Repair Instruction: Precaution

1. HINTS ON OPERATIONS
   Fig 1: Identifying Basic Repair Hint And Operations Components

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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
   1. Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.
      Fig 2: Identifying Bolts Coated With Seal Lock Adhesive

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   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
   1. When inspecting a fuse, check that the wire of the fuse is not broken.
   2. When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.
      Fig 3: Identifying Fuses Condition

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      FUSES SYMBOL PART NAME
      
      

      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 REMOVAL/INSTALLATION CHART
      
      

      Shape (Example)	Removal/Installation
      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. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 ILLUSTRATION CHART
      
      

      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
   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.
      Fig 4: Precaution For Disconnecting Vacuum Hose

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   2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
      Fig 5: Disconnecting And Tagging Vacuum Hoses

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   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 Wrench With Extension Tool

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    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 

       TORQUE WRENCH WITH EXTENSION TOOL CHART
       
       

       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 manual, 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.

      CAUTION: 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.

      (See INSTALLATION for steering pad)

      (See REMOVAL for front passenger airbag assembly)

      (See REMOVAL for front driver side knee airbags assembly)

      (See FRONT SEAT SIDE AIRBAG ASSEMBLY for front seat side airbag assembly)

      (See INSTALLATION for curtain shield airbag assembly)

      (See INSTALLATION 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 airbag sensor assembly, horn button assembly, instrument panel passenger airbag assembly, curtain shield airbag assembly, front seat airbag assembly, instrument panel lower airbag assembly or seat belt pretensioner.
   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
   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 the information about correct installation of the steering wheel (See REMOVAL ).
      Fig 7: Identifying Aligning Mark

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3. STEERING PAD
   1. When removing the horn button assembly or handling a new horn button, it should be placed with the pad surface facing up. See illustration below.
      Fig 8: Identifying Horn Button Assembly

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      placing the horn button with 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 horn button.

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

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   3. Grease or detergents of any kind should not be applied to the steering wheel 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 airbag ECU connectors (4 pins). 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 horn button assembly by itself, the airbag should be inflated using an SST before disposal (See DISPOSAL ). Activate in a safe away from electrical noise.
4. FRONT PASSENGER AIRBAG ASSEMBLY
   1. Always place a removed or new instrument panel 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 Front Passenger Airbag Assembly

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   3. Grease or detergents of any kind should not be applied to the instrument panel passenger airbag assembly.
      Fig 11: Precaution For Never Measuring Resistance Of Airbag Squib

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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 airbag ECU connectors (4 pins). 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 (See DISPOSAL ).

      Activate in a safe place away from electrical noise.

5. FRONT DRIVER SIDE KNEE AIRBAG ASSEMBLY
   1. Always store a removed or new instrument panel lower airbag assembly with the airbag inflating direction facing upward.
      Fig 12: Identifying Front Driver Side Knee Airbag Assembly

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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

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   3. Grease or detergents of any kind should not be applied to the front seat airbag assembly.
   4. Store the instrument panel lower 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, first disconnect the airbag connector (2 pins) installed on the instrument panel lower airbag assembly before starting work.
   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 (See REMOVAL ).

      Activate in a safe place away from electrical noise.

6. FRONT SEAT AIRBAG ASSEMBLY
   1. Always place a removed or new front seat 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: Precaution For Never Measuring Resistance Of Airbag Front Seat Squib

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   3. Grease or detergents of any kind should not be applied to the front 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 airbag ECU connectors (2 pins). 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 (See FRONT SEAT SIDE AIRBAG ASSEMBLY ).

      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: Identifying Curtain Shield Airbag Assembly

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