TOYOTA AVENSIS 2002 Repair Manual

H42663
H42770
BatterySST(s)
H40007
10 m (33 ft) or more
SST(s)
60±48
±
SUPPLEMENTAL RESTRAINT SYSTEM FRONT SEAT AIRBAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(b)Remove the front seat assy LH (See page 72±16).
(c) Disconnect the front seat airbag connector.
NOTICE:
When handling the airbag connector, take care not to
damage the airbag wire harness.
(d) Install the SST(s). (1) Connect the connectors of the SST(s) to the front
seat airbag connector.
SST 09082±00700, 09082±00750
NOTICE:
To avoid damaging the SST(s) connector and wire harness,
do not lock the secondary lock of the twin lock.
(2) Move the SST(s) at least 10 m (33 ft) away from thefront of the vehicle.
(3) Close all the doors and windows of the vehicle.
NOTICE:
Take care not to damage the SST(s) wire harness. (4) Connect the red clip of the SST(s) to the batterypositive (+) terminal and the black clip of the SST(s)
to the battery negative (±) terminal.
(e) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a10 m (33 ft) radius of the vehicle.
(2) Press the activation switch in the SST(s) and deploy the airbag.
HINT:
The airbag is deploys as the LED of the SST(s) activation switch
comes on.
(f) Dispose the front seat airbag assy LH.
CAUTION:

The front seat airbag assy LH is extremely hot when
the airbag is deployed, so do not touch it for at least
30 minutes after deployment.

Use gloves and safety glasses when handling the
front seat airbag assy LH with the deployed airbag.

When moving the vehicle for scrapping which has the
front seat airbag assy LH with the deployed airbag,
use gloves and safety glasses.

Do not apply water, etc. to the front seat airbag assy
LH with the deployed airbag.

Always wash your hands with water after completing
the operation.

H40005
SST(s)Battery
H40008
Wire Harness
Diameter
Stripped Wire Harness Section
±
SUPPLEMENTAL RESTRAINT SYSTEM FRONT SEAT AIRBAG ASSY LH
60±49
AVENSIS REPAIR MANUAL (RM1018E)
HINT:
When scrapping a vehicle, deploy the airbag and scrap the ve-
hicle with the front seat airbag assy LH being installed.
2. DISPOSE OF FRONT SEAT AIRBAG ASSY LH (WHEN
DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT
METHOD)
NOTICE:

When disposing of the front seat airbag assy LH only,
never use the customer's vehicle to deploy the air-
bag.

Be sure to follow the procedure detailed below when
deploying the airbag.
HINT:
Prepare a battery as the power source to deploy the airbag.
(a)Check the function of the SST(s) (See step 1± (a) on page 60±19).
(b) Remove the front seat airbag assy LH. (1)Remove the front seat assy LH (See page 72±16).
(2) Remove the 2 nuts and the front seat airbag assy LH from the seatback assembly.
CAUTION:

When removing the front seat airbag assy LH, work
must be started 90 seconds after the ignition switch
is turned to the ºLOCKº position and the negative (±)
terminal cable is disconnected from the battery.

When storing the front seat airbag assy LH, keep the
upper surface of the airbag deployment side facing
upward.
(c) Using a service±purpose wire harness for the vehicle, tie down the front seat airbag assy LH to the tire.
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in2 or more)
HINT:
To calculate the square of the stripped wire harness section:
Square = 3.14 x (Diameter)
2 divided by 4
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the front seat airbag assy LH, it may be
snapped by the shock when the airbag is deployed. This is
highly dangerous. Always use a wire harness for vehicle
use which has a diameter at least 1.25 mm
2 (0.0019 in2).

H41437
H41438
H40526
H42897
SST(s)
60±50
± SUPPLEMENTAL RESTRAINT SYSTEMFRONT SEAT AIRBAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(1) Install the 2 nuts in the front seat airbag assy LH.
(2) Wind the wire harness around the stud bolts of the
front seat airbag assy LH as shown in the illustra-
tion.
(3) Position the front seat airbag assy LH inside the tire
with the airbag deployment direction facing inside.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:

Make sure the wire harness is tight. It is highly dan-
gerous when looseness in the wire harness results in
the front seat airbag assy LH coming free due to the
shock from the airbag deployment.

Always tie down the front seat airbag assy LH with the
airbag deployment direction facing inside the tire.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(d) Install the SST(s).
Connect the connector of SST(s) to the front seat airbag
assy LH connect.
SST 09082±00750

H42898
Tires
(5 or More)
SST(s)
H42763
SST(s)
H43006
Front Seat
Airbag Assy SST(s)
10 m (33ft) or more
Battery
± SUPPLEMENTAL RESTRAINT SYSTEMFRONT SEAT AIRBAG ASSY LH
60±51
AVENSIS REPAIR MANUAL (RM1018E)
(e) Place the tires.
(1) Place at least 2 tires under the tire to which the front
seat airbag assy LH is tied.
(2) Place at least 2 tires over the tire to which the front
seat airbag assy LH is tied. The top tire should have
the disc wheel installed.
NOTICE:
Do not place the SST(s) connector under the tire because
the SST(s) connector could be damaged.
(3) Tie the tires together with 2 wire harnesses.
CAUTION:
Make sure that the wire harness is tight. It is highly danger-
ous when looseness in the wire harness results in the tires
coming free due to the shock from the airbag deployment.
HINT:
Place the SST(s) connector and the wire harness inside tires.
Secure at least 1 m (3 ft) of slack for the wire harness.
(f) Install the SST(s).
Connect the connector of the SST(s).
SST 09082±00700
NOTICE:
To avoid damaging the SST(s) connector and wire harness,
do not lock the secondary lock of the twin lock. Also, se-
cure some slack for the SST(s) wire harness inside the tire.
(g) Deploy the airbag.
(1) Connect the red clip of the SST(s) to the battery
positive (+) terminal and the black clip of the SST(s)
to the battery negative (±) terminal.
(2) Check that no one is within a 10 m (33 ft) radius of
the tire to which the front seat airbag assy LH is tied.
(3) Press the activation switch of the SST(s) and
deploy the airbag.
HINT:
The airbag is deployed as the LED of the SST(s) activation
switch comes on.

H00544
60±52
± SUPPLEMENTAL RESTRAINT SYSTEMFRONT SEAT AIRBAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(h) Dispose of the front seat airbag assy LH.
CAUTION:

The front seat airbag assy LH is extremely hot when
the airbag is deployed, so do not touch it for at least
30 minutes after deployment.

Use gloves and safety glasses when handling the
front seat airbag assy LH with the deployed airbag.

Always wash your hands with water after completing
the operation.

Do not apply water etc. to the front seat airbag assy
LH with the deployed airbag.
(1) Remove the front seat airbag assy LH from the tire.
(2) Place the front seat airbag assy LH in a plastic bag,
tie the end tightly and dispose of it in the same way
as other general parts disposal.

6009O±06
H42639N
m (kgf
cm, ft
lbf): Specified torqueTorx Screw
Steering Column Cover
w/Instrument Cluster Fin-
ish Panel Assy
Torx Screw
Horn Button Assy Steering Column Cover AssySpiral Cable Sub±Assy
Steering Wheel Assy
50 (510, 37)
Instrument Panel Airbag Assy
Instrument Panel Hole Cover
8.8 (90, 78 in.
lbf)8.8 (90, 78 in.
lbf)
60±16
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
STEERING WHEEL ASSY
COMPONENTS

6009P±04
H42622
H43002
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
60±17
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. REMOVE HORN BUTTON ASSY
(a) Place the front wheels facing straight ahead.
(b) Using a torx socket wrench (T30), loosen the 2 torxscrews until the groove along the screw circumference
catches on the screw case.
(c) Pull out the horn button assy from the steering wheel assy and support the horn button assy with one hand as shown
in the illustration.
NOTICE:
When removing the horn button assy, do not pull the airbag
wire harness.
(d) Using a screwdriver, disconnect the airbag connectors.
(e) Disconnect the horn connector.
(f) Remove the horn button assy.

H43003
H42615
60±18
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
4. INSTALL HORN BUTTON ASSY
(a) Support the horn button assy with the hand as shown in the illustration.
(b) Connect the airbag connectors.
(c) Connect the horn connector.
(d) Confirm that the circumference groove of the torx screw fits in the screw case, and place the horn button assy onto
the steering wheel assy.
(e) Using a torx socket wrench (T 30), install the 2 screws. Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
5.INSPECT HORN BUTTON ASSY (See page 60±11)
(a) Do a visual check which includes the following items with the horn button assy installed in the vehicle:
Cuts, minute cracks or marked discoloration on the horn
button assy top surface and in the grooved portion.
6.INSPECT SRS WARNING LIGHT (See page 05±1184)

600JW±01
H40004
SST(s)
H40004
SST(s)
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
60±19
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
When scrapping a vehicle equipped with the SRS or disposing of a horn button assy, be sure to deploy the
airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag de-
ployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
CAUTION:

Never dispose of the horn button assy that has an un-
deployed airbag.

The airbag produces an extremely exploding sound
when it is deployed, so perform the operation out-
doors and where it will not create a nuisance to
nearby residents.

When deploying the airbag, always use the specified
SST(s) (SRS Airbag Deployment Tool). Perform the
operation in a place away from electrical noise.

When deploying the airbag, perform the operation at
least 10 m (33 ft) away from the horn button assy.

The horn button assy is extremely hot when the air-
bag is deployed, so do not touch it for at least 30 min-
utes after deployment.

Use gloves and safety glasses when handling the
horn button assy with the deployed airbag.

Do not apply water, etc. to the horn button assy with
the deployed airbag.

Always wash your hands with water after completing
the operation.
1. DISPOSE OF HORN BUTTON ASSY (WHEN
SCRAPPING VEHICLE DEPLOYMENT METHOD)
HINT:
Prepare a battery as the power source to deploy the airbag.
(a) Check the function of the SST(s).
CAUTION:
When deploying the airbag, always use the specified
SST(s): SRS Airbag Deployment Tool.
SST 09082±00700

H40005
Battery
SST(s)
H40006
SST(s)
H42625
H42626SST(s)
60±20
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(1) Connect the SST(s) to the battery. Connect the red clip of the SST(s) to the battery
positive (+) terminal and the black clip of the SST(s)
to the battery negative (±) terminal.
HINT:
Do not connect the yellow connector of the SST(s) which is to
be connected with the supplemental restraint system.
(2) Check the function of the SST(s).Press the SST(s) activation switch, and check that
the LED of the SST(s) activation switch comes on.
CAUTION:
If the LED comes on when the activation switch is not being
pressed, SST(s) malfunction is posible, so be sure not to
use the SST(s). (3) Disconnect the SST(s) from the battery.
(b) Install the SST(s).
CAUTION:
Check that there is no looseness in the steering wheel assy
and horn button assy. (1)Remove the instrument panel hole (See page
60±54).
(2) Remove the instrument panel airbag assy (See page 60±54).
(3) While turning the steering wheel right and left, re-
move the 3 screws and steering column cover.
(4) Disconnect the airbag connector of the spiral cable sub±assy.
(5) Connect the connector of the SST(s) to the airbag connector of the spiral cable sub±assy.
SST 09082±00700, 09082±00780
NOTICE:
To avoid damaging the SST(s) connector and wire harness,
do not lock the secondary lock of the twin lock.