warning light TOYOTA RAV4 1996 Service Owner's Manual

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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may allow air bag to deploy until 90 seconds after disconnecting negative battery cable.
If vehicle was in a minor collision but air bags did not deploy, inspect all system components for any sign
of damage, and replace as necessary.
Never use air bag system components from another vehicle. Replace air bag system components with new
parts.
Remove air bag sensor assembly if repairing the vehicle requires impacting (shocking) the vehicle.
Air bag sensor assembly contains mercury. After replacement, DO NOT destroy old part. When
scrapping vehicle or replacing air bag sensor assembly, remove air bag sensor assembly and dispose of it
as toxic waste.
Never disassemble and repair air bag sensor assembly, front air bag sensors, passenger-side or driver-side
air bag modules or seat belt pretensioners.
Replace dropped, cracked, dented or otherwise damaged components.
DO NOT expose air bag sensor assembly, front air bag sensors or air bag modules directly to heat or
flame.
When diagnosing electrical circuits, use a volt/ohm meter with high impedance (10,000 ohms minimum).
Information labels are attached to air bag components. Follow all notices on labels.
After work on air bag system is complete, 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 and away
from surface. This will reduce motion of module if it is accidentally deployed.
After deployment, air bag surface may contain deposits of sodium hydroxide, which irritates skin. Always
wear safety glasses, rubber gloves, and long-sleeved shirt during clean-up. After clean-up, wash hands
using mild soap and water.
Carry a live air bag module with trim cover (air bag) pointed away from your body to minimize injury in
case accidental deployment.
If air bag system is not fully functional for any reason, vehicle should not be driven until system is
repaired and again becomes operational. DO NOT remove bulbs, modules, sensors or other components,
or in any way disable system from operating normally. If air bag system is not functional, park vehicle
until it is repaired and functions properly.
ADJUSTMENTS
SPIRAL CABLE
Ensure front wheels are in straight-ahead position. Turn spiral cable counterclockwise until it becomes difficult
to turn. Turn spiral cable clockwise about 2 1/2 turns to align match marks. See Fig. 2
. Install steering wheel.

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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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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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bag sensor connector with sensor installed. Remove inner fender panel. Remove 3 bolts and move air
intake resonator aside. Remove 2 mounting bolts and remove sensor.
3. For right front air bag sensor, remove right front end panel and headlight. See Fig. 12
. Disconnect front
air bag sensor connector with sensor installed. Remove 2 mounting bolts and remove sensor.
4. To install, reverse removal procedure. Tighten front air bag sensor mounting screws to specification. See
TORQUE SPECIFICATIONS
. Check AIR BAG warning light to ensure system is functioning
properly. See SYSTEM OPERATION CHECK
.
Fig. 12: Removing Front Air Bag Sensors

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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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

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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.
Remove steering wheel. See STEERING WHEEL
.
2. Remove lower finish panel and instrument panel lower insert. Remove upper and lower steering column
covers. Disconnect and remove combination switch with spiral cable attached. Remove heater-to-register
duct. Match mark steering shaft and steering gear shaft for reassembly performance. Remove steering
column.
3. 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
.
STEERING WHEEL
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.
Remove driver-side air bag module. See DRIVER
-SIDE AIR BAG MODULE .
2. Remove steering wheel nut. Match mark steering wheel and steering column for reassembly reference.
Using appropriate puller, remove steering wheel.
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 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
.
SYSTEM OPERATION CHECK
Turn ignition switch to ACC or ON position. AIR BAG warning light should come on for about 6 seconds and
then go out. If AIR BAG warning light does not operate as specified, see DIAGNOSIS & TESTING
.
DIAGNOSIS & TESTING
AIR BAG WARNING LIGHT CHECK
Turn ignition switch to ACC or ON position. If air bag warning light comes on for about 6 seconds and then
goes off, system is functioning properly. If AIR BAG warning light comes on and stays on (or flashes),
Diagnostic Trouble Code (DTC) is stored in air bag sensor assembly. Go to RETRIEVING CODES
. If AIR
BAG warning light responds in any other way, go to DIAGNOSTIC TESTS
.
RETRIEVING CODES
CAUTION: System may be damaged if jumper wire is incorrectly connected across
terminals of Data Link Connector (DLC1). Use Diagnosis Check Wire
(09843-18020) when connecting terminals of DLC1.

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Using Diagnosis Check Wire
1. Turn ignition switch to ACC or ON position. Wait about 20 seconds. Using Diagnosis Check Wiring
(09843-18020), connect terminals Tc and E1 of Data Link Connector (DLC1). See Fig. 14
. DLC1 is
located forward of right (passenger-side) front strut tower.
2. If AIR BAG warning light flashes 2 times per second, system is normal (normal code). If AIR BAG
warning light does not flash Diagnostic Trouble Codes (DTCs) or flashes DTCs without DLC1
connection, proceed to DTCS NOT DISPLAYED
under DIAGNOSTIC TESTS or DTCS
CONTINUOUSLY DISPLAYED under DIAGNOSTIC TESTS. If AIR BAG warning light is on
continuously and DTC is normal (flashes 2 times per second), source voltage is low. Go to SOURCE
VOLTAGE DROP under DIAGNOSTIC TESTS.
3. If AIR BAG warning light flashes, count number of flashes to determine DTCs that are set. For example,
DTC 12 is: FLASH, 1.5-second pause, FLASH, FLASH. If more than one DTC is displayed, a 2.5-
second pause will occur between each DTC. Lowest numbered DTC will be displayed first, followed by
next higher number DTC until all DTCs have been displayed.
4. After all DTCs are displayed, a 4-second pause will occur, and DTC display will be repeated. See
appropriate DTC under DIAGNOSTIC TESTS. After repairing, clear DTCs. See CLEARING CODES
.
Using Toyota Hand-Held Tester
Install Toyota hand-held tester to DLC1 or DLC3. DLC1 is located forward of right (passenger-side) front strut
tower. See Fig. 14
. DLC3 is located under left side of instrument panel, to right of steering column. Read DTC
by following prompts on tester. See tester operator's manual for instructions. NOTE: If DTCs other than those listed under DIAGNOSTIC TESTS
are displayed,
replace the air bag sensor assembly. If the air bag warning light does not
function as described, proceed to appropriate test under DIAGNOSTIC TESTS
.

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Fig. 14: Identifying Data Link Connector 1 (DLC1) Terminals
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
CLEARING CODES
Using Jumper Wire
1. Use 2 jumper wires. Connect one end of first jumper wire to DLC1 terminal Tc and one end of second
jumper wire to DLC1 terminal AB. See Fig. 14
. Turn ignition switch to ACC or ON position. Wait about
6 seconds.
2. Starting with jumper wire connected to terminal Tc, apply body ground alternately to terminal Tc and
terminal AB twice each, in cycles of 1/2 to 1 1/2 seconds (sequence is: Tc, AB, Tc, AB). Finally, keep
appl
ying body ground to terminal Tc until AIR BAG warning light flashes quickly, indicating DTCs are
NOTE: When alternately grounding terminals Tc and AB, release ground from one
terminal and immediately ground the other terminal within 0.2 second. If
time interval exceeds 0.2 second, DTCs will not be cleared.

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