TOYOTA AVENSIS 2002 Repair Manual

H40007
10 m (33 ft) or more
Battery
SST(s)
H40005
Battery
SST(s)
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
60±21
AVENSIS REPAIR MANUAL (RM1018E)
(6) Move the SST(s) at least 10 m (33 ft) away from the
front of the vehicle.
(7) Close all the doors and windows in the vehicle.
NOTICE:
Take care not to damage the SST(s) wire harness. (8) Connect the red clip of the SST(s) to the batterypositive (+) terminal and the black clip of the SST(s)
to the negative (±) terminal.
(c) 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 of the SST(s) and
deploy the airbag.
HINT:
The airbag is deployed as the LED of the SST(s) activation
switch comes on.
(d) Dispose of the horn button assy.
CAUTION:

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.

When moving the vehicle which has the horn button
assy with the deployed airbag for scrapping, use
gloves and safety glasses.

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

Always wash your hands with water after completing
the operation.

Do not apply water, etc. to the horn button assy with
the deployed airbag.
HINT:
When scrapping a vehicle, deploy the airbag and scrap the ve-
hicle with the horn button assy still installed.
2. DISPOSE OF HORN BUTTON ASSY (WHEN DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT
METHOD)
NOTICE:

When disposing of the horn button assy only, never
use the customer's vehicle to deploy the airbag.

Be sure to follow the procedure detailed below when
deploying the airbag.
HINT:
Have a battery as the power source to deploy the airbag.
(a) Check the function of the SST(s) (See step 1±(a)).
(b)Remove the horn button assy (See page 60±17).

H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42627
L
M
H42628
SST(s) 60±22
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
CAUTION:

When removing the horn button assy, 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 horn button assy, keep the upper
surface of the airbag deployment side facing upward.
(c) Using a service±purpose wire harness for the vehicle, tie
down the horn button assy to the disc wheel.
Wire harness: Stripped wire harness section
1.25 mm
2
or more (0.0019 in2. or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the horn button assy, 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 of at least 1.25 mm
2
(0.0019 in2).
HINT:
To calculate the square of the stripped wire harness section:
Square = 3.14 x (Diameter)
2
divided by 4
(1) Install the 2 bolts with washers in the 2 bolts holes
of the horn button assy.
Bolt:
L: 35.0 mm (1.378 in.)
M: 6.0 mm (0.236 in.)
Pitch: 1.0 mm (0.039 in.)
NOTICE:

Tighten the bolts by hand until the bolts become diffi-
cult to turn.

Do not tighten the bolts too much.
(2) After connecting the SST(s) below to each other,
connect them to the horn button assy.
SST 09082±00802 (09082±10801, 09082±30801)

H42629
2 Times or more
H42630SST(s)
H42631
SST(s)
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
60±23
AVENSIS REPAIR MANUAL (RM1018E)
(3) Using 3 wire harnesses, wind each wire harness at
least 2 times each around the bolts installed on the
left and right sides of the horn button assy.
CAUTION:

Tightly wind the wire harness around the bolts so that
there is no slack.

If there is slack in the wire harness, the horn button
assy may become loose due to the shock when the
airbag is deployed. This is highly dangerous.
(4) Face the upper surface of the horn button assy up-
ward. Separately tie the left and right sides of the
horn button assy to the disc wheel through the hub
nut holes. Position the SST(s) connector so that it
hangs downward through a hub hole in the disc
wheel.
CAUTION:

Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the horn button assy coming free due to the
shock from the airbag deployment.

Always tie down the horn button assy with the pad
side facing upward. It is highly dangerous if the horn
button assy is tied down with the metal surface facing
upward as the wire harness will be cut by the shock
caused by the airbag deployment and the horn button
assy will be thrown into the air.
NOTICE:
The disc wheel will be marked by the airbag deployment,
so use a redundant disc wheel.
(d) Install the SST(s).
CAUTION:
Place the disc wheel on the level ground.
(1) 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 disc
wheel.

H4263210 m (33 ft) or moreBattery
SST(s)
H42633Weight
X Y
Y
H40013
Inner Diam.
Tires
(3 or More)Width 60±24
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(2) Move the SST(s) to at least 10 m (33 ft) away from
the horn button assy tied down to the disc wheel.
(e) Cover the horn button assy with a cardboard box or tires.

Covering method using a cardboard box:
Cover the horn button assy with the cardboard box
and weigh the cardboard box down in 4 places with
at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
X = 460 mm (18.11 in.)
Y = 650 mm (25.59 in.)
NOTICE:

When the dimension Y of the cardboard box exceeds
the diameter of the disc wheel with tire to which the
horn button assy is tied, X should be the following
size.
X = 460 mm (18.11 in.) + width of tire

If a cardboard box smaller than the specified size is
used, the cardboard box will be broken by the shock
from the airbag deployment.

Covering method using tires:
Place at least 3 tires with no disc wheels on top of
the tire with disc wheel to which the horn button assy
is tied.
Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.
NOTICE:

The tires may be marked by the airbag deployment,
so use a redundant tires.

Do not place the SST(s) connector under the tire be-
cause the SST(s) connector could be damaged.

H4263210 m (33 ft) or moreBattery
SST(s)
H42635
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
60±25
AVENSIS REPAIR MANUAL (RM1018E)
(f) 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 disc wheel which the horn button assy is tied to.
(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.
(g) Dispose of the horn button assy.
CAUTION:

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) Remove the horn button assy from the disc wheel.
(2) Place the horn button assy in a plastic bag, tie the
end tightly and dispose of it as other general parts
disposal.

600K3±01
H42798
Instrument Panel Hole Cover
18 (184, 13)
18 (184, 13)
18 (184, 13)
18 (184, 13)
Instrument Panel Airbag Assy
N
m (kgf
cm, ft
lbf): Specified torque
18 (184, 13)
18 (184, 13)
± SUPPLEMENTAL RESTRAINT SYSTEMINSTRUMENT PANEL AIR BAG ASSY
60±53
AVENSIS REPAIR MANUAL (RM1018E)
INSTRUMENT PANEL AIR BAG ASSY
COMPONENTS

600K4±01
H42660
H42661
H42665
60±54
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. REMOVE INSTRUMENT PANEL HOLE COVER
(a) Using a screwdriver, remove the 2 instrument panel hole cover. 4. REMOVE INSTRUMENT PANEL AIR BAG ASSY
(a) Using a screwdriver disconnect the airbag connector.
(b) Remove the 4 bolts, 2 nuts and the instrument panel air-bag assy.
5. INSTALL INSTRUMENT PANEL AIR BAG ASSY
(a) Install the instrument panel airbag assy.
(b) Connect the airbag connector.
(c) Install the 4 bolts and the 2 nuts. Torque: 18.0 N
m (184 kgf
cm, 13 ft
lbf)
(d) Install the instrument panel hole cover.
6.INSPECT INSTRUMENT PANEL AIR BAG ASSY (See page 60±11)
7.INSPECT SRS WARNING LIGHT (See page 05±1184)

600K5±01
H40004
SST(s)
H40005
SST(s)Battery
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
60±55
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
When scrapping a vehicle equipped with the SRS or disposing of the instrument panel airbag assy, be sure
to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with
the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
CAUTION:

Never dispose of the instrument panel airbag assy
that has an undeployed airbag.

The airbag produces an extremely loud exploding
sound when it is deployed, so perform the operation
outdoors 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 instrument panel air-
bag assy.

The instrument panel airbag assy 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
instrument panel airbag assy with the deployed air-
bag.

Do not apply water, etc. to the instrument panel airbag
assy with the deployed airbag.

Always wash your hands with water after completing
the operation.
1. DISPOSE OF INSTRUMENT PANEL AIR BAG ASSY (WHEN SCRAPPING VEHICLE DEPLOYMENT
METHOD)
HINT:
Prepare a battery as the power source to deploy the airbag.
(a)Check performance of the SST(s) (See step 1±(a) on page 60±17).

H42660
H42662
SST(s)
SST(s)
H41078
10 m (33 ft) or more
SST(s)Battery 60±56
± SUPPLEMENTAL RESTRAINT SYSTEMINSTRUMENT PANEL AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(b) Disconnect the airbag connector.
(1) Using a screwdriver, disconnect the instrument
panel airbag connector.
(c) Install the SST(s).
(1) Connect the connectors of the SST(s) to the instru-
ment panel airbag assy.
SST 09082±00700, 09082±00802 (09082±10801,
09082±20801)
NOTICE:
Take care not to damage the SST(s) wire harness.
(2) Move the SST(s) to at least 10 m (33 ft) away from
the rear of the vehicle.
(3) Close all the doors and windows in the vehicle.
NOTICE:
Take care not to damage the SST(s) wire harness.
(4) Connect the red clip of the SST(s) to the battery
positive (+) terminal and the black clip of the SST(s)
to the negative (±) terminal.
(d) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a
10 m (33 ft) radius of the vehicle.
(2) Press the activation switch of the SST(s) and
deploy the airbag.
HINT:
The airbag deploys as the LED of the SST(s) activation switch
comes on.

H40005
Battery
SST(s)
H42661
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
60±57
AVENSIS REPAIR MANUAL (RM1018E)
(e) Dispose of the instrument panel airbag assy.
CAUTION:

The instrument panel airbag assy 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
instrument panel airbag assy with the deployed air-
bag.

When moving the vehicle for scrapping which has the
instrument panel airbag assy with the deployed air-
bag, use gloves and safety glasses.

Do not apply water, etc. to the instrument panel airbag
assy with the deployed airbag.

Always wash your hands with water after completing
the operation.
HINT:
When scrapping a vehicle, deploy the airbag and scrap the ve-
hicle with the instrument panel airbag assy still installed.
2. DISPOSE OF INSTRUMENT PANEL AIR BAG ASSY
(WHEN DISPOSING OF AIRBAG A SSEMBLY
DEPLOYMENT METHOD)
NOTICE:

When disposing of the instrument panel airbag assy
only, never use the customer's vehicle to deploy the
airbag.

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 performance of the SST(s) (See step 1±(a) on page 60±19).
(b) Using a screwdriver, remove the 2 instrument panel hole
cover.
(c)Remove the instrument panel airbag assy (See page 60±54).
CAUTION:

When removing the instrument panel airbag assy,
work must be started 90 seconds after the ignition
switch is turned to the ºLOCKº position and the nega-
tive (±) terminal cable is disconnected from the bat-
tery.

When storing the instrument panel airbag assy, keep
the upper surface of the airbag deployment side fac-
ing upward.