TOYOTA AVENSIS 2003 Service Repair Manual

H42906
(a)Yellow Part Yellow Part
Mark
(b)
H43151
Yellow Part
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±7
AVENSIS REPAIR MANUAL (RM1018E)
2. DISCONNECTION OF CONNECTORS FOR HORN BUTTON ASSY AND CURTAIN SHIELD AIR-
BAG ASSY
HINT:
Tape up the screwdriver tip before use.
(a) Release the yellow part of the connector using a screwdriver.
(b) Insert a screwdriver tip between the connector and the base, and then le\
ver up connector.
3. DISCONNECTION OF CONNECTORS FOR HORN BUTTON ASSY AND CURTAIN SHIELD AIR-
BAG ASSY
(a) Connect the connector.
(b) Push down securely on the yellow part of the connector.
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H43007
(a)Black PartMark
(b)
Black Part
H43259
Black Part
60±8
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
4. DISCONNECTION OF CONNECTORS FOR INSTRUMENT PANEL AIRBAG ASSY
HINT:
Tape up the screwdriver tip before use.
(a) Release the black part of the connector using a screwdriver.
(b) Insert a screwdriver tip between the connector and the base, and then le\
ver up connector.
5. DISCONNECTION OF CONNECTORS FOR INSTRUMENT PANEL AIRBAG ASSY
(a) Connect the connector.
(b) Push down securely on the yellow part of the connector.
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H01584
SliderSlider
Disconnection is completed
H01585
SliderSlider
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
60±9
AVENSIS REPAIR MANUAL (RM1018E)
6. DISCONNECTION OF CONNECTOR FRONT SEAT AIRBAG ASSY
(a) Place a finger on the slider.
(b) Slide the slider to release lock.
(c) Disconnect the connector.
7. CONNECTION OF CONNECTOR FOR FRONT SEAT AIRBAG ASSY
(a) Align the lock part of the male connector and the slider of the female connec\
tor in the same direction
as shown in the illustration, connect them without rubbing together.
(b) Be sure to insert the connectors until they are locked. After connecting t\
hem, pull them slightly to check
that they are locked. (When locking, make sure that the slider returns to its origina\
l position and a click
sound can be heard.)
HINT:
When connecting them, the slider slides. Be sure not to touch the slider whil\
e connecting, as it may result
in an insecure fit.
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H02763
Outer
H02764
Connector lock is releasedDisconnection is completed
H02768
OuterOuter
Connection is completed
60±10
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
8. DISCONNECTION OF AIRBAG FRONT SENSOR, SIDE AIRBAG SENSOR AND AIRBAG SENSOR REAR CON-
NECTOR
(a) While holding both outer flank sides of the outer, slide the outer to the direction shown by the arrow.
(b) When the connector lock is released, the connectors are disconnected.
HINT:
Be sure to hold both outer flank sides. If the top and bottom
sides are held, it will obstruct disconnection.
9. CONNECTION OF CONNECTORS FOR AIRBAG FRONT SENSOR, SIDE AIRBAG SENSOR AND AIRBAG SENSOR REAR
(a) Align the male connector (on the side of sensor) and female connector in th\
e same direction as shown in the illustration and connect them without rubbing together.
(b) Be sure to insert the connectors until they are locked. After connecting t\
hem, pull them slightly to check that they are locked. (When locking, make sure that the outer returns to its original position and a click
sound can be heard.)
HINT:
When connecting them, the outer slides. Be sure not to hold the outer while connecting, as it may result in
an insecure fit.
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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.
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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.
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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.
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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).
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±
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.
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610E8±01
B69710
±
SEAT BELT FRONT SEAT BELT
61±5
AVENSIS REPAIR MANUAL (RM1018E)
FRONT SEAT BELT
PRECAUTION
CAUTION:
Replace the faulty parts of the seat belt systems (outer belt, inner belt, bol\
ts, nuts, adjustable shoul-
der anchor, tether anchor hardware, sill±bar, etc.)
Seat belt systems not in use at the time of a collision should also be inspected and replaced if found
to be damaged or working improperly.
1. RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 16 km/h (10 mph) and slam on the brakes.Check the belt locks and cannot be extended at this time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt assembly and perform the following static check. Also
whenever installing a new belt assembly, verify the proper op-
eration before installation.
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