nudge bar fitting instructions - parts db

PZQ2975050-FINS Issue: 3 - 16/04/1914

HIACE

Page 01 of

Nudge Bar

Fitting Instructions

Fitting Time: 90 minutes

Accessory Part No: PZQ2975050/055

FEBRUARY 2019 PRODUCTION ONWARDS

PZQ2975050-FINS Issue: 3 - 16/04/1914

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- Read through the tting instructions before installation of accessory.

- Always install the accessory following the tting instructions. Failure to do so may cause damage to the vehicle or the accessory.

- Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local recycling regulations.

- It is always recommended that this accessory is tted by a qualied Toyota Technician.

- Safely store and protect any removed vehicle components.

- Ensure all bare metal surfaces are protected using Automotive Bare Metal Primer and touch-up paint.

- Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.

- Check that all work practices comply with safety standards.

- Please wear appropriate clothing and use safety equipment.

90 minutes

General Notes

Safety Notes

Fitting Time

Page 02 of

General User Information

- Do not attach the nudge bar to the vehicle using anchorages not intended for this purpose (e.g. engine mounting bolts).

- Do not use any other mounting location/mehod other than described in these fitting instructions.

- Do not use this product for any vehicle make or model other than those specified by the nudge bar manufacturer.

- Do not repair or modify the structure of the nudge bar and/or it’s mounting bracket in any way. Repair or modification can result in non compliance with ADR 69/00 Frontal Impact Requirements and may effect proper operation of the air bag system resulting in serious injury.

- Do not remove the compliance plaque or label from the nudge bar.

- After installation, place these fitting instructions in the vehicle with the Owner’s Manual.

- This accessory is an airbag compatible accessory.

- Non recommended use of the nudge bar (e.g. ladder rack support or fishing rod holder) may cause damage to the accessory or vehicle and may impair the operation of the airbag system.

- Nudge bar fixings must be checked and re-tightened to the specified torque during every service.

- Daily exposure to pollution in the air, road grime and corrosive environments such as sea side roads can affect the appearance and finish of the accessory. Regularly wash the accessory using a reputable automotive wash detergent, rinse with fresh water and chamois to dry.

- Occasionally:® - Polish metal surfaces with Autosol or similar product.

- Protect plastic surfaces with Nulon Ezi-Glide ® or similar product

- To minimise damage of the Nudge Bar during tment, do not remove the plastic wrap guard until the end of the tment.

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Page 03 of

Parts SuppliedA B C D E

Upper Bracket LHQty x1

Lower Support Bracket LHQty x1

F G

Nudge Bar AssemblyQty x1

H I J K

Rear Reinforcement Bracket LH

Qty x1

Rear Reinforcement Bracket RH

Qty x1

L M N O P Q

M8 x 25 Flange BoltQty x14

R S


T U

M6 x 25 Torx Bolt Qty x2

M6 Washer Qty x2

V

X

Number Plate GrommetQty x2

Cable TieQty x1

Y

Lower Bracket RHQty x1

Lower Support Bracket RHQty x1

Upper Bracket RHQty x1

Lower Bracket LHQty x1

Upper Support Bracket LH

Qty x1

Upper Support Bracket RH

Qty x1

Fitting InstructionsQty x1

M10 Flange Nut Qty x2

M8 Flange Nut Qty x2

M8 Nut PlateQty x2


M8 Spacer Qty x2

M10 Spacer Qty x2

W

Number Plate ScrewQty x2

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Page 04 of

Tools Required

File or Deburring ToolTorque Wrench7.5Nm - 64Nm

Combi Spanner - 13mm Phillips Head Screwdriver

Drill Bit - Ø6mm,Ø10mm

Multi Tool

Battery Drill

Socket Set - 10mm, 12mm, 13mm

14mm, T30 Socket Extension Bar

Layout Diagram

Spike / Bradle

A

H

F

I

G

J

Q

E

B

Q

D

L M

N

O

UT

P

K

S

R

C

PP

N

P

N

(N) - 30Nm(O) - 30Nm(P) - 64Nm(S) - 64Nm(T) - 7.5Nm

Drill Stop

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Step 1

Step 2

Step 3

Page 05 of

• Locate the battery in the LH door sill area.

• Remove the plastic cover (1) by turning the latches (2).

• Remove the steel cover.

• Disconnect negative terminal from battery and apply tape.

• Remove and retain all clips and radiator cover.

- 9 push clips in total.

• Remove and retain grille and bumper cover fasteners.

- 4 bolts on top edge of grille.

- 3 bolts on lower edge of grille.

Important

Always refer to the vehicle’s Workshop Manual when removing vehicle components.

Tools Required:

10mm socket and extension

Tools Required:

Trim removal tool

Tools Required:


1

1

1

1

1 1

1 1

1 1

1 1

212

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Step 4

Step 5

Page 06 of

• Remove and retain bumper cover fasteners from both sides.

- 10 push clips (1).

- 2 screws (2).

• Remove and retain lower grille covers and fasteners.

- 2 covers.

- 2 bolts (4).

Step 6

Tools Required:

Trim removal tool.

10mm socket and extension or Phillips head screwdriver.

Tools Required:


• Disconnect two connectors (5) before removing the bumper cover.

• Remove and retain bumper cover.

Note: Two people recommended to remove bumper cover.

2

1

1

1

1

LH SHOWN

4 4

5

5

1

Important

The Milli-Wave Radar must be re-calibrated as per the worshop manual procedure after vehicle re-assembly.

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Step 8

Step 9

Page 07 of

• Remove and retain fasteners and lower absorber.

- 4 screws (1), 4 clips (2).

• Discard the screws marked with an ‘X’.

Step 7

• On the inner LHS of the bumper, drill a 6mm hole in the position shown.

• Route the wiring harness with a cable tie as shown.

Tools Required:

Drill

6mm Drill bit

10mm Drill stop

Tools Required:

10mm socket

Trim removal tool

• Cut holes in bumper cover with templates provided.

• Remove and discard tow hook covers.

Tools Required:

Drill

10mm Drill bit

Multi Tool

File / Deburring tool

Spike / Bradle

LH SHOWN

10mm

10mm

Important

Use 10mm drill stop to avoid bumper cover damage.Do not drill through bumper cover.

2

2 1 1 1 1 2

2

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Step 11

Page 08 of

• Remove and retain marked clips (1) so that the engine under cover can hang down for access.

- 6 clips in total.

Step 10

Step 12

• Remove and trim foam absorber as shown.

Tools Required:

Trim removal tool

Tools Required:

Multi tool

• If fitted to the vehicle, remove and retain clips and centre air deflector.

- 2 push clips (2), 3 clip locations.

• Remove and retain LH and RH air deflector.

- 2 clips on each part .

Tools Required:

Trim removal tool

1

1

1

2

2

1

11

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Step 15

Step 14

Step 13

Page 09 of

• Remove 4 bumper reinforcement bolts (1)(2) from each side. Discard the bolts marked with a (2).

• Remove and retain bumper reinforcement.

Tools Required:


• Install reinforcement bracket (1) and tighten with M10 bolt (2) in the direction shown, to ensure no gap between the bracket and the weld nut.

• Install M8 Bolt (3) and nut and torque to 30Nm .

• Repeat for other side.

Hint: Sit nut in ring spanner before inserting into chassis rail as shown.

• Remove M10 bolt (4).

• Repeat for the other side.

Tools Required:

13mm ring spanner

Tools Required:


Torque wrench

13mm ring spanner

LH SHOWN

4

LH SHOWN

2

1

330Nm

30Nm

22

2

1

22

2

1

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Step 18

Step 17

Step 16

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• Loosely re-install bumper reinforcement using one original bolt (1) on either side.

• Loosely install main upper bracket and support bracket using two M10x45 Flange Bolts.

• Loosely install two M8x25 Flange Bolts to join the brackets.

• Repeat for the other side.

• Remove and discard two M8 bolts (1) and one M10 bolt (2) from each side.

Tools Required:

12mm and 14mm sockets

Tools Required:


Tools Required:


RH SHOWN

1 1

12 12

UNDERNEATH OF VEHICLE SHOWN

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Step 21

Step 20

Step 19

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• Loosely install main lower bracket with two M8x70 bolts (1), one M10x45 bolt (2) and spacers as shown


• Loosely install lower support bracket with one M10x45 bolt.

Tools Required:

13mm socket

Tools Required:


• Trial fit the nudgebar assembly to brackets with 4x M8x25 bolts each side and nut plates on lower brackets.

• Adjust brackets to ensure correct fitment of nudgebar.

• Align the bar to the centre of the vehicle using the two scribe lines behind the licence plate and the radiator support bracket.

Tools Required:


RH SHOWN

LH SHOWN

LH SHOWN

LH SHOWN

1

2

PZQ2975050-FINS Issue: 3 - 16/04/1914

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RH SHOWN• Tighten 4 bumper reinforcement M10 fasteners each side to 64Nm (refer to Step 13 for locations).

• Tighten upper bracket joining M8 fasteners to 30Nm.


Tools Required:

13mm and 14mm sockets and extension

Torque wrench

• Install nut onto reinforcement bracket torque to 64Nm.

Note: Use spanner on bolt head to prevent bolt from turning.

Step 23

Step 22

Step 24

of

Tools Required:

14mm socket

Torque wrench

13mm ring spanner

• Remove nudge bar assembly with the fasteners shown

• Note: leave the brackets installed on the vehicle

Tools Required:

13mm socket

64Nm

64Nm

30Nm

30Nm

64Nm

64Nm

LH SHOWN

LH SHOWN

LH SHOWN

Qty

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Step 27

Step 26

Step 25

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• Re-install cut bumper cover, upper grille and radiator cover in reverse order from steps 6, 5, 3 and 2.

• Re-connect the two connectors on the bumper wiring harness removed in Step 6.

• Re-install nudge bar assembly with four M8 x 25 bolts and one M8 nut plate each side.

• Confirm gap conditions to vehicle (target 10mm between over-riders and bumper cover).

• Tighten nudge bar attachment M8 x 25 bolts to 30Nm.

• Tighten lower bracket M8 fasteners to 30Nm.

• Tighten lower bracket M10 fasteners to 64Nm.

Hint: Access top bracket fasteners through nudgebar tow hook cover opening.

• Re-install cut foam absorber.

• Re-install air deflectors removed in Step 12.

Tools Required:


Torque wrench

• Re-install engine undercover.

• Re-install lower absorber with original fasteners and two supplied M6x25 screws and washers.

Torque to 7.5Nm

• Re-attach lower bumper cover as per Step 4.

Tools Required:

Torque wrench

10mm and T30 sockets

LH SHOWN

30Nm

30Nm

30Nm

30Nm

30Nm

30Nm

64Nm

64Nm

PZQ2975050-FINS Issue: 3 - 16/04/1914

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Step 28• Install tow hook covers.

• Remove plastic wrap guard if applicable.

• Install number plate (1) to nudge bar with two Number Plate Screws (2) and two Number Plate Grommets (3).

of

Step 29• Wipe down the nudge bar using a clean cloth to remove any

marks or residue resulting from the installation.

• Place the fitting instructions in the vehicle with the Owner’s Manual.

Step 30• Re-connect battery negative terminal after removing tape.

Torque to 5.3 +/- 1Nm.

• Re-install steel battery cover.

• Re-install plastic battery cover.

Important

The Milli-Wave Radar must be re-calibrated as per the worshop manual procedure.

1

2

3

1

nudge bar fitting instructions - parts db

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