Knee airbag module
Components Inspection Removal / installation
SRS AIRBAG
KNEE AIRBAG MODULE
EXPLODED VIEW
REMOVAL
WARNING:
The following service operations include the works which may affect the SRS airbag system. Before starting work, always be sure to confirm the precautions related to the SRS airbag system. (Refer to 
)
)1. Precautions
CAUTION:
After turning the ignition switch to OFF, you may have to wait for a while before disconnecting the battery terminals. Check appropriate precautions for battery terminal disconnection before proceeding. (Refer to )
)2. Disconnection of the battery ground terminal
(1) Turn the ignition switch to OFF, disconnect the battery ground terminal, and then wait for 60 seconds before starting the work. (Refer to )
)WARNING:
The air bag and pretensioner system are fitted with a backup power supply. If you start the work within 60 seconds after disconnecting the battery ground terminal, the air bag may be activated.
CAUTION:
To avoid damage to the molding, be sure to fully open the door glasses on both driver’s and passenger’s sides.
3. Removal of instrument side panel LH (Refer to )
)4. Removal of instrument panel under cover SUB-ASSY NO.1 (Refer to )
)5. Removal of instrument panel under cover SUB-ASSY NO.2 (Refer to )
)6. Removal of knee airbag module
WARNING:
When storing a removed knee airbag module, even if it is a temporary storage, be sure to place the airbag module with the deploying side facing upward.
(1) Check that the ignition switch is turned to OFF.
(2) Check that the battery ground terminal is disconnected.
WARNING:
After disconnecting the battery ground terminal, do not start the work before waiting for 60 seconds.
(3)
Remove 2 nuts and remove the knee airbag module.
CAUTION:
When removing the knee airbag module, be careful not to pull the airbag wiring harness.
(4) Using the fine flat tip screwdriver wrapped with protective tape, pull up the lock of the airbag connectors to unlock it.
Captions in illustration
| *1 |
Protective tape |
| *2 |
Airbag connector |
| *3 |
Airbag connector lock |
(5) Using the fine flat tip screwdriver wrapped with protective tape, disconnect the airbag connector and remove the knee airbag module.
INSTALLATION
WARNING:
The following service operations include the works which may affect the SRS airbag system. Before starting work, always be sure to confirm the precautions related to the SRS airbag system. (Refer to )
)CAUTION:
Do not allow the harnesses and the connectors to interfere or get tangled with other parts.
1. Installation of the knee airbag module
(1) Before installation, inspect the following items and replace any faulty part with a new one.
·Airbag module is cracked or deformed.
·Knee airbag module bracket is cracked or deformed.
·Harness and/or connector is cracked, deformed or broken.
·Harness wire is exposed.
·The condition of the instrument panel reinforcement ASSY makes the installation of the knee airbag module difficult.
·Knee airbag module bracket is cracked or deformed.
·Harness and/or connector is cracked, deformed or broken.
·Harness wire is exposed.
·The condition of the instrument panel reinforcement ASSY makes the installation of the knee airbag module difficult.
(2) Check that the ignition switch is turned to OFF.
(3) Check that the battery ground terminal is disconnected.
WARNING:
After disconnecting the battery ground terminal, do not start the work before waiting for 60 seconds.
(4) Connect the airbag connector to the knee airbag module.
Captions in illustration
| *1 |
Airbag connector |
| *2 |
Airbag connector lock |
(5) Push in the lock of the airbag connector.
CAUTION:
Lock it securely.
(6) Using 2 nuts, install the knee airbag module.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
CAUTION:
Check that the knee airbag module is securely installed without extra gap and protruding outside.
2. Installation of instrument panel under-cover SUB-ASSY NO.2 (Refer to )
)3. Installation of instrument panel under-cover SUB-ASSY NO.1 (Refer to )
)4. Installation of the instrument side panel LH (Refer to )
)5. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
6. Inspection of the airbag warning light (Refer to )
)DISPOSAL
1. Precautions for handling the device
WARNING:
The following service operations include the works which may affect the SRS airbag system. Before starting work, always be sure to confirm the precautions related to the SRS airbag system. (Refer to )
)2. Disposal of knee airbag module (for module only)
WARNING:
·Perform the operation outdoors on a level surface where safety can be ensured. Avoid performing the operation in residential and similar areas as much as possible.
·Before operation, notify people in the surrounding area because the operation makes a loud noise.
·Before operation, notify people in the surrounding area because the operation makes a loud noise.
(1) Removal of knee airbag module (Refer to )
)(2) Securing of knee airbag module
(a) Using wiring harnesses (with a core of 1.25 mm2 {0.00194 sq in} or more), secure the knee airbag module to a tire.
WARNING:
Strictly follow the two instructions below. Failure to do so may result in serious damage suffered by flying debris of the deployed airbag (knee airbag module) or tire, etc.
·When activating the airbag (knee airbag module), a force of approx. 1 t is applied on the wiring harnesses. Therefore, secure the module tightly with triple wiring harnesses without slack.
·As shown in the figure, be sure to install the airbag (knee airbag module) with the deploying side facing the center of the tire.
·As shown in the figure, be sure to install the airbag (knee airbag module) with the deploying side facing the center of the tire.
CAUTION:
Use waste tires for disposal operation.
Captions in illustration
| *a |
Width |
*b |
Inner Diameter |
(3) Activation of knee airbag module
(a) Short the alligator clip and the terminal of SST (98299PA030).
SST
98299PA030
Captions in illustration
| *a |
Short the circuit |
(b) Connect the following SSTs together.
SST
98299PA030 (airbag deployment tool)
98299SA010 (test harness adapter D)
(c) Connect the SST (98299SA010) to the airbag (knee airbag module), and lock it securely.
NOTE:
If the connector of the test harness adapter on the inflator side is melted, replace it with a repair connector (98299FJ010). (Refer to )
)(d) As shown in the figure, place two tires on top of each other, and then pile the tire-mounted knee airbag module, a tire, and a tire with disc wheel in that order.
Captions in illustration
| *1 |
Tire with disc wheel |
*2 |
Tire without disc wheel |
| *a |
Wrap the wire twice or more (without slack) |
*b |
Fully extend the SST |
| *c |
Keep 5 m {16.4 ft} or more from the tires |
- |
- |
(e) Using a wire with a diameter of 1.8 mm {0.07 in} or more (usual iron wire for general-purpose: corresponding to JIS SWM-B), wrap the entire tires twice or more without slack to secure them tightly.
CAUTION:
·Secure them so that the total load capacity becomes 1 t or more.
·Use waste tires and disc wheels for disposal operation.
·Use waste tires and disc wheels for disposal operation.
(f) Fully expand the SST (98299PA030) from the knee airbag module and place the battery 5 m {16.4 ft} or more away from the tires.
(g) Place pylons with ropes, etc. around the tires to keep out of the area within a radius of 5 m {16.4 ft} from the outside of the tires.
Captions in illustration
| *a |
Keep 5 m {16.4 ft} or more |
(h) After ensuring the safety of the surrounding area, connect the alligator clip of the SST (98299PA030) to the battery ground terminal.
(i) Connect the terminal of the SST (98299PA030) to the battery positive terminal to activate the knee airbag module.
WARNING:
·Perform the operation outdoors on a level surface where safety can be ensured. Avoid performing the operation in residential and similar areas as much as possible.
·Before operating, notify people in the surrounding area because the operation makes a quite loud noise.
·Before the operation, ensure that nobody is in the area.
·Before the operation, notify people near the operating area in a loud voice.
·Before operating, notify people in the surrounding area because the operation makes a quite loud noise.
·Before the operation, ensure that nobody is in the area.
·Before the operation, notify people near the operating area in a loud voice.
(4) Disposal of knee airbag module
(a) Put an activated knee airbag module in a strong clear vinyl bag and seal the bag before disposal.
WARNING:
·Because some parts of an activated airbag (knee airbag module) may be very hot (hundreds of degrees Celsius or more), leave it 40 minutes or more after operation.
·Do not put water on an activated airbag (knee airbag module).
·Wear dustproof safety goggles and gloves when handling an activated airbag (knee airbag module).
·Never discard any undeployed airbag (knee airbag module).
·Be sure to wash your hands with water after completion of the operation.
·Do not put water on an activated airbag (knee airbag module).
·Wear dustproof safety goggles and gloves when handling an activated airbag (knee airbag module).
·Never discard any undeployed airbag (knee airbag module).
·Be sure to wash your hands with water after completion of the operation.
3. Disposal of knee airbag module (for vehicle-mounted module)
CAUTION:
·When disposing a knee airbag module, do not use the customer’s vehicle to activate the airbag.
·When activating an airbag, follow the instructions below.
·When activating an airbag, follow the instructions below.
NOTE:
Prepare a battery as a power supply for activating the airbag.
(1) Refer to the precautions. (Refer to )
)(2) Remove the instrument panel under cover SUB-ASSY NO.1. (Refer to )
)(3) Remove the instrument panel under cover SUB-ASSY NO.2. (Refer to )
)(4) Disconnect the cable from the battery ground terminal.
WARNING:
To disable the SRS system, disconnect the battery ground terminal, and then wait for at least 60 seconds before starting the work.
(5) Activation of knee airbag module
(a) Disconnect the connector from the knee airbag module.
Captions in illustration
| *1 |
Protective tape |
| *2 |
Airbag connector |
| *3 |
Airbag connector lock |
(b) Short the alligator clip and the terminal of SST (98299PA030).
SST
98299PA030
Captions in illustration
| *a |
Short the circuit |
CAUTION:
Keep the short condition between terminals of the airbag deployment tool until just before the activation process.
(c) Connect the following SSTs together.
SST
98299PA030 (airbag deployment tool)
98299SA010 (test harness adapter D)
(d) Connect the SST (98299SA010) to the airbag (knee airbag module), and lock it securely.
NOTE:
If the connector of the test harness adapter on the inflator side is melted, replace it with a repair connector (98299FJ010). (Refer to )
)
(e) Move the SST to the position at least 5 m {16.4 ft} away from the vehicle front side window.
Captions in illustration
| *1 |
Battery |
| *a |
5 m {16.4 ft} or more |
(f) Fully expand the SST, and then fully close the windows, doors and trunk.
(6) Activate the airbag.
(a) Check that nobody is in the vehicle and within a radius of 5 m {16.4 ft} from the vehicle.
(b) Connect the SST clip to the battery positive terminal.
(c) Connect the SST terminal to the battery ground terminal to activate the knee airbag module.
WARNING:
·Because some parts of an activated airbag (knee airbag module) may be 100°C or more, leave it 40 minutes or more after operation.
·Do not put water on an activated airbag (knee airbag module).
·Wear dustproof safety goggles and gloves when handling an activated airbag (knee airbag module).
· Never discard any undeployed airbag (knee airbag module).
·Be sure to wash your hands with water after completion of the operation.
·Do not put water on an activated airbag (knee airbag module).
·Wear dustproof safety goggles and gloves when handling an activated airbag (knee airbag module).
· Never discard any undeployed airbag (knee airbag module).
·Be sure to wash your hands with water after completion of the operation.