airbag TOYOTA RAV4 1996 Service Repair Manual

Airbag SensorInflator Sensor Lock Release BoltBagSteering Wheel PadSteering Wheel Bolt Cap Airbag SensorInflatorBag
HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. SRS AIRBAG
The TOYOTA RAV4 is equipped with an SRS (Supplemental Restraint System) airbag as an option.
Failure to carry out service operations in the correct sequence could cause the airbag system to unexœ
pectedly deploy during servicing, possibly leading to a serious accident.
Further, if a mistake is made in servicing the airbag system, it is possible the airbag may fail to operate
when required.
Before performing servicing (including removal or installation of parts, inspection or replacement), be
sure to read the following items carefully, then follow the correct procedure described in the repair
manual for relevant model.
Location of Components
INTRODUCTIONINœ6

Component to be alignedSection of repair manual
for relevant model
Front Wheels
Suspension and Axle (SA) section
Rear Wheels
Suspension and Axle (SA) section
1. Never disassemble the steering wheel pad assembly.
2. Do not subject the steering wheel pad to shocks or bring magnets close to it.
3. Do not expose the steering wheel pad to high temperatures or fire.
4. If grease, cleaner, oil or water gets on the steering wheel pad, promptly wipe it off with a dry cloth.
5. Do not drop the steering wheel pad. Never use a steering wheel pad which has been dropped.
6. Never install the steering wheel and pad in another vehicle.
7. When the steering wheel pad is removed, store it on a stable, flat place with the pad surface facing upœ
wards. Never place anything on top of the pad.
8. When work on the vehicle will produce too strong a shock, first loosen the sensor lock release bolt until
it turns freely and perform the work after sensor lock occurs.
9. Even in cases where the vehicle is in a low-impact accident where the airbag is not activated, always
check the pad surface and airbag sensor part. If dents, cracks or deformation is visible, replace the airœ
bag with a new assembly.
10. When disposing of the vehicle or steering wheel, always deploy the airbag first.
11. The deployed inflator inside the steering wheel pad is hot, so dispose of it after it has been cooled by
atmospheric air. Never apply water to cool it down.
2. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in section BR of the repair manual for the relevant model year when handling brake system
parts.
3. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance
and vibration resistance of the vehicle. After installing components in the sections listed in the table
below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate
repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions
given in the repair manual for the relevant model during alignment and section DI of this manual.
INTRODUCTIONINœ7

30
G ELECTRICAL WIRING ROUTING
Position of Parts in Instrument Panel
A 12 A/C Amplifier C 6 Cigarette Lighter Illumination
A 13 A/C Control SW C 7 Clock
A 14 A/C Thermistor C 8 Clutch Start SW
A 15 ABS Deceleration Sensor C 9 Combination Meter
A 16 ABS ECU C 10 Combination Meter
A 17 ABS ECU C 11 Combination Meter
A 18 Airbag Sensor Assembly C 12 Combination SW
A 19 Airbag Squib (Front Passenger Airbag Assembly) C 13 Combination SW
A 20 Airbag Squib (Steering Wheel Pad) C 14 Combination SW
C 15 Cruise Control Clutch SW
B 3 Blower Motor C 16 Cruise Control ECU
B 4 Blower Resisitor
B 5 Blower SW D 2 Data Link Connector 3
B 6 Buckle SW LH D 3 Defroster Mode SW
D 4 Diode (Engine Idle-Up)
C 4 Center Diff. Lock Control SW D 5 Door Lock Control Relay
C 5 Cigarette Lighter

11 5
SRS
NOTICE: When inspecting or repairing the SRS, perform the operation in accordance with the following
precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model
year.

Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble
codes become the most important source of information when troubleshooting.
When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before
disconnecting the battery.

Work must be started after 90 seconds from the time the ignition SW is turned to the LOCKº position and the
negative (-) terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped with a back-up power source so that if work is started within
90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be activated.)
When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio
systems will be canceled. So before starting work, make a record of the contents memorized by each memory
system. When work is finished, reset the clock and audio system as before and adjust the clock.
To avoid erasing the memory of each memory system, never use a back-up power supply from outside the
vehicle.

When removing the steering wheel pad or handling a new steering wheel pad, keep the pad upper surface
facing upward. Also, lock the lock lever of the twin lock type connector at the rear of the pad and take care
not to damage the connector.
(Storing the pad with its metallic surface up may lead to a serious accident if the SRS inflates for some reason.)

Always store a removed or new front passenger airbag assembly with the airbag door facing up. Storing the
airbag assembly with the airbag door facing down could cause a serious accident if the airbag inflates.

Store the steering wheel pad where the ambient temperature remains below 935C (2005F), without high
humidity and away from electrical noise.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly, airbag sensor
assembly.

Before repairing the body, remove the airbag sensor if during repair shocks are likely to be applied to the
sensors due to vibration of the body or direct tapping with tools or other parts.

Do not reuse a steering wheel pad or front airbag sensors.
After evaluating whether the center airbag sensor assembly is damaged or not, decide whether or not to reuse
it. (See the Repair Manual for the method for evaluating the center airbag sensor assembly.)

When troubleshooting the supplemental restraint system, use a high-impedance (Min. 10kW/V) tester.

The wire harness of the supplemental restraint system is integrated with the instrument panel wire harness
assembly.
The vehicle wiring harness exclusively for the airbag system is distinguished by corrugated yellow tubing, as
are the connectors.

Do not measure the resistance of the airbag squibs.
(It is possible this will deploy the airbag and is very dangerous.)

If the wire harness used in the supplemental restraint system is damaged, replace the whole wire harness
assembly.

INFORMATION LABELS (NOTICES) are attached to the periphery of the SRS components. Follow the
instructions on the notices.

11 8
SRS
FROM POW ER SOURCE SYSTEM (
SEE PAGE 54)
IB1 17 IG218
EA1 3
11
GR
B-O
B-R W-G GR
B-O
W-L
W-L W-L
W-L
V W-L RNING LIGHT
METER]
CTOR J 7
IE IDEC
W-B
W-B
L
B
WR
BR BR
AIRBAG SQUIB
(
STEERING
W HEEL PAD) A20
AIRBAG SQUIB
(
FRONT PASSENGER' S
AIRBAG ASSEM BLY) A19DATA LINK
CONNECTO R 1
J 2
JUNCTIO N
CONNECTO
A 125
15A
CIG & RAD7. 5A
IG N7. 5A
SRS
71116 61015
FUSE
BLOCK F 8
1E 4
1M 21E 1
1M 31E 7
1M 4
4 3
W-G
SRS WA
[CO M B. C11
AAC
CBC
B JUNCTIO N CONNE
W-L
V W-B
W-B
12
SPIRAL
CABLE
TC A B
E
3 D 1
A
R
10 9 8 7
ACC IG2 LA TC
E1 E2 D+ D- P+ P-AIRBAG SENSOR ASSEMBLY A18
43 21 65

11 9
THE SRS IS A DRIVER AND PASSENGER PROTECTION DEVICE WHICH HAS A SUPPLEMENTAL ROLE TO THE SEAT BELTS.
WHEN THE IGNITION SW IS TURNED TO ACC OR ON, CURRENT FROM THE CIG & RAD FUSE FLOWS TO TERMINAL 10 OF THE
AIRBAG SENSOR ASSEMBLY. ONLY WHEN THE IGNITION SW IS ON DOES THE CURRENT FROM THE IGN FUSE TO TERMINAL 9.
IF AN ACCIDENT OCCURS WHILE DRIVING, WHEN THE FRONTAL IMPACT EXCEEDS A SET LEVEL, CURRENT FROM THE CIG & RAD
OR IGN FUSE FLOWS TO TERMINALS 4 AND 2 OF THE AIRBAG SENSOR ASSEMBLY " TERMINAL 1 OF THE AIRBAG SQUIB "
TERMINAL 2 " TERMINALS 3 AND 1 OF THE AIRBAG SENSOR ASSEMBLY " TERMINAL 5 OR TERMINAL 6 OR BODY GROUND "
GROUND, SO THAT CURRENT FLOWS TO THE AIRBAG SQUIBS AND CAUSES IT TO OPERATE.
THE AIRBAG STORED INSIDE THE STEERING WHEEL PAD IS INSTANTANEOUSLY EXPANDED TO SOFTEN THE SHOCK TO THE
DRIVER.
THE AIRBAG STORED INSIDE THE PASSENGER'S INSTRUMENT PANEL IS INSTANTANEOUSLY EXPANDED TO SOFTEN THE SHOCK
TO THE PASSENGER.
: PARTS LOCATION
CODESEE PAGECODESEE PAGECODESEE PAGE
A1830C1130J 231
A1930D 128J 731
A2030F 831
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CODESEE PAGEJUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION)
IE20FUSE BLOCK ASSY WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
IM20INSTRUMENT PANEL WIRE AND J/B NO. 1 (LOWER FINISH PANEL)
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CODESEE PAGEJOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION)
EA134ENGINE WIRE AND ENGINE ROOM MAIN WIRE (INSIDE OF R/B NO. 2)
IB136ENGINE ROOM MAIN WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL)
IG238ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE INSTRUMENT PANEL CENTER)
: GROUND POINTS
CODESEE PAGEGROUND POINTS LOCATION
EC34INTAKE MANIFOLD
ID36LEFT KICK PANEL
IE36INSTRUMENT PANEL BRACE LH
AB 12
34
5678910A18
YELLOW
12A19
YELLOW
12A20
YELLOW
4 3 XC11
GRAY
XX3
X5X
XX X11
XXX
XXX
X
X D 1
BL ACKF 8
(
SEE PAGE 26)A A A A A
AAAAAAAJ 2
BLUE
(
HINT : SEE PAGE 7)C C A A
AA CCJ 7
GRAY
(
HINT : SEE PAGE 7) B
BBB
SYSTEM OUTLINE

153
A15A
DOME FROM POWER SOURCE SYSTEM (
SEE PAGE 54)
2
IG 2 2
EA
ILL UM INATIONOPEN DOORCHARGEO/D OFF A/T O IL TEMP. BRAKE
C 10 C 2 C 9
A 1 B 11 B12 C 8 A 5 B 10 C 7
G W-GR-W
R-WY YLGR-B W-B
BR
LE
SW
J
C
B 2
J
TO O /D M AIN SW
TO G ENERATORR
(
4W D A /T)
(
A/T) (
4W D A /T)
TO DOOR COURTESY SW
TO BACK DOOR OPEN
DETECTION SW
TO RHEOSTAT
CO M BINATIO N M E TE R2 19 10 18 1
7. 5 A IG N
[FUSE BLO CK F 8
SRS
C 3
C 4
B-R W-L
TO AIRBAG
SENSOR ASSEMBLY
18 17
C 5
Y-B
TO IN TE G R ATIO N
RELAYBELT
BULB CHECK
B 3
NEUTRAL POSITION
H START SW
FUSE BLOCK
1J 5 1E 1
1B 9 1C 11
G G L-Y B-O
L- Y B- O
B C 9 , C10AC, C1 1
W- W-G
B AA A
AJUNCTION
CONNECTORB J 8 , J 9
A
OR
C
J 5
JUNCTION
CONNECTO
C
FROM PARK/
SW
FROM CLUTC
B
B
B-W (
A/T)
(
M/T)
(
A/T)
AIG 2 17
2
R R R W-B
AKE FLUID
VEL W ARNIN
UNCTION
OOR 1
11 ]
10A
TAIL7. 5A
SRS
F 8
1E 3
1I 21E 7
1M 4
G
1B 19
1J 15 1I10
-B -B
1 1 1
G
P 2
A 5
A/T FLUID
TEM P . SW PARKING
BRAKE SW
NNECT
R
A
JUNCTION
CONNECT J 7

165
PERSONAL LIGHT
W IPER AND W ASHER SW
[COMB. SW ]
REAR WINDOW
DEFOGGER SW
COMBINATION M ETER
CRUISE CONTROL ECU
DOOR LO CK CONTROL
SW (
FRONT
PASSENGER' S SIDE)
DOOR KEY LOCK AND
UNLOCK SW (
FR ON T
PASSENGER' S SIDE)
BLOW ER SWTU RN SIG NA L FLA SHER
DATA LINK
CONNECTOR 3
CIGARETTE LIGHTER
O /D M AIN SW
REM OTE CONTROL
MIRROR SW
BUCKLE SW LH
CLOCK
CRUISE CONTROL SW
[COMB. SW ]
UNLOCK W ARNING SW
LIGHT CONTROL SW
[COMB. SW ]
FUEL SENDER (
MAIN)
RADIO AND PLAYER
C O M B IN A TIO N M E TE R SHIFT LOCK ECU
KEY INTERLOCK
SOLENOID
A/C AMPLIFIER
BLOW ER RESISTOR
DOOR LO CK CONTROL
RELAY
POWER W INDOW MASTER
SW
DOOR KEY LOCK AND
UNLOCK SW
(
DRIVER' S SIDE)
RHEOSTATIE 16
A A
A A
A A
A A
A A
IGA AB A
B A
B A
B A
B A
B 8
II1 16
B C
B C
B C A B
A B
A B
ID I 2 IC 116
B 2
IF IEID 110 W-B
W-B
W-BW-B
W-B
W-B
W-B
W-B
W-BW-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
W-B
BR
BR
BR W-
W-
W-
W-
W-
W-B
W-B
W-B
W-B
W-B W -B5
(
A/T)
B J10 , J11
A
JUNCTION CONNECTOR
B J10 , J11
A
JUNCTION CONNECTOR
(
A/
W-B
W-B W-B
W W-B
BR-B
W-B W-B
(
E2)
(
E1) AIRBAG SENSOR
ASSEMBLY
B
B
B
B
B T)W-B -BW
-B
4C3
4C10
4C7
4C8
4C94C 1
4C2
W
1D5
1H16
1H 71I 9

K OVERALL ELECTRICAL WIRING DIAGRAM
1
234
2 RAV4
ACC
IG1
IG2
ST2 AM1
6 7AM2
1H 14
21E 2
5566 21I 171B 1 8IG1
11 IB 1
2 1
5 3
2 1
5 31 2
1 2
1 2
1 2 3IG1
20 IB2 7EA1 11 IG1
1C 12A 11A 10A12 C A 8 B 22 A 23 A 6 B
2B 7B C C C C
14C13 21
1 2
1 2
B
B-R
R- W LG
B-OB R- Y Y- GL
L-Y
B-O
B-R B-RB-R B-R B-R
B-R
B-L B- Y R- WP B-W
B- R B- R
B- O B-Y
B-Y
B-R
B-R B-O B-O
B-Y
B-R
B-Y
B- RB-OB-R B-Y
B-R B-R B-R B-R
B- O
FC ELS ACT AC1 OD1 PTNK PIM17 15
21
20
2
80A MAIN
5566
4ID1
EA BH
L-B B-R
11 2
A A53
5 BB4A 17A C
L-WRG R
C
14 A A
16B A4BE1 EO2 EO3 IG F TH W
B 1BVTA VC
B
B
L- Y
B WL
L- R
Y
11 12 2
LG-RBR
BR BR
BR BR BR
BR
BR BR BRY
432 323
E2 E2
R-W
2EA1 I10
IG NIT IO N SW
I 5
IN JE C TO R NO . 1 I 7
IN JE C TO R NO . 3 I 6
IN JE C TO R NO . 2 I 8
IN JE C TO R NO . 4
R- W
9
5
11
I 1
IDLE AIR CONTROL VALVEV 9
VSV(
Vapor Pressure Sensor) V 8
VSV(
EVAP) V 7
VSV(
EG R) O 3
OXYGEN SENSOR(
Bank 1 Sensor 2)
2
BR
BATT # 10 # 20 +B ISCO ISCC TPC EVP EGR OX1 OX2
20A A M2E F I M A IN R EL AY
CIRCUIT OPENING RELAYF11
FUEL PU M P
Under the center
p illar L HR adiator right
From D iode(
Engine Idle-Up)
< 8- 2 <12-4
E 4 A , E 6 C
J 1
JUNCTION
CONNECTOR From A/C A mplifier
<20-4 To A/C Amplifier
<20-4 To Cruise Control ECU
<13-4
PTN K VCC PIM VCV 1
VAPOR PRESSURE SENSOR M 1
MANIFOLD ABSOLUTE PRESSURE SENSOR
16
F rom M alfunction Indicator
Lamp[Comb. M eter]< 18-2
From Igniter
<5-4
26 3
T 1
THROTTLE POSITION SENSOR
E 2
ENG INE COOLANT TEMP. SENSORI 9
INTAKE AIR TEM P. SENSOR
TE1 W N E+ N E- SD LE1
AB D 1
DATA LINK
CONNECTOR
1
ENGINE CONTROL MODULE
Power
SourceEngine Control
BATTERY
G-R
B-R G-R
, E 5 B
B- O
17
M 54
W-B
L-BW-B W-B
20 10 21C
G-W(
A/T)B/KFrom Stop Light SW
<9-34 22C
B-W(
A/T)NSWTo P ark /N eutral
Position SW<1-3C
To ST Relay< 1-3 B-W(
M/T)
STA
11
R-W F 8
7. 5A O B D
[FUSE BLOCK]
F 7
FUSIBLE LINK BLOCK G-R
IG 1 9
15
B-R
9BR
20B BKNK E2
B
A IG T
10
15A EFI16 2
171D 8
1E 9
100A ALT62 2
W
W
1F 8
1K 1
R-W
#30 25 A
#40 24 A2 1
1 2
5IG1
Y-B(
A/T)To Cruise C ontrol
E CU < 13- 3
BR
EC Intake manifold 11
TC
O 2
OXYGEN SENSOR(
Bank 1 Sensor 1)
Y
Y
1 THA
B 3
Y-BK 1
KNOCK SENSOR
EO1
13ABRBR BR
5A
G+ 10
F 8
7. 5A IG N
[FUSE BLOCK]B-O11
1E 1
1J 2B-O
W
IG Right kick panel
(
SH IE LD E D)
A A
AA
A
A
A
A
A
A
(SHIELDED)
(
SHIELDED)
AAB
AA
(
SHIELDED)54 216
IG 211
BR
BR
BR
BR
(
SHIELDED)
12
34567891011 12 13
14 15
16 17 18 19 20 21 22 2324 25 2612345678
9 1011121314151612
34567891011
12 13
14 15 16 17 18 19 20 2122
J10 A , J11 B
JUNCTIO N CONNECTOR
AAAAAA
BBBCCC B E 5 D AR K G RAY CE 6 DARK GRAY
B J11A J10
GRAY A E 4 DARK GRAY
ENGINE CONTROL MODULEJUNCTION CONNECTOR
J 2
JU NC T IO N
CONNECTOR
BR BR BR BRW-BW-B
SG CG SD L BAT
(
SHIELDED)
W WW-LBR BRL
W
D 2
DATA LINK CONNECTOR 3
GRAY
C SPD
To S peedometer[C omb. M eter]
<18-19V- W
B(
A/T)
To ST Relay< 1-3 C 2
CRANKSHAFT POSITION SEN SORFrom Ignition Coil
and D istributor< 5-3
2
1
G WW From C ruise C ontrol
ECU< 13-4
From Airbag Sensor
Assembly< 11-2
+B 12
B-R8TE1
From
Airbag
Sensor
Assembly
<11-2
W-L

K
1
234
11 RAV4
2AC C
IG 1
IG 2
ST2 AM13
4
6 7AM2
40A AM 1
1D 9
1K 411IG1
7EA1
2
20A
AM2
2 2
2
80A MAIN
100A ALT
20 1
21 2
2 6W
W B- R
W B-R
BATTERY
IE Instrument
panel brace
LHIDLeft kick
panel 1D 8
1E 91F51D 6
1M 31E 1
1M 21E 41E 7
1M 4
3EA1 18 IG2
W-B W-B RLB W
B-OGR
B-OGR
B- OL-RWW-LVVW-L
W-L
W-L W-G W-G B-R
B-R
B
W
W-L
6 543 21B C4 A
11 7 16
910 87B C3 A
15 6 10
12
12 E1 E2 D+ D - P+ P- F 8
FUSE
BLOCK
7. 5A IGN15A CIG
& RAD 7. 5A SRS
C
A20
AIRBAG SQUIB
(
Steering
Wheel Pad)A19
AIRBAG SQUIB
(
Front P assenger` s
Airbag Assembly) IG A CC LA TCA18
AIRBAG SENSOR
ASSEMBLYJ 7
JU NC TIO N
CO N NEC TO R
C11
SRS INDICATOR LIGHT
[COMB. METER]
J 7
JUNCTION
CO N NEC TO R
J 7
JUNCTION
CONNECTOR
T o D ate Link
C onnector 1
<2-3
R-L
Y-B
R- G 4 3
F 8
10A
GAUGE
[FUSE BLOCK]
81B1E 8
, C 10
J 1
JUNCTION
CONNECTOR 2 1
2 113 B 1 810Y- B Y- BW-BY-B
V 5
VSV(
C en ter D iff.
Lock No. 1) V 6
VSV(
C en ter D iff.
Lock No. 2)
C 4
CENTER DIFF.
LOCK CONTROL SWC 1
CENTER DIFF.
LOCK W ARNING
BUZZER SW
C OM BIN A TIO N M ET E R
C. DIFF
LOCK
EA IGRadiator right Right kick
panel A A 10 EA1W-B W-B W-BW-B
W-B W-B B
BUZZER
B
R- L R-L
IH214A C 9 BROW N
B C10 BLUE C OM B INA TIO N M ET E R
IG 21
IG 213
2 7
R-B
Y- B Y- BR-B R- G
Y-B
A 3
2B
A C 9
13 9 8 7 6 5 4 3 2 1 101112
13 9 8 7 6 5 4 3 2 1 101112
A A
J10
JU NC TIO N
CO NN ECTO R C
BC
BBJ10
JU NC TIO N
CONNECTOR
J 3
JUNCTION
CONNECTOR
Center Diff. Lock(
4WD M/T)
F 7
FUSIBLE LINK
BLOCK7
1D1
1F B-YL- RW
W
B-RB-R
I1 0
IGN ITIO N S W
SRS Power Source
SPIRAL
CABLE17 IB1
W-L W-L LOCK UNLOCK