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TECHNICAL INSTRUCTIONS - toyotachile.cl · COROLLA ZZE121 6000002 - 6002929 8000005 - 8009088 ......
Transcript of TECHNICAL INSTRUCTIONS - toyotachile.cl · COROLLA ZZE121 6000002 - 6002929 8000005 - 8009088 ......
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
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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 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
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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
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 - -
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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. 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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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.
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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.
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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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8. COMPONENTS
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15
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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.
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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.
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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.
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(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” .