Bullbar fitting instructions for toyota 300 series landcruISER

BULLBAR FITTING INSTRUCTIONS FOR TOYOTA 300 SERIES LANDCRUISER Last update: 220221

PLEASE REMOVE FROM FITTING INSTRUCTIONS AND PUT IN THE GLOVE BOX OF THE CLIENT’S VEHICLE

Your TUFF bar complies with all current Australia standards

Thank you for purchasing a TUFF Bullbar to protect you, your family and your investment. The purpose of a good bullbar is to prevent/reduce damage to the front of the vehicle in the event of an accident, collision or animal strike.

Manufacturing of TUFF bars

To ensure a TUFF bullbar properly serves its purpose, the design and engineering team at TUFF, take a number of factors into consideration, such as crush rate, air bag deployment, reflection, profile, airflow and accessory fitment just to name a few.

The shape and dimensions of a bullbar strongly influence the degree of protection offered to other road users too. TUFF bars follow the profile of the vehicle and when fitting the bullbar, we ensure that the width of the vehicle is not exceeded.

What requirements are needed to meet to comply with current Australia Standards?

After the bullbar has been fitted you can be assured that TUFF Bullbars comply with the Australia Standard Guidelines and relevant Australian Design Rules (ADR’s). Main requirements include:

1. Airbag Compatible. 2. Posts do not lean forward. 3. Indicator/Park lights fitted to bullbar. 4. Rounded Corners. 5. Rounded tubes to outside stays. 6. Radius Edges. 7. All UHF Aerials/Spotlights are mounted behind the forward face of the bullbar. 8. The bullbar is manufactured by a reputable and responsible manufacturer.


2 | P a g e T U F F B Y N A M E , T U F F B Y N A T U R E

A bullbar mounting system is the most important part of any design, and as every vehicle is different, our TUFF Heavy duty steel mounting systems are designed specifically to suit the vehicles chassis and the bullbar bolting onto it. All TUFF mounts are cut from 8 – 10mm steel plate and are designed and independently tested to ensure they are compatible with the vehicles standard safety equipment, without compromising the strength and performance of the TUFFbar. TUFFbars meet the requirements of ADR 69/00. Vehicle Frontal Protection System Impact Test – Air Bag Compatibility Certificates are available on request. *Pictured TUFF Heavy Duty Mounting system.

The front face of a TUFFbar has been carefully designed to ensure that it does not lean outward from the vehicle. Aerial tabs and driving light mounts are fixed to the bullbar in a manner that prevents them from becoming dangerous projections. All accessory fixtures are positioned on the rear of all TUFFbars. *Pictured an example of accessory fixtures positioned to the rear surface.

The ends of TUFFbars are curved to wrap around the front of the vehicle. They do not protrude beyond the legal maximum width of the vehicle. The overall height of a TUFFbar has been designed to be practical and protective. Bars extending too high over the bonnet are not permitted. *Pictured TUFFbar ends curved to wrap around the profile.

Research conducted by insurance companies and the 4WD industry show that the cost of repairing vehicles due to animal-related collisions, run into the millions of dollars across Australia annually. Therefore, protecting your investment with a TUFF bar provides you with the ULTIMATE Protection for you and your family, and assists with reducing insurance claims and premiums.

We are proud of our products and the superior protection they offer. Further product information relating to compliance and safety, can be obtained by contacting 1300 BE TUFF (1300 23 8833).

TUFF looks forward to protecting you!

Anton Griffiths Chief Executive Officer

1300 23 8833 or (07) 4615 0000

10 Carrington Rd (PO Box 1977) Toowoomba QLD 4350



TUFF BULLBARS AUSTRALIA [email protected] 10 Carrington Rd, (PO Box 1977) [email protected] TOOWOOMBA QLD 4350 [email protected] Phone: 1300 23 8833 www.tuffaustralia.com.au or (07) 4615 0000

BULLBAR Fitting instructions to fit TUFF Range Bullbars (2-5 Post, Aerostyle and TUFF4x4) to TOYOTA 300 SERIES

Estimated fit time: 3 hours

Call 1300 BE TUFF (1300 23 8833) for assistance with fitting

Read Fitting instructions carefully before fitting product to vehicle

v When installed in accordance with these instructions, the front protection bar does not affect operation of the SRS airbag. This product has been tested for Air Bag Compatibility and therefore the mounting system MUST NOT be modified

v This product must be installed exactly as per these instructions using only the parts supplied v In the event of damage to any bullbar component, contact the tuff team ASAP v Do not use this product for any vehicle make or model, other than those specified by Tuff v Do not remove any labels from the bullbar and/or brush rails & steps v Bullbar installations should be done by a qualified person and it is the responsibility of this person

to ensure correct fitment



Tools suggested for fitment

Bolt and Bracket kit for fitment BOLT KIT

Quantity Item Use CHECKLIST 2 Bar Brackets 2 7” Rubbers 8 M12 x 40 (Fine)

Bar Bracket

8 M12 Washers

16 M12 Spring Washers 4 M12 x 50 (Coarse) 4 M12 Nylock nut 4 M16 x 50 (Coarse)

Crash Box

8 M16 Washers 4 M16 Nylock nut 2 300mm Stabilisers

Stabilisers

4 M10 x 50 (Coarse) 4 M10 Nylock nut 8 M10 Washers

6 Snap lock crimp Wiring 2 Wiring Harness Indicators 2 Indicators 4 Sensor Housing Sensors

Flat Blade Screw Driver 14mm Socket and spanners 16mm Socket and spanners 17mm Socket and Spanners 18mm Socket and spanners 19mm Socket and spanners 24mm Socket, ratchet and spanners Soldering Iron Jigsaw or other cutting tool (Bumper cut) Linisher or other sanding tool (To neaten Bumper cut) Set square Masking tape Pliers Electrical tape



Read through the fitting instructions and pictures below

Photos Comments

Prepare the car for fitting: Remove the top section of the bumper.



Undo the plugs on top of the bumper. This will be for the tech pack and other sensors on the bumper.

Undo these bolts behind the bumper.

Remove the under-body bolts, holding the bumper on.



Undo all the bolts in the wheel well, past the point to where the bullbar will sit.

Remove any bolts holding the underbody protection and these plastic bits.



Gently remove the bumper.

Undo the plastic pins on the side of the radiator ventilation guide.



Remove the black plastic fin and the crash box. We will not be using them for this build.



Attach Bar Brackets to the car as shown, using the bolts provided. X6 bolts per bracket.



Attach crash box as shown, using the bolt kits provided.

Cut out a section of the air vent guides so they fit back onto the car clearing the bar bracket.



Wiring diagram for the indicators is as follows: PIN 1: EARTH -> WHITE PIN 4: PARK -> BLACK PIN 8: INDICATOR -> YELLOW Pins need to be located on the plug as shown in the picture. The connection diagram reads, Pin 1 is Earth on the plug which gets connected to the White wire in the indicator harness and so on. NOTE: The wire colours on the vehicle may differ from the original photo shown. Join the wires as such and use the provided snap locks for the connections. NOTE: Please test the lights before continuing with the fit.



NOTE: When placing the bar onto the car PLEASE use at least two people for this job. Secure the bullbar in place and loosely position the bolts ready to align and tighten TIP: TIGHTENING THE BOTTOM BOLTS MOVES THE WING OF THE BULLBAR UPWARDS. TIGHTENING THE TOP BOLT MOVES THE WING DOWN MAKE SURE BOLTS ARE TIGHT! NOTE: Wings of Bullbar should follow the body line of vehicle.

THE TOP HALF OF THE ORIGINAL BUMPER HAS TO BE PREPARED

TO BE CUT AND RE-FITTED TO THE VEHICLE THERE WILL BE A 10MM GAP BETWEEN THE BULLBAR AND THE BUMPER

WE DO THIS BY MEASURING SIX MEASUREMENTS FROM THE BULLBAR TO THE CAR BODY POSITIONS – THREE EACH SIDE (SUBTRACT 20MM FROM THESE MEASUREMENTS)

Preparing to cut the bumper: 1st measurement: Measure the verticle distance between the bullbar and the end of the flare arch.



Preparing to cut the bumper: 2nd measurement: Measure the verticle distance just outside the of the headlight to the bullbar. (Please note: this is not a 300 series image and is only used to show bumper measurement positions).

Preparing to cut the bumper: 3rd measurement: Measure the verticle distance just under the inside of the headlight to the bullbar. (Please note; this is not a 300 series image and is only used to show bumper measurement positions). TIP: Write these measurements on a piece of masking tape and stick onto the bumper, ready to measure the bumper for cutting.



Cut the bumper in marked areas.



Place the bumper back on the car and remeasure using some datum points. Level out the bullbar, using the bumper cut as a guide. Trim any excess material off the bumper to make sure there is a 10mm gap from the top of the bullbar channel to the bumper cut for the bumper edging to be put on later.

Mark out a central position on the bottom of the banding (where the cut outs are provided for the sensor holes).



Drill a 27mm hole per sensor in the relevant banding. Attach sensor housing as per photos.



Cable management for the sensors is also as per photos.



Sensor placement for reference.

Connect 25 x 25 RHS Stabiliser rod between the bullbar and the bracket.



Mark out the holes in the RHS Stabiliers to be drilled.

Using two 10 x 50mm bolts, nuts and washers each side.

***Do Not Forget to reinstall the tow eyes ***

Reinstall all the trimmings back onto the vehicle in the reverse order to the fitting instructions. However, as mentioned earlier, the stock crash box and the plastic trim

on the crash box do not get reinstalled on the car. We hope you enjoy your new TUFF product.



Please don’t hesitate to call us on 1300 BE TUFF (1300 23 88 33) if you have any problems with fitting

We are always looking for ways to improve our fitting instructions and encourage you to give us feedback on this.

Please send your feedback to: [email protected]

Best regards the TUFF TEAM! J



FITTING INSTRUCTIONS FEEDBACK FORM

VEHICLE: MAKE____________ MODEL________________ YEAR_____

TUFF ORDER NO: __________

PRODUCT: NUDGE BAR AEROSTYLE BAR 4X4 BAR __ POST BAR (Please circle or insert post number) TRAY BRUSH RAILS SIDE STEPS ONLY

What condition was the PACKAGING in? (please circle) GOOD DAMAGED

Was the BOLT KIT complete? (please circle) YES NO If no, please note what was missing:

Please help us improve our fitting instructions by providing any feedback or suggestions you have.

Your feedback is highly valued. Please provide your details so we may contact you if any of the above information needs to be clarified.

NAME: __________________________ PH: ______________ EMAIL: __________________

ORGANISATION: __________________

DATE: _________

Thank you for taking the time to provide us with your feedback.

Please email this form and any supporting photos to: [email protected]

Bullbar fitting instructions for toyota 300 series landcruISER

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