1996 TOYOTA RAV4 steering wheel

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

ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
w/ with
w/o without
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
INTRODUCTIONINœ15

BE4061N15553I09117
43 Disconnect
DI−350
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
3 Check control switch.
PREPARATION:
(a) Remove steering wheel center pad (See page SR−12).
(b) Disconnect control switch connector.
CHECK:
Measure resistance between terminals 3 and 4 of control switch
connector when control switch is operated.
OK:
Switch positionResistance
Neutral1 MΩ or higher
RES/ACC50 − 80 Ω
SET/COAST180 − 220 Ω
CANCEL400 − 440 Ω
HINT:
When DTC 34 is displayed, carefully check that resistance is al-
ways ∞ in neutral position, particularly when switching between
RES/ACC and SET/COAST.
NG Replace cruise control switch.
OK
4 Check for open and short in harness and connector between ECU and control
switch (See page IN−30).
NG Repair or replace harness or connector.
OK
Check and replace ECU.

BE3840N14706I09125
ON
GND
CMS (−)
(+)
N15555
42
DI−372
− DIAGNOSTICSCRUISE CONTROL SYSTEM
1996 RAV4 (RM447U)
INSPECTION PROCEDURE
1 Check voltage between terminal CMS and GND of cruise control ECU connector.
PREPARATION:
Remove cruise control ECU with connectors still connected.
CHECK:
(a) Turn ignition switch ON.
(b) Measure voltage between terminal CMS and GND of
cruise control ECU connector when main switch is held
ON and OFF.
OK:
Main switchVoltage
OFF10 − 16 V
ONBelow 1 V
OK Proceed to next circuit inspection shown on
matrix chart (See page DI−336).
NG
2 Check main switch.
PREPARATION:
(a) Remove steering wheel center pad (See page SR−12).
(b) Disconnect cruise control switch connector.
CHECK:
Check continuity between terminals 2 and 4 of cruise control
switch connector when main switch is held ON and OFF.
OK:
Main switchTerminal No. to continuity
OFF
ON2 − 4
NG Replace control switch.
OK

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 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