Toyota - Hilux - Owners Manual - 2015 - 2015 (2)

HILUX / FORTUNER July 2015 Production Onwards Kit Part No: PZQ59-89050 Kit Part No: PZQ59-89030 Fitting Time: 30 minutes Driving Lamp Harness Fitting Instructions FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 19 HILUX / FORTUNER General Notes - Read through the fitting instructions before installation of accessory. - Always install the accessory following the fitting 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 fitted by a qualified 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. Safety Notes - Check that all work practices comply with safety standards. - Please wear appropriate clothing and use safety equipment. Fitting Time 30 minutes --- Parts Supplied ----------------------------------------------------------------------------------------------------------------------------------B A Engine Harness x1 G I M6 Nyloc x1 Relay Bracket x1 M6 Bolt x1 Switch x1 L K J M6 Flat Washer x1 F E Relay x1 Patch Harness x1 Cabin Harness x1 H Relay Connector Base x1 D C Cable Tie x50 Mini Blade Fuse x1 M Template x1 --- Tools Required ---------------------------------------------------------------------------------------------------------------------------------- Ø10mm Ø3mm Phillips & Flat Head Screw Drivers Ratchet Sockets Clip Remover Tool Wire Cutters Drill Ø19mm Stepped Drill bit Trim Removal Tools Hand File Masking Tape FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 3mm Drill Bit Page 02 of 19 HILUX / FORTUNER --- Step 1 --------------------------------------------------------------------------------------------------------------------------------------------------• Rotate the steering wheel to the right to gain access to the steering wheel surround RH fastener (1). • Remove RH fastener (1). • Repeat for LH fastener (not shown). • Remove the lower steering surround fastener (2). 2 1 --- Step 2 --------------------------------------------------------------------------------------------------------------------------------------------------• Remove cluster surround (1) by removing two screws (2). For vehicles fitted with leather trim. • Dislodge the cluster surround (3). • Unclip the dust cover if present. • Remove the cluster surround (3). 1 Leather trim vehicle 3 4 120 2 3 --- Step 3 --------------------------------------------------------------------------------------------------------------------------------------------------Important Always refer to the vehicle’s Workshop Manual when removing vehicle components. 1 • Note down all clock and radio settings. • In the engine bay, disconnect the negative battery terminal (1). Always refer to the workshop manual for assistance with parts removal. FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 03 of 19 HILUX / FORTUNER --- Step 4 --------------------------------------------------------------------------------------------------------------------------------------------------• Unclip the glove box dampener (1) if present. • Remove LH retaining clip (2) by rotating anti-clockwise. • Remove the glove box (3). • Remove the passenger lower dash garnish (4) if present. 2 1 3 4 --- Step 5 --------------------------------------------------------------------------------------------------------------------------------------------------For Hilux models only. • Dislodge and remove dash trim (1). • Unclip the upper glove box (2) and remove. 1 Proceed to step 7. 2 --- Step 6 --------------------------------------------------------------------------------------------------------------------------------------------------For Fortuner models only. • Remove the vent cover (1). 3 • Remove the audio side trim on both the LH and RH (2). • Unclip the upper glove box (3) and remove. 2 1 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 04 of 19 HILUX / FORTUNER --- Step 7 --------------------------------------------------------------------------------------------------------------------------------------------------• In the passenger side cabin area, remove the LHS scuff plate (1). 1 --- Step 8 --------------------------------------------------------------------------------------------------------------------------------------------------• Remove the fastener (1) from LHS kick panel (2) and remove the panel (2) from the vehicle. 1 2 --- Step 9 --------------------------------------------------------------------------------------------------------------------------------------------------For Hilux models only. • Remove heater control knobs (1) & radio surround trim (2). Proceed to step 12. 2 1 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 05 of 19 HILUX / FORTUNER --- Step 10 --------------------------------------------------------------------------------------------------------------------------------------------------For Fortuner models only. • Remove heater control knobs & dislodge the radio surround trim (1). 1 Proceed to step 12. --- Step 11 --------------------------------------------------------------------------------------------------------------------------------------------------For SR5 model only. • Dislodge and remove heater control panel (1). • Unclip and remove any connectors (2) & aircon vents (3) from the back of the heater control panel (1). 1 3 2 --- Step 12 --------------------------------------------------------------------------------------------------------------------------------------------------• Remove the four screws (1) securing the audio unit (2). • Dislodge and remove the audio unit, disconnecting all connectors. 2 1 1 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 06 of 19 HILUX / FORTUNER --- Step 13 --------------------------------------------------------------------------------------------------------------------------------------------------• Dislodge the cluster (1) by removing the four screws (2). • Remove the two fasteners (3) from the cluster (1) if present. 2 2 • Disconnect all cluster connectors and clips and then remove the cluster (1). 1 3 2 2 --- Step 14 --------------------------------------------------------------------------------------------------------------------------------------------------• Secure the Engine Harness (1) to the guide wire (2). • Cut the LHS access point (3). Note: If LHS access point is occupied, use the RHS access point. 4 • Feed the guide wire (2) into the firewall grommet (4). • Feed through until the harness loop (5) reaches the grammet and is facing down. • Seal with silicon, then cable tie (6) around the access point. 2 1 3 6 2 1 1 5 --- Step 15 --------------------------------------------------------------------------------------------------------------------------------------------------• Route Engine Harness (1) towards the battery, following the vehicle harness down the LHS of the engine bay. • Cable tie (2) Engine Harness (1) in the locations shown. 2 1 2 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 07 of 19 HILUX / FORTUNER --- Step 16 ------------------------------------------------------------------------------------------------------------------------------------------------For vehicles fitted with Accessory fuse block, skip to step 17. • Remove fuse from engine harness in-line fuse connector (1). • Route the fused orange wire 8mm ring terminal (2) to the positive battery terminal (3). 2 • Secure the vehicle harness positive battery ring terminal (2) to the back section of the battery positive terminal (3) using the existing nut (4). 1 4 2 • Secure harness with Cable ties every 200mm. Skip to Step 19. 3 --- Step 17 ------------------------------------------------------------------------------------------------------------------------------------------------If vehicle is fitted with accessory fuse block continue with step 17 otherwise skip to step 19. 1 • Remove the accessory fuse block cover (1). • Disconnect the accessory fuse block (2) from its mounting bracket (3). • Using side cutters, remove and discard the cable tie (4) from the wire bundle. • Unclip and dislodge the fuse holder (5) from fuse block (2). 2 5 3 3 --- Step 18 ------------------------------------------------------------------------------------------------------------------------------------------------• Feed the Driving lamp harness orange terminal wire (1) through the fuse block funnel. 1 • Insert the orange wire fuse terminal (2) into the cavity as shown. Important Ensure audible "Click" is heard. Important Check Fuse Terminal retention. • Secure cables with Cable tie (3) where shown. 10 9 Replace accessory fuse box onto the mounting bracket (4). 8 7 6 5 4 3 2 1 4 2 3 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 08 of 19 HILUX / FORTUNER --- Step 19 ------------------------------------------------------------------------------------------------------------------------------------------------Note: Dislodge and move battery to gain access to M6 earth bolt at junction connectors on fender. • Using the existing M6 earth bolt (1), fasten ring terminal (2) to the vehicle body. 2 1 Step 20 ------------------------------------------------------------------------------------------------------------------------------------------------• Route the Engine Harness (1) towards the LHS head lamp following the vehicle harness. 2 • Cable tie (2) the Engine Harness (1) to the vehicle harness every 200mm. 1 2 2 Step 21 ------------------------------------------------------------------------------------------------------------------------------------------------• Route the Driving Lamp Connectors (1) under the LH head lamp, following the vehicle harness. • Cable tie every 200mm. 1 • Route the Driving Lamp Connectors across the bumper support towards the center of the grille support (2). 2 1 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 09 of 19 HILUX / FORTUNER --- Step 22 ------------------------------------------------------------------------------------------------------------------------------------------------• Following the vehicle harness, route the Driving Lamp Connectors (1) across the bumper support and up the centre support bracket (2). • Cable tie every 200 mm. 1 Important If vehicle is fitted with Winch Kit, OE Harness and Driving Lamp Harness needs to be moved for clearance. 2 --- Step 23 ------------------------------------------------------------------------------------------------------------------------------------------------• Cut out the switch template provided on page 18. • Line up the template with edges of the lower steering surround trim (1) and adhere the template to the trim using masking tape. • Drill a 3 mm pilot hole in the drilling point. • Discard the template. • Using a stepped drill bit, drill out the pilot hole to Ø19 mm. • Smooth and deburr any sharp edges from the hole using a file. 1 --- Step 24 ------------------------------------------------------------------------------------------------------------------------------------------------• In the cabin on the driver’s side locate the 20-Way connector (1) on the steering column switch assembly and disconnect. 1 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 10 of 19 HILUX / FORTUNER --- Step 25 ------------------------------------------------------------------------------------------------------------------------------------------------• Connect the Driving Lamp Cabin Harness male and female T-Patch connectors (1) to the steering column switch connectors (2). 2 1 --- Step 26 ------------------------------------------------------------------------------------------------------------------------------------------------• Route the Cabin Harness (1) down the steering column following the vehicle harness. • Cable tie (2) every 100 mm where shown. Ensure the vehicle harness is followed carefully. Adjust the steering column up, down, in and out and check for harness pinch points and snags. 1 2 2 1 2 2 2 --- Step 27 ------------------------------------------------------------------------------------------------------------------------------------------------• Insert the Driving Lamp Switch (1) into the previously drilled out hole (2) and tighten the locking nut (3). • Connect the Cabin Harness terminals (4) to the switch (1). 2 4 FI Doc No: PZQ59-89050FI - 3 Issue: 3 - 08/10/15 2 1 Page 11 of 19 HILUX / FORTUNER --- Step 28 ------------------------------------------------------------------------------------------------------------------------------------------------• Following the vehicle harness, route the Cabin Harness (1) up the RH driver's side towards the RH side of the cluster cavity. • Route the Cabin Harness (1) across the cluster cavity, following the vehicle harness. • Cable tie (2) every 200mm where shown. 1 2 --- Step 29 ------------------------------------------------------------------------------------------------------------------------------------------------• Route the Cabin Harness (1) across the audio unit cavity towards the glove box cavity, following the vehicle harness. 1 • Cable tie (2) the harness to the vehicle harness every 200mm. 2 --- Step 30 ------------------------------------------------------------------------------------------------------------------------------------------------• Route the Cabin Harness (1) across the glove box cavity unit towards the passenger LHS, following the vehicle harness.. • Cable tie (2) the harness to the vehicle harness every 200mm. 1 2 2 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 2 Page 12 of 19 HILUX / FORTUNER --- Step 31 ------------------------------------------------------------------------------------------------------------------------------------------------• From inside the cabin in the glove box area, retrieve the previously routed Engine Harness (1) from the firewall grommet (2). 2 1 --- Step 32 ------------------------------------------------------------------------------------------------------------------------------------------------• Locate the 40-way combimeter connector (1). • Apply the Driving Lamp Patch Harness Scotch Lock (2) to the combimeter connector BLUE wire (3), Pin 1. • Route the Driving Lamp Patch Harness (4) across the cluster cavity, following the vehicle harness. 4 • Cable tie (5) every 200mm where shown. 5 40-way Connector 1 Pin 1 FRONT FACE OF CONNECTOR 3 3 2 2 --- Step 33 ------------------------------------------------------------------------------------------------------------------------------------------------• Route the Driving Lamp Patch Harness (1) across the audio unit cavity towards the glove box cavity, following the vehicle harness. 1 • Cable tie (2) the harness to the vehicle harness every 200mm. 2 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 13 of 19 HILUX / FORTUNER --- Step 34 ------------------------------------------------------------------------------------------------------------------------------------------------• Route the Driving Lamp Patch Harness (1) across the glove box cavity unit towards the passenger LHS, following the vehicle harness. • Cable tie (2) the harness to the vehicle harness every 200mm. 1 2 2 2 --- Step 35 ------------------------------------------------------------------------------------------------------------------------------------------------• Disengage the relay holder secondary lock (1). 2 • On the Engine Harness, locate the large red wire terminal (2) and house that terminal into the supplied relay connector (6) into position [A]. • House the large orange wire (3) terminal in position [B]. A B 3 6 • On the Driving Lamp Patch Harness, house the small blue wire (4) terminal in position [C]. • On the Cabin Harness, house the small white wire (5) terminal in position [D]. C 4 6 1 • Re-engage the secondary lock (1). 5 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 14 of 19 HILUX / FORTUNER --- Step 36 ------------------------------------------------------------------------------------------------------------------------------------------------• On the Engine Harness, locate the small orange wire terminal (1). m 10m • Using side cutters, remove the small orange wire terminal (1) by cutting the wire approximately 10mm back from the terminal (1). 1 • Fold back the orange wire end (2) and tape wire end to pvc tube (3) using pvc tape (4). Important Ensure wire end is completely insulated by PVC tape. 2 4 3 --- Step 37 ------------------------------------------------------------------------------------------------------------------------------------------------• Connect the relay (1) to the relay holder (2) & connect the relay holder (2) to the relay bracket (3). 1 2 3 2 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 15 of 19 HILUX / FORTUNER --- Step 38 ------------------------------------------------------------------------------------------------------------------------------------------------• Remove the ECU bracket front bolt (1) and loosen the rear bolt (2) from the ECU bracket (3). 5 • Slide the Relay Bracket assembly (4) between the ECU Bracket (3) and the ECU (5). 4 3 • Secure the Relay Bracket (4) by using the previously removed front bolt (1). • Tighten both bolts (1)(2). 1 Note: ECU bracket (3) may vary depending on vehicle models. 2 --- Step 39 ------------------------------------------------------------------------------------------------------------------------------------------------For Lamps with suitable connector: • Connect the LHS 2-pin female Driving Lamp Harness connector (1) to the LHS driving lamp connector (2). Ensure an audible “click” is heard. • Repeat for the RHS. 1 2 Go to Step 41. --- Step 40 ------------------------------------------------------------------------------------------------------------------------------------------------If Driving Lamps are not fitted with suitable 2-pin driving lamp connector, continue: • Fit Driving Lamp Harness (1) to the driving lamp (2) by cutting the driving lamp wiring harness to the suitable length then strip the driving lamp wiring harness to 6 mm [A]. Note: 2-pin driving lamp connectors can be discarded. • Feed the solder sleeves to each of the Driving Lamp and Harness wires then over lap the strip in the solder sleeve [B] joint and heat the solder sleeves using a heat gun [C]. 2 • Ensure that the solder sleeve has been taken by the two wires in the joint. 1 FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 16 of 19 HILUX / FORTUNER --- Step 41 ------------------------------------------------------------------------------------------------------------------------------------------------• Mount the Driving Lights on to the bull bar by referring to the driving lights fitting instructions. --- Step 42 ------------------------------------------------------------------------------------------------------------------------------------------------• For vehicles fitted with accessory fuse block: - Insert the supplied 20A mini blade fuse (1) into the wired slot. • For vehicles fitted with ring terminal power wire fastened directly to the positive battery terminal: 10 9 8 7 6 1 5 4 3 2 1 - Insert 20A fuse to inline fuse holder. --- Step 43 ------------------------------------------------------------------------------------------------------------------------------------------------• Ensure all sections of the driving lamp harnesses are secured to the existing vehicle harness every 200 mm using the supplied cable ties. • Reconnect the negative battery to Test the operation of the driving lamp. • The driving lamps should only be functional when high beams engaged and the driving lamp switch is engaged. Important Post Terminal Torque to be between 2.9 ~ 7.8 Nm. Important Positive Battery Ring Terminal Nut Torque to be tightened to 13 Nm. Important Earth Bolt Torque to be between 6.9 ~ 9.8 Nm. Important Refit all removed parts and secure all fasteners to the Service Manual torque specifications. Cable tie the Driving Lamp Harness to the vehicle harness every 200mm. Ensure the harness is not crushed or stretched during Driving Lamp Harness installation. Reprogram all radio stations and clock settings by referring to the vehicle's owner manual. Please place the Fitting Instructions in the glove box after installation is completed. FI Doc No: PZQ59-89050FI - Issue: 3 - 08/10/15 Page 17 of 19 - Earth Ring Terminal Engine Bay FI Doc No: PZQ59-89050FI Issue: 3 - 08/10/15 Cabin BK 2 GND TERM. 1 COL. BK RELAY TERM. COL. 1 OR 2 OR 3 RD FUSE TERM. 1 2 1 RD COL. BL BL FUNCTION +12V +12V (RLY) LAMP + Location: LHS Panel (Engine Bay) BK LH DRIVING LAMP TERM. COL. 1 RD 2 BK 2A OR COL. OR OR 21 BL BL RD OR BATT+ TERM. COL. 1 OR WH OR 1 Pin 1 - HI-Beam Indicator 40-Pin Female Connector Scotch Lock Location: Combimeter 20 40 Driving Lamp Switch Location: Steering Column Surround 1 11 WH +12V Ring Terminal (Alternative: Accessory Fuse Block) +12V Battery RD 1 Driving Lamp Relay Location: Rear Glove Box Cavity 20A FUSE TERM. 1 2 BK 2 RH DRIVING LAMP TERM. COL. 1 RD 2 BK Driving Lamp Connectors (Front Bumper/Bullbar)l Location: Steering Column Surround Pin 17 - HI-Beam 20-Pin Female Connector T-Patch. 10 20 Fire Wall Grommet HILUX / FORTUNER Harness Diagram Page 18 of 19