Ironman4x4 BB060-SL Installation Manual Download

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BBT034/ BBC034/ BBCD034

BBCD060/ BBT060-NL/

BB060-TL/ BB060-SL

VOLKSWAGEN AMAROK

INSTALLATION

GUIDE

•

Ironman 4x4 BBT/ BBC/ BBCD034 BBCD060/ BBT060-NL/

BB060-TL/ BB060-SL Bull Bars fit to a Volkswagen Amarok.

•

It will take about 3 hours to install.

IMPORTANT - If your vehicle has front parking sensors and you

wish to refit them, refer to drilling diagram on back pages of

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

080518

Summary of Contents for BB060-SL

Page 1: ...rs to install IMPORTANT If your vehicle has front parking sensors and you wish to refit them refer to drilling diagram on back pages of 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 N...

Page 2: ...m ends of bumper bar 4 Mask a straight line level with the top of the lower grill opening in the bumper across the top of the fog light housing to the ends of the bumper as shown 5 Using an air hack saw or similar cut along the line previously marked to remove the lower section of the bumper 6 Mask a line down the bumper ends where the edges of the flares contact the bumper ...

Page 3: ...nual 8 Remove ambient air temperature sensor and fit to plastic panel as shown 9 Place chassis bracket in position on chassis and mark location of all mounting holes onto front cross member Remove chassis bracket and drill all holes to 12 5mm 7 x Holes will need to be drilled to 12 5mm in front cross member 10 Refit chassis bracket and secure in place using M12 hardware provided ...

Page 4: ...ting holes of chassis bracket as a guide drill four outer holes in front cross member and fit inner and outer reinforcing brackets to chassis as shown NOTE Nut flat washer and spring washer between bracket and crossmember INNER OUTER 14 Using flare cutting templates mark and cut flares previously removed from the bumper bar ...

Page 5: ...to chassis bracket using M12 hardware provided Align bar with vehicle and tighten all bolts 15 Refit small sections of flare removed in previous step Using factory screws and double sided tape provided along the edge of flare that contacts the bumper Double sided tape along this edge 20 Once bar is aligned with vehicle and tightened drill through pinning holes between bull bar and chassis bracket ...

Page 6: ...2 Fit protection plates to underneath of bull bar using M8 bolts spring washers and flat washers into bull bar 21 Connect park lights indicators and fog lights as per wiring diagrams at the back of instruction manual ...

Page 7: ... 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 motor ...

Page 8: ... 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 battery cable to the earth connection on the opposite side of winch motor ...

Page 9: ...Blue Relay Connector Ground Fuse Red 30 85 86 87 87a Red Lamp Black Lamp Battery Ground Ground White Switch SPST Park Light Indicator Ground Ground Indicator Circuit Park Light Circuit Black Yellow White Black PARK LIGHT INDICATOR FOG LIGHTS ...

Page 10: ... U T N O N F L A R E D M O D E L O N L Y C U T F L A R E D M O D E L O N L Y RIGHT SIDE T O P C U T PREVIOUS CUT TOP CUT LEFT SIDE 61 3 9532 1111 1300 731 137 www ironman4x4 com CUT OUT TEMPLATE C U T CUT OUT TEMPLATE W H E E L A R C H W H E E L A R C H VOLKSWAGEN AMAROK IRONMAN 4X4 BULLBAR BUMPER CUTTING TEMPLATE ...

Page 11: ...FLA RE CUT BUMPER RIGHT SIDE C U T VOLKSWAGEN AMAROK IRONMAN 4X4 BULLBAR FLARE CUTTING TEMPLATE CUT OUT TEMPLATE CUT OUT TEMPLATE LEFT SIDE 61 3 9532 1111 1300 731 137 www ironman4x4 com Drawn October 2011 TOP EDGE OF FLARE ...

Page 12: ...will be inside the bar mounting hardware box IMPORTANT Parking sensors should be installed as close to the same direction as when they sit in the factory bumper 2 The bars come with a rubberplug in the sensors hole This plug needs to be pushed out if you need to install the sensors into the bar Plastic Parking Sensor Installation Page 12 of 17 ...

Page 13: ...n around the sensor hole on the INSIDE of the bar 4 The kit comes with double sided stickers to enable you to stick the sensor holder in place 5 Remove the middle of the sensor holder to allow the vehicle sensor to go through Page 13 of 17 ...

Page 14: ...tall the double sided sticker 7 Remove the double sided stickers protective layer and install the sensor holder into the bar IMPORTANT Parking sensors should be installed as close to the same direction as when they sit in the factory bumper Page 14 of 17 ...

Page 15: ...ce 9 The parking sensor kit allows the backing plate to go 2 ways Depending on the thickness of the sensor you can adjust fitment If the sensor is larger install the sensor backing plate with the smooth side down If the sensor is smaller install the packing plate with the spacer side down Page 15 of 17 ...

Page 16: ...Page 5 of 5 10 Install the backing plate to suit the sensor 11 Ensure that the sensor is installed correctly and centred Page 16 of 17 ...

Page 17: ...Page 17 of 17 ...

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