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) 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) 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 e.g. Panel Pry Tool #1 Toyota SST # 00002 06001 01 Utility Knife Masking Tape Mallet Special Chemicals Sealant Cleaner General Applicability (2" wide) 3M TM Ultra Pro Body Sealant 3M TM Prep Solvent 70 Recommended Sequence of Application Item # Accessory 1 TVIP 2 Satellite Receiver 3 Audio 4 Subwoofer (SB) Additional Items Required For Installation Item # Quantity Reqd. Description 1 2 Conflicts Note: 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 14 pages Supplier Ref #: DIO
Section I Installation Preparation (This part is not used.) (This part is not used.) (This part is not used.) (This part is not used.) 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 14 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 Socket (10 mm), Ratchet Phillips Screwdriver Clips (x 4) Negative Battery Cable i. Protect the fender before starting. ii. Do not touch the positive terminal with any tool when removing cable. Claws (x 2) 2. Remove rear cargo tonneau cover. Fig. A 2 i. Protect the rear bumper. 3. Remove the deck trim cover (Fig. A 2). i. Remove clips. ii. Disengage claws and remove the deck trim cover. 4. Remove the deck board and tool bag from the cargo area. 5. Unscrew and remove the deck floor box. (Fig. A 3) 6. 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 4) Fig. A 3 Socket (10 mm), Ratchet, Extension Buckle Release Button Screws (x 2) Fig. A 4 Page 3 of 14 pages Supplier Ref #: DIO
7. Disassemble the rear seat as follows: 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 5) Bolts (x 2) 8. Disengage the hooks and remove the rear seat cushion. (Fig. A 6) NOTE: Be careful not to damage the seat, door and other vehicle parts when removing the seat from the vehicle. Fig. A 5 Socket (12 mm), Ratchet, Extension 9. Disengage the clips and claws and remove the front passenger side door scuff plates. (Fig. A 7) 10. Disengage the clips and claws and remove the rear passenger side door scuff plates. (Fig. A 8) Hooks( x 3) Fig. A 6 Claws (x 3) Clips( x 4) Fig. A 7 Rear Claws (x 3) Fig. A 8 Clips (x 3) Page 4 of 14 pages Supplier Ref #: DIO
11. Remove the passenger side cowl side trim (Fig. A 9) as follows: i. Remove clip A. ii. Disengage clip B and remove the cowl side trim. Clip B 12. Disengage the claws and remove the passenger side center pillar garnish lower. (A 10) Fig. A 9 Clip A 13. Disassemble the passenger front seat belt as follows (Fig. A 11): i. Remove the passenger front seat belt anchor cover. Claws x 4 ii. Unbolt and detach the passenger front seat belt anchor plate. 14. Remove the passenger side deck trim side panel as follows (Fig. A 12): i. Remove screws and bolt A. Fig. A 10 Socket (14 mm), Ratchet, Extension ii. Remove bolt B, then remove the rear seatback hinge. Bolt 15. Remove bolt C and remove the rear seat belt anchor plate. 16. Remove the weather strip (Fig. A 12) 17. Disengage the clips and claws, and then remove the deck trim side panel. Fig. A 11 Weather strip Claw Bolt A Rear Seatback Hinge Screws (x 2) Bolt B Clips (x 4) Fig. A 12 Bolt C ÂÂÂÂÂÂÂÂ Phillips Screwdriver ÂÂÂÂÂÂÂÂ Sockets (10 mm, 14 mm) ÂÂÂÂÂÂÂÂ Ratchet, Extension Page 5 of 14 pages Supplier Ref #: DIO
FOR VEHICLES WITH CURTAIN SHIELD AIRBAG ONLY. (Step A. 18.) SRS CURTAIN AIRBAG is shown on the upper left of the roof side inner garnish. 18. Remove the passenger side roof inner garnish as follows: Clips (x 3) i. Disengage the clips except for the upper left one. (Fig. A 13) NOTE: Do not attempt to remove the roof side inner garnish upper left clip. The SRS curtain shield airbag may be damaged. FOR VEHICLES WITHOUT CURTAIN SHIELD AIRBAG ONLY. (Step A. 19.) 19. Remove the passenger side roof inner garnish as follows: i. Disengage the clips. (Fig. A 14) Fig. A 13 Clips (x 4) ii. Route the rear seat belt through the slot in the roof side inner garnish, then remove it. 20. Remove the center cluster as follows: i. Disengage the clips and claws and remove the instrument cluster finish panel. (Fig. A 15) ii. Disconnect the heater control knobs and remove the four (4) screws. (Fig. A 16) Fig. A 14 Clips (x 4) Claws (x 4) iii. Disengage the clips and claws and remove the instrument cluster finish panel. (Fig. A 16) iv. Disconnect the connectors. Fig. A 15 Claws (x 5) Clips (x 4) Phillips Screwdriver Fig. A 16 Screws (x 4) Page 6 of 14 pages Supplier Ref #: DIO
B. Remove the Radio/Player Head Unit 1. Unscrew the four (4) screws, retain the screws, and remove the head unit. (Fig. B 1) Phillips Screwdriver 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. D. Disassemble Passenger Seat Fig. B 1 Screws (x 4) Stoppers (x 2) 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. Fig. C 1 Claws (x 2) 4. Slide the seat back. 5. Remove the front seat bolts. 6. Disconnect the connectors. Socket (14 mm), Ratchet, Extension Bracket Cover Bolts (x 4) 7. Tilt the seat rearwards, exposing the floor under the front passenger seat, and lay the seat in the rear seat area. E. Route the Satellite Tuner Cable 1. Route the tuner cable, foam side, from the center cluster to the head unit. (Fig. E 1) Fig. D 1 Fig. E 1 Page 7 of 14 pages Supplier Ref #: DIO
2. Secure the tuner cable with the vehicle wire harness. Install lock tie A and cushion tape as shown. (Fig. E 2) F. Route the Tuner Ground Cable Lock Ties (x 3) 1. Install the end of the tuner ground cable onto the bolt located on the cowl side. (Fig. F 1) End of Cushion 2. Secure the tuner ground cable and tuner cable using the vehicle wire harness clamps. Lock Tie Clamp Cushion Tape Fig. E 2 G. Install the Antenna Clamps (x 2) 1. Clean the template (template B) mounting area with 3M TM Prep Solvent 70. (Fig. G 1) i. When cleaning with 3M TM Prep Solvent 70 follow the manufacturer s directions. Do not allow cleaner to air dry. 2. Position template B on the near right corner of the roof as shown. Secure the template with masking tape. (Fig. G 1) 3. Remove the release paper from the back of antenna, and then affix the antenna onto the roof. (Fig. G 2) Fig. F 1 Masking Tape Socket (10 mm) Ratchet, Extension Template B Masking Tapes (x 3) i. Align the front edge of the antenna with the template as shown and install it carefully. Template Template Ditch Molding ii. Once attached, the antenna cannot be easily removed. Fig. G 1 Antenna Fig. G 2 Page 8 of 14 pages Supplier Ref #: DIO
H. Route Antenna Cable through Body Opening 1. Remove and discard the grommet covering the body opening. 2. The roof and roof/hatch area where the cord rail A and B attach must be cleaned with 3M TM Prep Solvent 70 using the method defined in Step G. 1.. (see cord rail A (20 mm) and B (30 mm) detail, Fig. H 1) 3. Cut a slit in cord rail B (30 mm), Fig H 1. 4. Secure the antenna cable with cord rail A (20 mm) and B (30 mm). 5. After cleaning, apply 3M TM Ultra Pro Body Sealant to the back side of the grommet as shown, then insert the grommet into the body opening. (Fig. H 1) Body Sealer Utility Knife 5 mm Slit Cord Rail A (20 mm) Cord Rail B (30 mm) Washer Vehicle Hose Wire Harness Antenna Cable Lock Tie Sealer Grommet Fig. H 1 i. Secure the antenna cable with cord rail A and B so the closed door does not contact or pinch the cable (see cord rail A and B detail, Fig. H 1). I. Secure the Antenna Cable Fig. I 1 Lock Tie B (x 5) Lock Tie B (x 3) 1. Secure the antenna cable to the vehicle wire harness using the five (5) lock ties (type B). (Fig. I 1) 2. Secure the antenna cable to the vehicle wire harness using the three (3) lock ties (type B). (Fig. I 2) Fig. I 2 Washer Hose Lock Tie Vehicle Wire Harness Antenna Cable NOTE: Do NOT secure the antenna cable to the washer hose. J. Install the Satellite Tuner Cushion A Cushion C Cushion C Cushion B 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) Fig. V1 J 1 Base Bracket LH Base Bracket RH Page 9 of 14 pages Supplier Ref #: DIO
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 with the arrow facing the front passenger side. (Fig. J 2) Base Bracket LH Base Bracket RH Cushion C Template Arrow 6. Remove the release paper from the double backed tape, and then secure the base bracket over template A as shown. Fig. J 2 Lock Ties x 2 Template A 7. Remove template A. 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) Rear Heater Duct 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 the carpet punch and mallet to cut 4 holes in the felt. (Fig. J 4) Fig.J 4 Carpet Punch, Mallet 10. Pass the base bracket bolts through the felt. Phillips Screwdriver 11. Repeat the same procedure (Step J. 9.) on the carpet, and then pass the base bracket bolts through the carpet. Screws (x 4) 12. Install the satellite tuner brackets and ground cable onto the tuner. (Fig. J 5) Fig.J 5 Ground Cable Page 10 of 14 pages Supplier Ref #: DIO
13. Secure the satellite tuner onto the base brackets so the connectors face toward the front of the vehicle. (Fig. J 6) 14. Plug the tuner cable and antenna cable into the tuner. (Fig. J 7) Nuts (x 4) i. Connect the antenna cable connectors of the same color to the tuner. 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) 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. Fig. J 6 Fig. J 7 Fig. K 1 Screws (x 4) Socket (10 mm) Ratchet, Extension Phillips Screwdriver Page 11 of 14 pages Supplier Ref #: DIO
M. Complete the Reassembly of Vehicle 1. Reconnect any disconnected connectors. 2. 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) 3. Re install the passenger side deck trim side panel as follows (Fig. M 1): i. Install the deck trim side panel, engage the clips and claws, and then re install the weather strip. Weather strip Claw Bolt A Screws (x 2) 4. Re install the rear seat belt anchor plate (bolt C Fig. M 1) Bolt B i. Tighten bolt C to 42 N m (31 lbf ft) 5. Install the rear seatback hinge and bolt B. i. Tighten bolt B to 42 N m (31 lbf ft) Fig. M 1 Clips (x 4) Bolt C Phillips Screwdriver Sockets (10 mm, 14 mm) Torque Wrench, Extension 6. Install two (2) screws and bolt A. 7. Re assemble the passenger front seat belt. i. Bolt and attach the passenger front seat belt anchor plate. (1) Tighten the bolt to 42 N m (31 lbf ft) ii. Attach the passenger front seat belt anchor cover. 8. 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. Page 12 of 14 pages Supplier Ref #: DIO
iii. Tighten bolts to 37 N m (27 lbf ft) iv. Fold up the seatback, and then fold down the cover over the bolts. 9. 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 13 of 14 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 "xa" by pressing the "SSP" button on the head unit for 5 seconds. (If not, press the volume control and set to "xa.") Page 14 of 14 pages Supplier Ref #: DIO