INSTALLATION GUIDE BULLBAR - GREAT WALL V200 / V240

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John Simmons
5 years ago
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1 INSTALLATION GUIDE BULLBAR - GREAT WALL V200 / V240 BA BF BULLBAR FORD FALCON 1 P a g e

Read Fitting instructions carefully before fitting product to vehicle When installed in accordance with these instructions, the front protection bar does not affect operation of the srs airbag This

2 Read Fitting instructions carefully before fitting product to vehicle When installed in accordance with these instructions, the front protection bar does not affect operation of the srs airbag This product must be installed exactly as per these instructions using only the parts supplied In the event of damage to any bullbar component, contact the tuff team ASAP Do not use this product for any vehicle make or model, other than those specified by tuff Do not remove any lables from the bullbar or brush rails & steps Ensure Number plate is Clearly Visible FITTING KIT BULLBAR 8 40mm x 10mm Bolts 4 16mm nylock nuts 4 16mm flat washers 4 50mm x 10mm Bolts 24 10mm Flat washers 12 10mm Nylock Nuts 2 Teck screws 2 ¼ x 1 ¼ mudguard washers 2 3/16 x 1 Bolts & Nuts 2 5 Rubber Pads 2 25 x 25 RHS Stabilisers cut to length 2 Bullbar Brackets 2 Indicators (brytec) 2 Indicator leads 6 Wire tap connectors 2 5 rubbers Please note when fitting / refitting the number plate to the vehicle, ensure that it is clearly visible accordance with local laws. Use the number plate mount if fitted. 2 P a g e

3 Remove grille Remove bumper and white plastic honeycombs Connect wiring kit to wiring harness using wire taps or solder Wiring goes under and behind headlights TIP: Try out LED lights before you fit bullbar YELLOW = INDICATOR WHITE = EARTH BLACK = PARK 3 P a g e

Hold bracket onto crash box as shown, mark

through the crash box (11mm - hole) Secure

4 Hold bracket onto crash box as shown, mark positions for drilling Drill 1 x 11mm hole and secure with 40 x 10mm bolts, nuts and washers Drill the 3 bottom horizontal holes through the crash box (11mm - hole) Secure bracket with 3 x 40 x10mm bolts, nuts and washers 4 P a g e

Left and right hand brackets on the vehicle Place

mounting bolts (They may be already fitted) Place Bullbar

Bolt it up loosely with washers and 16 mm nuts.

5 Left and right hand brackets on the vehicle Place rectangular, two holed, rubber washers onto the bullbar mounting bolts (They may be already fitted) Place Bullbar onto the brackets. Bolt it up loosely with washers and 16 mm nuts. Align the bullbar left and right and make sure that the wings follow the line of the vehicle. Tighten all bolts 5 P a g e

Cutting the Bumper The top half of the original bumper has to be cut & re-fitted to the vehicle there should be a final gap of 12mm 15mm between the bullbar

6 Bullbar should run parallel to vehicle edge Tip: tightening the bottom bolts moves the wing of the bullbar. Tightening the top bolt moves the wing down make sure bolts are tight! Cutting the Bumper The top half of the original bumper has to be cut & re-fitted to the vehicle there should be a final gap of 12mm 15mm between the bullbar & the bumper. To do this measure six measurements from bullbar to vehicle body positions three each side, as shown. 1 st Measurement Measure the vertical distance between the end of the bullbar and the end of the wheel arch. TIP: Push the square off the edge of the Bullbar to measure 6 P a g e

2 nd Measurement Measure the vertical distance just under the

3 rd Measurement Measure the distance between just under the

Mark all six measurements (3 on each side) on the bumper (less 10

7 2 nd Measurement Measure the vertical distance just under the outside of the headlight to the bullbar as shown in the picture. 3 rd Measurement Measure the distance between just under the inside of the headlight to the bullbar as shown in the picture. Mark all six measurements (3 on each side) on the bumper (less 10 mm to accommodate a gap between the bullbar and the bumper) 3 rd 2 nd 1 st 7 P a g e

Run a tape along the six marked position to

Once the top bumper is ready it will look like

8 Run a tape along the six marked position to highlight a cutting line Cut along the line with a jigsaw or a similar tool. Clean up the cutting edge. Once the top bumper is ready it will look like this. Try it on the vehicle. You may need to trim it if it is not fitting evenly. 8 P a g e

Fit top half of the bumper to the vehicle.

the bullbar corner and the bracket as shown

9 Fit top half of the bumper to the vehicle. Fit top half of the bumper to the vehicle. Connect 25 x 25 RHS Stabiliser Rod between the bullbar corner and the bracket as shown Holes in RHS will have to be marked and drilled. Use two 10 x 50 Bolts, Nuts & Washers. 9 P a g e

indicator/park lights connect lights into

10 Teck screw plastic mud flaps to the bullbar or support. Use large washers supplied, trim flap if necessary Fit number plate and indicator/park lights connect lights into wiring harness Use 3mm Bolts and Nuts supplied Completed!! Well done 10 P a g e

11 PARK LIGHT & INDICATOR DIAGRAM PARK LIGHT INDICATOR Black Yellow Park Light Circuit Indicator Circuit Earth (white) 11 P a g e

1300 BE TUFF TUFF BY NAME * TUFF BY NATURE

1300 BE TUFF TUFF BY NAME * TUFF BY NATURE TUFF BULLBARS AUSTRALIA, Ph: 1300 BE TUFF (1300 23 88 33) 5-7 Holt Drive, (P.O. Box 1977) Fax: 07 4633 1236 Torrington, sales@tuffbullbars.com.au Toowoomba, admin@tuffbullbars.com.au Queensland 4350, feedback@tuffbullbars.com.au