Content .. 104 105 106 107 ..

Toyota Corolla (2004+). Manual - part 106

60-9

SUPPLEMENTAL RESTRAINT SYSTEM

- SUPPLEMENTAL RESTRAINT SYSTEM

HORN BUTTON ASSY(VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)

(a) Check the diagnostic system (See page 05-424).

(b) Visually check the following item with the horn button assy (with airbag) removed from the vehicle.

Check the damage on the spiral cable connector and wire harness.

HINT:

There should be no interference between the horn button assy and steering wheel, and the clearance should

be uniform all the way around when the new horn button assy is installed on the steering wheel.

INSTRUMENT PANEL PASSENGER AIRBAG

ASSY(VEHICLE NOT INVOLVED IN COLLISION)

(a) Check the diagnostic system (See page 05-424).

(b) Visually check the following item with the instrument pan-

el passenger airbag assy installed in the vehicle.

Check cuts, minute cracks or marked discoloration on the

instrument panel passenger airbag assy and instrument

panel.

H42043

INSTRUMENT PANEL PASSENGER AIRBAG

ASSY(VEHICLE INVOLVED IN COLLISION AND AIR-

BAG IS NOT DEPLOYED)

(a) Check the diagnostic system (See page 05-424).

(b) Visually check the following items with the instrument

panel passenger airbag assy removed from the vehicle.

Check cuts, minute cracks or marked discoloration

on the instrument panel passenger airbag assy.

H42044

Check cuts and cracks in wire harness, and for chip-

ping in connectors.

Check the deformation or cracks on the instrument

panel and instrument panel reinforcement.

HINT:

If the instrument panel or instrument panel reinforcement is de-

formed or cracked, never repair it. Always replace it with a new

one.

CAUTION:

For removal and installation of the instrument panel pas-

senger airbag assy, see page

60-25, and be sure to follow

the correct procedure.

H42043

60-10

SUPPLEMENTAL RESTRAINT SYSTEM

- SUPPLEMENTAL RESTRAINT SYSTEM

INSTRUMENT PANEL PASSENGER AIRBAG ASSY(VEHICLE INVOLVED IN COLLISION AND

AIRBAG IS DEPLOYED)

(a) Check the diagnostic system (See page 05-424).

(b) Visually check the following items with the instrument panel passenger airbag assy removed from the

vehicle.

Check the deformation or cracks on the instrument panel and instrument panel reinforcement.

Check the damage on the connector and wire harness.

HINT:

If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always

replace it with a new one.

FRONT SEAT AIRBAG A SSY(VEHICLE NOT IN-

VOLVED IN COLLISION)

(a) Check the diagnostic system (See page 05-424).

(b) Visually check the following item with the front seat airbag

assy installed in the vehicle.

Check cuts, minute cracks or marked discoloration on the

front seat airbag assy and the front seat assy.

H42042

FRONT SEAT AIRBAG ASSY(VEHICLE INVOLVED IN

COLLISION AND AIRBAG IS NOT DEPLOYED)

(a) Check the diagnostic system (See page 05-424).

(b) Visually check the following items with the front seat air-

bag assy removed from the front seat assy.

Check cuts, minute cracks or marked discoloration

on the front seat airbag assy.

Check cuts and cracks in wire harness, and for chip-

H41401

ping in connectors.

AIRBAG SENSOR ASSY CENTER(VEHICLE NOT INVOLVED IN COLLISION)

(a)

Check the diagnostic system (See page 05-424).

10.

AIRBAG SENSOR ASSY CENTER(VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT

DEPLOYED)

(a)

Check the diagnostic system (See page 05-424).

11.

AIRBAG SENSOR ASSY CENTER(VEHICLE INVOLVED IN COLLISION AND AIRBAG IS

DEPLOYED)

(a)

Replace the airbag sensor assy center (See page 60-38).

60-11

SUPPLEMENTAL RESTRAINT SYSTEM

- SUPPLEMENTAL RESTRAINT SYSTEM

12. AIRBAG FRONT SENSOR(VEHICLE NOT INVOLVED

IN COLLISION)

(a) Check the diagnostic system (See page 05-424).

13. AIRBAG FRONT SENSOR(VEHICLE INVOLVED IN

COLLISION)

(a) Check the diagnostic system (See page 05-424).

(b) If the front fender of the car or its periphery is damaged,

Visually check for damage to the airbag front sensor,

H42122

which includes the following items even if the airbag was

not deployed:

Cracks, dents or chips in the case

Cracks, dents, chipping and scratches in the con-

nector

Peeling off of the label or damage to the serial num-

ber

H41961

14. SIDE AIRBAG SENSOR ASSY(VEHICLE NOT INVOLVED IN COLLISION)

(a) Check the diagnostic system (See page 05-424).

15. SIDE AIRBAG SENSOR A SSY(VEHICLE INVOLVED IN COLLISION AND AI RBAG IS NOT

DEPLOYED)

(a) Check the diagnostic system (See page 05-424).

16. SIDE AIRBAG SENSOR ASSY(VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)

(a) Replace the front seat airbag assy and side airbag sensor assy (See page 60-44, 72-2).

17. SEAT POSITION AIRBAG SENSOR(VEHICLES NOT INVOLVED IN COLLISION)

(a) Check the diagnostic system (See page 05-424).

18. SEAT POSITION AIRBAG SENSOR(VEHICLE INVOLVED IN COLLISION)

(a) Check the diagnostic system (See page 05-424).

(b) Visually check for damage to the seat position airbag sensor, which includes the following items even

if the airbag was not deployed:

Cracks, dents or chips in the case

Cracks, dents, chipping and scratches in the connector

19. WIRE HARNESS AND CONNECTOR(VEHICLE NOT INVOLVED IN COLLISION)

(a) Check the diagnostic system (See page 05-424).

20. WIRE HARNESS AND CONNECTOR(VEHICLE INVOLVED IN COLLISION)

(a) Check the diagnostic system (See page 05-424).

(b) Check breaks in all wires of the SRS wire harness, and exposed conductors.

(c)

Check to see if the SRS wire harness connectors are cracked or chipped.

HINT:

The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in

the system are standard yellow.

60-24

SUPPLEMENTAL RESTRAINT SYSTEM

- INSTRUMENT PANEL PASSENGER AIR BAG ASSY

INSTRUMENT PANEL PASSENGER AIR BAG ASSY

600C0-01

COMPONENTS

Instrument Panel Passenger Airbag Assy

20 (204, 15)

Glove Compartment Door

Stopper Sub-Assy

Instrument Panel Sub-Assy Lower

Nm(kgfcm, ftlbf)

: Specified torque

H42046

60-26

SUPPLEMENTAL RESTRAINT SYSTEM

- INSTRUMENT PANEL PASSENGER AIR BAG ASSY

600C2-02

DISPOSAL

HINT:

When scrapping vehicle equipped with an SRS or disposing of a instrument panel passenger airbag assy,

always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs

with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.

CAUTION:

Never dispose of a instrument panel passenger air-

bag assy which has an undeployed airbag.

The airbag produces a sizeable exploding sound

when it deploys, so perform the operation out of

doors and the place where it will not create a nuisance

to nearby residents.

When deploying the airbag, always use the specified

SST (SRS Airbag Deployment Tool). Perform the op-

eration in a place away from electrical noise.

When deploying an airbag, perform the operation at

SST

least 10 m (33 ft) away from the instrument panel pas-

senger airbag assy.

The instrument panel passenger airbag assy is very

hot when the airbag is deployed, so leave it alone for

H40004

at least 30 minutes after deployment.

Use gloves and safety glasses when handling a

instrument panel passenger airbag assy with the

deployed airbag.

Always wash your hands with water after completing

the operation.

Do not apply water, etc. to a instrument panel passen-

ger airbag assy with the deployed airbag.

DISPOSE INSTRUMENT PANEL PASSENGER AIR

BAG ASSY

(WHEN SCRAPPING VEHICLE

DEPLOYMENT METHOD)

HINT:

Prepare a battery for the power source to deploy the airbag.

(a) Check the function of SST (See step 1-(a) on page

60-14).

H40005

60-27

SUPPLEMENTAL RESTRAINT SYSTEM

- INSTRUMENT PANEL PASSENGER AIR BAG ASSY

(b) Disconnect the airbag connector.

(1)

Remove the instrument panel sub-assy lower.

NOTICE:

When handling the airbag connector, take care not to dam-

age the airbag wire harness.

(2)

Disconnect the airbag connectors.

H42049

(c)

Set SST.

(1)

Connect the connectors of the 2 SST to the instru-

ment panel passenger airbag assy connectors.

SST

09082-00700, 09082-00780

NOTICE:

To avoid damaging the SST connector and wire harness,

do not lock the secondary lock of the twin lock.

SST

H42047

(2)

Move the SST at least 10 m (33 ft) away from the

front of the vehicle.

(3)

Close all the doors and windows of the vehicle.

NOTICE:

Battery

Take care not to damage the SST wire harness.

(4)

Connect the red clip of the SST to the battery posi-

SST

tive (+) terminal and the black clip to the negative (-)

10 m (33 ft) or more

terminal.

H40007

(d) Deploy the airbag.

(1)

Check that no one is inside the vehicle or within 10

m (33 ft) area around the vehicle.

(2)

Press the SST activation switch and deploy the air-

bag.

HINT:

The airbag deploys simultaneously when the LED of the SST

activation switch lights up.

(e) Dispose the instrument panel passenger airbag assy.

CAUTION:

The instrument panel passenger airbag assy is very

hot when the airbag is deployed, so leave it for at least

30 minutes after deployment.

Use gloves and safety glasses when handling a

instrument panel passenger airbag assy with the

deployed airbag.

Always wash your hands with water after completing

the operation.

Do not apply water, etc. to a instrument panel passen-

ger airbag assy with the deployed airbag.

60-28

SUPPLEMENTAL RESTRAINT SYSTEM

- INSTRUMENT PANEL PASSENGER AIR BAG ASSY

When moving a vehicle for scrapping which has a

instrument panel passenger airbag assy with the

deployed airbag, use gloves and safety glasses.

HINT:

When scrapping a vehicle, deploy the airbag and scrap the ve-

hicle with the instrument panel passenger airbag assy being

installed.

DISPOSE INSTRUMENT PANEL PASSENGER AIR

BAG ASSY (WHEN DISPOSING OF AIRBAG

ASSEMBLY DEPLOYMENT METHOD)

NOTICE:

When disposing of the instrument panel passenger

airbag assy only, never use the customer’s vehicle to

deploy the airbag.

Be sure to follow the procedure given below when de-

ploying the airbag.

HINT:

Prepare a battery for the power source to deploy the airbag.

(a) Remove the instrument panel passenger airbag assy

(See page 60-25).

CAUTION:

When removing the instrument panel passenger air-

bag assy, work must be started 90 seconds after the

ignition switch is turned to the ”LOCK” position and

the negative (-) terminal cable is disconnected from

the battery.

H42044

Store the instrument panel passenger airbag assy

with the airbag deployment side facing upward.

(b) Using a service-purpose wire harness for the vehicle, tie

Wire Harness

down the instrument panel passenger airbag assy to the

Diameter

tire.

Wire harness: Stripped wire harness section

1.25 mm 2 or more (0.0019 in. 2 or more)

CAUTION:

If the instrument panel passenger airbag assy is tied

down

with too thin wire harness, it may snap. This is highly dan-

Stripped Wire Harness Section

H40008

gerous. Always use a wire harness which is at least 1.25

mm 2 (0.0019 in. 2).

HINT:

To calculate the area of the stripped wire harness section:

Area = 3.14 X (Diameter) 2 divided by 4

60-29

SUPPLEMENTAL RESTRAINT SYSTEM

- INSTRUMENT PANEL PASSENGER AIR BAG ASSY

(1)

Install the 2 nuts to the instrument panel passenger

airbag assy.

H42023

(2)

Wind the wire harness around the brackets, as

shown in the illustration.

(3)

Position the instrument panel passenger airbag

assy inside the tire with the airbag deployment side

facing inside.

Tire size: Must exceed the following dimensions-

Width: 185 mm (7.28 in.)

Inner diameter: 360 mm (14.17 in.)

H42024

CAUTION:

Make sure that the wire harness is tight. It is very dangerous if the loosened wire harness re-

sults in the instrument panel passenger airbag assy coming free due to the shock from the air-

bag deployment.

Always tie down the instrument panel passenger airbag assy with the airbag deployment side

facing inside.

NOTICE:

The tire will be marked by the airbag deployment, so use a redundant tire.

Inner

Diam.

Width

Wheel

H40311

60-30

SUPPLEMENTAL RESTRAINT SYSTEM

- INSTRUMENT PANEL PASSENGER AIR BAG ASSY

(c)

Check the function of SST (See step 1-(a) on page

60-14).

Battery

SST

H40005

(d) Place tires.

(1)

Place at least 2 tires under the tire to which the

instrument panel passenger airbag assy is tied.

(2)

Place at least 2 tires over the tire to which the instru-

Tires

ment panel passenger airbag assy is tied. The top

(5 or more)

tire should have the wheel installed.

H40015

(3)

Tie the tires together with 2 wire harness.

CAUTION:

Make sure that the wire harness is tight. It is very danger-

ous if loosened wire harness result in the tires coming free

due to the shock from the airbag deploying.

HINT:

Place the SST connector and wire harness inside tires. Secure

at least 1 m (3 ft) of slack for the wire harness.

H40016

Instrument Panel

(e) Set SST.

Passenger Airbag Assy

Connect the connectors of the 2 SST to the instrument

panel passenger airbag assy connector.

Battery

SST

09082-00700, 09082-00780

NOTICE:

SST

To avoid damaging the SST connector and wire harness,

do not lock the secondary lock of the twin lock.

(f)

Deploy the airbag.

10 m (33 ft) or more

H40017

(1)

Connect the SST red clip to the battery positive (+)

terminal and the black clip to the battery negative

(-) terminal.

(2)

Check that no one is within 10 m (33 ft) radius

around the tire which the instrument panel passen-

ger airbag assy is tied to.

(3)

Press the SST activation switch and deploy the air-

bag.

HINT:

The airbag deploys simultaneously when the LED of the SST

activation switch lights up.

60-31

SUPPLEMENTAL RESTRAINT SYSTEM

- INSTRUMENT PANEL PASSENGER AIR BAG ASSY

(g) Dispose of the instrument panel passenger airbag assy.

CAUTION:

The instrument panel passenger airbag assy is very

hot when the airbag is deployed, so leave it alone for

at least 30 minutes after deployment.

Use gloves and safety glasses when handling a

instrument panel passenger airbag assy with the

deployed airbag.

H41436

Always wash your hands with water after completing

the operation.

Do not apply water, etc. to a instrument panel passen-

ger airbag assy with the deployed airbag.

(1)

Remove the instrument panel passenger airbag

assy from the tire.

(2)

Place the instrument panel passenger airbag assy

in a vinyl bag, tie the end tightly and dispose of it in

the same way as other general parts.

60-25

SUPPLEMENTAL RESTRAINT SYSTEM

- INSTRUMENT PANEL PASSENGER AIR BAG ASSY

600C1-02

REPLACEMENT

HINT:

COMPONENTS: See page 60-24

PRECAUTION (See page 60-1)

DISCONNECT BATTERY NEGATIVE TERMINAL (See page 60-1)

REMOVE INSTRUMENT PANEL SUB-ASSY LOWER

: 2 Clips

(a) Remove the screw from the glove compartment door

stopper sub-assy.

(b) Pull the instrument panel sub-assy lower to remove it.

H42050

SEPARATE PASSENGER AIRBAG CONNECTOR

(a) Separate the instrument panel passenger airbag assy

connector.

H42049

REMOVE INSTRUMENT PANEL PASSENGER AIR

BAG ASSY

(a) Remove the bolt.

(b) Remove the 2 nuts and instrument panel passenger air-

bag assy.

H42048

INSTALL INSTRUMENT PANEL PASSENGER AIR BAG ASSY

Torque:

Bolt: 20 N m (204 kgf cm, 15 ft lbf)

INSPECT INSTRUMENT PANEL PASSENGER AIR BAG ASSY (See page

60-8)

INSPECT SRS WARNING LIGHT (See page 05-424)

60-1

SUPPLEMENTAL RESTRAINT SYSTEM

- SUPPLEMENTAL RESTRAINT SYSTEM

SUPPLEMENTAL RESTRAINT SYSTEM

600BX-02

PRECAUTION

CAUTION:

The COROLLA is equipped with SRS, which comprises a driver airbag, front passenger airbag

and side airbag. Failure to carry out service operations in the correct sequence could cause

the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Fur-

ther, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate

when required. Before performing servicing (including removal or installation of parts, inspec-

tion or replacement), be sure to read the following items carefully, then follow the correct proce-

dures described in the repair manual.

Work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and

the negative (-) terminal cable is disconnected from the battery.

(The SRS is equipped with a back-up power source so that if work is started within 90 seconds

from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)

Do not expose the horn button assy, instrument panel passenger airbag assy, airbag sensor

assy center, airbag front sensor, front seat airbag assy, side airbag sensor assy or seat position

airbag sensor directly to hot air or flames.

NOTICE:

Malfunction sym ptoms of the SRS are difficult to confirm, so the DTCs become the most impor-

tant source of information when troubleshooting. When troubleshooting the SRS, always in-

spect the DTCs before disconnecting the battery.

Even in cases of a minor collision where the SRS does not deploy, the horn button assy, instru-

ment panel passenger airbag assy, airbag sensor assy center, airbag front sensor, front seat

airbag assy, side airbag sensor assy and seat position airbag sensor should be inspected (See

page 60-8).

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during

repairs.

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the horn button assy, instrument panel passenger airbag assy,

airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag sensor assy

or seat position airbag sensor in order to reuse it.

If the horn button assy, instrument panel passenger airbag assy, airbag sensor assy center, air-

bag front sensor, front seat airbag assy, side airbag sensor assy, seat position airbag sensor

has been dropped, or if there are cracks, dents or other defects in the case, bracket or connec-

tor, replace it with a new one.

Use a volt/ohmmeter with high impedance (10 k

W/V minimum) for troubleshooting the system’s

electrical circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruc-

tions on the notices.

After work on the SRS is completed, perform the SRS warning light check (See page

05-424).

When the negative (-) terminal cable is disconnected from the battery, the memory of the clock

and audio system will be canceled. So before starting work, make a record of the contents mem-

orized in the audio memory system. When work is finished, reset the audio systems as they

were before and adjust the clock. To avoid erasing the memory in each memory system, never

use a back-up power supply from outside the vehicle.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the

INTRODUCTION section.

60-2

SUPPLEMENTAL RESTRAINT SYSTEM

- SUPPLEMENTAL RESTRAINT SYSTEM

SRS CONNECTORS

Seat Belt

Side Airbag

2526

Pretensioner

Sensor Assy (RH)

(RH)

Front Seat

Airbag Front

23 24

Airbag Assy

RH Sensor

(RH) (Squib)

Spiral Cable

Horn Button

1718

19 20

Sub-Assy

Assy (Squib)

Airbag Sensor

Instrument Panel

Assy Center

1516

Junction Block Assy

Instrument Panel

Passenger

21 22

Airbag

Assy (Squib)

Airbag Sensor

Front Seat

Front LH

23 24

Airbag Assy

(LH) (Squib)

Side Airbag

Seat Belt

Sensor Assy (LH)

25 26

Pretensioner

(LH)

Seat Position

Airbag Sensor

H42030

60-3

SUPPLEMENTAL RESTRAINT SYSTEM

- SUPPLEMENTAL RESTRAINT SYSTEM

No.

Item

Application

(1)

Terminal Twin-Lock Mechanism

Connectors 2, 4, 6, 8, 10, 11, 12, 13, 14, 15, 17, 21, 22

(2)

Airbag Activation Prevention Mechanism

Connectors 2, 4, 16, 18, 20, 22, 24

(3)

Electrical Connection Check Mechanism

Connectors 1, 2, 3, 4

(4)

Half Connection Prevention Mechanism

Connectors 6, 8, 12, 21

(5)

Connector Lock Mechanism

Connectors 17, 19, 23

(a) All connectors in the SRS are colored in yellow to distin-

guish them from other connectors. Connectors having

special functions and specifically designed for the SRS

are used in the locations shown on the previous page to

ensure high reliability. These connectors use durable

gold-plated terminals.

(1)

Terminal twin-lock mechanism:

Spacer

Each connector has a two-piece component con-

sisting of a housing and a spacer. This design en-

Housing

ables the terminal to be locked securely by two lock-

ing devices (the retainer and the lance) to prevent

terminals from coming out.

(2)

Airbag activation prevention mechanism:

Each connector contains a short spring plate. When

Female

Male

Z05953

the connector is disconnected, the short spring

plate automatically connects positive (+) terminal

and negative (-) terminal of the squib.

When Connector is Connected

When Connector is Disconnected

Short Spring Plate

Housing

Contacting Male Terminal

Housing

Short Spring Plate ON

Terminal

Squib

Connectors Short Spring Plate

Closed Circuit

R10587

60-4

SUPPLEMENTAL RESTRAINT SYSTEM

- SUPPLEMENTAL RESTRAINT SYSTEM

HINT:

The type of connector is shown in the diagram on the previous

page.

(3)

Electrical connection check mechanism:

This mechanism electrically checks that connectors

are connected correctly and completely. The electri-

cal connection check mechanism is designed so

Disconnection

Detection

that the disconnection detection pin connects with

the diagnosis terminals when the connector hous-

ing lock is locked.

Airbag Sensor Assy Center

H41646

FHalf Connection

FComplete Connection

Terminal for Diagnosis

Terminal for

Diagnosis

Disconnection Detection Pin

H01315

HINT:

The connectors shown in this illustration are connectors, ”1”,

”2”, ”3” and ”4” in step 1.

(4)

Half connection prevention mechanism:

If the connector is not completely connected, the

connector is disconnected due to the spring opera-

tion to the extent that no continuity exists.

Spring

Stopper

Slider

Stopper

Locking Arm

Locking Part

Rebounded by Slider

(Spring)

C51019

H40180

Content .. 104 105 106 107 ..