headlight TOYOTA RAV4 1996 Service Repair Manual

3. With squib circuit connector disconnected, insert paper into female terminal, sliding it under shorting bar
spring. This lifts the spring, breaking the circuit and allowing the test procedure to be performed as
specified.
TESTING - DIAGNOSTIC
NO CODES - SOURCE VOLTAGE DROP
1. Disconnect negative battery cable. Wait at least 90 seconds. Remove steering wheel pad. See
STEERING WHEEL PAD & SPIRAL CABLE
under REMOVAL & INSTALLATION. Disconnect
passenger-side air bag harness connector, accessible through finish plate in glove box. See Fig. 2
.
Disconnect air bag sensor assembly connector.
2. Reconnect negative battery cable. Turn ignition switch to ON position. Measure voltage between ground
and terminals IG2 and ACC of air bag sensor connector. See Fig. 13
. Operate electrical components
(defogger, wiper, headlights, heater blower, etc.). If voltage is 8-14 volts, go to next step. If voltage is not
8-14 volts, check harness between battery and air bag sensor assembly and check battery and charging
system.
3. Turn ignition switch to LOCK position. Connect steering wheel pad connector. Connect passenger-side
air bag connector. Turn ignition switch to ON position. Operate electrical components as in step 2) and
check that SRS warning light goes off. If light does not go off, check diagnostic trouble code and go to
appropriate CODE under TESTING - DIAGNOSTIC. If a normal code is output, replace air bag sensor
assembly. If warning light goes off, no problem detected at this time.
CODE 11
1. Disconnect negative battery cable. Wait at least 90 seconds. Remove steering wheel pad. See
STEERING WHEEL PAD & SPIRAL CABLE
under REMOVAL & INSTALLATION. Disconnect
passenger-side air bag harness connector, accessible through finish plate in glove box. See Fig. 2
.
Disconnect air bag sensor assembly connector.
2. Measure resistance on spiral cable side of connector between spiral cable and steering wheel pad between
D+, D- and ground. If resistance is 1000 ohms or more, go to next step. If resistance is less than 1000
ohms, go to step 7).
3. Measure resistance on air ba
g sensor assembly side of connector between air bag sensor and passenger- WARNING:Paper must not be thicker than male terminal. If paper is thicker,
connector terminal may be damaged, possible resulting in system
fault.
NOTE: Use Diagnosis Check Wiring (09843-18020) when connecting jumper wire
between terminals of DLC. Spiral cable upper connector is same as steering
wheel pad (squib) connector. Spiral cable lower connector (located under
steering column) connects the harness between spiral cable and center air bag
sensor.
NOTE: During testing, if codes other than Code 11 are displayed, disregard them.

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

1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota
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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.

1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota
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When DLC1 terminals Tc and E1 are connected together, air bag sensor assembly is set in Diagnostic Trouble
Code (DTC) output mode. DTC is displayed by flashing AIR BAG warning light.
Diagnostic Procedure
1. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds.
Access and disconnect air bag sensor assembly connector C20 (center connector). See AIR BAG
SENSOR ASSEMBLY under REMOVAL & INSTALLATION
.
2. Measure resistance between ground and air bag sensor assembly connector C20, terminal No. 19 (circuit
Tc, Pink/Black wire). See Fig. 16
. If resistance is more than one megohm, replace air bag sensor
assembly. If resistance is less than one megohm, replace harness and connector.
SOURCE VOLTAGE DROP
Description
The air bag sensor assembly is equipped with a voltage-increase circuit to allow system operation in case source
(battery) voltage drops below minimum. When battery voltage drops, voltage-increase circuit functions to
increase voltage of air bag system to normal voltage.
The malfunction display for this circuit is different from other air bag system circuits. When source voltage
drop is detected and no other DTCs are present, the AIR BAG warning light remains illuminated constantly.
Source voltage drop is not recorded in air bag sensor assembly as a malfunction, and when source voltage
returns to normal, AIR BAG warning light will turn off.
Diagnostic Procedure
1. Turn ignition switch to LOCK position. Disable air bag system. See DISABLING SYSTEM under
DISABLING AND ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable.
2. Turn ignition switch to ON position. Turn on electrical accessories (defogger, wipers, headlights, blower
motor, etc.). Measure voltage between ground and air bag sensor assembly connector C20, terminals No.
5 (circuit IG2, Black/Orange wire) and No. 6 (circuit ACC, Gray wire). See Fig. 16
. Turn electrical
accessories off. If voltage is 10-14 volts, go to next step. If voltage is not 10-14 volts, check harness
between battery and air bag sensor assembly and check battery and charging system.
3. Turn ignition switch to LOCK position. Activate air bag system. See ACTIVATING SYSTEM
under
DISABLING & ACTIVATING AIR BAG SYSTEM. Turn ignition switch to ON position. Turn on
electrical accessories again. If AIR BAG warning light goes out, system operation is normal at this time.
If AIR BAG warning light does not go out, check for DTCs. See RETRIEVING CODES
under
DIAGNOSIS & TESTING. If DTC is displayed, go to appropriate DTC. If a normal code is displayed (2
flashes per second), replace air bag sensor assembly.
DTC 11/B0102: DRIVER-SIDE AIR BAG SQUIB CIRCUIT SHORT TO GROUND
Description
The driver-side air bag squib circuit consists of the air bag sensor assembly, spiral cable and driver-side air bag
module. The squib causes drive
r-side air bag to deploy when all deployment conditions are satisfied.

1999 Toyota RAV4
AIR BAG RESTRAINT SYSTEM 1999 Toyota
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Fig. 3: Testing Generator Full Field Output (Typical)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
LOAD TEST
1. Connect an ammeter as described in NO
-LOAD TEST , step 1) . See Fig. 2 . Start engine. Turn on high
beam headlights and place heater blower control on HI. Increase engine speed to 2000 RPM.
2. Check ammeter reading. Ammeter should read 30 amps or more. If amperage is less than specified, repair
or replace generator.
BENCH TESTING
BRUSHES
1. Brushes should slide smoothly in holders. Replace brushes if damaged or worn. On Tundra and 4Runner,
new brush exposed length should be .374-.453" (9.5-11.5 mm). On all other models, new brush exposed
length should be .413" (10.5 mm).
2. On all models, minimum exposed length should be more than .059" (1.5 mm). There are 2 different brush
holders used. One brush holder is replaced as an assembl
y, and the other has replaceable brushes. If
NOTE: If battery is fully charged, disable ignition system. Crank engine for about 15
seconds to partially discharge battery.
NOTE: If battery is fully charged, generator load test results may be less than 30 amps.

1999 Toyota RAV4
1999-2000 STARTING & CHARGING SYSTEMS Generators & Regulators
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SPLICES
SPLICES
COMPONENT LOCATION GRAPHICS
BI (4 Door)At right rear quarterpanel.
BJAt left side of back door.
BKAt left side of roof.
EAAt right side of radiator. See Fig. 2 .
EBAt left side of radiator. See Fig. 2 .
ECAt intake manifold. See Fig. 2 .
IDAt left kick panel. See Fig. 4 .
IEBelow center of dash, at left dash brace. See Fig. 4 .
IFBelow center of dash, at right dash brace. See Fig. 4 .
IGAt right kick panel. See Fig. 4 .
ComponentComponent Location
B1 (2 Door)In body harness, at left side of windshield header.
B1 (4 Door)In body harness, at top of left "A" pillar.
B2In body harness, at left side of back door.
E1In engine compartment harness, behind left headlight. See Fig. 2 .
I1In dash harness, behind lower right side of dash.
I2In dash harness, behind right side of dash.
NOTE: Figures may show multiple component locations. Refer to appropriate table for
proper figure references.

1999 Toyota RAV4
1999 TOYOTA RAV4
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1999-2000 ACCESSORIES & EQUIPMENT
Instrument Panels - Trucks
DESCRIPTION & OPERATION
GAUGES
Standard instrument clusters contain fuel and temperature gauges with telltale warning lights. Some optional
instrument panels are equipped with a tachometer, oil pressure gauge and voltmeter. Gauge internal operating
components use either a 2-terminal bimetallic strip type or a 3-terminal coil type. The 2-terminal type gauges
are generally used on clusters without tachometers.
SWITCHES
All models contain hazard warning switch on instrument panel. All models use a combination switch for
headlight, turn signal, wiper/washer, and cruise control switches. Combination switch is mounted on steering
column. For testing and/or removal and installation procedures for combination switch components, see
appropriate STEERING COLUMN SWITCHES article.
COMPONENT TESTS
A/T OIL TEMPERATURE SWITCH
RAV4
1. Turn ignition switch to OFF position. Disconnect A/T oil temperature switch 1-pin connector. Switch is
located on side of transaxle, near park/neutral position switch. Remove A/T oil temperature switch. Place
probe end of switch and thermometer in a container of water.
2. Connect an ohmmeter between switch terminal and switch body. Heat water and check for continuity.
With temperature at 284-302°F (140-150°C), continuity should exist. If continuity does not exist, replace
switch.
A/T OIL TEMPERATURE WARNING LIGHT
RAV4
Disconnect A/T oil temperature switch connector. Switch is located on side of transaxle, near park/neutral
position switch. Using a jumper wire, connect switch connector terminal to ground. Turn ignition switch to ON
position. A/T oil temperature warning light should be on. If warning light is off, check bulb and wiring harness.
Repair as necessary. WARNING:Deactivate air bag system before performing any service operation. See
AIR BAG RESTRAINT SYSTEMS article. DO NOT apply electrical power to
any component on steering column without first deactivating air bag
system. Air bag may deploy.

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Instrument Panels - Trucks

1999 Toyota RAV4
1999-2000 ACCESSORIES & EQUIPMENT Instrument Panels - Trucks
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System
2 - DOME 15 Amp Personal Lights, Open Door Warning Light, Clock
3 - EFI 15 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System
4 - HAZ-HORN 15 Amp Emergency Flashers, Horns
5 - ALT-S 5 Amp Charging system
6 - SPARE 15 Amp Spare fuse
7 - SPARE 7.5 Amp Spare fues
8 - H-LP (LH) 15 Amp Left-Hand Headlight
9 - H-LP (RH) 15 Amp Right-Hand Headlight
10 - DRL 7.5 Amp Daytime Running Light System
11 - H-LP LH-L 10 Amp Left Hand Headlight (Low Beam)
12 - H-LP RH-L 10 Amp Right Hand Headlight (Low Beam)
13 - H-LP LH-H 10 Amp Left Hand Headlight (High Beam)
14 - H-LP RH-H 10 Amp Right Hand Headlight (High Beam)
15 - TAIL 10 Amp Tail Lights, Parking Lights, License Plate Lights, Interior Lights
16 - GAUGE 10 Amp Gauges And Meters, Service Reminder Indicators (Except Discharge And Open
Door Warning Lights), Back-up Lights, Air Conditioning System, Power Windows, Rear Window
Defogger, Center Differential Lock System, Electronically Controlled Automatic Transaxle System
17 - TURN 7.5 Amp Turn Signal Lights
18 - CIG & RAD 15 Amp Cigarette Lighter, Clock, Car Audio System, Power Rear View Mirrors
19 - DEF-I/UP 7.5 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System
20 - IGN 7.5 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System,
Discharge Warning Light
21 - ECU-IG 7.5 Amp Anti-Lock Brake Syste, Electronically Controlled Automatic Transmission
System
22 - WIPER 20 Amp Windshield Wipers And Washer, Rear Window Wiper And Washer
23 - SRS 7.5 Amp SRS Airbag System
24 - OBD 7.5 Amp On-Board Diagnostic System
25 - STOP 10 Amp Stop Lights
26 - A/C 7.5 Amp Air Conditioning System
27 - MAIN No. 1 30 Amp Starting System, Headlights
28 - RDI FAN 30 Amp Electric Cooling Fan
29 - CDS FAN 30 Amp Electric Cooling Fan
30 - POWER 30 Amp Power Windows, Power Door Lock System
31 - DEF 30 Amp Rear Window Defogger
32 - AM 1 40 Amp CIG & RAD, WIPER, GAUGE, ECU-IG, TURN, TAIL, and PANEL fuses
33 - MAIN 80 Amp AM 2, HAZ-HORN, EFI, DOME, RADIO and ALT-S fuses
34 - ALT 100 Amp Tail lights, ABS, RADIO, HTR, AM 1, POWER, STOP and DEF fuses

1999 Toyota RAV4
MAINTENANCE INFORMATION 1997-99 MAINTENANCE Toyota Maintenance Information
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35 - HTR 50 Amp Air Conditioning system
36 - ABS 60 Amp Anti-Lock brake system
Fuse & Circuit Breaker Identificatio - 1998
1 - H-LP (LH) 15 Amp Left-Hand Headlight
2 - H-LP (RH) 15 Amp Right-Hand Headlight
3 - SPARE 10 Amp Spare fuse
4 - SPARE 15 Amp Spare fuse
5 - AM2 5 Amp Multiport Fuel Injection System/Sequential Multiport Fuel Injection System, SRS
Airbag System, Seat Belt Pretensioners, Starting System, Discharge Warning Light
6 - ALT-S 5 Amp Charging system
7 - HAZ 10 Amp Emergency Flashers
8 - EFI 20 Amp (USA) or 15 Amp (Canada)Multiport Fuel Injection System/Sequential Multiport Fuel
Injection System
9 - DOME 15 Amp Personal Lights, Open Door Warning Light, Clock
10 - IGN 20 Amp Charging System
11 - H-LP LH-H 10 Amp Left Hand Headlight (High Beam)
12 - H-LP RH-H 10 Amp Right Hand Headlight (High Beam)
13 - H-LP LH-L 10 Amp Left Hand Headlight (Low Beam)
14 - H-LP RH-L 10 Amp Right Hand Headlight (Low Beam)
15 - SEAT-HTR 10 Amp No Circuit
16 - PWR OUTLET 15 Amp Power Outlet
17 - CIG 15 Amp Cigarette Lighter, Clock, Car Audio System, Power Rear View Mirrors, Electronically
Controlled Automatic Transmission
18 - SRS-SCC 10 Amp SRS Airbag System, Seat Belt Pretensioners
19 - WIPER 20 Amp Windshield Wipers And Washer, Rear Window Wiper And Washer
20 - ECU-IG 10 Amp Electronically Controlled Automatic Transmission System, Rear Window
Defogger, Center Differential Lock System, Electric Moon Roof, Multiport Fuel Injection System,
Electric Cooling Fan, Anti-Lock Brake System, Cruise Control System
21 - TURN & GAUGE 10 Amp Turn Signal Lights, Gauges & Meters, Back-Up Lights, Service
Reminder Indicators, Air Conditioning System, Daytime Running Light System
22 - STOP 10 Amp Stop Lights, High Mounted Stop Light, Electronically Controlled Automatic
Transmission System, Anti-Lock Brake System
23 - TAIL 15 Amp Gauges & Meters, Emergency Flashers, Cigarette Lighter, Center Differential Lock
System, Clock, Rear Window Defogger, Air Conditioning System, Electronically Controlled Automatic
Transmission System, Car Audio System, Tail Lights, License Plate Lights, Parking Lights, Instrument
Panel Light Control, Side Marker Lights
24 - OBD 10 Amp On-Board Diagnosis System
25 - SRS-B 10 Amp SRS Air Bag Warning Light

1999 Toyota RAV4
MAINTENANCE INFORMATION 1997-99 MAINTENANCE Toyota Maintenance Information
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1999 ACCESSORIES & EQUIPMENT
Steering Column Switches - Trucks
DESCRIPTION
Headlight and turn signal switch (left side of column) and wiper/washer switch (right side of column) are part of
the combination switch. Lever for tilt steering (if equipped) is on left side of column.
COMPONENT TESTS
HEADLIGHT, DIMMER & PASSING SWITCHES
With headlight switch in specified position, check continuity between specified terminals of headlight switch
connectors. See HEADLIGHT SWITCH CONTINUITY TEST
table and/or DIMMER & PASSING
SWITCHES CONTINUITY TEST table. For switch terminal locations, see Fig. 1 . If continuity is not as
specified, replace headlight switch.
HEADLIGHT SWITCH CONTINUITY TEST
DIMMER & PASSING SWITCHES CONTINUITY TEST (ALL MODELS) WARNING:Deactivate air bag system before performing any service operation. See
AIR BAG RESTRAINT SYSTEMS article. DO NOT apply electrical power to
any component on steering column without first deactivating air bag
system. Air bag may deploy.
NOTE: For information on cruise control switch (right side of column), see appropriate
CRUISE CONTROL SYSTEMS article.
Application & Switch Position(1) Terminals No.Continuity
Land Cruiser, Sienna, RAV4, Tacoma & 4Runner
OFFNoneNo
TAIL14 & 16Yes
HEAD13, 14 & 16Yes
With AUTO (2) 12 & 16Yes
(1)See Fig. 1 .
(2)Land Cruiser and Sienna only.
Switch Position(1) Terminals No.Continuity
High Beam7 & 16Yes
Low Beam16 & 17Yes
Passing7, 8 & 16Yes

1999 Toyota RAV4
1999 ACCESSORIES & EQUIPMENT Steering Column Switches - Trucks

1999 Toyota RAV4
1999 ACCESSORIES & EQUIPMENT Steering Column Switches - Trucks
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