TJM T15 User manual

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 1 of 18

15/03/2021

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.

•Left hand & 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.

•Be aware that a number of government / fleet departments require that the

tow points be painted red.

•Ensure that the “Rated Recovery Point Label” is affixed alongside the

compliance label, in the driver’s side doorjamb.

Bolt tensions

Dia. (mm)

ft.lbs

Dia. (inch)

ft.lbs

All bolt tensions are

as follows unless

otherwise

specified.

1/4”

5/16”

3/8”

7/16”

1/2”

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 2 of 18

15/03/2021

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 3 of 18

15/03/2021

ITEM

NO.

Description

Qty

Part

Number

PARTS LIST

FPS

F-17359

Bar Mount / Winch Frame

F-7855

Chassis Mount LH

F-8430L

Chassis Mount RH

F-8430R

Center Guard

F-8690

Wing Guard RH

F-25212R

Wing Guard LH

F-25212L

Hinged No Plate

F-25211

Grill Centre

F-7892

Grill RH

F-9971R

Grill LH

F-9971L

FITTING KIT

Wing Guard Mount

F-10994

Bend Angle LH

F-17394L

Bend Angle RH

F-17394R

Bending Washer Plate

F-7870

Outer Washer Plate

F-17393

Spacer

F-9007

Rear Inner Chassis Support

F-9008

Spacer

F-9009

Mount Spacer

86528

Grille Latch

F-9969

Spring Latch Spacer

F-18168

Hinge Bush

K1292

LED Parker/Indicator

92600

Fog Light Blanking

92091

Bumperette LH

F-17368L

Bumperette RH

F-17368R

Fog Light Washer Plate

88057

Parking Sensor Blanking Plug

K0663

N/A

Pinch-Weld (285mm Long)

93154

N/A

Nylon Plug

K0665

N/A

Rated Recovery Point Label

HC0064

N/A

Recovery Point Use Guide

F-1768

N/A

Parking Sensor Housing Sicker

F-50070

N/A

2020 Model Trim Template

F-31638

FACTORY FITTED

N/A

Rated Recovery Point Label

HC0064

N/A

TJM Logo Sticker

K3550

N/A

Warning Label - ABC

HC0057

ITEM

NO.

Description

Qty

Part

Number

BOLT KIT

N/A

R-Clip

91130

N/A

M5 x 0.8 x 20mm Pan Head Screw

K0688

N/A

M5 x Ø10mm Flat Washer

K0417

N/A

M5 x 0.8 Nyloc Nut

K0604

N/A

M6 x 1.0 x 20mm Hex Head Bolt

K0550

N/A

M6 x 1.0 x 16mm SS Button Head Bolt

K1630

N/A

M6 x 1.0 x 20mm SS Button Head Bolt

K3218

N/A

M6 x 1.0 SS Nyloc Nut

K1549

N/A

M6 x 1.0 Flange Nut

K3033

N/A

M6 Spring Washer

K0915

N/A

M6 SS Spring Washer

K1552

N/A

M6 x Ø12.5mm SS Flat Washer

K1551

N/A

M6 x Ø12.5mm Flat Washer

K0897

N/A

M6 x Ø18mm x 1.6mm Flat Washer

K2905

N/A

M6 x Ø18mm SS Flat Washer

K1554

N/A

M6 Cage Nut Type B

K1550

N/A

M8 x 1.25 x 25mm Hex Head Screw

K0553

N/A

M8 x 1.25 x 35mm Hex Head Screw

K0555

N/A

M8 x 1.25 x 40mm Hex Head Screw

K0556

N/A

M8 Spring Washer

K0620

N/A

M8 x Ø19mm Flat Washer

K0628

N/A

M8 x 1.25 Cage Nut Type B

K1560

N/A

M8 x 1.25 Nyloc Nut

K0606

N/A

M10 x 1.25 x 30mm Hex Head Screw

K0564

N/A

M10 x 1.25 Nyloc Nut

K3099

N/A

M10 x Ø30mm Flat Washer

WSST-W13

N/A

M10 Spring Washer

K0621

N/A

M12 x 1.25 x 35mm Hex Head Screw

K0570

N/A

M12 x 1.25 x 40mm Hex Head Screw

K0571

N/A

M12 x 1.25 x 100mm Hex Head Bolt

K1240

N/A

M12 x 1.25 Nyloc Nut

K1200

N/A

M12 Spring Washer

K0977

N/A

M12 x 32mm x 2.5mm Flat Washer

K0623

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 4 of 18

15/03/2021

MARK BUMPER WHILE STILL ON VEHICLE.

NOTE: BUMPER TRIM GARNISH SHOULD

REMAIN ON BUMPER TO BE MARKED/CUT

1. Affix the supplied bumper trim template

(F-31638) to the vehicle.

2. Mark a point on the indicated bumper

contour 125mm verticaly down from the

headlight bumper contour.

3. Extend a line across the bumper from the

bumper trim template to the point marked in

step 2.

4. Extend a line from the point marked in step

2 to the bottom spar in the lower grille

opening.

REPEAT ABOVE STEPS FOR THE

OPPOSITE SIDE OF THE VEHICLE

5. Remove & retain the number-plate,

discarding the fasteners.

6. Remove & retain the plastic clips /

fasteners (8) that secure the top of the

grille/radiator shroud.

7. Remove shroud.

RHS SHOWN

STEP 2

125mm

GARNISH TO

REMAIN ON BUMPER

STEP 4

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 5 of 18

15/03/2021

8. Locate and remove grill retaining screws (4)

upper and (4) lower.

9. Disconnect radar plug from back of grill then

remove and retain grill

10. Release the plastic inner guard from the

bumper, discarding all of the fasteners.

11. Remove bumper to fender screw both sides

and retain.

Repeat on LHS.

12. Remove and discard lower bumper clips

13. If there are fog lights and parking sensors

fitted to the vehicle, disconnect the plugs

from the back of the sensors and fog lights.

14. Remove the bumper from the vehicle and

retain.

RHS SHOWN

STEP 10

STEP 11

RETAIN

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 6 of 18

15/03/2021

15. Remove & discard the front intrusion beam

using the following steps:

15.1. Remove & discard all plastics in front

and below beam.

15.2. Remove and discard front intrusion

beam and fasteners (4).

These steps only apply for vehicles fitted

with parking sensors

16. Looking at the lower bumper section from

the rear, record each parking sensor’s

position and orientation.

17. Remove the parking sensors.

18. Carefully remove the blue parking sensor

housing from the bumper and remove

excess double sided tape from the housing.

Reinsert the sensor into the housing and set

aside to be reinstalled to the FPS.

DISCARD LOWER

PLASTIC PANEL

LHS SHOWN

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 7 of 18

15/03/2021

Fit the Indicator / Parker flying lead or plug and play harness to the vehicle loom as per

instructions.

Temporarily plug in supplied indicator/park.

Check the operation then disconnect the light assemblies.

19. Cut the bumper and grille along the

previously marked trim lines.

20. Refit the grille and bumper to the vehicle,

using the OE fasteners retained previously

21. Reconnect the radar.

22. Assemble outer chassis mount with spacer

(item-19) using M12 x 1.25 x 100mm hex

bolt (2), & M12 x 32mm x 2.5mm flat

washer (2) in position shown holding spacer

in place. Fit spacer (item-17) (2) onto bolts.

LHS SHOWN

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 8 of 18

15/03/2021

23. Position the assembled outer chassis mount

on the outer face of the chassis rail aligning

the respective holes to the chassis.

24. Slide rear inner chassis support onto bolts

and fasten loosely using M12 nyloc nuts (2)

& M12 x 32mm x 2.5mm flat washer (2).

Important:

Spacers must pass through chassis

holes and fit against the inner and

outer chassis mounts.

Repeat chassis mount steps on both

RHS.

25. Fit the wing guard mount and loosely secure

it in place, using M12 x 1.25 x 40mm hex

screws (1), M12 spring washers (1) &

M12 x 32mm x 2.5mm flat washer (1) into

captive nut in the chassis rail.

26. Insert 2-off M8 X 1.25 cage nuts as shown.

Repeat on RHS.

LHS SHOWN

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 9 of 18

15/03/2021

27. Loosely secure in place at the positions

shown using M10 x 1.25 x 30mm hex

screws (4), M10 spring washer (4) and

M10 x Ø30mm flat washer (4).

28. Secure bracket loosely using the following

fasteners:

28.1. M10 x 1.25 x 30mm hex screws (3),

M10 x Ø30mm flat washers (6) &

M10 nyloc nuts (3).

28.2. M12 x 1.25 x 35mm hex screws (2),

M12 x Ø32mm x 2.5mm flat

Washers (4) & M12 nyloc nuts (2).

Repeat on LHS.

29. Centralize the bar mount / winch frame to

the vehicle by measuring diagonally from

mount tip to headlamp corner as shown,

equalize as close as practical.

Tighten all winch frame and chassis mount

bolts from previous steps to relevant torque

settings listed on page 1.

RHS SHOWN

28.2

28.1

FITTING INSTRUCTIONS

Product:

T15 Signature Frontal Protection System

Vehicle:

Toyota HiLux (MY2020)

Part No.

070AP15N87J

For product warranty please refer to our website www.tjm.com.au

F-31649

Page 10 of 18

15/03/2021

30. Fit clamp Angle bracket to inboard face of

winch frame and washer plate to front using

M12 x 1.25 x 35mm bolts (3),

M12 x 32mm x 2.5mm flat washer (6) & M12

nyloc nuts (3).

Important –fit M12 bolt assembly with bolt

head on front face.

31. Align plate with existing holes and edges,

tighten to specified torque. Check holes and

slots align after tightening to allow easy bolt

fitment/clearance.

Repeat on LHS.

NUTS

TO INSIDE!

RHS SHOWN

Clamping

angle

Holes must

align

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