door TOYOTA RAV4 1996 Service User Guide

DISPOSAL PROCEDURES
ON-VEHICLE DEPLOYMENT (SCRAPPED VEHICLES ONLY)
Driver-Side & Passenger-Side Air Bag Module
1. Before proceeding, see SERVICE PRECAUTIONS . Ensure steering wheel, driver-side air bag module
and passenger-side air bag are not loose. If components are loose, deploy air bag(s) using OFF
-
VEHICLE DEPLOYMENT procedure.
2. If deploying driver-side air bag module, disconnect spiral cable connector accessible by removal of lower
steering column cover. If deploying passenger-side air bag module, disconnect passenger-side air bag
connector, accessible by removal of glove box. See Fig. 3
. For either air bag, connect Deployment Tool
(09082-00700) connector to air bag module 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 inside or within 33 feet of vehicle. Press
activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes after
deployment.
Seat Belt Pretensioner
1. Before proceeding, see SERVICE PRECAUTIONS . Ensure seat belt pretensioner is not loose. If
components are loose, remove and deploy using OFF
-VEHICLE DEPLOYMENT procedure. Access
and disconnect appropriate seat belt pretensioner connector. See SEAT BELT PRETENSIONER under
REMOVAL & INSTALLATION
.
2. Connect Deployment Tools (09082-00700 and 09082-00740) to appropriate seat belt pretensioner
connector. Position deployment tool at least 33 feet from front of vehicle. Close all doors and windows of
vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery
terminal.
3. Ensure no one is inside vehicle or within 33 feet of vehicle. Press activation switch to deploy air bag.
Because of heat, DO NOT touch air bag for at least 30 minutes after deployment. Scrap vehicle with air
bag(s) still installed.
OFF-VEHICLE DEPLOYMENT
Driver-Side Air Bag Module
1. Before proceeding, see SERVICE PRECAUTIONS. Disable air bag system. See DISABLING
WARNING:Undeployed air bags contain substances that can cause illness or injury if
improperly handled. Disposing of an undeployed air bag may violate
federal, state and/or local laws. If scrapping vehicle, air bag must be
deployed while still mounted in vehicle. DO NOT deploy air bags inside
vehicle unless vehicle is to be scrapped. Wear gloves and safety glasses
when handling air bag. Wrap deployed air bag in a sturdy plastic bag and
dispose of it like any other part.

1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota
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INSTRUMENT PANEL
Removal & Installation
1. Before proceeding, see SERVICE PRECAUTIONS . Turn ignition switch to LOCK position.
Disconnect negative battery cable. Wait at least 90 seconds.
2. Access and disconnect right and left seat belt pretensioner connectors. See SEAT BELT
PRETENSIONERS . Remove front door scuff plates and cowl side trim boards. See Fig. 13 . Remove
steering wheel. See STEERING WHEEL
. Remove steering column covers and cluster finish panel.
Remove instrument cluster. Remove hood lock release lever.
3. Remove lower finish panel and instrument panel lower insert. Remove No. 2 heater-to-register duct.
Remove steering column assembly. See STEERING COLUMN
. Remove 2 screws and center cluster
finish panel. Pull off heater control knobs and pry off heater control name plate. Pry off cluster instrument
panel, then remove 3 screws from heater control assembly. Disconnect connectors and remove cluster
instrument panel.
4. Disconnect control cables and remove heater control assembly. Remove radio assembly. Remove console
box. Tape tip of screwdriver and remove lower center cluster finish panel. Disconnect connectors.
Remove stereo opening cover. Remove glove box assembly. Remove side trim cover. Disconnect
remaining connectors and remove bolts, then remove instrument panel.
5. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE
SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See
SYSTEM OPERATION CHECK
.

1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota
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Removal & Installation
1. Before proceeding, see SERVICE PRECAUTIONS . Turn ignition switch to LOCK position.
Disconnect negative battery cable. Wait at least 90 seconds.
2. Remove glove box door. Disconnect passenger-side air bag module connector. See Fig. 3
. Remove
instrument panel. See INSTRUMENT PANEL
. Working from reverse side of instrument panel, remove
2 bolts and passenger-side air bag module. Remove 3 bolts and pry up 7 clips and remove air bag door.
3. To install, reverse removal procedure. Tighten passenger-side air bag bolts to specification. See
TORQUE SPECIFICATIONS
. There should be no interference between passenger-side air bag door
and instrument panel and clearance should be uniform. Check AIR BAG warning light to ensure system
is functioning properly. See SYSTEM OPERATION CHECK
.
SEAT BELT PRETENSIONERS
Removal & Installation
1. Before proceeding, see SERVICE PRECAUTIONS . Turn ignition switch to LOCK position.
Disconnect negative battery cable. Wait at least 90 seconds.
2. On 2-door models, remove rear seat, rear floor finish panel front door scuff plate, quarter trim and roof
side inner garnish. On 4-door models, remove rear door scuff plate, front door scuff plate and center pillar
lower garnish.
3. On all models, remove bolts and floor anchor. Tape tip of screwdriver and remove seat belt assembly
anchor caps. Remove bolt and shoulder anchor. Disconnect pretensioner connector. Remove 2 bolts and
seat belt pretensioner assembly.
4. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE
SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See
SYSTEM OPERATION CHECK
.
SPIRAL CABLE
Removal & Installation
1. Before proceeding, see SERVICE PRECAUTIONS . Turn ignition switch to LOCK position.
Disconnect negative battery cable. Wait at least 90 seconds. Remove driver-side air bag module. See
DRIVER
-SIDE AIR BAG MODULE .
2. Remove steering wheel. See STEERING WHEEL
. Remove lower steering column cover. Disconnect
lower spiral cable connector. Remove 4 screws and spiral cable.
3. To install, reverse removal procedure. Before installing spiral cable, ensure front wheels are in straight-
ahead position and spiral cable is properly aligned. See SPIRAL CABLE under ADJUSTMENTS
.
Tighten steering wheel nut and driver-side air bag module screws to specification. See TORQUE
SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See
SYSTEM OPERATION CHECK
.
STEERING COLUMN
Removal & Installation

1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota
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1997-99 AUTOMATIC TRANSMISSIONS
Toyota A-540E, A-540H & A-541E Overhaul
APPLICATION
TRANSMISSION APPLICATIONS
IDENTIFICATION
Vehicle Identification Number (VIN) is used for correct application of component parts and assemblies. VIN is
stamped on vehicle identification number plate, located at top left corner of dash and on certification label,
located on driver's door jam.
GEAR RATIOS
GEAR RATIOS NOTE: 1999 Lexus ES300 is equipped with a U140E automatic transaxle. For diagnosis
of this transaxle, see LEXUS U140E & U140F OVERHAUL article or LEXUS
U140E & U140F ELECTRONIC CONTROLS article.
Vehicle ApplicationTransmission Model
Lexus
ES300A-541E
Toyota
AvalonA-541E
Camry (V6) LE, SE & XLEA-541E
Camry Solara (V6) SE & SLEA-541E
RAV4 4WDA-540H
SiennaA-540E
NOTE: RAV4 is equipped with a transfer case. For transfer case overhaul procedures,
see appropriate TRANSFER CASES article in AXLE SHAFTS & TRANSFER
CASES.
CAUTION: All models are equipped with a Supplemental Restraint System (SRS).
When servicing vehicle, use care to avoid accidental air bag deployment.
All SRS electrical connections and wiring harness are covered by Yellow
insulation. SRS-related components are located in steering column, center
console, instrument panel and lower panel on instrument panel. DO NOT
use electrical test equipment on these circuits. If necessary, deactivate
SRS before servicing components. See AIR BAG DEACTIVATION
PROCEDURES article in GENERAL INFORMATION.

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul

1998 Toyota Avalon XLS
1997-99 AUTOMATIC TRANSMISSIONS Toyota A-540E, A-540H & A-541E Overhaul
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Center Bearing Bracket Bolt47 (64)
No. 1 Lower Suspension Arm Bolt/Nut76 (103)
No. 2 Lower Suspension Arm Bolt/Nut36 (49)
Shock Absorber Nut (Lower)128 (173)
Strut Rod Bolt/Nut58 (78)
Wheel Lug Nut76 (103)
RAV4
ABS Speed Sensor Bolt(1)
Axle Shaft Flange Bolt41 (56)
Axle Shaft Nut
Front159 (216)
Rear159 (216)
Bearing Bracket Bolt47 (64)
Lower Control Arm-To-Ball Joint Bolt/Nut94 (127)
Stabilizer Bar Link-To-Lower Control Arm Nut
2-Door33 (45)
4-Door54 (73)
Tie Rod End Nut36 (49)
Wheel Lug Nut76 (103)
(1)Tighten bolt to 69 INCH lbs. (7.8 N.m).

1999 Toyota RAV4
1999-2000 DRIVE AXLES AWD & FWD Axle Shafts - RAV4 & RWD Axle Shafts - MR2
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
Axle Shaft Flange-To-Side Gear Shaft Nut41 (56)
Bearing Cap Bolt58 (79)
Center Support Bearing Bolts27 (37)
Differential Assembly Mounting Bolt
Front Mount-To-Carrier Bolt98 (133)
Rear Mount-To-Carrier Bolt101 (137)
Rear Mount-To-Frame Bolt48 (65)
Differential Carrier Cover Bolt34 (46)
Drain & Filler Plugs36 (49)
Drive Pinion Nut (1) 80 (108)
Drive Shaft Companion Flange Bolt/Nut54 (73)
Hub Nut159 (216)
Lower Control Arm-To-Strut Bolt/Nut94 (127)
Ring Gear Bolt71 (96)
Stabilizer Bar Link Bolt/Nut
2-Door33 (45)
4-Door54 (73)
(1)Tighten to 174 ft. lbs. (236 N.m) when setting drive pinion preload.

1999 Toyota RAV4
1999-2000 DRIVE AXLES Differentials, Axle Shafts & Drive Shafts -- Rear Integral Housing -- RAV4
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1999-2000 ACCESSORIES & EQUIPMENT
Power Door Locks - Trucks
DESCRIPTION & OPERATION
Power door locks are all controlled through a multipurpose Electronic Control Unit (ECU) or integration relay.
The Land Cruiser is controlled through the instrument cluster ECU. The 4Runner is controlled through the body
ECU, and the Sienna, Tundra, RAV4 and Tacoma are all controlled through the integration relay. Each system
also consists of a door lock motor at each door, tailgate, liftgate and sliding door, a master door lock switch at
driver's door, which controls all other doors, tailgate, liftgate and sliding doors and a switch at each door,
tailgate, liftgate and sliding doors.
To operate door locks from the outside, insert door key into door lock cylinder and turn it to the right
(clockwise) once will unlock the driver's door and turning it a second time will unlock all other doors, tailgate,
liftgate and sliding doors. Passenger door will unlock all other doors when it is unlocked. When either front
door lock is turned to left (counter clockwise) all other doors will lock. The driver's door has a master lock
switch which will lock all doors on the vehicle. Each door and sliding doors have a switch inside that controls
each door lock.
COMPONENT LOCATIONS
COMPONENT LOCATIONS NOTE: This article also applies to Lexus LX470. Refer to Land Cruiser, unless
otherwise indicated.
NOTE: For information on keyless entry systems, see appropriate KEYLESS ENTRY
SYSTEMS article.
ComponentLocation
Body ECU (4Runner)Lower Left Side Of Dashboard
Instrument ECU (Land Cruiser)Under Center Of Dashboard
Integration Relay (RAV4)On Rear Of Instrument Panel Fuse Box, Lower Left
Side Of Dashboard
Integration Relay (Sienna)On Instrument Panel Fuse Box, Lower Left Side Of
Dashboard
Integration Relay (Tacoma)On Instrument Panel Fuse Box, Lower Left Side Of
Dashboard
Integration Relay (Tundra)On Instrument Panel Fuse Box, Lower Left Side Of
Dashboard
Unlock Warning Switch (Land Cruiser)Under Dashboard, Left Side Of Center Console
Unlock Warning Switch (RAV4)Under Dashboard, Left Side Of Center Console
Unlock Warning Switch (Sienna)Under Dashboard, Left Side Of Center Console
Unlock Warning Switch (Tacoma)Under Dashboard, Left Side Of Center Console

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Door Locks - Trucks

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Door Locks - Trucks
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COMPONENT TESTING
DRIVER'S DOOR LOCK MASTER SWITCH
Inspect drivers door lock master switch continuity. See DRIVER'S DOOR CONTROL SWITCH
CONTINUITY TEST table. If continuity is not as specified, replace driver's door lock master switch. See Fig.
1 -Fig. 6 .
DRIVER'S DOOR CONTROL SWITCH CONTINUITY TEST
Unlock Warning Switch (Tundra)Under Dashboard, Left Side Of Center Console
Unlock Warning Switch (4Runner)Under Dashboard, Left Side Of Center Console
Application & Switch PositionTerminals No.Continuity
Land Cruiser
LOCK4 & 6; 5 & 6Yes
UNLOCK4 & 12; 5 & 12Yes
LX470
LOCK9 & 15Yes
UNLOCK9 & 16Yes
RAV4 (2-Door)
LOCK2 & 3Yes
UNLOCK3 & 9Yes
RAV4 (4-Door)
LOCK4 & 6; 5 & 6Yes
UNLOCK4 & 12; 5 & 12Yes
Sienna
LOCK1 & 2Yes
UNLOCK1 & 5Yes
Tacoma
LOCK1 & 5; 2 & 6Yes
UNLOCK2 & 5; 1 & 6Yes
Tundra
LOCK1 & 2Yes
OFF1 & 2; 1 & 5No
UNLOCK1 & 5Yes
4Runner
LOCK4 & 6Yes
UNLOCK4 & 12Yes

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Door Locks - Trucks
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Fig. 1: Identifying Power Door Lock Master Switch Harness Connector Terminals (Land Cruiser, RAV4
4-Door & 4Runner With Power Windows)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Door Locks - Trucks
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Fig. 2: Identifying Power Door Lock Master Switch Harness Connector Terminals (Lexus LX470)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 3: Identifying Power Door Lock Master Switch Harness Connector Terminals (RAV4 2
-Door)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Power Door Locks - Trucks
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