1. Genuine N1. Conversion Installation manual LC 120 5D 2003
TOYOTA MOTOR MARKETING EUROPE
Rev March 2003, Loyds Industrier AS

2. Ordering part numbers Notes Not included in kit FLOORMATS
Full Carpet floor - Cargo Area PZ449-J2C41-51
BASE SETS
3.0mm thick metal floor & lower separator PZ449-J2C40-00
SPECIFIC SETS
Denmark - Half Top Separator PZ449-J2C46-00
Denmark - Full Top Separator PZ449-J2C46-10
Notes
Tools
The tools needed for the installation are: A torque meter, 10mm and 14mm socket wrench, a socket wrench extension, a knife, 10mm key, plastic wedge (for removing panels), philips screwdriver, pop rivet gun, power drill, ø5,5mm drillbit and a small wire cutter.
Consumables
EVA melting glue.
Applied torque values
10 Nm for bolts and nuts M6. 40 Nm for larger bolts and nuts.
Not included in kit
PLUGS FOR COVERING HOLES
Plugs (4 Pieces, Supplier Toyota) B1
COVER
Back door cover (GREY) (1Piece, QUP 15) PZ449-J0C42-12

3. Contents of this manual
Product Overview Page
Pre- installation procedure page
Floor and separators page
Denmark Installation Kit page
Disconnection of curtain air bag page 17
Full Carpet Floor Page 18

4. PZ449-J2C40-00 3.0mm thick metal fl. & lower sep.
Product overview
PZ449-J2C mm thick metal fl. & lower sep.
QTY PART NUMBER DESCRIPTION
Base Set Fitting Kit Floor Floor Support Floor Support Lower Separator Service Hatch 236x236
Floor Support 1
Floor / Service Hatch 236x236
Floor Support 2
Lower Separator
Base Set Fitting Kit
QTY PART NUMBER DESCRIPTION 10 5x10 NSS 5x10mm Rivet, Black 8 6x12 6k Taptite ( ) Bolt 6x12 6K Taptite D 2 6x16 6k Taptite Self Tapping Bolt, DIN Plastic-cover Fixation Eye M06SW10 S Black 10mm Plastic Cap Seatbelt Fixation Cover Seat fixation recess cover 0, sided tape 19mm Fixation Eye Typ 500/8mm

5. PZ449-J2C46-00 Denmark - Half Top Separator
QTY PART NUMBER DESCRIPTION PZ449-J2C mm thick metal floor & lower sep Driver Side Separator Denmark Installation Kit PZ449-J2C41-51 LC 120 5D Carpet
Half Top Separator
QTY PART NUMBER DESCRIPTION Driver Side Separator Fitting Kit Driver Side Separator Upper Right Bracket Upper Left Bracket
Driver Side Separator
Upper Right Bracket
Upper Left Bracket
Driver Side Separator Fitting Kit
QTY PART NUMBER DESCRIPTION
5 6x16 6k Taptite Self Tapping Bolt, DIN x16 6k M6 Bolt, DIN ,3x16 6,3x16mm Bolt, DIN NMU M6 Self locking nut, DIN ,4x15x1,5 M6 Washer, DIN M06SW10 S Black 10mm Plastic Cap

6. PZ449-J2C46-10 Denmark - Full Top Separator
QTY PART NUMBER DESCRIPTION
PZ449-J2C mm thick metal floor & lower sep Full Top Separator Denmark Installation Kit PZ449-J2C41-51 LC 120 5D Carpet
Full Top Separator
QTY PART NUMBER DESCRIPTION Full top separator fitting kit
Full Top Separator Upper Right Bracket Upper Left Bracket
Upper Left Bracket Mirrored
Upper Left Bracket Mirrored
Full Top Separator
Full top separator fitting kit
QTY PART NUMBER DESCRIPTION
10 6x16 6k Taptite Self Tapping Bolt, DIN x16 6k M6 Bolt, DIN ,3x16 6,3x16mm Bolt, DIN NMU M6 Self locking nut, DIN ,4x15x1,5 M6 Washer, DIN M06SW10 S Black 10mm Plastic Cap

7. PZ449-J2C41-51 Full Carpet floor - Cargo Area
QTY PART NUMBER DESCRIPTION Felt Carpet
Felt
Carpet

8. 05-89392 Denmark Installation Kit
QTY PART NUMBER DESCRIPTION Forward Seatbelt Cover Left Forward Seatbelt Cover Right Upper B-column Cover L+R
Lower B-column Cover L+R
Cover Air bag
Door Handle Cover Left
Door Handle Cover Right
A-coloumn decal 45x20
2 60SGN01122 Clips for Door Handle Cover
2 5x16spax Screw 5x16 x-panhead
Seat Fixation Recess Cover
0,64m sided tape 19mm
Lower B-column Cover L+R
Backdoor- Handle Cover
Seatbelt- Fixation Cover
Forward Seatbelt Cover Left
Upper B-column Cover L+R
(36,3x25,6mm)
(35,9x23,5mm)
Forward Seatbelt Cover Right
60SGN01122
Doorhandle Cover

9. Pre- installation procedure
1. Remove rear seats and fixation brackets
2. Remove the rear part of the carpet.
2.b Remove rear door step .
3. Remove steps on both sides and reinstall bolts.
4.a Fold carpet temporarily to the front of the vehicle
FUEL PUMP
4. Remove & discard the PE foam around the fixation points.
Fixation points for support #2
5. Make 2 cutouts in the carpet for fixation points for support #2

10. Only for Specific Sets - Denmark step 6-11
If not specified: for Half top separator only perform instructions at LH side, for Full top separator both at RH & LH side
Both at RH & LH side
6.a Remove sign ‘SRS Curtain Airbag.
6.b Remove C-pillar garnish
6.c Remove seatbelt
Both at RH & LH side
7.a Remove B-Pillar garnish
7.b Remove window control panels
Both at RH & LH side
7.c Remove handles (2 x 2 bolts)
9.a Install bracket (RH bracket: )
9.b Align bracket with roof lining.
Note
Torque 10 Nm

11. 10.a Cut off & discard indicated “ear”.
10.b Reinstall B-Pillar garnish
11. Disable the child safety switch on both doors

12. Floor and lower separator
1. Fasten the 2 cargo latches to the floor ( ) using M6x20 bolts, locknuts and washers.
Note
Eyelets should face towards the middle of the car.
Note
Torque 10 Nm
2.a Install support #2 ( ) in the car and fasten with two M6 locknuts.
2.b Fold the carpet back again in original position.
Note
The upper flange of the support should face forward.
Note
Torque 10 Nm
3. Install support #1 ( ) in the car and re-use bolts from the rear seat.
Note
The upper flange of the support should face forward.
Note
Reinstall all original bolts
Note
Torque 37 Nm

13. 4.a Place the floor in the vehicle via the back door.
4.b Adjust the floor to have even spaces at both RH & LH side.
4.c Drill & rivet the floor to support #1.
Note
Order of drilling & riveting: outside holes first, then middle one, then the last 2.
5. Drill and rivet the floor to support #2.
Note
Order of drilling & riveting: outside holes first, then middle one, then the last 2.
6.a Place the lower separator ( ) in the vehicle via side door.
6.b Adjust the lower separator in position on the floor.
6.c Install the lower separator to the floor with 7 M6x12 bolts.
Note
Start from the centre of the car, working outwards.

14. Only for Specific Sets - Denmark step 7-11
Only for Specific Set – Denmark – Half top separator step 7-10
7.a Place the driver side separator on the lower separator.
7.b Install the driver side separator to the lower separator by using 3 M6 bolts, locknuts and washers.
Note
The upper left bracket ( ) should be placed on the front side of the driver separator.
8.a Install the driver side separator to “ Upper Left Bracket” using M6 bolt, locknut and washer
8.b Install the right bracket ( ) to the driver side separator.
8.c Make a mark in the roof for the fixation point, and drill a hole ø2,5mm for the mounting screw.
Note
The bracket should be placed on the forward face of the driver separator.
9. Install the right bracket and fasten to the roof with the supplied 6,3x16 PZ screw.
10. Tighten all bolts and mount the supplied screw caps.
Note
Torque 10 Nm
Only for Specific Set – Denmark – Full top separator step 11
11. Repeat steps 7-10 above for RH side.
Note
Use 6 M6 bolts, locknuts and washers in step 7.b.
Fasten the separator to Upper Left Bracket and Upper Left Bracket Mirrored both in step 8.a.

15. Only for Specific Sets - Denmark step 1-8
If not specified: for Half top separator only perform instructions at LH side, for Full top separator both at RH & LH side
Note
All the covers to be installed with melting glue, except the seat fixation cover
1. Install “Cover Air bag” ( ) on C-Pillar (On RH & LH side).
2. Install “Forward Seatbelt Cover Left” ( ) on LH C-Pillar & “Forward Seatbelt Cover Right” ( ) on RH C-pillar.
3. Install “Upper B-column Cover L+R” ( ) in holes left by removed handles at upper side. (On RH & LH side).
4. Install “Lower B-column Cover L+R” ( ) in holes left by removed handles at lower side. (On RH & LH side).
Only for 7- seater step 5
5.a Peel backing tape off the double side tape at back of the 4 “Seat Fixation Recess Covers” ( ).
5.b Install the 4 “Seat Fixation Recess Covers” over the four recesses in the floor.

16. 6. Install “Seatbelt Fixation Cover” ( ) over the holes left by the removed lower seatbelt fixations (On RH & LH side).
7. Install “Decal A-column (air bag)” ( ) over the imprinted Air bag decal on the A-column.
8. Install “Doorhandle covers” ( ) . Mount with 60SGN01122 and screw 5x16spax. (On RH & LH side).

17. Only for Specific Sets – Denmark step 1 - 6
Disconnection of curtain air bag
For Half top separator only perform instructions at LH side, for Full top separator both at RH & LH side
(Pictures are from RH side of the vehicle)
1. Disconnect the battery -terminal
2. Loosen roof-lining and remove D-column cover. To faciliate removal of the D-coloumn cover; loosen the lower panel first.
Note
Curtain air bag is placed behind the roof-lining. (one on each side of the car)
3. Release the contact by pulling back the yellow locking clip.
4.a Install the “Air Bag Terminal Connector” ( ).
4.b Close the locking clips on the cable contact and terminal connector.
5. Attach the terminal connector to the wire with tape.
Note
Make sure the terminal connector does not 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.

18. Full Carpet floor
1. Place the the felt, , in the car behind Floor.
2. Place the carpet on the floor and roll it out towards the rear
3. Pull the eyelets for the cargo latches through the cutouts in the carpet.