TOYOTA AVENSIS 2002 Repair Manual

H42763
SST(s)
H43299
Battery Instrument Panel
Passenger Airbag Assy
10 m (33 ft) or more
SST(s) SST(s)
H42648
± SUPPLEMENTAL RESTRAINT SYSTEMINSTRUMENT PANEL PASSENGER AIR BAG ASSY
60±35
AVENSIS REPAIR MANUAL (RM1018E)
(3) Tie the tires together with 2 wire harnesses.
CAUTION:
Make sure that the wire harness is tight. It is very danger-
ous when looseness in the wire harness result 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 to
the battery negative (±) terminal.
(2) Check that no one is within a 10 m (33 ft) radius of
the tire to which the instrument panel passenger air-
bag assy is tied.
(3) Press the activation switch of the SST(s) and
deploy the airbag.
HINT:
The airbag is deploys as the LED of the SST(s) activation switch
comes on.
(h) Dispose of the instrument panel passenger airbag assy.
CAUTION:

The instrument panel passenger airbag assy is very
hot when the airbag is deployed, so leave it alone for
at least 30 minutes after deployment.

Use gloves and safety glasses when handling the
instrument panel passenger airbag assy with the
deployed airbag.

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

Always wash your hands with water after completing
the operation.
(1) Remove the instrument panel passenger airbag
assy from the tire.
(2) Place the instrument panel passenger airbag assy
in a plastic bag, tie the end tightly and dispose of it
in the same way as other general parts disposal.

600AA±04
H42641N
m (kgf
cm, ft
lbf): Specified torqueFront Seat Assy LH
8.0 (82, 71 in.
lbf)
Seat Track Cover LH
Seat Track Bracket
Cover Inner LH
Seat Position Airbag Sensor
37 (375, 27)
37 (375, 27)
37 (375, 27)


± SUPPLEMENTAL RESTRAINT SYSTEMSEAT POSITION AIR BAG SENSOR
60±69
AVENSIS REPAIR MANUAL (RM1018E)
SEAT POSITION AIR BAG SENSOR
COMPONENTS

600AB±04
H42640
60±70
±
SUPPLEMENTAL RESTRAINT SYSTEM SEAT POSITION AIR BAG SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Replacement procedure of the RH side is the same as that of the LH side.
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE SEAT TRACK COVER LH (See page 72±16)
4.REMOVE SEAT TRACK BRACKET COVER INNER LH (See page 72±16)
5.REMOVE FRONT SEAT ASSY LH (See page 72±16) 6. REMOVE SEAT POSITION AIR BAG SENSOR
(a) Disconnect the connector of the seat position airbag sen-sor.
(b) Using a torx socket wrench (T30), remove the torx screw and seat position airbag sensor.
7. INSTALL SEAT POSITION AIR BAG SENSOR
(a) Check that the ignition switch is off.
(b) Check that the battery negative (±) terminal is disconnected.
NOTICE:
Do not start the operation for 90 seconds after removing the terminal.
(c) Using a torx socket wrench (T30), install the seat position airbag sen\
sor with the torx screw. Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
NOTICE:

If the seat position airbag sensor has been dropped, or there are any cracks, dents or other de-
fects in the case, bracket or connector, replace the seat position airbag sensor with a new one.

When installing the seat position airbag sensor, take care that the SRS wiring does not interfere
with other parts and is not pinched between other parts.
(d) Connect the connector of the seat position airbag sensor.
(e) Check that no play is identified.
8.INSTALL FRONT SEAT ASSY LH (See page 72±16)
Torque: 37 N
m (375 kgf
cm, 27 ft
lbf)
9.SRS WARNING LIGHT (See page 05±1184)

600A6±03
H42766N
m (kgf
cm, ft
lbf) : Specified torque Rear Door Opening
Trim Weatherstrip LH
Rear Door Scuff
Plate LH
Center Pillar
Garnish Lower LH
Front Door Scuff
Plate LHFront Door Opening Trim
Weatherstrip LHFront Seat
Outer Belt Assy LH
8.0 (82, 70 in.
lbf)
Side Airbag Sensor Assy LH
± SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIR BAG SENSOR ASSY LH
60±65
AVENSIS REPAIR MANUAL (RM1018E)
SIDE AIR BAG SENSOR ASSY LH
COMPONENTS

600A7±03
H42767
60±66
±
SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIR BAG SENSOR ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Replacement procedure of the RH side is the same as that for with LH side.
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE FRONT DOOR SCUFF PLATE LH (See page 76±36)
4.REMOVE REAR DOOR SCUFF PLATE LH (See page 76±36)
5.REMOVE FRONT DOOR WEATHERSTRIP LH (See page 76±36)
6.REMOVE REAR DOOR WEATHERSTRIP LH (See page 76±36)
7.REMOVE CENTER PILLAR GARNISH LOWER LH (See page 76±36)
8.REMOVE FRONT SEAT OUTER BELT ASSY LH (See page 61±7) 9. REMOVE SIDE AIR BAG SENSOR ASSY LH
(a) Remove the bolt and the side airbag sensor assy LH.
(b) Disconnect the connector from the side airbag sensorassy LH.
10. INSTALL SIDE AIR BAG SENSOR ASSY LH
(a) Check that the ignition switch is off.
(b) Check that the battery negative (±) terminal is disconnected.
NOTICE:
Do not start the operation for 90 seconds after removing the terminal.
(c) Install the side airbag sensor assy LH with the nut. Torque: 8.0 N
m (82 kgf
cm, 70 in.
lbf)
NOTICE:

If the side airbag sensor assy LH has been dropped, or there are any cra\
cks, dents or other de-
fects in the case, bracket or connector, replace the side airbag sensor assy LH with a new one.

When installing the side airbag sensor assy LH, take care that the SRS wiring\
does not interfere
with other parts and is not pinched between other parts.
(d) Connect the connector of the side airbag sensor assy LH.
(e) Check that no play is identified.
11.INSTALL FRONT SEAT OUTER BELT ASSY LH (See page 61±7)
12.INSPECT SRS WARNING LIGHT (See page 05±1184)

6009S±04
H42634
H42636 Claw
60±26
±
SUPPLEMENTAL RESTRAINT SYSTEM SPIRAL CABLE SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
SPIRAL CABLE SUB±ASSY
REPLACEMENT
HINT:
COMPONENTS: See page 60±16
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4.REMOVE HORN BUTTON ASSY (See page 60±17)
5.REMOVE STEERING WHEEL ASSY (See page 50±9) SST 09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±\
05021)
6.REMOVE INSTRUMENT PANEL HOLE COVER (See page 60±54)
7.REMOVE INSTRUMENT PANEL AIR BAG ASSY (See page 60±54)
8. REMOVE STEERING COLUMN COVER SUB±ASSYLOWER
(a) Remove the 3 screws and the steering column cover sub± assy lower.
9. REMOVE STEERING COLUMN COVER
W/INSTRUMENT CLUSTER FINISH PANEL ASSY
(a) Remove the steering column cover w/instrument cluster finish panel assy.
10. REMOVE SPIRAL CABLE SUB±ASSY
(a) Disconnect the airbag connector and the connector from the spiral cable sub±assy.
(b) Disengage the 3 claws and remove the spiral cable sub±
assy.
11.INSPECT SPIRAL CABLE SUB±ASSY (See page 60±11)
(a) If the following condition is identified, replace the spiral cable sub±\
assy with a new one. Condition:
Scratches or cracks on the connector
Cracks, dents or chips in the spiral cable sub±assy
12. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
(a) Check that the front wheels are facing straight ahead.

H42637
H42638Marks
±
SUPPLEMENTAL RESTRAINT SYSTEM SPIRAL CABLE SUB±ASSY
60±27
AVENSIS REPAIR MANUAL (RM1018E)
13. INSTALL SPIRAL CABLE SUB±ASSY
(a) Set the turn signal switch to the neutral position.
NOTICE:
Make sure of the neutral position since the pin of the turn signal switc\
h may be snapped.
(b) Install the spiral cable sub±assy.
NOTICE:
When replacing the spiral cable sub±assy with a new one, remove the l\
ock pin before installing the
steering wheel assy.
(c) Connect the airbag connector and the connector.
(d) Install the steering column cover with the 3 screws.
14. ADJUST SPIRAL CABLE SUB±ASSY
(a) Check that the ignition switch is off.
(b) Check that the battery negative terminal is disconnected.
NOTICE:
Do not start the operation for 90 seconds after removing
the terminal.
(c) Turn the spiral cable sub±assy counterclockwise slowlyby hand until it feels firm.
(d) Then rotate the spiral cable sub±assy clockwise about 2.5 turns to align the marks.
HINT:
The spiral cable sub±assy will rotate about 2.5 turns to both left
and right of the center.
15.INSTALL STEERING COLUMN COVER SUB±ASSY LOWER (See page 50±9)
16.INSTALL INSTRUMENT PANEL AIR BAG ASSY (See page 60±54)
17.INSTALL STEERING WHEEL ASSY (See page 50±9)
18. INSPECT STEERING WHEEL CENTER POINT
19.INSTALL HORN BUTTON ASSY (See page 60±17)
20.INSPECT HORN BUTTON ASSY (See page 60±11)
21.INSPECT SRS WARNING LIGHT (See page 05±1184)

600JU±01
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±1
AVENSIS REPAIR MANUAL (RM1018E)
SUPPLEMENTAL RESTRAINT SYSTEM
PRECAUTION
CAUTION:

AVENSIS is equipped with SRS, which comprises of a driver airbag, front passeng\
er airbag,
side airbag, curtain shield airbag and driver knee airbag. Failure to carry \
out service operations
in the correct sequence could cause the SRS to unexpectedly deploy during \
servicing, possibly
leading to serious accident. Further, if a mistake is made in servicing the SRS, it is possible that
the SRS may fail to operate when required. Before performing servicing (in\
cluding removal or
installation of parts, inspection or replacement), be sure to read the \
following items carefully,
then follow the correct procedures indicated in the repair manual.

Work must be started 90 seconds after the ignition switch is turned to the º\
LOCKº position and
the negative (±) terminal cable is disconnected from the battery.
(The SRS is equipped with a back±up power source so that if work is started wi\
thin 90 seconds
after disconnecting the negative (±) terminal cable of the battery, the SRS may be deployed.)

Do not expose the horn button assy, instrument panel passenger airbag assy, instrument panel
airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag
sensor assy, curtain shield airbag assy, airbag sensor rear or seat position airbag sensor di-
rectly to hot air or flames.
NOTICE:

Malfunction symptoms of the SRS are difficult to confirm, so DTCs are th\
e most important in-
formation source of information when troubleshooting. When troubleshooting the SRS, always
inspect DTCs before disconnecting the battery.

Even in the case of a minor collision when the SRS does not deploy, the horn button assy, instru-
ment panel passenger airbag assy, instrument panel airbag assy, airbag sensor assy center,
airbag front sensor, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy,
airbag sensor rear and seat position sensor must be inspected (See page 60±11).

Before repairs work, remove the airbag sensor if any kind of shock is likely to occur to the sen-
sor during operation.

Never use SRS parts from another vehicle. When replacing the parts, repl\
ace them with new
ones.

Never disassemble nor repair the horn button assy, instrument panel passenger airbag assy,
instrument panel airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag
assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear or seat position
airbag sensor in order to reuse it.

If the horn button assy, instrument panel passenger airbag assy, instrument panel airbag assy,
airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag sensor assy,
curtain shield airbag assy, airbag sensor rear or seat position airbag sensor has been dropped,
or if there are any cracks, dents or other defects in the case, bracket \
or connector, replace it
with a new one.

Use a volt/ohmmeter with high impedance (10 k
/V minimum) for troubleshooting the electrical
circuits circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruc-
tions the notice.

After work on the SRS is completed, perform the SRS warning light check \
(See page 05±1184).

60±2
± SUPPLEMENTAL RESTRAINT SYSTEMSUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)

When the negative (±) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as they
were before and adjust the clock. To avoid erasing the memory in each memory system, never
use a back±up power supply from outside the vehicle.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
INTRODUCTION section.

H42671
Side Airbag
Sensor Assy RH
Airbag Front
RH Sensor
Airbag Sensor
Assy Center
Airbag Sensor
Front LH
Side Airbag
Sensor Assy LH
Airbag Sensor
Rear LH (*1)
Seat Position
Airbag Sensor
(*2)Horn Button Assy
(Squib) Instrument Panel
Passenger Airbag
Assy (Squib)Front Seat Outer
Belt Assy RH
(Squib)
Front Seat
Airbag Assy RH
(Squib)
Front Seat
Airbag Assy
LH (Squib)
Curtain Shield
Airbag Assy LH
(Squib) (*1) Airbag Sensor
Rear RH (*1)Curtain Shield
Airbag Assy RH
(Squib) (*1)
Front Seat Outer
Belt Assy LH
(Squib) Seat Position
Airbag Sensor
(*3)
Instrument Panel
Airbag Assy (Squib)
Spiral Cable
Sub±assy 7
15 8
16
513
614 3 11
412
19
210
23
24 2129
2230
1927
2028
17 25
1826
34 5
6
78
11
12 9
1025
26
27
28
29
30
*1: w/ Curtain Shield Airbag
*2: LHD
*3: RHD
*4: Knee Airbag
± SUPPLEMENTAL RESTRAINT SYSTEMSUPPLEMENTAL RESTRAINT SYSTEM
60±3
AVENSIS REPAIR MANUAL (RM1018E)
1. SRS CONNECTORS