1

TECHNICAL INSTRUCTIONS

REPLACEMENT THE INFLATOR

AVENSIS

1. OPERATION FLOWCHART ················································································· 3

2. IDENTIFICATION OF AFFECTED VEHICLES··························································· 4

3. PREPARATON ·································································································· 5

4. GENERAL WORK PROCEDURES········································································· 6

5. IMPORTANT INFORMATION ON CONNECTOR OF NEW INFLATOR ···························· 7

6. PRECAUTIONS FOR AIRBAG REMOVAL/INSTALLATION ········································· 8

7. PRECAUTIONS FOR INTERIOR WORK IN AGING VEHICLES ···································· 10

8. PRECAUTIONS FOR ENTIRE WORK ···································································· 11

9. COMPONENTS ································································································· 13

10. WORK PROCEDURES ······················································································ 15

10. 1 REMOVE THE INSTRUMENT PANEL PASSENGER AIRBAG ASSY························ 15

10. 2 REPLACEMENT THE INFLATOR ···································································· 20

10. 3 REINSTALL THE INSTRUMENT PANEL PASSENGER AIRBAG ASSY ···················· 36

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<<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 and

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 to 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.

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1. OPERATION FLOWCHART

※ NOTICE:

The inflator is hazardous material (Hazmat).

We will inform how to dispose original inflator after you replace with new one.

Please hold them at safe place in your end until we inform disposal method.

Check whether or not the vehicle has the

affected vehicle VIN number.

Replace the inflator.

Check the airbag warning light.

Finish.

No

※ Yes

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2. IDENTIFICATION OF AFFECTED VEHICLES

AFFECTED VEHICLE IDENTIFICATION NUMBER

Model WMI VIN Range

VDS Range

AVENSIS SB1

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.

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.

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3. PREPARATION PARTS

For LHD

Part Number Part Description Quantity Others

04003-11105 Instrument Panel Airbag Inflator Kit 1 For LHD

- Inflator 1 -

- Self Locking Nut 4 -

- Position Determining Plate 1 Dual E

- Electro Tap 1 -

For RHD

Part Number Part Description Quantity Others

04003-11205 Instrument Panel Airbag Inflator Kit 1 For RHD

- Inflator 1 -

- Self Locking Nut 4 -

- Position Determining Plate 1 Dual E

- Electro Tap 1 -

TOOLS&EQUIPMENT

Part Number Name Quantity Others

- Standard Hand Tools - -

- Torque Wrench - -

- Global TechStream - -

- Moulding Remover - -

SUPPLIES

Name Quantity Others

Protective eyewear - -

Work Gloves - -

Protective Tape - -

Marking Pen - -

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4. GENERAL WORK PROCEDURES

1. Remove the instrument panel sub-assy upper from the vehicle. 2. Replace the inflator inside the passenger airbag and install to

the vehicle.

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5. IMPORTANT INFORMATION ON CONNECTOR OF NEW INFLATOR

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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6. PRECAUTIONS FOR AIRBAG REMOVAL/INSTALLATION

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.

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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.

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7. PRECAUTIONS FOR INTERIOR WORK IN AGING VEHICLES

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.

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8. PRECAUTIONS FOR ENTIRE WORK

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.

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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.

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9. COMPONENTS

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10. WORK PROCEDURES

10. 1 REMOVE THE INSTRUMENT PANEL PASSENGER AIRBAG ASSY

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.

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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.

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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

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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.

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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.

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10. 2 REPLACEMENT THE INFLATOR 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.

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.

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3. 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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(a) 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.

(b) Cut off the portion of the electro tap

(included in the kit) shown in the

illustration.

(c) 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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4. 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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5. PUT A MARK ON THE SELF LOCKING

NUTS

(a) 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.

6. 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.

(a) Remove the 2 nuts on the yellow wire

harness side.

NOTICE:

DO NOT use an air driven tool.

(b) 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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(c) Put a mark on the removed stopper plate

and store it in a replacement part box etc.

(d) 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.

(e) Remove the 2 nuts on the red wire harness

side.

NOTICE:

DO NOT use an air driven tool.

(f) Remove the stopper plate.

(1) Plate on the red wire harness side:

The removed stopper plate will be

reused.

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(g) 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.

7. 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.

8. INSERT A NEW INFLATOR

(a) Insert a NEW inflator into the airbag case

as shown in the illustration.

NOTICE:

DO NOT mistake the insertion orientation of

the inflator.

9. 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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10. PLACE THE REUSED STOPPER PLATE

(a) Confirm that a mark is put on each of the 4

old self locking nuts.

(b) Remove the 2 old self locking nuts on the

red wire harness side.

(c) Put a mark on the removed self locking

nuts and store it in a replacement part box

etc.

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(d) 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.

(e) 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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11. 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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12. CONNECT THE CONNECTOR OF THE INFLATOR

(a) Remove the seal of inflator.

NOTICE:

After removal of the seal, immediately connect the connector. DO 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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13. 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 yellow harness faces toward

positioning plate.)

(c) Check that the flats of the inflator and the position determining plate are aligned.

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10. 3 REINSTALLL THE INSTRUMENT PANEL PASSENGER AIRBAG ASSY

Perform installation in the reverse order of removal. (Refer to COMPONENTS for the tightening torques.) Check the SRS warning light at the last.

1. INSPECT SRS WARNING LIGHT

(a) Turn the ignition switch to the ON position

and check that the SRS warning light lights

up.

(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” .