TOYOTA AVENSIS 2003 Service Repair Manual

H4263210 m (33 ft) or moreBattery
SST(s)
H42633Weight
X
Y
Y
H40013
Inner Diam.
Tires
(3 or More) Width
60±24
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN 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.
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H4263210 m (33 ft) or moreBattery
SST(s)
H42635
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
60±25
AVENSIS REPAIR MANUAL (RM1018E)
(f) Deploy the airbag.
(1) Connect the red clip of the SST(s) to the batterypositive (+) terminal and the black clip of the SST(s)
to the battery negative (±) terminal.
(2) Check that no one is within a 10 m (33 ft) radius of the disc wheel which the horn button assy is tied to.
(3) 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.
(g) Dispose of the horn button assy.
CAUTION:

The horn button assy is extremely hot when the air-
bag is deployed, so do not touch it for at least 30 min-
utes after deployment.

Use gloves and safety glasses when handling the
horn button assy with the deployed airbag.

Do not apply water, etc. to the horn button assy with
the deployed airbag.

Always wash your hands with water after completing
the operation.
(1) Remove the horn button assy from the disc wheel.
(2) Place the horn button assy in a plastic bag, tie the end tightly and dispose of it as other general parts
disposal.
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600K3±01
H42798
Instrument Panel Hole Cover
18 (184, 13)
18 (184, 13)
18 (184, 13)
18 (184, 13)
Instrument Panel Airbag Assy
N
m (kgf
cm, ft
lbf): Specified torque
18 (184, 13)
18 (184, 13)
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
60±53
AVENSIS REPAIR MANUAL (RM1018E)
INSTRUMENT PANEL AIR BAG ASSY
COMPONENTS
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600K4±01
H42660
H42661
H42665
60±54
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. REMOVE INSTRUMENT PANEL HOLE COVER
(a) Using a screwdriver, remove the 2 instrument panel hole cover. 4. REMOVE INSTRUMENT PANEL AIR BAG ASSY
(a) Using a screwdriver disconnect the airbag connector.
(b) Remove the 4 bolts, 2 nuts and the instrument panel air-bag assy.
5. INSTALL INSTRUMENT PANEL AIR BAG ASSY
(a) Install the instrument panel airbag assy.
(b) Connect the airbag connector.
(c) Install the 4 bolts and the 2 nuts. Torque: 18.0 N
m (184 kgf
cm, 13 ft
lbf)
(d) Install the instrument panel hole cover.
6.INSPECT INSTRUMENT PANEL AIR BAG ASSY (See page 60±11)
7.INSPECT SRS WARNING LIGHT (See page 05±1184)
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600K5±01
H40004
SST(s)
H40005
SST(s)Battery
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
60±55
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
When scrapping a vehicle equipped with the SRS or disposing of the instrument panel airbag assy, be sure
to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with
the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
CAUTION:

Never dispose of the instrument panel airbag assy
that has an undeployed airbag.

The airbag produces an extremely loud exploding
sound when it is deployed, so perform the operation
outdoors 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 air-
bag assy.

The instrument panel airbag assy is extremely 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 airbag assy with the deployed air-
bag.

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

Always wash your hands with water after completing
the operation.
1. DISPOSE OF INSTRUMENT PANEL AIR BAG ASSY (WHEN SCRAPPING VEHICLE DEPLOYMENT
METHOD)
HINT:
Prepare a battery as the power source to deploy the airbag.
(a)Check performance of the SST(s) (See step 1±(a) on page 60±17).
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H42660
H42662
SST(s)SST(s)
H41078
10 m (33 ft) or more
SST(s)Battery
60±56
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(b) Disconnect the airbag connector. (1) Using a screwdriver, disconnect the instrumentpanel airbag connector.
(c) Install the SST(s). (1) Connect the connectors of the SST(s) to the instru-
ment panel airbag assy.
SST 09082±00700, 09082±00802 (09082±10801, 09082±20801)
NOTICE:
Take care not to damage the SST(s) wire harness.
(2) Move the SST(s) to at least 10 m (33 ft) away fromthe rear 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.
(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 deploys as the LED of the SST(s) activation switch
comes on.
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H40005
Battery
SST(s)
H42661
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
60±57
AVENSIS REPAIR MANUAL (RM1018E)
(e) Dispose of the instrument panel airbag assy.
CAUTION:

The instrument panel airbag assy is extremely 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 airbag assy with the deployed air-
bag.

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

Do not apply water, etc. to the instrument panel 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 airbag assy still installed.
2. DISPOSE OF INSTRUMENT PANEL AIR BAG ASSY
(WHEN DISPOSING OF AIRBAG A SSEMBLY
DEPLOYMENT METHOD)
NOTICE:

When disposing of the instrument panel 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 performance of the SST(s) (See step 1±(a) on page 60±19).
(b) Using a screwdriver, remove the 2 instrument panel hole
cover.
(c)Remove the instrument panel airbag assy (See page 60±54).
CAUTION:

When removing the instrument panel airbag assy,
work must be started 90 seconds after the ignition
switch is turned to the ºLOCKº position and the nega-
tive (±) terminal cable is disconnected from the bat-
tery.

When storing the instrument panel airbag assy, keep
the upper surface of the airbag deployment side fac-
ing upward.
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H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42664
Inner Diam. WidthTire
60±58
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT 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.
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H43258
SST(s)
H42668
Tires
(5 or more)
SST(s)
H42763
SST(s)
H4266910 m (33 ft) or more
SST(s)
Battery
Instrument Panel
Airbag Assy
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
60±59
AVENSIS REPAIR MANUAL (RM1018E)
(e) Install the SST(s).
Connect the connector of the SST(s) to the instrument
panel airbag assy.
SST 09082±00770
(f) Place the tires. (1) Place at least 2 tires under the tire to which the
instrument panel airbag assy is tied.
(2) Place at least 2 tires over the tire to which the instru- ment panel airbag assy is tied. The top tire should
have the disc wheel installed.
NOTICE:
Do not place the SST(s) connector under the tire because
the SST(s) connector could be damaged.
(3) Tie the tires together with 2 wire harnesses.
CAUTION:
Make sure that the wire harness is tight. It is highly danger-
ous when looseness in the wire harness results in the tires
coming free due to the shock from the airbag deployment.
(g) Install the SST(s). Connect the connectors of the SST(s).
SST 09082±00700, 09082±00802 (09082±10801, 09082±20801)
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.
(h) Deploy the airbag. (1) Connect the red clip of the SST(s) to the batterypositive (+) terminal and the black clip of the SST(s)
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 airbag assy
lower No.1 is tied.
(3) 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.
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H42670
60±60
±
SUPPLEMENTAL RESTRAINT SYSTEM INSTRUMENT PANEL AIR BAG ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(i) Dispose of the instrument panel airbag assy.
CAUTION:

The instrument panel airbag assy is extremely 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 airbag assy with the deployed air-
bag.

Always wash your hands with water after completing
the operation.

Do not apply water etc. to the instrument panel airbag
assy with the deployed airbag.
(1) Remove the instrument panel airbag assy from the tire.
(2) Place the instrument panel airbag assy in a plastic bag, tie the end tightly and dispose of it in the same
way as for other general parts disposal.
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