1

TECHNICAL INSTRUCTIONS

REPLACEMENT THE INFLATOR

COROLLA

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

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

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

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

5. PRECAUTIONS FOR AIRBAG REMOVAL/INSTALLATION ········································· 7

6. PRECAUTIONS FOR INTERIOR WORK IN AGING VEHICLES ···································· 9

7. PRECAUTIONS FOR ENTIRE WORK ···································································· 10

8. COMPONENTS ································································································· 12

9. WORK PROCEDURES ······················································································· 15

9. 1 REMOVE THE INSTR PNL PASS L/DOOR AIR BAG ASSY ···································· 15

9. 2 REPLACEMENT THE INFLATOR ······································································ 22

9. 3 REINSTALL THE INSTR PNL PASS L/DOOR AIR BAG ASSY ································ 37

2

<<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.

3

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

4

2. IDENTIFICATION OF AFFECTED VEHICLES

AFFECTED VEHICLE IDENTIFICATION NUMBER

Model Frame type Frame No.

COROLLA

ZZE121 6000002 - 6002929

8000005 - 8009088

ZZE122

9501218 - 9501218

6000000 - 7014562

5000010 - 9001709

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.

Model WMI VIN Range

VDS Range

COROLLA

NMT

BM#### R000001 - R039410

BX#### R000001 - R005184

BZ#### R000001 - R027719

EM#### R001874 - R017653

EX#### R000304 - R005182

EZ#### R001512 - R027723

SB1

JM#### E001001 - E081129

JW#### E000540 - E028584

JX#### E000544 - E028611

JY#### E000533 - E007892

JZ#### E000533 - E077544

KM#### E000534 - E066931

KW#### E001004 - E028613

KX#### E001005 - E043887

KY#### E001007 - E007893

KZ#### E001001 - E062296

MHF 53#### 8000000 - 8008245

MR0 53#### 7000000 - 7058826

Model WMI VIN Range

VDS Range

COROLLA

1NX BR#### Z000001 - ZPP4315

2T1 BR#### C000082 - C836386

9BR 53#### 8500004 - 8531416

JTD

BJ#### 2000003 - 4000825

BM#### 0001009 - 0049218

BR#### 0002007 - 3074259

BT#### 0015629 - 3203256

BW#### 0006951 - 3039985

BZ#### 0001801 - 3035691

EM#### 0001001 - 0009443

ER#### 0013935 - 0151722

EW#### 0008142 - 0060691

EX#### 3000005 - 3005199

EZ#### 0002150 - 0016837

KM#### 0009695 - 0025709

KR#### 0034118 - 2018046

KX#### 3005201 - 3013745

KZ#### 0017809 - 0035299

AHT 53#### 6500000 - 7513229

AHT 54#### 6500023 - 7513681

5

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.

6

3. PREPARATION PARTS

Part Number Part Description Quantity Others

04000-44212 Instrument Panel Airbag Inflator Kit 1 For LHD

- Inflator 1 -

- Self Locking Nut 4 -

- Position Determining Plate 1 Single B

Part Number Part Description Quantity Others

04000-44112 Instrument Panel Airbag Inflator Kit 1 For RHD

- Inflator 1 -

- Self Locking Nut 4 -

- Position Determining Plate 1 Single A

SST

Part Number Name Quantity Others

09950-50013 Puller C Set 1 -

TOOLS&EQUIPMENT

Part Number Name Quantity Others

- Standard Hand Tools - -

- Torque Wrench - -

- Global TechStream - -

- Torx® Socket Wrench (T30) - -

- Moulding Remover - -

SUPPLIES

Name Quantity Others

Protective Eyewear - -

Work Gloves - -

Protective Tape - -

Marking Pen - -

7

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.

8

5. 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.

9

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.

10

6. 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.

11

7. 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.

12

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.

13

8. COMPONENTS

14

15

16

9. WORK PROCEDURES

9. 1 REMOVE THE INSTR PNL PASS L/DOOR AIR BAG ASSY

1. DISCONNECT 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. PLACE FRONT WHEELS FACING

STRAIGHT AHEAD

3. REMOVE HORN BUTTON ASSY

NOTICE:

If the airbag connector is disconnected with

the ignition switch at ON or ACC, DTCs will be

recorded.

(a) Place the front wheels facing straight

ahead.

(b) Using a torx socket wrench (T30), loosen

the 2 torxscrews until the groove along the

screw circumference catches on the screw

case.

(c) Pull out the wheel pad from the horn button

assy.

(d) Disconnect the airbag connector and

remove the horn button assy.

17

4. REMOVE STEERING WHEEL ASSY

(a) Remove the steering wheel set nut.

(b) Place matchmarks on the steering wheel

and main shaft assembly.

(c) Using SST, remove the steering wheel.

SST 09950−50013

(09951−05010, 09952−05010,

09953−05020, 09954−05021)

5. REMOVE METER HOOD SUB−ASSY

(a) Remove the clip.

(b) Using a screwdriver, disengage the 3 clips

and 4 claws, then remove the meter hood.

HINT:

Tape the screwdriver tip before use.

6. REMOVE COMBINATION METER ASSY

(a) Remove the screw.

(b) Disengage the 2 clips as shown in the

illustration.

(c) Disconnect the connector, then remove the

combination meter.

18

7. REMOVE INSTRUMENT PANEL REGISTER

ASSY NO.3

(a) Using a moulding remover, remove the

instrument panel register No.3.

HINT:

Tape the moulding remover tip before use.

8. REMOVE INSTRUMENT PANEL REGISTER

ASSY NO.1

9. REMOVE FRONT ASH RECEPTACLE BOX

SUB−ASSY

10. REMOVE CONSOLE PANEL UPPER

(a) M/T:

(1) Remove the shift level knob.

(b) Using a screwdriver, disengage the 6

claws.

HINT:

Tape the screwdriver tip before use.

(c) Disconnect the connector, then remove the

console upper panel.

11. REMOVE INSTRUMENT CLUSTER FINISH

PANEL

(a) Manual A/C:

(1) Center the control lever.

(2) Apply protective tape to the instrument

cluster finish panel as shown in the

illustration.

19

(3) Remove the control knob.

(4) Remove the screw.

(5) Using a screwdriver, disengage the 4

clips and 5 claws, then remove the

instrument cluster finish panel.

HINT:

Tape the screwdriver tip before use.

NOTICE:

Do not pull the lid of auxiliarybox.

(b) Auto A/C:

(1) Using a screwdriver, disengage the 4

clips and 4 claws, then remove the

instrument cluster finish panel.

HINT:

Tape the screwdriver tip before use.

NOTICE:

Do not pull the lid of auxiliarybox.

(2) Disconnect the connectors.

12. REMOVE INSTRUMENT CLUSTER FINISH

PANEL SUB−ASSY LOWER CENTER

(a) Remove the 4 screws.

20

(b) Using a screwdriver, disengage the 8 clips,

then remove the instrument cluster finish

panel and radio turner opening cover.

HINT:

Tape the screwdriver tip before use.

(c) Remove the instrument cluster finish panel

from the radio turner opening cover.

13. REMOVE GLOVE COMPARTMENT DOOR

ASSY

(a) Remove the screw and glove compartment

door stopper from the glove compartment

door.

(b) Deform the upper part of the glove

compartment door to release the stoppers.

(c) Pull the glove compartment door upward to

remove it.

14. REMOVE FRONT PILLAR GARNISH RH

(a) Disengage the 2 clips.

(b) Pull the front pillar garnish RH upward to

remove it.

15. REMOVE FRONT PILLAR GARNISH LH

16. SEPARATE PASSENGER AIRBAG

CONNECTOR

(a) Remove the connector cover from the

lower instrument panel.

NOTICE:

When handling the airbag connector, take

care not to damage

the airbag wire harness.

(b) Disconnect the front passenger airbag

connector.

21

17. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER

(a) Remove the bolt and 2 screws.

(b) Using a moulding remover, disengage the 6 clips.

(c) Remove the instrument panel upper.

18. REMOVE INSTR PNL PASS L/DOOR AIR

BAG ASSY

(a) Remove the 2 bolts and 2 strings from the

right and left brackets of the instrument

panel passenger airbag assy.

(b) Remove the 3 nuts and instr pnl l/door air

bag assy from the instrument panel UPR.

22

9. 2 REPLACEMENT THE INFLATOR

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.

23

3. LOOSEN THE SELF LOCKING NUTS

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) Loosen the 4 self locking nuts until each

face becomes flush with the edge of the

stud bolt.

NOTICE:

DO NOT use an air driven tool.

4. PUT A MARK ON THE SELF LOCKING

NUTS

(a) Put a mark on each of the 4 loosened 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.

24

5. REMOVE THE INFLATOR

(a) Push it down until the loosened nuts come into contact with the airbag case and release the

stopper.

25

(b) In the same manner as shown on the

previous page, remove the inflator while

releasing the stopper.

(c) Put a mark on the removed inflator and

store it in a replacement part box etc.

26

6. INSERT A NEW INFLATOR

(a) Release the stopper in the same manner

as during removal.

(b) Insert a NEW inflator into the airbag case.

NOTICE:

DO NOT mistake the insertion orientation of

the inflator.

7. TIGHTEN THE SELF LOCKING NUTS

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

old self locking nuts.

(b) Remove the 2 old self locking nuts.

(c) Put a mark on the removed self locking

nuts and store it in a replacement part box

etc.

27

(d) 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.

(e) Install temporarily 2 NEW self locking

nuts by hand on the stud bolts to which

the position determining plate was

installed.

(f) Remove the 2 remaining old self locking

nuts and install temporarily 2 NEW self

locking nuts by hand.

(g) Put a mark on the removed self locking

nuts and store it in a replacement part box

etc.

28

(h) Push the inflator towards the position determining plate to eliminate any gap.

NOTICE:

If any gap exists, the aligned flats may move apart, resulting in failure in normal deployment of

the airbag.

(i) 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.

29

8. 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 harness should face towards the

position determining plate.)

(c) Check that positions of the inflator and the position determining plate are correct.

(The flats should be aligned and there should be no gap.)

30

3. LOOSEN THE SELF LOCKING NUTS

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) Loosen the 4 self locking nuts until each

face becomes flush with the edge of the

stud bolt.

NOTICE:

DO NOT use an air driven tool.

4. PUT A MARK ON THE SELF LOCKING

NUTS

(a) Put a mark on each of the 4 loosened 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.

31

5. REMOVE THE INFLATOR

(a) Push it down until the loosened nuts come into contact with the airbag case and release the

stopper.

32

(b) In the same manner as shown on the

previous page, remove the inflator while

releasing the stopper.

(c) Put a mark on the removed inflator and

store it in a replacement part box etc.

33

6. INSERT A NEW INFLATOR

(a) Release the stopper in the same manner

as during removal.

(b) Insert a NEW inflator into the airbag case.

NOTICE:

DO NOT mistake the insertion orientation of

the inflator.

7. TIGHTEN THE SELF LOCKING NUTS

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

old self locking nuts.

(b) Remove the 2 old self locking nuts.

(c) Put a mark on the removed self locking

nuts and store it in a replacement part box

etc.

34

(d) 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.

(e) Install temporarily 2 NEW self locking

nuts by hand on the stud bolts to which

the position determining plate was

installed.

(f) Remove the 2 remaining old self locking

nuts and install temporarily 2 NEW self

locking nuts by hand.

(g) Put a mark on the removed self locking

nuts and store it in a replacement part box

etc.

35

(h) Push the inflator towards the position determining plate to eliminate any gap.

NOTICE:

If any gap exists, the aligned flats may move apart, resulting in failure in normal deployment

of the airbag.

(i) 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.

36

8. 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 harness should face towards the

position determining plate.)

(c) Check that positions of the inflator and the position determining plate are correct.

(The flats should be aligned and there should be no gap.)

37

9. 3 REINSTALLL THE INSTR PNL PASS L/DOOR AIR BAG ASSY

Perform installation in the reverse order of removal. (Refer to COMPONENTS for the tightening torques.) Perform surely centering of the steering wheel and the spiral cable. Check the SRS warning light at the last.

1. CENTER SPIRAL CABLE

(a) Check that the ignition switch is OFF.

(b) Check that the battery negative terminal is

disconnected.

NOTICE:

Do not start the operation for 90 seconds after

removing the terminal.

(c) Turn the cable counterclockwise by hand

until it becomes harder to turn.

HINT:

The cable will rotate about 2.5 turns to either left

or right of the center.

(d) Then rotate the cable clockwise about 2.5

turns to align the marks.

2. INSPECT SRS WARNING LIGHT

(a) Turn the ignition switch to ON, and check

that the SRS warning light comes on.

(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” .