Document # 3801
TOYOTA
REVISION E 1/9/06
Tundra C&D-Cab/Sequoia
2005-06
Section I - Installation Preperation
Part Number:00016-00060
Accessory Code:IL1
Interior Light Upgrade
REVISION
E
Color Applicability/Trim Level
1
2
3
4
5
6
7
8
Quantity Reqd.
2
1
1
2
1
2
1
1
Description
Accessory
Color
Item #
13” Light Rod
Wire harness
Hardware Kit
White Light Engines
Switch Kit
Amber cup holder kits
Customer Information card
Die cut adhesive tape
Hardware Bag Contents
Item #
1
2
3
4
5
6
7
Quantity Reqd.
4
4
4
4
4
5
2
Description
Catamount
8-32 x .375 screw
“U” nut
Wire tie .187
Wire tie .0625
foam pads
T-Taps
1
2
3
4
5
6
Quantity Reqd.
1
1
1
1
1
1
All models of Tundra C & D-Cab/Sequoia except bench seat model
Recommended Sequence of Application
Switch Bag Contents
Item #
General Applicability
Description
Switch
End Cap, Black
Illumination Nameplate
Installation tool
Bezel
Black spacer
Item #
Accessory
1*
2
3
Overlay
*Mandatory
STOP: Damage to the vehicle may occur. Do Not proceed until process has
been completed with.
Recommended Tools
OPERATORS SAFETY: Use caution to avoid risk of injury.
Safety Tools
CRITICAL PROCESS: Proceed with caution to ensure a quality installation. there points will be audited on a completed vehicle installation.
Vehicle protection
Safety glasses
Installation Tools
1/8" Drill Bit
Phillips screwdriver
Nylon Remove Tool
Pliers
Diagonal cutter
Stubby screwdriver
Drill motor
Scissors
1/2” Drill bit.
Scribe or Center punch
Masking tape
Panel clip tool
9/32” Drill bit
Wiping cloth Non-scratch
Special Chemicals
Window cleaner
Alcohol/Water Solution
Apply any overlay first
Torque Wrench (36 in. lbs)
GENERAL PROCESS: This highlights specific processes to ensre a quality
installation. These poins will be audited durring the accessory installation.
#2
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.
or wire tie tool
#2 Phillips
SPECIAL NOTE: Installation Sequences
UniBit or step drill rec.
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.
Also some items listed to be removed may not need to be removed
if caution is taken to not damage vehicle.
Page 1 of 9
TOYOTA
Tundra C&D-Cab/Sequoia
2005-06
Section II - Installation Procedure
A . Check kit for contents
1. Check kit for content and damage.
(Fig. A 1)
Switch
Interior Light Upgrade
Light Guide
Harness
B . Vehicle prepar ation
1. Disconnect battery negative terminal.
Cup Holder
2. A pply protective covering to car.
C . Remove console.
1. R emove Center console inlay
i. Use panel safe tool.
Attachment
LED Modules
ii. Carefully pry around edges of center
console inlay (Fig. C1)
Fig. A1
iii. L ift straight up and put aside.
2. R emove center console storage bin.
i. R emove CD organizer tray. (Fig. C2)
ii. R emove (2) 10 mm bolts below tray.
iii. L ift front edge of storage bin lift rear
and remove from vehicle. (Fig. C3)
Fig. C1
Fig.C2
Fig. C4
If equiiped w/ Rear seat entertainment:
i.
R emove the disc bracket.
ii.
R emove the 3 bolts and disc player
Fig. C3
iii. Disconnect the connector
(Fig. C4)
3. L oosen front edge of center console to
facilitate harness installation.
i. L oosen and remove captive fasteners
on both side of console. (Fig. C5).
Fig. C5
ii. R emove (2) 10 mm bolts. (Fig. C6)
iii. Remove (2) 10 mm bolts. (Fig. C7)
iv. Slide console back about two inches.
v. Do not remove from vehicle.
Fig. C7
Page 2 of 9
Fig. C6
TOYOTA
Tundra C&D-Cab/Sequoia
2005-06
Section II - Installation Procedure
Interior Light Upgrade
D. Install Light Guide
1. Attach LED module to light guide.
2. Install the light guide in the catamounts using
1/4” wire ties.
i. Feed the wire ties into the plastic mounts.
Fig. D1
ii. Insert the light guide assemblies into
the mounts. The light guide assemblies
should be orientated with the white “reflector” at the top, with the LED module positioned toward the center of the
vehicle. (Fig. D1)
iii. Fully tighten the wire ties and cut off excess
when completed.
Fig. D3
Fig. D2
iv. The light guide can be re-oriented as desired.
3. Install right side light guide.
i. Remove (2) screws securing glove box
and remove door. (Fig. D2)
Fig. D5
ii. Due to the tightness of this install it is
useful to loosely pre-assemble the light
guide assembly as shown. (Fig. D3)
Fig. D4
iii. Attach catamount to “U” nut using screws.
Remove duct to gain room. (Fig. D4)
iv. Space clips carefully using glove box
attachment point as a point of reference.
(Fig. D5)
v. Pushing firmly, attach “U” nut and catamount to metal support piece (Fig. D6)
Fig. D6
Fig.
Fig. D7A
D7
4. Install left side light guide.
i. Apply double stick tape as shown.
(Fig. D7A & D7B)
ii. Pull knee bolster towards interior of car.
iii. Before inserting light guide make sure
white strip is orient towards top.
Fig. D7B
iv. Carefully slip light guide assembly up
into space between knee bolster and air
duct. (Fig. D8)
Page 3 of 9
Fig. D8
TOYOTA
Tundra C&D-Cab/Sequoia
2005-06
Section II - Installation Procedure
Interior Light Upgrade
E. Install Cup Holder Lights.
1. Remove (6) screws securing cup holder to
bezel. (Fig. E1)
2. Drill holes for cup holder lights
i. Cut out “Tundra Sequoia Cup Holder” template.
Fig. E1
Fig. E2
ii. Align template with edge as shown.
(Fig. E2)
iii. Use punch or scribe to mark where to
drill.
iv. Drill pilot holes with 1/8” drill bit. (OPTIONAL)
v. Drill the lamp hole with a 9/32” drill bit.
vi. De-burr holes with de-burring tool.
3. Insert lens from inside of cup holder.
4. From the back of the cup holder, install the LEDʼs
onto the lenses. Press firmly while holding the
Lens from the inside (Fig. E3)
Fig. E3
F. Install Switch in Center Console Inlay.
1. Drill hole for switch.
i. Use screw hole indicated as drill guide.
(Fig. F1)
ii. Using a 1/2” drill bit (Unibit or step drill
is highly recommended), drill the switch
hole. Remove plastic ribs if needed.
(Fig. F2)
Fig. F1
2. Clean console 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.
Fig. F3
3. Insert switch bezel into switch plate. (Fig. F3)
Page 4 of 9
Fig. F2
TOYOTA
Tundra C&D-Cab/Sequoia
2005-06
Section II - Installation Procedure
Interior Light Upgrade
4. Using the pull-tab, remove the tape liner
from the back of the switch plate. (FIG. F4)
i. Avoid finger contact with the adhesive.
5. Using the bezel as a guide, install switch
plate into the previously drilled 1/2” hole.
Fig. F4
i. Align the printing “ILLUMINATION”
square to the console. (FIG. F5)
Fig. F5
ii. Once aligned, press down firmly to adhere tape.
6. Install sleeve to bezel.
i. The “white” ink end of the sleeve must be
installed against the console. (FIG. F6)
Fig. F6
Fig. F7
ii. If overlay applied remove 1/8” of blackend of sleeve with sandpaper
7. Install switch to bezel as shown. (Fig. F7))
i. Turn switch 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.
Fig. F8A
8. Insert push button into bezel pressing to engage.
9. Cut out screw hole indicated using cutters and
nippers, allow clearance for back side of switch.
Cut edges away from tower if needed.(Fig. F8A
and F8B)
10. Reinstall (5) screws (Fig. F9)
Page 5 of 9
Fig. F9
Fig. F8B
TOYOTA
Tundra C&D-Cab/Sequoia
2005-06
Section II - Installation Procedure
Interior Light Upgrade
G. Install Storage Box Lights
1. Disconnect wire harness that supplies rear
accessory outlet. (Fig. G1)
2. Remove (8) screws from bottom of storage
box. (Fig. G2)
3. Remove rear air control panel. (If equipped)
4. Remove
(Fig.
G3) (2) screws from either side of storage box. (Fig. G4)
Fig. G1
Fig. G2
5. Separate bottom from top half, and place as
shown. (Fig. G5)
6. Install storage box lights.
i. Cut out “Tundra/Seq. storage box” template.
Fig. G3
ii. Align template with lower edge and center. (Fig. G5)
iii. Use a punch/scribe to mark the center of
the hole to be drilled.
Fig. G4
Fig. G5
iv. Drill pilot holes with 1/8” drill bit. (OPTIONAL)
v. Drill the lamp hole with a 9/32” drill bit.
vi. De-burr holes with de-burring tool.
Fig. G6
7. Insert lens from inside storage box. (Fig. G6)
8. From the back of the storage box install the LEDʼs
onto the lenses. Press firmly while holding the
Lens from the inside. (Fig. G7)
9. Reassemble storage box.
i. Replace bottom half. It helps to place all
the screws in place ahead of time before
lowering bottom assembly. (Fig. G8)
Fig. G7
Fig. G8
ii. Be careful not to bump LED assemblies
on housing. (Fig G9)
iii. Replace (2) screws on either side.
(Fig. G10)
10. Attach “Y” connector to storage box LED
assembly.
Fig. G9
11.Run leads forward towards front of vehicle and
Page 6 of 9
Fig. G10
TOYOTA
Tundra C&D-Cab/Sequoia
2005-06
Interior Light Upgrade
Section II - Installation Procedure
use small cable ties to secure alongside existing
harness. (Fig. G10)
11 Lead to power and cup holder LED assembly will
exit from front of console. (Fig G11)
H. Install harness
1. Lay out harness as shown and identify connectors. (Fig. H1)
Fig. G11
Fig. G10
2. B ulk of harness will reside under center console inlay
3. Locate power.
i. (D-Cab & Sequoia)Locate connector
below center console inlay. (Fig. H2a)
ii. (C-Cab )Locate connector
front of center console. (Fig. H2b)
iii. (Sequoia)Locate connector in center
console. (Fig. H3)
console inlay. (Fig. H2)
Fig. H1
TUNDRA C-CAB CONNECTOR P7 (Fig. H4)
iii. Pin #1 white/black wire ground (-)
iv. Pin #2 green/black 12 volt (+)
TUNDRA D-CAB CONNECTOR IM1 (Fig. H4)
iv. Pin #8 white/black wire ground (-)
Fig. H2a
Fig. H2b
Fig. H3
v. Pin #7 blue/white 12 volt (+)
SEQUOIA CONNECTOR F12 (Fig H4)
v. Pin #2 white/black wire ground (-)
vi. Pin #1 blue/red 12 volt (+)
4. Attach harness to LED modules.
TUNDRA D-CAB
TUNDRA C-CAB
i. Attach left side light guide. (Fig. H5)
ii. Attach right side light guide. (Fig. H6)
iii. Make sure wires will be hidden from
view when center console is secured.
5. A ttach harness to power. (Fig. H3)
Fig. H5
i. B lack wire on harness to ground (-).
ii.White wire on harness to 12 volt (+).
Page 7 of 9
Fig. H6
SEQUOIA
Fig. H4
TOYOTA
Tundra C&D-Cab/Sequoia
2005-06
Section II - Installation Procedure
Interior Light Upgrade
6. Reinstall center console
i. Slide console forward.
ii. Secure (2) 10 mm bolts. (Fig. H7)
iii. Secure (2) captive screws on either side.
(Fig. H8)
Fig. H7
7 Reinstall Rear half of center console making
sure that the “Y” adapter leads are pointed
forward. (Fig. H9)
Fig. H8
8. Bring “Y” adapter lead forward and route
under “bridge “ in center console. (Fig. H10)
9. Attach “Y” adapter to main harness.
(Fig. H11)
10.Tie wrap excess wire as needed.
11 Reinstall center console insert
Fig. H9
Fig. H10
i. Attach switch leads . They are labeled to
indicate connection. (Fig. H12)
ii. Attach cup holder lead (Fig. H13)
iii Gently press insert into place
Fig. H11
M. Post Installation
1. Reinstall interior.
2. Re-attach negative battery terminal & torque
to 36 in. lbs.
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.
Fig. H12
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.
Page 8 of 9
Fig. H13
TOYOTA
Tundra C&D-Cab/Sequoia
Section III - Functional Verification
2005-06
Interior Light Upgrade
Check:
Look for:
___________________________________
___________________________________
Single Unoperational Module
Full engagement of affected LED module to
LED wire harness pigtail connector.
Light guide inserted incorrectly (wrong end)
No Operational Modules
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
center console)
Blown shift console illumination fuse (see
Operation of seat heaters (low & high operation)
Seat heater switches
Power mirror switches
10/25/04 • Draft Copy
Power operation of outside mirrors
Page 9 of 8 pages
Page 9 of 9
Tundra C & D-Cab/Sequoia Storage Box
TOP
Tundra C & D-Cab/Sequoia Storage Box
9/32”
9/32”
towards top
9/32”
Tundra C &D-Cab/Sequoia
Cup Holder
Should
touch
center
divider
towards top
9/32”
Should
touch
center
divider
Tundra C &D-Cab/Sequoia
Cup Holder
2 inches