BULLBARS FITTING INSTRUCTIONS FOR TOYOTA FORTUNER Last updated 9/2/16 TUFF BULLBARS AUSTRALIA sales@tuffbullbars.com.au 6 Tews Ct, (PO Box 1977) marketing@tuffbullbars.com.au TOOWOOMBA QLD 4350 feedback@tuffbullbars.com.au Phone: 1300 BE TUFF www.tuffbullbars.com.au (1300 23 8833) Fax: (07) 4633 1236 BULLBAR Fitting instructions to fit TUFF Range Bullbars (2-5 Post and Aerostyle) to TOYOTA FORTUNER Estimated fit time: 3 hours Call 1300 BE TUFF (1300 23 8833) for assistance
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 has been tested for Air Bag Compatibility and therefore the mounting system MUST NOT be modified 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 labels from the bullbar and/or brush rails & steps Bullbar installations should be done by a qualified person and it is the responsibility of this person to ensure correct fitment Tools suggested for fitment Phillips Screw Driver Flat Blade Screw Driver 10mm Socket 16mm Socket 18 or 19mm Socket 17mm Spanner Ratchet Jigsaw or other cutting tool (Bumper cut) Linersher or other filling tool (To neaten Bumper cut) Bolt and Bracket kit for fitment Items sent 2 90 x 10mm bolts 2 50 x 50mm Flat washers 2 12mm x 40mm x 1.25 fine thread bolts 2 12mm Spring washers 2 12mm Flat washers 4 50mm x 10mm bolts 6 10mm Nylock Nuts 4 Tech screws 8 10mm Flat washers 2 ¼ x 1 ¼ Mudguard washers 2 3/16 bolts and nuts 2 Bullbar Brackets 2 Indicators (Brytec) 2 Indicator leads 6 Wire tap connectors 2 7 Rubbers 2 Curved shaped Aluminium brackets 2 25mm x 25mm RHS (approx. 540mm long) 2.5m Small pinch weld rubber Items received (your check list) 2 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Read through the fitting instructions and pictures below. Fitting video to come shortly Prepare the vehicle ready for fitment: First remove the plastic radiator cover using the flat blade screw driver by popping out the clips (x8). Using a 10mm socket or phillips screw driver, remove the self tapping screws from either side of the grille and x2 from in the middle. Remove the grill by popping out the clips at the bottom of the grill. Once the grill is removed, using a 10mm socket remove the self tapping screws located underneath the grille. 3 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Cont. Prepare the vehicle ready for fitment: Remove the 10mm bolts from the bottom of the bumper (x9) Remove the clips from the wheel arch (x2) using a screw driver. INDICATOR LIGHTS 4 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Cont. Prepare the vehicle ready for fitment: Remove the bumper and all plastics (one down each side of the light and one across the crash box) Indicator Lights Installing the indicator lights: Connect the wiring kit to the wiring harness using wire taps or solder TIP: Try out the LED indicator lights before you install the bullbar YELLOW: INDICATOR WHITE: EARTH BLACK: PARK (Please note: On the indicator, colours may change on the wiring harness) Once completed, position wiring under and behind the headlights 5 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Installing the TUFF brackets: Slide the bracket on by placing the tubing into the chassis. Repeat on both sides Using the 90 x 10mm bolts, put through the chassis with the 50 x 50 flat washers, 10mm flat washer and nylock nut, on the inside of the chassis. At the back of the bracket, use the 12mm x 40 x 1.25 fine thread bolt with 12mm flat and spring washer. Loosely tighten 6 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Cont. Installing the TUFF brackets: Fully tighten the 90 x 10mm bolts first using a 16mm socket and 17mm spanner. Before tightening the back, make sure the brackets are facing straight up and down. Tighten the back of the bracket with a 19 or 18mm socket. If they haven t already been put on, place the two holed rubber on the thread inside the bullbar channel. TIP: Spray a lubricant spray on the bolts before you put the bullbar on to help the bullbar go on smoothly 7 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Cont. Installing the TUFF Crash box and brackets: The vehicle should be prepared for the bullbar to be installed (Indicator lights done, TUFF brackets tightened and in position ready for the bullbar) Ready to install the TUFF bullbar Installing the TUFF bullbar: Place the bullbar onto the brackets. Please note: for safety reasons, this is a two person job Secure the bullbar in place and loosely position the bolts ready to align and tighten TIP: to even the the bullbar, you may need to use a couple of shimes between the rubber and brackets to assist in evening both sides (washers work as shimes to give you the adjustment you may require) Installing the TUFF bullbar: Align the bullbar with the square Make sure that the wings follow the line of the vehicle. Once alighed, tighten all bolts TIP: tightening the bottom bolts moves the wing of the bullbar up. Tighten the top bolt moves the wing down. Please make sure all bolts are tight! 8 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
CUTTING THE BUMPER THE TOP HALF OF THE ORIGINAL BUMPER HAS TO BE PREPARED TO BE CUT AND RE-FITTED TO THE VEHICLE THERE WILL BE A 5-10MM GAP BETWEEN THE BULLBAR AND THE BUMPER WE DO THIS BY MEASURING SIX MEASUREMENTS FROM THE BULLBAR TO THE CAR BODY POSITIONS THREE EACH SIDE (SUBRACT 20MM FROM THESE MEASUREMENTS) Preparing to cut the bumper: Ist measurement: Measure the verticle distance beteen the bullbar and the end of the flare arch 2nd measurement: Measure the verticle distance just outside the of the headlight to the bullbar 3rd measurement: Measure the verticle distance just under the inside of the headlight to the bullbar TIP: write these measurements on a piece of masking tape and stick onto the bumper, ready to measure the bumper for cutting 9 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Preparing to cut the bumper: Mark all six measurments (1 st, 2 nd and 3 rd from above on each side) on the bumper Ist measurement from above place masking tape to measure the bumper 2nd measurement from above place masking tape to measure the bumper 3rd measurement from above place masking tape to measure the bumper Using making tap and your measurements, run the tap to accommodate a gap between the bumper and bullbar) along the bumper ready to cut 10 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Preparing to cut the bumper: Cut along the masking tape with a Jigsaw or other cutting tool Using your gap (maxiumn of 20mm with a minumn of 10mm) trim the bumper up with a Linisher or other sanding tool to neaten the bumper cut. Please make sure the end bumper looks neat Once the bumper is ready, try fitting it back to the vehicle. You may need to trim it if it s not fitting evenly Once you are happy with the bumper fit, place the pinch weld rubber on the bumper cut and position back onto the vehicle 11 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Secure original clips back on and tighten the original bolts at the top of the grill Fit the radiator guard back to the vehicle 12 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Mud Flaps Cut inner guard plastic, to make a slight round shape Install the curve shaped aluminium bracket to support the inner plastic mud guard. Teck screw plastic mud flaps to the bracket 13 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
PREPARING THE STABILISERS Preparing the stabilisers: Mark out the wholes in the RHS Stabiliers to be drilled Connect 25 x 25 RHS Stabiliser rod between the bullbar and the bracket Using two 10x50mm bolts, nuts and washers each side Last step; fit the number plate using the 3/16 x 1 bolts and nuts supplied and position and fit the indicator/park lights into the bullbar 14 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Job completed! PLEASE DON T HESITATE TO CALL US ON 1300 BE TUFF (1300 23 88 33) IF YOU HAVE ANY PROBLEMS WITH FITTING BEST REGARDS THE TUFF TEAM! 15 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E