TOYOTA AVENSIS 2005 Service Repair Manual

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)

600JW±01
H40004
SST(s)
H40004
SST(s)
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
60±19
AVENSIS REPAIR MANUAL (RM1018E)
DISPOSAL
HINT:
When scrapping a vehicle equipped with the SRS or disposing of a horn button assy, be sure to deploy the
airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag de-
ployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.
CAUTION:

Never dispose of the horn button assy that has an un-
deployed airbag.

The airbag produces an extremely exploding sound
when it is deployed, so perform the operation out-
doors 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 horn button assy.

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. DISPOSE OF HORN BUTTON ASSY (WHEN
SCRAPPING VEHICLE DEPLOYMENT METHOD)
HINT:
Prepare a battery as the power source to deploy the airbag.
(a) Check the function of the SST(s).
CAUTION:
When deploying the airbag, always use the specified
SST(s): SRS Airbag Deployment Tool.
SST 09082±00700

H40005
Battery
SST(s)
H40006
SST(s)
H42625
H42626SST(s)
60±20
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(1) Connect the SST(s) to the battery. Connect the red clip of the SST(s) to the battery
positive (+) terminal and the black clip of the SST(s)
to the battery negative (±) terminal.
HINT:
Do not connect the yellow connector of the SST(s) which is to
be connected with the supplemental restraint system.
(2) Check the function of the SST(s).Press the SST(s) activation switch, and check that
the LED of the SST(s) activation switch comes on.
CAUTION:
If the LED comes on when the activation switch is not being
pressed, SST(s) malfunction is posible, so be sure not to
use the SST(s). (3) Disconnect the SST(s) from the battery.
(b) Install the SST(s).
CAUTION:
Check that there is no looseness in the steering wheel assy
and horn button assy. (1)Remove the instrument panel hole (See page
60±54).
(2) Remove the instrument panel airbag assy (See page 60±54).
(3) While turning the steering wheel right and left, re-
move the 3 screws and steering column cover.
(4) Disconnect the airbag connector of the spiral cable sub±assy.
(5) Connect the connector of the SST(s) to the airbag connector of the spiral cable sub±assy.
SST 09082±00700, 09082±00780
NOTICE:
To avoid damaging the SST(s) connector and wire harness,
do not lock the secondary lock of the twin lock.

H40007
10 m (33 ft) or more
Battery
SST(s)
H40005
Battery
SST(s)
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
60±21
AVENSIS REPAIR MANUAL (RM1018E)
(6) Move the SST(s) at least 10 m (33 ft) away from the
front of the vehicle.
(7) Close all the doors and windows in the vehicle.
NOTICE:
Take care not to damage the SST(s) wire harness. (8) Connect the red clip of the SST(s) to the batterypositive (+) terminal and the black clip of the SST(s)
to the negative (±) terminal.
(c) 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 is deployed as the LED of the SST(s) activation
switch comes on.
(d) 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.

When moving the vehicle which has the horn button
assy with the deployed airbag for scrapping, use
gloves and safety glasses.

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

Always wash your hands with water after completing
the operation.

Do not apply water, etc. to the horn button assy with
the deployed airbag.
HINT:
When scrapping a vehicle, deploy the airbag and scrap the ve-
hicle with the horn button assy still installed.
2. DISPOSE OF HORN BUTTON ASSY (WHEN DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT
METHOD)
NOTICE:

When disposing of the horn button 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:
Have a battery as the power source to deploy the airbag.
(a) Check the function of the SST(s) (See step 1±(a)).
(b)Remove the horn button assy (See page 60±17).

H40008
Wire Harness
Diameter
Stripped Wire Harness Section
H42627
L
M
H42628
SST(s) 60±22
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
CAUTION:

When removing the horn button 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 horn button assy, keep the upper
surface of the airbag deployment side facing upward.
(c) Using a service±purpose wire harness for the vehicle, tie
down the horn button assy to the disc wheel.
Wire harness: Stripped wire harness section
1.25 mm
2
or more (0.0019 in2. or more)
CAUTION:
If a wire harness which is too thin or an alternative object
is used to tie down the horn button assy, it may be snapped
by the shock when the airbag is deployed. This is highly
dangerous. Always use a wire harness for vehicle use
which has a diameter of at least 1.25 mm
2
(0.0019 in2).
HINT:
To calculate the square of the stripped wire harness section:
Square = 3.14 x (Diameter)
2
divided by 4
(1) Install the 2 bolts with washers in the 2 bolts holes
of the horn button assy.
Bolt:
L: 35.0 mm (1.378 in.)
M: 6.0 mm (0.236 in.)
Pitch: 1.0 mm (0.039 in.)
NOTICE:

Tighten the bolts by hand until the bolts become diffi-
cult to turn.

Do not tighten the bolts too much.
(2) After connecting the SST(s) below to each other,
connect them to the horn button assy.
SST 09082±00802 (09082±10801, 09082±30801)

H42629
2 Times or more
H42630SST(s)
H42631
SST(s)
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
60±23
AVENSIS REPAIR MANUAL (RM1018E)
(3) Using 3 wire harnesses, wind each wire harness at
least 2 times each around the bolts installed on the
left and right sides of the horn button assy.
CAUTION:

Tightly wind the wire harness around the bolts so that
there is no slack.

If there is slack in the wire harness, the horn button
assy may become loose due to the shock when the
airbag is deployed. This is highly dangerous.
(4) Face the upper surface of the horn button assy up-
ward. Separately tie the left and right sides of the
horn button assy to the disc wheel through the hub
nut holes. Position the SST(s) connector so that it
hangs downward through a hub hole in the disc
wheel.
CAUTION:

Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the horn button assy coming free due to the
shock from the airbag deployment.

Always tie down the horn button assy with the pad
side facing upward. It is highly dangerous if the horn
button assy is tied down with the metal surface facing
upward as the wire harness will be cut by the shock
caused by the airbag deployment and the horn button
assy will be thrown into the air.
NOTICE:
The disc wheel will be marked by the airbag deployment,
so use a redundant disc wheel.
(d) Install the SST(s).
CAUTION:
Place the disc wheel on the level ground.
(1) Connect the connector of the SST(s).
SST 09082±00700
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 disc
wheel.

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.

H4263210 m (33 ft) or moreBattery
SST(s)
H42635
± SUPPLEMENTAL RESTRAINT SYSTEMHORN BUTTON ASSY
60±25
AVENSIS REPAIR MANUAL (RM1018E)
(f) Deploy the airbag.
(1) Connect the red clip of the SST(s) to the battery
positive (+) 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.

6009P±04
H42622
H43002
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
60±17
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. REMOVE HORN BUTTON ASSY
(a) Place the front wheels facing straight ahead.
(b) Using a torx socket wrench (T30), loosen the 2 torxscrews until the groove along the screw circumference
catches on the screw case.
(c) Pull out the horn button assy from the steering wheel assy and support the horn button assy with one hand as shown
in the illustration.
NOTICE:
When removing the horn button assy, do not pull the airbag
wire harness.
(d) Using a screwdriver, disconnect the airbag connectors.
(e) Disconnect the horn connector.
(f) Remove the horn button assy.

H43003
H42615
60±18
±
SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY
AVENSIS REPAIR MANUAL (RM1018E)
4. INSTALL HORN BUTTON ASSY
(a) Support the horn button assy with the hand as shown in the illustration.
(b) Connect the airbag connectors.
(c) Connect the horn connector.
(d) Confirm that the circumference groove of the torx screw fits in the screw case, and place the horn button assy onto
the steering wheel assy.
(e) Using a torx socket wrench (T 30), install the 2 screws. Torque: 8.8 N
m (90 kgf
cm, 78 in.
lbf)
5.INSPECT HORN BUTTON ASSY (See page 60±11)
(a) 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.
6.INSPECT SRS WARNING LIGHT (See page 05±1184)