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TECHNICAL INSTRUCTIONS

PASSENGER SIDE AIRBAG MODULE

YARIS/ VIOS

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 ENTIRE WORK ········································································ 9

7. COMPONENTS ······································································································ 11

8. WORK PROCEDURES ···························································································· 12

8.1 REMOVAL OF PASSENGER SIDE AIRBAG MODULE ·············································· 12

8.2 INSTALLATION OF A NEW PASSENGER SIDE AIRBAG MODULE (LHD) ··················· 15

8.3 INSTALLATION OF A NEW PASSENGER SIDE AIRBAG MODULE (RHD) ·················· 17

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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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Verify Vehicle Eligibility

1. Check the VIN range.

Verify Vehicle Eligibility

1. Check the VIN range.

No further action required.

Remove the passenger side

airbag module.

Campaign completed, return the

vehicle to the customer.

Replace the airbag module with a

NEW one and return the vehicle

to the original state.

1. OPERATION FLOWCHART

※ NOTICE:

The airbag module is hazardous material (Hazmat).

We will inform how to dispose original airbag module after you replace with NEW

one. Please hold them at safe place in your end until we inform disposal method.

Not Involved

Not Involved

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2. IDENTIFICATION OF AFFECTED VEHICLES

AFFECTED VEHICLE IDENTIFICATION NUMBER

Model Model Code WMI VDS Frame Range Production period

BELT/YARIS

NCP92 JTD

BW903# 1000114-4030710 20051021-20081225

BW923# 1000106-4033044 20051005-20081225

BW933# 1000113-1000113 20051007-20051007

NCP93 JTD

BT903# 1000114-1337991 20050927-20081225

BT923# 1000126-4060410 20051003-20081225

BT933# 1000131-1000131 20051007-20051007

NBC5

NCP92 LFM AU92A# 0002000-0016829 20080218-20081224

NCP93

MR0 53HY9# 5000001-9018874 20061031-20081227

PN1 53HY9# 7000021-7041143 20070927-20081224

RL4 BT913# 9500496-9500496 20071112-20071112

BT923# 9500001-9503810 20070913-20081231

ZSP92 LFM AP90A# 0019335-0022724 20081008-20081224

AP92A# 0002000-0022276 20080219-20081208

Model Model Code Frame range Production period

NBC5 NCP93 8000000-9001948 20070508-20081219

NCP93L 8000002-8000002 20070601-20070601

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.

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.

China: Thailand: Indonesia:

Malaysia: Philippines:

Vietnam:

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3. PREPARATION

PARTS

Part Number Part Description Quantity Others

04006-0210D Instrument Panel Airbag Inflator Assy Kit 1 -

73960-0D330 Airbag Module 1 -

04005-28252 Instrument Panel Wire Assy Kit 1 -

82140-52150 Wire Harness 1 -

Part Number Part Description Quantity Others

04005-5210D Instrument Panel Airbag Inflator Assy Kit 1 -

73960-0D320 Airbag Module 1 -

04005-28252 Instrument Panel Wire Assy Kit 1 -

82140-52150 Wire Harness 1 -

TOOLS&EQUIPMENT

Part Number Name Quantity Others

- Standard Hand Tools - -

- Torque Wrench - -

- Global TechStream - -

SUPPLIES

Name Quantity Others

Protective Eyewear 1 -

Work Gloves 1 -

Protective Tape - -

Marking Pen - -

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4. GENERAL WORK PROCEDURES

Replace the airbag module with a NEW one.

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5. PRECAUTIONS FOR AIRBAG REMOVAL/INSTALLATION

If handled with incorrect procedures or methods, an airbag system may deploy accidentally during work and cause a fatal accident, or it may become undeployable when necessary. 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 PASSENGER AIRBAG PROPERLY

(a) Keep the deploying side facing upward except for when the inflator is replaced.

DO NOT place an object on an airbag. DO NOT allow foreign matters including water and oil to

adhere to or enter into an airbag.

(b) Even a NEW airbag module cannot be

used if it has been dropped because such

an airbag module has a risk of malfunction.

(c) To dispose an airbag, be sure to make the

airbag deploy according to the instruction

in the repair manual or ask collection

service for the deployment work.

If an airbag is disposed as normal steel

scrap, it may deploy unexpectedly during

disposal process and cause a severe

accident.

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6. PRECAUTIONS FOR ENTIRE WORK

1. PRECAUTIONS WHEN RAISING VEHICLE USING A LIFT OR JACK

(a) Refer to the respective repair manual and follow the instructions within the Introduction section to ensure safety when working.

(b) Ensure the safety of all personnel near the lift or jack, including yourself, before beginning work. Also announce all lift and jack operations out loud to prevent any personnel from being caught or harmed in any way.

2. WEAR PROTECTIVE EYEWEAR (a) Wear protective eyewear when working under

vehicle or where there is any risk of flying parts or debris.

3. DO NOT USE BRAKE CLEANER AS STAIN REMOVER

(a) DO NOT spray brake cleaner onto any clothes since it is a flammable solvent that vaporizes easily. DO NOT use it near cigarettes or stoves as this can cause serious burns and injuries.

4. AVOID BURNS (a) If the engine is hot, wear protective gloves to

prevent burns.

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5. PROTECT THE VEHICLE (a) A fender cover, a grill cover, seat covers tape

etc. must be used to protect the vehicle from dirt or scratches.

NOTICE: The protective measures listed above may not be shown in some illustrations to allow easy identification simple and easy to read.

6. HANDLING OF REMOVED PARTS (a) Destroy or mark and then store removed

parts in a separate container so as to not be assembled again in error.

(b) Check the removed parts when performing the completion inspection.

NOTICE: The parts shown in the illustration to the left are examples only and differ from the actual replacement parts.

7. DO NOT BREAK PARTS WHEN WORKING INSIDE ENGINE COMPARTMENT

(a) DO NOT break parts by carelessly placing hands inside and leaning on the engine compartment while being preoccupied by work.

8. CHECK INSIDE ENGINE COMPARTMENT BEFORE ENGINE START-UP

(a) Check that all necessary parts are installed. (b) Check that no tools or pieces of cloth are left

inside the engine compartment.

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7. COMPONENTS

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8. WORK PROCEDURES

8.1 REMOVAL OF PASSENGER SIDE AIRBAG MODULE

1. PRECAUTIONS FOR INTERIOR WORK

IN AGING VEHICLES

NOTICE: 【PREVENT DAMAGE OF INTERIOR

PARTS】

Interior parts are brittle due to aging.

Handle parts carefully.

Before attaching protective tape, check for

aging of the part.

NOTICE: 【DISENGAGE CLIPS GENTLY】

If pulled forcibly and locally, parts may be

damaged or clips may drop off.

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.

NOTICE: 【PLACE THE REMOVED PART

PROPERLY】

Keep the removed parts orderly to prevent

damage.

For work on a removed part, lay a soft cloth

under the part as needed in order to

prevent damage of the design surface.

2. 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.

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3. REMOVE THE FRONT PASSENGER AIRBAG ASSEMBLY

HINT:

For removal of the front passenger airbag assembly and instrument panel wire assembly, refer to the

VIOS repair manual.

4. REMOVE THE AIRBAG MODULE

NOTICE:

DO NOT allow foreign objects to enter into

an airbag.

If foreign objects enter, they may fly off

and cause a serious accident when the

airbag is activated.

(a) Wear protective eyewear and work gloves

throughout remove work of an airbag

module from the beginning to the end.

(b) For remove work of an airbag module, avoid standing directly in front of the parts.

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(c) Wrap protective tape around a flathead

screwdriver.

(d) Disengage the claws from the one on the vehicle rear side using the flathead screwdriver to

remove the airbag module.

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8.2 INSTALLATION OF A NEW PASSENGER SIDE AIRBAG MODULE (LHD)

1. INSERT THE AIRBAG MODULE

(a) Install the NEW airbag module taking care not to mistake the mounting direction.

(b) Check that the 10 claws of the airbag

module have engaged securely.

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2. INSTALL THE FRONT PASSENGER AIRBAG ASSEMBLY

HINT:

For installation of the front passenger airbag assembly and instrument panel wire assembly, refer to

the VIOS repair manual.

NOTICES:

(1) Pass the harness under the airbag module bracket.

(2) Connect the connector and push the locking button fully.

(3) Fit the NEW harness into the clamp

on the instrument panel so that the

harness does not become slack or

tensioned.

(4) INSPECT SRS WARNING LIGHT

CHECK

① Turn the ignition switch to ON, and

check that the SRS warning light

comes on.

② Check that the SRS warning light

goes out after approx. 6 seconds.

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8.3 INSTALLATION OF A NEW PASSENGER SIDE AIRBAG MODULE (RHD)

1. INSERT THE AIRBAG MODULE

(a) Install the NEW airbag module taking care not to mistake the mounting direction.

(b) Check that the 10 claws of the airbag

module have engaged securely.

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2. INSTALL THE FRONT PASSENGER AIRBAG ASSEMBLY

HINT:

For installation of the front passenger airbag assembly and instrument panel wire assembly, refer to

the VIOS repair manual.

NOTICES:

(1) Pass the harness under the airbag module bracket.

(2) Connect the connector and push the locking button fully.

(3) Fit the NEW harness into the clamp

on the instrument panel so that the

harness does not become slack or

tensioned.

(4) INSPECT SRS WARNING LIGHT

CHECK

① Turn the ignition switch to ON, and

check that the SRS warning light

comes on.

② Check that the SRS warning light

goes out after approx. 6 seconds.