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Procedimiento Tecnico Avensis PDF
Procedimiento Tecnico Avensis PDF
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<<SAFETY PRECAUTIONS>>
<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
Yes
※
Replace the inflator.
Finish.
※ 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.
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2. IDENTIFICATION OF AFFECTED VEHICLES
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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
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5. IMPORTANT INFORMATION ON CONNECTOR OF NEW INFLATOR
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6. PRECAUTIONS FOR AIRBAG REMOVAL/INSTALLATION
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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.
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7. PRECAUTIONS FOR INTERIOR WORK IN AGING VEHICLES
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8. PRECAUTIONS FOR ENTIRE WORK
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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.
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9. COMPONENTS
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10. WORK PROCEDURES
10. 1 REMOVE THE INSTRUMENT PANEL PASSENGER AIRBAG ASSY
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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.
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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.
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12. REMOVE FRONT PILLAR GARNISH LH
(a) Disengage the 2 clips, and remove the
front pillar garnish LH.
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.
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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.
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.
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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.
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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.
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(c) Put a mark on the removed stopper plate
and store it in a replacement part box etc.
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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.
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(b) Remove the inflator with the nuts pushed
in.
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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.
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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.
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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.
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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
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