1. Genuine N1. Conversion Installation manual LC 120 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-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) B1
Plugs (Full top separator: 2 Pieces, Supplier Toyota) B1
COVER
Back door cover (GREY) (1Piece, QUP 15) PZ449-J0C42-12

3. Contents of this manual
Product Overview Page 4 - 9
Pre- installation procedure page
Floor and separators page
Specific sets Denmark page
Disconnection of curtain air bag page 18
Full Carpet Floor Page 19

4. PZ449-J1C40-00 3.0mm thick metal fl. & lower sep.
Product overview
PZ449-J1C mm thick metal fl. & lower sep.
QTY PART NUMBER DESCRIPTION
LC125 3D Floor LC125 3D Floor Support LC125 3D Lower Separator Front Floor Bracket Rear Floor Bracket Base Set Fitting Kit
Floor
Floor Support 1
Lower Separator
Front Floor Bracket
Rear Floor Bracket

5. Base Set Fitting Kit
QTY PART NUMBER DESCRIPTION 4 6x16 6k Taptite Self Tapping Bolt, DIN M06SW10 S Black 10mm Plastic Cap 2 6,4x15x1,5 M6 Washer, DIN NMU M6 Self locking nut, DIN x12 6k Taptite ( ) Bolt 6x12 6K Taptite D Cargo fastener 500/8mm x30-UNF Bolt, 7/16-UNF S x12x1 Washer, shimz 2 13x20x10 Spacer, U x10 NSS 5x10mm Rivet, Black Plastic cover fixation eye Edge Profile (3mm), lenght 20mm

6. PZ449-J1C46-00 Denmark - Half Top Separator
QTY PART NUMBER DESCRIPTION PZ449-J1C mm floor + lower separator Driver Side Separator PZ449-J1C41-51 Full carpet floor (cargo area) Specific set for Denmark, Fitting Kit
Driver Side Separator
QTY PART NUMBER DESCRIPTION
Driver Side Separator Upper Right Bracket Upper Left Bracket Driver Side Separator Fitting Kit
Upper Right Bracket
Upper Left Bracket
Driver Side Separator
Driver Side Separator Fitting Kit
QTY PART NUMBER DESCRIPTION M06SW10 S Black 10mm Plastic Cap 6 6x16 6k Taptite Self Tapping Bolt, DIN ,4x18x1,5 M6 Washer, DIN NMU M6 Self locking nut, DIN ,3x16 6,3x16mm Bolt, DIN 7976

7. 05-91512 Shelf Fixation Cover Left
Specific set for Denmark, Fitting Kit QTY PART NUMBER DESCRIPTION 6 6x16 6k Taptite Self Tapping Bolt, DIN ,4x18x1,5 M6 Washer, DIN NMU M6 Self locking nut, DIN M06SW10 S Black 10mm Plastic Cap 1 6,3x16 6,3x16mm Bolt, DIN Cupholder Cover Shelf Fixation Cover Left Self Fixation Cover Right C-Column Belt Cover LC 90 3D Right C-Column Belt Cover LC 90 3D Left Decal A-column (air bag) unicom Airbag Terminal Connector
Cupholder Cover
Shelf Fixation Cover Left
Shelf Fixation Cover Right
C-Column Belt Cover LC 90 3D Right C-Column Belt Cover LC 90 3D Left
Airbag Terminal Connector
Decal A-column (air bag) unicom

8. PZ449-J1C46-10 Denmark - Full Top Separator
QTY PART NUMBER DESCRIPTION PZ449-J1C mm floor + lower separator PZ449-J1C41-51 Full carpet floor (cargo area) Specific set for Denmark, Fitting Kit Full Top Separator Fitting Kit Full Top Separator Upper Right Bracket Upper Left Bracket Upper Left Bracket Mirrored Airbag Terminal Connector
Upper Left Bracket Mirrored
Full Top Separator
Full Top Separator Fitting Kit
QTY PART NUMBER DESCRIPTION 10 6x16 6k Taptite Self Tapping Bolt, DIN x12 6k Taptite ( ) Bolt 6x12 6K Taptite D 2 6,3x16 6,3x16mm Bolt, DIN ,4x18x1,5 M6 Washer, DIN M06SW10 S Black 10mm Plastic Cap 10 6 NMU M6 Self locking nut, DIN 985-8

9. PZ449-J1C41-51 Full Carpet floor - Cargo Area
QTY PART NUMBER DESCRIPTION Carpet
PZ449-J1C41-51 Carpet

10. Pre- installation procedure Only for specific sets – Denmark step 3-5
1. Remove rear seats.
Fixation points for Floor Support, and
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.

11. 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.

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

13. 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.

14. 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 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

15. 13. Centre the separator and tighten all the bolts.
12. Place 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

16. Only for specific sets – Denmark step 1-10
1. Mount the 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 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 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.

17. Only for specific sets – Denmark step 1-10
6. Mount, with EVA melting glue, C-column Belt cover LC90 3D Right.
( C-column Belt Cover LC90 3D left on the cars left side.)
7. Mount Shelf Fixation Cover Right
( Shelf Fixation Cover Left on the cars left side.)
8. Mount Cupholder Cover over the cupholder with EVA melting glue.
9. Glue shut the ashtray on the cars right side, with melting glue
10. Mount 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.

18. 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 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.

19. 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.