TOYOTA RAV4 2006 - TRAILER WIRE HARNESS

Section I – Installation Preparation

Part Number: 08921-42900 NOTE: Part number of this accessory may not be
the same as the part number shown.
Kit Contents
Item # Quantity Reqd. Description Special Chemicals Notes
1 1 Converter
2 1 Wire harness
3 1 Sub wire harness No.1 General Applicability
4 2 Plastic Tie (300mm)
5 21 Plastic Tie (150mm) Recommended Sequence of Application
6 1 Plastic Tie Item # Accessory
7 5 Packing 1 Trailer Hitch*
8 1 Bolt (M6) 2 Trailer Wire Harness
9 2 Bolt (M5)
10 1 Connector clip *Mandatory
11 1 Nut (M6)
12 1 Owner’s manual Vehicle Service Parts (may be required for reassembly)
13 1 Fuse (30A) Item # Quantity Reqd. Description
14 1 Sub wire harness No.2 1
15 1 Fuse (15A) 2
16 1 Label 3

Hardware Bag Contents Legend

Item # Quantity Reqd. Description
STOP: Damage to the vehicle may occur. Do not
proceed until process has been complied with.
Additional Items Required For Installation OPERATOR SAFETY: Use caution to avoid risk of
Item # Quantity Reqd. Description injury.
CAUTION: A process that must be carefully observed
in order to reduce the risk of damage to the
Conflicts accessory/vehicle and to ensure a quality installation.
TOOLS & EQUIPMENT: Used in Figures calls out the
Recommended Tools specific tools and equipment recommended for this
process.
Personal & Vehicle Notes REVISION MARK: This mark highlights a change in
Protection installation with respect to previous issue.
Safety Goggles
Seat Covers
Floor Protectors

Special Tools Notes

L.E.D. Tester S.S.T. 00002-62195

Installation Tools Notes

Torque Wrench
Ratchet 3/8” Drive
6” Extension
8mm Socket
10mm Socket
14mm Socket
Clip Removal Tool
Nylon Removal Tool
Nipper
061896-1150
Screw driver
Slot Precision Screw Driver (52100105E)

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Section I – Installation Preparation

Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this
accessory should follow approved guidelines to ensure quality installation.

These guidelines can be found in the “Accessory Installation Practices” document.

This document covers such items as:

• Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.).
• Safety (eye protection, rechecking torque procedure, etc.).
• Vehicle Disassembly/Reassembly (panel removal, part storage, etc.).
• Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.).

Please see your Toyota dealer for a copy of this document

1. Supplemental Restraint System SRS

(a) Failure to carry out procedures listed below

could result in possible deployment of
airbag, personal injury, or unnecessary
repairs to SRS.

(b) Turn the key switch to the LOCK position.

(Fig. 1)

(c) Remove the key from the ignition switch.

(d) Disconnect the negative battery cable.

(Fig. 2)

(e) Never use a voltmeter to trouble shoot any of

Accidentally probing the connectors to the
SRS can lead to deployment of the airbag.
(Fig 3)

(f) SRS wire harness loom/cover is bright

yellow in color.

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Section I – Installation Preparation
2. Wiring Precautions

(a) DO NOT pull on vehicle wires and/or

wireharness. To uncouple electrical
connectors, pull only on the connector itself.
(Fig. 4)

(b) Use nylon ties and adhesive foam strips to

secure the vehicle harness and the trailer wire
harness.

(c) Ensure all wires are properly insulated from

ground.

(d) When installing the trailer wire harness make

sure it is not cut or perforated by any sharp
metal objects.

3. General Practices and Procedures

(a) Before starting installation, refer to the

supplemental restraint system procedures in
Section 1.

(b) Take care not to scratch any part of the

vehicle. Bind the tips of tools (clip remover,
slot screw driver, etc.) with vinyl tape to
prevent damage to any part of the car, or use
a nylon removal tool (resin based prying
tool). (Fig. 5)

(c) Use a small parts container to store removed

bolts and tapping screws so that they can be
reassembled correctly.

(d) Ensure seat/floor protectors are in position.

(e) After fastening plastic ties, clip away all the

excess of the ties using diagonal pliers.
(Fig. 6)

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Section I – Installation Preparation

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Section I – Installation Preparation

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Section II – Installation Procedure
1. Parts Removal No.1

(a) Before installation, remove the negative (-)

terminal of the battery.

(b) Lower finish panel.

(1) Remove 2 screws from lower finish panel

and remove lower finish panel. (Fig. 1-1)

(c) Junction block cover.

(1) Remove junction block cover. (Fig. 1-2)

(d) Front scuff plate (LH).

(1) Remove front scuff plate (LH). (Fig. 1-3)

(e) Cowl side trim (LH).

(1) Remove the clip from cowl side trim (LH)

by turning it counter clockwise. Remove
cowl side trim (LH). (Fig. 1-4)

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Section II – Installation Procedure
(f) Rear scuff plate (LH).

(1) Remove rear scuff plate (LH).

(Fig. 1-5)

(g) Center pillar garnish (LH).

(1) Remove the bolt from center pillar garnish

(LH) and remove center pillar garnish
(LH). (Fig. 1-6)
(h) Upon reassembly, tighten the bolt with 42.0
N·m [374 lbf·in] of torque. (Fig. 1-6)

(i) Vehicle without third seats only (j).

(j) Separation net.

(1) Remove separation net.

(Fig. 1-7)

(k) Vehicle without third seats only (l).

(l) Tonneau cover.

(1) Remove tonneau cover. (Fig. 1-8)

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Section II – Installation Procedure

(m) Second seats (RH, LH).

(1) Move the second seats (RH, LH) forward

as shown.
(Fig. 1-9)

(n) Vehicle with third seats only (o).

(o) Third seats (RH, LH).

(1) Move the third seat (RH, LH) forward as

shown.
(Fig. 1-10)

(p) Vehicle without third seats only (q).

(q) Rear deck board No. 1.

(1) Remove rear deck board No. 1.

(Fig. 1-11)

(r) Vehicle without third seats only (s).

(s) Rear deck board No. 2.

(1) Remove rear deck board No. 2.

(Fig. 1-12)

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Section II – Installation Procedure
(t) Vehicle without third seats only (u).

(u) Luggage compartment tray.

(1) Remove luggage compartment tray.

(Fig. 1-13)

(v) Vehicle with third seats only (w).

(w) Rear deck floor board.

(1) Remove rear dock floor board. (Fig. 1-14)

(x) Rear side deck board (LH).

(1) Remove rear side deck board (LH).

(Fig. 1-15)

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Section II – Installation Procedure

2. Parts Removal No.2

(a) Rear floor finish plate.

(1) Remove rear floor finish plate.

(Fig. 2-1)

(b) Vehicle without third seats only (c)-(d).

(c) Deck side trim panel (LH).

(1) Remove rear seat back lever cover and cap

from deck side trim panel.
(2) Remove 3 bolts from deck side trim panel
(LH) and remove deck side trim cover.
(d) Upon reassembly, tighten the bolt with 42.0
N·m [374 lbf·in] of torque. (Fig. 2-2)

(e) Vehicle without third seats only (f).

(f) Deck side trim panel (LH).

(1) Remove deck side trim panel (LH).

(Fig. 2-3)

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Section II – Installation Procedure
(g) Vehicle with third seats only (h)-(i).

(h) Deck side trim panel (LH).

(1) Remove cap from deck side trim panel.

(2) Remove 3 bolts from deck side trim panel.
(LH) and remove deck side trim cover.
(Fig. 2-4)
(i) Upon reassembly, tighten the bolt with: 42.0
N·m [374 lbf·in] of torque. (Fig. 2-4)

(j) Vehicle with third seats only (k).

(k) Remove 2 screws and 1 bolt from deck side

trim panel (LH). (Fig. 2-5)

(l) Vehicle with third seats only (m).

(m) Third seat (LH).

(1) Move the third seat (LH) forward as

shown. (Fig. 2-6)

(n) Vehicle with third seats only (o).

VEHICLE WITH THIRD SEATS (o) Deck side trim panel (LH).

(1) Remove deck side trim panel (LH).

(Fig. 2-7)

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Section II – Installation Procedure
(p) Vehicle with third seat only (q).

(q) Third seats. Move the third seat (LH)

backwards as shown. (Fig. 2-8)

(1) Remove deck side trim panel (LH).

PB220023.jpg (Fig. 2-8)

(r) Vehicle grommet.

(1) Remove vehicle grommet. (Fig. 2-9)

(s) Vehicle clips.

(1) Remove vehicle clips. (Fig. 2-9)

(t) Vehicle without third seat only (u).

(u) Seat back lever.

(1) Remove 2 bolts from seat back lever and

leave the cable attached. Wrap in cloth.
(Fig. 2-10)
(2) Upon reassembly, tighten the bolt with
18.0 N·m [160 lbf·in] of torque.
(Fig. 2-10)
3. Converter installation
Fig. 2-10
(a) Install the converter to the vehicle hole with a
bolt (M6) (included in kit) and nut (M6)
(included in kit). (Fig. 3-1)

(b) Upon reassembly, tighten the bolt with 5.5

N·m [49 lbf·in] of torque. (Fig. 3-1)

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Section II – Installation Procedure
4. Wire harness installation No. 1

(a) Securing wire harness.

(1) Tie the wire harness and vehicle harness at

their branch points so that they are secured
in a bundle with a plastic tie (150 mm).
(2) Secure wire harness to vehicle harness
with a plastic tie (150mm) as shown.
(Fig. 4-1)
(b) Connecting wire harness (10P).

(1) Connect the wire harness (10P) to the con-

verter (10P). (Fig. 4-2)

(c) Securing wire harness.

(1) Secure the wire harness to the vehicle har-

ness with two plastic ties (150mm).
(Fig. 4-3)

(d) Routing of wire harness.

(1) Route the wire harness as shown.

(Fig. 4-4)
(e) Route the wire harness to the vehicle harness,
fasten the wire harness ground terminal to the
ground bolt (original bolt).

(f) Tighten the bolt with: 8.5 N·m [75lbf·in] of

torque. (Fig. 4-4)

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Section II – Installation Procedure
(g) Routing of wire harness.

(1) Route the wire harness as shown.

(Fig. 4-5)

(h) Securing wire harness.

(1) Lift the 2 vehicle clamps and route the

wire harness (1P) along the vehicle
harness. (Fig. 4-6)

(i) Routing of wire harness.

(1) Route the wire harness as shown.

(Fig. 4-7)

(j) Securing wire harness.

(1) Lift the 3 vehicle clamps and route the

wire harness along the vehicle harness.
(Fig. 4-8)

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Section II – Installation Procedure
(k) Routing of wire harness.

(1) Route the wire harness as shown.

(Fig. 4-9)

(l) Routing of wire harness.

(1) Route the wire harness as shown.

(Fig. 4-10)

(m) Disconnect the rear junction block connector

(18P).
(Fig. 4-11)

(n) Route the wire harness as shown and connect

it to the junction block connector (18P).
(Fig. 4-12)

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Section II – Installation Procedure
(o) Securing wire harness.

(1) Secure the wire harness to the vehicle

harness with a plastic tie (150mm).
(Fig. 4-13)

(p) With towing package only (q).

(q) Connect the wire harness connector (1P) to

the vehicle harness connector (1P).
(Fig. 4-14)

5. Sub wire harness No. 2 installation

(a) Without towing package only (b).

(b) Connecting the wire harness connector (1P)

to the sub wire harness No. 2 connector (1P).
(Fig. 5-1)

(c) Without towing package only (d).

(d) Disconnect the vehicle connector (30P) at the

position of junction block as shown.
(Fig. 5-2)

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Section II – Installation Procedure

(e) Without towing package only (f).

(f) Insert the terminal of sub wire harness No. 2

into No. 2 of vehicle connector (30P).

(1) Remove connector cover.

(2) Lift the double hook of vehicle connector
(30P) with a slot precision screwdriver.
(Fig. 5-3)

(3) Insert the terminal of sub wire harness No.

2 into the position as shown.
(Fig. 5-4)
(4) Do not insert the terminal of sub wire har-
ness No. 2 into other connectors than the
connector No. 2.
(5) Put back the double hook to the original
position.
(Fig. 5-4)
(6) Connect the vehicle connector (30P) to the
original position.

(g) Without towing package only (h).

(h) Securing sub wire harness No. 2.

(1) Secure the sub wire harness No. 2 to the

vehicle harness with a plastic tie (150mm).
(Fig. 5-5)

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Section II – Installation Procedure
(i) Without towing package only (j).

(j) Securing sub wire harness No. 2.

(1) Secure the sub wire harness No. 2 and

wire Harness to the vehicle harness with
two plastic ties (150mm). (Fig. 5-6)

6. Wire harness installation No.2

(a) Securing wire harness.

(1) Secure the wire harness to the vehicle

harness with two plastic ties (150mm).
(Fig. 6-1)

(b) Securing wire harness.

(1) Secure the wire harness to the vehicle

harness with two plastic ties (150mm).
(Fig. 6-2)

(c) Securing wire harness.

(1) Secure the wire harness to the vehicle

harness with two plastic ties (150mm).
(Fig. 6-3)

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Section II – Installation Procedure
(d) Securing wire harness.

(1) Secure the wire harness to the vehicle

harness with three plastic ties (150mm).
(Fig. 6-4)

(e) Routing of wire harness.

(1) Route the wire harness as shown.

(Fig. 6-5)

(f) Disconnect the rear combination light (LH)

vehicle connector (6P).
(Fig. 6-6)

(g) Route the wire harness as shown and connect

it to the combination light (LH) vehicle
connector (6P).
(Fig. 6-7)

(h) Wrap a packing around the branch connector

connection.
(Fig. 6-7)

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Section II – Installation Procedure
(i) Wire harness routing and securing.

(1) Pass the wire harness through the vehicle

hole and fit wire harness grommet to the
vehicle hole.
(Fig. 6-8)

(j) Securing wire harness.

(1) Secure the wire harness to the vehicle

harness with four plastic ties (150mm).
(Fig. 6-9)

(k) Securing wire harness.

(1) Secure the wire harness to the vehicle

harness with a plastic tie (150 mm).
(Fig. 6-10)
(l) When the connector connection is not
secured as shown, deck side trim panel
cannot be reattached.

(m) Securing wire harness.

(1) Secure wire harness to vehicle body with

four packings as shown.
(Fig. 6-11)

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Section II – Installation Procedure
(n) After passing the wire harness (4P) connector
through the vehicle hole, assemble wire
harness (4P) connector and connector clip
(included in kit).
(Fig. 6-12)

(o) Confirm that the connector clip (included in

kit) and the connector are securely fitted.

(p) Connect the wire harness (4P) to the sub

wire harness No.1 (4P).
(Fig. 6-13)

(q) Securing wire harness clip.

(1) Secure the wire harness with 2 clips to the

vehicle body.
(Fig. 6-14)

7. Sub wire harness No. 1 installation

(a) Fastening flat (4P) connector

(1) Fasten flat (4P) connector with 2 bolts

(M5) (included in kit).
(Fig. 7-1)
(2) Torque bolts to: 3.9 N·m [36lbf·in]
(Fig. 7-1)

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Section II – Installation Procedure
(b) Tie the sub wire harness No. 1 and secure to
the trailer hitch with a plastic tie (300mm).
(Fig. 7-2)

(c) Secure the sub wire harness No.1 as shown to

bracket of the trailer hitch with the plastic tie.
(Fig. 7-3)

(d) Tie the sub wire harness No.1 and secure to

the trailer hitch with a plastic tie (300mm).
(Fig. 7-4)

(e) Secure the sub wire harness with a plastic tie

(300mm) so that it does not interfere with
trailer hitch.

8. Installing the fuse

(a) With towing package only (b).

(b) Relay box cover.

(1) Remove relay box cover.

(Fig. 8-1)

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Section II – Installation Procedure
(c) With towing package only (d)-(e).

(d) Install the fuse (30A) (included in kit) to the

position as shown.
(Fig. 8-2)

(e) Be sure to use a 30A fuse. Do not use a 15A

fuse.

(f) Without towing package only (g).

(g) Fuse box cover.

(1) Remove fuse box cover.

(Fig. 8-3)

(h) Without towing package only (i)-(j).

(i) Install the fuse (15A) (included in kit) to the

position as shown.
(Fig. 8-4)

(j) Be sure to use a 15A fuse. Do not use a 30A

fuse.

(k) Without towing package only (l).

(l) Apply label (included in kit) to the position

on the fuse box cover reverse side as shown.
(Fig8-5)

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Section II – Installation Procedure
(m) If the part of the fuel tank cable with yellow
tape comes off from the vehicle clamp, attach
it to the vehicle clamp.
(Fig. 8-6)

(n) Put Owner’s Manual into the glove box.

(o) Reconnect the vehicle’s negative battery

cable to original factory position.
(Fig. 8-7)

(1) Torque nut to: 3.9 N•m [36lbf•in].

(Fig. 8-7)
(2) Be careful not to touch the positive battery
cable. (Fig. 8-7)
9. Reinstallation.

(a) After functional verification, reinstall all

temporarily removed body parts.

(1) Tighten seatbelt bolt (center pillar

garnish) to 42 N-m (374 lbf-in) of torque.
(2) Tighten deck side trim panel bolts (LH)
to 42 N-m (374 lbf-in) of torque.
(3) Tighten seat back lever bolts to 18 N-m
(160 lbf-in) of torque.
(4) Tighten the converter bolt to 5.5 N-m
(49 lbf-in) of torque.

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Section III – Functional Verifications
Check: Look For:
Accessory Function Checks

Faults in the wiring harness installation. Correct routing of the wire harness.

Converter mounting. Pushing or pulling of the converter by any

outside force.
Wire harness Pinching of the wire harness.
Plastic tie locations. Positioning of the plastic tie locations.

Vehicle Function Checks

Removed parts.

With the Special Service Tool (SST) (Part Scratches or other damage
Number 00002-62195) attached to the
trailer sub wire harness plug and with the
engine running, perform the following steps:

Caution: Be sure the exhaust gas is

completely ventilated.

Caution: Be sure the vehicle is in “Park”

and that the parking brake is applied.

Turn on headlamps. Marker and tail lights on both SST and

vehicle are lit.
Turn on left turn signal. Left turn lights on both SST and vehicle are
flashing.
Turn on right turn signal. Right turn lights on both SST and vehicle
are flashing.
Apply foot brake. Stop lights on both SST and vehicle are lit.

Turn on left turn signal and apply foot Left turn lights are flashing and right stop
brake. Lights are lit on both SST and vehicle.
Turn on right turn signal and apply foot Right turn lights are flashing and right stop
brake. lights are lit on both SST and vehicle.

Turn on hazard lights switch. All turn signal lights are flashing on both
SST and vehicle.

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Section III – Functional Verifications
Check: Look For:

With hazard lights switch on, apply the foot Both stop lights on the vehicle are lit, both
brake. turn/stop lights on the SST and the turn
lights the vehicle are flashing.
Turn off the hazard light switch, apply the Both turn/stop lights on the SST and the
foot brake. stop lights on the vehicle are lit.
The following checks are to be performed
With the ignition switch off and the engine
Stopped.

Turn on headlamps. Marker and tail lights on both SST and

vehicles are lit.
Apply foot brake. Stop lights on both SST and vehicle are lit.

Turn on left turn signal. Left turn lights are not lit on both SST and
vehicle.
Turn on right turn signal. Right turn lights are not lit on both SST and
vehicle.

Turn on left turn signal and apply foot Both stop lights are lit and not flashing on
brake. both SST and vehicle.

Turn on right turn signal and apply foot Both stop lights are lit and not flashing on
brake. both SST and vehicle.

With hazard lights switch on, apply the foot All turn signal lights are flashing on both
brake. SST and vehicle.

Turn off the hazard light switch, apply foot Both stop lights on the vehicle and the
brake. turn/stop lights on the SST are lit but not
flashing.

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Section IV – Wiring Diagram

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Section IV – Wiring Diagram

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