TOYOTA AVENSIS 2005 Service Repair Manual

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

600JV±01
H42615
H42616
H43001
Horn Button Contact Plate
H42618
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±11
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. HORN BUTTON ASSY (VEHICLES NOT INVOLVED IN
COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) 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.
2. HORN BUTTON ASSY (VEHICLE INVOLVED IN COLLI- SION AND AIRBAG IS NOT DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check of the horn button assy removed from the vehicle:

Cuts, minute cracks or marked discoloration on the
horn button assy top surface and in the grooved
portion.

Cuts and cracks in wire harness, and chipping in
connectors.

Deformation of the horn button assy.

The deformation of the horn button contact plate of
the steering wheel assy.
HINT:

If the horn button contact plate of the steering wheel assy
is deformed, replace it with a new one. Always replace the
steering wheel assy with a new one.

Never repair it in order for reuse or replacement.

There should be no interference between the horn button
assy and steering wheel assy, and the clearance should
be uniform all the way around when the new horn button
assy is installed on the steering wheel assy.
CAUTION:
For removal and installation procedures of the horn button
assy, see ºReplacementº on page 60±17, and be sure to fol-
low the correct procedure.

H42619
H42620
H42621
60±12
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
3. INSTRUMENT PANEL PASSENGER AIRBAG ASSY (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check which includes the following items with
the instrument panel passenger airbag assy installed in
the vehicle:
Cuts, minute cracks or marked discoloration on the instru-
ment panel around the instrument panel passenger air-
bag assy.
4. INSTRUMENT PANEL PASSENGER AIRBAG ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
NOT DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check of the instrument panel passenger air- bag assy removed from the vehicle:

Cuts, minute cracks or marked discoloration on the
instrument panel passenger airbag assy.

Cuts and cracks in wire harness, and chipping in
connectors.

Deformation or cracks on the instrument panel and
instrument panel reinforcement.
HINT:

If the instrument panel or instrument panel reinforcement
is deformed or cracked, never repair it. Always replace it
with a new one.

Never repair it in order for reuse.
CAUTION:
For removal and installation of procedures the instrument
panel passenger airbag assy, see ºReplacementº on page
60±29, and be sure to follow the correct procedure.

H42654
H41401
H42655
H42759
H42656
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±13
AVENSIS REPAIR MANUAL (RM1018E)
5. FRONT SEAT AIRBAG ASSY (VEHICLE NOT IN-
VOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check which includes the following items with
the front seat airbag assy installed in the vehicle:
Cuts, minute cracks or marked discoloration on the front
seat back assy around the front seat airbag assy.
6. FRONT SEAT AIRBAG ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check which includes the following items with the front seat airbag assy removed from the vehicle:

Cuts, minute cracks or marked discoloration on the
front seat airbag assy.

Cuts and cracks in wire harness, and chipping in
connectors.
7. CURTAIN SHIELD AIRBAG ASSY (VEHICLE NOT IN- VOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check of the curtain shield airbag assy installed in the vehicle:
Cuts, minute cracks or marked discoloration on the front
pillar garnish and roof headlining assy around the curtain
shield airbag assy.
8. CURTAIN SHIELD AIRBAG ASSY (VEHICLE IN- VOLVED IN COLLISION AND AIRBAG IS NOT
DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check which includes the following items with
the curtain shield airbag assy removed from the vehicle:

Cuts, minute cracks or marked discoloration on the
curtain shield airbag assy.

Cuts and cracks in wire harness, and chipping in the
connectors.
9. INSTRUMENT PANEL AIRBAG ASSY (VEHICLE IN- VOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check of the instrument panel airbag assy
installed in the vehicle:
Cuts, minute cracks of marked discoloration on the instru-
ment panel airbag assy.

H42657
H42659
60±14
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTRUMENT PANEL AIRBAG ASSY (VEHICLE IN- VOLVED IN COLLISION AND AIRBAG IS NOT
DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check of the instrument panel airbag assy re- moved from the vehicle:

Cuts, minute cracks or marked discoloration on the
instrument panel airbag assy.
HINT:

Never repair it in order for reuse or replacement.

There should be no interference between the horn button
assy and steering wheel assy, and the clearance should
be uniform all the around when the new horn button assy
is installed on the steering wheel assy.
CAUTION:
For removal and installation procedures of the horn button
assy, see ºReplacementº on page 60±54, and be sure to fol-
low the correct procedure.
11. AIRBAG SENSOR ASSY CENTER (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
12. AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
13. AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a)Replace the airbag sensor assy center (See page 60±62).
14. AIRBAG FRONT SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
15. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) When the headlamp of the vehicle or its periphery is damaged, check if t\
here is any damage to the airbag front sensor. If there are any defects as mentioned below, replace the airbag front sensor with
a new one:
If there are any defects as mentioned below, replace the airbag front sensor with a new one:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.

Peeling off of the label or damage to the serial number.
16. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)
(a)Replace the airbag front sensor assy (See page 60±64).
17. SIDE AIRBAG SENSOR ASSY (VEHICLES NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).

±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±15
AVENSIS REPAIR MANUAL (RM1018E)
18. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT
DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) When the center pillar of the vehicle or its periphery is damaged, check if \
there is any damage to the
side airbag sensor. If there are any defects as mentioned below, replace the side airbag sensor with
a new one:
If there are any defects as mentioned below, replace the side airbag sensor with a new one:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.

Peeling off of the label or damage to the serial number.
19. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)
(a)Replace the front seat airbag assy and side airbag sensor assy (See page 60±66).
20. AIRBAG SENSOR REAR (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
21. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) When the quarter panel of the vehicle or its periphery is damaged, check if \
there is any damage to the airbag sensor rear. If there are any defects as mentioned below, replace the airbag sensor rear with
a new one:
If there are any defects as mentioned below, replace the airbag sensor rear with a new one:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.

Peeling off of the label or damage to the serial number.
22. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)
(a)Replace the curtain shield airbag assy and airbag sensor rear (See page 60±68).
23. SEAT POSITION AIRBAG SENSOR (VEHICLES NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
24. SEAT POSITION AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check for damage to the seat position airbag sensor even if th\
e airbag was not deployed:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.
25. WIRE HARNESS AND CONNECTOR (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
26. WIRE HARNESS AND CONNECTOR (VEHICLE INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) Check for breaks in all wires of the SRS wire harness, and exposed condu\
ctors.
(c) Check to see if the SRS wire harness connectors are cracked or chipped.
HINT:
The SRS wire harness is integrated with the engine room main wire, instrume\
nt panel wire floor wire, floor
wire No.2 harness assembly.

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

Z05953
Spacer
Housing
Female Male
R10587
When Connector is Connected When Connector is Disconnected
Short Spring Plate
Housing
Housing
Terminal
ConnectorsShort Spring PlateSquib
Closed CircuitSquib Short Spring Plate ONContacting Male Terminal Short Spring Plate
60±4
± SUPPLEMENTAL RESTRAINT SYSTEMSUPPLEMENTAL 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.