Toyota Prius: Knee Airbag Assembly

Toyota Prius (XW60) 2023-2025 Service Manual / Vehicle Interior / Supplemental Restraint Systems / Knee Airbag Assembly

Removal
Installation
Disposal

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during lower No. 1 instrument panel airbag assembly removal/installation are shown below.

CAUTION / NOTICE / HINT

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when Toyota Prius vehicle is driven

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the Toyota Prius vehicle straight ahead at 35 km/h (22 mph) or more for 5 seconds or more.

Learning completes when vehicle is operated normally

Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
1: w/o Power Back Door System 2: w/ Power Back Door System
Power Door Lock Control System*1 Back door opener	Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.
Power Back Door System*2	Reset back door close position
Air Conditioning System	for HEV Model: After the ignition switch is turned to ON, the servo motor standard position is recognized. for PHEV Model: After the ignition switch is turned to ON, the servo motor and expansion valve standard position is recognized.	-

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	PRECAUTION	-		-	-
2	DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL	-		-	-
3	FRONT DOOR SCUFF PLATE LH	67914	-	-	-
4	COWL SIDE TRIM BOARD LH	62112	-	-	-
5	NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY	55606	-	-	-
6	LOWER CENTER INSTRUMENT PANEL FINISH PANEL	55434B	-	-	-
7	LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY	55480D	-	-	-
8	LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY	73900		-	-

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read Precaution thoroughly before servicing.

Click here

NOTICE:

After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

Click here

2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

CAUTION:

Wait at least 60 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

for M20A-FXS:
Click here
for 2ZR-FXE:
Click here

3. REMOVE FRONT DOOR SCUFF PLATE LH

Click here

4. REMOVE COWL SIDE TRIM BOARD LH

Click here

5. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here

6. REMOVE LOWER CENTER INSTRUMENT PANEL FINISH PANEL

Click here

7. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY

Click here

8. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

CAUTION:

When storing the lower No. 1 instrument panel airbag assembly, keep the airbag deployment side facing upward.

Illumination off

(1) Check that the ignition switch is off.

(2) Check that the cable is disconnected from the negative (-) auxiliary battery terminal.

CAUTION:

Wait at least 60 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

(1) Remove the 2 bolts.

(2) Disengage the 2 claws and 2 hooks to separate the lower No. 1 instrument panel airbag assembly.

NOTICE:

When separating the lower No. 1 instrument panel airbag assembly, do not pull the airbag wire harness.

(3) Disconnect the airbag connector to remove the lower No. 1 instrument panel airbag assembly.

NOTICE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

HINT:

Refer to How to Connect or Disconnect Airbag Connector.

Click here

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY	73900		-	-
2	LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY	55480D	-	-	-
3	LOWER CENTER INSTRUMENT PANEL FINISH PANEL	55434B	-	-	-
4	NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY	55606	-	-	-
5	COWL SIDE TRIM BOARD LH	62112	-	-	-
6	FRONT DOOR SCUFF PLATE LH	67914	-	-	-
7	CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL	-		-	-
8	INSPECT SRS WARNING LIGHT	-	-	-
9	INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL	-	-	-

Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

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

PROCEDURE

1. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

Illumination off

(1) Check that the ignition switch is off.

(2) Check that the cable is disconnected from the negative (-) auxiliary battery terminal.

CAUTION:

Wait at least 60 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

(1) Connect the airbag connector to the lower No. 1 instrument panel airbag assembly.

NOTICE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

HINT:

Refer to How to Connect or Disconnect Airbag Connector.

Click here

(2) Engage the 2 hooks to temporarily install the lower No. 1 instrument panel airbag assembly.

(3) Engage the 2 claws.

(4) Install the lower No. 1 instrument panel airbag assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

NOTICE:

Confirm that the lower No. 1 instrument panel airbag assembly is installed securely without any excessive gaps and is not protruding outward.

2. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY

3. INSTALL LOWER CENTER INSTRUMENT PANEL FINISH PANEL

4. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

5. INSTALL COWL SIDE TRIM BOARD LH

6. INSTALL FRONT DOOR SCUFF PLATE LH

7. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

for M20A-FXS:
Click here
for 2ZR-FXE:
Click here

8. INSPECT SRS WARNING LIGHT

Click here

9. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click here

Disposal

DISPOSAL

CAUTION / NOTICE / HINT

CAUTION:

Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material treatment.

PROCEDURE

1. PRECAUTION

CAUTION:

An airbag or pretensioner may be accidentally deployed by static electricity. To prevent this, be sure to touch a metal surface with your bare hands to discharge static electricity before performing this procedure.
Never dispose of a lower No. 1 instrument panel airbag assembly with an undeployed airbag.
The airbag produces an exploding sound when it is deployed, so perform the operation outdoors where it will not disturb nearby residents.
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 the airbag, perform the operation at least 10 m (32.8 ft.) away from the lower No. 1 instrument panel airbag assembly.
The lower No. 1 instrument panel 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 lower No. 1 instrument panel airbag assembly with a deployed airbag.
Do not apply water, etc. to a lower No. 1 instrument panel airbag assembly with a deployed airbag.
Always wash your hands with water after completing the operation.

HINT:

When scrapping a Toyota Prius vehicle equipped with an SRS or disposing of the lower No. 1 instrument panel airbag assembly, be sure to deploy the airbag first in accordance with the following procedure. If any abnormality occurs with the airbag deployment, contact the Service Department of the distributor.

2. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (When Installed to Toyota Prius Vehicle)

NOTICE:

When disposing of a lower No. 1 instrument panel airbag assembly, never use the customer's vehicle to deploy the airbag.
Be sure to perform the following procedure when deploying the airbag.

HINT:

Prepare an auxiliary battery as the power source to deploy the airbag.

(a) Check the function of SST.

Click here

SST: 09082-00700

(b) Refer to Precaution.

Click here

for M20A-FXS:
Click here
for 2ZR-FXE:
Click here

CAUTION:

Wait at least 60 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

(d) Remove the No. 1 instrument panel under cover sub-assembly.

Click here

(e) Disconnect the lower No. 1 instrument panel airbag assembly connector.

NOTICE:

When disconnecting any airbag connector, take care not to damage the airbag wire harness.

HINT:

Refer to How to Connect or Disconnect Airbag Connector.

Click here

(f) Install SST.

CAUTION:

Check that there is no looseness in the lower No. 1 instrument panel airbag assembly.

(1) After connecting the following SST to each other, connect them to the lower No. 1 instrument panel airbag assembly.

SST: 09082-00700

SST: 09082-00770

NOTICE:

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

(2) Move SST at least 10 m (32.8 ft.) away from the front side window of the Toyota Prius vehicle.

*a	Auxiliary Battery
*b	10 m (32.8 ft.) or more

(3) Maintaining sufficient clearance for the SST wire harness in the front side window, close all doors and windows of the Toyota Prius vehicle.

NOTICE:

Take care not to damage the SST wire harness.

(4) Connect the red clip of SST to the positive ( ) auxiliary battery terminal and the black clip of SST to the negative (-) auxiliary battery terminal.

(g) Deploy the airbag.

(1) Check that no one is inside the Toyota Prius vehicle or within a 10 m (32.8 ft.) radius of the vehicle.

(2) Press the SST activation switch to deploy the airbag.

CAUTION:

Before deployment, make sure that no one is inside or near the vehicle.
The lower No. 1 instrument panel 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 lower No. 1 instrument panel airbag assembly with a deployed airbag.
Do not apply water, etc. to a lower No. 1 instrument panel airbag assembly with a deployed airbag.
Always wash your hands with water after completing the operation.

HINT:

The airbag is deployed as the LED of the SST activation switch comes on.

3. DISPOSE OF LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY (When not Installed to Toyota Prius Vehicle)

NOTICE:

Be sure to perform the following procedure when deploying the airbag.

HINT:

Prepare an auxiliary battery as the power source to deploy the airbag.

(a) Check the function of SST.

Click here

SST: 09082-00700

(b) Remove the lower No. 1 instrument panel airbag assembly.

Click here

CAUTION:

Before removing the lower No. 1 instrument panel airbag assembly, wait at least 60 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) auxiliary battery terminal.
When storing the lower No. 1 instrument panel airbag assembly, keep the airbag deployment side facing upward.

Deployment Side

*a	Wire Diameter
*b	Stripped Wire Cross Sectional Area

Wire:

Stripped Wire Cross Sectional Area

1.25 mm2 (0.0019 in.2) or more

CAUTION:

If the wire is too thin or an alternative object is used to tie down the lower No. 1 instrument panel airbag assembly, it may snap when the airbag is deployed. Always use a wire for Toyota Prius vehicle use with a cross sectional area of at least 1.25 mm2 (0.0019 in.2).

HINT:

To calculate the cross sectional area of the stripped wire:

Cross sectional area = 3.14 x (Diameter)2 / 4

(1) Position the lower No. 1 instrument panel airbag assembly inside the tire with the airbag deployment side facing inward.

Minimum Tire Size:

Width

185 mm (7.28 in.)

Inner Diameter

360 mm (1.18 ft.)

Width

Inner Diameter

CAUTION:

Make sure that the wires are tight. If there is slack in the wires, the lower No. 1 instrument panel airbag assembly may break loose when the airbag is deployed.
Always tie down the lower No. 1 instrument panel airbag assembly with the airbag deployment side facing inside the tire.

Deployment Side

NOTICE:

The tire may be damaged by the airbag deployment, so use an unneeded tire.

(d) Install SST.

(1) After connecting the following SST to each other, connect them to the lower No. 1 instrument panel airbag assembly.

SST: 09082-00770

(e) Place the tires.

(1) Place at least 2 tires under the tire to which the lower No. 1 instrument panel airbag assembly is tied.

Minimum Tire Size:

Width

185 mm (7.28 in.)

Inner Diameter

360 mm (1.18 ft.)

NOTICE:

Do not place the SST connector under the tire because it could be damaged.

*a	Tires (2 or more)

(2) Place at least 2 tires onto the tire to which the lower No. 1 instrument panel airbag assembly is tied. The top tire should have a wheel installed.

NOTICE:

The wheel and tires may be damaged by the airbag deployment, so use an unneeded wheel and tires.

(3) Tie the tires together with 2 wires.

CAUTION:

Make sure that the wires are tight. Looseness in the wires will result in the tires breaking loose when the airbag is deployed.

(f) Install SST.

(1) Connect the SST connector.

SST: 09082-00700

NOTICE:

To avoid damaging the SST connector or wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire.

*1	Lower No. 1 Instrument Panel Airbag Assembly
*a	Auxiliary Battery
*b	10 m (32.8 ft.) or more

(2) Move SST at least 10 m (32.8 ft.) away from the airbag tied down to the tire.

(g) Deploy the airbag.

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

(2) Check that no one is within a 10 m (32.8 ft.) radius of the tire to which the lower No. 1 instrument panel airbag assembly is tied.

(3) Press the SST activation switch to deploy the airbag.

CAUTION:

Before deployment, make sure that no one is near the airbag.

HINT:

The airbag is deployed as the LED of the SST activation switch comes on.

(h) Dispose of the lower No. 1 instrument panel airbag assembly.

CAUTION:

The lower No. 1 instrument panel 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 lower No. 1 instrument panel airbag assembly with a deployed airbag.
Do not apply water, etc. to a lower No. 1 instrument panel airbag assembly with a deployed airbag.
Always wash your hands with water after completing the operation.