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INSTALLATION
GUIDE
BBCD079
BULL BAR TO SUIT MITSUBISHI PAJERO SPORT MY21+
• Ironman 4x4 BBCD079 Bull Bar to suit Mitsubishi Pajero Sport MY21+.
• It will take approximately 4 hours to install.
NOTE: This product has been tested for air bag compatibility
and therefore the mounting system MUST NOT be modified
IMPORTANT: Bull bar installations should only be done by a qualified person
and it's the responsibility of this person to ensure correct fitment.
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
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Table of Contents
Related Manuals for Ironman Fitness BBCD079
Summary of Contents for Ironman Fitness BBCD079
- Page 1 BBCD079 BULL BAR TO SUIT MITSUBISHI PAJERO SPORT MY21+ • Ironman 4x4 BBCD079 Bull Bar to suit Mitsubishi Pajero Sport MY21+. • It will take approximately 4 hours to install. NOTE: This product has been tested for air bag compatibility...
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Page 2: Before Installation
Installation Guide Installation Guide BBCD079 Before Installation PLEASE NOTE: It is always good practice to disconnect the battery while working on 12-Volt systems. Please check the owner’s manual to see vehicle-specific requirements as some models may need battery backup. Caution: Auto electrical work should only be carried out by a competent person. Vehicle wire colours are listed as a guide and may vary on some makes and models. -
Page 3: Parts List
Installation Guide BBCD079 Parts List 1. Bull Bar 2. Mid Skid Plate 3. Side Skid Plates LHS-RHS QTY-1 QTY-1 QTY-2 4. Main Mounting Cradle 5. Washer Bottle 6. Eye Brow LHS-RHS 7. Support Inside Brackets 8. Special Outside Bracket LHS-RHS... -
Page 4: Tools Required
Installation Guide BBCD079 QTY- QTY- QTY- QTY- QTY- Tools Required Parts List Tools Required Parts List Air hacksaw Screwdriver set Metric spanner set Metric socket set Tape measure Drill and drill bits Bolt Tension Chart Page 4 of 14 ©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd... - Page 5 Installation Guide BBCD079 Before installation, check bull bar application is compatible with your vehicle. Remove and retain number plate, if fitted, to be reinstalled later. Disconnect the negative battery terminal. Please check the owner’s manual to see vehicle-specific requirements as some models may need battery backup.
- Page 6 Installation Guide BBCD079 Unclip the inner guard clips and unbolt the lower bumper to guard liner bolts. Remove factory washer bottle. Remove the inner wheel arch clip from the bumper to the body. Unbolt the 3 x 10mm bolts that retain the bar to the upper Reinforcement.
- Page 7 Installation Guide BBCD079 10. The factory bumper upper support will need to be cut and trimmed to be reinstalled to support the grille. 11. Test fit upper support but don’t reinstall at this stage NOTE: you may be required to trim the factory outer tabs off on both sides of the lower radiator support.
- Page 8 Installation Guide BBCD079 14. Mark 8 holes to be drilled through cross member and remove bull bar cradle. 15. Drill the holes using a 21mm hole saw, only drill through outer skin of front chassis tie bar. Drill a pilot hole using the centre drill bit of the hole saw through the inner skin as shown.
- Page 9 Installation Guide BBCD079 17. Debur holes and paint all exposed metal edges. 18. Mount both the right and left chassis support brackets to inner and outer faces of the chassis rail using hardware provided. NOTE: a crush tube is used on top of the inner bracket Do not tighten.
- Page 10 Installation Guide BBCD079 21. Install supplied outer and inner infill panel brackets with supplied hardware to both sides of the vehicle. NOTE: it is advised to paint in behind guard section 22. Install the factory grille. Now install the headlight infill panel with the hardware supplied.
- Page 11 Installation Guide BBCD079 25. Remove the pump from the factory washer bottle. Fit the pump upside down into the supplied washer bottle as shown. 26. If a winch is being installed, refer to the winch installation instructions on page 16-17.
- Page 12 Installation Guide BBCD079 29. IMPORTANT: For parking sensors to function correctly these instructions must be followed closely. Before removing sensors from the original bumper bar, note the location and orientation of each sensor so when they are fitted back into the bull bar this can be replicated.
- Page 13 Installation Guide BBCD079 33. Apply adhesion promoter to mounting surfaces around sensor holes and on sensor holders. This step is important to ensure sensor holders adhere properly to the bull bar. 34. Remove protective film from one side of double-sided tape and apply to mounting surface of sensor holder.
- Page 14 Installation Guide BBCD079 37. Install Bull bar into position, aligned to the chassis mounting holes. We recommend 2 people when lifting the bumper into position to avoid injury or damage to the vehicle and components. Centralize the bull bar to the vehicle’s bodywork.
- Page 15 Installation Guide BBCD079 42. Install number plate and number plate to the vehicle with M6 hardware supplied. 43. Trim guard liners on both sides. 44. Reinstall top plenum grille and connect negative battery terminal if applicable. Page 15 of 19...
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Page 16: Winch Installation
Installation Guide BBCD079 Winch Installation Bolt winch to cradle with gearbox to the left hand side of vehicle and cable spooling from bottom of the cable drum using bolts and washers provided. Bolt fairlead to recess in front of bull bar using bolts, washers and nuts provided. - Page 17 Installation Guide BBCD079 Connect three colour coded cables to the corresponding poles on winch motor. Connect the thin black earth wire and negative battery cable to the earth connection on the opposite side of winch motor. Run the positive and negative battery...
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Page 18: Wiring Diagrams
Installation Guide BBCD079 Wiring Diagrams DRL/PARKING/INDICATOR LIGHTS Daytime Running Light Brown Park Light Yellow Indicator Light White Ground If vehicle is not tted with DRL, leave red wire disconnected FOG LIGHTS Ground Lamp Fuse Connector Relay Black Blue Battery Lamp... - Page 19 Installation Guide BBCD079 Once Bull Bar is Installed Ensure all bolts are tensioned correctly, it is good practice to do a vehicle pre trip check before heading away or every 10k kms. Visually inspect bull bar and hardware, retention bull bar hardware or when needed.
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