TOYOTA RAV4 1996 Service Repair Manual

PR07S−01
Q05756
65.5 − 70.5 mm
(2.579 − 2.776 in.)
Q06145
11.5 − 13.5 mm
(0.453 − 0.536 in.)
− PROPELLER SHAFTPROPELLER SHAFT ASSEMBLY
PR−9
1996 RAV4 (RM447U)
INSTALLATION
1. INSTALL INTERMEDIATE SHAFT
(a) Remove SST from the transfer.
(b) Insert the yoke into the transfer.
2. INSTALL CENTER SUPPORT BEARING TEMPORARI-
LY
3. INSTALL PROPELLER SHAFT
(a) Align the matchmarks on the flanges and connect the
shaft with the 4 bolts, washers and nuts.
(b) Torque the bolts and nuts.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
4. TIGHTEN CROSS GROOVE JOINT SET BOLT
(a) Depress the brake pedal and hold it.
(b) Using a hexagon wrench, tighten the cross groove joint
set bolts.
Torque: 27 N·m (275 kgf·cm, 20 ft·lbf)
5. INSTALL CENTER SUPPORT BEARING
(a) With the vehicle in the unladen condition, adjust the di-
mension between the rear side of cover and the shaft, as
shown in the illustration.
(b) With the same condition, adjust the dimension between
the rear side of center bearing housing and the rear side
of cushion at 11.5 − 13.5 mm (0.4528 − 0.5315 in.), as
shown in the illustration below, then torque the bolts.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(c) Check that the center line of the bracket is at right angles
at the shaft axial direction.

RS02X−12
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−7
1996 RAV4 (RM447U)
STEERING WHEEL PAD AND SPIRAL CABLE
COMPONENTS

RS02Y−08
RS−8
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
REMOVAL
(See page SR−12)

RS02Z−11
H13549
H13550
H13551
H13549
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−9
1996 RAV4 (RM447U)
INSPECTION
1. VEHICLE NOT INVOLVED IN COLLISION
(a) Do a diagnostic system check (See page DI−285).
(b) Do a visual check which includes the following items with
the steering wheel pad (with airbag) installed in the ve-
hicle.
Check for cuts, minute cracks or marked discoloration of
the steering wheel pad top surface and grooved portion.
2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
NOT DEPLOYED
(a) Do a diagnostic system check (See page DI−285).
(b) Do a visual check which includes the following items with
the steering wheel pad (with airbag) installed in the ve-
hicle.
Check for cuts and cracks in, or marked discolor-
ation of the steering wheel pad top surface and
grooved portion.
Check for cuts and cracks in wire harnesses, and for
chipping in connectors.
Check for deformation of the horn button contact
plate of the steering wheel.
HINT:
If the horn button contact plate of the steering wheel is de-
formed, never repair it. Always replace the steering wheel
assembly with a new one.
There should be no interference between the steering
wheel pad and the steering wheel, and the clearance
should be uniform all the way around when the new steer-
ing wheel pad is installed on the steering wheel.
CAUTION:
For removal and installation of the steering wheel pad, see
page SR−12 and SR−19, and be sure to follow the correct
procedure.

RS−10
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED
(a) Do diagnostic system check (See page DI−285).
(b) Do a visual check which includes the following items with
the steering wheel pad (with airbag) removed from the ve-
hicle.
Check for deformation of the horn button contact
plate of the steering wheel.
Check for damage to the spiral cable connector and
wire harness.
HINT:
If the horn button contact plate of the steering wheel is de-
formed, never repair it. Always replace the steering wheel
assembly with a new one.
There should be no interference between the steering
wheel pad and the steering wheel, and the clearance
should be uniform all the way around when the new steer-
ing wheel pad is installed on the steering wheel.

RS0QA−02
AB0152
SST
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−11
1996 RAV4 (RM447U)
DISPOSAL
HINT:
When scrapping vehicle equipped with an SRS or disposing of
a steering wheel pad (with airbag), always first deploy the air-
bag in accordance with the procedure described below. If any
abnormality occurs with the airbag deployment, contact the
SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
When disposing of a steering wheel pad with an airbag
deployed in a collision, follow the same procedure given in step
1−(d) in ”DISPOSAL”.
CAUTION:
Never dispose of a steering wheel pad which has an
undeployed airbag.
The airbag produces a sizeable exploding sound
when it deploys, so perform the operation out−of−
doors and where it will not create a nuisance to
nearby residents.
When deploying the airbag, always use the specified
SST (SRS Airbag Deployment Tool). Perform the op-
eration in a place away from electrical noise.
SST 09082−00700
When deploying an airbag, perform the operation at
least 10 m (33 ft) away from the steering wheel pad.
The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.
Use gloves and safety glasses when handling a steer-
ing wheel pad with deployed airbag.
Always wash your hands with water after completing
the operation.
Do not apply water, etc. to a steering wheel pad with
deployed airbag.

AB0158
Battery
SST
AB0152
SST
AB0158
Battery
SST
H01580
SST
RS−12
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
1. AIRBAG DEPLOYMENT WHEN SCRAPPING VE-
HICLE
HINT:
Have a battery ready as the power source to deploy the airbag.
(a) Check functioning of the SST.
CAUTION:
When deploying the airbag, always use the specified SST:
SRS Airbag Deployment Tool.
SST 09082−00700
(1) Connect the SST to battery.
Connect the red clip of the SST to the battery posi-
tive (+) terminal and the black clip to the battery neg-
ative (−) terminal.
HINT:
Do not connect the yellow connector which will be connected
with the supplemental restraint system.
(2) Check functioning of the SST.
Press the SST activation switch, and confirm the
LED of the SST activation switch lights up.
CAUTION:
If the LED lights up when the activation switch is not being
pressed, SST malfunction is probable, so definitely do not
use the SST.
(b) Install the SST.
CAUTION:
Check that there is no looseness in the steering wheel and
steering wheel pad.
(1) Remove the steering column lower cover.
(2) Disconnect the airbag connector of the spiral cable.

H13548SST
R13455
10 m (33 ft) or more←→
H03199
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−13
1996 RAV4 (RM447U)
(3) Connect the SST connector to the airbag connector
of the spiral cable.
SST 09082−00700
(4) Move the SST to at least 10 m (33 ft) away from the
front of the vehicle.
(5) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST wire harness.
(6) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the negative (+) termi-
nal.
(c) Deploy the airbag.
(1) Check that no one is inside the vehicle or within 10
m (33 ft) area around the vehicle.
(2) Press the SST activation switch and deploy the air-
bag.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
(d) Dispose of the steering wheel pad (with airbag).
CAUTION:
The steering wheel pad is very hot when the airbag is
deployed, so leave it alone for at least 30 minutes af-
ter deployment.
Use gloves and safety glasses when handling a steer-
ing wheel pad with deployed airbag.
Always wash your hands with water after completing
the operation.
Do not apply water, etc. to a steering wheel pad with
deployed airbag.
(1) When scrapping a vehicle, deploy the airbag and
scrap the vehicle with the steering wheel pad still
installed.
(2) When moving a vehicle for scrapping which has a
steering wheel pad with deployed airbag, use
gloves and safety glasses.

AB0163
Wire Harness
Diameter
Stripped Wire Harness Section
R05748
L
M RS−14
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 RAV4 (RM447U)
2. DEPLOYMENT WHEN DISPOSING OF STEERING
WHEEL PAD ONLY
NOTICE:
When disposing of the steering wheel pad (with air-
bag) only, never use the customers vehicle to deploy
the airbag.
Be sure to follow the procedure given below when de-
ploying the airbag.
HINT:
Have a battery ready as the power source to deploy the airbag.
(a) Remove the steering wheel pad (See page SR−12).
CAUTION:
When storing the steering wheel pad, keep the upper sur-
face of the pad facing upward.
(b) Using a service−purpose wire harness for the vehicle tie
down the steering wheel pad to the disc wheel
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in.2 or more).
CAUTION:
If a wire harness which is too thin or some other thing is
used to tie down the steering wheel pad, it may be snapped
by the shock when the airbag is deployed. This is highly
dangerous. Always use a wire harness for vehicle use
which is at least 1.25 mm
2 (0.0019 in.2).
HINT:
To calculate the square of the stripped wire harness section:
Square = 3.14 X (Diameter)
2 divided by 4
(1) .Install the 2 bolts with washer in the 2 bolt holes in
the steering wheel pad.
Bolt:
L: 35.0 mm (1.387 in.)
M: 6.0 mm (0.236 in.)
Pitch: 1.0 mm (0.039 in.)
NOTICE:
Tighten the bolts by hand until the bolts become diffi-
cult to turn.
Do not tighten the bolts too much.

R05749
2 Times or more
R05751
AB0158
Battery
SST
− SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS−15
1996 RAV4 (RM447U)
(2) Using 3 wire harness, wind the wire harness at least
2 times each around the bolts installed on the left
and right sides of the steering wheel pad.
CAUTION:
Tightly wind the wire harness around the bolts so that
there is no slack.
If there is slackness in the wire harness, the steering
wheel pad may come loose due to the shock when the
airbag is deployed. This is highly dangerous.
(3) Face the upper surface of the steering wheel pad
upward. Separately tie the left and right sides of the
steering wheel pad to the disc wheel through the
hub nut holes. Position the steering wheel pad con-
nector so that it hangs downward through a hub
hole in the disc wheel.
CAUTION:
Make sure that the wire harness is tight. It is very dan-
gerous if looseness in the wire harness results in the
steering wheel pad coming free through the shock of
the airbag deploying.
Always tie down the steering wheel pad with the pad
side facing upward. It is very dangerous if the steer-
ing wheel pad is tied down with the metal surface fac-
ing to the airbag deploying direction and the steering
wheel pad will be thrown into the air.
HINT:
The disc wheel will be marked by airbag deployment, so when
disposing of the airbag use a redundant disc wheel.
(c) Check functioning of the SST.
SST 09082−00700