ARB 321 4450 Fitting Instructions Manual Download Page 21 | Manualshive

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05/10/11

Page 21 of 21

378 7983

Indicator
Loom Part
No 6821152

Relay Loom
Part No
6821198

Indicator
Loom Part
No 6821152

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Summary of Contents for 321 4450

Page 1: ... WARNING NOTE THE FOLLOWING This product must be installed exactly as per these instructions using only the hardware supplied In the event of damage to any bull bar component contact your nearest authorised ARB stockist Repairs or modifications to the impact absorption system must not be attempted Do not use this product for any vehicle make or model other than those specified by ARB Do not remove...

Page 2: ...n or on an annual basis it is recommended that a thorough visual inspection of the bar is carried out making sure that all bolts and other components are torqued to the correct specification Also check that all wiring sheaths connectors and fittings are free of damage Replace any components as necessary This service can be performed by your local authorized ARB Stockist HAVE AVAILABLE THESE SAFETY...

Page 3: ...RHS 6821151L 1 INDICATOR KIT LHS 6821116 4 NYLON PLUG 6151308 4 SCREW SELF TAPPING 6821152 2 WIRING LOOM 6821198 1 INDICATOR RELAY LOOM 3163052R 1 TRIM WING LH HILUX 11 WING TRIM FITMENT 3163052L 1 TRIM WING RH HILUX 11 4581082 10 WASHER FLAT M6 BLACK 20 OD 6151384 2 PAN HEAD SCREW 5X16MM BZ 6151162 8 NUT NYLOC M6x1 3756721 1 BRKT CHASSIS MOUNT HILUX 05 IMPACT ABSORBER TO CHASSIS 4581040 4 WASHER ...

Page 4: ...4581287 10 WASHER SPRING M6 BLACK 6151213 10 BOLT M6 x 1 0 x 20 BLACK 6151094 2 BOLT M12 x 1 25 x 30 LONG 4581049 2 WASHER FLAT M12 4581050 2 WASHER SPRING M12 6151234 2 BOLT M8 x 1 25 x 25 LONG BLACK 6151303 2 CAGE NUT M8 3mm PLATE 4581045 2 WASHER FLAT M8 BLACK 4581047 2 WASHER SPRING M8 BLACK 3758190R 1 BRACKET WING STONE SHIELD RH 3758190L 1 BRACKET WING STONE SHIELD LH Tools required 10 mm 5 ...

Page 5: ...r of the light fitting Remove the bumper braces and discard Remove the chassis cross brace and discard Remove the factory fog lamps from the bumper bar and keep aside 2 Remove the plastic bumper retention blocks from either side of the vehicle 3 Replace the front most screws these secure the head lights 4 Spray paint the metal underside of the fender and the underside of the headlamp black Ensure ...

Page 6: ... grill removed at step 1 make sure the 2 lower grill tabs are pushed into the clips in the lower grill bracket Bend lower grill bracket tab upwards slightly 7 Remove the vehicles headlights 8 Carefully read the wiring diagram supplied at the end of these instructions 9 Take the relay loom 6821198 from the kit and position in the engine bay so that all wires will reach the appropriate connections ...

Page 7: ...k wire from the vehicles left indicator 12 Connect the Yellow and Black wires from the relay loom to the Green and Black wires from the indicator loom 13 Let the indicator loom hang freely for connecting to the bull bar indicators later on 14 Do the same for the drivers side using the wiring diagram supplied as a reference for the correct wire colors 15 Find a suitable place and mount the relay NO...

Page 8: ...ny hot sharp or moving surfaces 19 Remove the protruding bracket in front of the radiator as it is no longer required note the vertical member of this bracket must not be removed as it holds the bonnet latch in position This may be done by either drilling out the existing spot welds with a 5mm drill as shown or by cutting it off with a grinder Re locate the air temp sender if fitted to one of the ...

Page 9: ...d portion is to top of bull bar 22 Remove the fastening screws and nuts supplied with the turn signal clearance lamps and replace these with the four screws provided in the kit Push the square plastic plugs into the holes on the turn signal bracket Fasten the turn signal lamps to the bull bar as shown NOTE The drain holes in the lamp are at the bottom As shown IMPORTANT The turn signal amber secti...

Page 10: ...lamp into the bracket bend the tabs on the bracket in towards the lamp with a screwdriver Repeat this on the other side NOTE If the removal of the fog light is necessary pry the tabs outward from the lamp and using a screw driver between the body of the lamp and bracket on the inner longer side of the bracket flex the bracket to disengage the fog lamp post from the bracket 26 The fog lamp surround...

Page 11: ...n an optimal position TO FIT A WINCH BAR If not fitting a winch proceed to step 51 28 To fit an 8 9 9 5 000lb winch rotate gearbox 72 counterclockwise 29 Stand the winch upright and undo the capped head screws Lift the gearbox up only a couple of millimeters to allow the gearbox to be rotated to the new position Once in position refit all screws and tighten firmly WARNING Do not lift gearbox more ...

Page 12: ... before closing control box cover 32 This must be done for whatever winch is to be fitted to the bull bar 33 If fitting the XP 9 5 winch remove the cover from the control box otherwise proceed to step 36 Remove the two cap screws nuts and spacer washers that hold the four solenoids in place 34 Remove the four solenoids from the base of the control box using the copper bus bar as an aid and hold to...

Page 13: ...washers and nuts removed in step 14 above into original holes Replace the black cover and refit the three cover screws DO NOT OVER TIGHTEN 38 Bolt the control box bracket to the control box 39 Fit the two grommets into the round holes in the top of the bull bar then thread the cables through 40 Mount the control box bracket onto the top pan using M8 bolts flat washers and flanged nuts Use the cabl...

Page 14: ...pplied in the kit in the lower two holes plus 3 8 spring and flat washers with each bolt 42 When all bolts are fitted and finger tight tighten top holes only using a stepped ring spanner and remove lower bolts Drill two new 13mm holes in the roller fairlead provided in the kit as shown on the adjacent picture 43 Fit roller fairlead into cutout and refit bolts and tighten firmly NOTE For ease of ti...

Page 15: ... see where to cable tie to bull bar 47 Fit the impact absorber to the bull bar using the two M10 x 30 bolts as shown M10 over sized washers and M10 spring washers Do not fully tighten these bolts as they will be tightened on the vehicle 48 Fit four M8 cage nuts to the impact absorber Cage nuts to suite 3mm plate Caged portion to top of bull bar 49 Position the bar on the vehicle and fasten it to t...

Page 16: ... step 46 Once satisfied with the position of the bull bar using a 10mm drill drill through the 10mm holes in the impact absorber 2 holes per side and secure using the M10 x 30 bolts two flat washers per bolt spring washers and hex nuts 51 Fasten the chassis stiffening bracket to the chassis and the impact absorber as shown Fasteners required include six M10 x 35 bolts twelve M10 flat washers six M...

Page 17: ...r two holes 53 Fit theM6 cage nuts to the wing stone guards as shown Make sure the plastic wheel liner on the LH side of the vehicle has been disconnected from the washer bottle before fitting the wing stone guards 54 Fit the M8 cage nuts to the stone guard brackets Loosely fit the brackets to the side of the chassis rails using M12 x 30 Hex bolts M12 Spring washers and M12 Washers ...

Page 18: ...ure the stone guard to the bracket fitted in step 55 56 Mark lines along the inner guards using the bottom edge of the stone guards as a guide 57 Remove the stone guards and cut along the lines marked in the previous step 58 Tuck the inner guards into the stone guards 59 If fitting optional driving lights to vehicle do so at this stage Guide ratchet spanner between the upper and lower pans as show...

Page 19: ...les in the lower or upper pan depending on fitment Fit the number plate to the bull bar using the black self tapping screws The two photos display the number plate positions for both winch and non winch bars Provision for a high lift jack has been provided on both sides of bar ...

Page 20: ...05 10 11 Page 20 of 21 378 7983 Another photo for non winch ...

Page 21: ...05 10 11 Page 21 of 21 378 7983 Indicator Loom Part No 6821152 Relay Loom Part No 6821198 Indicator Loom Part No 6821152 ...

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