Toyota - Highlander - Workshop Manual - 2008 - 2010 (3)

TOYOTA HIGHLANDER/KLUGER 2008 - 2010 MUDGUARD Preparation Part Number: PT908-48080 NOTE: Part number of this accessory may not be the same as the part number shown. Kit Contents Recommended Sequence of Application Item # 1 2 3 4 Quantity Reqd. 2 2 1 1 Description Front Mud guard Rear Mud guard DIO installation instructions Hardware Bag Item # 1 2 3 Accessory *Mandatory Hardware Bag Contents Item # 1 2 3 4 5 Quantity Reqd. 4 4 2 2 2 Description #10 x 0.6” self-piercing screws #10 nut spring M6 x 22 bolt M6 nut spring M6 x 23 push pin fastener Additional Items Required For Installation Item # 1 Quantity Reqd. Notes None Notes Installation Tools Notes Ratchet 6” extension Hex Socket Hex Socket Hex wrench Nylon Pry Tool Lint Free Cloth ¼” ¼” drive 10mm 8mm 4mm Special Chemicals Notes Cleaner 3M Prep Sol-70 General Applicability All 2008 Highlander Regular and Hybrid vehicles (USA) All 2008 Kluger vehicles (Australia) 6/30/10 Description Legend None Issue: D Quantity Reqd. STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. None Special Tools Item # 1 2 3 Description Conflicts Recommended Tools Personal & Vehicle Protection Vehicle Service Parts (may be required for reassembly) Page 1 of 5 pages TOYOTA HIGHLANDER/KLUGER 2008 - 2010 MUDGUARD Procedure Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). Safety (eye protection, rechecking torque procedure, etc.). Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Clean Mudguard Mounting Areas. - Hex Wrench (a) Clean and degrease front and rear body panels where mudguard is to be located using 3M Prep Sol-70. Screw 2. Installation of Front Mudguard Screw (a) Starting with the passenger side front wheel well, remove the two socket head screws and retain. (Fig 2-1) Fig. 2-1 (b) Using the nylon pry tool, remove and discard the vehicle’s bottom plastic fastener as shown. (Fig 2-2) - Nylon Pry Tool Vehicle Plastic Fastener Fig. 2-2 (c) Position front mud guard in place and align the three mounting locations. Insert the plastic fastener included in the kit into the bottom mount location. Ensure fastener body is fully seated and depress center pin fully until it locks into place. (Fig 2-3) Plastic Fastener Fig. 2-3 Issue: D 6/30/10 Page 2 of 5 pages TOYOTA HIGHLANDER/KLUGER 2008 - 2010 MUDGUARD Procedure - Hex Wrench 1st Screw 2nd Screw (d) Using the two screws removed in step 2-a, install the top screw first. Push mudguard tightly against fender and tighten. Then install the (2nd) lower screw. Push mudguard tightly against fender and tighten. (Fig 2-4) NOTE: Turn the steering wheel to make it easier to work inside the tire area. (e) Fully tighten the screws so they will not become loose. Fig. 2-4 - Hex Socket, 10mm (f) Repeat above steps for driver side. M6 Nut Spring Vehicle bolt Fig. 3-1 3. Installation of Rear Mudguard NOTE: FOR KLUGER VEHICLE APPLICATION (AUSTRALIA) ONLY: If Vehicle is fitted with OE rear mudguard (plain type), remove and install accessory mudguard PT908-48080 (moulded type) using existing holes and existing fasteners. (a) Starting with the passenger side, locate the two bolts directly behind the rear wheel. Remove and retain the vehicle’s bottom bolt closest to the tire and install the M6 nut spring on the bottom inboard hole. (Fig 3-1) (b) Locate the lower dimples on the rear bumper lip. (fig 3-2) (c) Install the #10 nut springs over the dimples on the rear bumper lip (1st and 3rd locations) (Fig 3-3) Fig. 3-2 (d) Screw the #10 x 0.6” screws into the nut springs ensuring the screws go through the dimples into the rear bumper. (e) Remove the two screws and retain. Fig. 3-3 Issue: D 6/30/10 Page 3 of 5 pages TOYOTA HIGHLANDER/KLUGER 2008 - 2010 MUDGUARD Procedure - Hex Socket, 8mm #10 Screws (f) Position the rear mudguard in place and secure it with the two screws, M6 x 22 bolt and the vehicle bolt removed in step 3.a (Fig 3-4 & 3-5) NOTE: When tightening the screws/bolts, push the rear mudguard onto the bumper to remove the gap between the rear mudguard and the bumper. Fig. 3-4 (g) Fully tighten all fasteners so they will not become loose. - Hex Sockets, 8mm & 10mm (h) Repeat above steps for driver side. 4. Final Checking (a) Check that the front and rear mudguards do not wobble. Fig. 3-5 Issue: D 6/30/10 Page 4 of 5 pages TOYOTA HIGHLANDER/KLUGER 2008 - MUDGUARD Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Front and rear mudguards. Check that they do not wobble. Check that part is firmly installed. Gaps between mudguards and body side. Issue: D 6/30/10 Page 5 of 5 pages Excessive gaps greater than 1.0 mm.