Accessory Kit Estimated Fitting Time: 120 Minutes (Prado) Estimated Fitting Time: 140 Minutes (Kluger)

Transcription

1 Tow-Pro Wiring Kit - Toyota Kluger / Prado Accessory Kit Estimated Fitting Time: 0 Minutes (Prado) Estimated Fitting Time: 0 Minutes (Kluger) FI99 Page 0 of Issue: Date: 0/0/0 0

2 General Notes 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 recommend 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 metals swarf and dust from all vehicle surface if surfaces is used for accessory installation. Safety Notes Check that all work practices comply with safety standards. Please wear appropriate clothing and use safety equipment. Parts Supplied A B C D E F.m Cat Cable x Electric Brake Harness x -way Connector x Brake Controller Bracket x Butt Splice x Ømm Heatshrink x G H I J K L Switch Insert x M Flat Washer x M Nyloc Nut x M Pan Head Screws x M Flat Washer x Mx Bolt x M N 00mm x0 900mm x0 Cable Ties x0 Fitting Instruction x Tools Required Phillips Head Screw Driver Ratchet Socket Set Trim Removal Tools Guide wire PVC Tape Silicone Spray Silicone Sealant FI99 Page 0 of Issue: Date: 0/0/0 0

3 Wiring Diagram Kluger (Page ) Prado (Page ) ECU Switch Switch ECU FI99 Page 0 of Issue: Date: 0/0/0 0

4 Step KLUGER (For Prado refer to Page ) Always refer to the vehicle s Workshop Manual when removing vehicle components. Note down radio settings, as per Toyota Workshop manual. In the engine bay, disconnect the negative battery terminal (). Step Inside the vehicle, remove the passenger side scuff plate trim (). Remove the kick panel trim nut (). Remove the kick panel (). Repeat for RHS. Step Remove the LHS dash side garnish (). Repeat for RHS. FI99 Page 0 of Issue: Date: 0/0/0 0

5 Step KLUGER Push down on the clips () and remove the lower glovebox cover (). Step Dislodge the glovebox damper (). Push the side walls inwards and then remove the glovebox (). Step Remove the three upper glovebox surround fasteners (). Remove the two lower glovebox surround fasteners (). Dislodge the glovebox surround (). Disconnect the light connector () from behind the glovebox surround (). Remove the glovebox surround (). FI99 Page 0 of Issue: Date: 0/0/0 0

6 Step KLUGER Remove the two fasteners () from the driver s garnish underside trim (). Press down on the clip () and remove driver s garnish underside trim (). Remove the one lower trim fastener (). Dislodge the driver s garnish lower trim (). Disconnect all switch connectors from behind the switch panel and one connector () next to the boot latch. SRS AIRBAG Disconnect the boot latch (). Remove the driver s garnish lower trim (). Step 8 In the front passenger side foot well, locate the upper grommet nipple () on the firewall grommet. Carefully cut off the grommet nipple () using a sharp knife. Step 9 In the engine bay, secure the section of the Electric Brake Harness () with the four terminals to a guide wire () using tape. Keep the thickness of the taped section small. On the LHS firewall grommet (), lubricate the upper grommet access point () with a suitable lubrication if required. Feed the guide wire () into the upper grommet access point (). Ensure the guide wire () breaks the internal seal and continue feeding the harness into the cabin until the corrugated section of the harness contacts the grommet (). FI99 Page 0 of Issue: Date: 0/0/0 0

7 Step 0 KLUGER Clean off any lubricant used in previous step. Seal the grommet () around the Electric Brake Harness () using silicone sealant, on both the engine bay and cabin sides of the grommet (). Secure the Electric Brake Harness () to the vehicles main harness using a supplied Cable Tie (). Step Inside the vehicle, route the Electric Brake Harness () from the grommet towards front passenger RHS footwell area. Secure the Electric Brake Harness () to the existing vehicle harness using the supplied 00mm Cable Ties () as shown. Ensure the Electric Brake Harness is kept away from any sharp or moving parts and clear of being pinched by trim re-fitment. Step Using the table below, house the terminals () from the Electric Brake Harness into the supplied -Way Connector () ensuring the terminals lock into the housing. Snap off the secondary lock () from behind the -Way Connector (). Fit the secondary lock () to the underside of the -Way Connector (). Terminal Wire Colour Red Blue White Black Rear View of Connector (Wire Entry Side) FI99 Page 0 of Issue: Date: 0/0/0 0

8 Step Secure the Brake Controller ECU () to the ECU Bracket () using the supplied M Pan Head Screws (), M Flat Washers () and M Nyloc Nuts (). Ensure to use the mounting holes () on the ECU Bracket () that are designed for the Toyota Kluger. Cat Cable KLUGER -way ECU connector Step On the support bar located in the RHS area of the glove box, release the two vehicle M8 nuts () from the threaded studs. Using the vehicle M8 nuts (), secure the ECU Bracket assembly () onto the two threaded studs as shown. Step Connect the -way connector () from the Electric Brake Harness to the Brake Controller ECU (). Connect the Cat Cable (), supplied in the wiring kit, to the Brake Controller ECU (). FI99 Page 08 of Issue: Date: 0/0/0 0

9 Step KLUGER Remove the switch blank () from the drivers under dash trim (). Route the Cat Cable () along the dash towards the under dash trim () area. Secure using the supplied Cable Ties. Ensure the Cat Cable () does not interfere with the steering column, any of the vehicle pedals or the airbag system. Step Insert the supplied Switch Insert () into the vacant cavity on the drivers under dash trim (). Insert the Electric Brake Switch () into the Switch Insert () from behind. Fasten the supplied Nut () locking the Electric Brake Switch () to the Switch Insert (). Torque the Nut () to 0.8Nm. Rotate the shaft () fully anti-clockwise and fit the knob () to the shaft with 0" pointing upwards as shown. Connect the Cat Cable () to the Electric Brake Switch () from behind. Secure the excess Cat Cable () with the supplied Cable Ties. Reinstall the drivers under dash trim (). (Kluger) Step 8 In the engine bay, locate the three loose wires on the Electric Brake Harness () and route down the firewall and towards the LHS chassis rail. Secure to the existing vehicle harness using the supplied Cable Ties. Ensure the Electric Brake Harness () does not make contact with any sharp edges or moving parts. Avoid areas of extreme temperatures. FI99 Page 09 of Issue: Date: 0/0/0 0

10 Step 9 KLUGER Under the LHS of the vehicle, remove the fasteners and dislodge the underbody cover (). Route the Electric Brake Harness () along the LHS chassis or along the air conditioning pipes towards the vehicles rear cross member. Secure using the supplied 900mm Cable Ties at 00mm intervals. Reinstall the underbody cover (). Step 0 At the rear cross member, route the Electric Brake Harness () towards the rear of the vehicle, following the existing vehicle harness. From the LHS of the rear cross member, route the Electric Brake Harness () behind the trim towards the trailer socket. Ensure the Electric Brake Harness () does not make contact with any sharp edges or moving parts. Avoid areas of extreme temperatures. Step At the rear of the vehicle, remove the vehicles trailer socket fasteners to release the trailer socket (). Remove the cover () from the trailer socket (). FI99 Page 0 of Issue: Date: 0/0/0 0

11 Step KLUGER Remove the BLUE wire () from the trailer wiring harness socket head (). Tape back and isolate. Insert new BLUE wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket. Pin No. Function Cable Colour Left-hand turn signal Reversing signal Earth return Right-hand signal Service brakes Stop lamp signal Rear lamps, clearance and side marker lamps Yellow Black White Green Blue Red Brown Step Locate RED wire () on the trailer wiring harness socket head. Cut the wire 0mm from the base of the socket. Remove the cut RED wire () from the trailer socket. 0mm Pin No. Function Cable Colour Left-hand turn signal Reversing signal Earth return Right-hand signal Service brakes Stop lamp signal Rear lamps, clearance and side marker lamps Yellow Black White Green Blue Red Brown X Step Butt-splice and heat shrink the previously cut RED wire on the vehicle end, to the RED/WHITE wire on the Electric Brake Harness. Slide the supplied Heatshrink over the wires before crimping both wires to the supplied Butt Splice using indent type crimpers. Solder the wires to the Butt Splice. Ensure that a good connection is made. Wait for the Butt Splice to cool, slip heatshrink over the joint and heat. Keep heatshrink away from joint until after soldering is complete and cooled. Red/White Red Red/White Insert new RED wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket. FI99 Page of Issue: Date: 0/0/0 0

12 Step KLUGER In the engine bay, route the Electric Brake Harness () along the existing vehicle harness towards the battery. Fasten the positive terminal of the Electric Brake Harness () to the positive battery terminal. Fasten the negative terminal of the Electric Brake Harness () to the negative battery terminal. Secure the harness with Cable Ties at 00mm intervals. Secure the harness fuse to the vehicle harness with a Cable Tie. Step Reconnect the engine bay 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. Secure all harnesses to the vehicle using the supplied cable ties. Refit all removed parts and secure all fasteners to Service Manual torque specifications. Reprogram all radio stations and clock settings by referring to the vehicle's Workshop Manual. Please place the Owners Manual in the glove box after the installation is completed. FI99 Page of Issue: Date: 0/0/0 0

13 Step PRADO (For Kluger refer to Page ) Always refer to the vehicle s Workshop Manual when removing vehicle components. Note down radio settings, as per Toyota Workshop manual. In the engine bay, disconnect the negative battery terminal (). Step Inside the vehicle, remove the passenger side scuff plate trim (). Remove the kick panel (). Open the glovebox () and dislodge the dampener. Remove the glovebox (). Remove the upper glovebox garnish (). Remove the LHS dash side garnish (). Step Remove the glovebox undertray () by first removing the screw (). Remove the four bolts () from the glovebox surround (). Remove the glovebox surround (). FI99 Page of Issue: Date: 0/0/0 0

14 Step Remove the RHS dash side garnish (). Dislodge the driver s garnish lower trim (). Remove the vehicle switch blank () by pushing from behind. PRADO Step On the LHS side of the engine bay, locate the grommet nipple () on the firewall grommet (). Carefully cut off the grommet nipple () using a sharp knife. Step Secure the section of the Electric Brake Harness () with the four terminals to a guide wire () using tape. Keep the thickness of the taped section small. On the LHS firewall grommet (), lubricate the upper grommet access point () with a suitable lubrication if required. Feed the guide wire () into the upper grommet access point (). Ensure the guide wire () breaks the internal seal and continue feeding the harness into the cabin until the corrugated section of the harness contacts the grommet (). FI99 Page of Issue: Date: 0/0/0 0

15 Step PRADO Clean off any lubricant used in previous step. Seal the grommet () around the Electric Brake Harness () using silicone sealant, on both the engine bay and cabin sides of the grommet (). Secure the Electric Brake Harness () to the vehicles main harness using a supplied Cable Tie (). Step 8 Using the table below, house the terminals () from the Electric Brake Harness into the supplied -Way Connector () ensuring the terminals lock into the housing. Snap off the secondary lock () from behind the -Way Connector (). Fit the secondary lock () to the underside of the -Way Connector (). Terminal Wire Colour Red Blue White Black Rear View of Connector (Wire Entry Side) Step 9 Secure the Brake Controller ECU () to the ECU Bracket () using the supplied M Pan Head Screws (), M Flat Washers () and M Nyloc Nuts (). Ensure to use the mounting holes () on the ECU Bracket () that are designed for the Toyota Prado. FI99 Page of Issue: Date: 0/0/0 0

16 Step 0 PRADO Using the supplied M Bolt () and M Flat Washer (), secure the ECU Bracket assembly () to the inside panel on the LHS of the glovebox area. Ensure the vehicle metal tab () is located in the slot of the ECU Bracket. Step Inside the vehicle, route the Electric Brake Harness () towards the front passenger kick panel area. Secure the Electric Brake Harness () to the existing vehicle harness using the supplied 00mm Cable Ties () as shown. Ensure the Electric Brake Harness is kept away from any sharp or moving parts and clear of being pinched by trim re-fitment. Step Connect the -way connector () from the Electric Brake Harness to the Brake Controller ECU (). Connect the Cat Cable (), supplied in the wiring kit, to the Brake Controller ECU (). FI99 Page of Issue: Date: 0/0/0 0

17 Step PRADO Route the Cat Cable () towards the drivers under dash trim area. Secure the Cat Cable () to the existing vehicle harness using the supplied 00mm Cable Ties. Step Insert the supplied Switch Insert () into the vacant cavity on the drivers under dash trim (). Insert the Electric Brake Switch () into the Switch Insert () from behind. Fasten the supplied Nut () locking the Electric Brake Switch () to the Switch Insert (). Torque the Nut () to 0.8Nm. Rotate the shaft () fully anti-clockwise and fit the knob () to the shaft with 0" pointing upwards as shown. Connect the Cat Cable () to the Electric Brake Switch () from behind. Secure the excess Cat Cable () with the supplied Cable Ties. Reinstall the drivers under dash trim (). Step In the engine bay, locate the three loose wires on the Electric Brake Harness () and route down the firewall and towards the LHS chassis rail. Secure to the existing vehicle harness using the supplied Cable Ties. Ensure the Electric Brake Harness () does not make contact with any sharp edges or moving parts. Avoid areas of extreme temperatures. FI99 Page of Issue: Date: 0/0/0 0

18 Step PRADO Under the LHS of the vehicle, continue routing the Electric Brake Harness () along the LHS chassis Secure using the supplied 900mm Cable Ties. Step At the rear cross member, route the Electric Brake Harness () towards the rear of the vehicle, following the existing vehicle harness. From the LHS of the rear cross member, route the Electric Brake Harness () behind the trim towards the trailer socket. Ensure the Electric Brake Harness () does not make contact with any sharp edges or moving parts. Avoid areas of extreme temperatures. Step 8 At the rear of the vehicle, remove the vehicles trailer socket fasteners to release the trailer socket (). Remove the cover () from the trailer socket (). FI99 Page 8 of Issue: Date: 0/0/0 0

19 Step 9 PRADO Remove the BLUE wire () from the trailer wiring harness socket head (). Tape back and isolate. Insert new BLUE wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket. Pin No. Function Cable Colour Left-hand turn signal Reversing signal Earth return Right-hand signal Service brakes Stop lamp signal Rear lamps, clearance and side marker lamps Yellow Black White Green Blue Red Brown Step 0 Locate RED wire () on the trailer wiring harness socket head. Cut the wire 0mm from the base of the socket. Remove the cut RED wire () from the trailer socket. 0mm Pin No. Function Cable Colour Left-hand turn signal Reversing signal Earth return Right-hand signal Service brakes Stop lamp signal Rear lamps, clearance and side marker lamps Yellow Black White Green Blue Red Brown X Step Butt-splice and heat shrink the previously cut RED wire on the vehicle end, to the RED/WHITE wire on the Electric Brake Harness. Slide the supplied Heatshrink over the wires before crimping both wires to the supplied Butt Splice using indent type crimpers. Solder the wires to the Butt Splice. Ensure that a good connection is made. Wait for the Butt Splice to cool, slip heatshrink over the joint and heat. Keep heatshrink away from joint until after soldering is complete and cooled. Red/White Red Red/White Insert new RED wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket. FI99 Page 9 of Issue: Date: 0/0/0 0

20 Step PRADO In the engine bay, route the Electric Brake Harness () along the existing vehicle harness towards the battery. Fasten the positive terminal of the Electric Brake Harness () to the positive battery terminal. Fasten the negative terminal of the Electric Brake Harness () to the negative battery terminal. Secure the harness with Cable Ties at 00mm intervals. Secure the harness fuse to the vehicle harness with a Cable Tie. Step Reconnect the engine bay 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. Secure all harnesses to the vehicle using the supplied cable ties. Refit all removed parts and secure all fasteners to Service Manual torque specifications. Reprogram all radio stations and clock settings by referring to the vehicle's Workshop Manual. Please place the Owners Manual in the glove box after the installation is completed. E. & O.E. This document is copyright and must not be used except as permitted below or under the Copyright Act 98. 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 noncommercial 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. FI99 Page 0 of Issue: Date: 0/0/0 0

21 Kluger / Prado FI99 0 Issue: Date: 0/0/0