Genuine N1. Conversion Installation manual LC 120 2003 TOYOTA MOTOR MARKETING EUROPE Rev. 3.1 04. March 2003, Loyds Industrier AS

Ordering part numbers Notes Not included in kit FLOORMATS Full Carpet floor - Cargo Area PZ449-J1C41-51 BASE SETS 3.0mm thick metal floor & lower separator PZ449-J1C40-00 SPECIFIC SETS Denmark - Half Top Separator PZ449-J1C46-00 Denmark - Full Top Separator PZ449-J1C46-10 Notes Tools The tools needed for the installation are: A torque meter, 10mm, 16mm and 14mm socket wrench, a socket wrench extension, a knife, plastic wedge (for removing panels, philips screwdriver, pop rivet gun , power drill, ø5.5 drillbit and a small wire cutter. Consumables EVA melting glue. Applied torque values Unless otherwise specified: 10 Nm for bolts and nuts M6. 40 Nm for larger bolts and nuts. Not included in kit PLUGS FOR COVERING HOLES Plugs (Half top separator: 3 Pieces, Supplier Toyota) 90467-05164-B1 Plugs (Full top separator: 2 Pieces, Supplier Toyota) 90467-05164-B1 COVER Back door cover (GREY) (1Piece, QUP 15) PZ449-J0C42-12

Contents of this manual Product Overview Page 4 - 9 Pre- installation procedure page 10 - 11 Floor and separators page 12 - 15 Specific sets Denmark page 16 - 17 Disconnection of curtain air bag page 18 Full Carpet Floor Page 19

PZ449-J1C40-00 3.0mm thick metal fl. & lower sep. Product overview PZ449-J1C40-00 3.0mm thick metal fl. & lower sep. QTY PART NUMBER DESCRIPTION 1 05-90402 LC125 3D Floor 1 05-90412 LC125 3D Floor Support 1 1 05-90432 LC125 3D Lower Separator 2 05-91412 Front Floor Bracket 2 05-91402 Rear Floor Bracket 1 05-90392 Base Set Fitting Kit 05-90402 Floor 05-90412 Floor Support 1 05-90432 Lower Separator 05-91412 Front Floor Bracket 05-91402 Rear Floor Bracket

05-90392 Base Set Fitting Kit QTY PART NUMBER DESCRIPTION 4 6x16 6k Taptite Self Tapping Bolt, DIN 7500 6 221 M06SW10 S Black 10mm Plastic Cap 2 6,4x15x1,5 M6 Washer, DIN 9021 2 6 NMU M6 Self locking nut, DIN 985-8 6 6x12 6k Taptite (211-06-012) Bolt 6x12 6K Taptite D 2 500250 Cargo fastener 500/8mm 2 7-16x30-UNF Bolt, 7/16-UNF S-67 2 24x12x1 Washer, shimz 2 13x20x10 Spacer, U-710 13 5x10 NSS 5x10mm Rivet, Black 2 500252 Plastic cover fixation eye 2 461-0074 Edge Profile (3mm), lenght 20mm

PZ449-J1C46-00 Denmark - Half Top Separator QTY PART NUMBER DESCRIPTION 1 05-90382 PZ449-J1C40-00 3mm floor + lower separator 1 05-90492 Driver Side Separator 1 05-90442 PZ449-J1C41-51 Full carpet floor (cargo area) 1 05-91432 Specific set for Denmark, Fitting Kit 05-90492 Driver Side Separator QTY PART NUMBER DESCRIPTION 1 05-90512 Driver Side Separator 1 05-90522 Upper Right Bracket 1 05-90532 Upper Left Bracket 1 05-90502 Driver Side Separator Fitting Kit 05-90522 Upper Right Bracket 05-90532 Upper Left Bracket 05-90512 Driver Side Separator 05-90502 Driver Side Separator Fitting Kit QTY PART NUMBER DESCRIPTION 9 221 M06SW10 S Black 10mm Plastic Cap 6 6x16 6k Taptite Self Tapping Bolt, DIN 7500 6 6,4x18x1,5 M6 Washer, DIN 9021 5 6 NMU M6 Self locking nut, DIN 985-8 1 6,3x16 6,3x16mm Bolt, DIN 7976

05-91512 Shelf Fixation Cover Left 05-91432 Specific set for Denmark, Fitting Kit QTY PART NUMBER DESCRIPTION 6 6x16 6k Taptite Self Tapping Bolt, DIN 7500 6 6,4x18x1,5 M6 Washer, DIN 9021 5 6 NMU M6 Self locking nut, DIN 985-8 9 221 M06SW10 S Black 10mm Plastic Cap 1 6,3x16 6,3x16mm Bolt, DIN 7976 2 05-90852 Cupholder Cover 1 05-91512 Shelf Fixation Cover Left 1 05-91522 Self Fixation Cover Right 1 05-89302 C-Column Belt Cover LC 90 3D Right 1 05-89292 C-Column Belt Cover LC 90 3D Left 2 05-91722 Decal A-column (air bag) unicom 1 05-92062 Airbag Terminal Connector 05-90852 Cupholder Cover 05-91512 Shelf Fixation Cover Left 05-91522 Shelf Fixation Cover Right 05-89302 C-Column Belt Cover LC 90 3D Right 05-89292 C-Column Belt Cover LC 90 3D Left 05-92062 Airbag Terminal Connector 05-91722 Decal A-column (air bag) unicom

PZ449-J1C46-10 Denmark - Full Top Separator QTY PART NUMBER DESCRIPTION 1 05-90382 PZ449-J1C40-00 3mm floor + lower separator 1 05-90442 PZ449-J1C41-51 Full carpet floor (cargo area) 1 05-91432 Specific set for Denmark, Fitting Kit 1 05-91442 Full Top Separator Fitting Kit 1 05-91292 Full Top Separator 2 05-90522 Upper Right Bracket 1 05-90532 Upper Left Bracket 1 05-91322 Upper Left Bracket Mirrored 1 05-92062 Airbag Terminal Connector 05-91322 Upper Left Bracket Mirrored 05-91292 Full Top Separator 05-91442 Full Top Separator Fitting Kit QTY PART NUMBER DESCRIPTION 10 6x16 6k Taptite Self Tapping Bolt, DIN 7500 2 6x12 6k Taptite (211-06-012) Bolt 6x12 6K Taptite D 2 6,3x16 6,3x16mm Bolt, DIN 7976 12 6,4x18x1,5 M6 Washer, DIN 9021 18 221 M06SW10 S Black 10mm Plastic Cap 10 6 NMU M6 Self locking nut, DIN 985-8

PZ449-J1C41-51 Full Carpet floor - Cargo Area QTY PART NUMBER DESCRIPTION 1 05-90442 Carpet 05-90442 PZ449-J1C41-51 Carpet

Pre- installation procedure Only for specific sets – Denmark step 3-5 1. Remove rear seats. Fixation points for 05-90412 Floor Support, and 05-91412 Front Floor Bracket 2. Remove a part of the felt in front of the rear carpet. (The felt under the carpet.) 535mm Remove the felt in front of this line on the rear carpet. Only for specific sets – Denmark step 3-5 Both at RH & LH side 3. Remove handles in the roof.

Both at RH & LH side 4.a Remove front door scuff plate 4. Remove seatbelt and seatbelt cover. Both at RH & LH side 5. Remove existing rail for cargo area curtain.

Floor and lower separator 1. Place 05-90412 Floor Support in the car. Note Install with Torque 37Nm 2. Place 05-91412 Front Floor Bracket in the car. Note Install with Torque 37Nm 3. Fasten the cargo latches to the floor (05-90402) using M6x20 bolts, locknuts and washers. Eyelets should face towards the middle of the car. 4. Rivet 05-91402 Rear Floor Bracket to the floor (05-90402). The “nose” must point backwards.

5. Place the rubber profile on the “nose” of the 05-91402 Rear Floor Bracket. 6. Place the floor in the car tilted forward, and lower the rear end down gently to avoid scratching. Note Install via back door in vehicle 7. Lift the front of the floor and push it backwards in the car, so the rear floor brackets slides under the fixations for the rear seats.

10. Rivet the floor to 05-91412 Front Floor Bracket. 8. Place the spacer 13x20x10 under the floor on both sides, and finger-tighten with bolt 7-16x30-UNF and washer 24x12x1. 9. Centre the floor in the car, and drill and rivet the floor to the floor support. Note Adjust the floor to have even spacing around. Drill diameter Ø5.5. Note Order of drilling and riveting. Work from the centre of the car towards each side respectively 10. Rivet the floor to 05-91412 Front Floor Bracket. 11. Tighten the two 7-16x30-UNF bolts, and make a cut-out in the plastic cover for the bolts. Note Install with Torque 20 Nm

13. Centre the separator and tighten all the bolts. 12. Place 05-90432 Lower Separator in the car, and loosely install the six bolts. Note Install via back door. 13. Centre the separator and tighten all the bolts. Note Torque 5 Nm. Start with the two middle bolts and work outwards to each side. 14. Also mount the separator to the floor with two bolts on the cargo area of the lower separator. Note Torque 10 Nm

Only for specific sets – Denmark step 1-10 1. Mount the 05-90532 Upper Left Bracket, aligned with the roof lining, in the forward handle fixation point, with a M6 bolt. Note Torque 10 Nm 2. Place the 05-90432 Lower Separator on the lower separator, and mount with M6 bolts, nuts and washers. The upper left bracket should be placed on the forward face of the driver side separator. 3. Mount the driver side separator to upper left bracket. Mount the 05-90522 Upper Right Bracket to the forward face of the driver side separator, and make a mark in the roof for the fixation point, and drill a hole Ø2,5mm for the mounting screw. 4. Tighten all bolts and nuts, and mount the supplied screwcaps. Note Torque 10Nm 5. Insert original plastic plug in the holes left by the removed handles.

Only for specific sets – Denmark step 1-10 6. Mount, with EVA melting glue, 05-89302 C-column Belt cover LC90 3D Right. (05-89292 C-column Belt Cover LC90 3D left on the cars left side.) 7. Mount 05-91522 Shelf Fixation Cover Right (05-91512 Shelf Fixation Cover Left on the cars left side.) 8. Mount 05-90852 Cupholder Cover over the cupholder with EVA melting glue. 9. Glue shut the ashtray on the cars right side, with melting glue 10. Mount 05-91722 Decal A-column (airbag) over the imprinted Air Bag decal on the A-column, with melting glue.(On both sides of the car.) Note Regard difference for Half & Full top separator. Left side only for Half separator. Left and Right both for full top separator.

Only for specific sets – Denmark step 1-6 Disconnection of curtain air bag (Pictures are from the cars right side) 1. Disconnect the battery -terminal Curtain air bag is placed behind the roof-lining. (one on each side of the car) 2. Loosen roof-lining and remove D-column cover. To faciliate removal of the D-coloumn cover; loosen the lower panel first. 3. Release the contact by pulling back the yellow locking clip. 4. Mount the 05-92062 Air Bag Terminal Connector. Close the locking clips on the cable contact and terminal connector. 5. Attach the terminal connector to the wire with tape. Make sure the terminal connector don’t get a chance to “rattle”. 6. Reconnect battery -terminal. Put on ignition. Make sure the SRS-lamp goes out. Replace Roof-lining and D-column cover. On cars with full separator: Disconnect curtain air bag on both sides of the car. On cars with half separator: Disconnect curtain air bag on the cars LEFT side. On cars with no upper separator: Do not disconnect curtain air bag.

Full Carpet floor 1. Place the carpet on the floor and roll it out towards the rear 2. Pull the eyelets for the cargo latches through the cut-outs in the carpet.