Dobinsons BU59-3541 User manual

Bullbar Installation Guide
Part Number: BU59-3541 & BU59-3706 & BU59-3707
Fits:
Toyota Hilux Revo 2015 on
This Bullbar will take approximately 3.5 hours to install
Tools required are
•Spanners and socket set.
•Screwdrivers
•Pliers and side cutters
Dobinsons BULLBARS should be installed by a qualified installer and it is
the installer responsibility to ensure correct fitment.
Fully read and understand the instructions before beginning the installation
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Fitting Guide
1. Remove the number plate.
2. Remove the screws and clips in the top of the
grill to radiator cover.
3. Remove the screws and bolts attached the
top of the grill.
4. Reach down in behind the grill and gently
unclip the lower grill tabs and slide the grill
forward to remove it from the vehicle.
5. Remove the screws and clips along both
wheel arch edges of the bumper and also
along the bottom edges of the bumper that
attached the bumper to the vehicle.
6. Remove the top clips that attached the under
grill air damn to the top of the bumper.
7. Unclip the fog light wiring plugs if fitted.
8. Starting from either side of the vehicle gently
unclip the bumper from the edge of the guard
and headlight.
9. Remove the bumper.
10. Remove the front horizontal air dam and the
LH and RH vertical air dam, keeping aside for
re-fitment later.
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11. Remove the front plastic bumper support by
sliding sideways to release from the clips and
remove the steel bumper mount. Keep the
original bolts for fitment of the bullbar
bracket. Remove the small plastic air dams
also.
12. Remove the lower bash plate and keep aside
for re-fitment.
13. Remove the 2 outer bumper support brackets.
14. Install the inner and outer bullbar bracket
supports to each side of the chassis using the
M12 fine bolts with washers for the rear 2
outer mounting points. The longer bolts pass
through the chassis through both brackets.
Use a washer on each side. Leave bolts loose
for now.
15. Install the bullbar bracket using the nuts, bolts
and washers supplied. Use the original bolts
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with the washers supplied in the original bolt
position.
16. Centralise the bracket to the vehicle and
tighten all fasteners.
17. Trim the original LH and RH vertical air dams
as seen in the photo below to clear the new
mounting bracket and bullbar.
18. Re-install the air dams to the vehicle.
19. Remove the plastic screw clips from the
original bumper mounts near the inner lower
corners of the headlights.
20. Drill a small hole in the air damns just in front
of this to attach a cable tie to, and cable tie it
to stop movement.
21. Install the new grill support bracket. It is
recommended to remove the screw plug and
use a nut and bolt to tighten it correctly.
22. Re-install the grill inserting the centre 2 tabs
into the new bracket and re-install the upper
bolts and screws. It is also recommended to
drill a hole in the outer lower tabs on each
side at the base and cable tie to the holes
drilled in step 20 to secure the grill.
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23. Now a good time to run the wiring for the
new parker lights and indicators.
24. In the base of the headlight you will see a light
grey and dark grey wire connector this will
slide out from the headlight and the plug can t
then be disconnected.
25. It is recommended to take the earth directly
off the vehicle body.
26. For the parker light positive feed it can be
taken from the vehicle side of the wiring loom
(the light grey plug) and taken from the grey
wire on the right hand side and green wire on
the left hand side (Australian vehicles) NOTE:
you must double check this with a multimeter
or test light to confirm.
27. For the indicator positive feed, there is a small
conduit that goes up into the back of the
indicator, this can be pulled down below the
headlight and the red wire on the right hand
side used, and the yellow on the left hand side
(Australian vehicles) NOTE: you must double
check this with a multimeter or test light to
confirm.
28. Using the diagram at the end of this manual,
join the corresponding wires to original
vehicle wires located in the previous step. The
wires can be joined by either using good
quality snap lock crimp connectors or by
soldering (soldering recommend. Ensure the
connection is secure and is sufficiently
insulated.
29. If fitting a bullbar with fog lights, the fog lights
can be connected using the original vehicle
fog light wires if fitted but this will require
cutting and joining the fog light plugs from the
loom supplied. If the vehicle is not fitted with
OEM fog lights the wiring loom supplied can
be used. Follow the wiring diagram at the end
of this manual.
30. Carefully un-wrap the bulbar taking care not
to scratch it especially on the top loops.
Reinstall the number plate. If installing driving
lights to the bullbar it is easiest to install now.
31. If not installing a winch skip to step 39.
32. See the Installation section of your Dobinsons
4x4 Winch manual for specific detailed fitting
instructions. For a brief overview see the
following steps.
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