Mahindra Pikup (009 Production Onwards) Steel Bull Bar INSTALLATION INSTRUCTIONS Accessory Part No. BBAR07 Installation Time: 60min Approx Bull Bar Weight: 60KG! Important: Please read each step of these instructions carefully, prior to commencing installation. Do not use this product on 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 Bull Bar and/or its mounting brackets, in any way. Repair or modification may affect proper operation of the airbag, resulting in serious injury. Do not remove the label from the Bull Bar. Flat + Phillips Screwdrivers Sharp Knife Hacksaw Tape Measure Tools Required 8mm Drill 8, 0, 3,, and 6mm Sockets Socket Extension 6mm Spanner Bolt Assembly Torques M6 = Nm M0 = Nm Parts List ITEM COMPONENT NAME QTY ICON ITEM COMPONENT NAME QTY ICON BULL BAR 3 M6 NYLOCK NUT FRONT BRACKET M0X30MM HEX BOLT 3 REAR BRACKET 5 M0X0MM HEX BOLT 6 LOWER BRACKET RHS 6 M0X0MM HEX BOLT 5 LOWER BRACKET LHS 7 M0 FLAT WASHER 6 NUT PLATE - DOUBLE 8 M0 CRUSH NUT 7 NUT PLATE TRIPLE 9 STEEL PIN 8 6GXMM TEKS SCREW 0 STEEL SPACER - TRIMMED 9 M5 FLAT WASHER STEEL SPACER - ROUND 0 M6X0MM HEX BOLT LED COMBINATION LAMP M6X6MM PHILLIPS HEAD 3 WIRING LOOM KIT M6 FLAT WASHER 09/07/0 Page of
Bull Bar- Exploded Diagram Mahindra Pikup - BULL BAR 8 9 3 7 8 6 9 0 5 7 3 8 7 7 5 9 0 7 6 Page of
Winch Kit - Exploded Diagram (Part # KIT0379) Mahindra Pikup - BULL BAR D G F F B C A F G F E Winch Kit Parts List ITEM COMPONENT NAME QTY ICON ITEM COMPONENT NAME QTY ICON A BOTTOM PLATE E M0X90MM HEX BOLT B TOP PLATE F M0 FLAT WASHER 8 C FRONT PLATE G M0 CRUSH NUT D M0X30MM HEX BOLT Page 3 of
. Remove the Numberplate Philips Screwdriver Undo the phillips head screws, and remove the number plate from the front bumper. Figure. Remove the Splashguard 3mm Socket Undo the 5 retaining bolts, to remove the plastic splash guard from the vehicle. Figure 3. Remove the Front Bumper mm Socket + Extension Flat Bladed Screwdriver Disconnect the wiring connectors from the back of the fog lamps. Remove the two plastic covers on the front bumper, by carefully levering them out using a flat screwdriver. Through the access holes, remove the nuts retaining the front bumper, and carefully remove the bumper from the vehicle. Figure 3 Page of
MOUNTING BOLTS. Remove the Radiator Shroud 3mm Socket Remove the bolts retaining the plastic radiator shroud, and remove the shroud from below. REMOVE SHROUD Figure 5. Remove the Rubber Strips from the Bumper Peel the rubber strips from the top edges of the front bumper. Figure 5 6. Remove the Fog Lamps from the Bumper Phillips Screwdriver Undo the 3 screws to remove the foglamps from the back of the front bumper. Figure 6 Page 5 of
7. Modify the Fog Lamps Hacksaw Sharp Knife 8mm Drill a) For both fog lamps, use a saw and a sharp knife to remove the outboard mounting tab, as shown. REMOVE OUTBOARD MOUNTING TAB HORIZONTAL FLANGE Ensure webs are trimmed flush to the horizontal flange. HORIZONTAL FLANGE Figure 7a b) Using the 8mm drill bit, drill a hole through the horizontal flange of each foglamp, in the location shown. 7mm 39mm Figure 7b 8. Fit the Rubber Strips to the Bull Bar Fit the rubber strips to the upper edges of the bull bar, in the same orientation that they were fitted on the bumper (i.e. with the flap side upwards). Figure 8 Page 6 of
TEKS SCREWS + WASHERS M6 HEX BOLT 9. Install the Fog Lamps in the Bull Bar Phillips Screwdriver 0mm Socket 0mm Spanner Loosely fit the foglamps to the bull bar, using the M5 (smallest) Flat Washers under the heads of the Teks Screws, for locations, and an M6 Hex Bolt with Washer and Nut, for the third location. Once all fasteners are installed, fully tighten. Figure 9 0. Install the Combination Lamps 8mm Socket Fit the combination lamps through the appropriate holes in the front the bull bar, and fasten from behind, using the hardware supplied with the lamps. Do not over-tighten. Figure 0. Install the Wiring Looms in the Vehicle POSITION a) Externally, from the front of the vehicle, install the RHS and LHS wiring looms into the engine bay, by feeding the bare (non-plugged) ends upwards, through the gap below the headlamps. SIGNAL Feed the looms until they can be accessed from the area behind the headlamps, as shown. Unplug the vehicle s loom connectors from the signal (indicator), and position (parker) lamps. Figure a Carefully peel back the corrugated plastic sheath from the cables. Page 7 of
Function RHS Signal Vehicle Wiring Colour BLUE BLACK RHS Patch Loom Colour YELLOW - LHS Patch Loom Colour - - b) Securely fit-off the new loom to the vehicle wiring, as shown in the table. Ensure the splicing connectors are securely crimped, and use a generous amount of electrical tape around the connections, to ensure no moisture can penetrate. LHS Signal ORANGE BLACK - YELLOW - - Use the cable ties to secure the loom to the vehicle loom, ensuring it is clear of sharp edges. Position Lamps WHITE BLACK BROWN BLACK BROWN BLACK Lightly pull the plugged-ends of the looms downwards, to take out excess wire from the engine bay. Figure b. Install the Chassis Brackets mm Socket Tape Measure 75mm Slide the chassis end plate stud-plates so they are centred vertically in their slots. Then fit the Rear Chassis Brackets, using the original flange nuts, which were removed in step #3. Evenly align the brackets with a 75mm spacing between the inside faces, and fully tighten. Figure BRACKET ROUND SPACER Figure 3 TRIMMED SPACER BRACKET 3. Install the Lower Brackets To fit the Lower Brackets, first insert the Steel Pins through the large holes in the chassis rails, then fit the Spacers to the appropriate sides of the Pins -> Round Spacers inboard sides, Trimmed Spacers to the outboard. See exploded diagram for more detail. After fitting the Lower Brackets, insert the Hex Bolts with Flat Washers through the assemblies, from the outboard sides of the chassis rails, and fit the remaining Flat Washers, and finally the Crush Nuts. Do not fully tighten. For installation of the Bull Bar without a winch, please skip to step #0 Page 8 of
. Install the Front Brackets 6mm Socket 6mm Spanner Whilst aligning the Lower Bracket slots with the Rear Brackets, fit the Front Brackets to the assembly. Fasten the assembly using M0x0mm Bolts, (inserted from the outboard side) along with Triple Nut Plates. Pull the Front Brackets to their forward-most position, and whilst ensuring the front flanges are aligned in a vertical plane, fully tighten the fasteners. Figure 5. Install the Winch Plates VEHICLE CROSSMEMBER 6mm Socket 6mm Spanner Fit the Upper and Lower Winch Plates to the chassis crossmember, and loosely fit the M0x90mm Hex Bolts, to hold the assembly in place, then loosely fit the M0x30mm Hex Bolts, as shown. SECTION VIEW SHOWING OVERLAP Figure 5 Pull the assembly to it's forward-most position, so the rear flanges are firmly seated against the chassis crossmember, and fully tighten all the fasteners. 6. Reposition the Horns MOUNT HORNS TO THESE TABS 3mm Socket Un-bolt the horns from the vehicle, and re-fit to the metal tabs, which are visible through the clearance holes in the Upper Winch Plate. Figure 6 Page 9 of
7.Fit the Winch to the Vehicle FRONT PLATE WINCH FEET MOUNTING HOLES Figure 7 Follow the fitting instructions supplied with your winch, to fit the winch to the Winch Plate assembly. Additional notes: Wiring should be fitted to the winch before mounting, as access to the rear and underside of the winch is limited, once it is in position. The main power cables (from the battery), should also be fitted, but do not attach to the battery terminals at this stage. In the feet-down orientation, the winch should be assembled with it's clutch lever shaft aligned vertically upwards. The two front winch feet bolts are also used to retain the Front Winch Plate, as shown. Do not fully tighten those two bolts at this stage. Orient the winch so the steel cable is exits forwards from the underside of the drum. 8. Fit the Bull Bar 6mm Socket NOTE: A minimum of THREE people are required for this step. There are two small hook-like features on the Bull Bar mounting flanges, which can hook over the front flanges of the Mounting Brackets, and hold the weight, whilst the required fasteners are fitted. Figure 8 FRONT Once the fasteners are in place, align the Bull Bar to the desired position, and fully tighten. 9. Remaining Winch-Related Steps a) Ensure the Front Winch Plate is pulled to it's forward-most position, seated against the inside face of the Bull Bar. b) Follow the fitting instructions supplied with your winch, to fit the fairlead rollers to the front of the Bull Bar. c) It is often easier to remove the side (short) rollers to allow access to the bolt heads. This can usually be done by removing the circlips which retain the roller pins. d) Fully tighten the winch mounting bolts, to the torque recommended in the fitting instructions supplied with your winch. e) Follow the fitting instructions supplied with your winch, to finalise the winch installation. eg. Wiring, solenoid, etc. Please skip to step # Page 0 of
Figure 0 FRONT 0. Fit the Bull Bar 6mm Socket NOTE: A minimum of THREE people are required for this step. There are two small hook-like features on the Bull Bar mounting flanges, which can hook over the front flanges of the Mounting Brackets, and hold the weight, whilst the required fasteners are fitted. Once the fasteners are in place, align the Bull Bar to the desired position, and fully tighten.. Re-connect the Fog Lamps, and Re-Fit the Number Plate a) b) c) Re-connect the wiring loom to the foglamps. Ensure the connectors make a positive "click" when plugged in to the lamps. Fit the number plate to the front of the Bull Bar. If a winch has been fitted to the vehicle, fit a slim-line number plate, and use the upper mounting holes, in order to clear the winch fairlead rollers. If a winch has not been fitted to the vehicle, fit the number plate to the lower mounting holes, in order to cover the fairlead opening. It is often easier to remove the side (short) fairlead rollers to allow access to the bolt heads. This can usually be done by removing the circlips which retain the roller pins. d) Fully tighten the winch mounting bolts, to the torque recommended in the fitting instructions supplied with your winch. e) Follow the fitting instructions supplied with your winch, to finalise the winch installation. eg. Wiring, solenoid, etc. **** END **** Page of