TOYOTA KLUGER / HIGHLANDER. (2010 Production Onwards) INTEGRATED SIDE STEPS INSTALLATION INSTRUCTION. 60 Minutes

Transcription

1 TOYOTA KLUGER / HIGHLANDER (2010 Production Onwards) INTEGRATED SIDE STEPS INSTALLATION INSTRUCTION Accessory Part No. STEP Minutes Approx Product Weight: 33 lbs 15KG IMPORTANT - PLEASE READ INSTRUCTIONS BEFORE COMMENCING INSTALLATION! max load 150 kg 330 lbs Place these instructions in the vehicle s glovebox after installation is complete Do not use this product in any other motor vehicle for which it is not designed. Do not use any other mounting location / method other than described in this instruction. It is advisable to seek assistance of another person when installing this product. Do not repair or modify the product and / or its mounting bracket in any way - repair or modification may effect proper operation of the airbag resulting in serious injury. MAINTENANCE To maintain your product properly, wash regularly with car wash detergent, hose off & chamois dry. Stubborn grime can be removed with kerosene. REQUIRED TOOLS EQUIPMENT 13mm and 17mm Socket ½ Drive Ratchet 13mm and 17mm wrench / spanner Right Angle Drill Ø8mm Drill Bit 10mm Socket 10mm wrench / spanner Torque Wrench (50 Nm/40 lbf) Cleaning Materials Pliers Scissors Tape Non Permanent Marker Personal Protective Equipment: Safety Glasses, Ear Plugs, Gloves

2 TOYOTA HIGHLANDER / KLUGER - SIDE STEP STEP0003 COMPONENTS LIST 3PC LAYOUT

3 STEP 1 CLEAN INSTALLATION AREA 1. Remove mudflaps if fitted and thoroughly clean & dry the installation area. Repeat process on the other side of the vehicle. REMOVE ALL MUDFLAPS, IF FITTED Item 1 PART 2 PART 3 PART 4 PART 5 PART ART Parts Li Component Nam STEP 2 STOCKTAKE OF PARTS Check supplied parts and fasteners against Parts List, before commencing fitment. STEP 3 FIT BOLTS AND ENDCAPS Slide in M8 bolts as per diagram. Fit front and rear end caps to both aluminium extrusions. Endcap Endcap M8 bolts x 8

4 STEP 4 TIGHTEN FASTENERS TO SECURE END CAPS TO EXTRUSION Tighten M8 nuts firmly with ratchet to secure endcap. cut along centre of channels cut line bisects centre circle STEP 5 REMOVE AND CUT SHROUD ACCORDING TO DIMENSIONS SHOWN 100 mm 4 Remove existing fasteners and screws to release shroud. Larger version of cutting guide for both shrouds can be found on the back pages of this document. 50mm mm 4 Right Hand Side Shroud cut along outer wall of channels cut line bisects centre circle STEP 6 REMOVE AND CUT SHROUD ACCORDING TO DIMENSIONS SHOWN 100 mm 4 Remove existing fasteners and screws to release shroud. Larger version of cutting guide for both shrouds can be found on the back pages of this document. 50mm mm 6 50mm 2 Left Hand Side Front Shroud

5 STEP 7 Remove fastener indicated Ease the cover off the blue fasteners and retain With the door OPEN: Gently lever this fastener from the hole shown STEP 8 Perform the procedure shown in picture. xample STEP 9 RETAIN COVER FOR POSSIBLE FUTURE USE Retain fastener, do not lose.

6 STEP 10 M8 T-bolt x 3 PRE-ASSEMBLE FRONT BRACKETS Pre-assemble M8 T-bolts, M8 flat washers, M8 spring washers and M8 nuts to Front Brackets. T-bolt Flat Washer Spring Washer Bracket LH Front Brackets shown as example Nut M8 T-bolt x 2 M10 T-bolt x 1 STEP 11 PRE-ASSEMBLE REAR BRACKETS Pre-assemble T-bolts, flat washers, spring washers and nuts for both M8 and M10 to Rear Brackets. T-bolt Bracket Flat Washer Spring Washer LH Front Brackets shown as example Nut FRONT OF VEHICLE STEP 12 INSTALL RHS FRONT BRACKET Taking the front bracket, fit the M8 T- bolts, M8 flat washers, M8 spring washers, and M8 nuts into the inboard and outboard holes. Hand tighten nuts only at this time.

7 STEP 13 INSTALL RHS REAR BRACKET Taking the rear bracket, fit the M8 and M10 T- bolts, flat washers, spring washers, and nuts into the inboard and outboard holes. Hand tighten nuts only at this time. STEP 14 At this point, slightly loosen the bolts on the side of each bracket to allow the step bar to be fitted and properly adjusted. Use a 17mm socket and a 17mm wrench / spanner. RHS Front Brackets shown as example STEP 15 Carefully place the Alumininium Side Step on front and rear brackets.

8 45 Nm 33 lbft STEP 16 Fit M8 Bolts, M8 Flat Washers, M8 Spring Washers and M8 nuts to brackets. Tighten to 45 Nm. STEP 17 With the bars now loosely secured to the brackets, rotate the steps upward so that the end caps meet the body of the car and the holes in the caps line up with the original holes on the car. 45 Nm flb STEP 18 Re-tighten the nuts on the brackets. Ensure that the endcaps are fitting tightly to the vehicle and no gaps are evident before final tightening. Use a 17mm socket and 17mm wrench. ( LH Rear Brackets shown as example. )

9 STEP 19 Re-check all fasteners have been tightened and there is no movement. Carefully place weight on the step for the first time to ensure that all fasteners and brackets are secure. Ensure rigid fit STEP 20 Replace fastener previously removed in STEP 7. STEP 21 As brackets are symmetrical, repeat steps 7-20 at the bracket locations for the opposite hand of the vehicle. Refit the cut shrouds from steps 5 and 6 to complete the installation.

10 100 mm 4 cut along centre of channels cut line bisects centre circle 50mm mm 4 Right Hand Side Shroud (NTS)

11 100 mm 4 cut along outer wall of channels cut line bisects centre circle 50mm mm 6 50mm 2 Left Hand Side Front Shroud (NTS)

12 PRODUCT CARE INFORMATION IMPORTANT: CUT-OUT AND STAPLE IN A SUITABLE LOCATION IN VEHICLE S OWNER MANUAL TOYOTA KLUGER / HIGHLANDER INTEGRATED SIDE STEPS APPEARANCE AND PRODUCT CARE: Wash regularly with car wash detergent, rinse with clean water and chamois. Stubborn grime can be removed with kerosene. EGR RUNNING BOARDS SIDE STEPS