INSTRUCCIONES TECNICAS
REEMPLAZO DEL INFLADOR EN
COROLLA/AVENSIS
Paso 1
1. DIAGRAMA DE LA OPERACION ·············································································· 3
2. IDENTIFICAR LOS VEHICULOS AFECTADOS ··························································· 4
3. PREPARACION ····································································································· 7
4. PROCEDIMIENTOS GENERALES DEL TRABAJO ······················································ 8
5. PRECAUCIONES DE AIRBAG REMOCION / INSTALACION ········································· 9
6. PRECAUCIONES PARA EL TRABAJO AL INTERIOR DE VEHÍCULOS ANTIGUOS ········· 11
7. PRECAUCIONES PARA REALIZAR EL TRABAJO ······················································ 12
8. COMPONENTES ···································································································· 14
Paso 2
9. VERIFICAR EL CÓDIGO DE BARRAS (Excepto Fabricados en TDB) ························· 16
10. VERIFICAR EL CÓDIGO DE BARRAS (Para los Fabricados en TDB) ······················· 17
VERIFICAR EL CÓDIGO DE BARRAS (AVENSIS) ··················································· 17
Paso 3
11. REMOVER PANEL DE INSTRUM/CONJUNTO AIRBAG PASAJERO (COROLLA) ······· 18
REMOVER PANEL DE INSTRUM/CONJUNTO AIRBAG PASAJERO (AVENSIS) ·········· 24
Paso 4
12. REEMPLAZO DEL INFLADOR (COROLLA) ··························································· 29
REEMPLAZO DEL INFLADOR (AVENSIS) ······························································ 37
Paso 5
13. REINSTALAR EL PANEL DE INSTRUMENTOS/CONJUNTO AIRBAG PASAJERO ······· 53
1
<<SAFETY PRECAUTIONS>>
A. Be sure to observe the following precautions to prevent accidents and
injuries.

Park the vehicle and chock the wheels.

If it is necessary to start the engine, perform the operation in a well ventilated area.
 Before removing and reinstalling heavy parts such as the engine, transmission an d
differential using lifting equipment, check that there are no problems with the equipment.

When working in a group of 2 or more, each person must work to ensure the safety of all
team members.
 To prevent burns and other injuries, use extra caution when handling parts that are
subject to high temperatures, as well as rotating, sliding, or vibrating parts.
 When lifting the vehicle using a jack, support it in the specified location using a rigid rack.

When lifting the vehicle using a lift, lock the lift for safety.
B. Also perform the following operation with care.
Use of auto lift
 Make absolutely certain that there are no other workers and no tools, parts, or other
objects within the movable range of the lift. Also, be sure to announce all lift operations
out loud (such as “Raising the lift!” and “Lowering the lift!”) to alert other workers.
 When raising or lowering the lift to adjust the vehicle position, etc., pay attention to the
positions of your arms, legs, and other body parts, and be extremely careful t o prevent
them from being caught in the lift.
Use of brake cleaner

Use brake cleaner for appropriate purposes in accordance with instructions in the
manual.
 Do not use brake cleaner to remove dirt or stains from work clothes, etc. It can catch on
fire and cause serious burns.
<Precautions>

Do not use brake cleaner near flame or fire.

Do not use large amounts of brake cleaner in a room where a fire is burning.
 Do not keep brake cleaner in a place subject to high temperatures exceeding 40° C , such as a
place subject to direct sunlight or near fire.

Do not put brake cleaner in fire.
Edges

When handling the edges of parts and panels, wear protective gloves or apply
protective tape to the edges to prevent injuries to your hands and fingers.
2
1. DIAGRAMA DE LA OPERACION
Compruebe si el vehículo esta dentro de
No
los número de VIN afectados.
Si
Verifique que el código de barras.
No está involucrado a los trabajos de sustitución
*Consulte el archivo 2.
Está involucrado a los trabajo de sustitución
Reemplace el inflador.
*Consulte el archivo 3, 4, 5.
Compruebe la luz de advertencia del
airbag.
* Consulte el archivo 5.
Fin de los trabajos.
※ AVISO:
El inflador es material peligroso (Hazmat).
Le informaremos cómo desechar inflador original después de sustituirlo por uno
nuevo. Por favor, mantenerlos en lugar seguro hasta que informamos el método de
eliminación.
3
2. IDENTIFICAR LOS VEHICULOS AFECTADOS
NUMERO DE IDENTIFICACION DE LOS VEHICULOS AFECTADOS
VIN Range
Model
VIN Range
WMI
VDS
Range
1NX
BR####
Z000001 - ZPP4315
2T1
BR####
C000082 - C836386
9BR
53####
8500004 - 8531416
BJ####
2000003 - 4000825
BM####
0001009 - 0049218
BR####
0002007 - 3074259
BT####
0015629 - 3203256
BW####
0006951 - 3039985
BZ####
0001801 - 3035691
EM####
0001001 - 0009443
ER####
0013935 - 0151722
EW####
0008142 - 0060691
EX####
3000005 - 3005199
EZ####
0002150 - 0016837
KM####
0009695 - 0025709
KR####
0034118 - 2018046
KX####
3005201 - 3013745
KZ####
0017809 - 0035299
AHT
53####
6500000 - 7513229
AHT
54####
6500023 - 7513681
Model
WMI
VDS
Range
BM####
R000001 - R039410
BX####
R000001 - R005184
BZ####
R000001 - R027719
EM####
R001874 - R017653
EX####
R000304 - R005182
EZ####
R001512 - R027723
JM####
E001001 - E081129
JW####
E000540 - E028584
JX####
E000544 - E028611
JY####
E000533 - E007892
JZ####
E000533 - E077544
KM####
E000534 - E066931
KW####
E001004 - E028613
KX####
E001005 - E043887
KY####
E001007 - E007893
KZ####
E001001 - E062296
MHF
53####
8000000 - 8008245
MR0
53####
7000000 - 7058826
NMT
COROLLA
COROLLA
JTD
Model
SB1
Frame type
Frame No.
6000002 - 6002929
ZZE121
8000005 - 8009088
9501218 - 9501218
COROLLA
ZZE122
6000000 - 7014562
5000010 - 9001709
4
NOTE:
# indicates that various characters may occupy that position. As for the total number of affected
vehicles shipped to your country, please refer to the attached VIN-list.
1.
CHECK THE VEHICLE IDENTIFICATION
NUMBER
(a) Confirm that the VIN is within the range
shown in the table above.
HINT:
The Vehicle Identification Number (VIN) is
stamped on location A and B shown in the
illustration.
5
AFFECTED VEHICLE IDENTIFICATION NUMBER
Model
AVENSIS
WMI
SB1
VIN Range
VDS
Range
BH####
E000520 - E006844
BJ####
E000504 - E006854
BR####
E000501 - E081944
BW####
E000502 - E038315
BZ####
E000516 - E003486
DJ####
E000522 - E006853
DR####
E000505 - E069217
DW####
E000542 - E081611
DZ####
E000531 - E003466
EH####
E000521 - E000602
EJ####
E000538 - E006860
ER####
E000533 - E049464
EW####
E000503 - E075436
EZ####
E000604 - E003474
NOTE:
# indicates that various characters may occupy that position. As for the total number of affected
vehicles shipped to your country, please refer to the attached VIN -list.
2.
CHECK THE VEHICLE IDENTIFICATION
NUMBER
(b) Confirm that the VIN is within the range
shown in the table above.
HINT:
The Vehicle Identification Number (VIN) is
stamped on location A and B shown in the
illustration.
6
3. PREPARACION
PARTES COROLLA
Part Number
04000-44212
PARTES AVENSIS
Part Number
04003-11105
-
Part Description
Kit del inflador del Air Bag
Inflador
Tuerca con autobloqueo
Placa para determinar la posición
Quantity
1
1
4
1
Others
For LHD
Single B
Part Description
Instrument Panel Airbag Inflator Kit
Inflador
Tuerca con autobloqueo
Placa para determinar la posición
Electro Tap
Quantity
1
1
4
1
1
Others
For LHD
Dual E
-
Quantity
1
Others
-
Quantity
-
Others
-
Quantity
-
Others
-
-
-
SST
Part Number
09950-50013
Name
Set extractor C
TOOLS&EQUIPMENT
Part Number
-
Name
Standard Hand Tools
Torque Wrench
Global TechStream (ITT3)
Torx® Socket Wrench (T30)
Moulding Remover
Scan Tool
SUPPLIES
Name
Protective Eyewear
Work Gloves
Protective Tape
Marking Pen
7
4. PROCEDIMIENTOS GENERALES DEL TRABAJO
1. Remove the instrument panel sub-assy upper from the vehicle.
2. Replace the inflator inside the passenger airbag and install to
the vehicle.
8
5. PRECAUCIONES DE AIRBAG REMOCION / INSTALACION
If an airbag system is not handled with proper procedures and methods, it
may be activated accidentally during work resulting in a life-threatening
serious accident.
Also if operation is wrong, the system may fail to be activated when
needed.
Be sure to perform proper work firmly and safely according to this
instruction manual.
1. DISCONNECT THE BATTERY NEGATIVE
TERMINAL
(a) Always be sure to disconnect the negative
terminal before performing work in order to
prevent improper operation of an airbag.
(b) Wait 90 seconds or more after
disconnecting the negative terminal before
performing any work due to the backup
power supply equipped to the airbag
system.
2.
ELIMINATE STATIC ELECTRICITY
(a) Before start of work, touch a metallic
portion of the vehicle with a bare hand to
discharge static electricity charged on your
body.
3. DO NOT MEASURE RESISTANCE USING
A CIRCUIT TESTER
(a) Do not measure resistance of airbag
components. Measuring current of a circuit
tester may cause accidental activation.
9
4.
HANDLE AN AIRBAG PROPERLY
(a) Keep the deploying side facing upward except for when the inflator is replaced. Do not put
anything on the airbag.
CAUTION:
Be sure to place parts properly. Otherwise a life-threatening serious accident may occur in
case of accidental activation.
(b) If an inflator is dropped accidentally,
replace it with a NEW one.
10
6. PRECAUCIONES PARA EL TRABAJO AL INTERIOR DE VEHÍCULOS
ANTIGUOS
1.
PREVENT DAMAGE OF INTERIOR
PARTS
(a) Interior parts are brittle due to aging.
Handle parts carefully.
(b) Before attaching protective tape, check for
aging of the part.
2.
DISENGAGE CLIPS GENTLY
(a) If pulled forcibly and locally, parts may be
damaged or clips may drop off.
(b) When it is possible to access the backside
of a clip and push it from the behind,
perform work from both frontside and
backside to reduce the burden on the part
as far as possible.
3.
PLACE THE REMOVED PART
PROPERLY
(a) Keep the removed parts orderly to prevent
damage.
(b) For work on a removed part, lay a soft cloth
under the part as needed in order to
prevent damage of the design surface.
11
7. PRECAUCIONES PARA REALIZAR EL TRABAJO
1. PAY ATTENTION TO LIFTING UP OR
JACKING UP A VEHICLE
(a) Perform safe and secure work according to
instructions in general description of a
repair manual.
(b) When operate a lifting or jacking device,
make sure that all workers around the
device including your self are safe and call
to each other in order to prevent a trample
accident.
2. WEAR PROTECTIVE EYEWEAR
(a) Always wear protective eyewear in
situations where gas or contaminations
may fly such as fuel leakage prevention,
carbon removal from a piston head, work
on underbody parts etc.
3. DO NOT CLEAN CLOTHES WITH BRAKE
CLEANER
(a) Never spray brake cleaner on your clothes
since it is easy to evaporate and flammable.
A cigarette or a stove may cause a serious
burn accident.
4. TAKE CARE NOT TO BURN YOURSELF
(a) When the engine is hot, wear gloves etc. to
protect yourself against burn injury.
12
5. PROTECT THE VEHICLE
(a) In order not to contaminate or damage the
vehicle, be sure to install the fender cover,
the grill cover and the seat cover, and
attach the masking tape etc.
HINT:
Some illustrations in the relevant instructions
manual may not show the above-mentioned
protective parts to make the target part easy and
simple to recognize.
6. PAY ATTENTION TO HANDLING
REPLACEMENT PARTS
(a) The removed parts shall be marked or
broken and stored in a replacement parts
box etc. to avoid reassembling in error.
(b) Check the replacement parts in final
inspection.
HINT:
Illustrations are for work description only and not
related to actual replacement parts.
7. DO NOT BREAK PARTS DURING WORK
INSIDE ENGINE ROOM
(a) Do not be absorbed in work and place your
hand carelessly in the engine room
resulting in breakage of parts.
8. CHECK THE ENGINE ROOM BEFORE
STARTING THE ENGINE
(a) Check if you have forgotten to attach any
parts.
(b) Check if you have forgotten to remove any
tools, shop cloths, etc.
13
8. COMPONENTES COROLLA
14
COMPONENTES AVENSIS
15
9. VERIFICAR EL CÓDIGO DE BARRAS (Excepto Fabricados en TDB)
1.
Escanear el código de barras en la etiqueta pegada en la carcasa del airbag.
AVISO:


La ubicación de la etiqueta varía dependiendo de las especificaciones.
Hay dos etiquetas idénticas pegadas en las caras inferiores y laterales. Puede escanear una
de las dos etiquetas.
SUGERENCIA:
Cuando el código de barras es escaneado con éxito, se produce sonido de confirmación .
2. Mira el resultado en la pantalla para determinar si procede o no es necesario la
sustitución del inflador.
RESULT (SCREEN)
ACTION
La sustitución del inflador es necesario..
Ir a REMOVER EL PANEL DE
INSTRUMENTOS/CONJUNTO AIRBAG
PASAJERO
La sustitución del inflador no es necesario.
Restaurar el vehículo y terminar el trabajo.
16
10. VERIFICAR EL CÓDIGO DE BARRAS (Para los Fabricados en TDB)
1. Escanear el código de barras en la etiqueta pegada en la carcasa del airbag.
SUGERENCIA:
Cuando el código de barras es escaneado con éxito, se produce sonido de confirmación.
VERIFICAR EL CÓDIGO DE BARRAS (AVENSIS)
17
11. REMOVER EL PANEL DE INSTRUMENTOS/CONJUNTO AIRBAG
PASAJERO EN COROLLA
1. DISCONNECT BATTERY NEGATIVE
TERMINAL
(a) Always be sure to disconnect the negative
terminal before performing work in order to
prevent improper operation of an airbag.
(b) Wait 90 seconds or more after
disconnecting the negative terminal before
performing any work due to the backup
power supply equipped to the airbag
system.
2. PLACE FRONT WHEELS FACING
STRAIGHT AHEAD
3. REMOVE HORN BUTTON ASSY
NOTICE:
If the airbag connector is disconnected with
the ignition switch at ON or ACC, DTCs will be
recorded.
(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 wheel pad from the horn button
assy.
(d) Disconnect the airbag connector and
remove the horn button assy.
18
4. REMOVE STEERING WHEEL ASSY
(a) Remove the steering wheel set nut.
(b) Place matchmarks on the steering wheel
and main shaft assembly.
(c) Using SST, remove the steering wheel.
SST 09950−50013
(09951−05010, 09952−05010,
09953−05020, 09954−05021)
5. REMOVE METER HOOD SUB−ASSY
(a) Remove the clip.
(b) Using a screwdriver, disengage the 3 clips
and 4 claws, then remove the meter hood.
HINT:
Tape the screwdriver tip before use.
6. REMOVE COMBINATION METER ASSY
(a) Remove the screw.
(b) Disengage the 2 clips as shown in the
illustration.
(c) Disconnect the connector, then remove the
combination meter.
19
7. REMOVE INSTRUMENT PANEL REGISTER
ASSY NO.3
(a) Using a moulding remover, remove the
instrument panel register No.3.
HINT:
Tape the moulding remover tip before use.
8. REMOVE INSTRUMENT PANEL REGISTER
ASSY NO.1
9. REMOVE FRONT ASH RECEPTACLE BOX
SUB−ASSY
10. REMOVE CONSOLE PANEL UPPER
(a) M/T:
(1) Remove the shift level knob.
(b) Using a screwdriver, disengage the 6
claws.
HINT:
Tape the screwdriver tip before use.
(c) Disconnect the connector, then remove the
console upper panel.
11. REMOVE INSTRUMENT CLUSTER FINISH
PANEL
(a) Manual A/C:
(1) Center the control lever.
(2) Apply protective tape to the instrument
cluster finish panel as shown in the
illustration.
20
(3) Remove the control knob.
(4) Remove the screw.
(5) Using a screwdriver, disengage the 4
clips and 5 claws, then remove the
instrument cluster finish panel.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Do not pull the lid of auxiliarybox.
(b) Auto A/C:
(1) Using a screwdriver, disengage the 4
clips and 4 claws, then remove the
instrument cluster finish panel.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Do not pull the lid of auxiliarybox.
(2) Disconnect the connectors.
12. REMOVE INSTRUMENT CLUSTER FINISH
PANEL SUB−ASSY LOWER CENTER
(a) Remove the 4 screws.
21
(b) Using a screwdriver, disengage the 8 clips,
then remove the instrument cluster finish
panel and radio turner opening cover.
HINT:
Tape the screwdriver tip before use.
(c) Remove the instrument cluster finish panel
from the radio turner opening cover.
13. REMOVE GLOVE COMPARTMENT DOOR
ASSY
(a) Remove the screw and glove compartment
door stopper from the glove compartment
door.
(b) Deform the upper part of the glove
compartment door to release the stoppers.
(c) Pull the glove compartment door upward to
remove it.
14. REMOVE FRONT PILLAR GARNISH RH
(a) Disengage the 2 clips.
(b) Pull the front pillar garnish RH upward to
remove it.
15. REMOVE FRONT PILLAR GARNISH LH
16. SEPARATE PASSENGER AIRBAG
CONNECTOR
(a) Remove the connector cover from the
lower instrument panel.
NOTICE:
When handling the airbag connector, take
care not to damage
the airbag wire harness.
(b) Disconnect the front passenger airbag
connector.
22
17. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER
(a) Remove the bolt and 2 screws.
(b) Using a moulding remover, disengage the 6 clips.
(c) Remove the instrument panel upper.
18. REMOVE INSTR PNL PASS L/DOOR AIR
BAG ASSY
(a) Remove the 2 bolts and 2 strings from the
right and left brackets of the instrument
panel passenger airbag assy.
(b) Remove the 3 nuts and instr pnl l/door air
bag assy from the instrument panel UPR.
23
11. REMOVER EL PANEL DE INSTRUMENTOS/CONJUNTO AIRBAG
PASAJERO EN AVENSIS
1. DISCONNECT THE BATTERY NEGATIVE
TERMINAL
(a) Always be sure to disconnect the negative
terminal before performing work in order to
prevent improper operation of an airbag.
(b) Wait 90 seconds or more after
disconnecting the negative terminal before
performing any work due to the backup
power supply equipped to the airbag
system.
2. REMOVE GLOVE COMPARTMENT DOOR
ASSY
(a) Remove the screw.
(b) Deform the upper part of the glove
compartment door assy to release the
stoppers.
(c) Pull the glove compartment door assy
upward to remove it.
3. DISCONNECT PASSENGER AIRBAG
CONNECTOR
(a) Remove the passenger airbag connector
clip.
(b) Disconnect the passenger airbag
connector.
24
4. REMOVE INSTRUMENT CLUSTER FINISH
PANEL GARNISH NO.1
(a) Disengage the 2 clips and remove the
instrument cluster finish panel garnish
No.1.
5. REMOVE INSTRUMENT CLUSTER FINISH
PANEL GARNISH NO.2
(a) Disengage the 5 clips and claw, and then
remove the instrument cluster finish panel
garnish No.2.
(b) Disconnect the connectors.
6. REMOVE INSTRUMENT PANEL
REGISTER ASSY CTR
(a) Remove the 2 screws.
(b) Disengage the 2 clips and remove the
instrument panel register assy CTR, and
then disconnect the connectors.
7. REMOVE STEERING COLUMN COVER
LWR
(a) Remove the 3 screws and steering
column cover LWR.
25
8. REMOVE STEERING COLUMN COVER W/
INSTRUMENT CLUSTER FINISH PANEL
ASSY
(a) Disengage the 2 clips and remove the
steering column cover w/ instrument
cluster finish panel assy.
9. REMOVE COMBINATION METER ASSY
(a) Remove the 2 screws and disengage the
2 clips.
(b) Pull out the combination meter assy, and
then disconnect the connectors.
10. REMOVE INSTRUMENT PANEL
REGISTER ASSY NO.1
(a) Insert a clip remover between the center
of the instrument panel register assy
No.1 lower and the instrument panel
sub–assy upper to disengage the 2 claws
shown in the illustration.
(b) Disengage the 2 claws and remove the
instrument panel register assy No.1.
11. REMOVE INSTRUMENT PANEL
REGISTER ASSY NO.2
26
12. REMOVE FRONT PILLAR GARNISH LH
(a) Disengage the 2 clips, and remove the
front pillar garnish LH.
13. REMOVE FRONT PILLAR GARNISH RH
14. REMOVE INSTRUMENT PANEL SUB–ASSY UPPER W/ INSTR PNL PASS L/DOOR AIRBAG
ASSY
(a) Remove the 2 screws and bolt.
(b) Disengage the 2 clips and 3 claws.
(c) Pull the instrument panel sub–assy upper w/ passenger airbag assy upper rearward to remove it.
(d) Disconnect the connectors.
27
15. REMOVE INSTRUMENT PANEL
PASSENGER AIRBAG ASSY
(a) Remove the 2 screws.
(b) Release the rear side wall of the airbag
door from the hook by slightly deflecting it
and roll the instrument panel passenger
airbag assy forward.
(c) Release the front side wall of the airbag
door from the other hook and remove the
instrument panel passenger airbag assy.
28
12. REEMPLAZO DEL INFLADOR EN COROLLA
NOTICE:
 DO NOT allow foreign objects to enter into
an airbag. Be sure to collect removed nuts.
 If foreign objects enter, they may fly off and
cause a serious accident when the airbag
is activated.
1.
WEAR PROTECTIVE GEAR
(a) Wear protective eyewear and work gloves
throughout replacement work of an inflator
from the beginning to the end.
2.
WORK POSITION
(a) For replacement work of an inflator, avoid standing directly in front of the parts.
29
3.
LOOSEN THE SELF LOCKING NUTS
NOTICE:
 If the stud bolt is pushed strongly with the
4 nuts removed, the folded bag assembly
may drop off.
 If a bag assembly is dropped accidentally,
replace it with a NEW one.
(a) Loosen the 4 self locking nuts until each
face becomes flush with the edge of the
stud bolt.
NOTICE:
DO NOT use an air driven tool.
4. PUT A MARK ON THE SELF LOCKING
NUTS
(a) Put a mark on each of the 4 loosened self
locking nuts to prevent accidental reuse.
NOTICE:
Be sure to put a mark in order not to mix old
and NEW nuts in the later steps.
30
5. REMOVE THE INFLATOR
(a) Push it down until the loosened nuts come into contact with the airbag case and release the
stopper.
31
(b) In the same manner as shown on the
previous page, remove the inflator while
releasing the stopper.
(c) Put a mark on the removed inflator and
store it in a replacement part box etc.
32
6.
INSERT A NEW INFLATOR
(a) Release the stopper in the same manner
as during removal.
(b) Insert a NEW inflator into the airbag case.
NOTICE:
DO NOT mistake the insertion orientation of
the inflator.
7.
TIGHTEN THE SELF LOCKING NUTS
(a) Confirm that a mark is put on each of the 4
old self locking nuts.
(b) Remove the 2 old self locking nuts.
(c) Put a mark on the removed self locking
nuts and store it in a replacement part box
etc.
33
(d) Install the position determining plate (additional part) with its flat aligned with the flat of the
inflator.
NOTICE:
If the flats are not aligned, the position of the inflator may be misaligned, resulting in failure in
normal deployment of the airbag.
(e) Install temporarily 2 NEW self locking
nuts by hand on the stud bolts to which
the position determining plate was
installed.
(f)
Remove the 2 remaining old self locking
nuts and install temporarily 2 NEW self
locking nuts by hand.
(g) Put a mark on the removed self locking
nuts and store it in a replacement part box
etc.
34
(h) Push the inflator towards the position determining plate to eliminate any gap.
NOTICE:
If any gap exists, the aligned flats may move apart, resulting in failure in normal deployment
of the airbag.
(i)
Tighten 4 NEW nuts evenly in several increments in the order shown in the illustration using a 10
mm socket driver while pushing the inflator. (You will encounter some resistance during
tightening because these nuts are self locking nuts.)
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
NOTICE:
The tightening torque is low (3.9 N∙m). Use of an air ratchet wrench or tightening strongly with
a T-handle wrench or a ratchet handle may cause deformation of the stud bolt.
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8. INTERMEDIATE INSPECTION
(a) Check that the inflator and the 4 self locking nuts are replaced and that the one of stopper plates
is replaced with the position determining plate.
(b) Check that the orientation of the inflator is correct. (The harness should face towards the
position determining plate.)
(c) Check that positions of the inflator and the position determining plate are correct.
(The flats should be aligned and there should be no gap.)
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12. REEMPLAZO DEL INFLADOR EN AVENSIS
NOTICE:
 Once connected, the connector of an inflator cannot be disconnected.
 Never remove the seal and connect the connector until the inflator is placed in place.
 If the connector is connected accidentally, DO NOT disconnect forcibly. Prepare a NEW
inflator again.
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NOTICE:
 DO NOT allow foreign objects to enter into
an airbag. Be sure to collect removed nuts.
 If foreign objects enter, they may fly off and
cause a serious accident when the airbag
is activated.
9.
WEAR PROTECTIVE GEAR
(b) Wear protective eyewear and work gloves
throughout replacement work of an inflator
from the beginning to the end.
10. WORK POSITION
(b) For replacement work of an inflator, avoid standing directly in front of the parts.
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11. CREATE A SHORT CIRCUIT BEFORE DISCONNECTION OF INFLATOR WIRE HARNESS
HINT:
The connector of an airbag inflator has a short-circuiting mechanism and eliminates voltage difference
when disconnected. (1)
In this work, however, it is necessary to cut the harness when removal of the inflator, and the circuit
will be opened.
Therefore create a new short circuit using an electro tap and cut the harness outside of the new short
circuit in order to maintain short-circuiting. (2)(3)
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(d) Cut open the corrugate tube on the yellow
harness approx. 10 cm (4 in.) using
nippers.
NOTICE:
 DO NOT damage the internal wires.
 DO NOT use a knife or the like that tends to
cause a mistake.
(e) Cut off the portion of the electro tap
(included in the kit) shown in the
illustration.
(f)
Short-circuit the 2 wires using the electro
tap.
(1) Place one wire in the electro tap as
shown in the figure.
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(2) Fold and pinch the half of the electro tap
where the wire is placed using pliers to
lock firmly.
NOTICE:
 Simultaneous work on the 2 wires tends to
cause a mistake. Be sure to set the wire in
the electro tap one by one.
 Lock the electro tap firmly using pliers. If
locked by hand, the electro tap may
unfasten.
(3) Set the other wire in the electro tap and
lock in a similar way.
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12. CUT THE INFLATOR WIRES
(a) Cut the 2 wires at the side of the electro tap opposite to the inflator.
NOTICE:
DO NOT mistake the cutting location.
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13. PUT A MARK ON THE SELF LOCKING
NUTS
(b) Put a mark on each of the 4 self locking
nuts to prevent accidental reuse.
NOTICE:
Be sure to put a mark in order not to mix old
and NEW nuts in the later steps.
14. REMOVE STOPPER PLATE
NOTICE:
 If the stud bolt is pushed strongly with the
4 nuts removed, the folded bag assembly
may drop off.
 If a bag assembly is dropped accidentally,
replace it with a NEW one.
(b) Remove the 2 nuts on the yellow wire
harness side.
NOTICE:
DO NOT use an air driven tool.
(c)
Remove the stopper plate.
(1) Plate on the yellow wire harness side
(the cut wire side):
The stopper plate will be replaced with
the position determining plate.
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(d) Put a mark on the removed stopper plate
and store it in a replacement part box etc.
(e) Install the 2 old self locking nuts
temporarily by hand so that the face of
each nut becomes flush with the edge of
the stud bolt.
(f)
Remove the 2 nuts on the red wire harness
side.
NOTICE:
DO NOT use an air driven tool.
(g) Remove the stopper plate.
(1) Plate on the red wire harness side:
The removed stopper plate will be
reused.
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(h) Install the 2 old self locking nuts
temporarily by hand so that the face of
each nut becomes flush with the edge of
the stud bolt.
15. REMOVE THE INFLATOR
(a) Push in the loosened nuts until they contact with the airbag case.
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(b) Remove the inflator with the nuts pushed
in.
(c) Put a mark on the removed inflator and
store it in a replacement part box etc.
16. INSERT A NEW INFLATOR
(c) Insert a NEW inflator into the airbag case
as shown in the illustration.
NOTICE:
DO NOT mistake the insertion orientation of
the inflator.
17. FOLD THE SEAL
NOTICE:
DO NOT remove the seal until just before
connecting the connector.
(a) Fold the seal in order to prevent it from
being caught under the position
determining plate.
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18. PLACE THE REUSED STOPPER PLATE
(j) Confirm that a mark is put on each of the 4
old self locking nuts.
(k) Remove the 2 old self locking nuts on the
red wire harness side.
(l)
Put a mark on the removed self locking
nuts and store it in a replacement part box
etc.
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(m) Place a stopper plate on the side where the harness is connected to the inflator (red wire).
NOTICE:
DO NOT route the harness between the plate and the inflator or the airbag case.
(n) Install temporarily 2 new self locking nuts
by hand on the stud bolts to which the
reused stopper plate was placed.
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19. TIGHTEN THE SELF LOCKING NUTS
(a) Remove the 2 old self locking nuts on the
yellow wire harness side.
(b) Put a mark on the removed self locking
nuts and store it in a replacement part box
etc.
(c) Install the position determining plate (additional part) with its flat aligned with the flat of the
inflator.
NOTICE:
If the flats are not aligned, the position of the inflator may be misaligned, resulting in failure
in normal deployment of the airbag.
(d) Install temporarily 2 NEW self locking nuts
by hand on the stud bolts to which the
position determining plate was installed.
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(e) Tighten 4 NEW nuts evenly in several increments in the order shown in the illustration using a 10
mm socket driver while pushing the inflator. (You will encounter some resistance during tightening
because these nuts are self locking nuts.)
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
NOTICE:
The tightening torque is low (3.9 N∙m). Use of an air ratchet wrench or tightening strongly with
a T-handle wrench or a ratchet handle may cause deformation of the stud bolt.
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20. CONNECT THE CONNECTOR OF THE INFLATOR
(a) Remove the seal of inflator.
NOTICE:
After removal of the seal, immediately connect the connector. D O NOT touch the terminal.
(b) Insert the connector in the direction shown in the illustration. Push in the connector until the claw
engages and a clicking sound is heard. (Push firmly because this engagement is tight.)
NOTICE:
 If the direction of the connector is wrong, the terminal of the inflator may be bent.
 Clicking sound at engagement of the claw is low. Move your ear close to the connector.
 If the connector is inserted wrongly with its position 180 degrees turned, the claw will be
tightly half-engaged though it will not be engaged fully. Be sure to check for correct
orientation of the connector.
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21. INTERMEDIATE INSPECTION
(d) Check that the inflator and the 4 self locking nuts are replaced and that the one of stopper
plates is replaced with the position determining plate.
(e) Check that the orientation of the inflator is correct. (The yellow harness faces toward
positioning plate.)
(f)
Check that the flats of the inflator and the position determining plate are aligned.
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13. REINSTALAR EL PANEL DE INSTRUMENTOS/CONJUNTO AIRBAG
PASAJERO
Perform installation in the reverse order of removal.
(Refer to COMPONENTS for the tightening torques.)
Perform surely centering of the steering wheel and the spiral cable.
Check the SRS warning light at the last.
1. CENTER SPIRAL CABLE
(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 cable counterclockwise by hand
until it becomes harder to turn.
HINT:
The cable will rotate about 2.5 turns to either left
or right of the center.
(d) Then rotate the cable clockwise about 2.5
turns to align the marks.
2. INSPECT SRS WARNING LIGHT
(a) Turn the ignition switch to ON, and check
that the SRS warning light comes on.
(b) Check that the SRS warning light goes out
after approx. 6 seconds.
HINT:
 When the ignition switch is at ON and the
SRS warning light remains on or flashes,
the airbag sensor assembly has detected a
malfunction code.
 If, after approx. 6 second have elapsed, the
SRS warning light sometimes lights up or
the SRS warning light lights up even when
the ignition switch is OFF, a short in the
SRS warning light circuit can be considered
likely. Proceed to ”SRS warning light circuit
malfunction” .
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