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 (2-3 Post and Aerostyle) to TOYOTA RAV4 (2016+) 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 and extension 14mm Socket and extension 17mm Socket and extension Ratchet Jigsaw or other cutting tool (Bumper cut) Linersher or other filling tool (To neaten Bumper cut) Black paint Set square Masking tape Bolt and Bracket kit for fitment Items sent 4 16mm Flat washers 4 16mm Nylock Nuts 8 40mm x 10mm fine thread bolts 8 Tech screws 8 10mm Internal tooth washers 8 10mm Flat washers 8 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 1 2.5m Bumper Rubber 2 7 Rubbers 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 Prepare the vehicle ready for fitment: Using a flat blade screw driver, remove the top middle clips from the top of the bumper Working outwards, using a Phillips head screw driver remove the next two clips (either side of the ones you just removed) from the top of the bumper Using a 10mm socket, remove the outside clips from the top of the bumper Remove the clip near the wheel arce using a flat blad screw driver (repeat on the other side). Put aside all orginal clips for use later Using a Phillips head screw driver Using a 10mm socket Using a flat blade screw driver 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 extra plastic guards from under the vehicle (like a mud guard) Remove the stone tray (and throw away) by removing the orginal 10mm bolts and put the bolts aside for use in a mintue. Using the orginal bolts (just removed) replace the back bolts only into their position (minus the stone tray) using a 10mm socket. This is to hold the plastic as shown in the pitcure Remove the bumper 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
Installing the TUFF Crash box and brackets: Remove the foam and throw away. Remove the temp sensor and unclip the wiring from the orginal crash box Using a 14mm socket and extension, remove the orginal bolts (top and bottom) from the crash box. Remove orgianl crash box Mark out trim lines on the orginal crash box to trim the sides Trim with a cut off wheel Clean up sharp edge with a linisher or grinder and touch up the cut surface with black paint 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
Cont. Installing the TUFF Crash box and brackets: Remove extra plastic and throw away TIP: prepare all 10mm Flat Spring washers on the 40x10x1.25 fine thread bolts before assembly Attach the TUFF brackets behind the orginal crash box abd position in place using the orginal bolts. Leave all bolts loose until they are all positioned. Ensure the brackets are facing outwards Move the air conditioning pipe gently away if touching the bracket Replace the 10mm back bolts with the 40x10mm Fine thread bolts (supplied) 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 Crash box and brackets: Tighten all bolts on the crash box and brackets using a 17mm socket and extension Re-attach wiring back to the crash box. Now the vehicle is ready for the indicators lights to be connected, followed by the bullbar being installed 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 Once completed, position wiring under and behind the headlights Please note: on the indicator, colours may change on the wiring harness TIP: If unsure on what colours are what, grab a test light to find out 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
PREPARING THE BULLBAR Preparing the bullbar: Place rectangular (two wholed) runnber washers onto the bullbar mounting bolts Please note: this may have already been fitted for you Use some lube to assit the threads going onto the bullbar Ready to install the TUFF bullbar Installing the TUFF bullbar: TIP: remove the bumper support before putting the bullbar on Place the bullbar onto the brackets. Please note: for safety reasons, this is a two person job Secure the bullbar in place with the 16mm Nylock nuts and washers. Bolt it up loosely. Align the bullbar left and right, and make sure that the wings follow the line of the vehicle TIP: to even the the bullbar, you may need to use a couple of washers between the rubber and brackets to assist in evening both sides 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
Cont. Installing the TUFF bullbar: Align the bullbar with the square (Gap should be approx. 60mm with a 5mm tolerance either way) 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! 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 10MM GAP BETWEEN THE BULLBAR AND THE BUMPER BEFORE THE BUMPER RUBBER IS FITTED WE DO THIS BY MEASURING SIX MEASUREMENTS FROM THE BULLBAR TO THE CAR BODY POSITIONS THREE EACH SIDE (SUBRACT 10MM FROM THESE MEASUREMENTS) Preparing to cut the bumper: Ist measurement: Measure the verticle distance beteen the bullbar and the end of the flare arch TIP: Push the sqaure off the edge of the bullbar to measure 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: 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. Please note: the square will not fit at the 3 rd measurement, so you will need to take the measurement at the second lug on the head light TIP: write these measurements on a piece of masking tape and stick onto the bumper, ready to measure the bumper for cutting 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
Cont. Preparing to cut 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 (less a maxiumn of 20mm with a minumn of 10mm, to accommodate a gap between the bumper and bullbar) along the bumper ready to cut 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
Cont. Preparing to cut the bumper: Cut along the masking tape with a Jigsaw or other cutting tool Bumper has been cut and is now ready to be trimmed and neatened Try the bumper back on the vehicle to mark out your trim line 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 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
Finishing the bumper: Remove the small piece behind the flare to enable the mounting of the rubber strip on the bumper Attach the rubber (supplied) to the cut edge of the trimmed bumper Once the bumper is ready, try fitting it back to the vehicle. You may need to trim it, if it s not fitting evenly 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
Mudflaps: Trim the mudflaps first to accommodate a neat fit with the teck screws. Teck screw the mudflaps to the bullbar and trim more if necessary At the bottom of the mudflap, replace the self tapping hex heads and washers to secure the side of the bumper to the mudflap Tidy up any wiring Fit the number plate and indicator lights/park and fog lights if applicable. Using the 3/16x1 bolts and nuts supplied, fit the number plate to 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 compeleted! Please don t hesitate to call us on 1300 BE TUFF (1300 23 88 33) if you have any problems with fitting We are always looking for ways to improve our fitting instructions and encourage you to give us feedback on this. Send your feedback to marketing@tuffbullbars.com.au 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