Toyota RAV4 1999 User 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
p
rotection 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),
p
assenge
r
-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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Fi
g
. 1: Locatin
g
Restraint S
y
stem Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
AIR BAG SENSOR ASSEMBLY
The air bag sensor assembly is located on the floor inside center console box. It consists of an air bag sensor,
safing sensor and diagnosis, ignition control and drive circuits. It receives signals from the air bag sensor and
determines whether air bag system must be deployed or not.
DRIVER-SIDE AIR BAG MODULE
The driver-side air bag and inflator is stored in the steering wheel pad. It contains a squib, igniter charge and gas
generant and inflates the air bag when instructed by air bag sensor assembly. Driver-side air bag module is also
called steering wheel pad.
FRONT AIR BAG SENSOR
The front air bag sensors are mounted inside right and left front side members. When sensor detects an impact
of sufficient force (above a predetermined limit), contacts inside the sensor close, sending a signal to the air bag
sensor assembly.
PASSENGER-SIDE AIR BAG MODULE
The passenger-side air bag and inflator is stored in the instrument panel above glove box. It contains a squib,
igniter charge and gas generant and inflates the air bag when instructed by air bag sensor assembly.
SEAT BELT PRETENSIONER
The seat belt pretensioner system is a component of the front outer seat belt assembly. It contains a squib, gas
generant, wire and piston and operates in the event of a front-end collision.
SPIRAL CABLE
The spiral cable is attached to combination switch and is used as an electrical joint between chassis wiring
harness and driver-side air bag module. Spiral cable is also known as clockspring.
SERVICE PRECAUTIONS
Observe the following precautions when servicing air bag system:
Disable air bag system before servicing any air bag system or steering column component. Failure to do
this could result in accidental air bag deployment and possible personal injury. See DISABLING &
ACTIVATING AIR BAG SYSTEM .
When diagnosing air bag system, always check for diagnostic codes before disconnecting battery.
After turning ignition switch to LOCK position and disconnecting negative battery cable, wait at least 90
seconds before workin
g
on air ba
g
s
y
stem. Air ba
g
s
y
stem is equipped with a bac
k
-up power source that
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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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Fig. 2: Adjusting Spiral Cable
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DISABLING & ACTIVATING AIR BAG SYSTEM
DISABLING SYSTEM
For Component Replacement
Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds
b
efore startin
g
an
y
work on vehicle.
WARNING: Back-up power supply maintains air bag system voltage for about 90
seconds after battery is disconnected. After disabling air bag system, wait
at least 90 seconds before servicing air bag system to prevent accidental
air bag deployment and possible personal injury.
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For Diagnosis & Testing
1. Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90
seconds. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE under
REMOVAL & INSTALLATION . Disconnect passenger-side air bag module connector, accessible by
removal of glove box assembly. See Fig. 3 .
2. Disconnect air bag sensor assembly connectors. See Fig. 4 . See AIR BAG SENSOR ASSEMBLY under
REMOVAL & INSTALLATION . Disconnect right and left front seat belt pretensioners. See SEAT
BELT PRETENSIONER under REMOVAL & INSTALLATION . Disconnect right and left front air
bag sensors. See FRONT AIR BAG SENSOR under REMOVAL & INSTALLATION .
Fig. 3: Disconnecting Passenger-Side Air Bag Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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Fig. 4: Disabling Air Bag System
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
ACTIVATING SYSTEM
For Component Replacement
Ensure ignition switch is in LOCK position. Reconnect negative battery cable. Perform SYSTEM
OPERATION CHECK .
For Diagnosis & Testing
Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds.
Reconnect right and left front air bag sensor connectors. Reconnect right and left seat belt pretensioners.
Reconnect passenger-side air bag connector. Install driver-side air bag module. Reconnect air bag sensor
assembl
y
connector. Reconnect ne
g
ative batter
y
cable. Perform SYSTEM OPERATION CHECK .
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DISPOSAL PROCEDURES
ON-VEHICLE DEPLOYMENT (SCRAPPED VEHICLES ONLY)
Driver-Side & Passenger-Side Air Bag Module
1. Before proceeding, see SERVICE PRECAUTIONS . Ensure steering wheel, driver-side air bag module
and passenger-side air bag are not loose. If components are loose, deploy air bag(s) using OFF-
VEHICLE DEPLOYMENT procedure.
2. If deploying driver-side air bag module, disconnect spiral cable connector accessible by removal of lower
steering column cover. If deploying passenger-side air bag module, disconnect passenger-side air bag
connector, accessible by removal of glove box. See Fig. 3 . For either air bag, connect Deployment Tool
(09082-00700) connector to air bag module connector. Position deployment tool at least 33 feet from
front of vehicle.
3. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal
and Black clip to negative battery terminal. Ensure no one is inside or within 33 feet of vehicle. Press
activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes after
deployment.
Seat Belt Pretensioner
1. Before proceeding, see SERVICE PRECAUTIONS . Ensure seat belt pretensioner is not loose. If
components are loose, remove and deploy using OFF-VEHICLE DEPLOYMENT procedure. Access
and disconnect appropriate seat belt pretensioner connector. See SEAT BELT PRETENSIONER under
REMOVAL & INSTALLATION .
2. Connect Deployment Tools (09082-00700 and 09082-00740) to appropriate seat belt pretensioner
connector. Position deployment tool at least 33 feet from front of vehicle. Close all doors and windows of
vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery
terminal.
3. Ensure no one is inside vehicle or within 33 feet of vehicle. Press activation switch to deploy air bag.
Because of heat, DO NOT touch air bag for at least 30 minutes after deployment. Scrap vehicle with air
bag(s) still installed.
OFF-VEHICLE DEPLOYMENT
Driver-Side Air Bag Module
1. Before proceeding, see SERVICE PRECAUTIONS . Disable air bag system. See DISABLING
WARNING: Undeployed air bags contain substances that can cause illness or injury if
improperly handled. Disposing of an undeployed air bag may violate
federal, state and/or local laws. If scrapping vehicle, air bag must be
deployed while still mounted in vehicle. DO NOT deploy air bags inside
vehicle unless vehicle is to be scrapped. Wear gloves and safety glasses
when handling air bag. Wrap deployed air bag in a sturdy plastic bag and
dispose of it like any other part.
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SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Remove drive
r
-side air bag
module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION . Remove
connector on rear of driver-side air bag module. See Fig. 5 . Disengage cover from driver-side air bag
module and remove cover.
2. Install 2 bolts (6 mm X 35 mm) with washers into holes located in rear of driver-side air bag module.
Tighten bolts by hand. DO NOT overtighten bolts. Wrap strong wire at least twice around each bolt. See
Fig. 6 . Ensure no slack is present in wire. If slack is present, or wire is not strong enough, driver-side air
bag module may become loose due to shock when air bag is deployed.
3. Position driver-side air bag module on rim of a scrap wheel and tire assembly with pad side facing
upward. See Fig. 7 . Securely tie driver-side air bag module to wheel rim through lug nut holes. Place a
large cardboard box (weighted at sides) or 3 scrap tires on top of driver-side air bag module.
4. Connect Deployment Tool (09082-00700) to driver-side air bag module connector. Position deployment
tool at least 33 feet away from driver-side air bag module. Press activation switch to deploy driver-side
air bag module. Because of heat, wait 30 minutes before handling driver-side air bag module. Seal
deployed air bag module in vinyl bag and dispose of in usual manner.
Fig. 5: Removing Driver-Side Air Bag Module Connector & Cover
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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Fig. 6: Securing Wire To Driver-Side Air Bag Module
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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Fig. 7: Securing Driver-Side Air Bag Module To Wheel
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Passenger-Side Air Bag Module
1. Before proceeding, see SERVICE PRECAUTIONS . Remove passenger-side air bag module. See
PASSENGER-SIDE AIR BAG under REMOVAL & INSTALLATION .
2. Position passenger-side air bag module inside a scrap tire with air bag trim cover facing inside. See Fig.
8. Secure passenger-side air bag module to tire with wire. Place this tire between 4 other tires (top tire
should have wheel installed). Securely tie all tires together with wire.
3. Connect Deployment Tool (09082-00700) to passenger-side air bag connector. Position deployment tool
at least 33 feet away from passenger-side air bag. Press activation switch to deploy passenger-side air
b
a
g
. Because of heat, wait 30 minutes before handlin
g
passen
g
e
r
-side air ba
g
.
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Fig. 8: Preparing Passenger-Side Air Bag Module For Deployment
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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Seat Belt Pretensioner
1. Before proceeding, see SERVICE PRECAUTIONS . Remove appropriate seat belt pretensioner. See
SEAT BELT PRETENSIONER under REMOVAL & INSTALLATION .
2. Connect Deployment Tools (09082-00700 and 09082-00740) to seat belt pretensioner connector. Position
seat belt pretensioner on ground an cover with wheel and tire assembly. See Fig. 9 . Position deployment
tool at least 33 feet away from seat belt pretensioner. Press activation switch to deploy seat belt
pretensioner. Because of heat, wait 30 minutes before handling. Dispose of deployed pretensioner in
usual manner.
Fig. 9: Deploying Seat Belt Pretensioner
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be
inspected or replaced. See PASSIVE RESTRAINT SYSTEM INSPECTION article in the GENERAL
INFORMATION section for post-collision inspection information.
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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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Fig. 10: Removing Air Bag Sensor Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
DRIVER-SIDE AIR BAG MODULE
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.
Working from back of steering wheel, loosen air bag module mounting Torx screws until groove around
screw circumference catches on screw case. See Fig. 11 .
2. Pull drive
r
-side air ba
g
module from steerin
g
wheel and disconnect drive
r
-side air ba
g
module connector.
NOTE: If steering wheel horn button contact plate is deformed, replace steering wheel
assembly.
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Place drive
r
-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 headli
g
ht. See Fig. 12 . Disconnect front air
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b
ag 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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Fig. 13: Removing Instrument Panel
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
PASSENGER-SIDE AIR BAG MODULE
NOTE: If instrument panel or instrument panel reinforcement is deformed, replace with
new part.
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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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