T.J.M. T13 Outback Frontal Protection System Fitting Instructions Manual Download

Page: 3 / 18

FITTING INSTRUCTIONS

Product:

T13 Outback Frontal Protection System

Vehicle:

Toyota LandCruiser 200 Series 2007+

Part No.

070SB13R82A

For further information contact T.J.M. Head Office on (07) 3865 9999. Distributors Australia

wide.

File: F-1434.docx

Page 3 of 18

11/12/2013

ITEM

NO.

Description

Qty Part

Number

PARTS LIST

Outback FPS

F-1656

Chassis Mount / Winch Frame

F-1604

Wing Guard LH

F-1574L

Wing Guard RH

F-1574R

Headlight Trim LH

92583L

Headlight Trim RH

92583R

FITTING KIT

Chassis Mount / Winch Frame Brace

F-2008

Wing Brace LH

F-2041L

Wing Brace RH

F-2041R

Chassis Rail End Spacer LH

F-2005L

Chassis Rail End Spacer RH

F-2005R

Spacer Plate

F-2052

Mounting Block

92547

M12 x 1.75 x 280mm Threaded Rod

F-1613

Grille Bracket

F-2777

Underbody Guard Cover

F-2825

Inner Guard Bracket LH

F-1668L

Inner Guard Bracket RH

F-1668R

Fog-Light Angle Bracket

89745

LED Indicator / Park Light

92600

LED General Fog-Light LH

92669L

LED General Fog-Light RH

92669R

Fairlead Cover

F-1669

Winch Slot Cover Insert

92106

N/A

Cable Tie – 300mm

K1148

N/A

3/16” Rubber Hose

92517

ITEM

NO.

Description

Qty Part

Number

BOLT KIT

N/A

10g x 3/4" Philips Head Screw

K0734

N/A

10g Speed Clip (U-Nut)

K2078

N/A

M5 x 0.8mm x 20mm Pan Screw

K0688

N/A

M5 x 0.5 Nyloc Nut

K0604

N/A

M5 x Ø10mm Flat Washer

K0417

N/A

3/16” x Ø3/4” Flat Washer

K2913

N/A

M6 x 1.0 x 16mm Hex Screw

K1232

N/A

M6 x 1.0 x 20mm Hex Bolt

K0550

N/A

M6 x 1.0 Flange Nut

K3033

N/A

M6 Spring Washer

K0915

N/A

M6 x Ø12.5 Flat Washer

K0897

N/A

M8 x 1.25 x 20mm Hex Bolt

K0552

N/A

M8 x 1.25 x 25mm Hex Bolt

K0553

N/A

M8 x 1.25 Nyloc Nut

K0606

N/A

M8 x Ø19mm Flat Washer

K0628

N/A

M10 x 1.25 x 30mm Hex Screw

K0564

N/A

M10 x 1.5 x 40mm Hex Screw

K0559

N/A

M10 x 1.25 Nyloc Nut

K3099

N/A

M10 Spring Washer

K0621

N/A

M10 x Ø30mm Flat Washer

WSST-W13

N/A

M12 x 1.25 x 40mm Hex Screw

K0571

N/A

M12 x 1.25 x 45mm Hex Bolt

K0772

N/A

M12 x 1.25 Nyloc nut

K1200

N/A

M12 x 1.75 Hex Nut

K0587

N/A

M12 Spring Washer

K0977

N/A

M12 x Ø24mm Flat Washer

K0425

N/A

1/2" x Ø1-1/4” Flat Washer

K0623

N/A

3/16” One Way Check Valve

92514

N/A

3/16” Y Connector

92515

N/A

3/8” to 1/4” Reducer Fitting

92516

N/A

Washer Nozzle

92501

N/A

Ø10mm Plastic Plug

92518

N/A

Plastic Push Clips

92629

N/A

Nylon Plug

K0665

Fog-Light Washer Plate

88057

Summary of Contents for T13 Outback Frontal Protection System

Page 1: ...riod of three 3 years after the date of purchase TJM shall repair at TJM s discretion the defective product or part 2 Any defect in a product distributed by TJM but not manufactured by TJM shall be dealt with in accordance with and to the extent of the warranty offered by the manufacturer of that product 3 TJM does not warranty that the products manufactured by it comply with the laws of the place...

Page 2: ...3 Outback Frontal Protection System Vehicle Toyota LandCruiser 200 Series 2007 Part No 070SB13R82A For further information contact T J M Head Office on 07 3865 9999 Distributors Australia wide File F 1434 docx Page 2 of 18 11 12 2013 ...

Page 3: ...e Tie 300mm 12 K1148 N A 3 16 Rubber Hose 2m 92517 ITEM NO Description Qty Part Number BOLT KIT N A 10g x 3 4 Philips Head Screw 10 K0734 N A 10g Speed Clip U Nut 10 K2078 N A M5 x 0 8mm x 20mm Pan Screw 4 K0688 N A M5 x 0 5 Nyloc Nut 4 K0604 N A M5 x Ø10mm Flat Washer 8 K0417 N A 3 16 x Ø3 4 Flat Washer 10 K2913 N A M6 x 1 0 x 16mm Hex Screw 12 K1232 N A M6 x 1 0 x 20mm Hex Bolt 8 K0550 N A M6 x ...

Page 4: ...taining the top of the grille Now release the eight clips along the bottom Retain all of the O E fasteners 5 Remove retain the grille 6 If fog lights are installed disconnect the wiring harness from the fog lights The OE fog lights are not required for the installation of this FPS 7 If O E headlight washers are installed disconnect the washer tube temporarily plug it 8 If O E parking sensors are i...

Page 5: ...Remove retain the upper bumper support OE fasteners indicated 12 Locate the fasteners securing the indicated plastic air guides to the vehicle Remove retain the air guides O E fasteners 13 Trim the plastic air guides removed in the previous step as shown Refer to the images on the following page also 14 Re fit the plastic air guides to the vehicle using the O E fasteners removed in step 12 15 Re f...

Page 6: ...of the chassis lower bumper retainers 17 Remove retain the tow lugs discarding the fasteners 18 Remove discard the shipping lugs 19 Remove retain the front 2 underbody guard fasteners 20 Fit the grille bracket to the upper bumper support using M8 x 1 25 x 20mm hex bolts 2 M8 x Ø19mm flat washers 4 M8 nyloc nuts 2 21 Remove Trim the bumper clips under the headlight so that they will not interfere w...

Page 7: ...tre line of the vehicle 24 Apply locktight to one end of the M12 x 1 75 x 280mm threaded rod then weave this end through the large hole in the chassis rail end secure it into the chassis rail mounting block that was installed in the previous step 25 Repeat the previous two steps for the opposite side of the vehicle 26 Orientating the chassis rail end spacers as shown position them on the end of th...

Page 8: ...acer plates 2 29 Secure both sides of the chassis mount in place to the captive studs using M10 x Ø30mm flat washers 2 M10 x 1 25 nyloc nuts 2 30 Reposition the tow lugs step 17 on the underside of the chassis mount as per their original orientation then secure the chassis mount in place using M12 x 1 25 x 45mm hex bolts 4 1 2 x Ø1 1 4 flat washers 4 M12 spring washers 4 31 Secure both sides of th...

Page 9: ...itted leave the 4 winch mounting holes vacant 33 Secure the upper locations with M8 x 1 25 25mm hex bolts 2 M8 x Ø19mm flat washers 4 M8 nyloc nuts 2 34 Ensuring that the indicated slots in the side of the chassis mount align with the respective slots in the centre support brace tighten the fasteners from the two previous steps to the specified torque settings listed on page 1 35 Fit the inner gua...

Page 10: ...1 12 2013 39 Trim the LHS plastic inner guard as shown 40 Trim the RHS plastic inner guard in line with the bottom of the radiator support panel Steps 41 through to 43 only apply if parking sensors are to be installed Otherwise proceed to step 44 41 On each side of the FPS drill the required Ø22mm hole for the parking sensors following the dimensions shown 42 De burr the holes then clean the area ...

Page 11: ...to install the 3 16 one way check valve near the headlight washer cut a length off the 3 16 rubber hose using the supplied cable ties fit one end to the headlight washer the other to the outlet end of the 3 16 one way check valve Ensure that the one way check valve is orientated correctly as it will only allow flow in one direction Steps 47 through to 51 only apply if a winch is to be fitted Other...

Page 12: ...lace through the two front fastening holes 50 2 M8 x 1 25 x 25mm hex screws 2 M8 x Ø19mm flat washers 4 M8 nyloc nuts 2 51 Using the fasteners retained in step 19 M8 x Ø19mm flat washers 2 secure the OE underbody guard at the indicated locations Steps 52 53 only apply if a winch is not fitted Otherwise proceed to step 54 52 With the OE underbody guard situated between the underbody guard cover the...

Page 13: ...nstall each fog light s wiring harness to the vehicle s wiring harness 55 Check the operation of the fog lights then un plug them 56 Loosely attach the fog light angle bracket to the fog light as shown using M6 x 1 0 x 16mm hex screws 2 M6 x Ø12 5mm flat washers 2 M6 flange nuts 2 The fog lights are left right Ensure that the wiring loom plug is facing the ground 57 Attach the fog light to the FPS...

Page 14: ...r park light s wiring to the vehicle then solder seal the joins LED WIRING Ground Parker Indicator White Brown Yellow 61 Check the operation of the indicator park lights then un plug them 62 Insert the nylon plugs supplied into the square cut outs for the indicator park lights as shown 63 Separate the indicator park light body from the backing plate 64 Secure the backing plate to the FPS using the...

Page 15: ...gh to 71 only apply if headlight washers were originally installed Otherwise proceed to step 72 69 Unplug the OE washer tube using the supplied cable tie connect it to the supplied 3 8 1 4 reducer fitting 70 Cut a length off the 3 16 rubber hose using the supplied cable ties fit one end to the 3 8 1 4 reducer fitting the other to the inlet of the 3 16 Y connector 71 Using the remaining 3 16 rubber...

Page 16: ...en the fasteners to the appropriate torque settings The minimum clearance between the wings and guards must be maintained to prevent clashing during off road driving 77 Adjust the headlight trims then tighten the screws The headlight trims must sit forward of the headlights to prevent clashing during off road driving 78 Using the indicated hole in the bar mount as a template drill a Ø10mm hole thr...

Page 17: ...osite side of the FPS 85 Re fit the grille back to its original position using the O E fasteners previously retained 86 Re fit the front plastic cover panel back to its original position using the O E fasteners previously retained 87 Re connect the indicator park lights 88 Position the wing guard as shown secure it in place using the fasteners listed below 88 1 M6 x 1 0 x 20mm hex bolts 4 M6 sprin...

Page 18: ... Office on 07 3865 9999 Distributors Australia wide File F 1434 docx Page 18 of 18 11 12 2013 92 Ensure that all of the relevant wiring looms are connected check that the indicators park lights winch fog lights etc are functioning correctly 93 Ensure that all fasteners are fully tightened that as a result of fitting the FPS no vehicle components are crushed of will chaff ...

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