Overhaul
DISASSEMBLY1. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY
a. Remove the 2 nuts holding the front passenger airbag assembly to the instrument panel.
b. Pry up the 6 clips shown in the illustration.
c. Remove the front passenger airbag assembly from the instrument panel.
CAUTION: Do not store the front passenger airbag assembly with the airbag deployment side facing down. Never disassemble the front passenger airbag assembly.
NOTE: When removing the front passenger airbag assembly, take care not to damage the wire harness.
2. REMOVE CENTER BRACKET
Remove the screw and center bracket.
3. REMOVE DOOR
4. REMOVE NO. 2 BOX
Remove the 2 screws and No. 2 box.
5. REMOVE NO. 1 BOX
a. When installed by ultrasonic welding:
Using a nipper, cut off the ultrasonic welding portion of the instrument panel along the No. 1 box to remove the No. 1 box from the instrument panel lower.
b. When installed with screw:
Remove the screw and No. 1 box from the instrument panel lower.
6. REMOVE REGISTERS
7. REMOVE NO. 1, NO. 2 AND NO. 3 HEATER TO REGISTER DUCT
HINT: For step 6 and 7, remove them in the same way as No.1 box.
REASSEMBLY
NOTE: Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.
1. When replacing instrument panel lower:
INSTALL NO. 1 BOX
a. Cut off the boss using a nipper to make the level of the surface equal to the No. 1 box.
NOTE: Ensure that the cut surface is flush with the surface of No. 1 box to prevent looseness.
b. Install the No. 1 box securely on the instrument panel with the tapping screw provided in the same packing.
HINT: Use the same manner to instrument panel upper.
2. When reusing instrument panel lower:
INSTALL NO. 1 BOX
Install the No. 1 box to the instrument panel lower with the screw.
3. INSTALL NO. 1, NO. 2 AND NO. 3 HEATER TO REGISTER DUCT
4. INSTALL NO. 1 AND NO. 2 SIDE DEFROSTER NOZZLE DUCT
5. INSTALL REGISTERS
HINT: For step 2 and 3, install them in the same way as No. 1 box.
6. INSTALL NO. 2 BOX
Install the No. 2 box with the 2 screws.
7. INSTALL DOOR
8. INSTALL CENTER BRACKET
Install the center bracket with the screw.
9. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY
a. Install the front passenger airbag assembly to the instrument panel.
b. Install the 2 nuts.
NOTE: If the front passenger airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front passenger airbag assembly withe a new one.