Toyota Avalon (XX50): Knee Airbag Assembly(for Front Passenger Side)

Components

COMPONENTS

ILLUSTRATION

ILLUSTRATION

*1	COWL SIDE TRIM SUB-ASSEMBLY RH	*2	FRONT DOOR OPENING TRIM WEATHERSTRIP RH
*3	FRONT DOOR SCUFF PLATE RH	*4	GLOVE COMPARTMENT PLATE
*5	INSTRUMENT PANEL FINISH PANEL END LH	*6	INSTRUMENT SIDE PANEL RH
*7	LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY	*8	NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)	-	-

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 a lower No. 2 instrument panel 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 lower No. 2 instrument panel airbag assembly.
• The lower No. 2 instrument panel 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 a lower No. 2 instrument panel airbag assembly with a deployed airbag.
• Do not apply water, etc. to a lower No. 2 instrument panel 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 lower No. 2 instrument panel 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 LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Installed to Vehicle)

NOTICE:

• When disposing of a lower No. 2 instrument panel 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 No. 2 instrument panel under cover sub-assembly.

Click here

(e) Disconnect the lower No. 2 instrument panel airbag assembly connector.

(1) Using a screwdriver with its tip wrapped with protective tape, disconnect the airbag connector.

NOTICE:

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

(f) Install SST.

CAUTION:

Check that there is no looseness in the lower No. 2 instrument panel airbag assembly.

(1) After connecting the following SST to each other, connect them to the lower No. 2 instrument panel airbag assembly. SST: 09082-00700 SST: 09082-00802 09082-10801 09082-20801 NOTICE: To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock.

(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 lower No. 2 instrument panel 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 a lower No. 2 instrument panel airbag assembly with a deployed airbag.
• Do not apply water, etc. to a lower No. 2 instrument panel 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 LOWER NO. 2 INSTRUMENT PANEL 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 lower No. 2 instrument panel airbag assembly.

Click here

CAUTION:

• Before removing the lower No. 2 instrument panel 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 lower No. 2 instrument panel airbag assembly, keep the airbag deployment side facing upward.

  Deployment Side

(c) Using braided wire, tie down the lower No. 2 instrument panel 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 lower No. 2 instrument panel 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 lower No. 2 instrument panel 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 lower No. 2 instrument panel airbag assembly may break loose when the airbag is deployed.
• Always tie down the lower No. 2 instrument panel 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.

(d) Install SST.

(1) After connecting the following SST to each other, connect them to the lower No. 2 instrument panel airbag assembly. SST: 09082-00802 09082-10801 09082-20801

(e) Place the tires.

(1) Place at least 2 tires under the tire to which the lower No. 2 instrument panel 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 lower No. 2 instrument panel 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 Lower No. 2 Instrument Panel 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 lower No. 2 instrument panel 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 lower No. 2 instrument panel airbag assembly.

CAUTION:

• The lower No. 2 instrument panel 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 a lower No. 2 instrument panel airbag assembly with a deployed airbag.
• Do not apply water, etc. to a lower No. 2 instrument panel airbag assembly with a deployed airbag.
• Always wash your hands with water after completing the operation.

(1) Remove the lower No. 2 instrument panel airbag assembly from the tire.

(2) Place the lower No. 2 instrument panel airbag assembly in a plastic bag, tie it tightly, and dispose of it according to local regulations.

Installation

INSTALLATION

PROCEDURE

1. INSTALL LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY

(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 airbag connector to the lower No. 2 instrument panel 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.

(d) Push in the airbag connector locking button to install the airbag connector.

(e) Engage the 3 claws to temporarily install the lower No. 2 instrument panel airbag assembly.

(f) Install the lower No. 2 instrument panel airbag assembly with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

NOTICE:

Confirm that the lower No. 2 instrument panel airbag assembly is installed securely without any excessive gaps and is not protruding outward.

2. INSTALL INSTRUMENT PANEL FINISH PANEL END LH

Click here

3. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here

4. INSTALL INSTRUMENT SIDE PANEL RH

Click here

5. INSTALL GLOVE COMPARTMENT PLATE

Click here

6. CONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH

7. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

Click here

8. INSTALL FRONT DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

Click here

9. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

for Gasoline Model: Click here

for HV Model: Click here

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here

10. INSTALL LUGGAGE TRIM SERVICE HOLE COVER (for HV Model)

Click here

11. PERFORM DIAGNOSTIC SYSTEM CHECK

for Gasoline Model: Click here

for HV Model: Click here

12. INSPECT SRS WARNING LIGHT

for Gasoline Model: Click here

for HV Model: Click here

On-vehicle Inspection

ON-VEHICLE INSPECTION

CAUTION / NOTICE / HINT

CAUTION:

Be sure to correctly follow the removal and installation procedures for the lower No. 2 instrument panel airbag assembly.

PROCEDURE

1. INSPECT LOWER NO. 2 INSTRUMENT PANEL 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 lower No. 2 instrument panel airbag assembly installed to the vehicle.

HINT:

The defects are as follows:

• Cuts
• Small cracks
• Significant discoloration

OK:

No defects are found.

If any defects are found, replace the lower No. 2 instrument panel airbag assembly with a new one.

2. INSPECT LOWER NO. 2 INSTRUMENT PANEL 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 lower No. 2 instrument panel 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 No. 2 instrument panel brace sub-assembly, instrument panel reinforcement or lower instrument panel sub-assembly

OK:

No defects are found.

If any defects are found, replace the lower No. 2 instrument panel airbag assembly, No. 2 instrument panel brace sub-assembly, instrument panel reinforcement or lower instrument panel sub-assembly 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 lower No. 2 instrument panel 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 LUGGAGE TRIM SERVICE HOLE COVER (for HV Model)

Click here

3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

for Gasoline Model: Click here

for HV Model: Click here

CAUTION:

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

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here

4. REMOVE FRONT DOOR SCUFF PLATE RH

HINT:

Use the same procedure as for the LH side.

Click here

5. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH

HINT:

Use the same procedure as for the LH side.

Click here

6. DISCONNECT FRONT DOOR OPENING TRIM WEATHERSTRIP RH

HINT:

Disconnect the front door opening trim weatherstrip RH to the extent that allows the removal of the instrument side panel RH.

7. REMOVE GLOVE COMPARTMENT PLATE

Click here

8. REMOVE INSTRUMENT SIDE PANEL RH

Click here

9. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here

10. REMOVE INSTRUMENT PANEL FINISH PANEL END LH

Click here

11. REMOVE LOWER NO. 2 INSTRUMENT PANEL AIRBAG ASSEMBLY

CAUTION:

When storing the lower No. 2 instrument panel airbag assembly, keep the airbag deployment side facing upward.

Deployment Side

(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) Remove the 3 bolts.

(d) Disengage the 3 claws to separate the lower No. 2 instrument panel airbag assembly. NOTICE: When separating the lower No. 2 instrument panel airbag assembly, do not pull the airbag wire harness.

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

(e) Using a screwdriver with its tip wrapped with protective tape, release the airbag connector locking button.

(f) Disconnect the airbag connector to remove the lower No. 2 instrument panel airbag assembly.

NOTICE:

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