2003-2008 Toyota 4Runner Service & Repair Manual

2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems DESCRIPTION & OPERATION Supplemental Restraint System (SRS), also known as air bag system, is designed to provide increased accident protection for driver, front and rear passengers by deploying air bags in a front-end or side collision. The air bag system is designed to be used in conjunction with 3-point seat belts. The air bag system includes the following components: dual-stage driver-side air bag module, dual-stage passenger-side air bag module, spiral cable, right and left side air bag modules, right and left front seat belt pretensioners, AIR BAG warning light, air bag sensor assembly, right and left head impact/side air bag sensors, right and left front impact sensors, right and left rear impact sensors, left front seat position sensor and associated wiring harnesses. See COMPONENT LOCATIONS . COMPONENT LOCATIONS Refer to illustration for component locations. See Fig. 1 . WARNING: Accidental air bag deployment is possible. Personal injury may result. Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS before working on air bag system or related components. 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 1: Locating Restraint System Components 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SYSTEM OPERATION CHECK Turn ignition switch to ACC or ON position. AIR BAG warning light should come on for about 6 seconds and then go out. If AIR BAG warning light does not operate as specified, see DIAGNOSTICS . AIR BAG SAFETY PRECAUTIONS Observe the following precautions when servicing air bag system:  Disable air bag system before servicing any air bag system or steering column component. Failure to do this could result in accidental air bag deployment and possible personal injury. See DISABLING & ACTIVATING AIR BAG SYSTEM .  When diagnosing air bag system, always check for diagnostic codes before disconnecting battery.  After turning ignition switch to LOCK position and disconnecting negative battery cable, wait at least 90 seconds before working on air bag system. Air bag system is equipped with a back-up power source that may allow air bag to deploy until 90 seconds after disconnecting negative battery cable.  If vehicle was in a minor collision but air bags did not deploy, inspect all system components for any sign of damage, and replace as necessary.  Never use air bag system components from another vehicle. Replace air bag system components with NEW parts.  Remove air bag sensor assembly, if repairing the vehicle requires impacting (shocking) the vehicle.  Air bag sensor assembly contains mercury. After replacement, DO NOT destroy old part. When scrapping vehicle or replacing air bag sensor assembly, remove air bag sensor assembly and dispose of it as toxic waste.  Never disassemble and repair air bag sensor assembly or steering wheel pad.  Replace dropped, cracked, dented or otherwise damaged components.  DO NOT expose air bag sensor assembly, front impact sensors, pretensioners or air bag modules directly to heat or flame.  When diagnosing electrical circuits, use a volt/ohm meter with high impedance (10,000 ohms minimum).  Information labels are attached to air bag components. Follow all notices on labels.  After work on air bag system is complete, check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .  Always wear safety glasses when servicing or handling an air bag.  When placing a live air bag on a bench or other surface, always face air bag and trim cover up and away from surface. This will reduce motion of module if it is accidentally deployed.  After deployment, air bag surface may contain deposits of sodium hydroxide, which irritates skin. Always wear safety glasses, rubber gloves, and long-sleeved shirt during clean- up. After clean-up, wash hands using mild soap and water.  Carry a live air bag module with trim cover (air bag) pointed away from your body to minimize injury in case accidental deployment. 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

 If air bag system is not fully functional for any reason, vehicle should not be driven until system is repaired and again becomes operational. DO NOT remove bulbs, modules, sensors or other components, or in any way disable system from operating normally. If air bag system is not functional, park vehicle until it is repaired and functions properly. ADJUSTMENTS CENTERING SPIRAL CABLE Ensure air bag system is disabled. Turn spiral cable counterclockwise until it becomes difficult to turn. Turn spiral cable clockwise about 2 1/2 turns to align match marks. See Fig. 2 . Install steering wheel. Fig. 2: Adjusting Spiral Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISABLING & ACTIVATING AIR BAG SYSTEM 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

DISABLING SYSTEM Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds before starting any work on vehicle. ACTIVATING SYSTEM For Component Replacement Ensure ignition switch is in LOCK position. Reconnect negative battery cable. Perform system operation check. See SYSTEM OPERATION CHECK . DISPOSAL PROCEDURES ON-VEHICLE DEPLOYMENT (SCRAPPED VEHICLES ONLY) Dual-stage Driver- & Passenger-side AIR Bag Module 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure steering wheel, driver-side air bag module and passenger-side air bag modules are not loose. If components are loose, deploy air bag(s) using OFF - VEHICLE DEPLOYMENT procedure. Test Deployment Tool (09082-00700). See TESTING DEPLOYMENT TOOL . 2. If deploying driver-side air bag module, access and disconnect spiral cable connector accessible by removing lower steering column cover. If deploying passenger-side air bag module, access and disconnect passenger-side air bag connector by removing glove box. See Fig. 3 . For either air bag, connect Deployment Tools (09082-00700 and 09082-00780) to air bag module connector. Position deployment tool at least 33 feet (10 m) from front of vehicle. 3. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. Ensure no one is inside or within 33 feet (10 m) of vehicle. WARNING: Unintentional air bag module deployment is possible. Personal injury may result. Never use memory savers when working on air bag system. Unintentional air bag module deployment is possible. Personal injury may result. Back-up power supply maintains air bag system voltage for about 90 seconds after battery is disconnected. After disabling air bag system, wait at least 90 seconds before servicing air bag system. WARNING: Undeployed air bags contain substances that can cause illness or injury if improperly handled. Disposing of an undeployed air bag may violate federal, state and/or local laws. If scrapping vehicle, air bag must be deployed while still mounted in vehicle. Air bags should not be deployed inside vehicle unless vehicle is to be scrapped. If not scrapping vehicle, use off-vehicle deployment procedures. See OFF - VEHICLE DEPLOYMENT . Wear gloves and safety glasses when handling air bag. Wrap deployed air bag in a sturdy plastic bag and dispose of it like any other part. 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Press activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes after deployment. Fig. 3: Identifying Passenger - side Air Bag Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Head Impact AIR Bag Module 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Remove headliner. See HEADLINER under REMOVAL & INSTALLATION. Disconnect head impact air bag electrical connector. Test Deployment Tool (09082-00700). See TESTING DEPLOYMENT TOOL . 2. Connect Deployment Tools (09082-00700 and 09082-00802) to head impact air bag module connector. Position deployment tool at least 33 feet (10 m) from front of vehicle. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. 3. Ensure no one is inside vehicle or within 33 feet (10 m) of vehicle. Press activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes after deployment. Scrap vehicle with 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

air bag(s) still installed. Seat Belt Pretensioner 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure seat belt pretensioner is not loose. If components are loose, remove and deploy using OFF - VEHICLE DEPLOYMENT procedure. Access and disconnect appropriate seat belt pretensioner connector. See SEAT BELT PRETENSIONER under REMOVAL & INSTALLATION. Test Deployment Tool (09082-00700). See TESTING DEPLOYMENT TOOL . 2. Connect Deployment Tools (09082-00700 and 09082-00740) to seat belt pretensioner connector. Position deployment tool at least 33 feet (10 m) from front of vehicle. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. 3. Ensure no one is inside vehicle or within 33 feet (10 m) of vehicle. Press activation switch to deploy seat belt pretensioner. Because of heat, DO NOT touch seat belt pretensioner for at least 30 minutes after deployment. Scrap vehicle with pretensioner(s) still installed. Side AIR Bag Module 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Ensure seat back is not loose. If components are loose, remove and deploy air bag(s) using OFF - VEHICLE DEPLOYMENT procedure. Disconnect appropriate side air bag connector, located under seat. Test Deployment Tool (09082-00700). See TESTING DEPLOYMENT TOOL . 2. Connect Deployment Tools (09082-00700 and 09082-00750) to appropriate air bag module connector. Position deployment tool at least 33 feet (10 m) from front of vehicle. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. 3. Ensure no one is inside vehicle or within 33 feet (10 m) of vehicle. Press activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes after deployment. Scrap vehicle with air bag(s) still installed. OFF-VEHICLE DEPLOYMENT Dual-stage Driver-side AIR Bag Module 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Remove driver-side air bag module. See DUAL - STAGE DRIVER - SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. 2. Install 2 bolts (6 mm X 35 mm) with washers into holes located in rear of driver-side air bag module. Tighten bolts by hand, until bolts become difficult to turn. DO NOT overtighten bolts. Wrap strong wire at least twice around each bolt. See Fig. 4 . Ensure no slack is present in wire. If slack is present, or wire is not strong enough, driver-side air bag module may become loose due to shock when air bag is deployed. 3. Position driver-side air bag module on rim of a scrap wheel and tire assembly with pad side facing upward. See Fig. 5 . Securely tie driver-side air bag module to wheel rim through lug nut holes. Place a large cardboard box (weighted at sides) or 3 scrap tires on top of driver-side air bag module. Test Deployment Tool (09082-00700). See TESTING DEPLOYMENT TOOL . 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

4. Connect Deployment Tool (09082-00700) to driver-side air bag module connector. Position deployment tool at least 33 feet (10 m) away from driver-side air bag module. Press activation switch to deploy driver-side air bag module. Because of heat, wait 30 minutes before handling driver-side air bag module. Seal deployed air bag module in vinyl bag and dispose of in usual manner. 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 4: Securing Wire To Driver - side Air Bag Module Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Fig. 5: Securing Driver - side Air Bag Module To Wheel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Head Impact AIR Bag Module 1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Remove head impact air bag module to be deployed. See HEAD IMPACT AIR BAG MODULE under REMOVAL & INSTALLATION. 2. Remove bolt from head impact air bag inflator. See Fig. 6 . Cut deployment section off of head impact air bag inflator. Pass strong wire through head impact air bag inflator mounting holes. See Fig. 7 . Position head impact air bag module inside a scrap tire with air bag deployment direction facing inside. See Fig. 8 . Secure head impact air bag module to tire with wire. Place this tire between 4 other tires (top tire 2003 Toyota 4Runner Limited 2003 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

2003-2008 Toyota 4Runner Service & Repair Manual

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