Preparation Part Number: Mounting Kit PT546-06061 Tuner Assy 86180-0W030 Tuner Assy Kit Contents (86180-0W030) 1 1 Tuner Assy, Stereo Component Mounting Kit Contents (PT546-06061) 1 Ground Cable 1 1 Wire, to Radio Installation 2 Bracket, Radio Receiver 2 2 Bracket, Radio Receiver Base 1 Template 4 pieces Butyl Cushions 3 1 Antenna 4 1 XM Brochure Hardware Bag Contents 1 (PT546-06061) 1 9 Cushion Tape A (Cord Styling) 2 9 Lock Tie A Hardware Bag Contents 2 (PT546-06061) 1 4 Nut (M6) 2 4 Screw (M5 x 8) Hardware Bag Contents - 3 (PT546-06061) 1 1 Antenna 2 1 Ground Plate 3 1 Corrugated Tube 4 4 Nylon Tape 5 3 Cushion Tape B Additional Items Required For Installation Conflicts Note: Page 1 of 13 pages NOTE: Part number of this accessory may not be the same as the part number shown. Recommended Tools Safety Tools Safety Goggles Seat Covers Floor Protectors Protective Cloth Special Tools None Installation Tools Ratchet Extension Socket Phillips Screwdriver Masking tape (50 mm wide) Torque Wrench Side Cutter Special Chemicals Cleaner 10mm, 12mm, 13mm, 14mm 36 lbf-in., and 31 lbf-ft. VDC approved cleaner and cleaning method General Applicability Note: - Convertible only. Premium Audio required. Recommended Sequence of Application Item # Accessory *Mandatory Vehicle Service Parts (may be required for reassembly) 1 As required Quarter panel trim clips. P/N: 75868-06020 & 90467-1016 Legend STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. REVISION MARK: This mark highlights a change in installation with respect to previous issue.
Preparation Parts Description of Tuner Assy (86180-0W030) Item # Parts Name Parts No. Qty 1 Tuner 86180-0W030 1 Item # Parts Name Parts No. Qty 1 GROUND CABLE 1 2 WIRE, TO RADIO INSTALLATION 1 3 CUSHION TAPE A 9 4 LOCK TIE A 9 5 BRACKET RADIO RECEIVER 2 6 BRACKET RADIO RECEIVER BASE 2 7 NUT (M6) 4 8 SCREW (M5 x L8) 4 9 TEMPLATE 1 10 BUTYL TAPE 4 A ANTENNA 1 B GROUND PLATE 1 11 C CORRUGATED TUBE 1 D NYLON TAPE 4 (1 Required + 3 Extra) E CUSHION TAPE B 3 (1 Required + 2 Extra) Page 2 of 13 pages
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.). Please see your Toyota dealer for a copy of this document. Negative Battery Cable 1. Ignition ON. (a) Lower the convertible top. (b) Slide the driver s seat forward. Fig. 2-1 Fig. 2-2 10 mm Socket Ratchet Extension Claws (c) Ignition OFF, then remove the key. 2. Vehicle Disassembly (a) Remove the negative battery cable. (Fig. 2-1) (b) Protect the fender before removing the battery cable. NOTE: Be careful not to touch the positive terminal. (c) Disassemble the rear seat. (1) Remove the seat bottom. Pull upward on the front of the seat cushion to release. (Fig. 2-2) Nuts (x2) Screws x 2 (2) Remove headrests. Remove the cover plates with a nylon removal tool, and then remove the two (2) nuts. (Fig. 2-3) Fig. 2-3 Cover Phillips Screwdriver 10mm Socket (3) Remove the seat belt covers with a nylon removal tool, and then remove the cover plate screws. Separate the plastic back from cushion with a nylon removal tool. (Fig. 2-3) Page 3 of 13 pages
(4) Unbolt the rear seatback, and then slide the seatback upward to remove. (Fig. 2-4) NOTE: Be careful not to damage the seat, door and other vehicle parts when removing the seat from the vehicle. Bolts x 2 Fig. 2-4 12 mm Socket (d) Remove the passenger side door scuff plate, disengage the clips and claws. (Fig. 2-5) (Clip P/N: 75868-06020) Claws x 4 Clips x 5 (e) Remove the passenger side rear quarter trim panel. Fig. 2-5 10mm Socket, Courtesy light Cover plate Bolt (1) Remove the seat belt cover plate, and then remove the bolt under the cover. (Fig. 2-6) (2) Remove and disconnect the courtesy light. (Fig. 2-6) Fig. 2-6 Screw x 2 Coaster Armrest (3) Remove the coaster at the bottom of the cup holder then remove the screw. (Fig. 2-7) Clips x 7 (4) Pull the armrest upward to disengage the clips, and then remove the screw under the armrest. (Fig. 2-7) Fig. 2-7 Phillips Screwdriver Page 4 of 13 pages
(5) Remove the front passenger seat belt anchor cover and bolt. (Fig. 2-8) Fig. 2-8 Seatbelt anchor cover and bolt 14 mm Socket Clips x 11 (6) Disengage the quarter panel trim clips. Remove the top section first, then the bottom section. (Fig. 2-9) (Clip P/N: 75868-06020 and 90467-1016) (f) Remove the passenger side cowl side trim. (Fig. 2-10) (1) Remove cap A. (2) Disengage clip B and remove the cowl side trim. Fig. 2-9 Cap A Clip B (g) Remove the upper console panel. (1) Open the front and rear console box lids. (2) Apply the parking brake. (3) Depress the shift lock button and shift into Neutral (N), and then unscrew the shift knob. (4) Disengage the clips and remove the upper console panel. (Fig. 2-11) Fig. 2-10 Clips x 8 Upper Console Panel Fig. 2-11 Page 5 of 13 pages
Fig. 2-12 Fig. 2-13 Front console box Clips x 4 Guide pins x 3 Masking tape Insert tool here Clips x 5 Masking Tape (h) Remove the front console box. (1) Disengage the clips, and then remove the front console box. (Fig. 2-12) (2) Disconnect the connectors. (i) Remove the instrument cluster upper finish panel. (1) Apply masking tape to protect the surface trim. (j) Insert the nylon removal tool at the side edge of the upper panel to disengage the clips, and then slide the upper panel toward the rear of the vehicle to remove it. (Fig. 2-13) (1) Place a protective cloth on the dash and place the upper panel on top of the dash. Clips x 4 NOTE: Connectors do not need to be disconnected. Do not put tension on the connectors. (k) Remove the instrument cluster finish panel lower and head unit. Fig. 2-14 Bolts x 4 Socket 10 mm (1) Remove the bolts, and then pull the instrument cluster lower finish panel toward you to remove the head unit. (Fig. 2-14) NOTE: Connectors do not need to be disconnected. Do not put tension on the connectors. Damper Screw (l) Remove the glove compartment door. (1) Disconnect the damper from the right end of the glove compartment box. (Fig. 2-15) Fig. 2-15 Phillips screwdriver Page 6 of 13 pages
Stoppers x 2 (2) Squeeze both ends of the glove compartment door, and then fully extend the box past the stoppers. (Fig. 2-16) (3) Disengage the claws, and then remove the glove compartment door. (Fig. 2-16) (m) Remove the lower glove box trim. Claws x 3 Fig. 2-16 Claw (1) Disengage the three (3) clips and claw to remove the lower glove box. (Fig. 2-17) (n) Remove the upper glove box trim. (Fig. 2-18) (1) Remove the four (4) screws and bolt as shown. (Fig. 2-18) Fig. 2-17 Clips x 3 Glove box lower trim (o) Remove the A pillar trim on the passenger side. (Fig. 2-19) Fig. 2-18 Screws x 4 10 mm Socket Glove box upper trim Bolt A pillar Clips x 2 Claw Fig. 2-19 Page 7 of 13 pages
3. Install the antenna. (a) Clean the ground plate mounting area. Ground Plate Fig. 3-1 Antenna Front Dashboard Passenger side (b) Peel off the backside protective sheet of ground plate and affix the ground plate onto the dashboard as shown. (Fig. 3-1) NOTE: Align the back edge of the ground plate with the dashboard line and right side of defroster vent as shown and install it carefully. Once attached, the antenna cannot be easily removed. Fig. 3-2 Front (c) Remove the backing from the antenna, and then fasten the antenna onto the middle of the ground plate with the antenna wire pointing forward. (Fig. 3-2) Antenna wire Nylon tape (d) Tuck the three foam-covered sections of the antenna wire into the space between the instrument panel and windshield. (Fig. 3-2, 3-3) Fig. 3-3 Front support bar Cushion tape B Corrugated tube (Antenna wire inside) (e) Insert the antenna wire into the corrugated tube right after the Nylon tape. Secure the corrugated tube with the cushion tape B. (Fig. 3-3, 3-4) (f) Route the antenna wire downward toward the cowl side trim board area along the existing harness then rearward along the front and rear passenger doorsills. Fig. 3-4 Page 8 of 13 pages
4. Route the Tuner Wire. Foam (a) Install and route the tuner wire from the center cluster and along the front support bar. (Fig. 4-1) Fig. 4-1 Fig. 4-2 Lock Tie x 4 Tuner wire Antenna wire Lock tie x 4 Lock tie A Existing clamps Antenna wire Cushion tape A Cushion tape A x 5 (b) Provide sufficient wire slack to connect to the tuner, and then secure the wire to the existing wire harness with five (5) lock ties A. (Fig. 4-1, Fig 4-2) (c) Route the tuner wire and the antenna wire along the doorsill using the existing clamps. Use the cushion tape A to secure the wire to the body as shown. (Fig. 4-2) (d) Route the tuner wire and the antenna wire along the existing cable and secure the tuner wire and the antenna wire to the existing cable with lock ties. Route the tuner wire and the antenna wire, then use the cushion tape A to secure the tuner wire and the antenna wire to the body as shown. (Fig. 4-3) 5. Install the Tuner. (a) Install the L-brackets and ground cable onto the tuner. (Fig. 5-1) Fig. 4-3 Phillips Screwdriver GND wire Fig. 5-1 Page 9 of 13 pages
Fig. 5-2 Mount nut x 4 Fig. 5-3 GND wire Cushion tape A Tuner cable Antenna cable Base bracket x 2 Template 10mm Socket (b) Clean the bottom of the base brackets and apply butyl tape on them as shown. (Fig. 5-2) (c) Clean the base bracket mounting area. Using the template, install base brackets with butyl tape to the rear floor pan of the vehicle. (Fig. 5-2) (d) Remove, and then discard the template. (e) Install the tuner and L-bracket assembly onto the base brackets using the M6 nuts. (Fig. 5-3) (f) Secure the GND cable to the existing GND point on the vehicle, then bundle and secure the remaining wire length with cushion tape as shown. (Fig. 5-4) (g) Plug in the tuner cable, then bundle and secure the remaining wire length with cushion tape A as shown. (Fig. 5-4) (h) Plug the antenna cable into the tuner. (Fig. 5-4) Fig. 5-4 Cushion tape A x 2 Page 10 of 13 pages
6. Reinstall the Radio/Player Head Unit. (a) Connect the satellite tuner cable and the connectors removed in Step 2. (i) (2) into the rear of the head unit. (b) Insert head unit into opening and re-install the four (4) screws. 7. In Process Functional Test. (a) Temporarily reconnect battery negative cable. (b) Turn ignition key to ACC position. (c) Press the power button on the receiver/player head unit. Verify the backlighting illuminates. (d) Press and release the "SAT" button on the head unit. (1) Verify that a satellite channel is received, or a "NO SIGNAL" message appears on the display. NOTE: If "ANTENNA" appears (flashing) on the display - then the antenna cable is disconnected from the satellite tuner. NOTE: If the head unit will not tune or go into satellite mode - then the tuner cable is disconnected from the satellite tuner. (e) Disconnect battery negative cable. 8. Complete the Reassembly of the Vehicle. (a) Reconnect any disconnected connectors. (b) Verify the panels fit together properly with no uneven gaps between them. (c) Rear seat back installation: Specified tightening torque: 18 N m (185 kgf cm) (13 lbf ft) Page 11 of 13 pages
(d) Front passenger seat belt installation: Specified tightening torque: 42 N-m (430 kgf cm) (31 lbf-ft) Socket (10 mm), Torque Wrench (e) Reconnect the vehicle s negative battery cable. (Fig. 8-1) Negative Battery Cable (1) Position the battery negative cable at the original factory position. (2) Tighten the nut to 4.1 N-m (36 lbf-in). Fig. 8-1 (3) Do not touch the positive terminal with any tool when replacing the cable. (f) Clean up and remove any trash. (g) Place the owner "XM Satellite Radio" brochure and the "Owners Manual" in the glove box. (h) Start engine to ON. Close the convertible top and reposition the driver s seat. Switch to OFF Page 12 of 13 pages
TOYOTA SOLARA (CONVERTIBLE) 2006 - XM SATELLITE RADIO Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Satellite Radio Tuner. Receiver/player Assembly. *Verify the proper operation of the Satellite Radio Tuner. *Verify the proper operation of the Receiver/player Assembly *(Refer to the receiver assembly and radio owner s manuals.) Vehicle Function Checks Courtesy light Hazard switch. Rear passenger seat back Proper operation of the removed seat lock mechanism. HVAC. Multi-information displays.(clock, Temp., and MPG meter) Operation of the L&R seat heater switch. Operation of the 12V outlet switch. Proper function of the courtesy light Proper operation of the hazard switch. Verify the rear passenger seat back is in the upright position and the latch secured Proper operation of the removed seat lock mechanism. Proper operation of the air conditioning system. Verify the proper operation of the multiinformation displays. Verify the proper operation of the L&R seat heater switch. Verify the proper operation of the 12V outlet switch. Page 13 of 13 pages