all models with accessory bull bar additional service

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Accessory Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

All Models with Accessory Bull Bar

Additional Service Requirement – Severe Conditions

Many new Toyota vehicles are fitted with Toyota Genuine Accessory Bull Bars and on occasions these ve-hicles are operated in severe operating conditions such as rough / corrugated roads either frequently or typically during four wheel drive holidays or similar. Maintenance for severe operating conditions for vehicles that are used in these conditions requires inspec-tion of chassis / under body mounting bolts. Inspection of the Bull Bar mounting bolts and brackets will now form part of the severe maintenance inspec-tion.

Note: Owners that operate their vehicles in any rough road conditions should confirm that a severe mainte-nance schedule is adopted and inspection of the Bull Bar mounting bolts and brackets be conducted by the servicing Dealer.

Typical Bull Bar Mounting Configuration

Inspection

During severe maintenance inspection interval if vehicle is fitted with an accessory Bull Bar

Inspect mounting bolts for Crash Boxes and Wing Braces for looseness or signs of movement.

Inspect Bull Bar brackets and braces for integrity, damage or looseness.

Wing Braces

Crash Boxes

( PZQ2989417 SHOWN )

Packer Mount Wing

Brace

Wing Brace bolts to be inspected

Crash Box bolts to be inspected

Braces and Bull Bar brackets to be in-

spected

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Please read these instructions carefully before installation, paying special attention to all Notice & Caution notes. Failure to do so may result in damaged parts or injury to the installer or customer.

IMPORTANT

Place these instructions in vehicle’s glove box after installation is complete.

Installation Time: 3 hrs

Accessory Part Nos.: PZQ29-89303 (Pick Up) PZQ29-89308 (Pick Up) Fog PZQ29-89313 (Pick Up) PZQ29-89317 (SUV) Fog PZQ29-89322 (SUV) Fog PZQ29-89347 (SUV) Fog PZQ29-89510 (Pick Up) PZQ29-89403 (Pick Up) PZQ29-89408 (Pick Up) Fog PZQ29-89413 (Pick Up) PZQ29-89417 (SUV) Fog PZQ29-89422 (SUV) Fog PZQ29-89447 (SUV) Fog PZQ29-89520 (Pick Up)

Toyota Hilux/Fortuner Hilux Narrow and Workmate Wide - July 2015 Production Onwards

Fortuner - August 2015 Production Onwards Hilux Rogue - December 2017 Production Onwards

Hilux SR Wide and SR5 Wide - June 2018 Production Onwards Alloy Bull Bar (SRS Compatible)

IMPORTANT If installing antenna (PZQ2900020), refer to relevant fitting instructions.

Win

ch

C

om

patible

N

on

– w

inch

Com

patible

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17-23mm UPPER PAN TO BUMPER

TOOLS REQUIRED

CARE INSTRUCTIONS

To maintain your bar, wash regularly using a neutral pH car wash detergent, hose off and chamois dry. Stubborn grime can be removed with kerosene. Do not use acidic or alka-line cleaners.

Polished surfaces can be maintained with Autosol® metal polish or similar.

Plastic components can be maintained with Nulon Ezi-Glide® silicon spray or similar.

A Torque Wrench must be used where specified and correct sequence must be followed.

CAUTION

Do not attach the VFPS to the vehicle using anchorages not intended for this purpose (e.g. engine mounting bolts).

Do not use this product for any vehicle make or model, other than those specified by the Vehicle Frontal Protection System manufacturer.

Do not remove the compliance plaque from the Vehicle Frontal Protection System.

Do not modify the structure of the Vehicle Frontal Protection System in any way.

Plastic Trim Removal Tool Kit 1/2” Torque Wrench Spade Drill/Hole Saw 22mm

Multi Tool Cutter 1/2” Socket Set Torque Screw Driver

Scribe/Marker Pen Ring/Open End Spanners Torx Key Bit Set

Masking Tape 70mm Allen Keys/Bits Deburring Tool

Side Cutters Gap Gauge Tape PVC

File Bumper Stand Power Drill & Drill Bit Set

Phillips Screwdriver Set 1/2” Ratchet Bumper Stand

Super Glue Centre Punch Sikaflex 221 or equivalent

Hole Saw 30-35mm

CAUTION—It is extremely important that bolts are tightened to the correct tor-ques in the correct sequence (refer to lettering in the layout diagram). Check that all bolts are fully torqued as per the fitment instructions.

For Pick Up Narrow, Wide Workmate and SUV only. For Pick Up Rogue, SR Wide and SR5 Wide Only.

25-30mm UPPER PAN

27-33mm UPPER PAN

23-30mm WING TO BUMPER

10-16mm WING TO BUMPER

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TYPICAL MOUNTING CONFIGURATION

View A (Bull bar not shown)

View A

View B

LEGEND

- Torque Nm

(e) 77 Nm 2x M12 flange bolts

(d) 70 Nm 4 x M10 flange nuts

Wing Braces

(e) 70 Nm 1x M10 flange bolt

View B (Bull bar not shown)

(a) 77 Nm 2x M12 flange bolts

Crash Box

(c) 70 Nm M10 flange nuts

Bolt Sequence: 1. Finger tighten

all bolts. 2. Tighten inner 4

diagonally. 3. Tighten outer

bolts.

(b) 70 Nm 6 x M10 flange bolts/screws

(b) 70 Nm M10 flange nut

View C

View C

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LAYOUT NON WINCH

LEGEND - Item 1

34

32

43

44

27

29

30

28

41

42

25

26

14

15

49

50

48

47

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LAYOUT WINCH

50

47

49

14

26

28

44

32

30

29

25

33

27

13

4

43

LEGEND - Item

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Parts List Important: Check contents of kit before commencing fitment and report any discrepancies.

Bull Bar Assembly

Item Component Name Part Number Qty

1 Alloy Winch Bull Bar Pickup Narrow PZQ2989303 1

2 Alloy Winch Bull Bar Pickup Workmate Wide PZQ2989308 1

3 Alloy Winch Bull Bar Pickup SR5 Wide with Fog Lamps PZQ2989313 1

4 Alloy Winch Bull Bar Fortuner GX PZQ2989317 1

5 Alloy Winch Bull Bar Fortuner Crusade with Fog Lamps PZQ2989322 1

6 Alloy Winch Bull Bar Fortuner GXL with Fog Lamps PZQ2989347 1

7 Alloy Bull Bar Pickup Narrow PZQ2989403 1

8 Alloy Bull Bar Pickup Workmate Wide PZQ2989408 1

9 Alloy Bull Bar Pickup SR5 Wide with Fog Lamps PZQ2989413 1

10 Alloy Bull Bar Fortuner GX PZQ2989417 1

11 Alloy Bull Bar Fortuner Crusade with Fog Lamps PZQ2989422 1

12 Alloy Bull Bar Fortuner GXL with Fog Lamps PZQ2989447 1

132 Alloy Winch Bull Bar Pickup SR Wide with Fog Lamps PZQ2989510 1

133 Alloy Bull Bar Pickup SR Wide with Fog Lamps PZQ2989520 1



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ITEM Component Name Component QTY Nm

PZQ29893BE

28 CHASSIS GUSSET OUTBOARD LH

Gusset Assem-bly Left

1

30 CHASSIS GUSSET INBOARD LH 1

31 CHASSIS GUSSET IN CHASSIS NUT PLATE 1

59 PLATE INNER GUSSET 2mm 1


64 BOLT FLANGE HEX HEAD M12 X 1.25P X 35 2 77

66 WASHER FLAT M12 X 26 X 4 2

68 BOLT FLANGE HEX HEAD M10 X 1.25P X 40 BLACK 1 70


74 NUT FLANGE HEX HEAD M10 X 1.25P 2 70

27 CHASSIS GUSSET OUTBOARD RH

Gusset Assem-bly Right

1

29 CHASSIS GUSSET INBOARD RH 1

31 CHASSIS GUSSET IN CHASSIS NUT PLATE 1








Non-winch Only

Winch Only

Pick Up - Wide Only

SUV Only

Wide & SUV Only

Fog Lamp Models Only

SUV Fog Lamp Models Only

SR Wide and SR5 Wide Only

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PZQ29893BJ

32 BULL BAR WING BRACE REAR (LEFT)

Bull Bar Wing Brace Set

1

134 BULL BAR WING BRACE REAR (RIGHT) 1

57 PLATE GUSSET OUTER 2mm 2

58 PLATE GUSSET OUTER 1mm 2



69 SCREW FLANGE HEX HEAD M10 X 1.25P X 40 SILVER 6 70


74 NUT FLANGE HEX HEAD M10 X 1.25P 6

84 NUT U M6 X 1.0P 6

Non-winch Only

Winch Only

Pick Up - Wide Only

SUV Only

Wide & SUV Only




72

64

85 85

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PZQ29893FA

46 BRACKET STONE TRAY Bracket Stone

Tray 1

PZQ29893BN

25 CRASH BOX RH

Crash Box Assembly

1

26 CRASH BOX LH 1

41 PACKER MOUNT BRACE WING RH 1

42 PACKER MOUNT BRACE WING LH 1

54 PACKER MOUNT 5mm 2



61 PLATE SHIM CHASSIS DOUBLE CRADLE 2

62 PLATE SHIM CHASSIS SINGLE CRADLE 2





103 CANOE CLIP 8

PZQ9389030

33 WINCH MOUNTING KIT 1

PZQ29893DF/3DH/3DO/3DU

35 HARNESS WIRING PATCH 1

35

Non-winch Only

Winch Only

Pick Up - Wide Only

SUV Only

Wide & SUV Only




33

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PZQ29893BA

44 BRACE WING FRONT LH

Brace Wing Left

1




43 BRACE WING FRONT RH

Brace Wing Right

1




PZQ29893FB

75 SCREW BUTTON HEAD TORX M8 X 1.25P X 25

Panel Stone Front and

Rear

3 22


78 SPACER M8 X 19 X 10 2

79 NUT U M8 X 1.25P 3

80 SCREW BUTTON HEAD TORX M6 X 1.0P X 25 SILVER 3 9

82 WASHER FLAT M6 X 16 X 1.2 3

84 NUT U M6 X 1.0P 3

98 SCREW HEX HEAD M8 X 1.25P X 30 2 22

47 PANEL STONE FRONT 1

126 SCREW BUTTON HEAD TORX M8 X 1.25P X 20 3 22

48 PANEL STONE REAR 1

PZQ29893AN

14 CAP END RH

End Caps

1

15 CAP END LH 1

104 CLIP U 6mm PINCH 13mm LONG 2

105 CLIP PLASTIC 24.9 X 20 6

106 CLIP XMAS TREE 2

Non-winch Only

Winch Only

Pick Up - Wide Only

SUV Only

Wide & SUV Only




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PZQ29893FF

50 PANEL UNDER LH

Panel Under LH

1


81 SCREW BUTTON HEAD TORX M6 X 1.0P X 25 BLACK 3 9



84 NUT U M6 X 1.0P 4

PZQ29893FK

49 PANEL UNDER RH

Panel Under RH

1





84 NUT U M6 X 1.0P 4

Non-winch Only

Winch Only

Pick Up - Wide Only

SUV Only

Wide & SUV Only




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Non-winch Only

Winch Only

Pick Up - Wide Only

SUV Only

Wide & SUV Only





PZQ29893FJ

51 BRACKET PANEL UNDER RH SUPPORT 1

Bracket Panel





84 NUT U M6 X 1.0P 1


PZQ29893HE

94 SCREW SELF TAPPING PHILLIPS HEAD 5.2 X 16 Fog Lamp 8 2

PZQ8589051

128 HARNESS EXTENSION FOG LAMP Fog Lamp 2

MISC

108 CABLE TIE 4.8 X 200 15

127 CABLE TIE 4.8 X 370 2

107 PIPE CLIP 1

86 SCREW HEX HEAD M5 X 0.8P X 20

Registration Plate

2

88 NUT NYLOC M5 X 0.8P 2

94 SCREW SELF TAPPING PHILLIPS HEAD 5.2 X 16 2 2

95 GROMMET ROUND 2

96 SCREW WAFER HEAD 10-32 SELF DRILLING 2 2

96 SCREW WAFER HEAD 10-32 SELF DRILLING 2 2

97 NUT U #10 2

130 PINCH WELD 88mm 2

125 PINCH WELD 412mm 2

129 TEMPLATES BUMPER CUT 1

130 CAP GRILLE RH 1

131 CAP GRILLE LH 1

NOTE: RHS Fog lamp brackets shown for clarity of

screw locations only, LHS opposite

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Step 1: Note down all clock and radio settings.

Disconnect –ve terminal from the battery.

Figure 1: Disconnect battery

Figure 2: Remove Registration plate

Figure 3: Remove push clips & cover

Step 2: Remove 2 x Phillips Head Screws that attach registration plate

to bumper.

Retain registration plate and discard screws.

Step 3: Using a trim removal tool, remove 8 x Push In Clips that se-

cure plastic radiator cover and retain,

Remove plastic radiator cover and retain

NOTE:

Refer to the TOYOTA “Repair Manual for Chas-sis & Body” for the Hilux/Fortuner and associ-ated Service Bulletins for the correct proce-

dure.

NOTE: For safety, wrap –ve battery terminal with insu-

lating PVC tape.

NOTE: Always refer to vehicle’s Workshop Manual

when removing vehicle components.

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Step 4: Remove and retain 2 x Phillips hex screws (A) , one from each

side of grille and 2 x hex screws (B) which attach each grille bracket to the radiator support panel.

Pick-up Narrow and Workmate Wide:

Carefully remove & retain grille by unclipping at 6-off positions along bottom edge.

Pick-up SR Wide and SR5 Wide:

Carefully remove & retain grille by unclipping at 6-off positions

along bottom edge, and 2-off positions on each side SUV:

Carefully remove & retain grille by unclipping at 6-off positions

along bottom edge & rear of chrome trim, 3-off per side .

Figure 4: Remove grille

Figure 5: Remove surround from grille

Step 5: Disassemble surround from grille by removing 11 x Phillips

head screws and unclipping at 10-off positions

Retain all components

B B

A A

TIP: Place surround and grille on bumper stand

ready for marking out for trimming.

NOTE:

Step 5 for Rogue, SR Wide and SR5 Wide

Models Only.

clip

screw

Figure 6: Remove upper absorber clips

Step 6: Using trim removal tool, remove 2 x Push Clips which attach

the upper absorber to the plastic grille within bumper and dis-card.

Remove and discard upper absorber.

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Figure 7: Remove bumper screws

Step 7: Remove & retain 2 x long screws from each side and 1 x short

screw in the centre which secure the bumper to the vehicle.

Step 8: Pick-up Only

Remove 1 x 1/4 turn fastener, 1 x Trim Clip and 1 x Scrivet

from bumper. Repeat for other side.

RH Shown

Trim Clip

Quarter turn fastener


Step 9: SUV Only

Remove 1 x 1/4 turn fastener and 1 x Phillips hex screw from

bumper. Repeat for other side.

Retain Philips screw and discard 1/4 turn fastener.

Quarter turn fastener

Phillips Head

Scrivet

Figure 8: Remove bumper trim clip & screw

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Step 10: Remove 3 x Phillips hex screws from each side and 3 x hex

screws in the centre which attach bumper to fender liners and under tray & discard.

RH Shown

Up

NOTE: Step 12 for Fog Lamp Models Only.

Figure 12: Unclip fog lamp

Step 12: Disconnect the fog lamps by unclipping the connectors from

the rear.

Catch Release Button

Figure 11: Remove & discard under panel

Step 11: Remove 5 x trim clips, 2 per side and one in the centre and 2

x hex screws, one per side that secure the plastic under pan-el and discard all items.

RH Shown

NOTE: Image shown with bumper removed for clarity.

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Figure 13: Remove & retain bumper

Step 13: Unclip bumper from clipping points each side of vehicle.

With the aid of an assistant , carefully remove bumper and

place on a clean non abrasive surface or bumper stand.

NOTE: First apply masking tape to fender adjacent to

the bumper edge on both sides.

TIP: Place bumper on bumper stand ready for mark-

ing out for trimming.

Figure 14: Remove of Flarette

Step 14: SUV Only

Remove 4 x Trim Clip and carefully remove Flarette.

Retain 1 x Trim Clip and Flarette, discard remaining 3 x Trim Clip.

Repeat for LH.

Trim Clip

Trim Clip

Trim Clip

Trim Clip

Figure 15: Remove & discard upper absorber

Step 15: Remove 3 x hex screws & clip that attach upper absorber to

vehicle.

Remove upper absorber and discard along with fasteners.

RH Shown

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Figure 16: Tape up sharp edges

Step 16:

WARNING: Tape up sharp edges to avoid injury.

Figure 17: Remove & retain upper air deflectors

Step 17: Remove 1 x RH and 1 x LH upper air deflectors as shown and

retain for trimming at steps 23 - 26.

Figure 18: Remove lower absorber & discard

Step 18: Remove lower absorber and discard.

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Figure 19: Remove & discard lower air deflectors

Step 19: Remove 2 x lower air deflectors behind bumper reinforcement,

by unclipping at 2-off locations each & discard.

Figure 20: Remove and discard bumper reinforce-ment beam

Step 20: Remove 2 x M10x1.25 screws on each side that secure bump-

er reinforcement beam and discard.

Figure 21: Remove 2 x M8 screws

Step 21: Remove 2 x M8 screws that secure stone guard to chassis &

discard.

NOTE: For Non-winch fitment only.

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Step 22: Remove 3 x Phillips screws that mount fog lamp assemblies to

plastic bumper.

Discard fasteners and retain fog lamp assemblies.

Repeat for LH.

Figure 22: Remove and retain fog lamp assem-blies

NOTE: Step 22 for Fog Lamp models only.

RH Shown

Screw Screw Screw

Screw

Figure 23: Trim RH upper air deflector

Step 23: Drill Ø22mm first.

Trim RH upper air deflector according to the appropriate cut-

ting guide.

Drill 1 x Ø7.0mm hole at location shown.

NOTE: Ensure to reference the correct cutting guide drawing for the applicable vehicle for step 23.

Templates at rear of fitting instructions.

RH Pick-Up Narrow/Workmate Wide shown

WARNING: Drilling operations can result in flying de-bris, safety glasses should be worn. Work

safely; keep fingers clear of cutting blade.

Figure 24: Trim LH upper air deflector

Step 24: Trim LH air deflector as shown according to dimensions

shown at left.

RH Pick-Up Narrow/Workmate Wide shown

NOTE: Ensure to reference the correct cutting guide

drawing for the applicable vehicle for step 24.

WARNING: Cutting and drilling operations can result in flying debris, safety glasses should be worn. Work safely; keep fingers clear of

cutting blade.

NOTE: Steps 23 - 24 for Pick Up Only

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Figure 25: Trim RH upper air deflector

Step 25: Drill Ø22mm first.

Trim RH upper air deflector according to the appropriate cut-

ting guide.

Drill 1 x Ø 7.0mm hole at location shown.


drawing for the applicable vehicle for step 25

RH SUV shown


cutting blade.

NOTE: Steps 25-26 for SUV models only.


Step 26: Trim LH air deflector as shown according to dimensions

shown at left.

LH SUV shown


drawing for the applicable vehicle for step 26.


cutting blade.

Step 27: For Diesel Models Only

Reinstall trimmed RH air upper deflector as shown.

Add cable tie 4.8 x 370 (Item 127) to secure at base around intercooler support leg.

Figure 27: Reinstall RH upper air deflector

Cable tie

NOTE: Steps 27-28 for diesel models only.

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Figure 28: Reinstall LH upper air deflector

Step 28: For Diesel Models Only

Reinstall trimmed LH upper air deflector as shown.

Use cable tie 4.8 x 370 (Item 127) to secure at base around intercooler support leg.

Cable tie


Step 29: For Petrol Models Only

Reinstall trimmed RH air upper deflector as shown.

Add cable tie 4.8 x 370 (Item 127) to secure at base around radiator support panel hole.

NOTE: Steps 29-30 for petrol models only.

Figure 30: Reinstall RH upper air deflector

Step 30 For Petrol Models Only

Reinstall trimmed LH upper air deflector as shown.

Add cable tie 4.8 x 370 (Item 127) to secure at base around radiator support panel hole.

Cable tie

Cable tie

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Figure 31: Cut out bumper templates

Step 31: Cut the A3 paper templates for the applicable vehicle model.

NOTE:

Ensure to reference the bumper cutting tem-plate drawing for the applicable vehicle for

step 31.

NOTE:

Mark centres for drilling using template posi-tion then use a sharp tool e.g. centre punch or

podger to indent position in plastic.

NOTE:

On each cutting instruction sheet there is a scale to confirm that the template is printed at 1:1 scale, confirm the scale before proceed-

ing.

NOTE: Be careful not to cut circles on template which

are to be drilled.

NOTE: NOTE: Do not tape along lower cutting edge.

Figure 32: Locate RHS outer template

Step 32: Use the Right Pick Up Narrow Outer Template and tape in

position as shown.

NOTE: Step 32-36 on template positioning for Pick Up

Narrow.

Figure 33: Locate RHS inner template

Step 33: Use the Right Pick Up Narrow Inner Template and tape in

position as shown.

NOTE: Follow instructions on template for position-

ing.

Inner template

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Figure 34: Mark out cutting lines

Step 34: Use a marker pen to mark out the cutting lines indicated by

the templates

Marker Pen

Cutting line

Figure 35: Connect cut lines between templates

Step 35: Use a marker pen to mark out points between the cut lines of

the outer and inner templates.

Mark centres of holes to be drilled.

Once profile is marked carefully remove the templates and any masking tape.

NOTE: Mark centres for drilling with template and

centre punch or podger.

Marker Pen

TIP: Apply and use a strip of masking tape to guide

marked line between templates.

Figure 36: Apply masking tape

Step 36: Before cutting, ensure 70mm wide masking tape is applied

above cutting line for cut edge on retained section of bumper cover with lower edge aligned with marked cut line

Reverse RHS templates and apply to LHS side of bumper and

follow same steps as RHS.

The bumper is now marked out for cutting.

Cutting line

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Step 37:

Use the Right Pick Up Wide Outer Template and tape in posi-

tion as shown.


(Generic Image Shown)

NOTE: Step 37-41 on template positioning for Pick Up

Wide.

Figure 38: Locate RHS inner template

(Generic Image Shown)

Step 38: Use the Right Pick Up Wide Inner Template and tape in posi-

tion as shown.

NOTE: Follow instructions on template for position-

ing .


Step 39: Use a marker pen to mark out the cutting lines indicated by

the templates.

Marker Pen

Cutting line

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Mark centres of holes to be drilled.

Once profile is marked carefully remove the templates.


NOTE: Mark centres for drilling with template and

centre punch or podger.

Marker Pen



Cutting line



above cutting line for cut edge on retained section of bumper cover with lower edge aligned with marked cut line.

Reverse RHS templates and apply to LHS side of bumper and

follow same steps as RHS.

The bumper is now marked out for cutting.

Step 42: Mark cutting line for bumper at positions shown

Figure 42: Mark Cutting Line

NOTE: Step 42-44 for Rogue, SR Wide and SR5 Wide

Only.

Masking tape

NOTE: If a winch is fitted, then refer to the grille sup-port kit PZQ9389040 fitting instructions for

additional grille and bumper cut detail.

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Figure 43: Mark Cutting Line

Step 43: Mark cutting line for grille through centre of outboard clipping

point on both sides as shown

Mark centre of hole by measuring from the features as shown

Apply masking tape to centre crossmember and mark cutting line as shown


Step 44: Identify cutting line for grille surround by measuring 3mm from

feature shown

Wrap section of grille surround with masking tape prior to marking cutting line on part

Step 45: Use the Right SUV Outer Template and tape in position as

shown.


NOTE: Step 45-50 for SUV Only.

WARNING: Ensure that there is sufficient coverage of masking tape on each side of cutting line to avoid chrome from splintering during cut-

ting operation.

3

11mm

11mm

Mark centre of hole

NOTE: Ensure grille is not damaged by protecting with masking tape and using a padded bumper

stand.

Cutting line

Feature

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Figure 46: Locate LHS outer template

Step 46: Use the Right SUV Inner Template and tape in position as

shown.


Step 47: Use the Right SUV Flare Template and tape in position as

shown.

Mark out cutting line with a marker pen.

Once profile is marked, carefully remove the template.

Mask up to cutting line on side to be kept.

Trim flarette cutting line using multi-tool.

Deburr edges.

Repeat on LHS by reversing RHS template and applying the LHS Flarette.


Step 48: Using a marker pen mark out the cutting lines indicated by the

templates.

Marker Pen

Cutting Line

Mask up and keep this side after cutting

Marker Pen

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Mark all hole centres.

Once profile is marked remove the templates and any mask-ing tape.


Cutting line

NOTE: Mark centres for drilling using template loca-

tion and centre punch or podger.




Step 50: Apply masking tape aligning edge to marked cut line as

shown.

Reverse RHS templates and apply to LHS side of bumper and follow same steps as RHS.

Drill hole centres.

The bumper is now marked for out for cutting.


above cutting line for cut edge on retained section of bumper cover with lower edge aligned with marked cut line.

Place bumper face up on a bumper stand or similar so there is

sufficient access for the cutting operation. Start By drilling out all Φ22mm holes.

Use a multi-tool cutter to cut along the lines as shown.

Remove burrs from the cut edge of the bumper, use deburring

tool or file.

Leave masking tape on until bull bar is fitted.

Figure 51: Cut out bumper

WARNING: Cutting operations can result in flying de-bris, safety glasses should be worn. Work


Lower Bumper

Retained Bumper

Multi-tool

Cutting Line

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Figure 52: Cut out grille

Step 52:

Place component to be cut face up on a bumper stand or simi-

lar so there is sufficient access for the cutting operation. Start by drilling out all Φ22mm holes with a hole saw.

Use a multi-tool cutter to cut along the lines as marked for the

grille surround and grille.

Remove burrs from the cut edge of the grille surround and grille, use deburring tool or file.

WARNING: Cutting operations can result in flying de-bris, safety glasses should be worn. Work


NOTE: Step 52 for Rogue, SR Wide and SR5 Wide

Only.

NOTE: Protect chrome and painted surfaces during

cutting operation.


Step 53: Assemble grille to each bumper half.

Mark centre for hole using feature shown on grille.

Drill hole using Φ30-35mm hole saw, through grille and bump-

er.

Repeat for LH

Separate grille from bumper and retain both.

Step 54: Apply Sikaflex 221 or equivalent glue to contact area of Cap

Grille

Assemble Cap Grille to cut end of grille surround

Wipe away any excess glue

Repeat for LH

Reassemble grille surround to grille/bumper assembly

Figure 54: Glue Cap Grille

NOTE: Step 53-54 for SR Wide and SR5 Wide Only.

WARNING: Do not use reactive cure adhesive.

5 Centre of feature

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Figure 55: Refit Flarette

Step 55:

SUV Only

Refit flarette using 1 x Trim Clip as shown.

Figure 57: Attach fender liner trim clip

Step 57: Attach 1 x trim clip and 1 x Scrivet on fender liner on RH side.

Repeat for LH side.

RH Shown

NOTE: Step 57 for Pick Up Only.

Step 56: Remove tape applied in step 16.

Carefully re-attach bumper to vehicle.

Re-attach to the three mounting points and 3 screws re-

moved in step 7 which secures bumper to the vehicle.

Tighten the three screws as shown.

NOTE: Refer to workshop manual.

Figure 56: Attach cut out bumper section

NOTE: If a winch is fitted, then refer to the winch fitting instructions for the additional bumper

cut detail.

NOTE:

For Rogue, SR Wide and SR5 Wide Only, refit screw to centre radiator support bracket for

future winch requirements.

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Figure 58: Attach bumper Flarette screw

Step 58: Re-install Phillips hex screw to trimmed bumper on LH side as

shown.

Repeat for RH side.

NOTE: Step 58 for SUV Only.

LH Shown

Figure 60: Trim LH fender liner

Step 60: Remove front 6 x trim clips that attach fender liner to vehicle

and retain.

Mark out cut profile according to cutting guide.

Temporarily re-mount bumper and fender liner to check cut profile. Adjust cut profile to align with bumper if required.

Trim LH fender liner as shown, refer to fender liner cutting

guide for exact dimensioning.

NOTE: Fender liner drawings located at back of fitting

instructions.

NOTE:

SUV ONLY: Fender liner corner will need to be lifted as shown in cutting guide at rear of fitting

instructions in order to align to bumper cut.

Step 59: Remove front 6 x trim clips that attach fender liner to vehicle

and retain.

Mark out cut profile according to cutting guide.

Temporarily re-mount bumper and fender liner to check cut profile. Adjust cut profile to align with bumper if required.

Trim RH fender liner as shown, refer to fender liner cutting

guide for the Pick Up Narrow, Pick Up Wide and SUV type models for exact dimensioning.

Figure 59: Trim RH fender liner

NOTE: Fender liner cutting guide located at rear of

fitting instructions.

NOTE:

SUV ONLY: Fender liner corner will need to be lifted as shown in cutting guide at rear of fitting

instructions in order to align to bumper cut.

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Figure 61: Attach washer hoses

Step 61: Secure washer hoses to foot of washer bottle using a pipe clip

(Item 107) as shown.

Reinstall fender liners and bumper.

NOTE: Pick up has 1 hose.

SUV has 2 hoses.

Figure 63: Pinch Weld to flarette

Step 63: SUV Only

Temporarily fit Pinch Weld 412mm (Item 125) to trimmed

flarette along the edges on both LH and RH of bumper.

Using a marker pen mark out where notch is to be cut on

the inside edge where the pinch weld transitions from the flarette to the bumper.

Remove Pinch Weld and cut out marked section, ensuring

that no stray steel is left in the notch.

Repeat for LHS

Figure 62: Bumper Retention

Step 62: Install Nut-U (Item 97) on fender liner as shown above cut line.

Use Screw Wafer Head Self Drilling Self Tapping (Item 96) to

drill a hole in the bumper above cutline, ensuring to centre hole on bumper laterally.

Hold Nut-U (Item 97) in position as shown as screw engages

it.

NOTE:

SUV ONLY: Fender liner will need to be lifted up prior to attaching with Screw Wafer head

Self Tapping Screw (Item 96)

Nut U fitted to fender liner In this position

Screw

Cut out notch

NOTE: The main purpose of the pinch weld is to hold

the flarette in the correct place.

Nut U orientation

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Figure 64: Pinch Weld to flarette

Pinch weld

Step 64: SUV Only

Apply some super glue to (Item 125) Pinch Weld 412mm

groove.

Fit Pinch Weld to trimmed flarette along the edges shown on

both LH and RH of bumper.

LH Shown

Step 66:

Fit grille back onto the four supporting mounts.

Using retained fasteners attach 2X Phillips Hex Screws, one

from each side of grille and 2X Hex Screws that attach each grille bracket to the radiator support panel and retain.

Check that protective tape is still in place on bumper where

bar is to be mounted and onto chrome portion of SUV Grille.

Figure 66: Reattach Grille

NOTE: Refer to workshop manual.

Figure 65: Pinch Weld to bumper cover

Pinch weld

Step 65: Pick Up (Wide) Models Only

Apply some super glue to (Item 125) Pinch Weld 412mm

groove.

Fit pinch weld along the edges shown on both LH and RH

of bumper.

LH Shown

Pinch weld

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Figure 67: Install fog lamp assemblies on bull bar

Step 67:

Install Fog lamp on bracket within bull bar using 4 x Phillips

Head 5.2 x 16 Screws (Item 94).

Repeat for LH.

Phillips Head Screws 5.2 torque: 2 Nm.

Step 68: Inspect chassis frames, both inboard and outboard flanges for

weld spatter around the areas shown.

Clean and file weld spatter if present then treat with anti-corrosion protection.

Figure 68: Inspect for weld spatter

Figure 69: Install inboard gusset

Step 69: Position RH Gusset inboard (Item 29) on chassis frame.

Mount the Gusset using 2 x M12 X 1.25 X 35 Screw Flange

(Item 64), 2 x M12 Flat Washer (Item 66), 1 x 2mm Shim (Item 59) and a Plate Nut (Item 31) as shown.

Before tightening M12 fasteners, align Gusset Inboard firm up

against Chassis End Plate with no air gap visible, using 1 x Bolt Flange Black M10 x 1.25 x 40 (Item 68), 1 x Washer Flat M10 x 25 x 4 (Item 72) and 1 x Nut Flange M10 x 1.25 (Item 74).

Nip up M10 fasteners followed by M12 fasteners.

Remove M10 fasteners.

RH Shown

NOTE: If screw binds on plate nut, remove screw and clean thread with a tap prior to re-installing

screw.

Nut Plate goes in this hole

Nut Plate Shim 2mm Gusset Bolt M12 x 1.25 x 35

Washer

NOTE: Ensure the nut plate is installed in the correct orientation: FRT towards the front of the chas-

sis.

FR

T ↑

Nut Plate

Inspect greyed out area.

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Figure 71: Inspect alignment of inboard gusset

Step 70: Check the alignment of the hole to slot on the chassis end

plate so that it is centred in the slot.

If aligned go to step 71.

If misaligned repeat step 69 utilising the (Item 60) 1mm Shim or (Item 60) 1mm and (Item 59) 2mm Shim stack up to correct alignment.

Align the hole and the slot

NOTE: As shown an adjustment to shim configura-

tion is required to correct alignment.

Step 71: Tighten the M12 fasteners ensuring that the bracket seats

firmly against chassis and meets firm up against the chassis end plate.

Repeat steps 69-71 for LH side.

Bolt Flange M12 torque: 77 Nm.

Figure 71: Tighten inboard gusset bolts

NOTE:

If fitting a Toyota Genuine Winch please refer to Winch Fitting Instructions for fitment of the Bracket Cable retention over the LH gusset.

Figure 72: Install under panel RH bracket

Step 72: Install Bracket Under Panel RH (Item 51) on RH Brace Wing

Rear using 2 x Screw Button Head Torx M6 x 1.0P x 25 Silver (Item 80), 2 x Washer Flat M6 x 16 x 1.2 (Item 82) and 2 x Nut Flange M6 x 1.0P(Item 85).

Install Nut U M6 x 1.0P on Bracket Panel under RH support as shown (Item 84).

Screw Button Head Torx M6 torque: 9 Nm.

U Nut M6 (Item 84)

Item 80 Screw Button Head

Torx

U Nut Orientation

M12 Fasteners to tighten

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Figure 73: Install nut clips to rear wing brace

Step 73: Attach Nut U M6 x 1.0P (Item 84) at 3 x locations on rear

wing brace.

Repeat for LH.

U Nut Orientation

Figure 74: Install RH outboard gusset

Step 74: Loosely assemble Rear Brace Wing to the outboard gusset as

shown using 1 x Screw Flange M10 x 1.25 x 40 (Item 69), 1 x Washer Flat M10 x 25 x 4 (Item 72) and 1 x Nut Flange M10 x 1.25 (Item 74).


Step 75: Loosely attach Rear Brace Wing and outboard Gusset assem-

bly to the RH chassis cross member using 1 x Bolt Flange M12 x 1.25 x 35 (Item 64) and 1 x Shim 12.5 x 30 x 1 (Item 58) on lower M12 hole as shown.

Pull outboard gusset forward using 1 x Bolt Flange black M10 x 1.25 x 40 (Item 68), 1 x Washer Flat M10 x 25 x 4 (Item 72) and 1 x Nut Flange M10 x 1.25 (Item 74), such that it lines up against Chassis End Plate with no air gap visible.

Nip up M10 Fasteners.

Nip up Bolt Flange M12 x 1.25 x 45 (Item 63).

HINT: Shim is installed between outboard gusset

and chassis frame.

Install M12 bolt (Item 64)


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Step 76: Insert and nip up Bolt Flange 1 x M12 x 1.25 x 45 (Item 63)

to upper inboard hole.

Remove M10 fasteners.

Repeat steps 75– 76 for LH.


Remove M10 bolt (Item 68)

Figure 77: Inspect alignment of RH outboard gus-set

Step 77: Check alignment of hole in gusset to slot in chassis end plate

hole in Packer Mount Brace Wing so that it is centred with respect to the slot.

If hole is offset towards the outboard direction of the slot, re-

move gusset outboard RH and repeat step 75 but with 1x shim 12.5 x 30 x 1 (Item 58) on upper hole and 1 x shim 12.5 x 30 x 2 (Item 57) on lower hole of gusset.

NOTE: The genuine Front Recovery Points, Winch Mounting Kit and Winch are to be fitted in con-junction with Steps 78-87. If fitting these acces-

sories, refer to the relevant instructions.

Figure 78: Check plate shims

Step 78: Non-winch Only

Ensure plate shims are securely fixed to packer mount wing

brace (Item 41).

NOTE: Do not use tape to secure.

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Figure 79: Check plate shims

Step 79: Winch Only

Ensure plate shims are securely fixed to Winch Cradle (Item

33).

NOTE: Do not use tape to secure.

Figure 80: Install crash box

Step 80: Winch Only

Position Winch Cradle (Item 33) and Crash Box RH on chas-

sis frame.

Figure 81: Nut flange and weld nut locations

Step 81: Winch Only

Ensure that Nut Flange M10 (Item 74) are fitted in positions

as shown.

Weld Nut

Nut Flange M10 Nut Flange

M10

Weld Nut

Nut Flange M10

Nut Flange

M10

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Figure 82: Outboard fastener layout

Washer Flat M10 x 25 x 4

Screw Flange Silver M10 x 1.25 x 40

Bolt Shank Black M10 x 1.25 x 40

Step 82: Winch Only

For outboard assembly, mount using 2 x M10 x 1.25 x 40

black bolts with shank (Item 68) 3 x Washer Flat M10 x 25 x 4 (Item 72), 1 x Screw Flange Silver M10 x 1.25 x 40 (Item 69) and 2 x Nut Flange M10 x 1.25 (Item 74) as shown.

See figure 81 for Nut Flange M10 x 1.25 (Item 74).

Do not tighten.

NOTE: Position of Screw Flange Silver and Bolt

Flange Black is critical.

NOTE: Screw Flange Silver M10 x 1.25 x 40 attaches

to weld nut.

Figure 83: Inboard fastener layout

Nut Flange M10 x 1.25



Step 83: Winch Only

For inboard assembly , mount using 1 x Washer Flat M10 x

25 x 4 (Item 72) and 1 x Nut Flange M10 x 1.25 (Item 74) on stud, followed by 2 x M10 x 1.25 x 40 black bolts with shank (Item 68), 1 x Screw Flange Silver M10 x 1.25 x 40 (Item 69), 3 x Washer Flat M10 x 25 x 4 (Item 72) and 3 x Nut Flange M10 x 1.25 (Item 74) on second upper hole.

See figure 74 for Nut Flange M10 x 1.25 (Item 74).



to weld nut.


Figure 84: Install crash box


Position Packer Mount Wing Brace RH (Item 41) and Crash

Box RH on chassis frame.

NOTE: Ensure correct side Packer Mount Wing Brace

is used in correct orientation.

Crash Box RH

Packer Mount Wing Brace RH

Chassis End Plate

NOTE: Don’t fit the 2 lower inboard fasteners until

step 89.



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Figure 85: Nut flange and weld nut locations


Ensure that Nut Flange M10 (Item 74) are fitted in positions

as shown.

Nut Flange M10

Nut Flange M10

Weld Nut

Nut Flange

M10

Figure 86: Outboard fastener layout





Figure 87: Inboard fastener layout





For outboard assembly, mount using 2 x M10 x 1.25 x 40

black bolts with shank (Item 68) 3 x Washer Flat M10 x 25 x 4 (Item 72), 1 x Screw Flange Silver M10 x 1.25 x 40 (Item 69) and 2 x Nut Flange M10 x 1.25 (Item 74) as shown.

Do not tighten.


For inboard assembly , mount using 1 x Washer Flat M10 x

25 x 4 (Item 72) and 1 x Nut Flange M10 x 1.25 (Item 74) on stud, followed by 1 x M10 x 1.25 x 40 black bolts with shank (Item 68), 1 x Washer Flat M10 x 25 x 4 (Item 72) and 1 x Nut Flange M10 x 1.25 (Item 74) on second upper hole.


Weld Nut


to weld nut.



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Figure 88: Install Nut U M8 to stone tray bracket


Install 3 x Nut U M8 x 1.25 (Item 79) to Stone Tray bracket in

3 x positions orientated as shown.

Figure 89: Install bracket for stone tray


Position Bracket Stone Tray on crash box as shown.

Fit to LHS as shown using 1 x Screw Flange Silver M10 x 1.25 x 40 (Item 69) on upper hole, 1 x Bolt Flange Black M10 x 1.25 x 40 (Item 68) , 2 x Washer Flat 10 x 25 x 4 (Item 72) and 1x Nut Flange M10 x 1.25 (Item 74) on lower hole.

Do not tighten.

Repeat for RHS.


Bolt Flange Black M10 x 1.25 x 40

Figure 90: Install end caps

Step 90: Pick Up Wide Only

Insert RHS end cap through the slots on the RH wing.

Fasten end cap to Wing using 3 x Clip Plastic 24.9 X 20 (Item 105).

Fit Xmas Tree Clip (Item 106) to bottom of end cap.

Repeat for LHS.

SUV Only

Fit Pinch Weld 88mm (Item 130) to top of the RH wing.

Insert RHS end cap through the slots on the RH wing.

Fasten end cap to Wing using 3 x Clip Plastic 24.9 X 20 (Item

105).

Fit Xmas Tree Clip (Item 106) to bottom of end cap.

Repeat for LHS.

Trim Clip Item 105

Xmas Tree Clip Item 106

Pinch Weld 88mm Item 130 LH Shown

NOTE: Pinch weld applies to SUV only.



to weld nut.

Weld Nut



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Figure 91: Install end cap U clip

Step 91: Pick Up Wide and SUV Only

Attach 1 x U Clip 6mm (Item 104) to the top of end cap slot

as shown.

U Clip Item 104

Figure 92: Install bull bar

Step 92: Using 1 x Shim Packer 5mm (Item 54) on each side present

Alloy Bull Bar to the crash boxes, ensuring each stud on the bull bar is fed into each slot on the crash boxes as shown.

NOTE: If fitting driving lights to the bull bar, fit them

prior to fitting bull bar to the vehicle.

Figure 93: Install bull bar washers and mounting nuts

Step 93: Mount alloy bull bar to crash boxes using 4 x Nut Flange

M10 x 1.25 (Item 74)and 4 x Washer Flat M10 x 25 x 4 (Item 72).

Do not tighten.

Repeat for LH.

RH Shown

RH Shown

NOTE: Be careful not to scratch or damage bull bar

or bumper cover.

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Figure 94: Install front wing brace

Step 94: Mount RH Brace Wing Front using 2 x Screw Flange Silver

M10 x 1.25 x 40 (Item 69), 4 x Washer Flat 10 x 25 x 4 (Item 72) and 2 x Nut Flange M10 x 1.25 (Item 74).

Do not tighten.

Repeat for LH.

RH Shown

Figure 95: Mount wing braces to bull bar

Step 95: Mount brace wing front and rear to the bull bar wing using 2

x Screw Flange Silver M10 x 1.25 x 40 (Item 69), 4 x Wash-er Flat M10 x 25 x 4 (Item 72) and 2 x Nut Flange M10 x 1.25 (Item 74).

Do not tighten.

Repeat for RH.

Figure 96 Check vertical bull bar positioning

Step 96: Adjust the bull bar vertically to achieve measurement of 75-

80mm as shown to fender at each end.

Hand tighten 2 x RH M10 crash box rear mounting screws (1 x inboard & 1 x outboard).

Repeat for LH to achieve an even gap for RH.

NOTE: Step 96 for PZQ29-89303/403 Only.

75—80m

m

LH Shown

M10 Screws

RH Shown

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Figure 97: Check vertical bull bar positioning

Step 97: Adjust the bull bar vertically to achieve a 20 - 36mm gap at

each end to the cut bumper as shown.

Also measure to fender and ensure a measurement of 115-120mm is achieved.

Nip up 2x RH M10 crash box rear mounting screws (1x in-

board & 1x outboard).

Repeat for LH to achieve the same gap to RH.

NOTE: Step 97 for PZQ29-89308/313/408/413/510/520

Only.

115 -120 m

m

20 - 36 mm

M10 Screws

RH Shown

Figure 98: Check vertical bull bar positioning

Step 98: Adjust the bull bar vertically to achieve a 20 - 36mm gap at

each end to the cut bumper.

Also measure to fender and ensure a measurement of mini-mum 90mm and a maximum of 95mm is achieved.

Hand tighten 2x RH M10 mounting screws (1x inboard & 1x

outboard).

Repeat for LH to achieve an even gap to RH.

NOTE: Step 98 for PZQ29-89317/322/347/417/422/447

Only.

90-95 m

m 20 - 36mm

M10 Screws

Figure 99: Tighten crash box fasteners

Step 99: Tighten the 7 x M10 Fasteners that mount the crash box to the

vehicle using a cross sequence.

Centre 4 diagonally.

Outer 3 diagonally.

Repeat for LH Side.

Screw Flange Hex M10 torque: 70 Nm.

Nut Flange Hex M10 torque: 70 Nm.

RH Shown

RH Shown

Pinch Weld

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Figure 100: Check horizontal bull bar positioning

Step 100: Adjust the bull bar laterally to achieve a consistent gap of

minimum 10mm LH and RH.

Ensure this gap is even on inner wing edge to bumper on both sides.

Figure 101: Torque M10 flange nuts to bull bar

M10 Fasteners torque: 70 Nm.

Step 101: Tighten the 8 X M10 Flange Nuts that mount the bull bar to the

2X crash box using a cross sequence.

RH Shown

Figure 102: Check overall bull bar positioning

Step 102: Check gap conditions to the vehicle bumper at 3 x locations

shown, ensure a horizontal gap of between 17- 23mm from bull bar upper pan and 23 - 30mm from bull bar wings to bumper fascia.

If gap range cannot be achieved proceed to step 104 where whole shims are added.

23 – 30mm 17 – 23mm 23 – 30mm

NOTE: Step 102 for Pick Up Narrow, Wide Workmate

and SUV Models only.

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Figure 103: Check overall bull bar positioning

Step 103: Check gap conditions to the vehicle bumper at 5 x locations

shown, ensure a horizontal gap of between 27– 33mm from bull bar upper pan to badge, 25 - 30mm from bull bar upper pan to grille and 23 - 30mm from bull bar wings to bumper fascia.

If gap range cannot be achieved proceed to step 104 where

whole shims are added. 27 – 33mm 23 – 30mm 23 – 30mm

25 – 30mm 25 – 30mm

NOTE: Step 103 for Pick Up Rogue, SR Wide and SR5

Wide Models Only.

Figure 104: Utilise the supplied shims

Step 104: Utilize 2mm and 3mm Shim Packers to pack the bull bar

forward, or remove the Shim Packers that have been in-stalled to bring bull bar closer to vehicle, and achieve re-quired clearance conditions.

Once adjustment is complete, proceed to next step.

RH Shown

Figure 105: Tighten wing brace fasteners

Step 105: Tighten 2X M10 fasteners that mount brace wing front

Repeat for LH


RH Shown

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Figure 106: Tighten bull bar to wing brace fasten-ers

Step 106: Tighten 2X M10 fasteners that mount front and rear wing

brace to bull bar.

Repeat for LH.

Torque up Fasteners in Step 75 & 76.


Rear Wing Brace Only:


RH Shown

Figure 107: Install rear stone tray

Step 107: Non-winch Only Position Tray Stone Rear over OE Under Cover.

Mount using 2 x Screw Hex Head M8 x 1.25 x 30 Black (Item

98) , 2 x Washer Flat M8 x 26 x 4 Black (Item 77) and 2 x spacer M8 x 19 x 10 (Item 78) between Tray Stone Rear and OE Under Cover.

Do not tighten fasteners.

Figure 108: Install Nut U

Step 108: Non-winch

Install 3 x Nut U M6 X 1.0 (Item 84) to Tray Stone Front orien-

tated as shown.

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Figure 109: Install front stone tray

Step 109: Non-winch

Position Tray Stone Front with short flange above lower edge

of Lower Pan, and rear section positioned under Stone Tray Rear.

Figure 110: Install front stone tray

Step 110: Non-winch

Mount using 3 x Nut U M6 1.0 (Item 84), 3 x Screw Button

Head M6 x 1.0 x 25 Silver (Item 80) Lower Pan, 3 x Washer Flat M6 x 16 x 1.2 (Item 82) Lower Pan, 3 x Nut U M8 1.25 (Item 79), 3 x Screw Button Head M8 X 1.25 X 25 Black (Item 75) Rear of Stone Tray and 3 x Washer Flat 8 X 26 X 4 Black (Item 77) Rear of Stone Tray.

Tighten all 8 x M8 Stone Tray Fasteners.



Figure 111: Apply Sikaflex 221 or equivalent to dampen plate.

Step 111: For Winch Compatible Bull Bar - All Locations

Install 3 x Nut U M6 X 1.0 (Item 84) to Tray Stone Front as per

step 108.

Apply Sikaflex 221 or equivalent to contact area between Tray

Stone Front and Winch Cradle, prior to installation as shown.

Mount using 3 x Screw Button Head M6 x 1.0 x 25 Silver (Item 80) and 3 x Washer Flat M6 x 16 x 1.2 (Item 82) to Lower Pan, followed by 3 x Screw Button Hex M8 X 1.25 X 20 Black (Item 126) and 3 x Washer Flat M8 X 26 X 4 Black (Item 77) to Winch Cradle.

Tighten all 6 x Stone Tray Fasteners.

.


Apply Sikaflex 221 or equivalent


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- Alloy Bull Bar


Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

Figure 112: Indicator wiring

Step 112:

Route the LH Indicator patch (1), Earth ring terminal (2) & Power wires (3) underneath the LH Vehicle Head Lamp cavity.

For high grade pickup, indicator wiring is routed in apron

cavity outboard of the headlamp.

Repeat for RH Indicator patch.

Figure 113: Battery terminal wiring

Step 113:

Feed the Orange and Orange/Black Power wire terminals (1) and White wire ring terminal (2) around the sides of the battery, following the vehicle harness.

Cable tie the harness to the vehicle harness every 200mm.

Figure 114: Fuse box removal

Step 114:

Remove the accessory fuse block cover (1).

Disconnect the accessory fuse block (2) from its mounting bracket (3).

Using side cutters, remove and discard the cable tie (4) from the wire bundle.

Unclip and dislodge the fuse holder (5).

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

Figure 115: Installation of terminal wire to fuse box

Step 115:

Feed the Bull bar harness Orange and Orange/Black terminal

wires through the fuse block funnel.

Insert the Orange wire fuse terminal (1) into the cavity 3 as shown.

Insert the Orange/Black wire fuse terminal (2) into the cavity 7

as shown.

Insert the supplied 2A mini blade fuses (3) into the wired slots and re-fit back into the accessory fuse box (4).

Secure cables with Cable tie (5) where shown.

Replace accessory fuse box onto it's mounting bracket.

NOTE: Ensure audible “Click” is heard.

NOTE: Check Fuse Terminal retention.

Figure 116: Fastening of ground bolt and wire

Step 116:

Using the existing M6 earth bolt (1), fasten white wire ring terminal (2) to the vehicle body.

Relocate battery to original location and torque.

NOTE: Earth Bolt Torque to be between 6.9 ~ 9.8 Nm.

NOTE: Dislodge and move battery to gain access to M6

earth bolt at junction connectors on fender.

Figure 117: Headlamp and harness wiring patch connector

Step 117:

At the rear of the LH Headlamp area, locate and disconnect the LH Vehicle Headlamp connector (1) that contains the Position Lamp circuit.

Connect the Position Lamp Harness Patch (Item 35) connectors (2) in between the vehicle harness and Lamp connectors (1).

NOTE:

Position Lamp Connectors will differ depending on Vehicle Headlamp.

Harness wiring patch (Item 35)

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

Figure 118: Harness wiring patch connector

Step 118:

Connect the Position Lamp Harness 4-way male connector (Item 35) (1) to the Bullbar Harness 4-way female connector (2).

4-Way Headlamp Position Connector location is shown in Step 112.

Figure 119: Indicator lamp harness connector and bull bar harness connector

Step 119:

Locate and disconnect the LH Indicator lamp connector (1).

Tip: on high grade Pick Up, remove indicator globe & housing

to gain access to connector (quarter turn to remove).

Route the Indicator patch above the wing brace and into the space behind the Indicator lamp.

Connect the Main Bull bar harness LH Indicator patch (2) in-

between the vehicle harness and Lamp connector.

Secure Bull bar Harness to vehicle harness every 200mm,

avoiding sharp edges

Repeat (indicator Patch Step) for RH Indicator connector patch.

NOTE:

Use Cable Ties to ensure that connectors and fuse holders are secured.

Figure 120: Cable tie RH indicator harness

Step 120:

From underneath the vehicle, cable tie the RH Indicator harness (1) to the vehicle harness.

Secure Bull bar Harness to vehicle harness every 200mm, avoiding sharp edges.

NOTE:

Ensure harness is routed away from sharp edges.

NOTE:


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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

Figure 121: Cable tie LH indicator harness

Step 121:

From underneath the vehicle, cable tie the LH Indicator harness (1) to the vehicle harness.

Secure Bull bar Harness to vehicle harness every 200mm, avoiding sharp edges.

NOTE:

Ensure harness is routed away from sharp edges.

NOTE:


Figure 122: Connect fog lamp harness

RH Shown

Step 122: Connect fog lamp harness for RH.

Repeat for LH.

NOTE:

SUV ONLY: Install bull bar extension harness wiring patch (Item 128) between vehicle har-ness and lamp.

Figure 123: Secure cables to front wing brace

NOTE:

Coil and secure excess cable, ensuring all ca-bles & wiring are clear from winch drum and do not rub on any hot, moving or sharp edges. Failure to do so could result in damage to the

electrical system.

Step 123: Route fog lamp harness as shown and cable tie connector to

top of brace wing front as shown.

NOTE:

Remove PVC tape reconnect negative battery terminal for system testing.

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

Step 124:

Check for correct functionality of the Bull bar Indicator and

Position lamp system :

Turn vehicle ignition ON. If vehicle is equipped with DRL's and they are ON, Bull bar Lamp DRL's should also turn ON. NOTE: Vehicle DRL's will only turn ON when headlamp switch is set to auto, position lamps and headlamps are OFF with vehicle in direct sunlight.

Turn vehicle position lamps ON. Bull bar DRL's should DIM.

Turn LH vehicle indicator ON. LH Bull bar Indicator should

also turn ON (flash) and LH Bull bar DRL should DIM.

Turn RH vehicle indicator ON. RH Bull bar Indicator should also turn ON (flash) and RH Bull bar DRL should DIM.

Turn vehicle hazards ON. Both Bull bar indicators should turn

ON (flash) and both Bull bar DRL's should DIM.

Turn vehicle hazards & indicators OFF and turn OFF vehicle.

All Bull bar Lamps should turn OFF.

Turn on fog lamps and check operation (adjust per step 125 if required) .

NOTE:

Disconnect negative terminal after checks are completed.

Figure 124: Important notes, Complete after com-pleting checks and notes on RHS

NOTE:

Cable tie the Bull bar Harness to the vehicle harness every 200mm. Ensure the harness is not crushed or stretched during Bull bar Harness installation.

NOTE:

Refit all removed parts and secure all fasteners to the Service Manual torque specifications.

NOTE:

Battery Post Terminal Clamp Torque to be between 2.9 ~ 7.8 N.m. Earth Bolt Torque to be between 6.9 ~ 9.8 Nm.

NOTE:

Refit battery in original location and tighten Battery bracket fasteners.

Step 125: Adjust Fog Lamp beam angle if required.

Figure 125: Adjust fog lamps

Adjustment mechanism for Fog Lamp

RH Shown

Figure 126: Install RH splash panel

Step 126: Install 4 x Nut U M6 x 1.0P (Item 84) to under panel RH.

Install Under Panel RH (Item 49) Using 4 x Screw Button

Head M6 x 1.0P x 25 Silver (Item 80) and 4 x Washer Flat M6 x 16 x 1.2 Silver (Item 82).

Repeat for LH.

Screw Button Head Torx M6 torque: 9 Nm.

RH Shown

Nut U Orientation

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

Step 127: Attach Panel Under RH to brace wing using 3 x Nut U M6

1.0P (Item 84), 3 x Screw Button Head Torx M6 x 1.0P x 25 Black (Item 81) and 3 x Washer Flat M6 x 25 x 2.8 Black (Item 83).

Repeat for LH.

Figure 127: Install rear RH splash panel

Screw Hex M6 torque: 9 Nm.

TIP:

Use screwdriver to align U Nut to slot in under panel prior to installation of fasteners.

RH Shown

Figure 128: Fasten RH Panel Under to bracket Under Panel

Step 128: Attach Panel Under RH to RH Bracket Under Panel using 1 x

Screw Button Head Torx M6 x 1.0P x 25 Black (Item 81), 1 x Washer Flat M6 x 25 x 2.8 (Item 83).

Screw Hex M6 torque: 9 Nm.

TIP:

Use screwdriver to align U Nut to slot in under panel prior to installation of fasteners.

Figure 129: Reattach Radiator Cover

Step 129: Reattach radiator cover using 8 X push clips.

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

WARNING: Do not over-tighten screws, over-tightening

could damage plastic components.

Screw Philips Head 5.2 x 16 torque: 2 Nm.

Screw Socket Head M5 x 20 torque: 5 Nm.

Figure 130: Install Registration Plate

Step 130: Winch

Install Registration Plate using 2 x Screw Socket Head M5 x

0.8 x 20 (Item 86) and 2 x Nut Flange M5 x 0.8 (Item 88) at upper holes, and 2 x screw wafer head 10-32 self drilling (Item 96) at 2 x bottom corners.

Non-winch

Mount Registration Plate using 2 x Screw Philips Head 5.2 x 16 (Item 94) , 2 x grommet (Item 95) at upper 2 x holes and 2 x screw wafer head 10-32 self drilling (Item 96) at 2 x bottom corners.

Figure 131: Reconnect negative battery terminal

NOTE: Ensure all cables & wiring are clear from winch drum and do not rub on any hot, moving or sharp edges. Failure to do so could result in

damage to the electrical system.

NOTE:

Remove the bull-bar to body clearance label

from the bar.

Leave the Fitment Card attached to the front of the bar. Remove this label when the car is de-livered to the customer and ensure the custom-

er understands the labels instruction.

NOTE: Reprogram all radio stations and clock settings by referring to vehicle’s owner manual.

NOTE: Battery Post Terminal Clamp Torque to be be-tween 2.9 ~ 7.8 N.m. Earth Bolt Torque to be between 6.9 ~ 9.8 Nm.

Step 131: Remove insulation tape and reconnect –ve terminal connect-

or.

ISSUE 01 : 17/05/18 of 70

- Alloy Bull Bar


Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

AIR DEFLECTOR PICK UP NARROW AND WORKMATE WIDE RH

ISSUE 01 : 17/05/18 of 70

- Alloy Bull Bar


Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

AIR DEFLECTOR PICK UP NARROW AND WORKMATE WIDE LH

ISSUE 01 : 17/05/18 of 70

- Alloy Bull Bar


Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

AIR DEFLECTOR PICK UP ROGUE, SR WIDE AND SR5 WIDE RH

FEA

TUR

E LIN

E

FO

LLOW

FEA

TUR

E LIN

E

ISSUE 01 : 17/05/18 of 70

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

AIR DEFLECTOR PICK UP ROGUE, SR WIDE AND SR5 WIDE LH

ISSUE 01 : 17/05/18 of 70

- Alloy Bull Bar


Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

AIR DEFLECTOR SUV RH

ISSUE 01 : 17/05/18 of 70

- Alloy Bull Bar


Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

AIR DEFLECTOR SUV LH

ISSUE 01 : 17/05/18 of 70

- Alloy Bull Bar


Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

FENDER LINER SUV RH

NO

TE

:

SU

V R

H O

nly

: Firs

t trim to

sp

ecifie

d le

ng

th a

s

sh

ow

n. W

hen

fitting

lift this

co

rner to

alig

n to

b

um

per c

ut b

efo

re fittin

g s

elf d

rilling

scre

w

into

U N

ut.

ISSUE 01 : 17/05/18 of 70

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

FENDER LINER SUV LH

NO

TE

:

Wh

en

reatta

ch

ing

fen

der lin

er, lift th

is c

orn

er

into

po

sitio

n in

bu

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er p

rior to

us

ing

cu

t b

um

per to

mark

ou

t an

d trim

this

pro

file s

o it

is flu

sh

with

bu

mp

er c

ut.

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

FENDER LINER PICK-UP NARROW RH

N

OT

E:

Th

is s

ectio

n trim

me

d a

fter fitte

d b

ack in

to

bu

mp

er to

pre

ven

t mis

ma

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to b

um

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ut.

N

OT

E:

Do

no

t cu

t un

til afte

r alig

nm

en

t with

bu

mp

er

cu

t

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

FENDER LINER PICK-UP NARROW LH

N

OT

E:

Do

no

t cu

t un

til afte

r alig

nm

en

t with

bu

mp

er

cu

t.

N

OT

E:

Th

is s

ectio

n trim

me

d a

fter fitte

d b

ack in

to

bu

mp

er to

pre

ven

t mis

ma

tch

to b

um

per c

ut.

ISSUE 01 : 17/05/18 of 70

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

FENDER LINER PICK-UP WIDE RH

N

OT

E:

Do

no

t cu

t un

til afte

r alig

nm

en

t with

bu

mp

er

cu

t.

N

OT

E:

Th

is s

ectio

n trim

med

afte

r fitted

ba

ck

into

b

um

per to

pre

ven

t mis

matc

h to

bu

mp

er c

ut.

ISSUE 01 : 17/05/18 of 70

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Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

FENDER LINER PICK-UP WIDE LH

N

OT

E:

Do

no

t cu

t un

til afte

r alig

nm

en

t with

bu

mp

er

cu

t. N

OT

E:

Th

is s

ectio

n trim

med

afte

r fitted

ba

ck

into

b

um

per to

pre

ven

t mis

matc

h to

bu

mp

er c

ut.

ISSUE 01 : 17/05/18 of 70

- Alloy Bull Bar


Part No. : PZQ2989303/308/313/317/322/347/403/408/413/417/422/447/510/520

all models with accessory bull bar additional service

Documents