TOYOTA AVENSIS 2003 Service Repair Manual

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 LHFront 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 SYSTEM SIDE AIR BAG SENSOR ASSY LH
60±65
AVENSIS REPAIR MANUAL (RM1018E)
SIDE AIR BAG SENSOR ASSY LH
COMPONENTS
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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)
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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.
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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)
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600JU±01
±
SUPPLEMENTAL RESTRAINT SYSTEMSUPPLEMENTAL 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).
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60±2
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)

When the negative (±) terminal cable is disconnected from the batte\
ry, the memory of the clock
and audio system will be canceled. So before starting work, make a record o\
f the contents mem-
orized in the audio memory system. When work is finished, reset the audio syst\
ems 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.
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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
5 13
6 14
3
11
412
1 9
210
2324
21 29
22 30
19 27
2028
17
25
1826
34
5
6
78
11 12
9
10 25
26
27
28
29
30
*1: w/ Curtain Shield Airbag
*2: LHD
*3: RHD
*4: Knee Airbag
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±3
AVENSIS REPAIR MANUAL (RM1018E)
1. SRS CONNECTORS
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Z05953
Spacer
Housing
Female Male
R10587
When Connector is Connected When Connector is Disconnected
Short Spring Plate
Housing
Housing
Terminal
Connectors Short Spring PlateSquib
Closed CircuitSquib
Short Spring Plate ON Contacting Male Terminal
Short Spring Plate
60±4
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E) No.
ItemApplication
(1)Terminal Twin±Lock MechanismConnectors 2, 4, 6, 8, 10, 12, 13, 14, 15, 19, 21, 22, 25
(2)Activation Prevention MechanismConnectors 2, 4, 16, 18, 20, 22, 24, 26, 28, 30
(3)Electrical Connection Check MechanismConnectors 1, 2, 3, 4
(4)Half Connection Prevention MechanismConnectors 6, 8, 10, 14, 15, 19, 21, 25
(5)Connector Lock MechanismConnectors 17, 23, 27, 29
(a) All connectors for the SRS are colored in yellow to distin-
guish them from other connectors. The connectors hav-
ing special functions and specifically designed for the
SRS are used in the locations shown on the previous
page to ensure high reliability. These connectors use du-
rable gold±plated terminals.
(1) Terminal twin±lock mechanism:Each connector has a two±piece component con-
sisting of a housing and a spacer. This design en-
ables the terminal to be locked securely by two lock-
ing devices (the retainer and the lance) to prevent
terminals from coming out.
(2) Activation prevention mechanism: Each connector contains a short spring plate. When
the connector is disconnected, the short spring
plate automatically connects positive (+) terminal
and negative (±) terminal of the squib.
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H41646
Disconnection
Detection
Pin
Airbag Sensor Assy Center
H01315
Terminal for Diagnosis
Disconnection Detection Pin


Half Connection
Complete Connection
Terminal for
Diagnosis

H40180
Stopper
Locking Part Spring
Slider
Locking Arm Rebounded by Slider
(Spring)Stopper
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±5
AVENSIS REPAIR MANUAL (RM1018E)
HINT:
The type of connector is shown in the diagram on the previous
page.
(3) Electrical connection check mechanism:This mechanism electrically checks that the con-
nectors are connected correctly and completely.
The electrical connection check mechanism is de-
signed so that the disconnection detection pin con-
nects with the diagnosis terminals when the con-
nector housing lock is locked.
HINT:
The connectors shown in this illustration are connectors, º1º,
º2º, º3º and º4º in the step 1. (4) Half connection prevention mechanism:
If the connector is not completely connected, the
connector is disconnected due to the spring opera-
tion to the extent that no continuity exists.
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H40181
Claw
Groove
H42905
Fig.1
Fig.2 Power Source
SafingSensor Squibs
Deceleration
Sensor
60±6
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(5) Connector lock mechanism: Locking the connector lock button connects the
connector securely.
(b) When the vehicle is involved in a frontal collision in the hatched area (Fig. 1) and the shock is larger than the pre-
determined level, the SRS is activated automatically. The
safing sensor is designed to go on at a smaller decelera-
tion rate than the airbag sensor. As illustrated in the Fig.
2, ignition is caused when current flows to the squib,
which happens when the safing sensor and the decelera-
tion sensor go on simultaneously. When a deceleration
force acts on the sensors, 3 squibs in the driver airbag,
front passenger airbag and knee airbag ignite and gener-
ate gas. The gas discharging into the driver airbag, front
passenger airbag and knee airbag rapidly increases the
pressure inside the bags, breaking the horn button assy
and instrument panel. The inflation of the bag then ends,
and the bags deflate as the gas is discharged through dis-
charge holes at the bag's rear or side.
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