Air Bag

2004 Toyota RAV4
2004 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems
2004 ACCESSORIES/SAFETY EQUIPMENT

Toyota - Air Bag Restraint Systems
DESCRIPTION & OPERATION

WARNING: Accidental air bag deployment is possible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS
before working on air bag system or related components.
Supplemental Restraint System (SRS), also known as air bag system, is designed to provide increased accident
protection for driver and passenger by deploying air bag modules and seat belt pretensioners in a front impact
collision. In the event a side impact occurs, curtain and side air bag modules will deploy on side of 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: dual-stage driver-side air bag module (steering wheel
pad), dual-stage passenger-side air bag module, spiral cable, right and left side air bag modules, right and left
side curtain air bag modules, right and left side air bag sensor, right and left rear air bag sensors, right and left
front air bag sensors, driver seat position sensor, right and left front seat belt pretensioners, AIR BAG warning
light, air bag sensor assembly and associated wiring harnesses.
COMPONENT LOCATIONS
Refer to illustration for component locations. See Fig. 1 & Fig. 2 .
Microsoft
Tuesday, July 21, 2009 4:34:55
4:34:46 PM
Page 1
2005 Mitchell Repair Information Company, LLC.
2004 Toyota RAV4

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 2
2004 Toyota RAV4

Fig. 1: Locating Restraint System Components (1 Of 2)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fig. 2: Locating Restraint System Components (2 Of 2)

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 3
2004 Toyota RAV4

SYSTEM OPERATION CHECK

Turn ignition switch to 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 DIAGNOSTICS .
AIR BAG SAFETY PRECAUTIONS

Observe these precautions when servicing the 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 working on air bag system. Air bag system is equipped with a back-up power source that
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
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 4
2004 Toyota RAV4

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.
DISABLING & ACTIVATING AIR BAG SYSTEM

WARNING: Unintentional air bag module deployment is possible. Personal injury may
result. Never use memory savers when working on air bag system.
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.
DISABLING SYSTEM
For Component Replacement
Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds
before starting any work on vehicle.
For Diagnostics
1. Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90
seconds. Disconnect air bag sensor assembly connectors. See AIR BAG SENSOR ASSEMBLY under
REMOVAL & INSTALLATION. 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 right and left side air bag module connectors. See SIDE AIR BAG MODULE under
REMOVAL & INSTALLATION. Disconnect right and left side curtain air bag module connectors. See
SIDE CURTAIN AIR BAG MODULE under REMOVAL & INSTALLATION. Disconnect right and
left front seat belt pretensioner connectors. See SEAT BELT PRETENSIONER under REMOVAL &
INSTALLATION.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 5
2004 Toyota RAV4

Fig. 3: Disconnecting Passenger-side Air Bag Module Connector

ACTIVATING SYSTEM
For Component Replacement
Ensure ignition switch is in LOCK position. Reconnect negative battery cable. Perform SYSTEM
OPERATION CHECK .
For Diagnostics
Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds.
Reconnect right and left seat belt pretensioner connectors. Reconnect right and left side curtain air bag module
connectors. Reconnect right and left side air bag module connectors. Reconnect passenger-side air bag
connector. Install driver-side air bag module. Reconnect air bag sensor assembly connectors. Reconnect
negative battery cable. Perform SYSTEM OPERATION CHECK .
DISPOSAL PROCEDURES
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 6
2004 Toyota RAV4

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. Air bags should not be deployed
inside vehicle unless vehicle is to be scrapped. If not scrapping vehicle,
use off-vehicle deployment procedures. See OFF-VEHICLE
DEPLOYMENT . 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.
TESTING DEPLOYMENT TOOL
WARNING: Malfunctioning deployment tool may cause accidental air bag
deployment. Personal injury may result. If deployment light illuminates
without pressing deployment button, deployment tool is malfunctioning
and should not be used.
Connect Red clip of Deployment Tool (09082-00700) to positive battery terminal of 12 volt battery. Connect
Black clip of deployment tool to negative terminal of battery. Press deployment tool activation switch and
ensure deployment light illuminates on deployment tool. Disconnect deployment tool Red and Black clips from
battery.
ON-VEHICLE DEPLOYMENT (SCRAPPED VEHICLES ONLY)
Driver-side AIR Bag Module
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure steering wheel and driver-side
air bag module are not loose. If components are loose, deploy air bag(s) using OFF-VEHICLE
DEPLOYMENT procedure. Test Deployment Tool (09082-00700). See TESTING DEPLOYMENT
TOOL .
2. Remove lower steering column cover. Disconnect spiral cable connector. Connect Deployment Tools
(09082-00700 and 09082-00760 single inflator] or 09082-00780 double inflator]) to air bag module
connector. Position deployment tool at least 33 feet (10 m) 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 (10 m) of vehicle.
Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal.
Press activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes
after deployment.
Passenger-side AIR Bag Module
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure passenger-side air bag module is
not loose. If air bag is loose, deploy air bag using OFF-VEHICLE DEPLOYMENT procedure. Test
Deployment Tool (09082-00700). See TESTING DEPLOYMENT TOOL .
2. Remove glove box. Disconnect passenger-side air bag connector. See Fig. 3 . Connect Deployment Tools
(09082-00700 and 09082-00760 single inflator] or 09082-00780 double inflator]) to air bag module
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 7
2004 Toyota RAV4

connector. Position deployment tool at least 33 feet (10 m) 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 (10 m) of vehicle.
Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal.
Press activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes
after deployment.
Side AIR Bag Module
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Ensure seat back is
not loose. If components are loose, remove and deploy air bag(s) using OFF-VEHICLE
TOOL . Disconnect appropriate side air bag connector, located under seat.
2. Connect Deployment Tool (09082-00700) and adapter (09082-00750) to side air bag connector, located
under appropriate front seat cushion. Position deployment tool at least 33 feet (10 m) 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 (10 m) 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.
Side Curtain AIR Bag Module
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Ensure there are no
loose components in vehicle. If components are loose, remove and deploy air bag(s) using OFFVEHICLE DEPLOYMENT procedure. Test Deployment Tool (09082-00700). See TESTING
DEPLOYMENT TOOL .
2. Disconnect side curtain air bag module harness connector. See SIDE CURTAIN AIR BAG MODULE
under REMOVAL & INSTALLATION. Connect Deployment Tool (09082-00700) and Adapter (0908200802) to side curtain air bag module connector. Position deployment tool at least 33 feet (10 m) 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 (10 m) 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.
Seat Belt Pretensioner
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure seat belt pretensioner is not
loose. If components are loose, remove seat belt pretensioner and deploy using OFF-VEHICLE
TOOL . Access and disconnect appropriate seat belt pretensioner connector. See SEAT BELT
PRETENSIONER under REMOVAL & INSTALLATION.
2. Connect Deployment Tools (09082-00700 and 09082-00770) to appropriate seat belt pretensioner
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 8
2004 Toyota RAV4

connector. Position deployment tool at least 33 feet (10 m) 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 (10 m) of vehicle. Connect deployment tool Red clip to
positive battery terminal and Black clip to negative battery terminal. Press activation switch to deploy air
bag. Because of heat, DO NOT touch pretensioner for at least 30 minutes after deployment. Scrap vehicle
with pretensioner(s) still installed.
OFF-VEHICLE DEPLOYMENT
Driver-side AIR Bag Module
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Test Deployment
Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove driver-side air bag module. See
DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION.
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. 4 . 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. 5 . 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 Tools (09082-00700 and 09082-00802) to driver-side air bag module connector.
Position deployment tool at least 33 feet (10 m) away from driver-side air bag module. Connect
deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. 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.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 9
2004 Toyota RAV4

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 10
2004 Toyota RAV4

Fig. 4: Securing Wire To Driver-side Air Bag Module

Fig. 5: Securing Driver-side Air Bag Module To Wheel

Passenger-side AIR Bag Module
Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove passenger-side air bag module.
See PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION.
2. Position passenger-side air bag module inside a scrap tire with air bag trim cover facing inside. See Fig.
6 . 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 Tools (09082-00700 and 09082-00802) to passenger-side air bag connector.
Position deployment tool at least 33 feet (10 m) away from passenger-side air bag. Connect deployment
tool Red clip to positive battery terminal and Black clip to negative battery terminal. Press activation
switch to deploy passenger-side air bag. Because of heat, wait 30 minutes before handling passenger-side
air bag module. Seal deployed air bag module in vinyl bag and dispose of in usual manner.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 11
2004 Toyota RAV4

Fig. 6: Preparing Passenger-side Air Bag Module For Deployment

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 12
2004 Toyota RAV4

Side AIR Bag Module
Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove appropriate side air bag. See
SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. Install 2 nuts on stud located on
rear side of air bag module. Wrap strong wire at least twice around each stud. See Fig. 7 . Ensure no slack
is present in wire.
2. Position side air bag inside a scrap tire with deployment side facing inside of tire and secure with strong
wire. Place this tire between 4 other tires (top tire should have wheel installed). Securely tie all tires
together with strong wire.
3. Connect Deployment Tool (09082-00700) and Adapter (09082-00750) to side air bag connector. Position
deployment tool at least 33 feet (10 m) away from side air bag. Press activation switch to deploy side air
bag. Because of heat, wait 30 minutes before handling side air bag. Seal deployed air bag module in vinyl
bag and dispose of in usual manner.
Fig. 7: Securing Wire To Side Air Bag Module

Side Curtain AIR Bag Module
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 13
2004 Toyota RAV4

Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove appropriate side curtain air bag
module. See SIDE CURTAIN AIR BAG MODULE under REMOVAL & INSTALLATION.
2. Cut off deployment section (air bag) from inflator. Position side curtain air bag inflator inside a scrap tire
and secure with strong wire. See Fig. 8 . 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) and Adapter (09082-00801) to inflator connector. Position
deployment tool at least 33 feet (10 m) away from side air bag. Press activation switch to deploy side air
bag. Because of heat, wait 30 minutes before handling inflator. Seal deployed inflator in vinyl bag and
dispose of in usual manner.
Fig. 8: Preparing Air Bag Inflator For Deployment

Seat Belt Pretensioner
Tool (09082-00700). See TESTING DEPLOYMENT TOOL . Remove appropriate seat belt
pretensioner. See SEAT BELT PRETENSIONER under REMOVAL & INSTALLATION.
2. Connect Deployment Tools (09082-00700 and 09082-00770) to seat belt pretensioner connector. Position
seat belt pretensioner on ground and cover with wheel and tire assembly. See Fig. 9 . Position deployment
tool at least 33 feet (10 m) away from seat belt pretensioner. Connect deployment tool Red clip to
positive battery terminal and Black clip to negative battery terminal. Press activation switch to deploy
seat belt pretensioner. Because of heat, wait 30 minutes before handling. Dispose of deployed
pretensioner in usual manner.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 14
2004 Toyota RAV4

Fig. 9: Deploying Seat Belt Pretensioner

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 AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES
article in the GENERAL INFORMATION section.
REMOVAL & INSTALLATION

Unintentional air bag module deployment is possible. Failure to follow
service precautions may result in air bag deployment and personal injury.
Read and carefully follow all WARNINGS and AIR BAG SAFETY
PRECAUTIONS before working on air bag system or related components.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 15
2004 Toyota RAV4

See AIR BAG SAFETY PRECAUTIONS . After component replacement,

check system operation. See SYSTEM OPERATION CHECK .
AIR BAG SENSOR ASSEMBLY
Removal & Installation
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM.
2. Remove instrument cluster finish center panel. See Fig. 10 . Remove upper console panel. Remove front
and rear console boxes. Remove No. 1 and 2 instrument panel under covers. Remove shifter assembly.
Remove 3 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 . Activate air bag system. See ACTIVATING SYSTEM under
DISABLING & ACTIVATING AIR BAG SYSTEM.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 16
2004 Toyota RAV4

Fig. 10: Identifying Air Bag Sensor Assembly

DRIVER-SIDE AIR BAG MODULE
NOTE:
If steering wheel horn button contact plate is deformed, replace steering wheel
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 17
2004 Toyota RAV4

assembly.
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Working from back
of steering wheel, loosen air bag module Torx screws until groove around screw circumference catches
on screw case. See Fig. 11 .
2. Pull driver-side air bag module from steering wheel and disconnect driver-side air bag module connector.
Place driver-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
Torx screws to specification. See TORQUE SPECIFICATIONS . Activate air bag system. See
ACTIVATING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM.
Fig. 11: Identifying Driver-side Air Bag Module Torx Screws

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 18
2004 Toyota RAV4

FRONT AIR BAG SENSOR

2. Disconnect appropriate front air bag sensor connector with sensor installed. See Fig. 12 . Remove 2
mounting bolts and remove front air bag sensor.
3. To install, reverse removal procedure. Tighten front air bag sensor mounting bolts to specification. See
Fig. 12: Identifying Front Air Bag Sensors

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 19
2004 Toyota RAV4

FRONT SEAT
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Remove seat belt
anchor bolt and anchor. Remove front seat anchor bolts. Disconnect electrical connectors, under front
seat. Remove front seat.
2. To install, reverse removal procedure. Tighten front seat and seat belt anchor bolts to specification. See
HEADLINER
2. Remove rear seats. See REAR SEAT . Using screwdriver, disengage clips and remove rear floor finish
plate. See Fig. 13 . Disengage claws and remove rear door scuff plates. Using screwdriver, pry out room
light cover. Remove screws, disconnect connector and remove room light. Remove assist grips and
covers. Disengage claws and remove front door scuff plates.
3. Remove screws from right and left sun visors. Using screwdriver, pry out roof console cover. Remove
screws from roof console box, disconnect connector and remove roof console box. Remove bolt and left
rear seat belt floor anchor. Remove screws, and using screwdriver, pry out left deck side trim, disconnect
connector and remove left deck side trim. Repeat procedure to remove right deck side trim.
4. Remove bolt and rear seat belt shoulder anchor. Remove clips, bolt and using screwdriver, disengage
clips and remove left roof side inner garnish. Repeat procedure to remove right roof side inner garnish.
Remove bolt and left front seat outer belt floor anchor. Pull garnish upward and remove left center pillar
lower garnish. Repeat procedure to remove right center pillar lower garnish.
5. Remove bolt and left front seat outer belt shoulder anchor. Using screwdriver, pry out and remove center
pillar upper garnish. Repeat procedure to remove right center pillar upper garnish.
6. Using screwdriver, disengage clips on left front pillar garnish. Pull pillar garnish and rotate 90 degrees
and remove pillar garnish. Using cloth or nylon, 27.56" (700 mm) X 4.72" (120 mm), cover exposed
portion of curtain air bag module. Secure cover material with tape. Repeat procedure for right front pillar
garnish and curtain air bag module.
7. Using screwdriver, remove roof headliner trim garnish. Remove sun visor holders and room partition net
hooks. Remove clips and roof headliner.
8. To install, reverse removal procedure. Activate air bag system. See ACTIVATING SYSTEM under
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 20
2004 Toyota RAV4

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 21
2004 Toyota RAV4

Fig. 13: Identifying Headliner

PASSENGER-SIDE AIR BAG MODULE
NOTE:
If instrument panel or instrument panel reinforcement is deformed, replace with

new part.
2. Remove glove box door. Disconnect passenger-side air bag module connector. See Fig. 3 . Remove 2
nuts, one bolt and passenger-side air bag module.
3. To install, reverse removal procedure. Tighten passenger-side air bag module bolt to specification. See
TORQUE SPECIFICATIONS . There should be no interference between passenger-side air bag door
and instrument panel and clearance should be uniform. Activate air bag system. See ACTIVATING
SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM.
REAR AIR BAG SENSOR
2. Remove appropriate rear seat. See REAR SEAT . Remove rear door scuff plate, door opening trim and
rear quarter trim. Disconnect connector, remove bolts, and rear air bag sensor.
3. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. See ACTIVATING SYSTEM under DISABLING &
ACTIVATING AIR BAG SYSTEM.
REAR SEAT
Rear seat removal and installation procedure is not available.

SEAT BELT BUCKLE SWITCH
DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Seat belt buckle
switch is integrated with front seat belt buckle. Remove appropriate front seat. Remove bolt and seat belt
buckle with switch.
2. To install, reverse removal procedure. Tighten seat belt buckle bolt to specification. See TORQUE
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 22
2004 Toyota RAV4

SEAT BELT PRETENSIONER
2. Remove appropriate front and rear door scuff plates. Remove front seat belt floor anchor bolt and floor
anchor. Pulling center pillar lower garnish upward to disengage, remove garnish. Remove front seat belt
shoulder anchor bolt and shoulder anchor. Disconnect pretensioner connector. Remove 2 bolts and seat
belt pretensioner assembly.
3. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE
SEAT POSITION SENSOR
2. Remove left front seat. Remove bolt, disconnect connector and remove seat position sensor.
3. To install, reverse removal procedure. Tighten seat position sensor bolt to specification. See TORQUE
SIDE AIR BAG MODULE
2. Remove appropriate front seat. See FRONT SEAT . Remove power seat knobs. See Fig. 14 . Remove
seat cushion shield and seat cushion inner shield. Remove front seat back board and seat back. Remove
headrest and headrest supports. Remove seat back cover, bolts and seat back frame.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 23
2004 Toyota RAV4

Fig. 14: Identifying Front Seat Components

SIDE AIR BAG SENSOR
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 24
2004 Toyota RAV4

2. Remove appropriate front and rear door scuff plates. See Fig. 15 . Remove seat belt anchor bolt and
anchor. Remove center pillar lower garnish. Disconnect electrical connector, remove bolt, and position
front seat belt retractor (pretensioner) aside. Disconnect electrical connector, remove bolts and remove
side air bag sensor.
Fig. 15: Identifying Side Air Bag Sensor

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 25
2004 Toyota RAV4


SIDE CURTAIN AIR BAG MODULE
2. Remove headliner. See HEADLINER . Remove bolts "A". See Fig. 16 . Bind front and rear sections of
curtain air bag to center section. Remove bolts "B" and curtain air bag module. Remove bolt and curtain
air bag module bracket. Place air bag module in plastic bag and store in safe place, if reusing air bag
module.
3. To install, reverse removal procedure. Ensure deployment section of air bag is not twisted during
installation. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Activate air bag system.
See ACTIVATING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM.
Fig. 16: Identifying Side Curtain Air Bag Module

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 26
2004 Toyota RAV4

SPIRAL CABLE
2. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE . Remove steering
wheel. See STEERING WHEEL . Remove 3 screws and lower steering column cover. Disengage upper
steering column cover from steering column tube. Disconnect electrical connectors from spiral cable.
Disengage spiral cable attaching claws and remove spiral cable.
3. To install, reverse removal procedure. Before installing spiral cable, ensure front wheels are in straightahead position and spiral cable is properly aligned. See SPIRAL CABLE under ADJUSTMENTS.
Tighten steering wheel nut and driver-side air bag module Torx screws to specification. See TORQUE
STEERING WHEEL
2. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE . Remove steering wheel
nut. Match mark steering wheel and steering shaft 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 Torx screws to specification. See TORQUE SPECIFICATIONS . Activate
air bag system. See ACTIVATING SYSTEM under DISABLING & ACTIVATING AIR BAG
SYSTEM.
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. 17 . Install steering wheel.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 27
2004 Toyota RAV4

Fig. 17: Adjusting Spiral Cable

WIRE REPAIR
DO NOT attempt wiring harness repairs. Replace entire wiring harness.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application
Front seat anchor bolts
Front seat back bolts
Passenger-side air bag module bolt
Rear air bag sensor bolts
Seat belt buckle bolt
Ft. Lbs. (N.m)

27 (37)
32 (44)
15 (20)
15 (20)
32 (43)
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 28
2004 Toyota RAV4

Seat belt floor anchor bolt

Seat belt shoulder anchor bolt
Side air bag sensor bolts
Steering wheel nut
32 (43)
32 (43)
15 (20)
25 (34)
INCH Lbs. (N.m)
133 (15)
78 (8.8)
71 (8.0)
71 (8.0)
75 (8.5)
87 (9.8)
Air bag sensor assembly Torx screws

Driver-side air bag module Torx screws
Front air bag sensor mounting bolts
Seat position sensor
Seat belt pretensioner upper bolt
Side curtain air bag module bolts "A" & "B"
DIAGNOSTICS
AIR BAG WARNING LIGHT CHECK
Turn ignition switch to 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: Air bag system damage is possible. System may be damaged if jumper
wire is incorrectly connected across terminals of Data Link Connector 3
(DLC 3). Use Diagnosis Check Wire (09843-18020) when connecting
terminals of DLC 3.
Retrieving AIR Bag System Dtcs Using Diagnosis Check Wire
1. Turn ignition switch to ON position. Wait about 20 seconds. Using Diagnosis Check Wiring (0984318020), connect terminals Tc and CG of Data Link Connector 3 (DLC 3), located under lower left side of
instrument panel. See Fig. 18 .
2. If AIR BAG warning light flashes 2 times per second, system is normal (normal code). If AIR BAG
warning light does not flash Diagnostic Trouble Codes (DTCs) or flashes DTCs without DLC 3
connection, proceed to DIAGNOSTIC TROUBLE CODES (DTCS) CANNOT BE DISPLAYED, OR
DTCS ARE DISPLAYED WITHOUT DATA LINK CONNECTOR 3 (DLC 3) CONNECTION . If
AIR BAG warning light is on continuously and DTC is normal (flashes 2 times per second), source
voltage is low. See SOURCE VOLTAGE DROP under DIAGNOSTIC TESTS.
3. If AIR BAG warning light flashes, count number of flashes to determine DTCs that are set. For example,
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 29
2004 Toyota RAV4

DTC 12 is: FLASH, 1.5-second pause, FLASH, FLASH. If more than one DTC is displayed, a 2.5second pause will occur between each DTC. Lowest numbered DTC will be displayed first, followed by
next higher number DTC until all DTCs have been displayed.
4. After all DTCs are displayed, a 4-second pause will occur, and DTC display will be repeated. See
appropriate DTC under DIAGNOSTIC TESTS . After repairing, clear DTCs. See CLEARING
CODES .
NOTE:
If DTCs other than those listed under DIAGNOSTIC TESTS are displayed,
replace air bag sensor assembly. If AIR BAG warning light does not
function as described, proceed to appropriate test under DIAGNOSTIC
TESTS .
Retrieving AIR Bag System Dtcs Using Toyota Hand-held Tester
Install Toyota hand-held tester to Data Link Connector 3 (DLC 3), located under left lower side of instrument
panel. See Fig. 18 . Read DTC by following prompts on tester. See tester operator"s manual for instructions.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 30
2004 Toyota RAV4

Fig. 18: Identifying Data Link Connector 3 (DLC 3) Terminals

CLEARING CODES
Clearing AIR Bag System Dtcs Using Jumper Wire
1. Using one jumper wire, connect one end of jumper wire to DLC 3 terminal Tc. See Fig. 18 . Connect
other end of jumper wire to ground. Turn ignition switch to ON position. Wait 3-10 seconds for DTC to
begin to be output.
2. After DTC has begun to be output, release jumper wire from ground. Wait 2-4 seconds for AIR BAG
warning light to illuminate. Reconnect jumper to ground within 1-5 seconds after AIR BAG warning light
has illuminated. Wait 2-4 seconds for AIR BAG warning light to turn off. Release jumper from ground
within 1-5 seconds after AIR BAG warning light has turned off. Wait 2-4 seconds for AIR BAG warning
light to illuminate. Reconnect jumper to ground within 1-5 seconds after AIR BAG warning light has
illuminated. Wait 2-4 seconds for AIR BAG warning light to turn off. Wait one second for AIR BAG
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 31
2004 Toyota RAV4

warning light to output normal code (2 flashes per second). If AIR BAG warning light does not output
normal code, repeat procedure until codes are cleared.
Clearing AIR Bag System Dtcs Using Toyota Hand-held Tester
Connect Toyota hand-held tester to DLC 3. Clear DTCs by following prompts on tester. See tester operator"s
manual for instructions.
CHECK MODE PROCEDURE
1. Check mode using Toyota hand-held tester
Connect Toyota hand-held tester to DLC 3. Turn ignition switch to ON position. Select "TEST MODE",
and proceed checking with hand-held tester.
RELEASING SHORT SPRING
CAUTION: Damage to air bag electrical connector terminal is possible. If paper
thicker than male terminal is used, connector terminal could be damaged.
Damaged connector terminal could result in system fault. Always use
paper that is same thickness as male terminal.
NOTE:
Perform this procedure only if you were sent here from DIAGNOSTIC TESTS.
1. Air bag squib circuit consists of circuit between air bag sensor assembly and air bag. If voltage is
accidentally applied across squib circuit (as when testing, for example), air bag will deploy.
2. To prevent accidental deployment, squib circuit connectors contain a spring-loaded shorting bar short
spring. When squib circuit connector is disconnected, short spring automatically shorts squib circuit
positive and negative circuits together. This prevents air bag deployment if voltage is accidentally applied
across squib circuit.
3. When connector halves are attached, shorting bar is in released position (no continuity exists between
terminals). When connector is disconnected, shorting bar is engaged (continuity exists between
terminals).
4. Some testing procedures require short spring to be in released position with connector disconnected (this
is opposite of its normal position). To hold short spring in released position, obtain a piece of paper that is
same thickness as male terminal blade that slides under short spring when connector is connected. See
Fig. 19 .
5. With squib circuit connector disconnected, insert paper into female terminal, sliding it under short spring.
This lifts spring, breaking circuit and allowing test procedure to be performed.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 32
2004 Toyota RAV4

Fig. 19: Releasing Short Spring

DIAGNOSTIC TESTS
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 33
2004 Toyota RAV4

WARNING: Accidental air bag deployment is possible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS
before working on air bag system or related components
CAUTION: Air bag center sensor may be damaged. Improper system operation
possible. Ensure ignition switch is in LOCK position before disconnecting
or connecting negative battery cable.
Connector terminal damage is possible. Improper system operation
possible. Avoid probing terminal ends. Instead, backprobe terminals
(probe terminal where wire enters harness connector).
NOTE:
In the following tests, the term squib and module may be used interchangeably.
AIR BAG WARNING LIGHT IS ALWAYS ILLUMINATED WHEN DIAGNOSTIC TROUBLE CODE
(DTC) IS NOT OUTPUT
Diagnostic Procedure
1. Measure battery voltage. If battery voltage is 11-14 volts, go to next step. If battery voltage is not 11-14
volts, replace battery.
2. Disconnect negative battery cable. Wait at least 90 seconds. Inspect air bag sensor assembly and ensure
harness connectors are properly connected. See AIR BAG SENSOR ASSEMBLY under REMOVAL &
INSTALLATION. If air bag sensor assembly harness connectors are properly connected, go to next step.
If air bag sensor assembly harness connectors are not properly connected, reconnect connectors.
3. Access instrument cluster and disconnect harness connectors. Measure resistance between harness side of
air bag sensor assembly connector C7, terminal No. 14 (Black/Yellow wire, circuit LA) and harness side
of instrument cluster connector C13, terminal No. 7 (White wire, circuit LA). See Fig. 20 & Fig. 21 .
Resistance should be less than one ohm. Measure resistance between ground and harness side of air bag
sensor assembly connector C7, terminal No. 14. Resistance should be more than one megohm. Ensure
ignition switch is in ON position. Measure voltage between ground and harness side of air bag sensor
assembly connector C7, terminal No. 14. Voltage should be less than one volt. If voltage and resistance
readings are normal, go to next step. If voltage and resistance readings are not normal, replace wire
harness between instrument cluster and air bag sensor assembly.
4. Connect instrument cluster harness connectors. Ensure negative battery cable is connected and ignition
switch is in ON position. Measure voltage between ground and harness side of instrument cluster
connector C7, terminal No. 40 (White wire). If voltage is 8-14 volts, replace air bag sensor assembly. If
voltage is not 8-14 volts, replace instrument cluster.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 34
2004 Toyota RAV4

Fig. 20: Identifying Instrument Cluster Connector C13

Fig. 21: Identifying Air Bag Sensor Assembly Connectors

AIR BAG WARNING LIGHT DOES NOT ILLUMINATE
1. Turn ignition switch to LOCK position. Disable air bag system. See DISABLING SYSTEM under
DISABLING & ACTIVATING AIR BAG SYSTEM. Measure battery voltage. If battery voltage is 11-14
volts, go to next step. If battery voltage is not 11-14 volts, replace battery.
2. Connect negative battery cable and wait at least 2 seconds. Turn ignition switch to ON position and
observe AIR BAG warning light. If AIR BAG warning light illuminates, replace instrument cluster. If
AIR BAG warning light does not illuminate, go to next step.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 35
2004 Toyota RAV4

3. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds.
Disconnect instrument cluster harness connectors. Measure voltage between ground and harness side of
air bag sensor assembly connector C7, terminal No. 14 (Black/Yellow wire, circuit LA). See Fig. 21 . If
voltage is less than one volt, replace air bag sensor assembly. If voltage is more than one volt, replace
wire harness between instrument cluster and air bag sensor assembly.
SOURCE VOLTAGE DROP
DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. Turn ignition
switch to ON position. Measure voltage between ground and air bag sensor assembly connector C7,
terminal No. 21 (Black/Orange wire, circuit IG2). See Fig. 21 . If voltage is 10-14 volts, go to next step.
If voltage is not 10-14 volts, repair or replace wiring harness between battery and air bag sensor assembly
and/or repair charging system. See WIRING DIAGRAMS .
Measure resistance between ground and air bag sensor assembly connector C7, terminal No. 25
(White/Black wire, circuit E1). Measure resistance between ground and air bag sensor assembly
connector C7, terminal No. 26 (White/Black wire, circuit E2). If resistance is less than one ohm, go to
next step. If resistance is more than one ohm, replace wiring harness between body ground and air bag
sensor assembly.
3. Activate air bag system. See ACTIVATING SYSTEM under DISABLING & ACTIVATING AIR BAG
SYSTEM. Turn on electrical accessories (defogger, wipers, headlights, blower motor, etc.). If AIR BAG
warning light does not come on, test is complete. If AIR BAG warning light does come on, replace air
bag sensor assembly. See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION.
DIAGNOSTIC TROUBLE CODES (DTCS) CANNOT BE DISPLAYED, OR DTCS ARE DISPLAYED
WITHOUT DATA LINK CONNECTOR 3 (DLC 3) CONNECTION
DISABLING & ACTIVATING AIR BAG SYSTEM. Measure resistance between DLC 3 connector
terminal No. 13 and harness side of air bag sensor assembly connector C7, terminal No. 15 (Pink/Black
wire, circuit TC). See Fig. 18 & Fig. 21 . If resistance is less than one ohm, go to next step. If resistance
is more than one ohm, replace wire harness between DLC 3 and air bag sensor assembly.
2. Measure resistance between ground and DLC 3 connector terminal No. 4. If resistance is less than one
ohm, go to next step. If resistance is more than one ohm, repair or replace wire harness between DLC 3
and body ground.
3. Measure resistance between ground and harness side of air bag sensor assembly connector C7, terminal
No. 15. If resistance is more than one megohm, replace air bag sensor assembly. If resistance is less than
one megohm, repair or replace appropriate wire harness, replace appropriate electronic control unit.
AIR BAG WARNING LIGHT INTERMITTENT
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 36
2004 Toyota RAV4

If AIR BAG warning light comes on intermittently, perform following tests to simulate driving conditions. If
problem cannot be found, replace all air bag system components including wiring harness.
Wiggle-test wiring harness.

Apply heat to components with a hair dryer.
Spray water onto entire vehicle (not directly onto electrical components) to simulate humidity.
DTC 31/B1000: AIR BAG SENSOR ASSEMBLY MALFUNCTION

Possible Causes
Diagnostic Trouble Code (DTC) 31/B1000 could be caused by air bag sensor assembly malfunction.
NOTE:
If a DTC other than DTCs 31/B1000 is displayed at same time as DTCs 31/B1000,
repair fault indicated by DTC other than DTCs 31/B1000 before using this
procedure.
Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Connect
negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds.
Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait
at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See
RETRIEVING CODES under DIAGNOSTICS. If DTC 31/B1000 is displayed, replace air bag sensor
assembly. If DTC 31/B1000 is not displayed, system is functioning properly at this time. Check for intermittent
fault. See AIR BAG WARNING LIGHT INTERMITTENT .
DTC 13/B1610: RIGHT FRONT AIR BAG SENSOR MALFUNCTION
Possible Causes
Diagnostic Trouble Code (DTC) 13/B1610 could be caused by an short to battery, short to ground or open in
right front air bag sensor wiring harness, right front air bag sensor malfunction or air bag sensor assembly
malfunction.
NOTE:
During testing, if DTCs other than DTC 13/B1610 are displayed, disregard them.
DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect air bag sensor assembly harness
connectors. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position.
Wait at least 60 seconds. Clear Diagnostic Trouble Codes (DTCs). See CLEARING CODES under
DIAGNOSTICS. Turn ignition switch to LOCK position. Turn ignition switch to ON position. Wait at
least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 13/B1610
is displayed, go to next step. If DTC 13/B1610 is not displayed, system is functioning properly at this
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 37
2004 Toyota RAV4

2.
3.
4.
5.
6.
7.
8.
9.
10.
time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT .
Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds.
Inspect air bag sensor assembly for proper connection of harness connectors. See AIR BAG SENSOR
ASSEMBLY under REMOVAL & INSTALLATION. Access right front air bag sensor and inspect for
proper connection of harness connector. See FRONT AIR BAG SENSOR under REMOVAL &
INSTALLATION. If right front air bag sensor and air bag sensor assembly connectors are not properly
connected, reconnect connectors and go to step 1 . If right front air bag sensor and air bag sensor
assembly connectors are properly connected, go to next step.
Disconnect air bag sensor assembly harness connector C7. Disconnect right front air bag sensor
connector. Connect jumper wire between Black/White wire (circuit SR+) and Brown/White wire (circuit
SR-) on harness side of front air bag sensor connector. Measure resistance between harness air bag sensor
assembly connector C7, terminals No. 29 (Black/White wire) and No. 27 (Brown/White wire). See Fig.
21 . If resistance is more then one ohm, go to step 8 . If resistance is less than one ohm, go to next step.
Remove jumper wire. Measure resistance between harness side air bag sensor assembly connector C7,
terminals No. 29 and (Black/White wire) and No. 27 (Brown/White wire). If resistance is less then one
megohm, go to step 9 . If resistance is more than one megohm, go to next step.
Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Measure
voltage between ground and harness side air bag sensor assembly connector C7, terminals No. 29
(Black/White wire) and No. 27 (Brown/White wire). If voltage is more than one volt, go to step 10 . If
voltage is less then one volt, go to next step.
Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds.
Measure resistance between ground and harness side of air bag sensor assembly connector C7, terminals
No. 29 (Black/White wire) and No. 27 (Brown/White wire). If resistance is less then one megohm, go to
step 11 . If resistance is more than one megohm, go to next step.
Connect air bag sensor assembly connector C7. Remove right and left front air bag sensors. Install right
front air bag sensor on left side and connect to left front air bag sensor harness connector. Install left front
air bag sensor on right side and connect to right front air bag sensor harness connector. Connect negative
battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear
DTCs. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ON
position. Wait at least 60 seconds. Retrieve DTCs. If DTC 13/B1610 and 14/B1615 are not displayed,
system is operating normally at this time. Check for intermittent fault. If DTC 13/B1610 is displayed,
replace air bag sensor assembly. If DTC 14/B1615 is displayed, replace right front air bag sensor.
Disconnect engine room main wire harness connector from instrument panel harness connector, located
behind right kick panel. See WIRING DIAGRAMS . Measure resistance between Black/White wire and
Brown/White wire on harness side of engine room main wire harness connector. If resistance is more then
one ohm, replace engine room main wire harness. If resistance is less than one ohm, replace instrument
panel harness.
behind right kick panel. See WIRING DIAGRAMS . Measure resistance in Black/White wire and
Brown/White wire on harness side of engine room main wire harness connector. If resistance is less then
one megohm, replace engine room main wire harness. If resistance is more than one megohm, replace
instrument panel harness.
behind right kick panel. See WIRING DIAGRAMS . Measure voltage between Black/White wire and
Brown/White wire on harness side of engine room main wire harness connector. If voltage is more than
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 38
2004 Toyota RAV4

one volt, replace instrument panel harness. If voltage is less then one volt, replace engine room main wire
harness.
11. Disconnect engine room main wire harness connector from instrument panel harness connector, located
behind right kick panel. See WIRING DIAGRAMS . Measure resistance in Black/White wire between
ground and harness side of engine room main wire harness connector. Measure resistance in
Brown/White wire between ground and harness side of engine room main wire harness connector. If
resistance is less then one megohm, replace engine room main wire harness. If resistance is more than one
megohm, replace instrument panel harness.
DTC 14/B1615: LEFT FRONT AIR BAG SENSOR MALFUNCTION
Possible Causes
Diagnostic Trouble Code (DTC) 14/B1615 could be caused by an short to battery, short to ground or open in
left front air bag sensor wiring harness, left front air bag sensor malfunction or air bag sensor assembly
malfunction.
NOTE:
connectors. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position.
Wait at least 60 seconds. Clear Diagnostic Trouble Codes (DTCs). See CLEARING CODES under
DIAGNOSTICS. Turn ignition switch to LOCK position. Turn ignition switch to ON position. Wait at
least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 14/B1615
is displayed, go to next step. If DTC 14/B1615 is not displayed, system is functioning properly at this
time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT .
2. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds.
Inspect air bag sensor assembly for proper connection of harness connectors. See AIR BAG SENSOR
ASSEMBLY under REMOVAL & INSTALLATION. Access left front air bag sensor and inspect for
proper connection of harness connector. See FRONT AIR BAG SENSOR under REMOVAL &
INSTALLATION. If left front air bag sensor and air bag sensor assembly connectors are not properly
connected, reconnect connectors and go to step 1 . If left front air bag sensor and air bag sensor assembly
connectors are properly connected, go to next step.
3. Disconnect air bag sensor assembly harness connector C7. Disconnect left front air bag sensor connector.
Connect jumper wire between White/Red wire (circuit SL+) and Brown wire (circuit SL-) on harness side
of front air bag sensor connector. Measure resistance between harness air bag sensor assembly connector
C7, terminals No. 30 (White/Red wire) and No. 28 (Brown wire). See Fig. 21 . If resistance is more then
one ohm, go to step 8 . If resistance is less than one ohm, go to next step.
4. Remove jumper wire. Measure resistance between harness side air bag sensor assembly connector C7,
terminals No. 30 (White/Red wire) and No. 28 (Brown wire). If resistance is less then one megohm, go to
step 9 . If resistance is more than one megohm, go to next step.
5. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Measure
voltage between ground and harness side air bag sensor assembly connector C7, terminals No. 30
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 39
2004 Toyota RAV4

6.
7.
8.
9.
10.
11.
(White/Red wire) and No. 28 (Brown wire). If voltage is more than one volt, go to step 10 . If voltage is
less then one volt, go to next step.
No. 30 (White/Red wire) and No. 28 (Brown wire). If resistance is less then one megohm, go to step 11 .
If resistance is more than one megohm, go to next step.
Connect air bag sensor assembly connector C7. Remove left and right front air bag sensors. Install left
front air bag sensor on right side and connect to right front air bag sensor harness connector. Install right
front air bag sensor on left side and connect to left front air bag sensor harness connector. Connect
negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60
seconds. Clear DTCs. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition
switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If DTC 14/B1615 and 13/B1610 are not
displayed, system is operating normally at this time. Check for intermittent fault. If DTC 14/B1615 is
displayed, replace air bag sensor assembly. If DTC 13/B1610 is displayed, replace left front air bag
sensor.
behind left kick panel. See WIRING DIAGRAMS . Measure resistance between White/Red wire and
Brown wire on harness side of engine room main wire harness connector. If resistance is more then one
ohm, replace engine room main wire harness. If resistance is less than one ohm, replace instrument panel
harness.
behind left kick panel. See WIRING DIAGRAMS . Measure resistance in White/Red wire and Brown
wire on harness side of engine room main wire harness connector. If resistance is less then one megohm,
replace engine room main wire harness. If resistance is more than one megohm, replace instrument panel
harness.
behind left kick panel. See WIRING DIAGRAMS . Measure voltage between White/Red wire and
Brown wire on harness side of engine room main wire harness connector. If voltage is more than one volt,
replace instrument panel harness. If voltage is less then one volt, replace engine room main wire harness.
behind left kick panel. See WIRING DIAGRAMS . Measure resistance in White/Red wire between
ground and harness side of engine room main wire harness connector. Measure resistance in Brown wire
between ground and harness side of engine room main wire harness connector. If resistance is less then
one megohm, replace engine room main wire harness. If resistance is more than one megohm, replace
instrument panel harness.
DTC 21/B1620: LEFT SIDE AIR BAG SENSOR MALFUNCTION

Possible Causes
Diagnostic Trouble Code (DTC) 21/B1620 could be caused by short to ground, short to battery or open in left
side air bag sensor wiring harness, left side air bag sensor malfunction or air bag sensor assembly malfunction.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 40
2004 Toyota RAV4

2.
3.
4.
5.
6.
7.
connectors. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING
CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn
ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See RETRIEVING CODES
under DIAGNOSTICS. If DTC 21/B1620 is not displayed, system is functioning normally at this time.
Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 21/B1620
is displayed, go to next step.
Access air bag sensor assembly. See AIR BAG SENSOR ASSEMBLY under REMOVAL &
INSTALLATION. Access left side air bag sensor. See SIDE AIR BAG SENSOR under REMOVAL &
INSTALLATION. Ensure left side air bag sensor and air bag sensor assembly harness connectors are
properly connected. If left side air bag sensor and air bag sensor assembly harness connectors are not
properly connected, reconnect connectors. If left side air bag sensor and air bag sensor assembly harness
Disconnect left side air bag sensor harness connector. Disconnect air bag sensor assembly harness
connector C6. Connect jumper wire between Pink/Blue wire (circuit VUP L) and Gray/Blue wire (circuit
ESL) on harness side of left side air bag sensor harness connector. Measure resistance between air bag
sensor assembly harness connector C6, terminals No. 19 and 21. See Fig. 21 . If resistance is less than
one ohm, go to next step. If resistance is more than one ohm, replace harness between left side air bag
sensor and air bag sensor assembly.
Remove jumper wire. Measure resistance between air bag sensor assembly harness connector C6,
terminals No. 19 and 21. If resistance is more than one megohm, go to next step. If resistance is less than
one megohm, replace harness between left side air bag sensor and air bag sensor assembly.
voltage between ground and air bag sensor assembly harness connector C6, terminals No. 19 and 21. If
voltage is less than one volt, go to next step. If voltage is more than one volt, replace harness between left
side air bag sensor and air bag sensor assembly.
Measure resistance between ground and air bag sensor assembly harness connector C6, terminals No. 19
and 21. If resistance is more than one megohm, go to next step. If resistance is less than one megohm,
replace harness between left side air bag sensor and air bag sensor assembly.
Remove right and left side air bag sensors. Install right side air bag sensor on left side and connect to left
side air bag sensor harness connector. Install left side air bag sensor on right side and connect to right side
air bag sensor harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition
switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch to LOCK position.
Wait at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If
DTC 21/B1620 and 22/B1625 are not displayed, check for intermittent fault. If DTC 21/B1620 is
displayed, replace air bag sensor assembly. If DTC 22/B1625 is displayed, replace left side air bag sensor.
DTC 22/B1625: RIGHT SIDE AIR BAG SENSOR MALFUNCTION

Possible Causes
Diagnostic Trouble Code (DTC) 22/B1625 could be caused by short to ground, short to battery or open in right
side air bag sensor wiring harness, right side air bag sensor malfunction or air bag sensor assembly malfunction.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 41
2004 Toyota RAV4

DISABLING & ACTIVATING AIR BAG SYSTEM. Turn ignition switch to ON position. Wait at least
60 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to
LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds.
Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 22/B1625 is not displayed,
system is functioning normally at this time. Check for intermittent fault. See AIR BAG WARNING
LIGHT INTERMITTENT . If DTC 22/B1625 is displayed, go to next step.
INSTALLATION. Access right side air bag sensor. See SIDE AIR BAG SENSOR under REMOVAL &
INSTALLATION. Ensure right side air bag sensor and air bag sensor assembly harness connectors are
properly connected. If right side air bag sensor and air bag sensor assembly harness connectors are not
properly connected, reconnect connectors and go to step 1 . If right side air bag sensor and air bag sensor
assembly harness connectors are properly connected, go to next step.
3. Disconnect right side air bag sensor harness connector. Disconnect air bag sensor assembly harness
connector C8. Connect jumper wire between Pink wire (circuit VUPR) and Gray wire (circuit ESR) on
harness side of right side air bag sensor harness connector. Measure resistance between air bag sensor
assembly harness connector C7, terminals No. 20 and 22. See Fig. 21 . If resistance is less than one ohm,
go to next step. If resistance is more than one ohm, replace harness between right side air bag sensor and
air bag sensor assembly.
4. Remove jumper wire. Measure resistance between ground and air bag sensor assembly harness connector
C8, terminals No. 20 and 22. If resistance is more than one megohm, go to next step. If resistance is less
than one megohm, replace harness between right side air bag sensor and air bag sensor assembly.
voltage is less than one volt, go to next step. If voltage is more than one volt, replace harness between
right side air bag sensor and air bag sensor assembly.
6. Measure resistance between ground and air bag sensor assembly harness connector C8, terminals No. 20
7. Connect air bag sensor assembly connector C8. Remove left and right side air bag sensors. Install left side
air bag sensor on right side and connect to right side air bag sensor harness connector. Install right side air
bag sensor on left side and connect to left side air bag sensor harness connector. Connect negative battery
cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs.
Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position.
Wait at least 60 seconds. Retrieve DTCs. If DTC 21/B1620 and 22/B1625 are not displayed, check for
intermittent fault. If DTC 22/B1625 is displayed, replace air bag sensor assembly. If DTC 21/B1620 is
displayed, replace right side air bag sensor.
DTC 23/B1630: LEFT REAR AIR BAG SENSOR MALFUNCTION
Possible Causes
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 42
2004 Toyota RAV4

rear air bag sensor wiring harness, left rear air bag sensor malfunction or air bag sensor assembly malfunction.
connectors. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING
under DIAGNOSTICS. If DTC 23/B1630 is not displayed, system is functioning normally at this time.
Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 23/B1630
is displayed, go to next step.
INSTALLATION. Access left rear air bag sensor. See REAR AIR BAG SENSOR under REMOVAL &
INSTALLATION. Ensure left rear air bag sensor and air bag sensor assembly harness connectors are
properly connected. If left rear air bag sensor and air bag sensor assembly harness connectors are not
properly connected, reconnect connectors. If left rear air bag sensor and air bag sensor assembly harness
3. Disconnect left rear air bag sensor harness connector. Disconnect air bag sensor assembly harness
connector C6. Connect jumper wire between Red wire (circuit VUCL) and Green wire (circuit ESCL) on
harness side of left rear air bag sensor harness connector. Measure resistance between air bag sensor
assembly harness connector C6, terminals No. 20 and 22. See Fig. 21 . If resistance is less than one ohm,
go to next step. If resistance is more than one ohm, replace harness between left rear air bag sensor and
air bag sensor assembly.
4. Remove jumper wire. Measure resistance between air bag sensor assembly harness connector C6,
one megohm, replace harness between left rear air bag sensor and air bag sensor assembly.
voltage is less than one volt, go to next step. If voltage is more than one volt, replace harness between left
rear air bag sensor and air bag sensor assembly.
replace harness between left rear air bag sensor and air bag sensor assembly.
Remove right and left rear air bag sensors. Install right side air bag sensor on left side and connect to left
rear air bag sensor harness connector. Install left rear air bag sensor on right side and connect to right rear
air bag sensor harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition
switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch to LOCK position.
Wait at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If
DTC 23/B1630 and 24/B1635 are not displayed, check for intermittent fault. If DTC 23/B1630 is
displayed, replace air bag sensor assembly. If DTC 24/B1635 is displayed, replace left rear air bag sensor.
DTC 22/B1635: RIGHT REAR AIR BAG SENSOR MALFUNCTION
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 43
2004 Toyota RAV4

Possible Causes
Diagnostic Trouble Code (DTC) 24/B1635 could be caused by short to ground, short to battery or open in right
rear air bag sensor wiring harness, right rear air bag sensor malfunction or air bag sensor assembly malfunction.
DISABLING & ACTIVATING AIR BAG SYSTEM. Turn ignition switch to ON position. Wait at least
60 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to
LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position. Wait at least 60 seconds.
Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 24/B1635 is not displayed,
system is functioning normally at this time. Check for intermittent fault. See AIR BAG WARNING
LIGHT INTERMITTENT . If DTC 24/B1635 is displayed, go to next step.
INSTALLATION. Access right rear air bag sensor. See REAR AIR BAG SENSOR under REMOVAL
& INSTALLATION. Ensure right rear air bag sensor and air bag sensor assembly harness connectors are
properly connected. If right rear air bag sensor and air bag sensor assembly harness connectors are not
properly connected, reconnect connectors and go to step 1 . If right rear air bag sensor and air bag sensor
assembly harness connectors are properly connected, go to next step.
3. Disconnect right rear air bag sensor harness connector. Disconnect air bag sensor assembly harness
connector C8. Connect jumper wire between White/Black wire (circuit VUCR) and Black/Orange wire
(circuit ESCR) on harness side of right rear air bag sensor harness connector. Measure resistance between
air bag sensor assembly harness connector C8, terminals No. 19 and 21. See Fig. 21 . If resistance is less
than one ohm, go to next step. If resistance is more than one ohm, replace harness between right rear air
bag sensor and air bag sensor assembly.
4. Remove jumper wire. Measure resistance between ground and air bag sensor assembly harness connector
C8, terminals No. 19 and 21. If resistance is more than one megohm, go to next step. If resistance is less
than one megohm, replace harness between right rear air bag sensor and air bag sensor assembly.
voltage is less than one volt, go to next step. If voltage is more than one volt, replace harness between
right rear air bag sensor and air bag sensor assembly.
7. Connect air bag sensor assembly connector C8. Remove left and right rear air bag sensors. Install left side
air bag sensor on right side and connect to right rear air bag sensor harness connector. Install right rear air
bag sensor on left side and connect to left side air bag sensor harness connector. Connect negative battery
cable. Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs.
Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position.
Wait at least 60 seconds. Retrieve DTCs. If DTC 23/B1630 and 24/B1635 are not displayed, check for
intermittent fault. If DTC 24/B1635 is displayed, replace air bag sensor assembly. If DTC 23/B1630 is
displayed, replace right rear air bag sensor.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 44
2004 Toyota RAV4

DTC 35/B1653: SEAT POSITION SENSOR MALFUNCTION

Possible Causes
Diagnostic Trouble Code (DTC) 35/B1653 could be caused by open, short to ground or short circuit in seat
position sensor wire harness, seat position sensor malfunction or air bag sensor assembly malfunction.
NOTE:
DISABLING & ACTIVATING AIR BAG SYSTEM. Connect negative battery cable. Wait at least 2
seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch
to LOCK position. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See
RETRIEVING CODES under DIAGNOSTICS. If DTC 35/B1653 is displayed, go to next step. If DTC
35/B1653 is not displayed, check for intermittent fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
2. Turn ignition switch to LOCK position. Disconnect negative battery cable. and wait at least 90 seconds.
INSTALLATION. Access seat position sensor. See SEAT POSITION SENSOR under REMOVAL &
INSTALLATION. Ensure harness connectors are properly connected to seat position sensor and air bag
sensor assembly. If connectors are properly connected, go to next step. If connectors are not properly
connected, reconnect connector and go to step 1 .
3. Disconnect air bag center connector C6. Disconnect left front seat harness connector. Connect jumper
wire between Green/Red wire (circuit DSP+) and Green/Black wire (circuit DSP-) on harness side of
front seat connector. Measure resistance between ground and harness side of air bag sensor assembly
connector C6, terminals No. 9 and 17. See Fig. 21 . If resistance is less than one ohm, go to next step. If
resistance is more than one ohm, replace wiring harness between front seat harness connector and air bag
sensor assembly. See WIRING DIAGRAMS .
4. Remove jumper wire. Measure resistance between harness side of air bag sensor assembly connector C6,
one megohm, replace wiring harness between front seat harness connector and air bag sensor assembly.
voltage between ground and harness side of air bag sensor assembly connector C6, terminals No. 9 and
No. 17. If voltage is less than one volt, go to next step. If voltage is more than one volt, replace wiring
harness between front seat harness connector and air bag sensor assembly.
No. 9 and No. 17. If resistance is more than one megohm, go to next step. If resistance is less than one
megohm, replace wiring harness between front seat harness connector and air bag sensor assembly.
7. Connect air bag sensor assembly and seat position sensor connectors. Connect negative battery cable.
Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn
ignition switch to LOCK position. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve
DTCs. If DTC 35/B1653 is displayed, go to next step. If DTC 35/B1653 is not displayed, check for
intermittent fault.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 45
2004 Toyota RAV4

Replace seat position sensor. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch
to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch to LOCK position. Turn
ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If DTC 35/B1653 is displayed,
air bag sensor assembly. If DTC 35/B1653 is not displayed, replace wiring harness between front seat
harness connector and air bag sensor assembly.
DTC 37/B1655: LEFT SEAT BELT SWITCH MALFUNCTION
Description
The left seat belt switch circuit consists of air bag sensor assembly, left front seat belt buckle and left seat belt
switch.
Possible Causes
seat belt buckle wire harness, left front seat belt buckle switch malfunction or air bag sensor assembly
malfunction.
NOTE:
DISABLING & ACTIVATING AIR BAG SYSTEM. Connect negative battery cable. Wait at least 2
seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch
to LOCK position. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See
RETRIEVING CODES under DIAGNOSTICS. If DTC 37/B1655 is displayed, go to next step. If DTC
37/B1655 is not displayed, check for intermittent fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
2. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Turn
ignition switch to ON position. Wait at least 90 seconds. Ensure harness connectors are properly
connected to left seat belt switch and air bag sensor assembly. If connectors are properly connected, go to
next step. If connectors are not properly connected, reconnect connector and go to step 1 .
3. Access air bag sensor assembly and disconnect connectors. See AIR BAG SENSOR ASSEMBLY under
REMOVAL & INSTALLATION. Disconnect seat belt switch harness connector. Connect jumper wire
between Green/Yellow wire (circuit DBE+) and Black wire (circuit DBE-) on harness side of left seat belt
switch connector. Measure resistance between harness side of air bag sensor assembly connector C6,
terminals No. 10 and 18. See Fig. 21 . If resistance is less than one ohm, go to next step. If resistance is
more than one ohm, replace wiring harness between left seat belt switch and air bag sensor assembly. See
WIRING DIAGRAMS .
4. Remove jumper wire. Measure resistance between ground and harness side of air bag sensor assembly
connector C6, terminal No. 2 (Red wire). Measure resistance between harness side of air bag sensor
assembly connector C6, terminals No. 10 and 18. If resistance is more than one megohm, go to next step.
If resistance is less than one megohm, replace wiring harness between left seat belt switch and air bag
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 46
2004 Toyota RAV4

5.
6.
7.
8.
sensor assembly.
voltage between ground and harness side of air bag sensor assembly connector C6, terminals No. 10 and
18. If voltage is less than one volt, go to next step. If voltage is more than one volt, replace wiring harness
between left seat belt switch and air bag sensor assembly.
No. 10 and 18. If resistance is more than one megohm, go to next step. If resistance is less than one
megohm, replace wiring harness between left seat belt switch and air bag sensor assembly.
Reconnect left seat belt switch and air bag sensor assembly connectors. Connect negative battery cable.
Wait at least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. Turn
ignition switch to LOCK position. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve
DTCs. If DTC 37/B1655 is displayed, go to next step. If DTC 37/B1655 is not displayed, system is
functioning properly at this time. Check for intermittent fault.
Replace left seat belt buckle switch. See SEAT BELT BUCKLE SWITCH under REMOVAL &
INSTALLATION. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON
position. Wait at least 60 seconds. Clear DTCs. Turn ignition switch to LOCK position. Turn ignition
switch to ON position. Wait at least 60 seconds. Retrieve DTCs. If DTC 37/B1655 is displayed, replace
air bag sensor assembly. If DTC 37/B1655 is not displayed, test is complete.
DTC 51/B1800, 51/B1801, 51/B1802, 51/B1803: DRIVER-SIDE AIR BAG NO. 1 SQUIB CIRCUIT
SHORT, OPEN, SHORT TO GROUND OR SHORT TO BATTERY
Possible Causes
Diagnostic Trouble Codes (DTCs) 51/B1800, 51/B1801, 51/B1802 or 51/B1803 could be caused by a short to
ground, open, short or short to battery in No. 1 squib circuit, squib malfunction, spiral cable malfunction or air
bag sensor assembly malfunction.
NOTE:
During testing, if DTCs other than DTC 51/B1800, 51/B1801, 51/B1802 or

51/B1803 are displayed, disregard them.
DISABLING & ACTIVATING AIR BAG SYSTEM. If using Toyota hand-held tester, retrieve 5 digit
DTC. See RETRIEVING AIR BAG SYSTEM DTCS USING TOYOTA HAND-HELD TESTER
under DIAGNOSTICS. If DTC B1800 is retrieved, go to next step. If DTC B1801 is retrieved, go to step
4 . If DTC B1802 is retrieved, go to step 5 . If DTC B1803 is retrieved, go to step 6 . If using diagnosis
check wire, retrieve 2 digit DTC. See RETRIEVING AIR BAG SYSTEM DTCS USING
DIAGNOSIS CHECK WIRE under DIAGNOSTICS. If DTC 51 is retrieved, go to step 7 .
2. Inspect spiral cable connectors for disengaged lock button or deformed or damaged lock claw. If
connectors are okay, go to next step. If connectors are not okay, replace spiral cable. See SPIRAL
CABLE under REMOVAL & INSTALLATION.
3. Release short spring mechanism on air bag sensor assembly connector C7. See RELEASING SHORT
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 47
2004 Toyota RAV4

4.
5.
6.
7.
8.
9.
10.
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire (circuit D+) and
Yellow wire (circuit D-) on harness side of Black upper spiral cable connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, go to step 13 . If resistance is more than one
megohm, go to step 10 .
Measure resistance between Yellow/Black wire (circuit D+) and Yellow wire (circuit D-) on harness side
of Black upper spiral cable connector. See WIRING DIAGRAMS . If resistance is less than one ohm, go
to step 11 . If resistance is more than one ohm, go to step 15 .
Measure resistance between ground and Yellow/Black wire (circuit D+) on harness side of Black upper
spiral cable connector. See WIRING DIAGRAMS . Measure resistance between ground and Yellow
(circuit D-) wire on harness side of Black upper spiral cable connector. If resistance is more than one
ohm, go to step 11 . If resistance is less than one megohm, go to step 17 .
voltage between ground and Yellow/Black wire (circuit D+) on harness side of Black upper spiral cable
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire (circuit D-)
on harness side of Black upper spiral cable connector. If voltage is less than one volt, go to step 11 . If
voltage is more than one volt, go to step 19 .
Inspect spiral cable connectors for disengaged lock button or deformed or damaged lock claw. If
CABLE under ADJUSTMENTS.
voltage between ground and Yellow/Black wire (circuit D+) on harness side of Black upper spiral cable
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire (circuit D-)
on harness side of Black upper spiral cable connector. Voltage should be less than one volt. Turn ignition
switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds. Measure
resistance between Yellow/Black wire and Yellow wire on harness side of Black upper spiral cable
connector. Resistance should be less than one ohm. Measure resistance between ground and
Yellow/Black wire on harness side of Black upper spiral cable connector. Measure resistance between
ground and Yellow wire on harness side of Black upper spiral cable connector. Resistance should be
more than one megohm. Release short spring mechanism on air bag sensor assembly connector C7. See
RELEASING SHORT SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black
wire and Yellow wire on harness side of Black upper spiral cable connector. Resistance should be more
than one megohm. If voltage and resistance readings are normal, go to next step. If voltage and resistance
readings are not normal, go to step 21 .
Replace driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL &
INSTALLATION. Reconnect air bag sensor assembly harness connectors. Turn ignition switch to ON
position. Wait at least 60 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn
ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ON position. Wait at
least 60 seconds. Retrieve DTCs. If DTC 51 is displayed, replace air bag sensor assembly. See AIR BAG
SENSOR ASSEMBLY under REMOVAL & INSTALLATION. If DTC 51 is not displayed, test is
complete.
Reconnect air bag sensor assembly connectors. Connect negative battery cable. Wait at least 2 seconds.
Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING CODES
under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition
switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under
DIAGNOSTICS. If DTC B1800 is displayed, replace air bag sensor assembly. See AIR BAG SENSOR
ASSEMBLY under REMOVAL & INSTALLATION. If DTC B1800 is not displayed, go to step 12 .
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 48
2004 Toyota RAV4

11. If sent here from step 6 , turn ignition switch to LOCK position. Disconnect negative battery cable and
wait at least 90 seconds. If sent here from any step, reconnect air bag sensor assembly connectors.
Connect jumper wire between Yellow/Black wire and Yellow wire on harness side of Black upper spiral
cable connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2 seconds.
DIAGNOSTICS. If DTCs B1801, B1802 or B1803 are displayed, replace air bag sensor assembly. See
AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. If DTC B1801, B1802 or
B1803 are not displayed, go to next step.
12. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds. If
sent here from step 11 , remove jumper wire. If sent here from any step, connect spiral cable harness
connectors to driver-side air bag module. Connect negative battery cable. Wait at least 2 seconds. Turn
ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING CODES under
DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch
to ON position. Wait at least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under
DIAGNOSTICS. If DTCs B1800, B1801, B1802 or B1803 are displayed, replace driver-side air bag
module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. If DTC
B1800, B1801, B1802 or B1803 are not displayed, ensure air bag sensor assembly is in check mode. See
CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag system fault. See
AIR BAG WARNING LIGHT INTERMITTENT .
13. Disconnect lower spiral cable harness connector. Measure resistance between Yellow/Black wire and
Yellow wire on harness side of lower spiral cable connector. If resistance is less than one megohm,
replace wiring harness between air bag sensor assembly and spiral cable. If resistance is more than one
megohm, go to next step.
14. Release short spring mechanism on lower spiral cable harness connector. Measure resistance between
Yellow/Black wire and Yellow wire on harness side of Black upper spiral cable connector. If resistance is
less than one megohm, replace spiral cable. See SPIRAL CABLE under REMOVAL &
INSTALLATION. If resistance is more than one megohm, ensure air bag sensor assembly is in check
mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag
system fault. See AIR BAG WARNING LIGHT INTERMITTENT .
15. Disconnect lower spiral cable harness connector. Measure resistance between Yellow/Black wire and
Yellow wire on harness side of lower spiral cable connector. If resistance is more than one ohm, replace
wiring harness between air bag sensor assembly and spiral cable. If resistance is less than one ohm, go to
next step.
16. Measure resistance between Yellow/Black wire and Yellow wire on harness side of Black upper spiral
cable connector. If resistance is more than one ohm, replace spiral cable. See SPIRAL CABLE under
REMOVAL & INSTALLATION. If resistance is less than one ohm, ensure air bag sensor assembly is in
check mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag
17. Disconnect lower spiral cable harness connector. Measure resistance between ground and Yellow/Black
wire on harness side of lower spiral cable connector. Measure resistance between ground and Yellow wire
on harness side of lower spiral cable connector. If resistance is more than one megohm, replace wiring
harness between air bag sensor assembly and spiral cable. If resistance is less than one megohm, go to
next step.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 49
2004 Toyota RAV4

18. Measure resistance between ground and Yellow/Black wire on harness side of Black upper spiral cable
connector. Measure resistance between ground and Yellow wire on harness side of Black upper spiral
cable connector. If resistance is more than one megohm, replace spiral cable. See SPIRAL CABLE
under REMOVAL & INSTALLATION. If resistance is less than one megohm, ensure air bag sensor
assembly is in check mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for
intermittent air bag system fault. See AIR BAG WARNING LIGHT INTERMITTENT .
Disconnect lower spiral cable harness connector. Measure voltage between ground and Yellow/Black
wire on harness side of lower spiral cable connector. Measure voltage between ground and Yellow wire
on harness side of lower spiral cable connector. If voltage is more than one volt, replace wiring harness
between air bag sensor assembly and spiral cable. If voltage is less than one volt, go to next step.
20. Measure voltage between ground and Yellow/Black wire on harness side of Black upper spiral cable
connector. Measure voltage between ground and Yellow wire on harness side of Black upper spiral cable
connector. If voltage is more than one volt, replace spiral cable. See SPIRAL CABLE under REMOVAL
& INSTALLATION. If voltage is less than one volt, ensure air bag sensor assembly is in check mode.
See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag system fault.
See AIR BAG WARNING LIGHT INTERMITTENT .
21. Restore short spring mechanism to original condition. Disconnect lower spiral cable harness connector.
voltage between ground and Yellow/Black wire on harness side of lower spiral cable connector. Measure
voltage between ground and Yellow wire on harness side of lower spiral cable connector. Voltage should
be less than one volt. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait
at least 90 seconds. Measure resistance between Yellow/Black wire and Yellow wire on harness side of
lower spiral cable connector. Resistance should be less than one ohm. Measure resistance between ground
and Yellow/Black wire on harness side of lower spiral cable connector. Measure resistance between
ground and Yellow wire on harness side of lower spiral cable connector. Resistance should be more than
one megohm. Release short spring mechanism on air bag sensor assembly connector C7. Measure
resistance between Yellow/Black wire and Yellow wire on harness side of lower spiral cable connector.
Resistance should be more than one megohm. If voltage and resistance readings are normal, go to next
step. If voltage and resistance readings are not normal, replace wiring harness between air bag sensor
assembly and spiral cable.
voltage between ground and Yellow/Black wire on harness side of Black upper spiral cable connector.
Measure voltage between ground and Yellow wire on harness side of Black upper spiral cable connector.
Voltage should be less than one volt. Turn ignition switch to LOCK position. Disconnect negative battery
cable and wait at least 90 seconds. Measure resistance between Yellow/Black wire and Yellow wire on
harness side of Black upper spiral cable connector. Resistance should be less than one ohm. Measure
resistance between ground and Yellow/Black wire on harness side of Black upper spiral cable connector.
Measure resistance between ground and Yellow wire on harness side of Black upper spiral cable
connector. Resistance should be more than one megohm. Release short spring mechanism on lower spiral
cable connector. Measure resistance between Yellow/Black wire and Yellow wire on harness side of
Black upper spiral cable connector. Resistance should be more than one megohm. If voltage and
resistance readings are normal, ensure air bag sensor assembly is in check mode. See CHECK MODE
PROCEDURE under DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG
WARNING LIGHT INTERMITTENT . If voltage and resistance readings are not normal, replace
spiral cable. See SPIRAL CABLE under REMOVAL & INSTALLATION.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 50
2004 Toyota RAV4

DTC 52/B1805, 52/B1806, 52/B1807, 52/B1808: PASSENGER-SIDE AIR BAG NO. 1 SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in No. 1 squib circuit, squib malfunction or air bag sensor assembly
malfunction.
NOTE:

2. Inspect passenger-side air bag module connectors for disengaged lock button or deformed or damaged
lock claw. If connectors are okay, go to next step. If connectors are not okay, replace instrument panel
wiring harness.
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Red wire (circuit P+) and
Yellow/Green wire (circuit P-) on harness side of passenger-side air bag module connector. See
WIRING DIAGRAMS . If resistance is less than one megohm, replace instrument panel wiring harness.
If resistance is more than one megohm, go to step 10 .
4. Measure resistance between Yellow/Red wire (circuit P+) and Yellow/Green wire (circuit P-) on harness
side of passenger-side air bag module connector. See WIRING DIAGRAMS . If resistance is less than
one ohm, go to step 11 . If resistance is more than one ohm, replace instrument panel wiring harness.
5. Measure resistance between ground and Yellow/Red wire (circuit P+) on harness side of passenger-side
air bag module connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow/Green (circuit P-) wire on harness side of passenger-side air bag module connector. If resistance
is more than one megohm, go to step 11 . If resistance is less than one megohm, replace instrument panel
wiring harness.
voltage between ground and Yellow/Red wire (circuit P+) on harness side of passenger-side air bag
module connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Green
wire (circuit P-) on harness side of passenger-side air bag module connector. If voltage is less than one
volt, go to step 11 . If voltage is more than one volt, replace instrument panel wiring harness.
7. Inspect passenger-side air bag module connectors for disengaged lock button or deformed or damaged
wiring harness.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 51
2004 Toyota RAV4

voltage between ground and Yellow/Red wire (circuit P+) on harness side of passenger-side air bag
wire (circuit P-) on harness side of passenger-side air bag module connector. Voltage should be less than
one volt. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90
seconds. Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of
passenger-side air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Red wire on harness side of passenger-side air bag module connector.
Measure resistance between ground and Yellow/Green wire on harness side of passenger-side air bag
module connector. Resistance should be more than one megohm. Release short spring mechanism on air
bag sensor assembly connector C7. See RELEASING SHORT SPRING under DIAGNOSTICS.
Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of passenger-side
air bag module connector. Resistance should be more than one megohm. If voltage and resistance
readings are normal, go to next step. If voltage and resistance readings are not normal, replace instrument
panel wiring harness.
9. Replace passenger-side air bag module. See PASSENGER-SIDE AIR BAG MODULE under
REMOVAL & INSTALLATION. Reconnect air bag sensor assembly harness connectors. Turn ignition
switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING CODES under
to ON position. Wait at least 60 seconds. Retrieve DTCs. If DTC 52 is displayed, replace air bag sensor
assembly. See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. If DTC 52 is
not displayed, test is complete.
10. Reconnect air bag sensor assembly connectors. Connect negative battery cable. Wait at least 2 seconds.
Connect jumper wire between Yellow/Red wire and Yellow/Green wire on harness side of passenger-side
air bag module connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING
under DIAGNOSTICS. If DTCs B1806, B1807 or B1808 are displayed, replace air bag sensor assembly.
See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. If DTC B1806, B1807
or B1808 are not displayed, go to next step.
connectors to passenger-side air bag module Connect negative battery cable. Wait at least 2 seconds. Turn
DIAGNOSTICS. If DTCs B1805, B1806, B1807 or B1808 are displayed, replace passenger-side air bag
module. See PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. If
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 52
2004 Toyota RAV4

DTC B1805, B1806, B1807 or B1808 are not displayed, ensure air bag sensor assembly is in check mode.
DTC 53/B1810, 53/B1811, 53/B1812, 53/B1813: DRIVER-SIDE AIR BAG NO. 2 SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in No. 2 squib circuit, squib malfunction, spiral cable malfunction or air
bag sensor assembly malfunction.
NOTE:

SPRING under DIAGNOSTICS. Measure resistance between Yellow/Violet wire (circuit D2+) and
Yellow/Orange wire (circuit D2-) on harness side of Orange upper spiral cable connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, go to step 13 . If resistance is more than one
megohm, go to step 10 .
4. Measure resistance between Yellow/Violet wire (circuit D2+) and Yellow/Orange wire (circuit D2-) on
harness side of Orange upper spiral cable connector. See WIRING DIAGRAMS . If resistance is less
than one ohm, go to step 11 . If resistance is more than one ohm, go to step 15 .
5. Measure resistance between ground and Yellow/Violet wire (circuit D2+) on harness side of Orange
upper spiral cable connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow (circuit D2-) wire on harness side of Orange upper spiral cable connector. If resistance is more
than one ohm, go to step 11 . If resistance is less than one megohm, go to step 17 .
voltage between ground and Yellow/Violet wire (circuit D2+) on harness side of Orange upper spiral
cable connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Orange wire
(circuit D2-) on harness side of Orange upper spiral cable connector. If voltage is less than one volt, go to
step 11 . If voltage is more than one volt, go to step 19 .
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 53
2004 Toyota RAV4

8.
9.
10.
11.
12.
voltage between ground and Yellow/Violet wire (circuit D2+) on harness side of Orange upper spiral
cable connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Orange wire
(circuit D2-) on harness side of Orange upper spiral cable connector. Voltage should be less than one volt.
Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of Orange
upper spiral cable connector. Resistance should be less than one ohm. Measure resistance between ground
and Yellow/Violet wire on harness side of Orange upper spiral cable connector. Measure resistance
between ground and Yellow/Orange wire on harness side of Orange upper spiral cable connector.
Resistance should be more than one megohm. Release short spring mechanism on air bag sensor
assembly connector C7. See RELEASING SHORT SPRING under DIAGNOSTICS. Measure
resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of Orange upper spiral
cable connector. Resistance should be more than one megohm. If voltage and resistance readings are
normal, go to next step. If voltage and resistance readings are not normal, go to step 21 .
Replace driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL &
complete.
If sent here from step 6 , turn ignition switch to LOCK position. Disconnect negative battery cable and
Connect jumper wire between Yellow/Violet wire and Yellow/Orange wire on harness side of Orange
upper spiral cable connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least
2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See CLEARING
Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds. If
connectors to driver-side air bag module. Connect negative battery cable. Wait at least 2 seconds. Turn
DIAGNOSTICS. If DTCs B1810, B1811, B1812 or B1813 are displayed, replace driver-side air bag
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 54
2004 Toyota RAV4

13.
14.
15.
16.
17.
18.
19.
20.
module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. If DTC
B1810, B1811, B1812 or B1813 are not displayed, ensure air bag sensor assembly is in check mode. See
CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag system fault. See
AIR BAG WARNING LIGHT INTERMITTENT .
Disconnect lower spiral cable harness connector. Measure resistance between Yellow/Violet wire and
Yellow/Orange wire on harness side of lower spiral cable connector. If resistance is less than one
megohm, replace wiring harness between air bag sensor assembly and spiral cable. If resistance is more
than one megohm, go to next step.
Release short spring mechanism on lower spiral cable harness connector. Measure resistance between
Yellow/Violet wire and Yellow/Orange wire on harness side of Orange upper spiral cable connector. If
resistance is less than one megohm, replace spiral cable. See SPIRAL CABLE under REMOVAL &
INSTALLATION. If resistance is more than one megohm, ensure air bag sensor assembly is in check
mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for intermittent air bag
Disconnect lower spiral cable harness connector. Measure resistance between Yellow/Violet wire and
Yellow/Orange wire on harness side of lower spiral cable connector. If resistance is more than one ohm,
replace wiring harness between air bag sensor assembly and spiral cable. If resistance is less than one
ohm, go to next step.
Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of Orange
upper spiral cable connector. If resistance is more than one ohm, replace spiral cable. See SPIRAL
CABLE under REMOVAL & INSTALLATION. If resistance is less than one ohm, ensure air bag sensor
assembly is in check mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check for
intermittent air bag system fault. See AIR BAG WARNING LIGHT INTERMITTENT .
Disconnect lower spiral cable harness connector. Measure resistance between ground and Yellow/Violet
wire on harness side of lower spiral cable connector. Measure resistance between ground and
Yellow/Orange wire on harness side of lower spiral cable connector. If resistance is more than one
megohm, replace wiring harness between air bag sensor assembly and spiral cable. If resistance is less
than one megohm, go to next step.
Measure resistance between ground and Yellow/Violet wire on harness side of Orange upper spiral cable
connector. Measure resistance between ground and Yellow/Orange wire on harness side of Orange upper
spiral cable connector. If resistance is more than one megohm, replace spiral cable. See SPIRAL
CABLE under REMOVAL & INSTALLATION. If resistance is less than one megohm, ensure air bag
sensor assembly is in check mode. See CHECK MODE PROCEDURE under DIAGNOSTICS. Check
for intermittent air bag system fault. See AIR BAG WARNING LIGHT INTERMITTENT .
Disconnect lower spiral cable harness connector. Measure voltage between ground and Yellow/Violet
wire on harness side of lower spiral cable connector. Measure voltage between ground and
Yellow/Orange wire on harness side of lower spiral cable connector. If voltage is more than one volt,
replace wiring harness between air bag sensor assembly and spiral cable. If voltage is less than one volt,
go to next step.
Measure voltage between ground and Yellow/Violet wire on harness side of Orange upper spiral cable
connector. Measure voltage between ground and Yellow/Orange wire on harness side of Orange upper
spiral cable connector. If voltage is more than one volt, replace spiral cable. See SPIRAL CABLE under
REMOVAL & INSTALLATION. If voltage is less than one volt, ensure air bag sensor assembly is in
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 55
2004 Toyota RAV4


21. Restore short spring mechanism to original condition. Disconnect lower spiral cable harness connector.
voltage between ground and Yellow/Violet wire on harness side of lower spiral cable connector. Measure
voltage between ground and Yellow/Orange wire on harness side of lower spiral cable connector. Voltage
should be less than one volt. Turn ignition switch to LOCK position. Disconnect negative battery cable
and wait at least 90 seconds. Measure resistance between Yellow/Violet wire and Yellow/Orange wire on
harness side of lower spiral cable connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Violet wire on harness side of lower spiral cable connector. Measure
resistance between ground and Yellow/Orange wire on harness side of lower spiral cable connector.
assembly connector C7. Measure resistance between Yellow/Violet wire and Yellow/Orange wire on
harness side of lower spiral cable connector. Resistance should be more than one megohm. If voltage and
resistance readings are normal, go to next step. If voltage and resistance readings are not normal, replace
wiring harness between air bag sensor assembly and spiral cable.
voltage between ground and Yellow/Violet wire on harness side of Orange upper spiral cable connector.
Measure voltage between ground and Yellow/Orange wire on harness side of Orange upper spiral cable
connector. Voltage should be less than one volt. Turn ignition switch to LOCK position. Disconnect
negative battery cable and wait at least 90 seconds. Measure resistance between Yellow/Violet wire and
Yellow/Orange wire on harness side of Orange upper spiral cable connector. Resistance should be less
than one ohm. Measure resistance between ground and Yellow/Violet wire on harness side of Orange
upper spiral cable connector. Measure resistance between ground and Yellow/Orange wire on harness
side of Orange upper spiral cable connector. Resistance should be more than one megohm. Release short
spring mechanism on lower spiral cable connector. Measure resistance between Yellow/Violet wire and
Yellow/Orange wire on harness side of Orange upper spiral cable connector. Resistance should be more
than one megohm. If voltage and resistance readings are normal, ensure air bag sensor assembly is in
system fault. See AIR BAG WARNING LIGHT INTERMITTENT . If voltage and resistance readings
are not normal, replace spiral cable. See SPIRAL CABLE under REMOVAL & INSTALLATION.
DTC 54/B1815, 54/B1816, 54/B1817, 54/B1818: PASSENGER-SIDE AIR BAG NO. 2 SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in No. 2 squib circuit, squib malfunction or air bag sensor assembly
malfunction.
NOTE:

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 56
2004 Toyota RAV4

2.
3.
4.
5.
6.
7.
8.
Inspect passenger-side air bag module connectors for disengaged lock button or deformed or damaged
wiring harness.
Release short spring mechanism on air bag sensor assembly connector C7. See RELEASING SHORT
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Gray wire (circuit P2+) and
Yellow/Pink wire (circuit P2-) on harness side of passenger-side air bag module connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, replace instrument panel wiring harness. If
resistance is more than one megohm, go to step 10 .
Measure resistance between Yellow/Gray wire (circuit P2+) and Yellow/Pink wire (circuit P2-) on
harness side of passenger-side air bag module connector. See WIRING DIAGRAMS . If resistance is
less than one ohm, go to step 11 . If resistance is more than one ohm, replace instrument panel wiring
harness.
Measure resistance between ground and Yellow/Gray wire (circuit P2+) on harness side of passenger-side
air bag module connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow/Pink (circuit P2-) wire on harness side of passenger-side air bag module connector. If resistance is
more than one megohm, go to step 11 . If resistance is less than one megohm, replace instrument panel
wiring harness.
voltage between ground and Yellow/Gray wire (circuit P2+) on harness side of passenger-side air bag
module connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Pink wire
(circuit P2-) on harness side of passenger-side air bag module connector. If voltage is less than one volt,
go to step 11 . If voltage is more than one volt, replace instrument panel wiring harness.
Inspect passenger-side air bag module connectors for disengaged lock button or deformed or damaged
wiring harness.
voltage between ground and Yellow/Gray wire (circuit P2+) on harness side of passenger-side air bag
module connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Pink wire
(circuit P2-) on harness side of passenger-side air bag module connector. Voltage should be less than one
volt. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90
seconds. Measure resistance between Yellow/Gray wire and Yellow/Pink wire on harness side of
passenger-side air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Gray wire on harness side of passenger-side air bag module connector.
Measure resistance between ground and Yellow/Pink wire on harness side of passenger-side air bag
Measure resistance between Yellow/Gray wire and Yellow/Pink wire on harness side of passenger-side
readings are normal, go to next step. If voltage and resistance readings are not normal, replace instrument
panel wiring harness.
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 57
2004 Toyota RAV4

9. Replace passenger-side air bag module. See PASSENGER-SIDE AIR BAG MODULE under
Connect jumper wire between Yellow/Gray wire and Yellow/Pink wire on harness side of passenger-side
air bag module connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
connectors to passenger-side air bag module Connect negative battery cable. Wait at least 2 seconds. Turn
DIAGNOSTICS. If DTCs B1815, B1816, B1817 or B1818 are displayed, replace passenger-side air bag
module. See PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. If
DTC B1815, B1816, B1817 or B1818 are not displayed, ensure air bag sensor assembly is in check mode.
DTC 55/B1820, 55/B1821, 55/B1822, 55/B1823: LEFT SIDE AIR BAG SQUIB CIRCUIT SHORT,
OPEN, SHORT TO GROUND OR SHORT TO BATTERY
Possible Causes
ground, open, short or short to battery in left side air bag squib circuit, squib malfunction or air bag sensor
assembly malfunction.
NOTE:

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 58
2004 Toyota RAV4

SPRING under DIAGNOSTICS. Measure resistance between Yellow/Red wire (circuit SFD+) and
Yellow/Green wire (circuit SFD-) on harness side of left side curtain air bag module connector. See
WIRING DIAGRAMS . If resistance is less than one megohm, replace wire harness between left side air
bag module and air bag sensor assembly. If resistance is more than one megohm, go to step 8 .
3. Measure resistance between Yellow/Red wire (circuit SFD+) and Yellow/Green wire (circuit SFD-) on
harness side of left side curtain air bag module connector. See WIRING DIAGRAMS . If resistance is
less than one ohm, go to step 9 . If resistance is more than one ohm, replace wire harness between left
side air bag module and air bag sensor assembly.
4. Measure resistance between ground and Yellow/Red wire (circuit SFD+) on harness side of left side
curtain air bag module connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow/Green (circuit SFD-) wire on harness side of left side curtain air bag module connector. If
resistance is more than one megohm, go to step 9 . If resistance is less than one megohm, replace wire
harness between left side air bag module and air bag sensor assembly.
voltage between ground and Yellow/Red wire (circuit SFD+) on harness side of left side curtain air bag
wire (circuit SFD-) on harness side of left side curtain air bag module connector. If voltage is less than
one volt, go to step 9 . If voltage is more than one volt, replace wire harness between left side air bag
module and air bag sensor assembly.
voltage between ground and Yellow/Red wire (circuit SFD+) on harness side of left side curtain air bag
wire (circuit SFD-) on harness side of left side curtain air bag module connector. Voltage should be less
than one volt. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least
90 seconds. Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of left
side curtain air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Red wire on harness side of left side curtain air bag module connector.
Measure resistance between ground and Yellow/Green wire on harness side of left side curtain air bag
Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of left side curtain
harness between left side air bag module and air bag sensor assembly.
7. Replace left side air bag module. See SIDE AIR BAG MODULE under REMOVAL &
Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 59
2004 Toyota RAV4

complete.
Connect jumper wire between Yellow/Red wire and Yellow/Green wire on harness side of left side
curtain air bag module connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at
least 2 seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Clear DTCs. See
CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20
seconds. Turn ignition switch to ON position. Wait at least 60 seconds. Retrieve DTCs. See
RETRIEVING CODES under DIAGNOSTICS. If DTCs B1821, B1822 or B1823 are displayed, replace
air bag sensor assembly. See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION.
If DTC B1821, B1822 or B1823 are not displayed, go to next step.
sent here from step 9 , remove jumper wire. If sent here from any step, connect left side air bag module
harness connectors. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ON
least 60 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTCs B1820,
B1821, B1822 or B1823 are displayed, replace left side air bag module. See SIDE AIR BAG MODULE
under REMOVAL & INSTALLATION. If DTC B1820, B1821, B1822 or B1823 are not displayed,
ensure air bag sensor assembly is in check mode. See CHECK MODE PROCEDURE under
DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
DTC 56/B1825, 56/B1826, 56/B1827, 56/B1828: RIGHT SIDE AIR BAG SQUIB CIRCUIT SHORT,
OPEN, SHORT TO GROUND OR SHORT TO BATTERY
Possible Causes
ground, open, short or short to battery in right side air bag squib circuit, squib malfunction or air bag sensor
assembly malfunction.
NOTE:

Microsoft
Tuesday, July 21, 2009 4:34:46 PM
Page 60
2004 Toyota RAV4

SPRING under DIAGNOSTICS. Measure resistance between Yellow/Red wire (circuit SFP+) and
Yellow/Green wire (circuit SFP-) on harness side of right side air bag module connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, replace wire harness between right side air bag
module and air bag sensor assembly. If resistance is more than one megohm, go to step 8 .
3. Measure resistance between Yellow/Red wire (circuit SFP+) and Yellow/Green wire (circuit SFP-) on
harness side of right side air bag module connector. See WIRING DIAGRAMS . If resistance is less
than one ohm, go to step 9 . If resistance is more than one ohm, replace wire harness between right side
air bag module and air bag sensor assembly.
4. Measure resistance between ground and Yellow/Red wire (circuit SFP+) on harness side of right side air
bag module connector. See WIRING DIAGRAMS . Measure resistance between ground and
Yellow/Green (circuit SFP-) wire on harness side of right side air bag module connector. If resistance is
more than one megohm, go to step 9 . If resistance is less than one megohm, replace wire harness
between right side air bag module and air bag sensor assembly.
voltage between ground and Yellow/Red wire (circuit SFP+) on harness side of right side air bag module
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Green wire
(circuit SFP-) on harness side of right side air bag module connector. If voltage is less than one volt, go to
step 9 . If voltage is more than one volt, replace wire harness between right side air bag module and air
bag sensor assembly.
voltage between ground and Yellow/Red wire (circuit SFP+) on harness side of right side air bag module
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Green wire
(circuit SFP-) on harness side of right side air bag module connector. Voltage should be less than one
seconds. Measure resistance between Yellow/Red wire and Yellow/Green wire on harness side of right
side air bag module connector. Resistance should be less than one ohm. Measure resistance between
ground and Yellow/Red wire on harness side of right side air bag module connector. Measure resistance
between ground and Yellow/Green wire on harness side of right side air bag module connector.
assembly connector C8. See RELEASING SHORT SPRING under DIAGNOSTICS. Measure
resistance between Yellow/Red wire and Yellow/Green wire on harness side of right side air bag module
connector. Resistance should be more than one megohm. If voltage and resistance readings are normal, go
to next step. If voltage and resistance readings are not normal, replace wire harness between right side air
bag module and air bag sensor assembly.
7. Replace right side air bag module. See SIDE AIR BAG MODULE under REMOVAL &
Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 61
2004 Toyota RAV4

complete.
Connect jumper wire between Yellow/Red wire and Yellow/Green wire on harness side of right side air
bag module connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
sent here from step 9 , remove jumper wire. If sent here from any step, connect right side air bag module
B1826, B1827 or B1828 are displayed, replace right side air bag module. See SIDE AIR BAG
MODULE under REMOVAL & INSTALLATION. If DTC B1825, B1826, B1827 or B1828 are not
displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE PROCEDURE under
DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
DTC 57/B1830, 57/B1831, 57/B1832, 57/B1833: LEFT SIDE CURTAIN AIR BAG SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in left side curtain air bag squib circuit, squib malfunction or air bag
sensor assembly malfunction.
NOTE:

Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 62
2004 Toyota RAV4

2.
3.
4.
5.
6.
7.
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Violet wire (circuit ICD+) and
Yellow/Orange wire (circuit ICD-) on harness side of left side curtain air bag module connector. See
WIRING DIAGRAMS . If resistance is less than one megohm, replace wire harness between left side
curtain air bag module and air bag sensor assembly. If resistance is more than one megohm, go to step 8 .
Measure resistance between Yellow/Violet wire (circuit ICD+) and Yellow/Orange wire (circuit ICD-) on
less than one ohm, go to step 9 . If resistance is more than one ohm, replace wire harness between left
side curtain air bag module and air bag sensor assembly.
Measure resistance between ground and Yellow/Violet wire (circuit ICD+) on harness side of left side
Yellow/Orange (circuit ICD-) wire on harness side of left side curtain air bag module connector. If
harness between left side curtain air bag module and air bag sensor assembly.
voltage between ground and Yellow/Violet wire (circuit ICD+) on harness side of left side curtain air bag
module connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow/Orange
wire (circuit ICD-) on harness side of left side curtain air bag module connector. If voltage is less than
one volt, go to step 9 . If voltage is more than one volt, replace wire harness between left side curtain air
bag module and air bag sensor assembly.
voltage between ground and Yellow/Violet wire (circuit ICD+) on harness side of left side curtain air bag
wire (circuit ICD-) on harness side of left side curtain air bag module connector. Voltage should be less
90 seconds. Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of
left side curtain air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Violet wire on harness side of left side curtain air bag module connector.
Measure resistance between ground and Yellow/Orange wire on harness side of left side curtain air bag
Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of left side
curtain air bag module connector. Resistance should be more than one megohm. If voltage and resistance
harness between left side curtain air bag module and air bag sensor assembly.
Replace left side curtain air bag module. See SIDE CURTAIN AIR BAG MODULE under REMOVAL
& INSTALLATION. Reconnect air bag sensor assembly harness connectors. Turn ignition switch to ON
Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 63
2004 Toyota RAV4

complete.
Connect jumper wire between Yellow/Violet wire and Yellow/Orange wire on harness side of left side
B1831, B1832 or B1833 are displayed, replace left side curtain air bag module. See SIDE CURTAIN
AIR BAG MODULE under REMOVAL & INSTALLATION. If DTC B1830, B1831, B1832 or B1833
are not displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE
WARNING LIGHT INTERMITTENT .
DTC 58/B1835, 58/B1836, 58/B1837, 58/B1838: RIGHT SIDE CURTAIN AIR BAG SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in right side curtain air bag squib circuit, squib malfunction or air bag
NOTE:

Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 64
2004 Toyota RAV4

2.
3.
4.
5.
6.
7.
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Violet wire (circuit ICP+) and
Yellow/Orange wire (circuit ICP-) on harness side of left side curtain air bag module connector. See
WIRING DIAGRAMS . If resistance is less than one megohm, replace wire harness between right side
curtain air bag module and air bag sensor assembly. If resistance is more than one megohm, go to step 8 .
Measure resistance between Yellow/Violet wire (circuit ICP+) and Yellow/Orange wire (circuit ICP-) on
less than one ohm, go to step 9 . If resistance is more than one ohm, replace wire harness between right
side curtain air bag module and air bag sensor assembly.
Measure resistance between ground and Yellow/Violet wire (circuit ICP+) on harness side of left side
Yellow/Orange (circuit ICP-) wire on harness side of left side curtain air bag module connector. If
harness between right side curtain air bag module and air bag sensor assembly.
voltage between ground and Yellow/Violet wire (circuit ICP+) on harness side of left side curtain air bag
wire (circuit ICP-) on harness side of left side curtain air bag module connector. If voltage is less than one
volt, go to step 9 . If voltage is more than one volt, replace wire harness between right side curtain air bag
module and air bag sensor assembly.
voltage between ground and Yellow/Violet wire (circuit ICP+) on harness side of left side curtain air bag
wire (circuit ICP-) on harness side of left side curtain air bag module connector. Voltage should be less
90 seconds. Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of
left side curtain air bag module connector. Resistance should be less than one ohm. Measure resistance
between ground and Yellow/Violet wire on harness side of left side curtain air bag module connector.
Measure resistance between ground and Yellow/Orange wire on harness side of left side curtain air bag
Measure resistance between Yellow/Violet wire and Yellow/Orange wire on harness side of left side
curtain air bag module connector. Resistance should be more than one megohm. If voltage and resistance
harness between right side curtain air bag module and air bag sensor assembly.
Replace right side curtain air bag module. See SIDE CURTAIN AIR BAG MODULE under
Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 65
2004 Toyota RAV4


Connect jumper wire between Yellow/Violet wire and Yellow/Orange wire on harness side of left side
B1836, B1837 or B1838 are displayed, replace right side curtain air bag module. See SIDE CURTAIN
AIR BAG MODULE under REMOVAL & INSTALLATION. If DTC B1835, B1836, B1837 or B1838
are not displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE
WARNING LIGHT INTERMITTENT .
DTC 73/B1900, 73/B1901, 73/B1902, 73/B1903: LEFT SEAT BELT PRETENSIONER SQUIB CIRCUIT
Possible Causes
ground, open, short or short to battery in left seat belt pretensioner squib circuit, squib malfunction or air bag
NOTE:

Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 66
2004 Toyota RAV4

2.
3.
4.
5.
6.
7.
8.
Inspect left seat belt pretensioner connector for disengaged lock button or deformed or damaged lock
claw. If connectors are okay, go to next step. If connectors are not okay, replace wire harness between left
seat belt pretensioner and air bag sensor assembly.
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire (circuit PD+) and
Yellow wire (circuit PD-) on harness side of left seat belt pretensioner connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, replace wire harness between left seat belt
pretensioner and air bag sensor assembly. If resistance is more than one megohm, go to step 10 .
Measure resistance between Yellow/Black wire (circuit PD+) and Yellow wire (circuit PD-) on harness
side of left seat belt pretensioner connector. See WIRING DIAGRAMS . If resistance is less than one
ohm, go to step 11 . If resistance is more than one ohm, replace wire harness between left seat belt
pretensioner and air bag sensor assembly.
Measure resistance between ground and Yellow/Black wire (circuit PD+) on harness side of left seat belt
pretensioner connector. See WIRING DIAGRAMS . Measure resistance between ground and Yellow
(circuit PD-) wire on harness side of left seat belt pretensioner connector. If resistance is more than one
megohm, go to step 11 . If resistance is less than one megohm, replace wire harness between left seat belt
voltage between ground and Yellow/Black wire (circuit PD+) on harness side of left seat belt pretensioner
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire (circuit PD-)
on harness side of left seat belt pretensioner connector. If voltage is less than one volt, go to step 11 . If
voltage is more than one volt, replace wire harness between left seat belt pretensioner and air bag sensor
assembly.
Inspect left seat belt pretensioner connector for disengaged lock button or deformed or damaged lock
claw. If connectors are okay, go to next step. If connectors are not okay, replace wire harness between left
seat belt pretensioner and air bag sensor assembly.
voltage between ground and Yellow/Black wire (circuit PD+) on harness side of left seat belt pretensioner
connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire (circuit PD-)
on harness side of left seat belt pretensioner connector. Voltage should be less than one volt. Turn
ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds.
Measure resistance between Yellow/Black wire and Yellow wire on harness side of left seat belt
pretensioner connector. Resistance should be less than one ohm. Measure resistance between ground and
Yellow/Black wire on harness side of left seat belt pretensioner connector. Measure resistance between
ground and Yellow wire on harness side of left seat belt pretensioner connector. Resistance should be
more than one megohm. Release short spring mechanism on air bag sensor assembly connector C6. See
RELEASING SHORT SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black
wire and Yellow wire on harness side of left seat belt pretensioner connector. Resistance should be more
than one megohm. If voltage and resistance readings are normal, go to next step. If voltage and resistance
readings are not normal, replace wire harness between left seat belt pretensioner and air bag sensor
assembly.
Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 67
2004 Toyota RAV4

9. Replace left seat belt pretensioner. See SEAT BELT PRETENSIONER under REMOVAL &
complete.
Connect jumper wire between Yellow/Black wire and Yellow wire on harness side of left seat belt
pretensioner connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
B1901, B1902 or B1903 are displayed, replace left seat belt pretensioner. See SEAT BELT
PRETENSIONER under REMOVAL & INSTALLATION. If DTC B1900, B1901, B1902 or B1903 are
not displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE PROCEDURE
under DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
DTC 74/B1905, 74/B1906, 74/B1907, 74/B1908: RIGHT SEAT BELT PRETENSIONER SQUIB
CIRCUIT SHORT, OPEN, SHORT TO GROUND OR SHORT TO BATTERY
Possible Causes
ground, open, short or short to battery in right seat belt pretensioner squib circuit, squib malfunction or air bag
NOTE:

Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 68
2004 Toyota RAV4

2. Inspect right seat belt pretensioner connector for disengaged lock button or deformed or damaged lock
claw. If connectors are okay, go to next step. If connectors are not okay, replace right seat belt
SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire (circuit PP+) and
Yellow wire (circuit PP-) on harness side of right seat belt pretensioner connector. See WIRING
DIAGRAMS . If resistance is less than one megohm, replace wire harness between right seat belt
pretensioner and air bag sensor assembly. If resistance is more than one megohm, go to step 10 .
4. Measure resistance between Yellow/Black wire (circuit PP+) and Yellow wire (circuit PP-) on harness
side of right seat belt pretensioner connector. See WIRING DIAGRAMS . If resistance is less than one
ohm, go to step 11 . If resistance is more than one ohm, replace wire harness between right seat belt
5. Measure resistance between ground and Yellow/Black wire (circuit PP+) on harness side of right seat belt
pretensioner connector. See WIRING DIAGRAMS . Measure resistance between ground and Yellow
(circuit PP-) wire on harness side of right seat belt pretensioner connector. If resistance is more than one
megohm, go to step 10 . If resistance is less than one megohm, replace wire harness between right seat
belt pretensioner and air bag sensor assembly.
voltage between ground and Yellow/Black wire (circuit PP+) on harness side of right seat belt
pretensioner connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire
(circuit PP-) on harness side of right seat belt pretensioner connector. If voltage is less than one volt, go to
step 11 . If voltage is more than one volt, replace wire harness between right seat belt pretensioner and air
bag sensor assembly.
7. Inspect right seat belt pretensioner connector for disengaged lock button or deformed or damaged lock
claw. If connectors are okay, go to next step. If connectors are not okay, replace right seat belt
voltage between ground and Yellow/Black wire (circuit PP+) on harness side of right seat belt
pretensioner connector. See WIRING DIAGRAMS . Measure voltage between ground and Yellow wire
(circuit PP-) on harness side of right seat belt pretensioner connector. Voltage should be less than one
seconds. Measure resistance between Yellow/Black wire and Yellow wire on harness side of right seat
belt pretensioner connector. Resistance should be less than one ohm. Measure resistance between ground
and Yellow/Black wire on harness side of right seat belt pretensioner connector. Measure resistance
between ground and Yellow wire on harness side of right seat belt pretensioner connector. Resistance
should be more than one megohm. Release short spring mechanism on air bag sensor assembly connector
C8. See RELEASING SHORT SPRING under DIAGNOSTICS. Measure resistance between
Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 69
2004 Toyota RAV4

9.
10.
11.
12.
Yellow/Black wire and Yellow wire on harness side of right seat belt pretensioner connector. Resistance
should be more than one megohm. If voltage and resistance readings are normal, go to next step. If
voltage and resistance readings are not normal, replace wire harness between right seat belt pretensioner
and air bag sensor assembly.
Replace right seat belt pretensioner. See SEAT BELT PRETENSIONER under REMOVAL &
complete.
If sent here from step 6 , turn ignition switch to LOCK position. Disconnect negative battery cable and
Connect jumper wire between Yellow/Black wire and Yellow wire on harness side of right seat belt
pretensioner connector. See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2
Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds. If
B1906, B1907 or B1908 are displayed, replace right seat belt pretensioner. See SEAT BELT
PRETENSIONER under REMOVAL & INSTALLATION. If DTC B1905, B1906, B1907 or B1908 are
not displayed, ensure air bag sensor assembly is in check mode. See CHECK MODE PROCEDURE
under DIAGNOSTICS. Check for intermittent air bag system fault. See AIR BAG WARNING LIGHT
INTERMITTENT .
WIRING DIAGRAMS
Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 70
2004 Toyota RAV4

Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 71
2004 Toyota RAV4

Fig. 22: Air Bag System Wiring Diagram (RAV4-1 Of 2)
Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 72
2004 Toyota RAV4

Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 73
2004 Toyota RAV4

Fig. 23: Air Bag System Wiring Diagram (RAV4-2 Of 2)
Microsoft
Tuesday, July 21, 2009 4:34:47 PM
Page 74

Air Bag

Uploaded by

Copyright:

Available Formats

Air Bag

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Air Bag

Uploaded by

Copyright:

Available Formats

2004 Toyota RAV4

2004 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

2004 ACCESSORIES/SAFETY EQUIPMENT

DESCRIPTION & OPERATION

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

Fig. 1: Locating Restraint System Components (1 Of 2)

Fig. 2: Locating Restraint System Components (2 Of 2)

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

SYSTEM OPERATION CHECK

AIR BAG SAFETY PRECAUTIONS

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

DISABLING & ACTIVATING AIR BAG SYSTEM

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

Fig. 3: Disconnecting Passenger-side Air Bag Module Connector

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

Fig. 4: Securing Wire To Driver-side Air Bag Module

Fig. 5: Securing Driver-side Air Bag Module To Wheel

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

Fig. 6: Preparing Passenger-side Air Bag Module For Deployment

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

Side AIR Bag Module

Fig. 7: Securing Wire To Side Air Bag Module

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

Fig. 8: Preparing Air Bag Inflator For Deployment

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

Fig. 9: Deploying Seat Belt Pretensioner

REMOVAL & INSTALLATION

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

See AIR BAG SAFETY PRECAUTIONS . After component replacement,

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

Fig. 10: Identifying Air Bag Sensor Assembly

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

Fig. 11: Identifying Driver-side Air Bag Module Torx Screws

2005 Mitchell Repair Information Company, LLC.

2004 Toyota RAV4

FRONT AIR BAG SENSOR

Fig. 12: Identifying Front Air Bag Sensors