2004-2005 Prius XM Radio Installation Instructions … Prius XM Radio Installation Instructions By...

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2004-2005 Prius XM Radio Installation Instructions

By

Eddie Bell

www.metrotpn.com

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Let me begin by saying this is an easy but time consuming job. Set aside a few hours of your time for the install. If you take your time, with the help of this guide you will be

rewarded with a tidy XM radio install.

I have spent a good bit of time on this guide. It is my first try at creating a pdf document so there may be some errors.

I offer this guide free of charge. All I ask in return is that if you find an error, please let me know. Also if you have additions that you feel may help someone else, let me know so that

I may make the changes.

Let’s get started.

What you will need:

10 mm socket

Socket wrench aka ratchet

Phillips head screwdriver (you know, the one that looks like this +)

Fish tape or coat hanger

A little patience

6716E–01

I40939

Multi–Display Assy

Instrument PanelRegister Assy No.4

Instrument PanelRegister Assy No.3

Radio ReceiverAssembly w/ Bracket

Instrument Cluster FinishPanel Assy Center

Radio Receiver Assy

Radio Bracket No.1

Stereo Opening Cover

Radio Bracket No.2

67–2–AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM

3801Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

COMPONENTS

710LL–01

B74067

Front Pillar Garnish LH

N·m (kgf·cm, ft·lbf) : Specified torque

Front Pillar Garnish RH

Instrument Panel Speaker Panel Sub–assy No.1 w/ CTR Speaker

Front Pillar Garnish Corner Piece RH

Front Pillar Garnish Corner Piece LH

Instrument Panel Register Assy No.2

Clock Assy

Multi–Display Assy

Instrument Panel Register Assy No.1

Instrument Panel Finish Panel Sub–assy Upper

Instrument Panel Register Assy No.3

Instrument Panel Register Assy No.4

Glove CompartmentDoor

Glove Compartment Door Stopper Sub–assy

Glove Compartment Door Assy

Instrument Panel Finish Panel Sub–assy Lower

20 (204, 15)

D

D

A

D

C

C

EE

w/ JBL Sound System:

Instrument Panel Cluster Finish Panel End

Instrument Panel Cushion

Instrument Panel Hole Cover

A

–INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER71–1

3884Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

INSTRUMENT PANEL/METERCOMPONENTS

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REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 Grasp at the very top and very bottom and pull towards you.The register is held on very tightly. A flat blade screwdriver wrapped in tape comes in handy.

710LN–01

B74072

ShapeCode ShapeCode ShapeCode

<A> <B> <C>

<E><D>

φ = 8(0.31)L = 20(0.79)

φ = 5(0.20)L = 16(0.63)

φ = 5(0.20)L = 14(0.55)

φ = 5(0.20)L = 18(0.71)

φ = 5(0.20)L = 14(0.55)

mm (in.) (L = Length)

B74044

2 Claws4 Clips

–INSTRUMENT PANEL/METER INSTRUMENT PANEL SUB–ASSY71–7

3890Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

INSTRUMENT PANEL SUB–ASSYREPLACEMENTHINT:� Installation is in the reverse order of removal.� COMPONENTS: SEE PAGE 71–1

1. TABLE OF BOLT, SCREW AND NUTHINT:All bolts, screws and nuts relevant to installing and removing the instrument panel are shown along with theiralphabet code in the table below.

2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60–1)

3. REMOVE INSTRUMENT PANEL REGISTER ASSYNO.1

(a) Disengage the 2 claws and the 4 clips and then removethe instrument panel register assy No.1.

4

REMOVE INSTRUMENT PANEL FINISH PANEL SUB–ASSY LOWER Remove the 2 screws.

B74045

4 Claws5 Clips

B74046

3 Claws4 Clips

B74047

Claw5 Clips

B740486 Clips

71–8–INSTRUMENT PANEL/METER INSTRUMENT PANEL SUB–ASSY

3891Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

4. REMOVE INSTRUMENT PANEL FINISH PANELSUB–ASSY LOWER

(a) Remove the 2 screws <E>.(b) Disconnect the hood lock control cable assy.(c) Disengage the 4 claws and the 5 clips.(d) Disconnect all connectors and then remove the instru-

ment panel finish panel sub–assy lower.

5. REMOVE INSTRUMENT PANEL FINISH PANELSUB–ASSY UPPER

(a) Disengage the 3 claws and the 4 clips.(b) Disconnect the connector and then remove the instru-

ment panel finish panel sub–assy upper.

6. REMOVE INSTRUMENT PANEL REGISTER ASSYNO.3

(a) Disengage the claw and the 5 clips.(b) Disconnect the connector and then remove the instru-

ment panel register assy No.3

7. REMOVE INSTRUMENT PANEL REGISTER ASSYNO.4

(a) Disengage the 6 clips and then remove the instrumentpanel register assy No.4.

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The panel is held on with the same clips as the ones for the register Grasp the panel and pop it loose.

Do the same here. You should have your technique down pat by now.

6

Let panel hang loose. REMOVE INSTRUMENT PANEL FINISH PANEL SUB–ASSY UPPER (a) Disengage the 3 claws and the 4 clips.

7

Do the same here. Remember that technique that you learned? What do you mean no.

Let this panel hang loose also.

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. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.3 (a) Disengage the claw and the 5 clips. (b) There is a small tab on the black connector. Disconnect the connector and then remove the instrument panel register assy No.3.

B74045

4 Claws5 Clips

B74046

3 Claws4 Clips

B74047

Claw5 Clips

B740486 Clips

71–8–INSTRUMENT PANEL/METER INSTRUMENT PANEL SUB–ASSY

3891Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

4. REMOVE INSTRUMENT PANEL FINISH PANELSUB–ASSY LOWER

(a) Remove the 2 screws <E>.(b) Disconnect the hood lock control cable assy.(c) Disengage the 4 claws and the 5 clips.(d) Disconnect all connectors and then remove the instru-

ment panel finish panel sub–assy lower.

5. REMOVE INSTRUMENT PANEL FINISH PANELSUB–ASSY UPPER

(a) Disengage the 3 claws and the 4 clips.(b) Disconnect the connector and then remove the instru-

ment panel finish panel sub–assy upper.

6. REMOVE INSTRUMENT PANEL REGISTER ASSYNO.3

(a) Disengage the claw and the 5 clips.(b) Disconnect the connector and then remove the instru-

ment panel register assy No.3

7. REMOVE INSTRUMENT PANEL REGISTER ASSYNO.4

(a) Disengage the 6 clips and then remove the instrumentpanel register assy No.4.

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REMOVE INSTRUMENT PANEL REGISTER ASSY NO.4 (a) Disengage the 6 clips and then remove the instrument panel register assy No.4. Might need that screwdriver again.

B74045

4 Claws5 Clips

B74046

3 Claws4 Clips

B74047

Claw5 Clips

B740486 Clips

71–8–INSTRUMENT PANEL/METER INSTRUMENT PANEL SUB–ASSY

3891Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

4. REMOVE INSTRUMENT PANEL FINISH PANELSUB–ASSY LOWER

(a) Remove the 2 screws <E>.(b) Disconnect the hood lock control cable assy.(c) Disengage the 4 claws and the 5 clips.(d) Disconnect all connectors and then remove the instru-

ment panel finish panel sub–assy lower.

5. REMOVE INSTRUMENT PANEL FINISH PANELSUB–ASSY UPPER

(a) Disengage the 3 claws and the 4 clips.(b) Disconnect the connector and then remove the instru-

ment panel finish panel sub–assy upper.

6. REMOVE INSTRUMENT PANEL REGISTER ASSYNO.3

(a) Disengage the claw and the 5 clips.(b) Disconnect the connector and then remove the instru-

ment panel register assy No.3

7. REMOVE INSTRUMENT PANEL REGISTER ASSYNO.4

(a) Disengage the 6 clips and then remove the instrumentpanel register assy No.4.

11

REMOVE INSTRUMENT PANEL REGISTER ASSY NO.2 (a) Disengage the 2 claws and the 4 clips, and then remove the instrument panel register assy No.2.

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REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (a)Remove the push in trim clip from the instrument panel finish panel lower center. Do like I did and get your fingers behind the panel and pull towards you. The clip will pop out. (b) Disengage the 4 claws and the 2 clips, and then remove the instrument panel finish panel lower center.

B740604 Clips

B74061

4 Claws2 Clips

B740626 Claws

B74063

71–14–INSTRUMENT PANEL/METER INSTRUMENT PANEL SUB–ASSY LOWER

3897Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

15. REMOVE INSTRUMENT CLUSTER FINISH PANELASSY CENTER

(a) Remove the 2 screws <B>.(b) Disengage the 4 clips and then remove the instrument

cluster finish panel assy center.

16. REMOVE CENTER CLUSTER CUSHION NO.117. REMOVE RADIO RECEIVER ASSY W/STEREO OPENING COVER (SEE PAGE 67–5)

18. REMOVE INSTRUMENT PANEL FINISH PANELLOWER CENTER

(a) Using a clip remover, remove the clip from the instrumentpanel finish panel lower center.

(b) Disengage the 4 claws and the 2 clips, and then removethe instrument panel finish panel lower center.

19. REMOVE GLOVE COMPARTMENT DOOR LOCKCOVER

(a) Disengage the 6 claws and then remove the glovecompartment door lock cover.

20. REMOVE GLOVE COMPARTMENT DOOR LOCKASSY

(a) Remove the 4 screws <B> and then the glove compart-ment door lock assy.

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Unplug connector. Put panel aside.

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REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (a) Remove the 2 screws. (b) Disengage the 4 clips and then remove the instrument cluster finish panel assy center.

B740604 Clips

B74061

4 Claws2 Clips

B740626 Claws

B74063

71–14–INSTRUMENT PANEL/METER INSTRUMENT PANEL SUB–ASSY LOWER

3897Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

15. REMOVE INSTRUMENT CLUSTER FINISH PANELASSY CENTER

(a) Remove the 2 screws <B>.(b) Disengage the 4 clips and then remove the instrument

cluster finish panel assy center.

16. REMOVE CENTER CLUSTER CUSHION NO.117. REMOVE RADIO RECEIVER ASSY W/STEREO OPENING COVER (SEE PAGE 67–5)

18. REMOVE INSTRUMENT PANEL FINISH PANELLOWER CENTER

(a) Using a clip remover, remove the clip from the instrumentpanel finish panel lower center.

(b) Disengage the 4 claws and the 2 clips, and then removethe instrument panel finish panel lower center.

19. REMOVE GLOVE COMPARTMENT DOOR LOCKCOVER

(a) Disengage the 6 claws and then remove the glovecompartment door lock cover.

20. REMOVE GLOVE COMPARTMENT DOOR LOCKASSY

(a) Remove the 4 screws <B> and then the glove compart-ment door lock assy.

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REMOVE MULTI–DISPLAY ASSY

(a) Remove the 2 bolts.

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It is not necessary to disconnect the cables to the multi display. It can sit off to the side of the dash. If you feel more comfortable, you can remove the cables to facilitate removing the display from the car.

17

Remove radio assembly. Remove the 4 screws.

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Grasp radio with both hands and pull it out of the dash.

19

Unplug antenna cable and the remaining connectors then remove the radio.

20

Remove instrument panel finish panel lower, right scuff plate and right cowl side trim.

7616H–02

B73586Clip

Claw AClaw B

Claw A

Clip

Claw B

Claw A

B73588Claw

Clip

76–28–EXTERIOR/INTERIOR TRIM ROOF HEADLINING ASSY

3987Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

REPLACEMENTHINT:� The installation procedures are the removal procedures in reverse order. However, only installation

procedures requiring additional information are included.� A bolt without a torque specification is shown in the standard bolt chart (see page 03–2).

1. REMOVE FRONT DOOR SCUFF PLATE LH(a) Using a screwdriver, disengage the 6 claws labeled A, 2

claws labeled B, and 2 clips. Then remove the scuff plate.HINT:Tape the screwdriver tip before use.

2. REMOVE FRONT DOOR SCUFF PLATE RHHINT:Use the same procedures described for the LH side.

3. REMOVE COWL SIDE TRIM BOARD LH(a) Using a screwdriver, disengage the claw and 2 clips, and

remove the trim board.HINT:Tape the screwdriver tip before use.

4. REMOVE COWL SIDE TRIM BOARD RHHINT:Use the same procedures described for the LH side.5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH6. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH

7616H–02

B73586Clip

Claw AClaw B

Claw A

Clip

Claw B

Claw A

B73588Claw

Clip

76–28–EXTERIOR/INTERIOR TRIM ROOF HEADLINING ASSY

3987Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

REPLACEMENTHINT:� The installation procedures are the removal procedures in reverse order. However, only installation

procedures requiring additional information are included.� A bolt without a torque specification is shown in the standard bolt chart (see page 03–2).

1. REMOVE FRONT DOOR SCUFF PLATE LH(a) Using a screwdriver, disengage the 6 claws labeled A, 2

claws labeled B, and 2 clips. Then remove the scuff plate.HINT:Tape the screwdriver tip before use.

2. REMOVE FRONT DOOR SCUFF PLATE RHHINT:Use the same procedures described for the LH side.

3. REMOVE COWL SIDE TRIM BOARD LH(a) Using a screwdriver, disengage the claw and 2 clips, and

remove the trim board.HINT:Tape the screwdriver tip before use.

4. REMOVE COWL SIDE TRIM BOARD RHHINT:Use the same procedures described for the LH side.5. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH6. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH

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Take the cable from the XM radio kit foam side first and feed it behind the dash.

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Feed the cable out of the register hole. You really only need to pull enough cable to make it to the radio assembly.

23

Feed the cable behind the glove box.

Open and lower the glove box, to make sure of cable placement.

24

Bring the cable out by the radio.

25

Make sure to run the XM radio cable under this bundle of wires.

Leave enough cable to plug into the radio then tie the XM cable off with oneof the zip ties located in the XM radio kit.

26

There is a special cable tie in the kit. It has sticky tape attached to it. Put the XM cable into the tie then stick the tie to the inside of the dash by register No.4.

Be sure the cable is pulled taught. What we are trying to do is have the cable not interfere with the glove box door. Be sure to check it’s operation and make adjustments to the cable as needed.

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Plug the XM Radio cable into the radio. Reinstall the radio, center dash, multi display. Reinstall all dash panels and registers. Reassemble everything except the RH cowl panel and the RH front sill plate. Take a quick break. Stretch your legs, have a drink. Water, beer or whatever. If it’s beer, have only one. Take your XM radio unit from the box and plug the XM cable into it. Take the antenna from the kit and plug it into the XM unit. You can temporarily place the antenna on the dash.Turn on the factory radio. Press the AM button on your radio until you see SAT 1.Tune to channel one which should show your XM radio ID. Jot down the ID. You will needt his to set up your subscription once your installis complete. Once that is done, you can browse the preview channels that are available.Don't sit there too long, you have work to do Remove the right rear sill plate.

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Pull the weatherstrip away from both sides of the B pillar panel(You know, that plastic panel between the front and rear doors).

7616G–02

B73602

Front Door Scuff Plate LH

Front Door Scuff Plate RH

Cowl Side Trim Board LH

Cowl Side Trim Board RH

Front Door Opening Trim Weatherstrip LH

Front Door Opening Trim Weatherstrip RH

Front Pillar Garnish Corner Piece LH

Front Pillar Garnish Corner Piece RH

Front Pillar Garnish LH

Front Pillar Garnish RH

Rear Door Scuff Plate LH

Rear Door Scuff Plate RH

Rear Door Opening Trim Weatherstrip LH

Rear Door Opening Trim Weatherstrip RH

Center Pillar Garnish Lower LH

Deck Trim Side Panel Assy LH

Deck Trim Side Panel Assy RH

Roof Side Garnish Assy Inner LH

Roof Side Garnish Assy Inner RH

Center Pillar (B) Garnish Lower RH

Center Pillar Garnish LH

Center Pillar Garnish RH

Front Seat Outer Belt Assy RH

Front Seat Outer Belt Assy LH

Lap Belt Outer Anchor Cover

Lap Belt Outer Anchor Cover

42 (430, 31)

42 (430, 31)

N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque

Rear Seat Belt Assy LH

Rear Seat BeltAssy RH

42 (430, 31)

42 (430, 31)

–EXTERIOR/INTERIOR TRIM ROOF HEADLINING ASSY76–25

3984Author�: Date�:

2005 PRIUS REPAIR MANUAL (RM1130U)

ROOF HEADLINING ASSYCOMPONENTS

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Pull the B pillar panel away from the B pillar.

30

Route the XM cable behind the B pillar panel.

31

Pull the cable out the otherside.

32

Here you will see that the rear seat is removed. It is not absolutely necessary but it is so easy to do and makes the install a little easier. The front of the rear seat pops into these plastic clips.

Grasps the lower front of the seat and with a quick snatching motion, pull the seat up and out of the clips.

33

Once the clips are disengaged, pull the seat forward and remove it from the car.

34

Fold down right rear seat. Remove cargo cover, spare tire cover and cargo tray. Peel back carpet (velcroed to seat back).

Pull carpet away from the rear quarter panel. It will pop back into place perfectly when we are done. 35

Remove right rear floor board panel. Remove upper panel.

Pull carpet away from the rear quarter panel. It will pop back into place perfectly when we are done.

36

Remove clip from carpeting located just behind the right rear seat.

37

Feed the XM radio cable up behind the folded rear seat on the outside of the seat belt.

38

Route the cable under the carpet and along the right quarter panel. A coat hanger or fish tape might come in handy here.

Pull the carpet liner out at the bottom, it's easier to see where the cable is being routed.

39

Pull the cable out through the hole in the carpet where the upper panel came from.

Take the XM radio unit and attach the duo lock tape from the kit to it. Plug the cable into the unit then mount the unit to the right quarter panel.

40

Make sure your plugs are facing down and not up when mounting. Find the flattest surface possible. There is a prime spot just above and ahead of the battery.

The duo-lock and XM unit will be going on the back of the exterior sheet metal (rear quarter).

41

Remove this bolt. Pull panel back slightly.

Take the XM radio antenna from the box. There is a black plastic sheathing tape to the antenna wire. Carefully remove the tape from both ends. Allow the sheathing to move freely on the antenna wire. You can remove the sheathing completely if you choose but it is not necessary.

42

Take the template for mounting the antenna out of the kit. Line the template upon the roof and mount the antenna. The antenna has double sided tape as well as a magnet to mount it. We choose not to permanently mount the antenna. If it ever needs to be replaced, it would be very difficult to remove it from the car. It’s up to you to decide.

43

Remove the backing from the tape on the antenna wire and stick it to the car. Be sure the area is clean.

44

Route antenna wire over the top of the hatch weather stripping. Make sure the sheathing is not in the way if you chose not to completely remove it.

Route the antenna wire behind the right finish panel. Plug the antenna into the XM radio unit. Test the XM radio operation once again.

Dress up your wiring and refit the panel.

45

Refit all of your panels. Replace the carpeting, cargo and spare tire covers. Replace the sill plates and any other items removed.

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And we are done!!!

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This Prius installation is my interpretation. It is by no means the only way to do the installation. I have presented this as a guide so that others may learn from it. If you feel there are errors or that additions need to be made, please contact me.