25 2005 2006 toyota hilux factory service manual supplemental restraint system he thong an toan

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8.8 (90, 78 in.*lbf) 8.8 (90, 78 in.*lbf)

STEERING PAD

AIRBAG CONNECTOR

SPIRAL CABLE

SUB-ASSEMBLY

LOWER STEERING COLUMN COVER UPPER STEERING COLUMN COVER

Cuts, minute cracks or marked discoloration on the steering pad top surface or in the grooved portion.

2 INSPECT STEERING PAD (for Vehicle Involved in Collision and Airbag not Deployed)

(a) Perform a diagnostic system check (see page

RS-37)

(b) With the steering pad removed from the vehicle, perform a visual check If there are any defects as mentioned below, replace the steering pad or steering wheel assembly with a new one:

• Cuts, minute cracks or marked discoloration on the horn button assembly top surface or in the grooved portion

• Cracks or other damage to the connectors

• Deformation of the steering wheel assembly

• Deformation of the horn button contact plate of the steering pad

• There should be no interference between the steering pad and steering wheel assembly, and the clearance should be uniform all the way around when the new steering pad is installed on the steering wheel assembly

CAUTION:

For removal and installation procedures of the steering pad Be sure to follow the correct procedure.

H042163E01

H100942E01

3 PLACE FRONT WHEELS FACING STRAIGHT AHEAD

4 REMOVE NO.2 LOWER STEERING WHEEL COVER (See page SR-9)

5 REMOVE NO.3 LOWER STEERING WHEEL COVER (See page SR-9)

6 REMOVE STEERING PAD (See page RS-558)

7 REMOVE STEERING WHEEL ASSEMBLY (See page SR-9)

8 REMOVE LOWER STEERING COLUMN COVER

(a) Remove the 2 screws

(b) Disengage the 2 claws to remove the steering column cover lower

9 REMOVE UPPER STEERING COLUMN COVER

(a) Disengage the claw, then remove the upper steering column cover

10 REMOVE SPIRAL CABLE SUB-ASSEMBLY

(a) Disconnect the airbag connector and the connector from the spiral cable sub-assembly

INSPECTION

1 INSPECT SPIRAL CABLE SUB-ASSEMBLY

(a) If any of the following conditions is identified, replace the spiral cable sub-assembly with a new one

Condition:

Scratches or cracks on the connector Cracks, dents or chipping of the spiral cable sub-assembly

RESTRAINTS

SUPPLEMENTAL RESTRAINT SYSTEM

FRONT PASSENGER AIRBAG ASSEMBLY

COMPONENTS

CLIP

CLIP SHIFT KNOB

SHIFT KNOB

BOX BOTTOM MAT

BOX BOTTOM MAT

for Automatic Transmission on Bench Seat Type:

for Manual Transmission on Bench Seat Type:

INSTRUMENT PANEL CUP HOLDER

INSTRUMENT PANEL CUP HOLDER

FRONT CONSOLE BOX

NO 2 BOX BOTTOM MAT

CONSOLE UPPER REAR PANEL SUB-ASSEMBLY

CONSOLE UPPER REAR PANEL SUB-ASSEMBLY

for Automatic Transmission

on Separate Seat Type :

for Manual Transmission

on Separate Seat Type:

SHIFT KNOB SHIFT KNOB

CONSOLE BOX CARPET

for Separate Seat Type:

INSTRUMENT PANEL CUP HOLDER TRAY

FRONT CONSOLE BOX

REAR CONSOLE BOX ASSEMBLY

FRONT CONSOLE BOX

AIR CONDITIONING CONTROL ASSEMBLY

FRONT DOOR SCUFF PLATE RH FRONT FLOOR FOOTREST

INSTRUMENT CLUSTER FINISH

PANEL SUB-ASSEMBLY

INSTRUMENT PANEL HOLE COVER

INSTRUMENT PANEL UNDER TRAY

CLIP

7.0 (71, 62 in.*lbf)

N*m (kgf*cm, ft*lbf) : Specified torque

2.5 (25, 22 in.*lbf)

for Pedal Type Parking Brake:

for Lever Type Parking Brake:

INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY

LOWER INSTRUMENT PANEL LH

LOWER NO 1 INSTRUMENT

PANEL FINISH PANEL

RADIO RECEIVER ASSEMBLY

FRONT PILLAR GARNISH LH

FRONT PILLAR GARNISH RH

GLOVE COMPARTMENT DOOR ASSEMBLY

INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY INSTRUMENT SIDE PANEL RH

INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY RH

CURTAIN SHIELD AIRBAG ASSEMBLY

C114181E02

Cuts, minute cracks or marked discoloration on the front pillar garnish or roof headlining assembly around the curtain shield airbag assembly.

2 INSPECT CURTAIN SHIELD AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not

• Cuts, minute cracks or marked discoloration on the curtain shield airbag assembly

• Cracks or other damage to the connectors

CAUTION:

For removal and installation procedures of the curtain shield airbag assembly Be sure to follow the correct procedure.

C106386

C106387

Cuts, minute cracks or marked discoloration on the front seat back assembly around the front seat airbag assembly.

2 FRONT SEAT SIDE AIRBAG ASSEMBLY (for Vehicle Involved in Collision and Airbag not Deployed)

(a) Perform a diagnostic system check (see page

RS-37)

(b) With the front seat airbag assembly removed from the vehicle, perform a visual check If there are any defects as mentioned below, replace the front seat airbag assembly with a new one:

• Cuts, minute cracks or marked discoloration on the front seat airbag assembly

• Cracks or other damage to the wire harness or connector

CAUTION:

For removal and installation procedures of the front seat airbag assembly Be sure to follow the correct procedure.

H044234E01

H041401E01

• When disposing of a front seat side airbag assembly with

an airbag deployed in a collision, follow the procedure in step 1-(e) in DISPOSAL

• When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool), perform the operation in a place away from electrical noise.

• When deploying an airbag, perform the operation at least 10 m (33 ft) away from the airbag assembly.

• The front seat side airbag assembly becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.

• Use gloves and safety glasses when handling a front seat side airbag assembly with a deployed airbag.

• Always wash your hands with water after completing the operation.

• Do not apply water, etc to a front seat side airbag assembly with the deployed airbag.

1 DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN SCRAPPING VEHICLE DEPLOYMENT METHOD)

To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock.

(2) Move SST at least 10 m (33 ft) away from the front of the vehicle

(3) Close all the doors and windows of the vehicle

(d) Deploy the airbag

(1) Check that no one is inside the vehicle or within

a 10 m (33 ft) radius of the vehicle

(2) Press the SST activation switch and deploy the airbag

• Use gloves and safety glasses when handling

a front seat side airbag assembly a the deployed airbag.

• Do not apply water, etc to a front seat side airbag assembly with the deployed airbag.

• Always wash your hands with water after completing the operation.

HINT:

When scrapping a vehicle, deploy the airbag and scrap the vehicle with the front seat side airbag assembly installed

2 DISPOSE OF FRONT SEAT SIDE AIRBAG ASSEMBLY (WHEN DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT METHOD)

NOTICE:

• When disposing of the front seat side airbag assembly only, never use the customers vehicle

to deploy the airbag.

• Be sure to follow the procedure given below when deploying the airbag.

HINT:

Prepare a battery as the power source to deploy the airbag

(a) Remove the front seat side airbag assembly

(1) Remove the 2 nuts and front seat side airbag assembly from the seatback assembly

CAUTION:

Place the front seat side airbag assembly with the airbag deployment side facing upward.

(b) Using a service-purpose wire harness, tie down the front seat side airbag assembly

Wire harness:

Stripped wire harness section 1.25 mm 2 or more (0.0019 in 2 or more)

CAUTION:

If the wire harness is too thin or any other object

is used to tie down the front seat side airbag assembly, it may be snapped by the shock when the airbag is deployed This is highly

dangerous Be sure to use a wire harness for vehicle use with the wire size of at least 1.25

Wire Harness Diameter

Stripped Wire Harness Section

H040008E05

H041437

H041438

(3) Position the front seat side airbag assembly 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.) CAUTION:

• Make sure that the wire harness is tight

It is very dangerous if it is loose, as this could cause the front seat side airbag assembly to come free due to the shock when the airbag is deployed.

• Always tie down the front seat side airbag assembly with the airbag deployment side facing inside.

(3) Tie the tires together with 2 wire harnesses

CAUTION:

Make sure that the wire harness is tight It is very dangerous if it is loose, as this could cause the tires to come free due to the shock when the airbag is deployed.

HINT:

Place the SST connector and wire harness inside the tires Secure at least 1 m (3 ft) of slack for the wire harness

H001336E01

H040016

(f) Deploy the airbag.

(1) Connect the red clip of SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal

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

of the tire to which the front seat side airbag assembly is tied

(3) Press the SST activation switch and deploy the airbag

HINT:

The airbag deploys simultaneously when the LED of the SST activation switch lights up.(g) Dispose of the front seat side airbag assembly

• Use gloves and safety glasses when handling

a front seat side airbag assembly with the deployed airbag.

• Do not apply water etc to a front seat side airbag assembly with the deployed airbag.

• Always wash your hands with water after completing the operation.

(1) Remove the front seat side airbag assembly from the tire

(2) Place the front seat side airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts

Battery SST

10 m (33 ft) or more

Front Seat Airbag Assembly

H001337E03

H000544

CONSOLE UPPER REAR PANEL SUB-ASSEMBLY

INSTRUMENT PANEL

CUP HOLDER TRAY

FRONT CONSOLE BOX

FRONT CONSOLE BOX

FRON TCONSOLE BOX

N*m (kgf*cm, ft.*lbf) : Specified torque

18 (178, 13)

SHIFT LEVER KNOB SUB-ASSEMBLY

SHIFT LEVER KNOB SUB-ASSEMBLY

SHIFT LEVER KNOB SUB-ASSEMBLY

CENTER AIRBAG

SENSOR ASSEMBLY

Automatic Transmission, Separate Seat:

Manual Transmission, Separate Seat:

Bench Seat:

REAR CONSOLE BOX ASSEMBLY

The front airbag sensor should be replaced after any of the airbags has deployed, as it has been subjected to the impact

• Cracks, dents or chips on the sensor housing.

• Cracks or other damage to the connector

• Peeling off of the label or damage to the serial number

CAUTION:

For removal and installation procedures of the front airbag sensor Be sure to follow the correct procedure.

3 INSPECT FRONT AIRBAG SENSOR (for Vehicle Involved in Collision)

(a) Replace the front airbag sensor

CAUTION:

For removal and installation procedures of the front airbag sensor Be sure to follow the correct procedure.

HINT:

The front airbag sensor on the impacted side should

be replaced after the steering pad, front passenger airbag assembly, driver side knee airbag assembly

or front passenger side knee airbag assembly has deployed

FRONT DOOR SCUFF PLATE LH

LAP BELT OUTER

ANCHOR COVER

REAR DOOR OPENING

TRIM WEATHERSTRIP LH

REAR DOOR SCUFF PLATE LH

N*m (kgf*cm, ft.*lbf) : Specified torque

9.0 (92, 80 in.*lbf)

42 (420, 31)

SIDE AIRBAG SENSOR

CENTER PILLAR LOWER GARNISH LH

• Cracks, dents or chips on the sensor housing.

• Cracks or other damage to the connector

• Peeling off of the label or damage to the serial number

CAUTION:

For removal and installation procedures of the side airbag sensor Be sure to follow the correct procedure.

3 INSPECT SIDE AIRBAG SENSOR (for Vehicle Involved in Collision)

(a) Replace the side airbag sensor

CAUTION:

For removal and installation procedures of the side airbag sensor Be sure to follow the correct procedure.

HINT:

The side airbag sensor on the impacted side should

be replaced after the front seat airbag assembly and curtain shield airbag assembly have deployed

REAR DOOR SCUFF PLATE LH

REAR SEAT BACK ASSEMBLY LH

• Cracks, dents or chips on the sensor housing.

• Cracks or other damage to the connector

• Peeling off of the label or damage to the serial number

CAUTION:

For removal and installation procedures of the rear airbag sensor Be sure to following the correct procedure.

3 INSPECT REAR AIRBAG SENSOR (for Vehicle Involved in Collision)

(a) Replace the rear airbag sensor

CAUTION:

For removal and installation procedures of the rear airbag sensor Be sure to follow the correct procedure.

HINT:

The rear airbag sensor on the impacted side should

be replaced after the curtain shield airbag assembly has deployed

RESTRAINTS

SUPPLEMENTAL RESTRAINT SYSTEM

SEAT POSITION SENSOR (for Separate Seat Type)

COMPONENTS

FRONT SEAT ASSEMBLY LH

N*m (kgf*cm, ft.*lbf) : Specified torque

SEAT TRACK INNER BRACKET COVER LH

8.0 (82, 71 in.*lbf)

SEAT POSITION SENSOR

C114186E02

• Cracks, dents or chips in the case.

• Cracks or other damage to the connector

CAUTION:

For removal and installation procedures of the seat position sensor, see page RS-617, RS-620, and be sure to follow the correct procedure.

SEAT POSITION SENSOR (for Bench Seat Type)

COMPONENTS

FRONT SEAT ASSEMBLY

FRONT SEAT HEADREST ASSEMBLY

FRONT SEAT INNER BELT ASSEMBLY LH

FRONT SEAT INNER BELT ASSEMBLY RH

SEAT POSITION SENSOR LH

FRONT CENTER SEAT OUTER BELT ASSEMBLY

SEAT POSITION SENSOR RH

• Cracks, dents or chips in the case.

• Cracks or other damage to the connector

CAUTION:

For removal and installation procedures of the seat position airbag sensor, see pages RS-620 and RS-621, and be sure to follow the correct procedure.

RESTRAINTS

SUPPLEMENTAL RESTRAINT SYSTEM

FRONT SEAT CUSHION ASSEMBLY (w/ Occupant

Classification ECU, Occupant Classification Sensor)

COMPONENTS

FRONT SEAT HEADREST ASSEMBLY

FRONT SEAT HINGE COVER LH

FRONT SEAT HINGE COVER RH

FRONT SEAT INNER BELT ASSEMBLY LH

FRONT SEAT INNER BELT ASSEMBLY RH

FRONT SEAT HEADREST ASSEMBLY

OCCUPANT CLASSIFICATION SENSOR

OCCUPANT CLASSIFICATION ECU

FRONT SEAT TRACK LOWER FRONT BRACKET LH

FRONT SEAT TRACK

LOWER FRONT

BRACKET RH

FRONT SEAT TRACK LOWER REAR BRACKET LH FRONT SEAT TRACK LOWER

REAR BRACKET RH

RESTRAINTS

SUPPLEMENTAL RESTRAINT SYSTEM

OCCUPANT CLASSIFICATION ECU (for Separate Seat Type)

COMPONENTS

FRONT RH SEAT ASSEMBLY

OCCUPANT CLASSIFICATION ECU

C114188E02

• Cracks, dents or chips in the case.

• Cracks or other damage to the connector

CAUTION:

For removal and installation procedures of the occupant classification ECU, see page RS-631, and be sure to follow the correct procedure.

RESTRAINTS

SUPPLEMENTAL RESTRAINT SYSTEM

OCCUPANT CLASSIFICATION ECU (for Bench Seat Type)

COMPONENTS

FRONT SEAT ASSEMBLY

FRONT SEAT HEADREST ASSEMBLY

FRONT SEAT INNER BELT ASSEMBLY LH

FRONT SEAT INNER BELT ASSEMBLY RH

OCCUPANT CLASSIFICATION ECU

FRONT SEAT HEADREST ASSEMBLY

(b) Even if the airbag was not deployed, check if there

is any damage to the occupant classification ECU If there are any defects as mentioned below, replace the occupant classification ECU with a new one:

• Cracks, dents or chips on the case

• Cracks or other damage to the connector

CAUTION:

Be sure to follow the correct removal and installation procedures.

AIRBAG CUT-OFF SWITCH

COMPONENTS

AIR CONDITIONING CONTROL ASSEMBLY

AIRBAG CUT OFF SWITCH

INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY

INSTRUMENT PANEL HOLE COVER

INSTRUMENT PANEL UNDER TRAY

SWITCH BASE HOLE COVER

CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY

INSTRUMENT LOWER PANEL LH

NO.1 LOWER INSTRUMENT PANEL FINISH PANEL

RADIO RECEIVER ASSEMBLY WITH BRACKET

12 REMOVE SWITCH BASE HOLE COVER

(a) Disengage the 3 claws and remove the switch base hole cover

C121180

13 REMOVE AIRBAG CUT OFF SWITCH

(a) Disconnect the airbag cut off switch connector

(b) Remove the instrument cluster finish panel assembly center while holding the 2 claws of the airbag cut off switch

sub-INSPECTION

1 INSPECT AIRBAG CUT OFF SWTCH

(a) Check the resistance

(1) Using an ohmmeter, measure the resistance between the terminals

Standard :

If the result is not as specified, replace the air bag cut off switch

INSTALLATION

1 INSTALL AIRBAG CUT-OFF SWITCH

(a) Engage the 2 claws of the cut off switch with the instrument cluster finish panel sub-assembly center

(b) Attach the connector to the airbag cut off switch

OCCUPANT CLASSIFICATION ECU

FRONT SEAT INNER BELT ASSEMBLY LH

HAZARD WARNING SIGNAL SWITCH ASSEMBLY

CENTER AIRBAG SENSOR ASSEMBLY

FRONT SEAT INNER BELT ASSEMBLY RH

COMBINATION METER ASSEMBLY

FRONT SEAT OUTER BELT ASSEMBLY RH

(BELT TENSION SENSOR)

FOR BENCH SEAT:

- DRIVER SIDE SEAT BELT WARNING LIGHT

DRIVER SIDE JUNCTION BLOCK

- MULTIPLEX NETWORK BODY ECU

CENTER AIRBAG SENSOR ASSEMBLY

OCCUPANT CLASSIFICATION ECU

FRONT SEAT INNER BELT ASSEMBLY LH

FRONT OCCUPANT CLASSIFICATION SENSOR LH

FRONT SEAT INNER BELT ASSEMBLY RH REAR OCCUPANT CLASSI-

HAZARD WARNING SIGNAL SWITCH ASSEMBLY

FOR SEPARATE SEAT:

DRIVER SIDE JUNCTION BLOCK - PASSENGER SIDE SEAT BELT WARNING LIGHT

COMBINATION METER ASSEMBLY

- DRIVER SIDE SEAT BELT WARNING LIGHT

- MULTIPLEX NETWORK BODY ECU

- GAUGE FUSE

- IG1 FUSE

- COMPONENTS PART