width TOYOTA AVENSIS 2002 User Guide

± PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
02±53
AVENSIS REPAIR MANUAL (RM1018E)
Recomended Tools
09042±00010Torx Socket T30HORN BUTTON ASSY
SPIRAL CABLE SUB±ASSY
09070±20010Moulding RemoverAIR BAG SENSOR ASSY CENTER
Equipment
Torque wrench
Bolt Length: 35.0 mm (1.378 in.) Pitch: 1.0 mm (0.039 in.)
Diam.: 6.0 mm (0.236 in.)Airbag disposal
Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel Width: 185 mm (7.28 in.)
Inner diam.: 360 mm (14.17 in.)Airbag disposal
Plastic bagAirbag disposal

030L1±03
± SERVICE SPECIFICATIONSCLUTCH
03±55
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH
SERVICE DATA
Pedal height from asphalt sheet
LHD steering position type
1CD±FTV engine type w/ intercooler
Others
154.0 ± 164.0 mm (6.063 ± 6.457 in.)
139.6 ± 149.6 mm (5.496 ± 5.890 in.)
Pedal height from asphalt sheet
RHD steering position type
1CD±FTV engine type w/ intercooler
Others
158.4 ± 168.4 mm (6.236 ± 6.630 in.)
148.4 ± 158.4 mm (5.843 ± 6.236 in.)
Clutch pedal free play5.0 ± 15.0 mm (0.197 ± 0591 in.)
Clutch pedal push rod play at pedal top1.0 ± 5.0 mm (0.039 ± 0.197 in.)
Slotted spring pin protrusion1.5 ± 3.5 mm (0.059 ± 0.138 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch disc rivet head depth Maximum0.3 mm (0.012 in.)
Clutch disc assy runout Minimum0.8 mm (0.031 in.)
Diaphragm spring finger wear Maximum depth:
Maximum width:0.5 mm (0.020 in.)
6.0 mm (0.236 in.)
Flywheel sub±assy runout Maximum0.1 mm (0.004 in.)
Diaphragm tip alignment Maximum0.5 mm (0.020 in.)

H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42761
Width
Inner
Diam.
H42792
SST(s) 60±44
± SUPPLEMENTAL RESTRAINT SYSTEMCURTAIN SHIELD AIR BAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a service±purpose wire harness for the vehicle, tie
down the curtain shield airbag assy LH 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 curtain shield airbag assy LH, it may
be snapped by the shock when the airbag is deployed. Al-
ways use a wire harness for vehicle use which has a diame-
ter 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 curtain shield airbag assy LH inside the tire
as shown in the illustration.
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 curtain shield airbag assy LH coming free
due to the shock from the airbag deployment.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(e) Install the SST(s).
Connect the connectors of the SST(s) to the curtain shield
airbag assy LH.
SST 09082±00802 (09082±10801, 09082±20801)

H41437
H41438
H40526
H42897
SST(s)
60±50
± SUPPLEMENTAL RESTRAINT SYSTEMFRONT SEAT AIRBAG ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
(1) Install the 2 nuts in the front seat airbag assy LH.
(2) Wind the wire harness around the stud bolts of the
front seat airbag assy LH as shown in the illustra-
tion.
(3) Position the front seat airbag assy LH inside the tire
with the airbag deployment direction 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 the wire harness is tight. It is highly dan-
gerous when looseness in the wire harness results in
the front seat airbag assy LH coming free due to the
shock from the airbag deployment.

Always tie down the front seat airbag assy LH with the
airbag deployment direction facing inside the tire.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(d) Install the SST(s).
Connect the connector of SST(s) to the front seat airbag
assy LH connect.
SST 09082±00750

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.

H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42664
Inner Diam.
WidthTire
60±58
± SUPPLEMENTAL RESTRAINT SYSTEMINSTRUMENT PANEL AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(d) Using a service±purpose wire harness for the vehicle, tie
down the instrument panel 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 the wire harness which is too thin or an alternative object
is used to tie down the instrument panel airbag assy, it may
be snapped by the shock when the airbag is deployed. Al-
ways use a wire harness for vehicle use which has a diame-
ter 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 airbag assy inside 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 airbag assy coming free
due to the shock from the airbag deployment.

Always tie down the instrument panel airbag assy
with the airbag deployment side facing inside the tire.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.

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.

H42646
Inner
Diam.
Width
Tire
H43004
SST(s)
H42647
Tires
(5 or more) 60±34
± SUPPLEMENTAL RESTRAINT SYSTEMINSTRUMENT 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 the
instrument 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.