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Ironman Fitness BB064, Installation Manual, Page: 1 / 20

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INSTALLATION

GUIDE

TO SUIT TOYOTA PRADO 150

12/2017+/MY2020 FACELIFT 

BB064

•  Ironman 4x4 BBP / BBT Bull Bar to suit a Toyota Prado 150 12/2017+ / MY 2020
•  It will take about 4 hours to install
•  All bolts, washers, spring washers and nuts are supplied unless otherwise indicated
•  All drilled holes must have anti-corrosion treatment applied

If your vehicle has front parking sensors and you wish to refit them, refer to fitting
diagram on back pages of this instruction manual

IMPORTANT: 

Bull Bar installations should only be done by a qualified person

and it is the responsibility of this person to ensure correct fitment.

NOTE: This product has been tested for air bag compatibility  

and therefore the mounting system MUST NOT BE modified

©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd

 BB064081220

Summary of Contents for BB064

Page 1: ... has front parking sensors and you wish to refit them refer to fitting diagram on back pages of this instruction manual IMPORTANT Bull Bar installations should only be done by a qualified person and it is the responsibility of this person to ensure correct fitment NOTE This product has been tested for air bag compatibility and therefore the mounting system MUST NOT BE modified Copyright 2020 Ironm...

Page 2: ... 10 Pinch Weld 1m QTY 1 17 STL Bottle Opener QTY 1 16 Logo QTY 1 13 Parking Sensor Set QTY 17 14 Bolt M12x1 25x40mm QTY 2 15 Bolt M12x1 25x40mm QTY 14 16 Bolt M8x1 25x20mm QTY 18 17 Bolt M10x1 0x30mm QTY 4 18 Bolt M12x1 25x100mm QTY 4 19 Bolt M8x1 25x25mm QTY 4 20 Cage Nut M6x1 QTY 2 21 Bolt M8x1 25x25mm QTY 2 22 Bolt M8x1 25x25mm QTY 2 23 Bolt M10x1 25x30mm QTY 12 24 Bolt M8x1 25x35mm QTY 2 25 Sp...

Page 3: ...grill front bumper bumper bar reinforcement bumper bar support brackets and front protection plate from under chassis 4 Only applicable to MY 2020 carefully lever chrome trims away from inside top corners of headlights using a soft tool to prevent damage 5 Only applicable to MY 2020 carefully remove 2 clips retaining the outer ends of the rubber attached to the top of the grill 6 Only applicable t...

Page 4: ... top of the grill carefully release the clips and remove the grill 8 Attach inner and outer chassis support brackets using the following 2 x M12 x 1 25 x 100 mm through holes A and B with flat washers spring washers and M12 nuts 1 x M12 x 1 25 x 90 mm bolt through hole C with spring washer flat washer and channel nut Black M8 bolt through hole D with spring washer and flat washer 1 x M12 x 40 mm b...

Page 5: ...efully adjust A C hose bracket towards A C condenser to allow clearance for winch cradle 10 Centralise bracket to the body of the vehicle and tighten all bolts 11 Attach winch cradle to chassis using 6 x M10 x 1 25 x 30 mm bolts spring washers and plate washers to outside holes with captive nuts 2 x M10 x 1 25 x 40 mm bolts 16 flat washers 8 x spring washers and 8 x M12 nuts to remaining holes ...

Page 6: ... Remove panel containing mirror controls 14 Solder green wire onto dash light wire using tester to locate correct wire Insulate soldered wire and re install panel Correct wire will be green or blue depending on model 15 Connect indicator wiring to connector shown in photograph Using an LED test light check for correct connection points or refer to your workshop manual if you are unsure Parker ligh...

Page 7: ...nes using template provided Mask a horizontal line across the bumper 20 mm below grill recess and align with cut lines previously marked Cut along lines previously marked remove lower section of bumper 20mm from the bottom of the grill to cut line 17 Re fit bumper bar and grill to the vehicle using factory mounting hardware 18 Remove parking sensors from bumper bar and fit to bull bar making sure ...

Page 8: ...nsors to function correctly these instructions must be followed closely Before removing sensors from original bumper bar note the location and orientation of each sensor so when they are fitted the bullbar this can be duplicated Universal Parking Sensor Installation 1 Remove rubber grommets from sensor holes in bullbar 2 Remove blank from sensor holder and trim any excess plastic from inside openi...

Page 9: ...sor holder and secure using clamping plate and screws provided Do not over tighten Clamping plate has a flat side for thicker sensors and a raised section on the other side for thinner sensors It is important that clamping plate is the correct way around as sensor will false alarm if excess pressure is applied to the sensor body 4 Clean inside of bullbar around sensor holes and mounting surface of...

Page 10: ...without the prior written consent of Ironman 4x4 Pty Ltd 5 Apply adhesion promoter to mounting surfaces around sensor holes and on sensor holders NOTE This step is important to ensure sensor holders adhere properly to the bullbar 6 Remove protective film from one side of double sided tape and apply to mounting surface of sensor holder ...

Page 11: ...emove protective film from double sided tape and apply sensor holder sensor to bullbar making sure sensors are in the same positions as they were in the original bumper and in the same orientation The two outer wing parking sensors will require the extra O ring placed over the silicone sleeve NOTE Sensor nuts only need to be nipped up Do not overtighten or sensor will not function as intended ...

Page 12: ...ckets using 6 x M12 x 40 mm bolts 12 x flat washers 6 x spring washers and 6 x M12 nuts provided 20 Align bull bar with vehicle leaving a 20 mm gap for body movement 21 Once bull bar is aligned with vehicle and tightened drill through pinning holes circled in yellow between bull bar and chassis bracket and secure with 4 x M10 x 1 25 x 30 mm bolts 8 x flat washers 4 x spring washers 4 x 10M flat wa...

Page 13: ...hts 22 Fit side wing supports to both sides using bolts provided 2 x black M8 bolts spring washers and flat washers per side and 1 x M10 x 30 mm bolt spring washer and flat washer per side 24 If applicable fit camera and parking sensor wiring loom The wiring loom to the sensors will be long enough without lengthening but may have to be removed from factory conduit in order for it to reach Replace ...

Page 14: ...y Ltd No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd 25 Attach centre protection plate to bull bar followed by side plates using M8 bolts spring washers flat washers and nuts Trim guard liners to suit ...

Page 15: ...earbox to the left hand side of vehicle and cable spooling from bottom of the cable drum using bolts and washers provided 2 Bolt fairlead to recess in front of bull bar using bolts washers and nuts provided 3 Fit bull bar to vehicle referring to steps of bull bar fitting instructions 4 Mount control box in desired location 5 Connect three colour coded cables to the corresponding poles on winch mot...

Page 16: ... Auxilliary Battery 9 Attach breather hose to barb fitting on winch motor Run hose to the highest available point in engine bay and cable tie in position Cable tie hose away from any sharp hot or moving objects 7 Run the positive and negative battery cables into the engine bay taking care to secure cables away from any sharp or moving objects 6 Connect the thin black earth wire and negative batter...

Page 17: ... not use factory parker light wiring Use bull bar parker light when wired with loom in step 8 of the bull bar fitting instructions White Switch SPST Yellow Red Brown Daytime Running Light Park Light Indicator Light Ground White If vehicle is not fitted with DRL leave red wire disconnected PARK LIGHT INDICATOR WITHOUT FACTORY FITTED FOG LIGHTS WITH FACTORY FITTED FOG LIGHTS Blue Relay Connector Pow...

Page 18: ...AR TEMPLATE TO SUIT TOYOTA PRADO 150 SERIES 2017 UNDER HEADLIGHT 0 10 20 30 40 50 60 70 80 90 100 MM TOWARD CENTRE OF VEHICLE JOIN HERE JOIN HERE DISABLE PAGE SCALING WHEN PRINTING CHECK RULER DIMENSIONS TO ENSURE ACCURACY BEFORE CUTTING ...

Page 19: ...MPLATE TO SUIT TOYOTA PRADO 150 SERIES 2017 UNDER HEADLIGHT FRONT GUARD CUT LINE 270720 0 10 20 30 40 50 60 70 80 90 100 MM ERE ERE JOIN HERE DISABLE PAGE SCALING WHEN PRINTING CHECK RULER DIMENSIONS TO ENSURE ACCURACY BEFORE CUTTING G ...

Page 20: ...4 BBT064 BULL BAR TEMPLATE TO SUIT TOYOTA PRADO 150 SERIES 2017 FRONT GUARD 270720 0 10 20 30 40 50 60 70 80 90 100 MM HERE DISABLE PAGE SCALING WHEN PRINTING CHECK RULER DIMENSIONS TO ENSURE ACCURACY BEFORE CUTTING ...

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