YARIS 4-DOOR 2007 INTERIOR LIGHT UPGRADE

Transcription

1 Document # /26/06 4-DOOR 2007 INTERIOR LIGHT UPGRADE Preparation Part Number: Code: IL1 Kit Contents Item # Quantity Reqd. Description Light Guide Light Guide 3 1 Hardware Kit 4 2 Blue Light Engines 5 1 Switch Kit 6 1 Blue cup holder kits 7 1 Wire Harness extension Templates Color Applicability/Trim Level Accessory Color Hardware Bag Contents Item # Quantity Reqd. Description 1 4 Catamounts x.3/4 screws 3 4 Catamount with bracket 4 4 Wire tie Wire tie foam pads 7 2 T-Taps Switch Bag Contents Item # Quantity Reqd. Description 1 1 Switch 2 1 End Cap, Black 3 1 Illumination Nameplate 4 1 Installation tool 5 1 Bezel 6 1 Black spacer Recommended Tools Safety Tools 1/2 spacer rivets rivet washers Vehicle protection Safety glasses Special Tools Installation Tools Phillips screwdriver #2 Nylon Removal Tool 1/8 Drill Bit Diagonal cutter or wire tie tool Stubby screwdriver #2 Phillips Drill Scissors 1/2 Drill bit. Torque Wrench Scribe or Center punch Rivet gun Masking tape De-burring Tool J Drill bit Rachet Pliers Wiping Cloth Non-scratch Special Chemicals Approved Cleaner UniBit or step drill rec. 36 in/lbs 10mm socket General Applicability All models of 4-door Yaris Recommended Sequence of Application Item # Accessory 1 * Appliques 2 Lighting 3 Arm rest STOP: Damage to the vehicle may occur. Do Not proceed until process has been completed with. OPERATORS SAFETY: Use caution to avoid risk of injury. CRITICAL PROCESS: Proceed with caution to ensure a quality installation. there points will be audited on a completed vehicle installation. GENERAL PROCESS: This highlights specific processes to ensre a quality installation. These poins will be audited durring the accessory installation. TOOLS & EQUIPMENT: This calls oout the specific tools and equipment required for this process. REVISION MARK: this mark highlights a change in installation with resect to previous issue. SPECIAL NOTE: Installation Sequences After TMS and Safety mandated preparatory steps have been taken, the installation sequence is the suggested method for completing the accessory installation. In some instances the suggested sequence is written for one associate to install and in others the sequence is given as part of a team accessory installation. Unless otherwise stated in the document, the associates may perform the installation steps in any order to make the installation as efficient as possible while maintaining consistent quality. Also some items listed to be removed may not need to be removed if caution is taken to not damage vehicle. 1 of 10

2 2007 INTERIOR LIGHT UPGRADE Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the Accessory Installation Practices document. This document covers such items as: Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). Safety (eye protection, rechecking torque procedure, etc.). Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). 1. Check kit for contents (a) Check kit of content and damage. (Fig. 1-1) 2. Vehicle preparation (a) Disconnect battery negative terminal. (b) Apply protective covering to car. (c) Wear eye protection as necessary Fig. 1-1 Fig. 3-1 Fig Remove Center Console (a) Set parking brake. Move shift lever out of park if equipped with automatic transmission. (b) Use panel safe tool. (c) Remove center control console lower trim piece. (Fig.3-1) (d) Prying around edges remove forward cover from center console shift surround. (Fig. 3-2) Fig. 3-3 (e) Remove storage box liner Fig. 3-4 (f) Remove bolts with 10mm socket. (Fig. 3-3) (g) Pry around edges of rear cover and raise slightly. (Fig. 3-4) (h) Disconnect lead to auxiliary power connector. (Fig. 3-5) Fig of 10

3 2007 INTERIOR LIGHT UPGRADE 4. Center Control Panel (a) Use panel safe tool. (b) Pry around edges of left and rignt trim piece. (Fig. 4-1) Fig. 4-1 (c) Remove right and left trim piece. (Fig. 4-2) Fig. 4-2 (d) Remove bolts with 10mm socket. (Fig. 4-3) (e) Slightly lift console to unhook from left and right storage area assemblies. (f) Remove left and right side storage area assemblies from center control panel. (Fig. 4-4) Fig. 4-3 Fig. 4-4 (g) Place aside. 5. Install Storage Box Lighting (a) Cut out marking template, and attach to storage box. (Fig. 5-1) (b) Align storage box marking template on bottom as shown, tape in place as shown and mark hole locations using center punch or scribe. (Fig. 5-2) (c) Drill pilot holes with an 1/8 drill bit. Fig. 5-1 Fig. 5-2 (d) Drill final holes with a letter J drill bit. (Fig. 5-3) (e) De-burr holes with de-burring tool. Fig. 5-3 Fig. 5-5 (f) From inside of storage box, insert the lenses into the previously drilled holes. Press firmly to ensure the lenses are fully seated. (Fig. 5-4) Fig. 5-4 (g) Re-attach storage boxes. (h) From back of storage box, install the LEDs onto the lenses. Press firmly to ensure the LEDs and lenses are fully engaged. Hold the lenses from inside of console while pressing. (Fig. 5-5) Fig. 5-6 (i) Run cup holder harness under shift mechanism. Secure with foam pad. (Fig. 5-6) (j) LED closest to connector illuminates right hand storage area. (Fig. 5-7) Fig of 10

4 4-DOOR 2007 INTERIOR LIGHT UPGRADE 6. Locate Power (a) Locate shielded cable that supplies auxiliary power adapter. (Fig. 6-1) (b) Open shielding and pull out power wires. (Fig. 6-2) Fig. 6-2 Fig. 6-1 (c) Install T-taps in staggered fashion to power leads connected to auxiliary power adapter using pliers. (Fig. 6-3) 7. Harness Installation (a) Review General wiring layout diagram. (Fig. 7-1) Fig. 6-3 (1) PW-Power, two male spade connectors. (2) SW-Switch, Three female spade connectors. (3) CH-Storage lighting, female modular connector. (4) LED-LED Module, (2) female modular connectors. LED LED CH (b) Install wire harness along right side of console follow harness under center console to auxiliary power harness. SW (c) Route harness to previously installed T-taps on auxiliary power harness. PW (d) Attach power leads to T-taps Fig. 7-1 (1) Black wire on harness to white/black wire on auxiliary power lead, negative (-). (Fig. 7-2) (2) White wire on harness to grey wire on auxiliary lighter, positive (+). (Fig. 7-2) Fig. 7-2 (e) Route LED module lead to Passenger side. (Fig. 7-3) Fig. 7-3 (f) Route LED module lead to drivers side LED module as shown. (Fig. 7-4) (g) Bundle and wire tie excess portion of cup holder harness. (Fig. 7-5) Fig. 7-4 (h) Wire tie bundle to main harness. Fig of 10

5 4-DOOR 2007 INTERIOR LIGHT UPGRADE 8. Switch Installation (a) Cut out marking template. Fig. 8-1 (b) Tape the drill template on the back of switch plate. Use center punch for pilot hole. (Fig. 8-1) (c) Remove paper template. (d) Drill pilot hole with 1/8 drill bit. (e) Using a 1/2 drill bit (Uni-bit or step bit is highly recommended), drill the switch hole. (Fig. 8-2) Fig. 8-2 (f) Clean the console surface to remove grease and wax. (1) Wipe the application area with approved cleaner and a clean no-scratch cloth. (2) Rinse application area with clean distilled water and a clean no-scratch cloth. Fig. 8-3 (3) Dry the installation area using a clean dry, lint free cloth. (g) Insert switch bezel into the switch plate. (Fig. 8-3) (h) Using pull-tab, remove the tape liner from back of the switch plate Fig. 8-4 (1) Avoid contact with adhesive surface. (i) Using the bezel as a guide, install switch plate/ bezel into the previously drilled 1/2 hole. Fig. 8-3 Fig. 8-4 (1) Align the edges of the switch plate even with the edges assembly. (Fig. 8-4) (2) Once aligned, press down firmly to adhere tape. (j) Firmly insert the switch installation tool into the front of the bezel. (1) Place spacer over switch shaft with white end of sleeve against switch panel. (Fig. 8-3) (2) Turn switch clockwise to tighten bezel to switch. Install switch end cap. (Fig. 8-4) 5 of 10 (3) Align leads so the switch panel can be reinstalled safely.

6 4-DOOR 2007 INTERIOR LIGHT UPGRADE 9. Drivers Side Light Guide Installation, no Cover (a) Using template mark inner and outer catamount attachment holes in tabs located under dash using punch or scribe. (Fig. 9-1) inner Fig. 9-1a Fig. 9-1b outer (b) Drill holes in under dash tabs using #21 drill. (Fig. 9-2) (1) Insert screw. (Fig. 9-3) (2) Place spacer over screw. (Fig. 9-4) Fig. 9-2 (c) Preassemble catamounts. Fig. 9-3 (1) Insert cable tie through first catamount bracket. Cable tie will go around LED module. (Fig. 9-5) (2) Thread cable tie into the second catamount bracket. (Fig 9-6) Fig. 9-4 (3) Secure catamount assembly to light guide as shown/ (Fig. 9-7) Fig. 9-5 (d) Position light guide inner assembly. and secure with screw. (Fig. 9-8) (e) Attach outer assembly as shown. (Fig. 9-9) Fig. 9-6 Fig. 9-7 inner outer (f) Tighten inner cable tie, trim excess. (g) Attach 12 extension to LED module lead. (h) Attach extension to previously installed harness. 10. Light Guide Installation Passenger side, No Cover Fig. 9-8 Fig. 9-9 (a) Using template marked passenger side catamount attachment, drill holes in tabs located under dash. Use punch or scribe. Fig. 9-8 (b) Drill holes in under dash tabs using #21 drill. (1) Insert screw. (Fig. 10-1) Fig.10-1 Fig.10-2 outer inner (2) Place spacer over screw. (Fig. 10-2) (c) Preassemble catamounts. (1) Insert cable tie into first catamount bracket. (Fig. 10-3) (2) Thread cable tie into second catamount bracket. (Fig 10-4) Fig.10-3 Fig of 10 (2) Secure extension with foam pad.

7 4-DOOR 2007 INTERIOR LIGHT UPGRADE (d) Attach inner assembly as shown. (Fig. 10-5) (e) Slide light guide into inner assembly. Position outer assembly and secure with screw. Fig.10-5 (f) Tighten inner cable tie, trim excess (Fig. 10-6) Fig.10-6 (g) Attach 12 extension to LED module. (Fig. 10-7) (1) Route wire as shown. (Fig. 10-8) (h) Attach lead to previously installed harness Fig.10-8 Fig Install Drivers Side Light guide, Cover Present (a) Remove drivers side cover. (1) Remove two (2) phillips screw, indicated by arrows. (Fig. 11-1) Fig (2) Lower front edge of shield and pull towards interior of vehicle. (b) Using template use punch or scribe to mark holes to be drilled. (Fig. 11-2) (c) Use 1/8 bit drill holes as marked. (Fig. 11-3) Fig (d) Attach light guide rod mounts with 1/8 rivet. Use rivet washer on backside of cover. (Fig. 11-4) (e) Cradles will be oriented as shown. (Fig. 11-5) Fig (f) Install LED module to 12 Light guide with reflector positioned as shown. Install LED module to clear end of light guide. (Fig. 11-6) Fig (g) Orient light guide with LED module on right side of cover as shown. (Fig. 11-7) (1) Attach light guide to cover using 7 wire ties, remove excess. (Fig. 11-7) Fig (h) Trim excess cable tie. (Fig. 11-8) Fig (i) Reinstall shield. (j) Attach LED module lead to previously installed harness. Fig Fig of 10

8 4-DOOR 2007 INTERIOR LIGHT UPGRADE 12. Install Passenger Side Light Guide, Cover Present (a) Remove Under dash shield. (1) Depress front edge tabs, drop shield pulling forward Fig Fig. 12-2a (b) Remove felt cover. (Fig. 12-1) (c) Mark cover for drilling use template and mark cover, using punch or scribe. (Fig. 12-2) (d) Use 1/8 drill bit and drill hole for rivet. (Fig. 12-3) Fig. 12-2b (e) Install rivet through light guide cradle. (Fig. 12-4) Fig (f) Install rivet washer to rivet and install using rivet gun. (Fig. 12-5) (g) Install LED module to clear end of 7 light guide as shown. Carefully note alignment of reflector. (Fig. 12-6) Fig Fig (1) Install light guide onto cover attach with 7 wire tie. (2) Feed wire ties into the plastic mounts from the rear to front, orienting the wire tie head towards the rear of the cover. (Fig 12-7) Fig (3) Fasten light guide as shown and remove excess wire tie. (Fig. 12-8) Fig (4) Light Guide mounted to cover. Route wires through hole in cover as shown. (Fig. 12-9) (h) Attach 12 extension harness to LED module. Fig (1) Secure connector to cover using foam pad. (Fig ) Fig (2) Run extension harness to left side of cover. (3) Secure 12 extension harness to cover. (Fig ) Fig Fig of 10

9 4-DOOR 2007 INTERIOR LIGHT UPGRADE (i) Reinstall felt pad to cover. (Fig ) (j) Reinstall shield (Fig ) Fig Fig (k) Connect LED lead to previously installed harness. Fig Post Installation (a) Re-secure storage box. Reconnect console to storage assembly. (b) Connect illumination switch leads. Secure excess wire with 4 wire ties. (Fig. 13-1) (c) Reinstall switch panel to console (d) Reinstall four (4) 10mm bolts in front of console and two (2) 10mm in storage box (e) Attach left and right center trim pieces and lower trim piece (f) Clean Light Guides using approved cleaner and a non-scratch cloth. (g) Reconnect negative battery terminal and torque to 36 in/lbs. (h) Cycle test the system with key in ACC or ON. The cycle may start from any step below but should cycle in this order. (1) All lights off. (2) Cup holder lights on only. (3) All lights on. (4) Floor lights on. (5) Back to step (1) (i) The switch should be cycled to step (1) (all lights off) for shipment. 9 of 10

10 4-DOOR 2007 INTERIOR LIGHT UPGRADE Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Single Unoperational Module or LED Full engagement of affected LED Module to LED wire harness pigtail connector. Dislodged cup holder LED. No Operational Modules or LEDs Full engagement of all LED Module to LED wire harness pigtail connectors. Power connection. Ground connection. Switch connections. Blown light kit fuse. (2Amp, located under shift console) Blown cigarette lighter fuse. (see vehicle owners manual for Amperage and location.) Vehicle Function Checks Cigarette Lighter Has the connector been re-connected? Blown fuse. (See vehicle owner s manual for Amperage and location.) 10 of 10

11 4-DOOR 2007 Under Dash Cover Templates Two (2) Inches Note: Scale to verify templates are correct size Passenger Side Cover 1/8 fold Passenger Side Cover p-side cover 1/8 fold fold Passenger Side Cover Drivers Side Cover Switch and Lamp Templates Drivers Side Storage Passenger Side Storage J J Drivers Side Storage Passenger Side Storage #21 #21 fold fold Light Guide Mount Drivers side 1/2 Switch Location #21 Light Guide Mount Passengers Side Switch Location