scion xa/xb 2004 - interior lighting upgrade section i ...tijil.org/manuals/installation...

for T-Taps

General Applicability

SCION xA/xB 2004 - INTERIOR LIGHTING UPGRADE Section I – Installation Preparation

Part Number: 00016-79001; -02; -03; -04; -05 Code: YI -1; -2; -3; -4

Light Guide Kit Contents Item # Quantity Reqd. Description 1 4 14” Light Guide 2 1 Wire harness 3 1 Switch 4 4 Bracket w/plastic mount 5 4 Plastic Mount 6 8 #6 Screw 7 4 U-clip 9 8 ¼” Wire ties 10 11 1/8” Wire ties 11 2 T-Tap 12

LED Kit Contents (any color) (PTS21-52035-XX, 2 kits required)

Item # Quantity Reqd. Description 1 2 per p/n LED modules

Additional Items Required For Installation Item # Quantity Reqd. Description

Conflicts Note:

Recommended Tools Safety Tools Vehicle protection Safety glasses

Special Tools Toque Wrench 36 in. lbs.

Installation Tools Phillips screwdriver #2 Nylon Remove Tool Pliers Diagonal cutter or wire tie tool Stubby screwdriver #2 Phillips Drill motor Scissors ¾” Drill bit. UniBit or step drill rec. Scribe or Center punch Masking tape

Panel clip tool Electrical tape Wiping cloth Non-scratch Special Chemicals Window cleaner

All xA/xB

Recommended Sequence of Application If any other accessories are to be installed, it is recommended they be installed in the order described below to ease installation and/or avoid redundant work.

Item # Accessory 1A Interior Light Upgrade Interior Light Upgrade

and Cup Holder light and/or Satellite Radio and/or Sub-Woofer should be installed concurrently

1B Cup Holder Light Cup Holder Light and Interior Light Upgrade should be installed concurrently

1C Satellite Radio Satellite Radio and Interior Light Upgrade should be installed concurrently

1D Sub-Woofer Sub-Woofer and Interior Light Upgrade should be installed concurrently

*Mandatory Legend

STOP 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 CRITICAL PROCESS: Proceed with caution to ensure a quality installation. GENERAL PROCESS: This highlights specific processes to ensure a quality installation. TOOLS & EQUIPMENT: This calls out the specific tools and equipment required for this process

Page 1 of 11 pages

cvjcramDocument # 2221 Created 12/17/03

SCION xA/xB 2004 - INTERIOR LIGHT UPGRADE Section II – Installation Procedure

A. Check Kit Contents

1. Check kit for content and damage.

B. Vehicle Preparation

STOP 1. Remove battery negative terminal

STOP 2. Apply protective covering to vehicle interior.

C. Remove Center/Lower Dash

xA Only

1. Remove the silver side trim. (Fig. C1)

Fig. C2

Fig. C1

STOP i. Use a panel safe removal tool.

ii. Pull the silver side trim straight back.

2. Remove storage box fascia by pulling straight back. (Fig. C2)

Fig. C4Fig. C3 3. Remove the lower cover.

STOP i. Using a clip removal tool, remove the (2) push fasteners.

ii. Remove the lower cover by pulling straight back. (Fig. C3)

Fig. C6Fig. C54. Remove the ashtray/lighter panel.

i. Remove the ashtray. (Fig. C4)

ii. Remove the (2) screws and pull the panel straight back. (Fig. C5 & C6)

Fig. C7

iii. Disconnect the lighter connector from the back of the panel. (Fig. C7)

Page 2 of 11 pages


xB Only Fig. C9Fig. C8

1. Remove the (2) outer ventilation knobs. (Fig. C8)

2. Remove the (2) screws. (Fig. C9)

Fig. C13

Fig. C11

Fig. C10

Fig. C12

3. Pull straight back on the panel. (Fig. C10)

4. Disconnect the (3) connectors from the back of the panel. (Fig. C11)

5. Remove the storage bin/ashtray/lighter panel by pulling straight back. (Fig. C12)

6. Disconnect the lighter connector from the panel. (Fig. C13)

7. Remove the lower cover.

i. Using Phillips screwdriver, remove the (1) screw on the passenger side.

ii. Remove the lower cover by pulling straight back.

D. Remove Jack (xB only)

Fig. D1 Fig. D2

1. Remove jack cover and jack from under Drivers seat. Seat removed for clarity (Figs. D1 & D2)

E. Remove Center Console

1. Remove the felt pad from the rear compartment.

Fig. E2

Fig. E1 2. For manual transmission vehicles, remove the

shift knob. (Fig. E1)

3. Remove the 10mm bolt from inside the rear compartment. (Fig. E2)

Page 3 of 11 pages


4. Remove the hand brake slot cover by lifting the rear edge. (Fig. E3)

Fig. E4

Fig. E3

5. Lift up at the front of the console to release the (2) clips. (Fig. E4)

6. Remove the console. Fig. F1 Front

Fuse

Switch

To RF LEDTo LF LED

To RR LEDTo LR LED

To C/L

F. Install Main Wire Harness

Distribute wire harness as shown. (Fig. F1)

1. Route the Red (power) and Black (ground) and the (2) short LED pigtails forward and under the carpet and out through the opening just under the heater duct. (Fig. F2 & F3)

Fig. F3Fig. F2

Front LED Pigtail Routing

2. Feed the (2) front LED pigtails connectors under the metal bracket. (Fig. F4)

FrontFig. F5

Wires behind bracket

Fig. F4

i. Feed the pigtails out in front of the heater ducts and to the sides. (Fig. F5)

Power Supply and Ground Routing

3. Feed the wires up and behind the metal bracket, between the heater ducts and follow the routing of the cigarette lighter (C/L) wire harness. (Fig.F6) Continue following the routing of the C/L harness (Fig. F7) and feed the wires until the end of the spade terminals are even with the end of the C/L connector. (Fig. F8)

Wires between ducts Fig. F6 Fig. F7

Fig. F8

All even

Fig. F9

5”4. Wire tie the Red and Black wires to the lighter harness about 5” from the connector. (Fig. F9)

Page 4 of 11 pages


5. Using scissors, slit the black plastic sleeve covering the C/L harness about 2” from the end of the sleeve. (Fig. F10)

Fig. F13

Fig. F12

Fig. F10

2”Fig. F116. Pull back the covering and apply the T-Tap

connectors to the C/L wires near the end of the slit in the covering.

i. Stagger the locations of the T-Taps, DO NOT line them up. (Fig. F11)

7. Close the sleeve and tape it closed just ahead of the T-Taps. (Fig. F12)

8. Insert spade connector of the Red wire into the T-Tap of the Black wire (xB) or the Gray wire (xA). (Fig. F13)

9. Insert spade connector of the Black wire into the T-Tap of the White/Blk wire (xB or xA). (Fig. F13)

G. Rear LED Pigtail Routing

1. Feed the (2) long rear light guide pigtails connectors and the Red power wire w/fuse holder rearward.

Front Fig. G1

Fig. G2

PS DSRear

i. Wire tie the harness as shown. Wire tie the fuse holder on top of the factory harness. (Fig. G1)

2. Feed the LED pigtail wires under the factory wire bundle, (Fig. G2) following the routing of the seat sensor wires toward the side.

Fig. G5

xB Driver Side

Fig. G6

xB Pass. Side

Fig. G4

xA Pass. Side

Fig. G3

xA Driver Side

i. The longer of the two pigtails should be routed under the Driver Side (LH) seat.

3. Feed the pigtails through the cutouts in the carpet, under the carpet and back out through the cutouts in the carpet for the seat sensor wires and heater ducts under the seats. Seats removed for clarity only. (Figs. G3 – G6)

Page 5 of 11 pages


H. Install the LED Modules to the Light Guides Reflector up

Fig. H2Wires forward

Do not install “reflector end” into Light Module

Fig. H1

1. Push the LED Module (L/M) firmly onto the Light Guide (L/G).

i. The L/M is installed on the “clear” end of the L/G. Do not install the “reflector end” of the L/G into the L/M. (Fig. H1)

Fig. H3

Front

RF

RRLR

LF

ii. The L/G should be oriented with the white “reflector” at the top with the wires of the L/M directed forward. (Fig. H2)

2. Assemble all (4) L/G assemblies.

i. The L/M are oriented toward the center of the vehicle with the wires directed forward. (Fig. H3)

I. Install Light Guide Assembly, Front

1. Apply masking tape to the lower edges of the dash. This will protect the dash and make the markings more visible.

2. Mark the mounting holes on the lower dash

xA Driver Side

i. Measure and mark 3-3/4” from where the lower edge of the dash meets the center dash lower cover and 3/16” from the edge of the panel. (Fig. I1)

Left

Fig. I1

10” 3-3/4” ii. Measure and mark an additional 10” from

your previous mark and 3/16” from the edge of the panel. (Fig. I1)

xA Passenger Side

i. Measure and mark 3-3/4” from where the lower edge of the dash meets the center dash lower cover and 3/16” from the edge of the panel. (Fig. I2)

Right

Fig. I2

10”3-3/4”ii. Measure and mark an additional 10” from your previous mark and 3/16” from the edge of the panel. (Fig. I2)

Page 6 of 11 pages


xB Driver Side

i. Measure and mark 3” from where the lower edge of the dash meets the bump from center dash and 3/16” from the edge of the panel. (Fig. I3)

Left Fig I3

10” 3”ii. Measure and mark an additional 10” from your previous mark and 3/16” from the edge of the panel. (Fig. I3)

xB Passenger Side

i. Measure and mark 3” starting at the RH bottom edge of the lower dash panel, 3/16” from the edge of the panel. (Fig. I4)

RightFig I4

10” 3” ii. Measure and mark an additional 10” from

your previous mark and 3/16” from the edge of the panel.(Fig. I4)

3. Drill the holes with a #20 drill bit.

4. Remove the masking tape.

5. Install the metal bracket/plastic mount assemblies to the lower dash holes. (Fig I5)

i. The plastic mount faces down. Fig. I5

Metal brkt/plastic mnt

Screw

ii. The threaded metal bracket/plastic mounts are installed behind the panels.

iii. The screws are threaded from the front of the panel into the brackets.

6. Tighten the 6-32 screws but be careful not to over tighten.

7. Install the Light Guide assembly to the plastic mounts using the ¼” wire ties.

Fig. I6

Front

i. Feed the wire ties into the plastic mounts from rear to front, orienting the wire tie “heads” toward the front of the vehicle. (Fig. I6)

ii. Do not fully tighten at this point.

Page 7 of 11 pages


iii. Insert the L/G assemblies into the mounts. The L/G assemblies should be oriented with the white “reflector” at the top, the L/M positioned toward the middle of the vehicle with the wires forward. (Figs. I7 & I8)

Center of vehicleFig. I8

Reflector up

Fig. I7Wires forward

iv. Fully tighten the wire ties and cut off excess.

Fig. I9

v. The L/G can still be re-oriented as desired.

8. Plug the L/M connector into the wire harness LED pigtail connector. (Fig. I9)

J. Install Light Guide Assembly, Rear

1. Install the U-clips

Fig. J1

i. Locate the square punched holes in the seat cushion pan. The holes are located on the bottom rear of the seat cushion under the fabric flap. (Fig. J1)

ii. Pull the fabric toward the center of the seat to expose the hole.

iii. Use caution. The seat cushion pan has sharp metal edges.

Fig. J2

iv. Install the U-clip as shown. The clip should be installed away from the center of the seat. (Fig. J2)

v. Pull the fabric back to cover the hole/U-clip.

2. Install the plastic mount.

i. Locate the previously installed U-clip through the seat fabric.

Page 8 of 11 pages


ii. Install the plastic mount by driving the 6-32 screw through the seat fabric and into the U-clip. (Fig. J3)

Fig. J3

iii. Align the plastic mount as shown and fully tighten the screw. (Fig. J3)

3. Install the Light Guide to the plastic mounts using the ¼” wire ties.

Forward

Fig. J5

Forward

Fig. J4

i. Feed the wire ties into the plastic mounts from rear to front, orienting the wire tie “head” towards the front of the vehicle. (Figs. J4 & J5)

ii. Do not fully tighten at this point.

iii. Insert the L/G assemblies into the mounts. The L/G assemblies should be oriented with the white “reflector” at the top, the L/M positioned toward the center of the vehicle with the wires forward. (Figs. J6 & J7)

LED Module

Center of vehicle

Fig. J7

Reflector up

Fig. J6 Wires forward

iv. Center the L/G assembly so it does not interfere with any under seat components when the seat is moved through its full travel.

Fig. J8

v. Fully tighten the wire ties and cut off excess.

Fig. J12Fig. J11

Fig. J10Fig. J9

xB PS xB DS

xA DSxA PS vi. The L/G can still be re-oriented as desired.

4. Plug the L/M connector into the wire harness LED pigtail connector. (Fig. J8)

5. Bundle the excess LED pigtail wire and wire tie the LED harness to the seat sensor harness as shown. Seats lifted for clarity only. (Figs. J9-J12)

Page 9 of 11 pages


K. Install Switch

1. Cut out the enclosed paper, switch hole, marking template.

Fig. K1

2. Align the template flush with the bottom of the pocket and use a center punch/scribe to mark the center of the hole to be drilled. (Fig. K1)

3. Using a ¾” drill bit (Uni-bit or step drill is highly recommended), drill the switch hole.

Left

Front

Fig. K2

Fig. K3

4. Align the switch as shown and press the switch into the hole. Make sure the switch is fully seated. (Fig. K2)

5. Connect switch wires to switch as shown. Either wire can be installed on either terminal. (Fig. K3)

L. Post Installation

1. Reinstall the Interior

2. Re-attach battery negative terminal

3. Clean Light Guides using window cleaner and a non-scratch cloth.

Page 10 of 11 pages

and torque to 36 in. lbs. at a 45 degree angle.

SCION xA/xB 2004 - INTERIOR LIGHT UPGRADE Section III – Functional Verifications Section III – Functional Verifications Check: Look For:

Operation of Light Guide assemblies

Single Unoperational Module

No Operational Modules

Seat slide clearance.

• Full engagement of affected LED

Module to LED wire harness pigtail

connector

• Full engagement of all LED Module

to LED wire harness pigtail

connectors.

• Power connnection.

• Ground connection.

• Switch connections.

• Blown light kit fuse. (2Amp, located

under center console)

• Blown cigarette lighter fuse (see

vehicle owners manual for

Amperage and location.)

• Interference between Light Guide

and all under seat components.

Re-position Light Guides to clear all

under seat components when seats are

moved through their full travel.

Page 11 of 11 pages

SWITCH TEMPLATE

DRILL HERE

LEFT

FORWARD

Part Number(s):PTS21-52034 (Light Guide Kit)PTS21-52035-03 (LED Kit, Red)PTS21-52035-05 (LED Kit, Amber)PTS21-52035-08 (LED Kit, Blue)Light Guide Kit Contents(PTS21-52034)Safety ToolsLegendCheck Kit ContentsVehicle PreparationRemove battery negative terminalApply protective covering to vehicle interior.Remove Center/Lower DashxA OnlyRemove the silver side trim. (Fig. C1)Use a panel safe removal tool.Pull the silver side trim straight back.Remove storage box fascia by pulling straight back. (Fig. C2)Remove the lower cover.Using a clip removal tool, remove the (2) push fasteners.Remove the lower cover by pulling straight back. (Fig. C3)Remove the ashtray/lighter panel.Remove the ashtray. (Fig. C4)Remove the (2) screws and pull the panel straight back. (Fig. C5 & C6)Disconnect the lighter connector from the back of the panel. (Fig. C7)xB OnlyRemove the (2) outer ventilation knobs. (Fig. C8)Remove the (2) screws. (Fig. C9)Pull straight back on the panel. (Fig. C10)Disconnect the (3) connectors from the back of the panel. (Fig. C11)Remove the storage bin/ashtray/lighter panel by pulling straight back. (Fig. C12)Disconnect the lighter connector from the panel. (Fig. C13)Remove the lower cover.Using Phillips screwdriver, remove the (1) screw on the passenger side.Remove the lower cover by pulling straight back.Remove Jack (xB only)

Remove jack cover and jack from under Drivers seat. Seat removed for clarity (Figs. D1 & D2)Remove Center Console

Remove the felt pad from the rear compartment.For manual transmission vehicles, remove the shift knob. (Fig. E1)Remove the 10mm bolt from inside the rear compartment. (Fig. E2)Remove the hand brake slot cover by lifting the rear edge. (Fig. E3)Lift up at the front of the console to release the (2) clips. (Fig. E4)Remove the console.Install Main Wire HarnessDistribute wire harness as shown. (Fig. F1)Front LED Pigtail RoutingPower Supply and Ground RoutingRear LED Pigtail RoutingInstall the LED Modules to the Light GuidesPush the LED Module (L/M) firmly onto the Light Guide (L/G).The L/M is installed on the “clear” end of the L/The L/G should be oriented with the white “reflecAssemble all (4) L/G assemblies.The L/M are oriented toward the center of the vehicle with the wires directed forward. (Fig. H3)Install Light Guide Assembly, FrontApply masking tape to the lower edges of the dash. This will protect the dash and make the markings more visible.Mark the mounting holes on the lower dashxA Driver SideMeasure and mark 3-3/4” from where the lower edgeMeasure and mark an additional 10” from your prevxA Passenger SideMeasure and mark 3-3/4” from where the lower edgeMeasure and mark an additional 10” from your prevxB Driver SideMeasure and mark 3” from where the lower edge of Measure and mark an additional 10” from your prevxB Passenger SideMeasure and mark 3” starting at the RH bottom edgMeasure and mark an additional 10” from your prevDrill the holes with a #20 drill bit.Remove the masking tape.Install the metal bracket/plastic mount assemblies to the lower dash holes. (Fig I5)The plastic mount faces down.The threaded metal bracket/plastic mounts are installed behind the panels.The screws are threaded from the front of the panel into the brackets.Tighten the 6-32 screws but be careful not to over tighten.Install Light Guide Assembly, RearInstall SwitchCut out the enclosed paper, switch hole, marking template.Align the template flush with the bottom of the pocket and use a center punch/scribe to mark the center of the hole to be drilled. (Fig. K1)Using a ¾” drill bit \(Uni-bit or step drill is�Align the switch as shown and press the switch into the hole. Make sure the switch is fully seated. (Fig. K2)Connect switch wires to switch as shown. Either wire can be installed on either terminal. (Fig. K3)Post InstallationReinstall the InteriorRe-attach battery negative terminalClean Light Guides using window cleaner and a non-scratch cloth.

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