ECB BIG TUBE BT128SY Fitting Instructions Manual

HILUX 09/11on 2WD / 4WD BIG TUBE™ PROTECTION BAR
Check installation hardware before commencing.
1. Lift bonnet
2. Remove grille, two plastic clips and two PK self-tappers along top, pull grille forward at top enough to access
and release five fixed clips along bottom inside of grille.
3. Remove bumper cover, three plastic clips along top (grille area), one plastic clip (each side) at bumper cover top
side returns, four 10mm head self-tapper on inner guard (each side), three plastic clips along bottom of bumper
cover. Pull bumper cover outward at sides to release off clips.
4. Remove steel chassis cross member from front of chassis, four 14mm nuts. See figure 1.
On 4WD models: Remove two plastic clips from plastic under body guard (each side).
5. On 4WD models trim plastic air deflectors at top of cross member. See figure 2.
6. Remove four bumper cover support brackets from vehicle. See figure 3.
7. Remove headlight / indicator assemblies from vehicle. Three 10mm head self-tappers and one 10mm head bolt.
Disconnect wiring as removing. See figure 4.
8. Remove plastic bumper cover support brackets from bottom of headlights. Two PK screws(per light) See figure5
9. Remove plastic bumper cover side supports from each guard. One 10mm head self-tapper. See figure 6.
10. Connect ECB Quick click indicator / park light wiring harness (supplied) to original wiring loom. Refit headlight
/ indicator assemblies connecting to the other side of the ECB wiring harness. Run ECB wiring harness out from
under headlight ensuring it is clear of all sharp edges and pinch points.
11. Remove steel under guard, four 12mm head bolts. Remove two cross member supports from chassis. See figure
7. Five 14mm head bolts (per support).
12. Rotate gearbox housing on winch if necessary. See figure 8. Remove ten allen head bolts – move housing out
just off spline to rotate.
13. Connect control box cables to winch and sit control box on top of winch.
14. Place winch mounting bracket (supplied) on trolley jack or similar, sit winch and control box in winch mount
with winch slightly toward passenger side. DO NOT BOLT winch to winch mount. See figure 9.
15. Jack up onto chassis just forward of chassis studs – once aligned push back onto chassis studs. Use original nuts
for chassis studs. FINGER TIGHTEN ONLY. See figures 10 and 11.
.
FITTING INSTRUCTIONS
WITH 9000LB WARN WINCH FITMENT
VEHICLE FRONTAL PROTECTION SYSTEM (VFPS)
FOR AIR BAG & ADR COMPLIANT VEHICLES
© Copyright – ECB Pty Ltd – 2012
BT128SY
REPLACES: 00.00.00
REVISED: 04.10.11
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