This procedure replaces a side airbag module (seat-mounted or door-mounted) on a 2019-2024 Toyota RAV4 2.5L I4. Side airbags are critical safety devices that must be handled carefully and the SRS system must be properly reset after replacement.

Warnings

Tools required

Parts

• Side airbag module (seat-mounted or side curtain airbag) × 1 — Use OEM specification - Toyota part varies by trim level and position
• Seat trim clips (if damaged during removal) × 3 — Use OEM specification

Preparation

1. Ensure ignition is OFF and key is removed from vehicle. For push-button start, ensure smart key is at least 10 feet away from vehicle
2. Disconnect negative battery terminal first, then positive terminal. Insulate terminals to prevent accidental contact
3. Wait minimum 90 seconds for SRS backup capacitor to discharge completely. Set timer to ensure full wait time
4. Identify which side airbag is being replaced (driver/passenger, seat-mounted or curtain). This procedure covers seat-mounted side airbags
5. Position seat to mid-travel for easiest access to mounting bolts
6. Photograph airbag connector orientation and wiring routing before removal for reference during reinstallation

Procedure

1. 1

   Remove seat from vehicle
   Slide seat fully rearward. Remove front seat mounting bolt plastic covers. Use 14mm socket to remove the two front seat mounting bolts. Slide seat fully forward and remove the two rear seat mounting bolts. Carefully tilt seat back and locate the seat wiring harness connector under the seat (power connector if equipped). Press release tab and disconnect. Carefully lift seat out of vehicle and place on protected work surface. Handle carefully to avoid jarring the airbag module.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
2. 2

   Remove seat side trim panel
   Locate the trim panel on the outboard side of the seat where the side airbag is housed (usually in the seat backrest bolster). Identify and remove any visible screws at the bottom or rear of the trim panel. Use plastic trim removal tools to carefully release the retaining clips securing the trim panel. Work slowly around the perimeter to avoid breaking clips. Remove the trim panel to expose the side airbag module mounted within the seat frame.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Disconnect side airbag connector
   Locate the side airbag module electrical connector. This is typically a yellow connector with a locking mechanism (yellow indicates SRS components). Note the exact routing and connector orientation. Slide or press the connector lock (design varies - may be sliding tab or press-release). Carefully disconnect the airbag connector from the module. Do NOT pull on wires. Use a zip tie or wire to secure the connector away from the deployment zone to prevent accidental contact during module removal.
4. 4

   Remove side airbag module mounting bolts
   Locate the side airbag module mounting bolts (typically 2-4 Torx bolts). These are usually T30 or T40 Torx head bolts. Remove each bolt carefully and retain for inspection. If bolts show any thread damage or stretching, replace with new OEM bolts. Carefully pull the airbag module from its mounting position within the seat frame. Keep deployment surface (cushion side) facing UP at all times. Place removed airbag on clean surface, deployment side UP, away from work area.
   Torque spec

   Side Airbag Module Bolts7 Nm (5 lb-ft)
5. 5

   Inspect mounting area and prepare new module
   Inspect the airbag mounting bracket within the seat frame for any damage, cracks, or deformation. Check that mounting threads are clean and undamaged. Inspect the wiring harness for any chafing, cuts, or damage. Verify the deployment path through the seat cover has no obstructions or modifications. Unpack the new side airbag module carefully. Verify part number matches the original. Check that the connector is clean and free of debris. Never connect power or test the new airbag with electrical equipment.
6. 6

   Install new side airbag module
   Position the new side airbag module into the seat frame mounting location, ensuring proper orientation (verify deployment side faces outboard toward seat cover). Align the mounting holes carefully. Insert the Torx mounting bolts by hand and thread in at least 3-4 turns to ensure proper engagement. Using a calibrated torque wrench, tighten the side airbag module bolts to exactly 7.0 Nm (5.0 lb-ft) in a crossing pattern (if 4 bolts) or evenly (if 2 bolts). This torque is critical - over-tightening can damage module housing, under-tightening can allow module movement during deployment.
   Torque spec

   Side Airbag Module Bolts7 Nm (5 lb-ft)
7. 7

   Reconnect airbag electrical connector
   Route the airbag wiring harness connector back to the module following the original path documented in preparation photos. Ensure no sharp bends or pinch points in wiring. Align the yellow SRS connector with the airbag module connector socket. Push firmly until you hear/feel a distinct click. Verify the locking mechanism is fully engaged. Tug gently on connector (not wires) to confirm secure connection. Ensure no wires are trapped between module and seat frame.
8. 8

   Reinstall seat side trim panel
   Verify airbag deployment path through seat cover seam is clear and properly aligned. Position the side trim panel back onto the seat, aligning all mounting points and clips. Press firmly around the perimeter to engage all retaining clips - you should hear/feel each clip snap into place. Install any mounting screws removed earlier and torque to 11.0 Nm (8.0 lb-ft) if covered in torque specs, or hand-tighten plus 1/4 turn if decorative plastic screws. Verify trim panel is flush and secure with no gaps.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
9. 9

   Reinstall seat in vehicle
   Carefully lift the seat and position it into the vehicle. Before bolting down, reconnect the seat wiring harness connector (if equipped with power seats or seat sensors). Align the seat mounting holes with floor brackets. Install all four seat mounting bolts hand-tight first. Using a calibrated torque wrench, torque each seat mounting bolt to exactly 61.0 Nm (45 lb-ft) in a crossing pattern (front left, rear right, front right, rear left). This is a safety-critical torque specification. Install seat mounting bolt covers.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
10. 10

    Reconnect battery and perform system check
    Reconnect positive battery terminal first, then negative terminal. Ensure connections are tight. Turn ignition to ON position (do not start engine). Observe the SRS warning light on instrument cluster - it should illuminate for approximately 6 seconds during bulb check, then may remain illuminated indicating stored diagnostic codes. Connect Toyota Techstream or equivalent professional SRS diagnostic scanner. Clear any stored SRS codes related to the side airbag replacement. Perform SRS system verification test through scanner to confirm proper communication with all airbag modules.
11. 11

    Verify SRS system operation
    Using the diagnostic scanner, verify the new side airbag module is communicating properly and showing no fault codes. Perform a complete SRS system check including all airbags and sensors. If any codes remain, diagnose before returning vehicle to service. Once all codes are cleared and system verification passes, turn ignition OFF then back to ON. Confirm SRS warning light performs normal bulb check (illuminates briefly then extinguishes). If SRS light remains on, do NOT return vehicle to service - further diagnosis required.

Reassembly

1. Verify seat operates normally through full range of motion (if power seat equipped) without binding or unusual sounds
2. Check that seat trim panel is properly secured with no gaps that could interfere with airbag deployment
3. Confirm seat belt buckle and pretensioner (if equipped) are properly routed and functional
4. Test seat position adjustment (manual or power) to ensure mounting bolts are properly torqued and seat is stable

Verification

• SRS warning light must illuminate briefly during ignition ON bulb check, then extinguish completely within 6 seconds
• Diagnostic scanner shows no active or stored SRS fault codes after clearing and re-checking
• All four seat mounting bolts verified torqued to exactly 61.0 Nm (45 lb-ft) using calibrated torque wrench
• Side airbag module bolts verified torqued to exactly 7.0 Nm (5.0 lb-ft) using calibrated torque wrench
• Physical inspection confirms no gaps in seat trim that could obstruct airbag deployment path
• Yellow SRS connector lock is fully engaged with positive click confirmation
• Seat stability test: push firmly on seat back and bottom - no movement at mounting points
• Professional diagnostic scanner confirms new side airbag module is communicating and ready status

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