service TOYOTA RAV4 1996 Service User Guide

AIR BAG RESTRAINT SYSTEM
1999 Toyota
DESCRIPTION & OPERATION
Supplemental Restraint System (SRS), also known as air bag system, is designed to provide increased accident
protection for driver and passenger by deploying air bags in a front-end collision. The air bag system is
designed to be used in conjunction with 3-point safety belts.
The air bag system includes the following components: driver-side air bag module (steering wheel pad),
passenger-side air bag module, spiral cable, AIR BAG warning light, air bag sensor assembly, right and left
front air bag sensors, right and left front seat belt pretensioners and associated wiring harnesses. See Fig. 1
. WARNING:To avoid injury from accidental air bag deployment, read and carefully
follow all WARNINGS and SERVICE PRECAUTIONS
.

1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota

1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota
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Fig. 1: Locating Restraint System Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
AIR BAG SENSOR ASSEMBLY
The air bag sensor assembly is located on the floor inside center console box. It consists of an air bag sensor,
safing sensor and diagnosis, ignition control and drive circuits. It receives signals from the air bag sensor and
determines whether air bag system must be deployed or not.
DRIVER-SIDE AIR BAG MODULE
The driver-side air bag and inflator is stored in the steering wheel pad. It contains a squib, igniter charge and gas
generant and inflates the air bag when instructed by air bag sensor assembly. Driver-side air bag module is also
called steering wheel pad.
FRONT AIR BAG SENSOR
The front air bag sensors are mounted inside right and left front side members. When sensor detects an impact
of sufficient force (above a predetermined limit), contacts inside the sensor close, sending a signal to the air bag
sensor assembly.
PASSENGER-SIDE AIR BAG MODULE
The passenger-side air bag and inflator is stored in the instrument panel above glove box. It contains a squib,
igniter charge and gas generant and inflates the air bag when instructed by air bag sensor assembly.
SEAT BELT PRETENSIONER
The seat belt pretensioner system is a component of the front outer seat belt assembly. It contains a squib, gas
generant, wire and piston and operates in the event of a front-end collision.
SPIRAL CABLE
The spiral cable is attached to combination switch and is used as an electrical joint between chassis wiring
harness and driver-side air bag module. Spiral cable is also known as clockspring.
SERVICE PRECAUTIONS
Observe the following precautions when servicing air bag system:
Disable air bag system before servicing any air bag system or steering column component. Failure to do
this could result in accidental air bag deployment and possible personal injury. See DISABLING &
ACTIVATING AIR BAG SYSTEM .
When diagnosing air bag system, always check for diagnostic codes before disconnecting battery.
After turning ignition switch to LOCK position and disconnecting negative battery cable, wait at least 90
seconds before workin
g on air bag system. Air bag system is equipped with a back-up power source that

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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.

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AIR BAG RESTRAINT SYSTEM 1999 Toyota
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Fig. 7: Securing Driver-Side Air Bag Module To Wheel
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Passenger-Side Air Bag Module
1. Before proceeding, see SERVICE PRECAUTIONS . Remove passenger-side air bag module. See
PASSENGER-SIDE AIR BAG under REMOVAL & INSTALLATION
.
2. Position passenger-side air bag module inside a scrap tire with air bag trim cover facing inside. See Fig.
8 . Secure passenger-side air bag module to tire with wire. Place this tire between 4 other tires (top tire
should have wheel installed). Securely tie all tires together with wire.
3. Connect Deployment Tool (09082-00700) to passenger-side air bag connector. Position deployment tool
at least 33 feet away from passenger-side air bag. Press activation switch to deploy passenger-side air
bag. Because of heat, wait 30 minutes before handling passenger-side air bag.

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Seat Belt Pretensioner
1. Before proceeding, see SERVICE PRECAUTIONS . Remove appropriate seat belt pretensioner. See
SEAT BELT PRETENSIONER under REMOVAL & INSTALLATION
.
2. Connect Deployment Tools (09082-00700 and 09082-00740) to seat belt pretensioner connector. Position
seat belt pretensioner on ground an cover with wheel and tire assembly. See Fig. 9
. Position deployment
tool at least 33 feet away from seat belt pretensioner. Press activation switch to deploy seat belt
pretensioner. Because of heat, wait 30 minutes before handling. Dispose of deployed pretensioner in
usual manner.
Fig. 9: Deploying Seat Belt Pretensioner

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be
inspected or replaced. See PASSIVE RESTRAINT SYSTEM INSPECTION article in the GENERAL
INFORMATION section for post-collision inspection information.

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REMOVAL & INSTALLATION
AIR BAG SENSOR ASSEMBLY
Removal & Installation
1. Before proceeding, see SERVICE PRECAUTIONS . Air bag sensor assembly is located on the floor
inside center console box. See Fig. 10
. Turn ignition switch to LOCK position. Disconnect negative
battery cable. Wait at least 90 seconds.
2. Remove shift lever and boot. Ash tray and console box hole cover. Remove console box. Remove 4 Torx
screws retaining air bag sensor assembly. Remove air bag sensor assembly.
3. To install, reverse removal procedure. Tighten air bag sensor assembly Torx screws to specification. See
TORQUE SPECIFICATIONS
. Check AIR BAG warning light to ensure system is functioning
properl
y. See SYSTEM OPERATION CHECK. WARNING:Failure to follow service precautions may result in air bag deployment and
personal injury. See SERVICE PRECAUTIONS
. After component
replacement, check system operation. See SYSTEM OPERATION CHECK
.

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Fig. 10: Removing Air Bag Sensor Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DRIVER-SIDE AIR BAG MODULE
Removal & Installation
1. Before proceeding, see SERVICE PRECAUTIONS . Ensure front wheels are in straight-ahead position.
Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds.
Working from back of steering wheel, loosen air bag module mounting Torx screws until groove around
screw circumference catches on screw case. See Fig. 11
.
2. Pull drive
r-side air bag module from steering wheel and disconnect driver-side air bag module connector.
NOTE: If steering wheel horn button contact plate is deformed, replace steering wheel
assembly.

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Place driver-side air bag module on a flat surface with pad side facing up.
3. To install, reverse removal procedure. Ensure front wheels are in straight-ahead position and spiral cable
is properly aligned. See SPIRAL CABLE under ADJUSTMENTS
. Tighten driver-side air bag module
mounting screws to specification. See TORQUE SPECIFICATIONS
. Check AIR BAG warning light
to ensure system is functioning properly. See SYSTEM OPERATION CHECK
.
Fig. 11: Removing Driver
-Side Air Bag Module
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
FRONT AIR BAG SENSOR
Removal & Installation
1. Before proceeding, see SERVICE PRECAUTIONS . Turn ignition switch to LOCK position.
Disconnect negative battery cable. Wait at least 90 seconds. The front air bag sensors are mounted inside
right and left front side members.
2. For left front air ba
g sensor, remove left front end panel and headlight. See Fig. 12 . Disconnect front air

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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
.

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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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