TOYOTA MOTOR EUROPE CA Products Division Tel : Fax :

Transcription

1 TOYOTA MOTOR EUROPE CA Products Division Tel : Fax :

2 Ordering part numbers Comments Part Numbers Wooden floor one hatch PZ449-D3C42-11 one hatch with carpet PZ449-D3C42-01 one hatch with rubber mat PZ449-D3C42-21 double hatch PZ449-D3C41-11 double hatch with carpet PZ449-D3C41-01 double hatch with rubber mat PZ449-D3C41-21 No hatches with rubber mat PZ449-D3C41-31 Lower separator space saver no carpet PZ449-D3C41-12 space saver one side carpet PZ449-D3C41-02 space saver two side carpet PZ449-D3C41-22 normal wheel no carpet normal wheel one side carpet normal wheel two side carpet PZ449-D3C42-12 PZ449-D3C42-02 PZ449-D3C42-22 Closed separator no carpet PZ449-D3C43-10 front side carpet PZ449-D3C43-00 both sides carpet PZ449-D3C43-20 Mesh separator PZ449-D3C44-00 Spare wheel cover no carpet PZ449-D3-C42-13 carpet PZ449-D3-C42-03 Side panels Rear door left PZ449-D3-C45-01 Rear door right PZ449-D3-C45-02 Rear panel left PZ449-D3-C45-03 Rear panel right PZ449-D3-C45-04 Rear door protection PZ449-D3-C45-05 CONTENTS OF THIS MANUAL Lower Separator Pages 4-6 Wooden Floor Pages 6-9 Wire Mesh / Full Separator Pages 9-10 Safety Pack Pages 10-13

3 Materials & tools required. Standard workshop hand tools Window removal wire cutter Real of strong masking tape 3 Racket straps 2 tubes of SIKAFLEX: 252, + a suitable cleaner.

4 LOWER SEPERATOR Side fixation points. Assemble the M8*65mmbolt / M8 washer & 45mm tube spacer as shown. Screw in the bolt finger tight into the bottom of the B pillar. Assembling the lower separator. Using a pop rivet gun & the supplied rivets assemble the two outer supports to the lower separator. There are 3 pop rivets each side. 2 Placing the lower separator into the vehicle Lift the assembled lower separator into the vehicle. Ensure that the slot fits behind the head of the bolt & washer Finger tighten bolt finger tight

5 LOWER SEPERATOR Securing the middle of the lower separator to the vehicle. Attach the middle support as shown. Fix the middle support securely in place with the M6 nut & bolt. Insert the 80mm long bolt on the reverse side of the lower separator. Use the M6 self locking nut to hold in place. 3. Attaching the side supports to the vehicle. Use the self taping bolts to hold the side supports in place. M8 * 25mm

6 WOODEN FLOOR Positioning of the wooden spacers. Place the wooden strip & the two small square spacers 40*40mm as shown. Remove the backing tape from them. Peal the backing tape off the metal frame. Attaching middle fixation eyes. Assemble the fixation eye with the bolt & the nylon washer Attach the fixation eye into the location of the lower point of the rear seat belt. Temporarily hold the eye out against the plastic trim with tape.

7 WOODEN FLOOR Placing the wooden floor. Angle the wooden floor & carefully slide it in through the rear door. Ensure that the floor is right in the corners before sticking it down. 3. Press firmly around the edges Remove the tape holding the fixation eye to the side panel. If carpet is fitted to the lower separator. 5. NB - ONLY if a wire mesh or full separator is going to be fitted & carpet is fitted to the lower separator drill through it in the five marked locations.

8 WIRE MESH / FULL SEPARATOR Cut out in head lining Follow the instructions on the enclosed A3 paper template for making the necessary holes for the wire mesh / full separator in the head lining. Peal the backing off the rectangular metal blocks 3. Take the 20mm tube + a M6 washer & slide it over the 65mm long M6 bolt Thread the bolt into the metal block with the sticky side towards the bolt head.

9 WIRE MESH / FULL SEPARATOR Attaching the L brackets. Holding the head of the bold guide the block to the most forward position through the hole in the head lining.. Pull the bolt head towards you so that the tape makes the metal block stick to the body of the car. Remove the bolt & place the spacer tube between the L shape bracket. Tighten finger tight 3. Position the separator on top of the lower separator Align the 6mm dia hole in the L bracket with the hole in the wire mesh or full separator. 5. Using the pop rivet gun attach the parts together 6. Tighten the top bolts on either side. 7. Press the black cover cap over the head of the bolt

10 WIRE MESH / FULL SEPARATOR Bottom fixation. Attach the lower separator to the bottom of the wire mesh / full separator with the 5 pop rivets supplied 3. SAFETY PACK Vehicle preparations for the side panels. Remove the rear interior panels from both sides. Remove the rear light cluster from both sides. Removal of black exterior door strip. When the glue becomes soft peal the strip off. Carefully heat the plastic black strip on the door with a hot air gun.

11 SAFETY PACK Removal of the rear side window. Using a wire cutter remove the rear side windows. Place protective tape around the edges of the rear window. 3. Cut the remaining excess glue off. Clean the window frame with Heptane. Glue the six rubber blocks, to ensure that the blanking panels are glued at the correct distance away from the frame. 5.

12 SAFETY PACK Sticking the blanking side panels Apply a thick bead of glue to the outer frame of the rear side window. Place the painted side panel onto the frame ridge. Hold the panel against the vehicle with strong tape. Allow to dry for 5 hours 3. Cut the outer rubber joint off around the two rear door windows to expose the ridge around the frame.. Apply a thick bead of glue to the ridge around the frame of the rear doors. Hold the panels in place using straps around the doors for a period of 5 hours

13 SAFETY PACK Placing of the rear privacy screen. Make sure the glass in the rear window is clean. Then centrally align the screen against the rear window. Using a center punch mark the center point of the provisional holes along the top & bottom. Drill a 2mm diameter hole in each of the fixation points. 3. Attach the screen to the frame of the rear door using the small self tapping screws supplied.