2003 TOYOTA AVENSIS Service Repair Manual

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Page 73 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual D25786
Shape (Example)Removal/Installation
Clip Remover
Pliers
Screwdriver
Scraper
Protective Tape
Clip

Protective Tape
±
INTRODUCTION REPAIR INSTRUCTION
01±7
AVENSIS REPAIR MANUAL (RM1

Page 74 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual V00012
Shape (Example)Removal/Installation
Removal Installation
Removal Installation
D25063
CORRECT
WRONG
D25064
01±8
±
INTRODUCTION REPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(h) REMOVAL

Page 75 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual L1L2L1L2L1L2
D02612
L2
L1L2
L1L2
L1
D01201
±
INTRODUCTIONREPAIR INSTRUCTION
01±9
AVENSIS REPAIR MANUAL (RM1018E)
(i)TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1)When the torque wrench

L1L2L1L2L1L2
D02612
L2
L1L2
L1L2
L1
D01201
±
INTRODUCTIONREPAIR INSTRUCTION
01±9
AVENSIS REPAIR MANUAL (RM1018E)
(i)TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1)When the torque wrench is combined with SST oran extension tool to extend the length, and you
tighten until the torque wrench reads the specified
torque value, the actual torque becomes excessive.
(2)In this manual, only the specified torque is de-
scribed. In case of using SST or extension tool, cal-
culate the reading of the torque wrench by the fol-
lowing formula.
(3)Formula T'=T x L2/(L1 + L2)
T'Reading of torque wrench Nmkgfcmftlbf
TTorque Nmkgfcmftlbf
L1Length of SST or extension tool (cm)
L2Length of torque wrench (cm)
2.FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The AVENSIS is equipped with an SRS (Supplemental Restraint System), which \
includes the driver airbag,
front passenger airbag and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause\
the supplemental restraint
system to unexpectedly deploy while servicing. This could cause a seriou\
s accident.
Furthermore, if a mistake is made when servicing the supplemental restra\
int system, it is possible that the
SRS will fail to operate when required. Before servicing (including remova\
l or installation of parts, inspection
or replacement), be sure to read the following items carefully. Then follow the correct procedures described
in this manual.
(a)GENERAL NOTICE (1)Malfunction symptoms of the supplemental restraint system are difficult to confirm so the diag-nostic trouble codes become the most important source of information when trou\
bleshooting.
When troubleshooting the supplemental restraint system, always check the dia\
gnostic trouble
codes before disconnecting the battery (See page 05±1184).
(2) Work must be started after 90 seconds from the time that the ignition switch\
is turned to the LOCK position and the negative (±) terminal cable is disconnected from the batte\
ry.
(The supplemental restraint system is equipped with a back±up power sourc\
e. So, if work is
started within 90 seconds after disconnecting the negative (±) terminal ca\
ble from the battery,
the SRS may deploy).
When the negative (±) terminal cable is disconnected from the battery, memory of the clock and
audio systems is cancelled. So, before starting work, make a record of the contents recorded
in each memory system. Then, when work is finished, reset the clock and audio systems as be-
fore.
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Page 76 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual D30401
Mark
01±10
±
INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(3)Even in the case of a minor collision where the SRS does not deploy, the horn button assembly, instrument pane

D30401
Mark
01±10
±
INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(3)Even in the case of a minor collision where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly and seat belt pretensioner should be in\
spected
(See pages 60±19, 60±19 and 61±9).
(4)Never use the SRS related parts from another vehicle. When replacing the part\
s, replace them with new parts.
(5)Before repairs, remove the airbag sensor if there is a possibility of sh\
ock during repairs.
(6)Never disassemble and repair the center airbag sensor assembly, side airbag sensor assembly, horn button assembly, instrument panel passenger airbag assembly, front seat airbag assembly,
curtain shield airbag assembly or seat belt pretensioner.
(7)If the center airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly have been dropped, or if the\
re are cracks,
dents or other defects in the case, bracket or connector, replace them with new ones.
(8)Do not directly expose the airbag sensor assembly, the side airbag sensor assembly, the horn button assembly, the instrument panel passenger airbag assembly or the seat belt pretensioner
to hot air or flames.
(9)Use a volt/ohmmeter with high impedance (10 k/V minimum) for troubleshooting electrical cir-
cuits.
(10)Information labels are attached to the SRS components. Follow the instru\
ctions on the notices.
(11)After work on the supplemental restraint system is completed, check the SRS w\
arning light (See page 05±1184)
(b)SPIRAL CABLE (in Combination Switch)(1)The steering wheel must be fitted correctly to thesteering column with the spiral cable at the neutral
position, otherwise cable disconnection and other
troubles may occur. Refer to page 60±26 of this
manual concerning the correct installation of the
steering wheel.
(c) HORN BUTTON ASSEMBLY (with Airbag) (1) When removing the horn button assembly or handling a new horn button, it sho\
uld be placed withthe top of the pad surface facing upward. Placing it with the pad surface facing downward may
lead to a serious accident if the airbag deploys for some reasons. Also, do \
not place anything
on top of the horn button.
(2) Never measure the resistance of the airbag squib (This may cause the airbag to inflate, which is very dangerous).
(3) Grease should not be applied to the horn button assembly, and the pad should not be cleaned with any type of detergent.
(4) Store the horn button assembly where the ambient temperature remains below 93 C (200 F),
without high humidity and away from electrical noise.
(5) When using electric welding, disconnect the airbag connector (4 yellow pins\
) under the steering column near the combination switch connector before starting work.
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Page 77 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual D25096
Example:CORRECTWRONG
Z13950
Example:
D27522
Example: CORRECT WRONG
±
INTRODUCTIONREPAIR INSTRUCTION
01±11
AVENSIS REPAIR MANUAL (RM1018E)
(6)When disposing the vehicle or the horn button as

Page 78 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual Z13951
Example:
D26612
Example:CORRECT WRONG
B01546
Example:
01±12
±
INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(e)FRONT SEAT AIRBAG ASSEMBLY (1)Always store a removed or new f

Page 79 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual D30399
Example:CORRECT WRONG
D30398
Example:
±
INTRODUCTIONREPAIR INSTRUCTION
01±13
AVENSIS REPAIR MANUAL (RM1018E)
(f)INSTRUMENT PANEL LOWER AIRBAG ASSEMBLY
(1)Always store a removed or new instr

Page 80 of 2234

TOYOTA AVENSIS 2003 Service Repair Manual D26602
Example:CORRECT WRONG
Clear Plastic Bag
D26603
Example:
01±14
±
INTRODUCTIONREPAIR INSTRUCTION
AVENSIS REPAIR MANUAL (RM1018E)
(3)Grease should not be attached to the curtain shield airbag

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