INSTALLATION GUIDE BBP064/ BBT064/ BBT064-NL TOYOTA PRADO 12/2017+ Ironman 4x4 BBP/ BBT Bull Bars fit to a Toyota Prado 12/2017+ It will take about 4 hours to install. IMPORTANT - If your vehicle has front parking sensors and you wish to refit them, refer to fitting diagram on back pages of instruction manual. NOTE: This product has been tested for air bag compatibility and therefore the mounting system MUST NOT be modified IMPORTANT: Bull Bar installations should only be done by a qualified person and it is the responsibility of this person to ensure correct fitment. 080518
1. Before installation check bull bar application is compatible with your vehicle. 2. Remove grill, front bumper, bumper bar reinforcement, bumper bar support brackets and front protection plate from under chassis. 3. Mark and trim plastic air deflector to clear bull bar bracket as shown. 4. Position channel nuts in adjusting slots for inner chassis strengthening brackets as shown. Page 2 of 16
5. Loosely attach inner and outer chassis strengthening brackets in position on chassis using supplied bolts. NOTE: Check bolt clearance on radiator, air conditioning condenser and air-conditioning lines 6. Install winch cradle as shown using hardware provided. 7. Centralise and tighten all bolts. Page 3 of 16
Wiring Diagrams PARK LIGHT & INDICATOR 8. Use supplied park light loom. Install loom into location as shown. Through firewall Relay Earth Battery + Parker light Parker light 9. Run green wire through firewall. Remove panel containing mirror controls. 10. Solder green wire onto dash light wire using tester to locate correct wire. Insulate soldered wire and re-install panel. 11. For indicator wiring, pick up from plug located under headlight. Page 4 of 16
12. Mark bumper bar with template provided on each side, continue line across bumper bar as shown. 20mm from the bottom of the grill to cut line 13. Re-fit bumper bar and grill to the vehicle Page 5 of 16
14. Unwrap bull bar. Check over riders and light assemblies are tight in bull bar before installation. 15. Remove parking sensors from bumper bar and fit to bull bar making sure they are centrally located to the holes. NOTE: Sensor nuts only need to be nipped up. Do not overtighten or sensor will not function as intended. 16. Fit bull bar to chassis brackets using M12 bolts, flat washers, spring washers and nuts provided. 17. Align bull bar with vehicle, allow adequate clearance for body movement. Be aware the Toyota Prado 150 has very soft body mounts, and the body will move a lot. Page 6 of 16
18. 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 bolts, washers and nuts provided. 19. Fit side wing supplorts to both sides using bolts provided - 2 x M8 and 1 x M10 per side. 20. Connect park lights, indicators and fog lights as per wiring diagrams at the rear of this Instruction Guide. Page 7 of 16
21. If applicable, fit camera and parker 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. 22. Attach centre protection plate to bull bar followed by side plates. Trim guard liners to suit. Page 8 of 16
Winch Installation 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 where it will not interfere with sensors behind the grill. 5. Connect three colour coded cables to the corresponding poles on winch motor. Page 9 of 16
6. Connect the thin black earth wire and negative battery cable to the earth connection on the opposite side of winch motor. 7. Run the positive and negative battery cables into the engine bay taking care to secure cables away from any sharp or moving objects. 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. Page 10 of 16
Wiring Diagrams PARK LIGHT & INDICATOR Park Light Indicator White Yellow Park Light Circuit Black Ground Ground Black Indicator Circuit WITH FACTORY FITTED FOG LIGHTS Ground Fuse Red 85 30 Red Lamp 87 86 87a Relay Connector Battery Blue Lamp Black Power from existing factory fog light WITHOUT FACTORY FITTED FOG LIGHTS Ground Fuse Red 85 30 Red Lamp 87 86 87a Relay Connector Battery Blue Lamp Black NOTE: Do not use factory parker light wiring. Use bull bar parker light when wired with loom in step 8 of the bull bar fitting instructions. Bull Bar Parklight Ground Ground White Switch SPST Page 11 of 16
Plastic Parking Sensor Installation IMPORTANT: Parking sensors should be installed as close to the same direction as when they sit in the factory bumper. 1. For new vehicles with parking sensors, the new bars will now come with a plastic parking sensor holder kit. The sensor mounting kit will be inside the bar mounting hardware box. 2. The bars come with a rubber plug in the sensors hole. This plug needs to be pushed out if you need to install the sensors into the bar. Page 12 of 16
3. Using some cleaner, clean around the sensor hole on the INSIDE of the bar. 4. The kit comes with double sided stickers to enable you to stick the sensor holder in place. 5. Remove the middle of the sensor holder to allow the vehicle sensor to go through. Page 13 of 16
6. Clean the plastic sensor holder and install the double sided sticker. 7. Remove the double sided stickers protective layer and install the sensor holder into the bar. IMPORTANT: Parking sensors should be installed as close to the same direction as when they sit in the factory bumper. Page 14 of 16
8. Remove the parking sensor from the factory bumper and ensure the rubber liner is in place. 9. The parking sensor kit allows the backing plate to go 2 ways. Depending on the thickness of the sensor, you can adjust fitment. If the sensor is larger, install the sensor backing plate with the smooth side down. If the sensor is smaller, install the packing plate with the spacer side down. Page 15 of 16
10. Install the backing plate to suit the sensor. 11. Ensure that the sensor is installed correctly and centred. Page 16 of 16