Section I Installation Preparation Part Number: PT546 52040 Section I Installation Preparation Kit Contents Item # Quantity Reqd. Description 1 1 Satellite Tuner 2 1 Ground Cable 3 1 Tuner Cable 4 2 Tuner Bracket 5 2 Base Bracket 6 1 Template A (to Locate Bracket) 7 1 Cushion A (Rear LHS) 8 1 Cushion B (Rear RHS) 9 2 Cushion C ( LHS, & RHS) 10 1 Antenna 11 3 Hardware Bags 12 1 xm Satellite Radio Brochure Hardware Bag Contents 1 Item # Quantity Reqd. Description 1 4 Screw (M5xL6) 2 4 Nut (M6) Hardware Bag Contents 2 Item # Quantity Reqd. Description 1 1 Template B (xa) not used. 2 1 Template C (xb) 3 2 Cord Rail (150mm) 4 1 Cord Rail (30mm) 5 1 Cord Rail (20mm) 6 8 Lock Tie B (Antenna Cable) 7 1 Clamper (Antenna Cable) 8 7 Tape (to Fix Antenna) Hardware Bag Contents 3 Item # Quantity Reqd. Description 1 2 Cushion Tape (Cord Styling) 2 6 Lock Tie A (AVC LAN) Additional Items Required For Installation Item # Quantity Reqd. Description 1 2 Conflicts Note: Recommended Tools Safety Tools Safety Goggles Seat Covers Floor Protectors Special Tools Arch (Carpet) Punch Installation Tools Ratchet Extension Sockets Torque Wrench (x2) 5/16 Hole Diameter (McMaster PN: 3427A12) 10 mm, 12 mm, 14 mm 0 4 N m (36 lbf in), 0 42 N m (31 lbf ft) Screwdriver Philips, #2 Nylon Panel Removal Tool e.g. Panel Pry Tool #1 Toyota SST # 00002 06001 01 Masking Tape Mallet Special Chemicals Sealant Cleaner (2" wide) 3M TM Ultra Pro Body Sealant 3M TM Prep Solvent 70 General Applicability Note: Recommended Sequence of Application Item # Accessory 1 TVIP 2 Satellite Receiver 3 Audio 4 Subwoofer (SB) Legend *Mandatory : Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CRITICAL PROCESS: Proceed with caution to ensure a quality installation. GENERAL PROCESS: This highlights specific processes to ensure a quality installation. TOOLS & EQUIPMENT: Calls out the specific tools and equipment recommended for this process. Page 1 of 15 pages Supplier Ref #: DIO
Section I Installation Preparation Item # Parts Name Qty 1 Satellite Tuner 1 A Ground Cable 1 2 B Tuner Cable 1 C Cushion Tape (cord styling) 2 D Lock Tie A (AVC LAN) 6 A Tuner Bracket 2 B Base Bracket 2 C Nut (M6) 4 3 D Screw (M5 x L6) 4 E Template A (to locate bracket) 1 F Cushion A (RL side) 1 G Cushion B (RR side) 1 H Cushion C (FL,FR side) 2 A Antenna 1 B Template B (to locate antenna for xa) 1 C Template C (to locate antenna for xb) 1 D Cord Rail A (20 mm) 1 4 E Cord Rail B (30 mm) 1 F Cord Rail C (150 mm) 2 G Lock Tie B (antenna cable) 8 H Clamper (antenna cable) 1 I Tape (to fix antenna cable) 7 Page 2 of 15 pages Supplier Ref #: DIO
NOTES Removed Parts: Place all removed parts on a protected surface. Connectors: When disconnecting connectors, do not pull on the wires; pull on the connectors. Wire Ties: When using wire ties to secure harness, clip the wire ties after securing them. Machine Screws: Start all machine screws by hand. A. Vehicle Disassembly 1. Remove the negative battery cable. (Fig. A 1) Fig. A 1 Clip A x 2 10 mm Socket, Ratchet Extension Panel Removal Tool Clip B x 4 Negative Battery Cable i. Protect the fender before starting. ii. Do not touch the positive terminal with any tool when removing cable. 2. Remove the deck board, tool bag and spare tire from the cargo area. 3. Unscrew and remove the deck floor box. Fig. A 2 Buckle Release Button 4. Remove the deck trim cover (Fig. A 2) as follows: i. Remove clips. ii. Disengage claws and remove the deck trim cover. 5. Disconnect the rear center seat belt by pressing the buckle release button with a non metallic tool (e.g. corner of nylon panel removal tool.) (Fig. A 3) Fig. A 3 12 mm Socket, Ratchet Extension 6. Disassemble the rear seat as follows: Bolts x 2 i. Fold down the seatback, and then fold back the cover to locate the bolts. ii. Unbolt and remove the right rear seatback. (Fig. A 4) Fig. A 4 Page 3 of 15 pages Supplier Ref #: DIO
7. Disengage the hooks and remove the rear seat cushion. (Fig. A 5) NOTE: Be careful not to damage the seat, door and other vehicle parts when removing the seat from the vehicle. 8. Disengage the clips and claws and remove the front passenger side door scuff plates. (Fig. A 6) 9. Disengage the clips and claws and remove the rear passenger side door scuff plates. (Fig. A 7) 10. Remove the passenger side cowl side trim (Fig. A 8) as follows: i. Remove clip A. Hooks x 3 Fig. A 5 Panel Removal Tool Claws x 2 ii. Disengage clip B and remove the cowl side trim. Fig. A 6 Clips x 3 Panel Removal Tool Claws x 2 Fig. A 7 Clips x 2 Panel Removal Tool Clip Fig. A 8 Page 4 of 15 pages Supplier Ref #: DIO
11. Disengage the claws and remove the passenger side center pillar garnish lower (Fig. A 9) Panel Removal Tool 12. Disassemble the passenger front seat belt as follows (Fig. A 10): i. Remove the passenger front seat belt anchor cover. ii. Unbolt and detach the passenger front seat belt anchor plate. 13. Remove the passenger side deck trim side panel as follows (Fig. A 11): Fig. A 9 Claws x 4 14 mm Socket Ratchet Extension i. Remove hexagon bolts and detach the luggage compartment trim hooks. Bolt ii. Remove bolt A, then remove the rear seatback hinge. iii. Remove bolt B and remove the rear seat belt anchor plate. 14. Disengage the clips and claws and remove the deck trim side panel. Fig. A 10 Clips x 5 Claws x 2 Hexagon Bolts x 2 Panel Removal Tool 8 mm Hexagon Wrench 14 mm Socket Ratchet Extension Bolt B Bolt A Fig. A 11 Page 5 of 15 pages Supplier Ref #: DIO
15. Disconnect the connector and remove the nuts, then detach the rear combination light. (Fig. A 12). 16. Remove the center cluster as follows: i. Disconnect the heater control knobs and remove the screws. 10 mm Socket, Ratchet Extension ii. Disengage the clips and claws and remove the instrument cluster finish panel (Fig. A 13). Fig. A 12 Nuts x 2 iii. Disconnect the connectors Panel Removal Tool, Phillips Screwdriver B. Remove the Radio/Player Head Unit: 1. Unscrew the four (4) screws, retain the screws, and remove the head unit (Fig. B 1). 2. Disconnect the connectors. C. Remove the Glove Compartment Door: 1. Squeeze both ends of the box together to fully extend the box, and then remove the stoppers (Fig. C 1). 2. Disengage the claws, and then remove the glove compartment door. 3. Remove the small storage box by lifting up. (Fig. C 1) Fig. A 13 Claws x 8 Phillips Screwdriver Clips x 8 Screws x 2 Fig B 1 Small Storage Box Screws x 4 Stoppers x 2 Fig. C 1 Claws x 2 Page 6 of 15 pages Supplier Ref #: DIO
D. Disassemble Passenger Seat 1. Protect the rear seat area, floor, and center console area. 2. Remove the seat track bracket covers. (Fig. D 1) 3. Remove the rear seat bolts. Socket (14 mm), Ratchet, Extension Bracket Cover Bolts (x 4) 4. Slide the seat back. 5. Remove the front seat bolts. 6. Disconnect the connectors. 7. Tilt the seat rearwards, exposing the floor under the front passenger seat, and lay the seat in the rear seat area. Fig. D 1 Connector i. Secure the seat to keep it from falling (optional). E. Route the Satellite Tuner Cable 1. Route the tuner cable, foam side, from the center cluster to the head unit. (Fig. E 1) 2. Secure the tuner cable with the vehicle wire harness. Install three (3) lock ties A and cushion tape as shown. (Fig. E 2) Fig. E 1 Lock Ties A x 3 F. Route the Tuner Ground Cable Lock Tie End of Cushion 1. Install the end of the tuner ground cable onto the bolt located on the cowl side. (Fig. F 1) 2. Secure the tuner ground cable and tuner cable using the vehicle wire harness clamps. Clamp Cushion Tape Clamps (x 2) Fig. E 2 Fig. F 1 Socket (10 mm) Ratchet, Extension Page 7 of 15 pages Supplier Ref #: DIO
G. Install the Antenna 1. Clean the template (template C) mounting area with 3M TM Prep Solvent 70. (Fig. G 1) Masking Tape Template C Masking Tape x 3 i. When cleaning with 3M TM Prep Solvent 70 follow the manufacturer s directions. Do not allow cleaner to air dry. Template Template Ditch Molding 2. Position template C on the near right corner of the roof as shown. Secure the template with masking tape. (Fig. G 1) Fig. G 1 Roof Roof 3. Remove the release paper from the back of antenna, and then affix the antenna onto the roof. (Fig. G 2) i. Align the front edge of the antenna with the template as shown and install it carefully. Antenna ii. Once attached, the antenna cannot be easily removed. 4. Slide the grommet on the antenna cable to the white mark (located 1.6 m (5.25 ft.) from the antenna). (Fig. G 3) Fig. G 2 1.6 m (5.25 ft.) White Mark H. Route Antenna Cable through Body Opening 1. The roof and roof/hatch area where the cord rails A, B, and C attach must be cleaned with 3M TM Prep Solvent 70 using the method defined in Step G. 1.. (Fig. H 1) Antenna Fig. G 3 Sealant Cord Rail B Cord Rail A Fig. H 1 Cord Rail C Page 8 of 15 pages Supplier Ref #: DIO
2. Secure the antenna cable with cord rails A, B, and C. (Fig. H 1) i. Locate with cord rails A, and B, so the closed door does not contact or pinch the antenna cable (detail in Fig. H 1). 3. Remove rear combination light. 4. Secure the antenna cable around the area where the rear combination light is installed as shown using seven (7) tape pieces. (Fig. H 2) ii. Make sure the tape does not contact the rubber on the back side of the rear combination lamp. 5. Remove and discard the vehicle grommet covering the body opening. (Fig. H 3) i. Locate grommet from underside of fender cover. 12 mm ± 2 mm Fig. H 2 Flat Part Tape Do not Tape the Flat Part. Tapes x 7 Grommet Right Cable ii. From the inside, push outward and remove the grommet plug under the right rear combination light, then route the antenna cable through the body hole. 6. The body opening where the antenna grommet attaches must be cleaned with 3M TM Prep Solvent 70 using the method defined in Step G. 1.. Fig. H 3 Body Opening Clamper 50 mm 7. After cleaning, apply 3M TM Ultra Pro Body Sealant to the back side of the grommet as shown (Fig. G 3). 8. Insert the antenna grommet (attached to cable) into the body opening. (Fig. H 3) i. Remove the release paper from the clamper and mount it below the grommet as shown with clip opening facing down. ii. Secure the cable by routing it through the clamper. (Fig. H 3) Page 9 of 15 pages Supplier Ref #: DIO
I. Secure the Antenna Cable 1. Secure the antenna cable to the vehicle wire harness using the four (4) lock ties (type B). (Fig. I 1) Lock Tie B x 4 2. Secure the antenna cable to the vehicle wire harness using the three (3) lock ties (type B). (Fig. I 2) NOTE: Do NOT secure the antenna cable to the washer hose. J. Install the Satellite Tuner Fig. I 1 Washer Hose Lock tie B x 3 Vehicle Wire Harness Antenna Cable Lock Tie 1. Clean the bracket mounting surface with 3M TM Prep Solvent 70 using the method defined in Step G. 1.. 2. Place cushioned double backed tape onto the bottom of each base bracket. (Fig. J 1) Washer Hose Vehicle Wire Harness 3. Peel back the carpet and felt. 4. Clean the bracket mounting surface on the floor with 3M TM Prep Solvent 70 using the method defined in Step G. 1.. 5. Position template A under the passenger s seat as shown. (Fig. J 2) Fig. I 2 Cushion A Cushion C Cushion C Cushion B Antenna Cable Lock Tie 6. Remove the release paper from the double backed tape, and then secure the base bracket over template A as shown. 7. Remove template A. Base Bracket LH Fig. J 1 Base Bracket RH Cushion C Base Bracket LH Base Bracket RH Fig. J 2 Template A Page 10 of 15 pages Supplier Ref #: DIO
8. Route the tuner cable, tuner ground cable and antenna cable together and secure the excess of the cables using cushion tape. (Fig. J 3) Lock Ties x 2 i. Route the cables under the carpet and through the rear heater duct. The length of the cables over the carpet required are; 200 mm of the tuner ground cable, 300 mm of the tuner cable and 400 mm of the antenna cable. Fig. J 3 Cushion Tape ii. Verify the cables do not block the rear heater duct. 9. Reinstall the carpet felt and verify the base bracket bolt positions. Transfer each bolt location onto the felt using carpet punch and mallet to cut four (4) holes in felt. (Fig. J 4) Carpet Punch, Mallet 10. Pass the base bracket bolts through the felt. 11. Repeat the same procedure (Step J. 9.) on the carpet, and then pass the base bracket bolts through the carpet. Fig. J 4 Phillips Screwdriver 12. Install the satellite tuner brackets and ground cable onto the tuner. (Fig. J 5) 13. Secure the satellite tuner onto the base brackets so the connectors face toward the front of the vehicle. (Fig. J 6) Screws x 4 Fig. J 5 Ground Cable 10 mm Socket, Ratchet Extension Nuts x 4 Fig. J 6 Page 11 of 15 pages Supplier Ref #: DIO
14. Plug the tuner cable and antenna cable into the tuner. (Fig. J 7) i. Connect the antenna cable connectors of the same color to the tuner. ii. Bundle the tuner cable, antenna cable, and ground wire securing with lock tie as shown. Lock Tie A K. Reinstall the Radio/Player Head Unit 1. Connect the satellite tuner cable and the connectors removed in Step B. 2. into the rear of the head unit. 2. Insert head unit into opening and re install the four (4) screws. (Fig. K 1) Fig. J 7 Phillips Screwdriver L. In Process Functional Test 1. Temporarily reconnect battery negative cable. 2. Turn ignition key to "ACC" position. 3. Press the power button on the receiver/player head unit. Verify the backlighting illuminates. 4. Press and release the "SAT" button on the head unit. i. 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 one or both of the antenna cables are 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. 5. Disconnect battery negative cable. M. Complete the Reassembly of Vehicle 1. Reinstall rear combination light. 2. Reconnect any disconnected connectors. Fig K 1 Screws x 4 Page 12 of 15 pages Supplier Ref #: DIO
3. Re install the front seat i. Reinstall the four (4) bolts loosely, then tighten them in the following order: Rear inner bolt Rear outer bolt inner bolt outer bolt ii. Tighten bolts to 37 N m (27 lbf ft) 4. Re install the passenger side deck trim side panel as follows (Fig. M 1): i. Install the deck trim side panel and engage the clips and claws. 5. R install the rear seat belt anchor plate (bolt B Fig. M 1) Claws x 2 i. Tighten bolt B to 42 N m (31 lbf ft) Clips x 5 6. Install the rear seatback hinge and bolt A. Hexagon Bolts x 2 i. Tighten bolt A to 42 N m (31 lbf ft) 7. Install the two (2) hexagon bolts. 8. Re assemble the passenger front seat belt. i. Bolt and attach the passenger front seat belt anchor plate. Panel Removal Tool 8 mm Hexagon Wrench Torque Wrench Ratchet Extension 14 mm Socket Bolt B Bolt A Fig. M 1 (1) Tighten the bolt to 42 N m (31 lbf ft) ii. Attach the passenger front seat belt anchor cover. 9. Re assemble the rear seat. i. Install the rear seat cushion, taking care that the retaining hooks are securely engaged. ii. Bolt and attach the right rear seatback. iii. Tighten bolts to 37 N m (27 lbf ft) iv. Fold up the seatback, and then fold down the cover over the bolts. Page 13 of 15 pages Supplier Ref #: DIO
10. Verify the panels fit together properly with no uneven gaps between them. N. Reconnect Battery Cable 1. Reconnect the vehicle s negative battery cable. (Fig. N 1) i. Position the negative terminal to the battery as shown (~45 deg.). ii. Tighten the nut to 4.1 N m (36 lbf in). iii. Do not touch the positive terminal with any tool when replacing the cable. 2. Clean up and remove any trash. 3. Place the owner "xm Satellite Radio" brochure in the glove box. Fig. N 1 Socket (10 mm) Torque Wrench 45 deg. Negative Battery Cable Page 14 of 15 pages Supplier Ref #: DIO
Section III Functional Verifications Section III Functional Verifications Check: Accessory Function Checks Satellite Radio Tuner. Receiver/player Assembly. Look For: *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 Hazard switch. Passenger s seat belt reminder light. Passenger front seat. Proper operation of the removed seat lock mechanism. SRS warning light. Proper operation of the hazard switch. Proper operation of the passenger s seat belt reminder light Removed seat is securely fastened. Proper operation of the removed seat lock mechanism. SRS warning light illuminates for approximately 6 seconds with the ignition ON, and then goes out. HVAC. SSP function. Proper operation of the air conditioning system. Verify the radio SSP function is set to "xb" by pressing the "SSP" button on the head unit for 5 seconds. (If not, press the volume control and set to "xb.") Page 15 of 15 pages Supplier Ref #: DIO