2002 TOYOTA AVENSIS Repair Manual

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.

H42763
SST(s)
H43299
Battery Instrument Panel
Passenger Airbag Assy
10 m (33 ft) or more
SST(s) SST(s)
H42648
± SUPPLEMENTAL RESTRAINT SYSTEMINSTRUMENT PANEL PASSENGER AIR BAG ASSY
60±35
AVENSIS REPAIR MANUAL (RM1018E)
(3) Tie the tires together with 2 wire harnesses.
CAUTION:
Make sure that the wire harness is tight. It is very danger-
ous when looseness in the wire harness result in the tires
coming free due to the shock from the airbag deployment.
HINT:
Place the SST(s) connector and the wire harness inside tires.
Secure at least 1 m (3 ft) of slack for the wire harness.
(f) Install the SST(s).
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 tire.
(g) Deploy the airbag.
(1) Connect the red clip of the SST(s) to the battery
positive (+) terminal and the black clip of the SST 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 passenger air-
bag assy is tied.
(3) Press the activation switch of the SST(s) and
deploy the airbag.
HINT:
The airbag is deploys as the LED of the SST(s) activation switch
comes on.
(h) Dispose of the instrument panel passenger airbag assy.
CAUTION:

The instrument panel passenger airbag assy is very
hot when the airbag is deployed, so leave it alone for
at least 30 minutes after deployment.

Use gloves and safety glasses when handling the
instrument panel passenger airbag assy with the
deployed airbag.

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

Always wash your hands with water after completing
the operation.
(1) Remove the instrument panel passenger airbag
assy from the tire.
(2) Place the instrument panel passenger airbag assy
in a plastic bag, tie the end tightly and dispose of it
in the same way as other general parts disposal.

600AA±04
H42641N
m (kgf
cm, ft
lbf): Specified torqueFront Seat Assy LH
8.0 (82, 71 in.
lbf)
Seat Track Cover LH
Seat Track Bracket
Cover Inner LH
Seat Position Airbag Sensor
37 (375, 27)
37 (375, 27)
37 (375, 27)


± SUPPLEMENTAL RESTRAINT SYSTEMSEAT POSITION AIR BAG SENSOR
60±69
AVENSIS REPAIR MANUAL (RM1018E)
SEAT POSITION AIR BAG SENSOR
COMPONENTS

600AB±04
H42640
60±70
±
SUPPLEMENTAL RESTRAINT SYSTEM SEAT POSITION AIR BAG SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Replacement procedure of the RH side is the same as that of the LH side.
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE SEAT TRACK COVER LH (See page 72±16)
4.REMOVE SEAT TRACK BRACKET COVER INNER LH (See page 72±16)
5.REMOVE FRONT SEAT ASSY LH (See page 72±16) 6. REMOVE SEAT POSITION AIR BAG SENSOR
(a) Disconnect the connector of the seat position airbag sen-sor.
(b) Using a torx socket wrench (T30), remove the torx screw and seat position airbag sensor.
7. INSTALL SEAT POSITION AIR BAG SENSOR
(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) Using a torx socket wrench (T30), install the seat position airbag sen\
sor with the torx screw. Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
NOTICE:

If the seat position airbag sensor has been dropped, or there are any cracks, dents or other de-
fects in the case, bracket or connector, replace the seat position airbag sensor with a new one.

When installing the seat position airbag sensor, take care that the SRS wiring does not interfere
with other parts and is not pinched between other parts.
(d) Connect the connector of the seat position airbag sensor.
(e) Check that no play is identified.
8.INSTALL FRONT SEAT ASSY LH (See page 72±16)
Torque: 37 N
m (375 kgf
cm, 27 ft
lbf)
9.SRS WARNING LIGHT (See page 05±1184)

600A6±03
H42766N
m (kgf
cm, ft
lbf) : Specified torque Rear Door Opening
Trim Weatherstrip LH
Rear Door Scuff
Plate LH
Center Pillar
Garnish Lower LH
Front Door Scuff
Plate LHFront Door Opening Trim
Weatherstrip LHFront Seat
Outer Belt Assy LH
8.0 (82, 70 in.
lbf)
Side Airbag Sensor Assy LH
± SUPPLEMENTAL RESTRAINT SYSTEMSIDE AIR BAG SENSOR ASSY LH
60±65
AVENSIS REPAIR MANUAL (RM1018E)
SIDE AIR BAG SENSOR ASSY LH
COMPONENTS

600A7±03
H42767
60±66
±
SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIR BAG SENSOR ASSY LH
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
Replacement procedure of the RH side is the same as that for with LH side.
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3.REMOVE FRONT DOOR SCUFF PLATE LH (See page 76±36)
4.REMOVE REAR DOOR SCUFF PLATE LH (See page 76±36)
5.REMOVE FRONT DOOR WEATHERSTRIP LH (See page 76±36)
6.REMOVE REAR DOOR WEATHERSTRIP LH (See page 76±36)
7.REMOVE CENTER PILLAR GARNISH LOWER LH (See page 76±36)
8.REMOVE FRONT SEAT OUTER BELT ASSY LH (See page 61±7) 9. REMOVE SIDE AIR BAG SENSOR ASSY LH
(a) Remove the bolt and the side airbag sensor assy LH.
(b) Disconnect the connector from the side airbag sensorassy LH.
10. INSTALL SIDE AIR BAG SENSOR ASSY LH
(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) Install the side airbag sensor assy LH with the nut. Torque: 8.0 N
m (82 kgf
cm, 70 in.
lbf)
NOTICE:

If the side airbag sensor assy LH has been dropped, or there are any cra\
cks, dents or other de-
fects in the case, bracket or connector, replace the side airbag sensor assy LH with a new one.

When installing the side airbag sensor assy LH, take care that the SRS wiring\
does not interfere
with other parts and is not pinched between other parts.
(d) Connect the connector of the side airbag sensor assy LH.
(e) Check that no play is identified.
11.INSTALL FRONT SEAT OUTER BELT ASSY LH (See page 61±7)
12.INSPECT SRS WARNING LIGHT (See page 05±1184)

6009S±04
H42634
H42636 Claw
60±26
±
SUPPLEMENTAL RESTRAINT SYSTEM SPIRAL CABLE SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
SPIRAL CABLE SUB±ASSY
REPLACEMENT
HINT:
COMPONENTS: See page 60±16
1.PRECAUTION (See page 60±1)
2.DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60±1)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4.REMOVE HORN BUTTON ASSY (See page 60±17)
5.REMOVE STEERING WHEEL ASSY (See page 50±9) SST 09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±\
05021)
6.REMOVE INSTRUMENT PANEL HOLE COVER (See page 60±54)
7.REMOVE INSTRUMENT PANEL AIR BAG ASSY (See page 60±54)
8. REMOVE STEERING COLUMN COVER SUB±ASSYLOWER
(a) Remove the 3 screws and the steering column cover sub± assy lower.
9. REMOVE STEERING COLUMN COVER
W/INSTRUMENT CLUSTER FINISH PANEL ASSY
(a) Remove the steering column cover w/instrument cluster finish panel assy.
10. REMOVE SPIRAL CABLE SUB±ASSY
(a) Disconnect the airbag connector and the connector from the spiral cable sub±assy.
(b) Disengage the 3 claws and remove the spiral cable sub±
assy.
11.INSPECT SPIRAL CABLE SUB±ASSY (See page 60±11)
(a) If the following condition is identified, replace the spiral cable sub±\
assy with a new one. Condition:
Scratches or cracks on the connector
Cracks, dents or chips in the spiral cable sub±assy
12. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
(a) Check that the front wheels are facing straight ahead.