Repair Procedure
INSTALLATION OF DRIVER'S AIRBAG OVERLAY HARNESSWARNING:
The "General Information" section in the RAVE/GTR Workshop Manual contains SRS precautions that must observed during this operation. The ten minute
1. Refer to the RAVE/GTR "General Information" section and review the SRS precautions prior to starting work.
2. Release fasteners and remove the battery cover.
3. Refer to RAVE/GTR Workshop Manual General Information - Electrical Precautions - Battery Disconnection and disconnect the battery ground lead.
WARNING:
Waiting ten minutes to ensure all elements of the SRS system are de-energized is an important precaution before commencing work.
4. Refer to RAVE/GTR Workshop Manual section 76.25.01 and remove the centre console.
5. Remove the screw securing the foot well heating duct (Arrowed in Figure 1).
6. Remove the duct.
7. Disconnect the electrical connector from the handbrake switch (Figure 2).
8. Remove the nut securing the ground lead. (Figure 3)
9. Disconnect electrical connector from the SRS Diagnostic and Control Unit (DCU). (Figure 4)
10. Remove the cable tie from the electrical connector. (Figure 5).
11. Remove the locking device from the electrical connector. (Figure 6)
12. Remove the electrical connector cover. (Figure 7)
13. Remove the screw securing the rear footwell duct. (Figure 8)
NOTE:
Right-hand duct shown for illustration purposes only (left-hand is mirror image).
14. Remove both rear air ducts and move aside.
15. Tape the wires together on the new airbag overlay harness for protection.
16. Route the harness underthe HEVAC unit to the SRS DCU.
17. Remove tape from the wires. (Figure 9)
18. Remove the red/yellow wire from cavity 1 of the ECU connector.
19. Install the red/yellow wire from the new airbag overlay harness into cavity 1.
20. Remove the red wire from cavity 2.
21. Install the red wire from the new airbag overlay harness into cavity 2.
22. Tape the wires, removed in steps 17 and 19, to the main harness.
23. Install the electrical connector cover.
24. Install the electrical connector locking device.
25. Install a new cable tie to the electrical connector. (Refer to Figure 5)
26. Connect the electrical connector to the SRS DCU.
27. Position the ground lead to stud and tighten nut. (Refer to Figure 3)
28. Connect the electrical connector to the handbrake switch. (Refer to Figure 2)
29. Remove three fasteners and release the drivers side lower closing panel.
30. Release the diagnostic socket and remove the closing panel.
31. Disconnect HEVAC drain tube. (arrowed in Figure 10)
32. Position the new airbag overlay harness under the HEVAC unit. (Figure 11)
33. Rotate the turnbuckles and lower the fuse box access panel.
34. Disconnect the airbag electrical connector. (Arrowed in Figure 12)
35. Tape the removed air bag electrical connector to the harness.
36. Feed the new airbag overlay harness behind the fascia.
37. Connect the new airbag overlay harness electrical connector. (Figure 13)
38. Tape the new airbag overlay harness to the existing harness.
39. Close and secure the fuse box access panel.
40. Connect the HEVAC drain tube.
41. Connect the rear footwell ducts and secure with screws. (Refer to Figure 8)
42. Install and secure the front footwell heating duct with screw. (Refer to Figure 1)
43. Refer to RAVE/GTR section 76.25.01 and install the centre console.
44. Position drivers side lower closing panel, secure diagnostic socket, align closing panel and install fasteners.
45. Connect the battery ground cable.
46. Install the battery cover and install fasteners.
47. Connect T4 to the vehicle and clear any logged fault codes.
INSTALLATION OF PASSENGER'S AIRBAG OVERLAY HARNESS
1. Release fasteners and remove the battery cover.
2. Refer to RAVE/GTR Workshop Manual General Information - Electrical Precautions - Battery Disconnection and disconnect the battery ground lead.
3. Refer to RAVE/GTR Workshop Manual section 76.25.01 and remove the centre console.
4. Remove the passenger side footwell closing panel.
5. Remove the glovebox.
6. Remove the screw securing the footwell heating duct.
7. Remove duct. (Arrowed in Figure 14)
8. Disconnect the HEVAC drain tube. (Arrowed in Figure 15)
9. Remove the screw securing the RH rear footwell duct. (Refer to Figure 8)
10. Release and move the duct aside.
11. Disconnect the electrical connector from the handbrake switch. (Refer to Figure 2)
12. Remove the nut securing the ground lead. (Refer to Figure 3)
13. Disconnect electrical connector from the SRS DCU. (Refer to Figure 4)
14. Remove the cable tie from the electrical connector. (Refer to Figure 5)
15. Remove the locking device from the electrical connector. (Refer to Figure 6)
16. Remove the electrical connector cover. (Refer to Figure 7)
17. Remove the white/yellow wire from cavity 3.
18. Install the white/yellow wire from the new airbag overlay harness into cavity 3.
19. Remove the white wire from cavity 4.
20. Install the white wire from the new airbag overlay harness into cavity 4.
21. Tape the wires, removed in steps 17 and 19, to the main harness.
22. Install the electrical connector cover.
23. Install the electrical connector locking device.
24. Install a new cable tie to the electrical connector. (Refer to Figure 5)
25. Connect the electrical connector to the SRS DCU. (Refer to Figure 4)
26. Position the ground lead to stud and tighten the nut. (Refer to Figure 3)
27. Connect electrical connector to the handbrake switch. (Refer to Figure 2)
28. Feed the new harness behind the fascia. (Refer to Figures 16 and 17)
29. Disconnect airbag electrical connector. (Arrowed in Figure 18)
30. Tape the removed airbag electrical connector to the vehicle harness.
31. Connect and secure the new airbag overlay harness connector to the airbag connector. (Figure 18)
32. Tape the new airbag overlay harness to the existing harness.
33. Install the glove box.
34. Install the passenger side foot well closing panel.
35. Connect the HEVAC drain tube. (Refer to Figure 11)
36. Connect the rear foot well duct and secure with screw.
37. Install and secure the foot well duct with screw.
38. Refer to RAVE/GTR section 76.25.01 and install the center console.
39. Connect the battery ground cable.
40. Install the battery cover and fasten in position
41. Connect T4 to the vehicle and clear any logged fault codes.
INSTALLATION OF PRE-TENSIONER OVERLAY HARNESS
1. Release fasteners and remove the battery cover.
2. Refer to RAVE/GTR Workshop Manual General Information - Electrical Precautions - Battery Disconnection and disconnect the battery ground lead.
3. Depending on which pre-tensioner overlay harness is required, refer to RAVE/GTR section 78.10.43.99 and remove the left-hand or right-hand front seat.
4. Refer to RAVE/GTR section 76.25.01 and remove the centre console.
5. Remove the centre console trim. (Arrowed in Figure 19)
6. Disconnect the electrical connector from the handbrake switch. (Refer to Figure 2)
7. Remove the nut securing the ground lead. (Refer to Figure 3)
8. Disconnect the electrical connector from the SRS DCU. (Refer to Figure 4)
9. Remove the cable tie from the electrical connector. (Refer to Figure 5)
10. Remove the locking device from the electrical connector. (Refer to Figure 6)
11. Remove the electrical connector cover. (Refer to Figure 7)
12. If the left-hand side is being repaired, remove and install wires into the SRS electrical connector as follows:
^ Remove the orange wire from cavity 10.
^ Install the orange wire from the new pretensioner overlay harness into cavity 10.
^ Remove the orange/red wire from cavity 11.
^ Install the orange/red wire from the new pre-tensioner overlay harness into cavity 11.
13. If the right-hand side is being repaired, remove and install wires into the SRS electrical connector as follows:
^ Remove the brown wire from cavity 6
^ Install the brown wire from the new airbag overlay harness into cavity 6.
^ Remove the brown/red wire from cavity 7
^ Install the brown/red wire from the new airbag overlay harness into cavity 7.
14. Tape the wires, removed in steps 12 or 13, to the main harness.
15. Install the electrical connector cover.
16. Install the electrical connector locking device.
17. Install a new cable tie to the electrical connector. (Refer to Figure 5)
18. Connect the electrical connector to the SRS DCU.
19. Position the ground lead to the stud and tighten nut. (Refer to Figure 3)
20. Connect the electrical connector to the handbrake switch. (Refer to Figure 2)
21. Route harness under the carpet following the route of the existing harness. (Figure 20)
22. Tape the new pre-tensioner overlay harness to the existing harness.
23. Remove the securing clips from the replaced pre-tensioner harness and tape to the new harness.
24. Tape the redundant pre-tensioner electrical connector and any excess wire to the harness.
25. Install the centre console finisher.
26. Refer to RAVE/GTR section 76.25.01 and install the centre console.
WARNING:
To prevent a potential problem, the harness must be clipped securely to the underside of the seat. The harness must not be under any tension or become trapped in the runners or any ECU mounted to the floor.
27. Refer to RAVE/GTR section 78.10.43.99 and install the front seat.
28. Verify that replacement pre-tensioner harness is properly located and the connector is firmly locked during seat installation.
29. Observe the wiring as the seat is traversed through the entire range of motion fully forward and fully backward.
30. Verify that the harness does not come in contact with the seat runners or any electrical or electronic components.
31. Connect the battery ground lead.
32. Install the battery cover and fasten in position.
33. Connect T4 to the vehicle and clear any logged fault codes.