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Toyota LANDCRUISER PZQ8460320, Fitting Instructions Manual

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Toyota LANDCRUISER PZQ8460320 Fitting Instructions Manual Download Page 9

© Toyota Motor Corporation Australia Ltd. 2011. All rights reserved. 

REPAIR MANUAL REFERENCE 

LANDCRUISER -  Steel S/Cab Tray Body 

ISSUE:  27/07/2012 

Page 

Refer to ServiceNet 

Accessory Part No.: PZQ8460320 

Fitting Instr. Part No.: PZQ8460320-FI 

9 of 35 

TOOLS REQUIRED 

1 

Screwdriver - Phillips 

2 

Screwdriver - Flat 

3 

Torque Wrench 

4 

Ratchet 

5 

Ratchet Extension 

6 

Socket    

         

- 10; 12; 13; 14; 16; 18; 19mm  

  

 

7 

Spanner  

           

- 10; 12; 13; 14; 16; 18; 19mm 

8 

Tape Measure 

9 

Drill Bit  

                  Ø 8.5mm

 

10 

Cordless Drill 

11 

Builders Square 

Summary of Contents for LANDCRUISER PZQ8460320

Page 1: ...b Tray Body ISSUE 27 07 2012 Page Refer to ServiceNet Accessory Part No PZQ8460320 Fitting Instr Part No PZQ8460320 FI 1 of 35 FITTING INSTRUCTIONS FOR SC 2400x1840 SGF TRAY BODY PART NUMBER PZQ8460320 PRODUCTION DATE SEPT 2012 ONWARDS LANDCRUISER PZQ8460320 SC 2400x1840 Steel Galvanized Flat Floor SGF TRAY BODY ...

Page 2: ...poration Australia Ltd recommends that this accessory is installed by a qualified Toyota Technician During the accessory fitment ensure all Australian automotive safety practices and regulations are followed Do not modify the vehicle in any way other than specified in these accessory fitting instructions as this may void the warranty General Vehicle Notes and Cautions Inspect the vehicle and note ...

Page 3: ... sponge Tray Body Ratings MAXIMUM LOADING CAPACITIES Tray Body Deck Vehicle payload capacity minus accessories Refer Owners manual Headboard Rear Rack 150Kg total weight shared over both headboard and rear rack Load Restraint Rails Lesser Value 450Kg or Strap load capacity Maximum loading only applies to vehicles sold new in Australia by Toyota Motor Corporation Australia Ltd Check that all work p...

Page 4: ...set Left Hand 1 5 Headboard Latch 2 6 3 8 Cone Lock Nut 2 7 3 8 x 5 32 x 3 32 Spring Washer 4 8 3 8 x 3 4 x 16G Round Washer 2 9PSS03005 Corner Post Step Kit 9 Corner Post Step Left Hand 1 10 Corner Post Step Right Hand 1 11 M8 16G Round Washer 28 12 M10x55 Hex Bolt 4 13 M10x25 Hex Bolt 4 14 M10 Nyloc Nut 8 15 M8x20 Hex Bolt 20 16 M8x30 Hex Bolt 4 17 M8 Nyloc Nut 24 1 16 5 9 14 3 4 15 13 12 6 7 11...

Page 5: ...Items 1 Tail Light Bracket 2 2 PP guard bracket LH 4 3 PP guard bracket RH 4 4 Tail Light Wiring Harness Patch 2EH02 2 5 Registration Plate Light Wiring Patch 2EH04 2 6 Reflector Bracket suits GPA and GPS trays 2 7 Reflector Bracket suits HDA and HDS trays 2 8 Retro Reflector 2 Bolt Bag 9 Saddleclip 8x13 Slegers BLUE 6 10 Cable Ties 300 4 8mm Black 2 11 1 4x1 1 4 Mudguard Washer 6 12 1 4x3 4x16G B...

Page 6: ...Toyota Rear Decal 1 Bolt Bag 5 Hinge Strap 6 6 M6x16 Set Screw 12 7 M6 Nyloc Nut 12 8 E Clip 4 Note Dropsides are fully assembled for painted tray bodies 2 1 3 5 6 7 4 8 Kit 9PTHHT22 Head Board Tyre Hanger Kit Item Description Qty Loose Items 1 HBTH Tyre Hanger Bracket 1 2 Number Plate Bracket suit GPA HDA Alloy trays 1 3 Number Plate Bracket suit SGF SGC Steel trays 1 4 Number Plate Extension Bra...

Page 7: ... 1 5 Front Bearer 1 6 Centre panel 1 7 Rear Bearer 1 8 Gate 1 9 Gate Bolt 1 10 Rear Hanger LH 1 11 Rear Hanger RH 1 12 Number Plate Bracket 1 13 Tyre spacer wide tyre 1 14 Lynch Pin and Chain 1 Bolt Bag 15 Packer 50x65x12mm 8 16 1 4x3 4x16G Bright Steel Washer 4 17 M12x38x4mm Washer 2 18 M12x50 Hex Bolt 8 19 M12x40 Hex Bolt 2 20 M10x25 Hex Bolt 10 21 M10x20 Hex Bolt 12 22 M8x20 Hex Bolt 2 23 M6x16...

Page 8: ...ASSEMBLY COMPONENTS Item Description Qty A Deck Assembly Galvanized 1 B Headboard Kit 1 C Corner Post Kit 1 D Dropside Assembly 1 E Mount Kit 1 F Rail Kit 1 G Body Kit 1 H Guard Kit 1 FIXINGS Description H T Class Torque M6 Countersunk Screw 9Nm M6 Set Screw 8 8 9Nm M6 Hex Bolt 8 8 9Nm M6 Pan Head Screw 9Nm M8 Hex Bolt 8 8 23Nm M10 Hex Bolt 8 8 45Nm M12 Hex Bolt 8 8 79Nm M6 Nyloc Nut M8 Nyloc Nut ...

Page 9: ...2 Page Refer to ServiceNet Accessory Part No PZQ8460320 Fitting Instr Part No PZQ8460320 FI 9 of 35 TOOLS REQUIRED 1 Screwdriver Phillips 2 Screwdriver Flat 3 Torque Wrench 4 Ratchet 5 Ratchet Extension 6 Socket 10 12 13 14 16 18 19mm 7 Spanner 10 12 13 14 16 18 19mm 8 Tape Measure 9 Drill Bit Ø 8 5mm 10 Cordless Drill 11 Builders Square ...

Page 10: ...or later use Discard the original tail light brackets Unplug and unwind harness Remove and discard fixings Original Tail Light Bracket IMPORTANT Take care not to damage any components of the vehicle STEP 1 Using a 17mm socket remove the spare tyre from the vehicle chassis as shown in adjacent diagram Remove and discard Steel Frame and J Bolt from underneath tyre Disconnect wiring harness from regi...

Page 11: ...Ensure fastener torque does not exceed the recommended torque for the specified fastener refer pg 8 STEP 6 Place assembled mount rail onto 3rd Chassis Mount using 12mm Spacers between mount and mount pad Install Fuel Bracket to RH as shown and loosely se cure mount rail and fuel bracket using M12x50 bolts 38x50x6mm washer and M12 Nyloc Nut For LH side secure mount rail using M12x50 bolts 38x50x6mm...

Page 12: ...am M12x50 Bolt 12x38x4 Washer 38x50x6 Washer longer edge to inside M12 Nyloc Nut IMPORTANT Ensure fastener torque does not exceed the recommended torque for the specified fastener refer pg 8 STEP 8 Pre assemble 105 130 External Mounts onto Mount Rail using M12x25 Bolt and M12 Nyloc Nut as shown in adjacent diagram Create 2 assembled mount rails one for 1st and 2nd Chassis Mounts M12x25 bolt 105 13...

Page 13: ...fastener refer pg 8 STEP 12 Fit 105 130 Mounts to the 3rd chassis mount Install Fuel Bracket to 3rd chassis mount as shown and loosely secure mounts and fuel bracket using M12x40 bolts 38x50x6mm Washer and M12 Nyloc Nut Ensure washer under the bolt head is orientated as shown in the adjacent diagram Repeat step for LH side M12x40 Bolt Fuel Bracket 38x50x6 Washer longer edge to inside M12 Nyloc Nut...

Page 14: ...l M12 Nyloc Nut IMPORTANT Ensure the fuel hose is not kinked or in a position that will deteriorate fuel flow STEP 13 Add Spiral wrap to fuel breather as shown Cable Tie fuel breather to fuel hose as shown Lift fuel filler up to the fuel bracket mounted to the chassis Fasten using M8x20 Bolts M8 Washers and M8 Nyloc nuts as shown in adjacent diagram Fuel Filler Bracket Cable Tie Spiral Wrap M8 Nyl...

Page 15: ...ue for the specified fastener refer pg 8 STEP 16 Place assembled Mount Rails onto 1st 2nd Chassis Mounts and Mount Rail with Mount Braces to the rear chassis mount refer image in Step 8 Loosely secure mount rails using M12x40 bolts 38x50x6mm Rectangle Washer M12x38x4mm Round Washer and M12 Nyloc Nut Ensure rectangular washer under the bolt head is ori entated as shown in the adjacent diagram Repea...

Page 16: ...d panel between the corner posts ensuring the orientation is correct to the adjacent diagram Remove and discard four M8 bolts fixing the deck cap to the deck in order to slide the headboard panel all the way down to the mounting holes Ensure the headboard panel sits neatly in front of the deck cap and all holes line up at the bottom of the headboard panel with the panel deck and deck cap Fasten th...

Page 17: ... Lugs to all 105 130 Mounts For Under Body Tyre Hanger option use the 2nd slot from the bottom of the Mounts as shown in adjacent diagram for Headboard Tyre Hanger option use the very bottom slot With an adequate number of people or a mechanical aid carefully lower the tray body assembly onto the Mounts ensuring the main bearers of the tray body are resting on the Mount Lugs To lessen the risk of ...

Page 18: ...n Bearer part of tray deck IMPORTANT Ensure fastener torque does not exceed the recommended torque for the specified fastener refer pg 8 STEP 26 Fasten Tray main bearer to Brace Mounts using M12x40 bolt M12x30x4mm washer M12x38x4mm washer and M12 Nyloc nut Ensure M12x38x4mm washer is used with the Nyloc nut side of the main bearer Tighten all fasteners to recommended torque Repeat for LH side M12x...

Page 19: ...r Bearer RH side shown IMPORTANT Ensure fastener torque does not exceed the recommended torque for the specified fastener refer pg 8 STEP 29 Loosely secure side rails to the inside of the rear bear er using M10x20 bolts and M10 Nyloc nuts RH side illustrated in adjacent diagram Repeat step for LH side M10x20 bolts M10 Nyloc nuts Side Rail Rear Bearer RH side shown IMPORTANT Ensure fastener torque ...

Page 20: ...0 bolt M10 Nyloc nut Side Rail Front Bearer Front Hangers IMPORTANT Ensure fastener torque does not exceed the recommended torque for the specified fastener refer pg 8 STEP 33 For vehicles with 265 70R16 Tyres fasten the Wide Tyre Spacer and Centre Panel to the Front Bearer using M10x25 bolts and M10 Nyloc nut See adjacent diagram M10x25 bolt M10 Nyloc nut Wide Tyre Spacer Front Bearer Centre Pane...

Page 21: ...agram Loosely secure using M10x20 bolts and M10 Nyloc nuts as illustrated in adjacent diagram Repeat for LH side M10x25 bolt M10 Nyloc nut Rear Hanger Rear Bearer IMPORTANT Ensure fastener torque does not exceed the recommended torque for the specified fastener refer pg 8 STEP 36 Slide the Under Body Tyre Hanger assembly under the tray so that the hole positions on the Front and Rear Hanger holes ...

Page 22: ...n in adjacent dia gram Ensure chain runs underneath the gate Safety chain M6x16 Bolt UBTH gate Front Bearer M6 Nyloc nut IMPORTANT Ensure fastener torque does not exceed the recommended torque for the specified fastener refer pg 8 STEP 37 Attach the number plate bracket to the right hand Rear Hanger as shown in adjacent diagram Secure using M8x20 bolts and M8 Nyloc nuts Number plate bracket M8 Nyl...

Page 23: ...es not exceed the recommended torque for the specified fastener refer pg 8 STEP 42 Secure Mount to the Tray Main Bearer using an M12x40 bolt Mount Lug M12x38x4mm washer and M12 Nyloc nut Repeat step for LH side 12x38x4mm Mount Lug M12x40 bolt M12 Nyloc Nut RH side shown 105 130 Mount M12x50 bolt IMPORTANT Ensure fastener torque does not exceed the recommended torque for the specified fastener refe...

Page 24: ...fastener torque does not exceed the recommended torque for the specified fastener refer pg 8 STEP 44 Secure the rope rails up under the side coaming using M8x20 bolts 40x34x3mm Rope Rail Washer and M8 Nyloc nuts corresponding to the positions indicated on Appendix A B at end of document Ensure to place the rope rail washers on the nut side of each fastener RH side shown M8x20 Bolts M8 Nyloc Nut 40...

Page 25: ...er Mud flap Mud flap washer Mudguard Mudguard brackets M6 Nyloc Nut M6 Nyloc Nut M6 washer NOTE Headboard Tyre Hanger Option STEP 48 Note Following steps are for Headboard Tyre Hanger Option only For Under Body Tyre Hanger option proceed to step 52 Find and unpack the Headboard Tyre Hanger kit 9PTHHT23 Check the contents of the kit to the kit contents page Pg 6 Lay the package contents out on an e...

Page 26: ... registration plate as shown in adjacent diagram Check the registration plate lamps are aimed directly toward the registration plate bracket Registration Plate M6x16 Bolts M6x16 Bolts Registration Bracket Registration Extension Bracket Registration Light Assembly Bracket Registration Light M8x20 Bolts M8 Nyloc Nut M6 Nyloc Nut M6 Nyloc Nut NOTE Headboard Tyre Hanger Option STEP 50 Mount the regist...

Page 27: ...cket and registration plate to the Underbody Tyre Hanger regis tration bracket using M8x20 bolts and M8 Nyloc Nut as shown in adjacent diagram Check the registration plate lamps are aimed directly toward the registration plate bracket M8x20 Bolt Under Body Tyre Hanger Registration Bracket M8 Nyloc Nut There are wiring harnesses attached to each side of the chassis Remove the zip ties attaching the...

Page 28: ...rays only Locate applicable Reflector Bracket refer to adjacent image and discard other reflector bracket and fasten Reflector Bracket to the Tail Light Protector using M6x16 Bolt and M6 Nyloc Nut Ensure bracket face is parallel with Light Protector Carefully adhere Reflector to Reflector Bracket ensur ing it is square and not overhanging any portion of the bracket Ensure prior to adhesion that th...

Page 29: ...ORTANT Take care not to damage any components of the vehicle STEP 58 The tail lights need an additional wiring harness patch part no 2EH02 to be installed to extend the wiring between the tail lights and the vehicle wiring harness Connect wiring harness patch to the vehicle harness and secure to main bearers of the tray using spring clips provided as shown in adjacent diagram Vehicle chassis Cable...

Page 30: ...ave been pre assembled to the tray body continue on to step 63 STEP 62 Attach 6 x hinge pins to the side channels 3 x LHS 3 x RHS using M8x20 bolts and M8 Nyloc nuts Refer to the drawing Appendix A B at end of document for positioning Attach two Hinge Pins to the rear channel using M8x20 bolts and M8 Nyloc nuts M8x20 Bolts Hinge Pin IMPORTANT If the dropsides have been pre assembled continue on to...

Page 31: ...g sure the drop side is kept parallel Line up the centre hinge pin to the centre hinge strap hole by sight while simultaneously lining up the other hinge pins and hinge strap holes by feel IMPORTANT Take care not to damage any components of the vehicle STEP 65 Place E clips on the hinge pins one on each Dropside and two on the Tailgate as shown in the adjacent diagram IMPORTANT Dropsides should be...

Page 32: ... contents page page 6 M8x40 Bolt M8 Nyloc Nuts IMPORTANT Take care not to damage any components of the vehicle STEP 68 Place top of Headboard Tyre Hanger Bracket on the drivers side flush to the headboard square tube mark and drill 8 5mm holes as shown in adjacent diagram Fasten Bracket to headboard using M8x40 bolts and M8 Nyloc nuts 342mm Tyre Hanger Bracket Ensure washer used under head of M14 ...

Page 33: ...rag and a PH neutral cleaner STEP 71 Attach the tailgate decal to the lower surface of the tailgate as shown in the adjacent diagram ensuring that the centre of the decal is aligned with the centre of the tailgate Ensure there are no creases or air bubbles in the decal once applied IMPORTANT Include all digits of the VIN number and tray body serial number on the fitting check sheet STEP 72 Complet...

Page 34: ...ia Ltd 2011 All rights reserved REPAIR MANUAL REFERENCE LANDCRUISER Steel S Cab Tray Body ISSUE 27 07 2012 Page Refer to ServiceNet Accessory Part No PZQ8460320 Fitting Instr Part No PZQ8460320 FI 34 of 35 APPENDIX A GENERAL DIMENSIONS ...

Page 35: ...alia Ltd 2011 All rights reserved REPAIR MANUAL REFERENCE LANDCRUISER Steel S Cab Tray Body ISSUE 27 07 2012 Page Refer to ServiceNet Accessory Part No PZQ8460320 Fitting Instr Part No PZQ8460320 FI 35 of 35 APPENDIX B SPECIFICATIONS ...

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