover must be pointed away from your body to minimize
injury in case of accidental deployment.
If SRS is not fully functional for any reason, vehicle should not be driven until system is repaired and
a
gain becomes operational. DO NOTremove bulbs, modules, sensors or other components or in any way

1996 Toyota 4Runner
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disable system from operating normally. If SRS is not functional, park vehicle until it is repaired and
functions properly.
DISABLING & ACTIVATING AIR BAG SYSTEM
DISABLING SYSTEM
Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds
before working on system. On the passenger side, remove glove box door. Disconnect passenger-side air bag
connector. See Fig. 2
. Remove steering column lower cover. Disconnect driver-side air bag connector-to-spiral
cable connector. See Fig. 3
. Disconnect connector of air bag sensor assembly, located forward of center
console. NOTE: If diagnosing SRS, check for diagnostic codes before disconnecting negative
battery cable.
WARNING:Back-up power supply maintains SRS voltage for about 90 seconds after
battery is disconnected. After disabling SRS, wait at least 90 seconds
before servicing SRS. Servicing SRS before 90 seconds may cause
accidental air bag deployment and possible personal injury.

1996 Toyota 4Runner
AIR BAG RESTRAINT SYSTEM 1996 ACCESSORIES/SAFETY EQUIPMENT Toyota Air Bag Restraint System
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Fig. 2: Disconnecting Passenger-Side Air Bag Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 3: Disconnecting Driver
-Side Air Bag Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
ACTIVATING SYSTEM
Reconnect air bag sensor assembly connector. Reconnect passenger-side air bag connector and driver-side air
bag-to-spiral cable connector. Reinstall steering wheel pad. Reconnect negative battery cable. Perform
SYSTEM OPERATION CHECK
.
DISPOSAL PROCEDURES
WARNING:Undeployed air bags contain substances that can cause illness or injury if
improperly handled. Disposing of undeployed components may violate
federal, state and/or local laws. If scrapping vehicle, components must be
deployed while still mounted in vehicle. DO NOT deploy components
inside vehicle unless vehicle is to be scrapped. Wear gloves and safety

1996 Toyota 4Runner
AIR BAG RESTRAINT SYSTEM 1996 ACCESSORIES/SAFETY EQUIPMENT Toyota Air Bag Restraint System
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DEPLOYING AIR BAG
On-Vehicle Deployment (Scrapped Vehicles Only)
1. Before proceeding, follow service precautions. See SERVICE PRECAUTIONS . Turn ignition switch
to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds before working
on system.
2. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM
. Connect
Deployment Tool (09082-00700) to air bag connector. Position deployment tool at least 33 feet from
front of vehicle.
3. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal
and Black clip to negative battery terminal. Ensure no one is within 33 feet of vehicle. Press deployment
tool activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes
after deployment.
Off-Vehicle Deployment (Driver-Side)
1. Before proceeding, see SERVICE PRECAUTIONS . Disable SRS. See DISABLING &
ACTIVATING AIR BAG SYSTEM . Remove steering wheel pad from vehicle. See STEERING
WHEEL PAD & SPIRAL CABLE under REMOVAL & INSTALLATION.
2. Remove connector on steering wheel pad rear surface and install 2.236" (6.0 mm) bolts (1.38" 35 mm
long) with washers in steering wheel pad. Bolts should have a pitch of .039" (1.0 mm). Tighten bolts by
hand until they become difficult to turn. DO NOT overtighten bolts. Obtain a wheel and tire assembly.
Using a service-purpose wire harness, tie down the steering wheel pad to the wheel and tire assembly.
3. Wrap heavy-gauge 3-wire harness around bolts at least twice. See Fig. 4
. Ensure no slack is present in
wire. If slack is present, or if wire is not strong enough, steering wheel pad may become loose due to
shock when air ba
g is deployed. glasses when handling components. Wrap deployed components in a
sturdy plastic bag. Dispose of components like any other part.
WARNING:When attaching air bag assembly to tire, ensure wire is tight. If slack
is present, or if wire is not strong enough, air bag assembly may
become loose due to shock when air bag is deployed.

1996 Toyota 4Runner
AIR BAG RESTRAINT SYSTEM 1996 ACCESSORIES/SAFETY EQUIPMENT Toyota Air Bag Restraint System
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Fig. 4: Installing Wire On Steering Wheel Pad
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
4. Position steering wheel pad on rim and tire assembly with pad side facing upward. Ensuring wire is tight,
separatel
y tie left and right sides of steering wheel pad to wheel rim through lug nut holes. See Fig. 5.

1996 Toyota 4Runner
AIR BAG RESTRAINT SYSTEM 1996 ACCESSORIES/SAFETY EQUIPMENT Toyota Air Bag Restraint System
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Fig. 5: Installing Steering Wheel Pad On Wheel Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
5. Connect Deployment Tool (09082-00700) to steering wheel pad connector. Position deployment tool at
least 33 feet from steering wheel pad. Obtain cardboard box larger than wheel assembly and place it over
wheel assembly, or stack 3 scrap tires on top of rim and tire assembly (but NOT directly on top of
steering wheel pad).
6. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal.
Ensure no one is within 33 feet of steering wheel pad. Press activation switch to deploy air bag. Because
of heat, wait 30 minutes before handling air bag. Place deployed air bag assembly in a vinyl bag, secure
tightly, and dispose of as with any general parts.
Off-Vehicle Deployment (Passenger-Side)
1. Before proceeding, read air bag service precautions section. See SERVICE PRECAUTIONS . Remove
the passenger-side air bag. See PASSENGER
-SIDE AIR BAG under REMOVAL & INSTALLATION.
2. Obtain a scrap tire without a rim. Thread heavy-gauge wire through mounting bolt holes on air bag
assembly. Wrap wire around each bolt for at least 2 turns. Position passenger-side air bag onto tire with
air ba
g facing center of tire. See Fig. 6. Attach air bag assembly to tire.
WARNING:When attaching air bag assembly to tire, ensure wire is tight. If slack
is present, or if wire is not strong enough, air bag assembly may
become loose due to shock when air bag is deployed.

1996 Toyota 4Runner
AIR BAG RESTRAINT SYSTEM 1996 ACCESSORIES/SAFETY EQUIPMENT Toyota Air Bag Restraint System
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