T.J.M. T13 Outback Frontal Protection System, Fitting Instructions Manual

Page 1: ...riod of three 3 years after the date of purchase TJM shall repair at TJM s discretion the defective product or part 2 Any defect in a product distributed by TJM but not manufactured by TJM shall be dealt with in accordance with and to the extent of the warranty offered by the manufacturer of that product 3 TJM does not warranty that the products manufactured by it comply with the laws of the place...

Page 2: ...3 Outback Frontal Protection System Vehicle Toyota LandCruiser 200 Series 2007 Part No 070SB13R82A For further information contact T J M Head Office on 07 3865 9999 Distributors Australia wide File F 1434 docx Page 2 of 18 11 12 2013 ...

Page 3: ...e Tie 300mm 12 K1148 N A 3 16 Rubber Hose 2m 92517 ITEM NO Description Qty Part Number BOLT KIT N A 10g x 3 4 Philips Head Screw 10 K0734 N A 10g Speed Clip U Nut 10 K2078 N A M5 x 0 8mm x 20mm Pan Screw 4 K0688 N A M5 x 0 5 Nyloc Nut 4 K0604 N A M5 x Ø10mm Flat Washer 8 K0417 N A 3 16 x Ø3 4 Flat Washer 10 K2913 N A M6 x 1 0 x 16mm Hex Screw 12 K1232 N A M6 x 1 0 x 20mm Hex Bolt 8 K0550 N A M6 x ...

Page 4: ...taining the top of the grille Now release the eight clips along the bottom Retain all of the O E fasteners 5 Remove retain the grille 6 If fog lights are installed disconnect the wiring harness from the fog lights The OE fog lights are not required for the installation of this FPS 7 If O E headlight washers are installed disconnect the washer tube temporarily plug it 8 If O E parking sensors are i...

Page 5: ...Remove retain the upper bumper support OE fasteners indicated 12 Locate the fasteners securing the indicated plastic air guides to the vehicle Remove retain the air guides O E fasteners 13 Trim the plastic air guides removed in the previous step as shown Refer to the images on the following page also 14 Re fit the plastic air guides to the vehicle using the O E fasteners removed in step 12 15 Re f...

Page 6: ...of the chassis lower bumper retainers 17 Remove retain the tow lugs discarding the fasteners 18 Remove discard the shipping lugs 19 Remove retain the front 2 underbody guard fasteners 20 Fit the grille bracket to the upper bumper support using M8 x 1 25 x 20mm hex bolts 2 M8 x Ø19mm flat washers 4 M8 nyloc nuts 2 21 Remove Trim the bumper clips under the headlight so that they will not interfere w...

Page 7: ...tre line of the vehicle 24 Apply locktight to one end of the M12 x 1 75 x 280mm threaded rod then weave this end through the large hole in the chassis rail end secure it into the chassis rail mounting block that was installed in the previous step 25 Repeat the previous two steps for the opposite side of the vehicle 26 Orientating the chassis rail end spacers as shown position them on the end of th...

Page 8: ...acer plates 2 29 Secure both sides of the chassis mount in place to the captive studs using M10 x Ø30mm flat washers 2 M10 x 1 25 nyloc nuts 2 30 Reposition the tow lugs step 17 on the underside of the chassis mount as per their original orientation then secure the chassis mount in place using M12 x 1 25 x 45mm hex bolts 4 1 2 x Ø1 1 4 flat washers 4 M12 spring washers 4 31 Secure both sides of th...

Page 9: ...itted leave the 4 winch mounting holes vacant 33 Secure the upper locations with M8 x 1 25 25mm hex bolts 2 M8 x Ø19mm flat washers 4 M8 nyloc nuts 2 34 Ensuring that the indicated slots in the side of the chassis mount align with the respective slots in the centre support brace tighten the fasteners from the two previous steps to the specified torque settings listed on page 1 35 Fit the inner gua...

Page 10: ...1 12 2013 39 Trim the LHS plastic inner guard as shown 40 Trim the RHS plastic inner guard in line with the bottom of the radiator support panel Steps 41 through to 43 only apply if parking sensors are to be installed Otherwise proceed to step 44 41 On each side of the FPS drill the required Ø22mm hole for the parking sensors following the dimensions shown 42 De burr the holes then clean the area ...

Page 11: ...to install the 3 16 one way check valve near the headlight washer cut a length off the 3 16 rubber hose using the supplied cable ties fit one end to the headlight washer the other to the outlet end of the 3 16 one way check valve Ensure that the one way check valve is orientated correctly as it will only allow flow in one direction Steps 47 through to 51 only apply if a winch is to be fitted Other...

Page 12: ...lace through the two front fastening holes 50 2 M8 x 1 25 x 25mm hex screws 2 M8 x Ø19mm flat washers 4 M8 nyloc nuts 2 51 Using the fasteners retained in step 19 M8 x Ø19mm flat washers 2 secure the OE underbody guard at the indicated locations Steps 52 53 only apply if a winch is not fitted Otherwise proceed to step 54 52 With the OE underbody guard situated between the underbody guard cover the...

Page 13: ...nstall each fog light s wiring harness to the vehicle s wiring harness 55 Check the operation of the fog lights then un plug them 56 Loosely attach the fog light angle bracket to the fog light as shown using M6 x 1 0 x 16mm hex screws 2 M6 x Ø12 5mm flat washers 2 M6 flange nuts 2 The fog lights are left right Ensure that the wiring loom plug is facing the ground 57 Attach the fog light to the FPS...

Page 14: ...r park light s wiring to the vehicle then solder seal the joins LED WIRING Ground Parker Indicator White Brown Yellow 61 Check the operation of the indicator park lights then un plug them 62 Insert the nylon plugs supplied into the square cut outs for the indicator park lights as shown 63 Separate the indicator park light body from the backing plate 64 Secure the backing plate to the FPS using the...

Page 15: ...gh to 71 only apply if headlight washers were originally installed Otherwise proceed to step 72 69 Unplug the OE washer tube using the supplied cable tie connect it to the supplied 3 8 1 4 reducer fitting 70 Cut a length off the 3 16 rubber hose using the supplied cable ties fit one end to the 3 8 1 4 reducer fitting the other to the inlet of the 3 16 Y connector 71 Using the remaining 3 16 rubber...

Page 16: ...en the fasteners to the appropriate torque settings The minimum clearance between the wings and guards must be maintained to prevent clashing during off road driving 77 Adjust the headlight trims then tighten the screws The headlight trims must sit forward of the headlights to prevent clashing during off road driving 78 Using the indicated hole in the bar mount as a template drill a Ø10mm hole thr...

Page 17: ...osite side of the FPS 85 Re fit the grille back to its original position using the O E fasteners previously retained 86 Re fit the front plastic cover panel back to its original position using the O E fasteners previously retained 87 Re connect the indicator park lights 88 Position the wing guard as shown secure it in place using the fasteners listed below 88 1 M6 x 1 0 x 20mm hex bolts 4 M6 sprin...

Page 18: ... Office on 07 3865 9999 Distributors Australia wide File F 1434 docx Page 18 of 18 11 12 2013 92 Ensure that all of the relevant wiring looms are connected check that the indicators park lights winch fog lights etc are functioning correctly 93 Ensure that all fasteners are fully tightened that as a result of fitting the FPS no vehicle components are crushed of will chaff ...