Repair Instruction: Precaution: Precaution

1. HINTS ON OPERATIONS
   Fig 1: Identifying Basic Repair Hints, Operations, Vehicle Protection And Preparation

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1	Attire	Always wear a clean uniform. Hat and safety shoes must be worn.
   2	Vehicle protection	Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation.
   3	Safe operation	When working with 2 or more persons, be sure to check safety for one another. When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop. If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others. When jacking up the vehicle, be sure to support the specified location with a safety stand. When lifting up the vehicle, use appropriate safety equipment.
   4	Preparation of tools and measuring gauge	Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement.
   5	Removal and installation, disassembly and assembly operations	Diagnose with a thorough understanding of proper procedures and of the reported problem. Before removing the parts, check the general condition of the assembly and for deformation and damage. When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. Temporarily mark hoses and their fittings if needed. Clean and wash the removed parts if necessary and assemble them after a thorough check.
   6	Removed parts	Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts. For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this service information . Retain the removed parts for customer inspection, if requested.
   7*	Checks to perform after work is finished	Make sure that removed and installed parts (oil filler cap, level dipstick, floor mat, etc.) are properly installed/tightened. Make sure that none of the cloths or tools that were used have been left in the engine compartment or within the vehicle. Check that there are no oil leaks.

   WARNING:

   *: Be sure to perform these checks properly, Not performing these checks properly after finishing work can lead to serious accident or injury.

2. JACKING UP AND SUPPORTING VEHICLE
   1. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.
3. PRECOATED PARTS
   Fig 2: Identifying Seal Lock Adhesive On Precoated Parts

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   1. Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.
   2. If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.
   3. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part.
   4. Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.
4. GASKETS
   1. When necessary, use a sealer on gaskets to prevent leaks.
5. BOLTS, NUTS AND SCREWS
   1. Carefully follow all the specifications for tightening torques. Always use a torque wrench.
      NOTE:

      Perform the torque with the lower limit value of the torque tolerance.

6. FUSES
   Fig 3: Identifying Fuse Condition

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   1. When inspecting a fuse, check that the wire of the fuse is not broken.
   2. If the wire of a fuse is broken, confirm that there are no shorts in its circuit.
   3. When a fuse is replaced, a fuse with the same amperage rating must be used.

      Illustration	Symbol	Part Name	Abbreviation
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSE	FUSE
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	MEDIUM CURRENT FUSE	M-FUSE
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	HIGH CURRENT FUSE	H-FUSE
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSIBLE LINK	FL
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	CIRCUIT BREAKER	CB

7. CLIPS
   1. The removal and installation methods of typical clips used in body parts are shown in the table below.

      HINT: 

      If clips are damaged during a procedure, always replace the damaged clip with a new clip.

      Shape (Example)	Removal/Installation
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove clips with clip remover or pliers.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove fasteners with clip remover or screwdriver.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove clips with wide scraper to prevent panel damage.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove clips by pushing center pin through and prying out shell.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove clips by unscrewing center pin and prying out shell.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002 Remove clips by prying out pin and then prying out shell.

8. CLAWS
   1. The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.

      HINT: 

      If claws are damaged during a procedure, always replace the damaged claws with a new caps or covers.

      Shape (Example)	Illustration	Procedures
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or covers.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or covers.
      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or covers.

9. REMOVAL AND INSTALLATION OF VACUUM HOSES
   Fig 4: Identifying Precaution For Disconnecting Vacuum Hoses
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.
   2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
      Fig 5: Identifying Use Of Tags On Vacuum Hoses

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. After completing the job, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
   4. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a step-down adapter if necessary.
10. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
    Fig 6: Identifying Torque Length Dimension

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench.

       Formula

       T' = L2/(L1 + L2) * T

       T'	Reading of torque wrench {N*m (kgf*cm, ft.*lbf)}
       T	Torque {N*m (kgf*cm, ft.*lbf)}
       L1	Length of SST or extension tool {cm (in.)}
       L2	Length of torque wrench {cm (in.)}

       NOTE:

       If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this service information , the actual torque will be excessive and parts will be damaged.

The AVALON is equipped with a Supplemental Restraint System (SRS).

1. GENERAL NOTICE
   1. As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery.
   2. Work must be started at least 90 seconds after the ignition switch is turned off and after the cable is disconnected from the negative (-) battery terminal.

      The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy.

      When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before.

      WARNING:

      Never use a back-up power source (battery or other) to avoid erasing system memory. The back-up power source may inadvertently power the SRS and cause it to deploy.

   3. In minor collisions where the SRS does not deploy, the steering pad, front passenger airbag assembly, driver side knee airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle.

      Refer to DISPOSAL for steering pad)

      Refer to DISPOSAL for front passenger airbag assembly)

      Refer to DISPOSAL for driver side knee airbag assembly)

      Refer to DISPOSAL for front seat side airbag assembly (for Manual Seat Type RH Side)

      Refer to DISPOSAL front seat side airbag assembly (for Power Seat)

      Refer to DISPOSAL for curtain shield airbag assembly)

      Refer to DISPOSAL for front seat outer belt assembly)

   4. Never use SRS parts from another vehicle. When replacing parts, use new parts.
   5. Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs.
   6. Never disassemble and repair the center airbag sensor assembly, steering pad, front passenger airbag assembly, curtain shield airbag assembly, front seat side airbag assembly, driver side knee airbag assembly or front seat outer belt assembly.
   7. Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.
   8. Do not directly expose the airbag sensor assembly or airbag assembly to hot air or flames.
   9. Use a voltmeter / ohmmeter with high impedance (minimum=10 kΩ) for troubleshooting electrical circuits.
   10. Information labels are attached to the SRS components. Follow the instructions on the labels.
   11. After work on the SRS is completed, check the SRS warning light.
2. SPIRAL CABLE
   Fig 7: Identifying Aligning Mark

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   1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to INSPECTION for the correct information about the correct installation of the steering wheel.
3. STEERING PAD
   1. When removing the steering pad or handling a new steering pad, it should be placed with the pad surface facing up. See example illustration below.
      Fig 8: Identifying Horn Button Assembly (Example)

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      Placing the steering pad of the pad surface facing down may lead to a serious accident if the airbag accidentally inflates. Also, do not place anything on top of the steering pad.

   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 9: Never Measuring Resistance Of Airbag Squib (Example)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the steering pad.
   4. Store the horn button assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby.
   5. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag or seat belt pretensioner deploying due to currents entering the squib wiring.
   6. When disposing of the vehicle or the steering pad by itself, the airbag should be inflated using an SST before disposal. Refer to DISPOSAL . Activate in a safe away from electrical noise.
4. FRONT PASSENGER AIRBAG ASSEMBLY
   1. Always place a removed or new front passenger airbag assembly with the airbag inflation direction facing up.

      Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates.

   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 10: Identifying Correct And Incorrect Position Of Front Passenger Airbag Assembly (Example)

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   3. Grease or detergents of any kind should not be applied to the front passenger airbag assembly.
      Fig 11: Precaution For Never Apply Grease or Detergents To Airbag Squib (Example)

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   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby.
   5. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.
   6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL .

      Activate in a safe place away from electrical noise.

5. DRIVER SIDE KNEE AIRBAG ASSEMBLY
   1. Always store a removed or new driver side knee airbag assembly with the airbag inflating direction facing upward.
      Fig 12: Identifying Correct And Incorrect Position Of Driver Side Knee Airbag Assembly (Example)

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      Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates.

   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 13: Precaution For Never Measuring Resistance Of Airbag Squib (Example)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the driver side knee airbag assembly.
   4. Store the driver side knee airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise.
   5. When using electric welding anywhere on the vehicle, disconnect center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or the instrument panel lower airbag assembly unit by itself, the airbag should be inflated using an SST before disposal. Refer to DISPOSAL .

      Activate in a safe place away from electrical noise.

6. FRONT SEAT SIDE AIRBAG ASSEMBLY
   1. Always place a removed or new front seat side airbag assembly with the airbag inflation direction facing up.

      Placing the airbag assembly with the airbag inflation direction facing download could cause a serious accident if the airbag deploys.

   2. Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.
      Fig 14: Never Measuring Resistance Of Airbag Squib (Example)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the front seat side airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby.
   5. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.
   6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Refer to DISPOSAL for Manual Seat Type RH Side. Refer to DISPOSAL for Power Seat).

      Activate in a safe place away from electrical noise.

7. CURTAIN SHIELD AIRBAG ASSEMBLY
   1. Always place the removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place.
      Fig 15: Covering Curtain Shield Airbag Assembly (Example)

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