Toyota Avalon (XX50): Front Passenger Airbag Assembly

Components

COMPONENTS

ILLUSTRATION

*1	INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)	-	-

ILLUSTRATION

Disposal

DISPOSAL

CAUTION / NOTICE / HINT

CAUTION:

Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment.

PROCEDURE

1. PRECAUTION

CAUTION:

• An airbag or pretensioner may be accidentally deployed by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure.
• Never dispose of an instrument panel passenger airbag assembly with an undeployed airbag.
• The airbag produces an exploding sound when it is deployed, so perform the operation outdoors where it will not disturb nearby residents.
• When deploying the airbag, always use the specified SST (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 (32.8 ft.) away from the instrument panel passenger airbag assembly.
• The instrument panel passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
• Use gloves and safety glasses when handling an instrument panel passenger airbag assembly with a deployed airbag.
• Do not apply water, etc. to an instrument panel passenger airbag assembly with a deployed airbag.
• Always wash your hands with water after completing the operation.

HINT:

When scrapping a vehicle equipped with an SRS or disposing of the instrument panel passenger airbag assembly, be sure to deploy the airbag first in accordance with the following procedure. If any abnormality occurs with the airbag deployment, contact the Service Department of TOYOTA MOTOR SALES, U.S.A., INC.

2. DISPOSE OF INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (When Installed to Vehicle)

NOTICE:

• When disposing of an instrument panel passenger airbag assembly, never use the customer's vehicle to deploy the airbag.
• Be sure to perform the following procedure when deploying the airbag.

HINT:

Prepare a 12 V battery as the power source to deploy the airbag.

(a) Check the function of SST. Click here SST: 09082-00700

(b) Refer to Precaution.

for Gasoline Model: Click here

for HV Model: Click here

(c) Disconnect the cable from the negative (-) auxiliary battery terminal.

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

(d) Remove the lower instrument panel sub-assembly.

Click here

(e) Disconnect the No. 2 instrument panel wire.

Click here

(f) Install SST.

CAUTION:

Check that there is no looseness in the instrument panel passenger airbag assembly or instrument panel safety pad sub-assembly.

(1) After connecting the following SST to each other, connect them to the No. 2 instrument panel wire. NOTICE: To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. SST: 09082-00700 SST: 09082-00780

(2) Move SST at least 10 m (32.8 ft.) away from the front side window of the vehicle.

*a 12 V Battery *b 10 m (32.8 ft.) or more

(3) Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle.

NOTICE:

Take care not to damage the SST wire harness.

(4) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal.

(g) Deploy the airbag.

(1) Check that no one is inside the vehicle or within a 10 m (32.8 ft.) radius of the vehicle.

(2) Press the SST activation switch to deploy the airbag.

CAUTION:

• Before deployment, make sure that no one is inside or near the vehicle.
• The instrument panel passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
• Use gloves and safety glasses when handling an instrument panel passenger airbag assembly with a deployed airbag.
• Do not apply water, etc. to an instrument panel passenger airbag assembly with a deployed airbag.
• Always wash your hands with water after completing the operation.

HINT:

The airbag is deployed as the LED of the SST activation switch comes on.

3. DISPOSE OF INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (When not Installed to Vehicle)

NOTICE:

Be sure to perform the following procedure when deploying the airbag.

HINT:

Prepare a 12 V battery as the power source to deploy the airbag.

(a) Check the function of SST. Click here SST: 09082-00700

(b) Remove the instrument panel passenger airbag assembly.

Click here

CAUTION:

• Before removing the instrument panel passenger airbag assembly, wait at least 90 seconds after turning the engine switch (for Gasoline Model) or power switch (for HV Model) off and disconnecting the cable from the negative (-) auxiliary battery terminal.
• When storing the instrument panel passenger airbag assembly, keep the airbag deployment side facing upward.

  Deployment Side

(c) Install SST.

(1) After connecting the following SST to each other, connect them to the instrument panel passenger airbag assembly. SST: 09082-00802 09082-10801 09082-30801

(d) Using braided wire, tie down the instrument panel passenger airbag assembly to an unneeded tire.

Wire:

Stripped Wire Cross Sectional Area

1.25 mm2 (0.0019 in.2) or more

CAUTION:

If the wire is too thin or an alternative object is used to tie down the instrument panel passenger airbag assembly, it may snap when the airbag is deployed. Always use a wire for vehicle use with a cross sectional area of at least 1.25 mm2 (0.0019 in.2).

HINT:

To calculate the cross sectional area of the stripped wire:

Cross sectional area = 3.14 x (Diameter)2 / 4

(1) Position the instrument panel passenger airbag assembly inside the tire with the airbag deployment side facing inward.

Minimum Tire Size:

Width

185 mm (7.28 in.)

Inner Diameter

360 mm (1.18 ft.)

CAUTION:

• Make sure that the wires are tight. If there is slack in the wires, the instrument panel passenger airbag assembly may break loose when the airbag is deployed.
• Always tie down the instrument panel passenger airbag assembly with the airbag deployment side facing inside the tire.

  Deployment Side

NOTICE:

The tire may be damaged by the airbag deployment, so use an unneeded tire.

(e) Place the tires.

(1) Place at least 2 tires under the tire to which the instrument panel passenger airbag assembly is tied. Minimum Tire Size: Width 185 mm (7.28 in.) Inner Diameter 360 mm (1.18 ft.) NOTICE: Do not place the SST connector under the tire because it could be damaged.

*a Tires (2 or more) *b Inner Diameter *c Width

(2) Place at least 2 tires onto the tire to which the instrument panel passenger airbag assembly is tied. The top tire should have a wheel installed.

NOTICE:

The wheel and tires may be damaged by the airbag deployment, so use an unneeded wheel and tires.

(3) Tie the tires together with 2 wires. CAUTION: Make sure that the wires are tight. Looseness in the wires will result in the tires breaking loose when the airbag is deployed.

(f) Install SST.

(1) Connect the SST connector. SST: 09082-00700 NOTICE: To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

*1 Instrument Panel Passenger Airbag Assembly *a 12 V Battery *b 10 m (32.8 ft.) or more

(2) Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire.

(g) Deploy the airbag.

(1) Connect the red clip of SST to the positive (+) battery terminal and the black clip of SST to the negative (-) battery terminal.

(2) Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the instrument panel passenger airbag assembly is tied.

(3) Press the SST activation switch to deploy the airbag.

CAUTION:

Before deployment, make sure that no one is near the airbag.

HINT:

The airbag is deployed as the LED of the SST activation switch comes on.

(h) Dispose of the instrument panel passenger airbag assembly.

CAUTION:

• The instrument panel passenger airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
• Use gloves and safety glasses when handling an instrument panel passenger airbag assembly with a deployed airbag.
• Do not apply water, etc. to an instrument panel passenger airbag assembly with a deployed airbag.
• Always wash your hands with water after completing the operation.

(1) Remove the instrument panel passenger airbag assembly from the tire.

(2) Place the instrument panel passenger airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 2 INSTRUMENT PANEL WIRE

(a) Connect the 2 airbag connectors of the No. 2 instrument panel wire to the instrument panel passenger airbag assembly.

*a	Airbag Connector
*b	Airbag Connector Locking Button
	Push in this Direction

NOTICE:

• When connecting any airbag connector, take care not to damage the airbag wire harness.
• Be sure to only connect the connectors to each corresponding color.

(b) Push in the 2 airbag connector locking buttons as shown in the illustration to install the 2 airbag connectors to the instrument panel passenger airbag assembly.

(c) Engage the clamp.

2. INSTALL INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY

(a) Engage the 3 hooks.

(b) Push in the instrument panel passenger airbag assembly to engage the 3 hooks.

(c) Install the instrument panel passenger airbag assembly with the 2 screws.

3. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Click here

4. CONNECT NO. 2 INSTRUMENT PANEL WIRE

(a) Check that the engine switch (for Gasoline Model) or power switch (for HV Model) is off.

(b) Check that the cable is disconnected from the negative (-) auxiliary battery terminal.

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

(c) Connect the connector. NOTICE: When connecting any airbag connector, take care not to damage the airbag wire harness.

(d) Engage the clamp.

5. INSTALL TURN SIGNAL SWITCH

Click here

On-vehicle Inspection

ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

CAUTION:

Be sure to correctly follow the removal and installation procedures for the instrument panel passenger airbag assembly.

PROCEDURE

1. INSPECT INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (for Vehicle not Involved in Collision)

(a) Perform a diagnostic system check.

for Gasoline Model: Click here

for HV Model: Click here

(b) Visually check for defects with the instrument panel passenger airbag assembly installed to the vehicle.

HINT:

The defects are as follows:

• Cuts on the instrument panel safety pad sub-assembly around the instrument panel passenger airbag assembly
• Small cracks on the instrument panel safety pad sub-assembly around the instrument panel passenger airbag assembly
• Significant discoloration on the instrument panel safety pad sub-assembly around the instrument panel passenger airbag assembly

OK:

No defects are found.

If any defects are found, replace the instrument panel safety pad sub-assembly with a new one.

2. INSPECT INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed)

(a) Perform a diagnostic system check.

for Gasoline Model: Click here

for HV Model: Click here

(b) Visually check for defects with the instrument panel passenger airbag assembly removed from the vehicle.

HINT:

The defects are as follows:

• Cuts
• Small cracks
• Significant discoloration
• Cracks or other damage to the connector
• Deformation or cracks on the instrument panel safety pad sub-assembly or instrument panel reinforcement

OK:

No defects are found.

If any defects are found, replace the instrument panel passenger airbag assembly, instrument panel safety pad sub-assembly or instrument panel reinforcement with a new one.

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during instrument panel passenger airbag assembly removal/installation are shown below.

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read Precaution thoroughly before servicing.

for Gasoline Model: Click here

for HV Model: Click here

NOTICE:

After turning the engine switch (for Gasoline Model) or power switch (for HV Model) off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

Click here

2. REMOVE TURN SIGNAL SWITCH

Click here

3. DISCONNECT NO. 2 INSTRUMENT PANEL WIRE

(a) Check that the engine switch (for Gasoline Model) or power switch (for HV Model) is off.

(b) Check that the cable is disconnected from the negative (-) auxiliary battery terminal.

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

(c) Disengage the clamp.

*a	Slider
	Release in this Direction

(d) Slide the slider to release the lock, and then disconnect the connector.

NOTICE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

4. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

Click here

5. REMOVE INSTRUMENT PANEL PASSENGER AIRBAG ASSEMBLY

CAUTION:

When storing the instrument panel passenger airbag assembly, keep the airbag deployment side facing upward.

Deployment Side

(a) Remove the 2 screws.

(b) Using a screwdriver, pry back the passenger airbag door retainer to disengage the 3 hooks as shown in the illustration.

*a	Passenger Airbag Door Retainer
	Move the screwdriver in this Direction

NOTICE:

Do not damage the deployment surface of the instrument panel passenger airbag assembly.

(c) Disengage the 3 hooks to remove the instrument panel passenger airbag assembly from the instrument panel safety pad sub-assembly.

6. REMOVE NO. 2 INSTRUMENT PANEL WIRE

(a) Disengage the clamp.

*a	Protective Tape
*b	Airbag Connector
*c	Airbag Connector Locking Button
	Release in this Direction

(b) Using a screwdriver with its tip wrapped with protective tape, release the 2 airbag connector locking buttons.

(c) Disconnect the 2 airbag connectors to remove the No. 2 instrument panel wire from the instrument panel passenger airbag assembly.

NOTICE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.