INSTALLATION GUIDE · Page 4 of 20 Installation Guide BB064 Copyit 2020 Ionan 44 Pty Lt. No pat o...

INSTALLATIONGUIDE

TO SUIT TOYOTA PRADO 15012/2017+/MY2020 FACELIFT

BB064

• Ironman 4x4 BBP / BBT Bull Bar to suit a Toyota Prado 150 12/2017+ / MY 2020

• It will take about 4 hours to install

• All bolts, washers, spring washers and nuts are supplied unless otherwise indicated

• All drilled holes must have anti-corrosion treatment applied

If your vehicle has front parking sensors and you wish to refit them, refer to fitting

diagram on back pages of this instruction manual

IMPORTANT: Bull Bar installations should only be done by a qualified person

and it is the responsibility of this person to ensure correct fitment.

NOTE: This product has been tested for air bag compatibility and therefore the mounting system MUST NOT BE modified

©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd

BB0

6408

1220

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BB064Installation Guide


Bull Bar Parts List

Bolt Tension Chart

1. Bull Bar

QTY-1

2. Park Light Loom

QTY-1

3. Mounting Bracket with Kits Box

QTY-1

4. Side protection L-R

QTY-2

5. Centre Protection

QTY-2

6. Support Bracket L-R

QTY-2

7. Support Bracket L-R

QTY-2

8. Bracket

QTY-2

9. License Plate Bracket

QTY-1

10. Pinch Weld 1m

QTY-1

17. STL Bottle Opener

QTY-1

16. Logo

QTY-1

13. Parking Sensor Set

QTY-17

14. Bolt M12x1.25x40mm

QTY-2


QTY-14


QTY-18


QTY-4

18. Bolt M12x1.25x100mm

QTY-4


QTY-4

20. Cage Nut M6x1

QTY-2


QTY-2


QTY-2


QTY-12


QTY-2

25. Special WasherOD 30mm ID 11mm

QTY-2


QTY-2

27. Washer M12

QTY-2

28. Special Plate Washer 25x80mm

QTY-2

29. Primer

QTY-1

Property Class TORQUE maNOMINAL DIAMETER - COARSE THREAD

M6 M 8 x 1 M 10 x 1.25 M 12 x 1.5

8.8Nm 10.5 25 49 88

ft/lb 7.7 18 36 64

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1. Before installation check bull bar application is compatible with your vehicle. Before making any cuts, please refer to bumper cutting instructions applicable to your vehicle model.

3. Remove grill, front bumper, bumper bar reinforcement, bumper bar support brackets and front protection plate from under chassis.

4. Only applicable to MY 2020 carefully lever chrome trims away from inside top corners of headlights using a soft tool to prevent damage.

5. Only applicable to MY 2020 carefully remove 2 clips retaining the outer ends of the rubber attached to the top of the grill.

6. Only applicable to MY 2020 disconnect the radar located behind the centre grill badge if applicable.

2. Unwrap bull bar. Check over riders and light assemblies are tight in bull bar before installation.

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7. Only applicable to MY 2020 remove the retaining screws from the top of the grill, carefully release the clips and remove the grill.

8. Attach inner and outer chassis support brackets using the following:

• 2 x M12 x 1.25 x 100 mm through holes A and B with flat washers, spring washers and M12 nuts

• 1 x M12 x 1.25 x 90 mm bolt through hole C with spring washer, flat washer and channel nut

• Black M8 bolt through hole D with spring washer and flat washer

• 1 x M12 x 40 mm bolt through hole E with spring and flat washer

A

DB

E

C

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9. Carefully adjust A/C hose bracket towards A/C condenser to allow clearance for winch cradle.

10. Centralise bracket to the body of the vehicle and tighten all bolts.

11. Attach winch cradle to chassis using 6 x M10 x 1.25 x 30 mm bolts, spring washers and plate washers to outside holes with captive nuts. 2 x M10 x 1.25 x 40 mm bolts, 16 flat washers, 8 x spring washers and 8 x M12 nuts to remaining holes.

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12. Install supplied park light loom as shown.

13. Run green wire through firewall.

Remove panel containing mirror controls.

14. Solder green wire onto dash light wire using tester to locate correct wire.

Insulate soldered wire and re-install panel.

Correct wire will be green or blue depending on model.

15. Connect indicator wiring to connector shown in photograph. Using an LED test light check for correct connection points or refer to your workshop manual if you are unsure.

Parker light Parker light

Battery +Earth

Relay

Through firewall

Wiring Instructions

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16. Mask ends of bumper as shown and mark cut lines using template provided. Mask a horizontal line across the bumper 20 mm below grill recess and align with cut lines previously marked.

Cut along lines previously marked, remove lower section of bumper.

20mm from the bottom of the grill to cut line

17. Re-fit bumper bar and grill to the vehicle using factory mounting hardware.

18. Remove parking sensors from bumper bar and fit to bull bar making sure they are centrally located to the holes.

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IMPORTANT: For parking sensors to function correctly these instructions must be followed closely.

Before removing sensors from original bumper bar, note the location and orientation of each sensor so when they are fitted the bullbar this can be

duplicated.

Universal Parking Sensor Installation

1. Remove rubber grommets from sensor holes in bullbar.

2. Remove blank from sensor holder and trim any excess plastic from inside opening if applicable.

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3. Fit sensor with factory silicone sleeve to the sensor holder and secure using clamping plate and screws provided. Do not over tighten. Clamping plate has a flat side for thicker sensors and a raised section on the other side for thinner sensors. It is important that clamping plate is the correct way around as sensor will false alarm if excess pressure is applied to the sensor body.

4. Clean inside of bullbar around sensor holes and mounting surface of sensor holders using wax and grease remover.

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5. Apply adhesion promoter to mounting surfaces around sensor holes and on sensor holders.

NOTE: This step is important to ensure sensor holders adhere properly to the bullbar.

6. Remove protective film from one side of double-sided tape and apply to mounting surface of sensor holder.

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7. Remove protective film from double-sided tape and apply sensor holder/sensor to bullbar making sure sensors are in the same positions as they were in the original bumper and in the same orientation.

The two outer wing parking sensors will require the extra ‘O’ ring placed over the silicone sleeve.

NOTE:

Sensor nuts only need to be ‘nipped’ up. Do not overtighten or sensor will not function as intended.

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19. Fit bull bar to chassis brackets using 6 x M12 x 40 mm bolts, 12 x flat washers, 6 x spring washers and 6 x M12 nuts provided.

20. Align bull bar with vehicle, leaving a 20 mm gap for body movement.

21. Once bull bar is aligned with vehicle and tightened, drill through pinning holes (circled in yellow) between bull bar and chassis bracket and secure with 4 x M10 x 1.25 x 30 mm bolts, 8 x flat washers, 4 x spring washers, 4 x 10M flat washers and nuts provided.

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23. Connect park lights, indicators and fog lights.

22. Fit side wing supports to both sides using bolts provided - 2 x black M8 bolts, spring washers and flat washers per side and 1 x M10 x 30 mm bolt, spring washer and flat washer per side.

24. If applicable, fit camera and parking sensor wiring loom. The wiring loom to the sensors will be long enough without lengthening but may have to be removed from factory conduit in order for it to reach. Replace conduit as required.

Do not cut wiring.

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25. Attach centre protection plate to bull bar followed by side plates using M8 bolts, spring washers, flat washers and nuts. Trim guard liners to suit.

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1. Bolt winch to cradle with gearbox to the left hand side of vehicle and cable spooling from bottom of the cable drum using bolts and washers provided.

2. Bolt fairlead to recess in front of bull bar using bolts, washers and nuts provided.

3. Fit bull bar to vehicle referring to steps of bull bar fitting instructions.

4. Mount control box in desired location.

5. Connect three colour coded cables to the corresponding poles on winch motor.

Winch Installation

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8. Connect positive and negative battery cables main battery of vehicle (Not Auxilliary Battery).

9. Attach breather hose to barb fitting on winch motor. Run hose to the highest available point in engine bay and cable tie in position. Cable tie hose away from any sharp, hot or moving objects.

7. Run the positive and negative battery cables into the engine bay taking care to secure cables away from any sharp or moving objects.

6. Connect the thin black earth wire and negative battery cable to the earth connection on the opposite side of winch motor.

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Bull Bar Parklight

Blue

Relay

Connector

Ground

Fuse

Red

3085

8687

87a

Red Lamp

Black

LampBattery

Ground

Ground

NOTE: Do not use factory parker light wiring. Use bull barparker light whenwired with loom instep 8 of the bull bar fitting instructions.

White

SwitchSPST

Yellow

Red

BrownDaytime Running Light

Park Light

Indicator Light

Ground

White

If vehicle is not �tted with DRL, leave red wire disconnected

PARK LIGHT & INDICATOR

WITHOUT FACTORY FITTED FOG LIGHTS

WITH FACTORY FITTED FOG LIGHTS

Blue

Relay

Connector

Power from existing factory fog light

Ground

Fuse

Red

3085

8687

87a

Red Lamp

Black

LampBattery

Wiring Instructions

/3 270720

BBP064 / BBT064BULL BAR TEMPLATETO SUIT TOYOTA PRADO 150 SERIES 2017+

UNDER HEADLIGHT

0

10

20

30

40

50

60

70

80

90

100 MM

TOWARD CENTRE OF VEHICLE

JOIN HERE

JOIN HERE

DISABLE PAGE SCALING WHEN PRINTINGCHECK RULER DIMENSIONS TO ENSURE ACCURACY BEFORE CUTTING

/3


UNDER HEADLIGHT

FRONT GUARD

CUT LINE

270720

0 10 20 30 40 50 60 70 80 90 100

MM

JOIN HERE

JOIN HERE

JOIN HERE



/3


FRONT GUARD

270720

0 10 20 30 40 50 60 70 80 90 100

MM

JOIN HERE


INSTALLATION GUIDE · Page 4 of 20 Installation Guide BB064 Copyit 2020 Ionan 44 Pty Lt. No pat o...

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