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TJM 070AP15N88O Fitting Instructions Manual

T15 signature frontal protection system toyota prado 150

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Product:
Vehicle:
Part No.
070AP15N88O
Australian Standards Relating to Installing Vehicle Frontal Protection Systems (VFPS): AS 4876.1-2002
a)
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.
b)
Do not use this product for any vehicle make or model other than those specified by the V.F.P.S. manufacturer (as above).
c)
Do not remove any plaques or labels from the V.F.P.S.
d)
Do not modify the structure of the V.F.P.S. in any way.
• Read instructions fully before commencing fitment.
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
• Left hand and Right hand components are determined as seated in the
vehicle.
• Check for (and remove) any build up in all captive nuts fitted to the FPS.
• When fitting accessories to TJM products (ie. driving lights and aerials),
ensure suitable washer plates are used under the mounting surface that
allow the accessory to be secured in a way that prevents it from damaging
the product.
• When removing protective coatings, ensure all new edges are deburred,
clean any swarf from the area and apply rust preventative to exposed
surfaces.
• Ensure that the "Rated Recovery Point Label" is affixed alongside the
compliance label, in the driver's side doorjamb.
Bolt tensions
All bolt tensions are
as follows unless
otherwise
specified.
For product warranty, please refer to our website, www.tjm.com.au
F-16745.DOCX
FITTING INSTRUCTIONS
T15 Signature Frontal Protection System
Dia. (mm)
5
6
8
10
12
Page 1 of 24
Toyota Prado 150
documentation.
Nm
ft.lbs
Dia. (inch)
1/4"
5
4
5/16"
9
7
3/8"
22
16
7/16"
44
32
1/2"
77
57
Nm
ft.lbs
9
7
22
15
33
27
55
43
86
66
26/10/2022

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Summary of Contents for TJM 070AP15N88O

  • Page 1 • Check for (and remove) any build up in all captive nuts fitted to the FPS. • When fitting accessories to TJM products (ie. driving lights and aerials), ensure suitable washer plates are used under the mounting surface that allow the accessory to be secured in a way that prevents it from damaging the product.
  • Page 2 FITTING INSTRUCTIONS Product: T15 Signature Frontal Protection System Vehicle: Toyota Prado 150 Part No. 070AP15N88O For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 2 of 24 26/10/2022...
  • Page 3: Parts List

    1/2" x Ø1-1/4” x 4mm Flat Washer K0638 Rated Recovery Point Label HC0064 1/2" x Ø1-1/4” Flat Washer K0623 Recovery Point Use Guide F-1768 Nylon Plug K0665 For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 3 of 24 26/10/2022...
  • Page 4 Extend the line across the front face of the bumper until joining the contour lines. 70mm For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 4 of 24 26/10/2022...
  • Page 5 Mask along the bumper cut lines to prevent damage from cutting. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 5 of 24 26/10/2022...
  • Page 6 BEFORE PROCEEDING. STEP 13 STEP 13 Remove (& retain) the grille. Remove (& retain) the four clips securing the bumper to the bumper support beam. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 6 of 24 26/10/2022...
  • Page 7 RETAIN HEADLIGHT WASHERS AND/OR FOGLIGHTS, DISCONNECT THEM BEFORE PROCEEDING. PLUG OR CLAMP THE HEADLIGHT WASHER LINE TO MINIMIZE FLUID LOSS. Carefully remove the bumper. DISCARD For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 7 of 24 26/10/2022...
  • Page 8 Trim the lower portion of both airdams RHS SHOWN removed in step 25 using the adjacent image as a reference. Reinstall the airdams to the vehicle. CONTOUR RADIUS 20mm For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 8 of 24 26/10/2022...
  • Page 9 IT MAY BE NECESSARY TO LOOSEN THE PHILLIPS HEAD SCREW CLAMPING THE HOSE TO THE BRACKET, ALLOWING THE BRACKET TO ROTATE ABOUT THE HOSE. RETIGHTEN SCREW FOLLOWING REPOSITIONING OF THE BRACKET. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 9 of 24 26/10/2022...
  • Page 10 Tighten fasteners only enough to fit mount STEP 41 against chassis but still allow movement. Repeat steps 37 through to 42 for the opposite side. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 10 of 24 26/10/2022...
  • Page 11 M12 x 1.25 x 40mm Hex Head Bolt (1), ½” x 1 ¼” Flat Washers (2) & M12 x 1.25 Nyloc Nut (1) STEP 47 For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 11 of 24 26/10/2022...
  • Page 12 Upper M8 bolt Repeat steps 50 to 53 for the opposite side of the vehicle. ENSURE THE WINCH FRAME IS CENTRED TO THE BODY BEFORE PROCEEDING For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 12 of 24 26/10/2022...
  • Page 13 Align plate with existing holes and tighten to specified torque. Check holes and slots align after tightening to allow easy bolt fitment/clearance. NUTS TO INSIDE! REPEAT ON OPPOSITE SIDE OF VEHICLE. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 13 of 24 26/10/2022...
  • Page 14 M6 x 1.0 x 16mm S/S button head bolts (2), M6 x Ø18mm S/S flat washer (2) and M6 S/S nyloc nuts (2). For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 14 of 24 26/10/2022...
  • Page 15 Reinstall the OE steering guard to the vehicle at the rear points only, using OE fasteners retained in step 22. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 15 of 24 26/10/2022...
  • Page 16 (ensuring that an adequate seal is achieved). ENSURE THAT THE PARK LIGHT IS POSITIONED TOWARDS THE OUTSIDE OF THE VEHICLE For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 16 of 24 26/10/2022...
  • Page 17 (4), secure the fog light blanking cover to the fog light mounting bracket. Repeat the previous three steps for the opposite side of the vehicle. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 17 of 24 26/10/2022...
  • Page 18 STEP 89 APPLIES ONLY IF A WINCH IS FITTED Using the fasteners supplied with the winch, secure the fairlead to the FPS. PROCEED TO STEP 91 For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 18 of 24 26/10/2022...
  • Page 19 CHAMFER TO TOP & M12 nyloc nuts (4) at the indicated locations. IMPORTANT: SLIDING WASHER PLATE MUST BE ORIENTATED CORRECTLY AS SHOWN! REPEAT ON LHS. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 19 of 24 26/10/2022...
  • Page 20 Tension the fasteners to the specified torque settings listed on page 1. Connect all wiring harnesses. Fit an M8 cage nut to each wing brace, as 100. shown. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 20 of 24 26/10/2022...
  • Page 21 Tighten the wing brace fasteners to their 104. specified torque settings. Repeat steps 101 to 104 for the opposite 105. side of the vehicle. STEP 103 For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 21 of 24 26/10/2022...
  • Page 22 Trim both inner wheel guards 5mm above the 109. line marked in the previous step. Insert M6 cage nuts (4) into each wing 110. guard, as shown opposite. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 22 of 24 26/10/2022...
  • Page 23 FPS using M6 x 1.0 x 20mm Hex Head Bolts (4), M6 spring washers (4) and M6 x Ø15.5-18mm Flat Washers (4), at the indicated location. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 23 of 24 26/10/2022...
  • Page 24 Ensure that all fasteners are fully tightened to 118. the appropriate torque settings & that, as a result of fitting the FPS, no vehicle components are crushed or will chafe. For product warranty, please refer to our website, www.tjm.com.au F-16745.DOCX Page 24 of 24 26/10/2022...