Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

Tow-Pro Wiring Kit - Landcruiser LC200

Accessory KitEstimated Fitting Time: 120 Minutes

Kit Part No: TPWKIT - 005

Page 01 of 13

Parts Supplied

Safety Notes

General Notes

Tools Required

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

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Read through the fitting instructions before installation of the accessory. Install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or the accessory.

Ensure all recyclables, discarded vehicle accessory components and packaging are recycled following local recycling regulations.

It is always recommended that this accessory is fitted by a qualified automotive Technician.

Safely store and protect any removed vehicle components.

Ensure all bare metal surfaces are protected using automotive bare metal primer and touch-up paint, or suitable automotive rust inhibitor.

Remove all metal swarf and dust from all vehicle surfaces if surfaces are used for accessory installation.

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Check that all work practices comply with safety standards.

Please wear appropriate clothing and use safety equipment.

Ratchet Socket Set Side CuttersPhillips Head Screw Driver Trim Removal Tools

A

Electric Brake Harness x1

D EB C F

Switch Bezel x1

G H I

ECU Bracket x1 Cable Ties x25

J K

M4 Nyloc Nut x4 Fitting Instructions x1

Crimper

Wire Stripper

Page 02 of

200mm x10900mm x15

4-way connector x1

M4 Flat Washer x4

Butt Splice x1

Black Heat Shrink x1Anti-abrasion Tape 100mmx100mm x1

Soldering Iron & Solder Wire Heat Gun Spanner Set

13

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

13Page 03 of

Wiring Diagram

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

Step 3

Step 1

Step 2

Important

Always refer to the vehicle’s Workshop Manual when removing vehicle components.

• Note down all clock and radio settings.

•

• If vehicle has a dual battery kit installed, disconnect the negative battery terminals on both batteries.

In the engine bay, disconnect the negative battery terminal (1).

1

• Remove the driver’s scuff plate (1) from the vehicle.

• For High-Spec models, disconnect the wiring from the illuminated scuff plate (2).

1

Page 04 of

• Remove the driver’s dash under guard (1) by releasing three clips (2) and two screws (3).

• Disconnect the footwell light wire if present.

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33

1

2

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Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

• Remove the RHS trim cover (1) on the center console.

1

Page 05 of

• Remove the driver’s kick panel (1) from the vehicle by removing the screw (2).

1

2

• Remove the bolt (1) and the trim clip (2).

2

1

Step 6

Step 4

Step 5

13

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

13

• Remove the RHS garnish (1) above the lower cluster finisher (2).

• Release the two bolts (3) and dislodge

• Disconnect all applicable connectors behind the switch panel (4).

• Remove the vacant switch blank as shown (5).

Note: If the indicated switch cavity is already occupied by another

switch, any other vacant switch blank can be removed.

• Remove the lower cluster finisher (2).

the lower cluster finisher (2).

2

3

3

5

4

• Dislodge the RHS center console trim (1) and disconnect the Engine start button (2) from behind.

• Remove the RHS center console trim (1).

• Remove the LHS garnish (3).

Page 06 of

Step 9

Step 7

Step 8

1

• In the engine bay remove the seven clips (1) securing the grill upper trim (2) and remove the grill upper trim from the vehicle.

21 111

1 11

2

3

1

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

Step 10

• Route the Electric Brake Harness (1) over the radiator shroud following the factory dual battery harness (2) if present.

• Secure the Electric Brake Harness (1) using the supplied Cable Ties (3).

• If the factory dual battery harness (2) is not present, route the Electric Brake Harness (1) in the same position.

• Route the Electric Brake Harness (1) behind the secondary battery (2) if present.

• Continue under the air box filter bracket and towards the driver side firewall.

• Secure the Electric Brake Harness (1) using the supplied cable ties.

• Secure the ground ring terminal from the Electric Brake Harness (1) to the vehicle chassis grounding point (3).

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1

1

2 33

3

Page 07 of

• Fasten the Fuse Holder positive ring terminal on the Electric Brake Harness (1) to the positive battery terminal.

• Secure the Fuse Holder (2) to the vehicle battery harness using the supplied Cable Ties (3).

Step 11

Step 12

Important

Ensure the vehicle positive battery terminal cover is seated fully and correctly after installation.

1

3

2

1

3

3

13

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

4

3

1

2

• Secure the Brake Controller ECU (1) to the ECU Bracket (2) using the supplied M4 Flat Washers (3) and M4 Nyloc Nuts (4).

• Locate the RHS firewall grommet. Cut an access point on the outer side of the RHS grommet. Lubricate the grommet access point (1) with a suitable lubrication if required.

• Secure the section of the Electric Brake Harness (2) with four terminals to a guide wire using tape. Keep the thickness of the taped section small. Feed the guide wire into the previously cut RHS access point of the firewall grommet.

• Ensure the guide wire breaks the internal seal and is fed into the RHS of the cabin.

• Continue feeding the soft tube section of the harness into the cabin until the junction meets the grommet.

• Secure the Electric Brake Harness to the vehicle harness and seal the grommet with silastic and a supplied Cable Tie (3).

• To reduce risk of water ingress, create a small loop (4) on the harness below the grommet entry using either tape or cable tie.

• Discard the guide wire after routing.

(1)

1

Page 08 of

Step 13

Step 14

Step 15

• Inside the vehicle, using the table below, house the terminals (1) from the Electric Brake Harness into the supplied 4-Way Connector (2), ensuring the terminals lock into the housing.

• Snap off the secondary lock (3) from behind the 4-Way Connector (2).

• Fit the secondary lock (3) to the underside of the 4-Way Connector (2).

Wire ColourTerminal

1234

RedBlue

WhiteBlack

Rear View of Connector(Wire Entry Side)

4 3 2 1

2

3

3

2

4-way ECUconnector

Cat 5 CableConnector

1

3

42

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Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

Page 09 of

• Connect the 4-Way connector (1) from the Electric Brake Harness to the Brake Controller ECU (2).

• Connect the supplied Cat 5 Cable (3) to the Brake Controller ECU (2).

Step 16

Step 17

Step 18

• On the RHS of the steering column, secure the Brake Controller bracket assembly (1) to the existing vehicle bolt (2) as shown.

• Adhere the supplied Anti-Abrasion Tape (3) to the top of the bracket assembly (1) to prevent damage to any vehicle wires.

• Insert the Switch Insert (1) into the vacant cavity on the switch panel (2).

Note: If the indicated switch cavity is already occupied, any other

vacant cavity can be used, including on the panel to the left of the

steering wheel.

• Insert the Electric Brake Switch (3) into the Switch Insert (1) from behind.

• Fasten the supplied Nut (4) locking the Electric Brake Switch (3) to the Switch Insert (1). Torque the Nut (4) to 0.8Nm.

• Rotate the shaft fully anti-clockwise and fit the knob (5) to the shaft with “0" pointing upwards as shown.

• Route the Cat 5 Cable (6) to the switch panel area (2) and connect to the Electric Brake Switch (3) from behind.

• Secure the excess Cat 5 Cable (6) with the supplied Cable Ties.

2 1

1

6

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5

4

2

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1

1

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2

13

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

13Page 10 of

• In the engine bay, route the Electric Brake Harness (1) (BLUE, RED & RED/WHITE wires) down to the RHS chassis rail.

Note: the harness joint should sit approximately 100mm forward of

the grommet.

Step 19

Step 20

Step 21

1

• Route the Electric Brake Harness (1) along the top of the chassis rail towards the rear of the vehicle.

• Continue routing the Electric Brake Harness (1) across the rear bumper towards the trailer socket head.

• Secure the Electric Brake Harness (1) at every 400mm using the supplied 900mm Cable Ties.

Note : Ensure Cable Ties are behind the fuel lines.

ImportantEnsure to keep the Electric Brake Harness (1) away from any suspension components, moving parts, exhaust pipes or sharp objects.

• Remove the ‘BLUE’ wire (pin 5) (1) from the trailer wiring harness socket head (2).

• Tape back and isolate.

• Insert the new ‘BLUE’ wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket.

Pin No. Function Cable Colour123456

7

Left-hand turn signalReversing signalEarth returnRight-hand signalService brakesStop lamp signalRear lamps, clearance andside marker lamps

YellowBlackWhiteGreenBlueRed

Brown

4

7

2

3

5

6

1

2

1

1

ImportantEnsure to keep the Electric Brake Harness (1) away from any suspension components, moving parts, exhaust pipes or sharp objects.

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

Page 11 of

Step 22

Step 23

• Locate ‘RED’ wire (pin 6) (1) on the trailer wiring harness socket head.

• Cut the wire 150mm from the base of the socket.

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7

2

3

5

6

1

Pin No. Function Cable Colour123456

7

Left-hand turn signalReversing signalEarth returnRight-hand signalService brakesStop lamp signalRear lamps, clearance andside marker lamps

YellowBlackWhiteGreenBlueRed

Brown

1

150mm

X

• Locate the ‘RED/WHITE’ (1) wire from the Electric Brake Harness.

• Slide the supplied Heatshrink over the ‘RED/WHITE’ (1) wire and the previously cut ‘RED’ (2) wire on the vehicle end.

• Crimp both wires using the supplied Butt Splice with an indent type crimper.

• Solder the wires to the Butt Splice. Ensure that a good connection is made.

1 2

3 4Keep heatshrink away from joint until after soldering is complete and cooled.

• Wait for the Butt Splice to cool, slip the heatshrink over the joint and heat.

• Remove the cut ‘RED’ wire (pin 6) from the trailer socket and discard.

• Insert new ‘RED’ wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket.

• Re-connect negative battery terminal.

• Test the operation of the Electric Brake Harness using a test lamp or a multimeter to ensure correct operation.

• Dispose of any parts not used from the fitment.

Please place the Owners Manual in the glov box after installation completed.

e the is

ImportantSecure all harnesses to the vehicle using the supplied cable ties. Refit all removed parts and secure all fasteners to Service Manual torque specifications.

Important

Reprogram all radio stations and clock settings by referring to the vehicle's Workshop Manual.

Step 24

11

2

Red

Red/White

Red/White

13

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

13

E. & O.E. This document is copyright and must not be used except as permitted below or under the Copyright Act 1968. You may reproduce and publish this document in whole or in part for your or your organisation's own personal or internal compliance, educational or non-commercial purposes. You must not alter or amend this document in any way. You must not reproduce or publish this document for commercial gain without the prior written consent of the copyright owner.

Page 12 of

Landcruiser LC200

FI11848 Issue: 3 Date: 27/09/2017

Kit Part No: TPWKIT-005

© 2017

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