TOYOTA AVENSIS 2003 Service Repair Manual

600JX±01
H42775
Instrument Panel Passenger Airbag Assy
Instrument Panel Sub±Assy Upper
Glove Compartment Door Assy
20 (200, 14)
N
m (kgf
cm, ft
lbf): Specified torque
60±28
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
INSTRUMENT PANEL PASSENGER AIR BAG ASSY
COMPONENTS
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600JY±01
H42642
H42643
H42644
Hook
Airbag DoorHook
Front
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
60±29
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71±11)
4. DISCONNECT PASSENGER AIRBAG CONNECTOR
(a) Remove the passenger airbag connector clip.
(b) Disconnect the passenger airbag connector.
5. REMOVE INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (See page 71±11)
6. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSY
(a) Remove the 2 screws.
(b) Release the rear side wall of the airbag door from the hook by slightly deflecting it and roll the instrument panel
passenger airbag assy forward.
(c) Release the front side wall of the airbag door from the oth-
er hook and remove the instrument panel passenger air-
bag assy.
7. INSTALL INSTRUMENT PANEL PASSENGER AIR BAG ASSY
8.INSPECT INSTRUMENT PANEL PASSENGER AIR BAG ASSY (See page 60±11)
9. INSTALL INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (See page 71±11)
10.INSPECT SRS WARNING LIGHT (See page 05±1184)
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600JZ±01
H40004
SST(s)
H40005
Battery
SST(s)
60±30
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
When scrapping a vehicle equipped with SRS or disposing of an instrument pan\
el passenger airbag assy,
be sure to deploy the airbag first in accordance with the procedure desc\
ribed below. If any abnormality oc-
curs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:

Never dispose of the instrument panel passenger
assy that has an undeployed 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 instrument panel pas-
senger airbag assy.

The instrument panel passenger airbag assy is ex-
tremely 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 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. DISPOSE OF INSTRUMENT PANEL PASSENGER AIR BAG ASSY (WHEN SCRAPPING VEHICLE
DEPLOYMENT METHOD)
HINT:
Prepare a battery as the power source to deploy the airbag.
(a)Check functioning of the SST(s) (See step 1±(a) on page 60±19).
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H42642
H42645
SST(s)
H40007
10 m (33 ft) or more
Battery
SST(s)
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
60±31
AVENSIS REPAIR MANUAL (RM1018E)
(b) Disconnect the airbag connector.
(1) Remove the glove compartment door assy (See step 71±11).
NOTICE:
When handling the airbag connector, take care not to dam-
age the airbag wire harness. (2) Disconnect the airbag connector.
(c) Install the SST(s). (1) Connect the connector of the SST(s) to the instru-
ment panel passenger airbag assy connector.
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.
(2) Move the SST(s) to at least 10 m (33 ft) away fromthe front 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 batterypositive (+) terminal and the black clip of the SST(s)
to the negative (±) terminal.
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H40005
Battery
SST(s)
60±32
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(d) 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.
(e) Dispose of the instrument panel passenger airbag assy.
CAUTION:

The instrument panel passenger airbag assy is ex-
tremely 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 passenger airbag assy with the
deployed airbag.

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

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.
HINT:
When scrapping a vehicle, deploy the airbag and scrap the ve-
hicle with the instrument panel passenger airbag assy still
installed.
2. DISPOSE OF INSTRUMENT PANEL PASSENGER AIR BAG ASSY (WHEN DISPOSING OF AIRBAG
ASSEMBLY DEPLOYMENT METHOD)
NOTICE:

When disposing of the instrument panel passenger
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 function of the SST(s) (See step 1±(a) on page 60±19).
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H42620
H40008
Wire Harness
Diameter
Stripped Wire Harness Section
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
60±33
AVENSIS REPAIR MANUAL (RM1018E)
(b) Remove the instrument panel passenger airbag assy
(See page 60±29).
CAUTION:

When removing the instrument panel passenger air-
bag 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 instrument panel passenger airbag
assy, keep the upper surface of the airbag deploy-
ment side facing upward.
(c) Using a service±purpose wire harness for the vehicle, tie down the instrument panel passenger airbag assy to the
tire.
Wire harness: Stripped wire harness section
1.25 mm
2 or more (0.0019 in.2 or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the instrument panel passenger airbag
assy, it may be snapped by the shock when the airbag is
deployed. This is highly dangerous. Always use a wire har-
ness for vehicle use which has a diameter of at least 1.25
mm
2 (0.0019 in.2).
HINT:

To calculate the square of the stripped wire harness sec-
tion:
Square = 3.14 x (Diameter)
2 divided by 4

Position the instrument panel passenger airbag assy in-
side the tire with the airbag deployment side 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 that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the instrument panel passenger airbag assy
coming free due to the shock from the airbag deploy-
ment.

Always tie down the instrument panel passenger air-
bag assy with the airbag deployment side facing in-
side the tire.
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H42646
Inner
Diam.WidthTire
H43004
SST(s)
H42647
Tires
(5 or more)
60±34
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL PASSENGER AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(d) Install the SST(s). Connect the connector of the SST(s) to the instrument
panel passenger airbag assy.
SST 09082±00780
(e) Place tires. (1) Place at least 2 tires under the tire to which theinstrument panel passenger airbag assy is tied.
(2) Place at least 2 tires over the tire to which the instru- ment panel passenger airbag assy is tied. The top
tire should have the disc wheel installed.
NOTICE:
Do not place the SST(s) connector under the fire because
the SST connector could be damaged.
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H42763
SST(s)
H43299
Battery
Instrument Panel
Passenger Airbag Assy
10 m (33 ft) or more
SST(s)
SST(s)
H42648
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT 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 batterypositive (+) 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.
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600AA±04
H42641N
m (kgf
cm, ft
lbf): Specified torque Front 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 SYSTEM SEAT POSITION AIR BAG SENSOR
60±69
AVENSIS REPAIR MANUAL (RM1018E)
SEAT POSITION AIR BAG SENSOR
COMPONENTS
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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)
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