TJM T24 Fitting Instructions Manual

Frontal protection system for toyota landcruiser 200 series

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Fitting instructions manual (31 pages)

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Product:

Vehicle:

Part No.

070SB24N82C

Australian Standards Relating to Installing Vehicle Frontal Protection Systems (VFPS): AS 4876.1-2002

Do not attach V.F.P.S. to vehicle using anchorages not intended for this purpose (e.g. engine mounting bolts), other than those

specified by the V.F.P.S. manufacturer in this instruction.

Do not use this product for any vehicle make or model other than those specified by the V.F.P.S. manufacturer (as above).

Do not remove any plaques or labels from the V.F.P.S.

Do not modify the structure of the V.F.P.S. in any way.

Bolt tensions

All bolt tensions

are as follows

unless otherwise

specified.

For product warranty please refer to our website www.tjm.com.au

File: F-29766

FITTING INSTRUCTIONS

T24 Frontal Protection System

Toyota Landcruiser 200 Series

Dia. (mm)

Page 1 of 26

ft.lbs

Dia. (inch)

1/4"

5/16"

3/8"

7/16"

1/2"

Parts List shown on Page 2

ft.lbs

11/03/2020

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Summary of Contents for TJM T24

Page 1 Parts List shown on Page 2 Bolt tensions Dia. (mm) ft.lbs Dia. (inch) ft.lbs 1/4” 5/16” All bolt tensions are as follows 3/8” unless otherwise 7/16” specified. 1/2” For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 1 of 26 11/03/2020...
Page 2: Parts List
Recovery Point Use Guide F-1768 Pinchweld (2m Long) 93151 FACTORY FITTED Rated Recovery Point Label HC0064 Warning Label - ABC HC0057 TJM Logo Sticker K3550 For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 2 of 26 11/03/2020...
Page 3 • Estimated Fitting Time: 4.5hrs (5hrs for winch provisions) • The fitment of TJM products does not nullify the OE manufacturer's operating guidelines and/or warnings. Ensure you are familiar with and adhere to the usage instructions specified by the manufacturer in the owner's manual or other official documentation.
Page 4 Remove (& retain) number plate if fitted. Remove (& retain) the front plastic radiator cover and fasteners (7) located under hood. Disconnect wiring looms from camera and radar if fitted. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 4 of 26 11/03/2020...
Page 5 If fitted, find the parking sensor / fog-light wiring loom plug and the headlight washer hose connection. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 5 of 26 11/03/2020...
Page 6 Clip in Bumper Support 10. Remove the clips across the top of the remaining bumper and discard. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 6 of 26 11/03/2020...
Page 7 14. Remove (& retain) the mud flaps and STEP 13 fasteners (6) from the lower outer cover. Discard the covers keeping mud flaps, fasteners and the backing plates. STEP 14 For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 7 of 26 11/03/2020...
Page 8 Retain the 8 flange nuts to secure the winch frame to the chassis. STEP 17 18. If necessary, remove the automatic transmission cooler air guide for trimming. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 8 of 26 11/03/2020...
Page 9 21. 23. Trim the plastic air guide along the lines drawn. 24. Refit the air guide after trimming if removed. Vertex For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 9 of 26 11/03/2020...
Page 10 (F-10478) is retained by the customer and continue to step 39. Remove Bolt 27. Remove the grille support mounting bolt. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 10 of 26 11/03/2020...
Page 11 Ensure the upper and lower holes STEP 32 are used. 32. Also, mark the lower section of the radiator support that requires trimming. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 11 of 26 11/03/2020...
Page 12 38. Refer to the winch fitting instructions to bolt the winch into winch frame. Note: TJM winch can have control box mounted in standard position. Others may have to relocate. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 12 of 26 11/03/2020...
Page 13 41. Apply Loctite 403 (or an equivalent) to a RHS SHOWN 40mm length of the M12 x 1.75 x 280mm threaded rod, 25mm from the end, as shown. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 13 of 26 11/03/2020...
Page 14 M12 x 35mm hex bolts (3), M12 x Ø32mm flat washers (6) and M12 x 1.25 nyloc nuts (3). For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 14 of 26 11/03/2020...
Page 15 M10 x Ø30mm flat washers (2) and the remaining OE flange nuts (2) retained in step 17. STEP 48 STEP 49 For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 15 of 26 11/03/2020...
Page 16 55. Refit the grille into the grille mount bracket and fasten using the original bolts (3) along the top of the grille removed in step 5. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 16 of 26...
Page 17 Fit the headlight washer blanks 58.4. to the inside face of the FPS, at the headlight washer openings. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 17 of 26 11/03/2020...
Page 18 LH side as shown. 62. Secure the wiring and tubing to the FPS so no damage can occur and connect sensors, fog-lights and washers. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 18 of 26 11/03/2020...
Page 19 ¾ x 1.6mm flat washers (8), M6 x Ø12.5 x 1.2mm flat washers (8) and M6 nyloc nuts (8). Note: Use Ø12.5mm washer on bolt head side. CHAMFER AT TOP For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 19 of 26 11/03/2020...
Page 20 Vehicle: Toyota Landcruiser 200 Series Part No. 070SB24N82C 66. Fit the TJM logo backing plate to the inside LHS SHOWN of both wings using M6 x 1.0 x 16mm socket head screws (4), ¼ x ¾ x 1.6mm flat washers (4), M6 x Ø12.5 x 1.2mm flat washers (4) and M6 nyloc nuts (4).
Page 21 1. The minimum clearance between the wings and guards must be maintained 20mm GAP to prevent clashing during off-road driving. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 21 of 26 11/03/2020...
Page 22 78. Fit the center guard mount angles using M8 x 25mm hex bolt (2) 5/16" x Ø7/8" flat washers (4) and M8 x 1.25 nyloc nuts (2). For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 22 of 26...
Page 23 79. Assemble M6 x 1.0 cage nuts (4) into the front of the center guard (F-9913). 80. Fit the TJM logo backing plate to the inside of the centre guard using M6 x 1.0 x 16mm socket head screws (2), ¼ x ¾ x 1.6mm flat washers (2), M6 x Ø12.5 x 1.2mm flat...
Page 24 90. Remove wing guard and tension the guard mount angle fasteners to the specified torque settings listed on page 1. 91. Trim the plastic inner guard closely above the marked line. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 24 of 26 11/03/2020...
Page 25 96. Vertically adjust the driver’s side nozzles by Outer Side View RHS SHOWN rotating them down to the positions shown. The outer nozzle will appear perpendicular with the ground. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 25 of 26 11/03/2020...
Page 26 Also ensure that all fasteners are tensioned and that, as a result of fitting the FPS, no vehicle components are crushed of will chafe. For product warranty please refer to our website www.tjm.com.au File: F-29766 Page 26 of 26 11/03/2020...

This manual is also suitable for:

070sb24n82c