toyota camry/solara 2005 - section ii - installation

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TOYOTA CAMRY/SOLARA 2005 - Section II - Installation Procedure

Kit ContentsItem # Quantity Reqd. Description1 2 13” Light Rod2 1 Wire harness3 1 Hardware Kit4 2 White Light Engines5 1 Switch Kit

6 2 Amber cup holder kits7 1 Customer Information card8 1 Die Cut Adhesive9 1 “Y” Adapter

Hardware Bag ContentsItem # Quantity Reqd. Description1 4 Catamount

2 4 8-32 x .375 screw

3 4 “U” nut

4 4 Wire tie .187

5 4 Wire tie .0625

6 6 foam pads

7 2 T-Taps

Switch Bag ContentsItem # Quantity Reqd. Description1 1 Switch

2 1 End Cap, Black

3 1 Illumination Nameplate

4 1 Installation tool

5 1 Bezel

6 1 Black spacer

Color Applicability/Trim Level

AccessoryC

olor

General ApplicabilityAll models of Camry and Solara

Recommended Sequence of ApplicationItem # Accessory1 * Overlay Apply any overlay first2

3

*Mandatory

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 installa-tion. 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.

TOYOTA CAMRY/SOLARA 2005 INTERIOR LIGHT UPGRADESection 1 - Installation Preparation

Part Number:TBDAccessory Code:TBD

Recommended toolsSafety ToolsVehicle protectionSafety glassesSpecial ToolsInstallation ToolsTorque wrench (36 in. lbs.)Phillips screwdriver #2Nylon Remove ToolPliersDiagonal cutter or wire tie toolStubby screwdriver #2 PhillipsDrillScissors1/2” Drill bit. UniBit or step drill rec.1/8” Drill bitScribe or Center punchMasking tapePanel clip tool9/32” Drill bitWiping cloth Non-scratchSpecial ChemicalsWindow cleaner

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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.

if caution is taken to not damage vehicle.

Also some items listed to be removed may not need to be removed

Part Number: 00016-00060 Code: IL1

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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.

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pages 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. if caution is taken to not damage vehicle. Also some items listed to be removed may not need to be removed

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Document # 3487 REVISION A 8/2/05

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R E V I S I O N A

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R E V I S I O N A

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TOYOTA CAMRY/SOLARA 2005 - INTERIOR LIGHT UPGRADESection II - Installation Procedure

Fig. A1

Harness

LED Modules

SwitchLight Guide

Cup HolderAttachment

A. Check Kit Contents1. Check kit for content and damage. (Fig. A1)

B. Vehicle Preparation1. Remove battery negative terminal.

2. Apply protective covering to vehicle

C. Remove center console1. Place shifter in “LOW” position.

i. Set parking brake.

ii. Use panel safe tool.

iii. Remove cover. (Fig. C1)

iv. Depress interlock and place shifter in “LOW” position. (Fig. C2)

2. Remove center console bezel.

i. Use panel safe tool.

ii. Carefully pry around bezel. (Fig. C3)

iii. Disconnect any cables.

iv. Remove from vehicle. (Fig. C4)

3. Remove center console storage box.

i. Disconnect auxiliary power cable. (Fig. C5)

ii. Remove felt insert. (Fig. C6)

iii. Remove (2) 12mm bolts. (Fig. C7)

iv. Remove (2) screws. (Fig. C8)

4. Slide console towards rear while lifting rear, remove from vehicle.

5. Remove forward bezel.

i. Carefully pry around bezel.

ii. Disconect lead to power outlet.

iii. Remove bezel from car. (Fig. C9)

Fig. C1 Fig. C2

Fig. C3 Fig. C4

Fig. C5 Fig. C6

Fig. C7 Fig. C8

Fig. C9

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D. Install Cup holder Lights1. Orient cup holder assembly as shown. (Fig. D1)

2. Remove (4) screws and remove cover. (Fig. D2)

3. Drill holes for cup holder lights.

i. Cut out enclosed paper template labeled “Camry cup holder ”.

ii. Align template as shown use a punch/scribe to mark the center of the hole to be drilled. (Fig. D2)

iii. Drill pilot holes with 1/8” drill bit.

iv. Finally drill the pilot hole with a 9/32” drill bit.

v. De-burr holes with de-burring tool. (Fig. D3)

4. Insert Lens from inside of cup holder

5. Firmly press LED assembly into lens. (Fig. D4)

6. Use adhesive pad to secure wires. (Fig. D5)

7. Place cover over cup holders routing wire as shown, Reinstall (4) screws. (Fig. D6)

E. Install Storage Box Lights.1. Drill holes for LEDs

i. Cut out “Camry storage box” template.

ii. Align template as shown using castings on either side for alignment then center. (Fig. E1)

iii. Use a punch/scribe to mark the center of the hole to be drilled.

iv. Drill pilot holes with 1/8” drill bit.

v. Drill the lamp hole with a 9/32” drill bit.

vi. De-burr holes with de-burring tool. (Fig. E2)

2. Insert lens from inside storage box. (Fig. E3)

3. From the back of the storage box, install the LED s̓ onto the lenses. Press firmly while holding the Lens from the inside. Secure with foam pad. (Fig. E4)

Fig. D1 Fig. D2

Fig. D3 Fig. D3

Fig. D4 Fig. D5

Fig. D6

Fig. E1 Fig. E2

Fig. E3 Fig. E4

REAR HOLE FRONT HOLE

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F. Install power Switch

1. Drill hole for switch.

i. Use bezel as a template.

ii. Place bezel so hole drilled will be orientedas pictured. (Fig. F1)

iii. Place template in area indicated. Use a punch or scribe to mark center of the hole to be drilled.

iv. Using a 1/2” drill bit (Unibit or step drill is highly recommended), drill the switch hole. (Fig. F2)

2. Clean bezel surface to remove grease and wax.

i. Wipe the application area clean with alcohol and a clean no-scratch cloth

ii. Dry the installation area using a clean, dry, lint free cloth.

3. Insert switch bezel into switch plate. (Fig. F3)

4. Using the pull-tab, remove the tape liner from the back of the switch plate. (Fig. F4)

i. Avoid finger contact with the ad hesive surface.

5. Using the bezel as a guide, install switch plate/bezel into the previously drilled 1/2” hole.

i. A lign the printing “ ILLUMINATION ” square to the console. (Fig. F5)

ii. Once aligned, press down firmly to ad here tape.

6. Install Sleeve to bezel.

i.

The “white” ink end of the sleeve must be

installed against the console. (Fig. F6)

Fig. F1 Fig. F2

Fig. F3 Fig. F4

Fig. F6Fig. F5

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Fig. E15

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8. Install switch to bezel as shown.

i. Using switch tool turn bezel clockwise to tighten.

ii. Be careful not to over tighten as this will “over ride” the threads on the switch. If this happens simply retighten being careful not to over tighten.

iii. Push button into bezel pressing to engage.

G. Install Light Guide 1. Install Drivers side plastic mount.

i. Attach “U” nut and catamount to air ducts as shown (Fig. G1)

ii. Make sure catamount is open towards rear of vehicle.

iii. Catamounts will be spaced as shown (Fig. G2)

2. Attach LED Module to Light Guide. (Fig. G3)

3. Install the light guide in the plastic mounts us-ing 1/4” wire ties.

i. Feed the wire ties into the plastic mount.

ii. Insert the light guide assemblies into the mounts. The light guide assemblies should be orientated with the white “reflector” at the top, the LED modules positioned toward the center of the vehicle. (Fig.G4)

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

iv. The light guide can be re-oriented as desired.

4. Install passenger side light guide.

i. Depress tabs on leading edge of under dash shield and remove.

ii. Orient as shown. (Fig. G5)

iii. Drill 9/32 hole 1” from edge as shown. (Fig.G6)

iv. Install catamount using the “U” nut as a nut on the reverse side. (Fig. G7a & b)

Fig. G1a Fig. G1b

Fig. G2

Fig. G3

Fig. G4

Fig. G5 Fig. G6

Fig. G7a Fig. G7b

Do not install reflector end into LED modules

Reflector up

Wire upward

Reflector up

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5. Remove plastic from highlighted area. (Fig. G8)

6. Drill 1/2" hole for wire routing. (Fig. G9)

7. Drill a 9/32" hole 1/2" from edge. (Fig G10)

i. Insert the light guide assembly into the cable ties. The light guide assemblies should be orientated with the white “refl ector” at the topthe LED modules positioned toward the center

of the vehicle. (Fig. G11)

ii. Orient wires so they feed up through shield. (G12)

iii. Orient ligh t guide as shown.

iv. Fully tighten the wire ties and cut off ex-cess.

Fig. G8 Fig. G9

Fig. G10

9. Install the light guides into cable ties.

8. Install catamount using the "U" nut as anut on the reverse side as previouslyshown in Fig.G7a & b.

Fig. G11 Fig. G12

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G10

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Fig. G10

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Fig. G11

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Fig. G12

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H. Install harness1. L ay out harness as shown and identify connec-

tors. (Fig. H1)2. B ulk of harness will reside under center console

inlay3. L ocate power.

CAMRYi. L ocate auxiliary power connector in center

of forward bezel,

SOLARAii. L ocate auxiliary power connector inside

storage area in forward bezel.iii. Install T-taps in staggered fashion. (Fig. H2)

4. A ttach harness to power. (Fig. H3)

CAMRYi. B lack wire on harness to wt/blk, connector

C4 pin 3.ii. White wire on harness to pink/wh, connec-

tor C4 pin 1.

SOLARA

iii. B lack wire on harness to wt/blk, connector P4 pin 1.

iv. White wire on harness to pink, connector P4 pin 2.

5. R einstall R ear half of center console.

i. Slide console forward. (Fig. H4)

ii. Secure (2) 12 mm bolts. (Fig. H5)

iii. Secure (2) screws on either side. (Fig. H6)

iv. Reconnect auxiliary power connector. (Fig. H7

6. Attach “Y ” adapter to rear storage lights. (Fig. H8)

7. R einstall forward bezel.

i. Reconnect auxiliary power connector. (Fig. H9)

ii Gently press insert into place

Fig. H2 Fig. H3

Fig. H4

Fig. H7

Fig. H8 Fig. H9

Fig. H5

Fig. H6

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8. Attach “Y” adapter to cup holder assembly. (Fig. H10)

9. Attach “Y” adapter to harness. (Fig. H11)

10. Bundle excess wire and secure in center of con-sole, reinstall cup holder assembly. (Fig.H12)

11. Attach harness to LED modules.

i. Attach left side LED module. (Fig. H13)

ii. Attach right side LED module. (Fig. H14)

12. Reinstall under dash shield.

13. Connect switch to main harness

i. Connect switch leads, make sure letters match respective connection. (Fig. H15)

Fig. H15

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Fig. H15

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M. Post Installation1. Reinstall interior.

2. Re-attach negative battery terminal, torque to 36 inch pounds.

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

4. Cycle test the system with the key in the ACC or ON position. The cycle may start from any step below but should cycle in this order.

i. All lights off.

ii. Cup holder lights on only.

iii. All lights on.

iv. Interior Light on only.

v. Back to step “i”.

5. The switch should be cycled to step “i” (all lights off) for shipment.

6. Place information card in glove box.

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TOYOTA CAMRY/SOLARA 2005 - INTERIOR LIGHT UPGRADESection III - Functional Verification

Draft Copy

Look for:

___________________________________

Full engagement of affected LED module to LED wire harness pigtail connector.

Light guide inserted incorrectly (wrong end)

Full engagement of all LED module to LED wire harness pigtail connectors.

Power connection.

Ground connection

Switch connections

Blown light kit fuse. (2 amp located under cen-ter console)

Blown shift console illumination fuse (see vehicle owners manual for amperage and location.).

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Check:

___________________________________

Single Unoperational Module

No Operational Modules

All disconnected accessories Proper operation of accessory

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BRA

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2 INCHES

TOWARDS REARTOWARDS FRONT

9/32” DRILL

9/32” DRILL

STORAGE BOX TEMPLATE

STORAGE BOX TEMPLATE

9/32” DRILL

9/32” DRILL

CUP HOLDER TEMPLATE

toyota camry/solara 2005 - section ii - installation

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