For All Vehicles: Precaution

1. The RAV4 is equipped with an Supplemental Restraint System (SRS), which includes the driver airbag, front passenger airbag assembly, side airbag assembly, curtain shield airbag assembly and seat belt pretensioners. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing and lead to serious injury.

   Furthermore, if a mistake is made in servicing the SRS, it is possible the SRS may fail to operate properly. Before 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 this information.

2. GENERAL NOTICE
   1. Malfunction symptoms of the SRS are difficult to confirm, so the diagnostic trouble codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery (see PRE-CHECK ).
   2. To avoid serious injury, servicing the SRS must be started 90 seconds after:
      • The ignition switch is turned to the LOCK position.
      • The negative (-) terminal cable is disconnected from the battery.

      (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable from the battery, the SRS may deploy.)

      Disconnecting the negative (-) terminal cable will erase clock memory and audio system presets. If you wish to do so, mark down data as necessary before disconnecting the cable. To avoid erasing the memory settings, never use a back-up power supply.

      Fig 1: Identifying Battery Negative Cable

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. In minor collisions where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly, curtain shield airbag assembly, front airbag sensor assembly and seat belt pretensioner should be inspected before further use of the vehicle (see AIR BAG RESTRAINT SYSTEMS and INSPECTION ).
   4. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
   5. Before repairs, remove the airbag sensor assembly if impacts are likely to be applied to the sensor during repairs.
   6. Never disassemble and repair the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly, curtain shield air-bag assembly, front airbag sensor or seat belt pretensioner.
   7. Replace if the airbag sensor, steering wheel pad, front passenger airbag assembly, side airbag assembly, curtain shield airbag assembly, front airbag sensor assembly or seat belt pretensioner if it has been dropped, or if there are cracks, dents or other defects in its case, bracket or connector.
   8. Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, front airbag sensor assembly or seat belt pretensioner to hot air or flames.
   9. Use a voltmeter/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuit.
   10. Information labels are attached to the periphery of the SRS components. Follow the instructions on the labels.
   11. After work on the SRS is completed, check the SRS warning light (see PRE-CHECK ).
3. SPIRAL CABLE (in Combination Switch)

   The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to AIR BAG RESTRAINT SYSTEMS concerning correct steering wheel installation.

   Fig 2: Locating Marks on Steering Wheel

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. STEERING WHEEL PAD (with Airbag)
   1. When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up see Fig 3. Storing the pad with its metallic surface facing upward may lead to a serious accident if the airbag inflates. In addition, do not store a steering wheel pad on top of one another.
   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which is could cause serious injury.
   3. Grease or detergents of any kind should not be applied to the steering wheel pad.
   4. Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), has low humidity and is away from electrical noise.
   5. Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 4 pins) under the steering column near the combination switch connector.
   6. As a safety measure, always deploy airbags using an SST before disposal (see AIR BAG RESTRAINT SYSTEMS ). Deploy airbags in a safe place away from electrical noise.
      Fig 3: Placing Method of Steering Wheel Pad

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 4: Precautions of Restraint System

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. FRONT PASSENGER AIRBAG ASSEMBLY
   1. Always store a removed or new front passenger airbag assembly with the airbag deployment direction facing up.

      Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflate.

   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which is could cause serious injury.
   3. Grease or detergents of any kind should not be applied to the steering wheel pad.
   4. Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), has low humidity and is away from electrical noise.
   5. Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 4 pins) under the steering column near the combination switch connector.
   6. As a safety measure, always deploy airbags using an SST before disposal (see AIR BAG RESTRAINT SYSTEMS ).

      Deploy airbags in a safe place away from electrical noise.

      Fig 5: Storing Method of Front Passenger Air Bag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 6: Precautions of Restraint System

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. SIDE AIRBAG ASSEMBLY
   1. Always store a removed or new side airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates.
   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
   3. Grease or detergents of any kind should not be applied to the steering wheel pad.
   4. Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), has low humidity and is away from electrical noise.
   5. Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 2 pins) under the steering column near the combination switch connector.
   6. As a safety measure, always deploy airbags using an SST before disposal (see AIR BAG RESTRAINT SYSTEMS ). Deploy airbags in safe place away from electrical noise.
      Fig 7: Storing Method of Side Air Bag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 8: Precautions Of Restraint System

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. CURTAIN SHIELD AIRBAG ASSEMBLY
   1. Always store a removed or new side airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates.
      NOTE: Plastic bag is not re-useable.
      CAUTION: Never disassemble the curtain shield airbag assembly.
   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
   3. Grease or detergents of any kind should not be applied to the curtain shield airbag assembly.
   4. Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), has low humidity and is away from electrical noise.
   5. Before using an electric welder, first disconnect the airbag connector (the connector is yellow and has 2 pins) under the steering column near the combination switch connector.
   6. As a safety measure, always deploy airbags using an SST before disposal (see AIR BAG RESTRAINT SYSTEMS ). Deploy airbags in a safe place away from electrical noise.
      Fig 9: Precaution Of Restraint System

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. SEAT BELT PRETENSIONER
   1. Never measure the resistance of the seat belt pretensioner. This may cause the seat belt pretensioner to activate, which could cause serious injury.
   2. Never disassemble the seat belt pretensioner.
   3. Never install the seat belt pretensioner in another vehicle.
   4. Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F), has low humidity and is away from electrical noise.
   5. Before using an electric welder, first disconnect the connector (the connector is yellow and has 2 pins).
   6. As a safety measure, always activate the seat belt pretensioner before disposal (see DISPOSAL ). Activate the pretensioner in safe place away from electrical noise.
   7. The seat belt pretensioner becomes hot after activation. Allow it to cool before disposing. Never use water to cool seat belt pretensioner.
      Fig 10: Precaution Of Restraint System

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. AIRBAG SENSOR ASSEMBLY
   1. If an airbag sensor assembly has been involved in a collision where its SRS has deployed, do not reuse it.
   2. The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. Failure to do so could cause undesired deployment of the SRS.
   3. To avoid serious injury, servicing the SRS must be started 90 seconds after:
      • The ignition switch is turned to the LOCK position.
      • The negative (-) terminal cable is disconnected from the battery.

      Even if only loosening the set bolts of the airbag sensor assembly, you must follow the above guidelines.

10. WIRE HARNESS AND CONNECTOR

    The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, etc., repair or replace it as shown in AIR BAG RESTRAINT SYSTEMS .

The Full-Time 4WD RAV4 is equipped with the mechanical lock type center differential system.

If incorrect preparations or test procedures are used, the test will not only be unsuccessful, but may be dangerous as well. Therefore, before beginning any such servicing or test, be sure to check the following items:

• Whether wheels should be touching ground or jacked up
• Transaxle gear position
• Maximum testing vehicle speed
• Maximum testing time
• Manual transaxle only:

  Center differential lock position

1. Manual Transaxle Only:

   Before Beginning Test

   During tests with a brake tester or chassis dynamometer, such as braking force tests or speedometer tests, if only the front or rear wheels are to be rotated, it is necessary to set the position of the center differential to the FREE position or to the LOCK position depending on the type of test being performed.

   • Select the position of the center differential by pushing the center differential lock switch.
   • After selecting the position, confirm the operation of indicator light.
2. Bring Force Test

   (Vehicle Speed: Below 0.5 km/h or 0.3 mph)

   When performing low-speed type brake tester measurements, observe the following instructions.

   1. Position the wheels to be tested (front or rear) on the tester.
   Fig 11: Positioning Wheels To Be Tested On Tester
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Shift the transaxle shift lever to Neutral (or "N" range).
   3. Idle the engine, operate the brake booster and perform the test.
3. Speedometer Test or Other Tests

   (Using Speedometer Tester or Chassis Dynamometer)

   When performing test at high speed or high load, use the methods shown in Fig 12.

   Fig 12: Various Method Of Performing Speedometer Test, Using Speedometer Tester Or Dynamometer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Confirm that the vehicle is securely immobilized.
   • Never operate the clutch or brakes to drive the wheels or stop them suddenly.
4. On-Vehicle Wheel Balancing

   When doing on-vehicle wheel balancing on a full-time 4WD vehicle, to prevent the wheels from rotating at different speeds in different directions from each other (which could damage the center differential), always be sure to observe the following precautions:

   1. All 4 wheels should be jacked up, clearing the ground completely.
   2. The parking brake lever should be fully released.
   3. None of the brakes should be allowed to drag.
   4. The wheels should be driven on the wheel balancer with the engine running.

      HINT:

      When doing this, be careful of the other wheels, which will rotate at the same time.

   5. Avoid sudden acceleration, deceleration and braking.
   6. Carry out the wheel balancing with the transaxle in 3rd or 4th gear (automatic transaxle in D range).
      Fig 13: Performing On-Vehicle Wheel Balancing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

• Use one of the methods shown in Fig 14 to tow the vehicle.
• If the vehicle has trouble in the chassis and drive train, use method 1 (flat bed truck).
  Fig 14: Methods Of Towing Full Time 4WD Vehicles

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE: Do not use any towing method other than those shown in Fig 14.
• For example, the towing methods shown in Fig 15 are dangerous or damage the vehicle, so do not use them.
  Fig 15: Wrong Method of Towing Vehicles

  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Use only unleaded gasoline.
2. Avoid prolonged idling.

   Avoid idling the engine for more than 20 minutes.

3. Avoid spark jump test.
   1. Perform spark jump tests only when absolutely necessary. Perform this test as rapidly as possible.
   2. While testing, never race the engine.
4. Avoid prolonged engine compression measurement.

   Engine compression tests must be done as rapidly as possible.

5. Do not run engine when fuel tank is nearly empty.

   This may cause the engine to misfire and create an extra load on the converter.

6. Avoid coasting with ignition turned off.
7. Do not dispose of used catalyst with gasoline or oil contaminated parts.

For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe the following precautions.

1. Install the antenna as far away as possible from the ECU and sensors of the vehicle's electronic system.
2. Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle's electronic systems. For details about ECU and sensors locations, refer to the applicable component's information
3. Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses.
4. Check that the antenna and feeder are correctly adjusted.
5. Do not install powerful mobile communications system.

Notice for using 2-wheel drum tester.

1. Press the VSC OFF switch.
2. Check that the VSC OFF indicator light comes on.
   Fig 16: Locating TRAC And VSC System Switches

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   The VSC OFF indicator light should be always OFF when the engine is restarted.

3. Begin measurements.
   Fig 17: Identifying Front Two Wheel Placed on Wheel Drum Tester

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Press the VSC OFF switch again to change the TRAC & VSC system to operational condition and check that the VSC OFF indicator light goes off.

   HINT:

   The SLIP indicator light blinks and the VSC buzzer sounds when the TRAC & VSC system is operational.

   Fig 18: Locating Slip Indicator Light

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002