Ironman4x4 BBP084 User manual

PREMIUM BULLBAR TO SUIT NISSAN PATROL Y62 SERIES 5
INSTALLATION
GUIDE
• Ironman 4x4 BBP084 Premium Bull Bar to suit Nissan Patrol Y62 Series 5.
• It will take approximately 4 hours to install.
IMPORTANT: Bull bar installations should only be done by a qualified person
and it’s the responsibility of this person to ensure correct fitment.
NOTE: This product has been tested for air bag compatibility
and therefore the mounting system MUST NOT be modified
BBP084/20012023
BBP084
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd

Page 2 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
PLEASE NOTE:
It is always good practice to disconnect the battery while working on 12-Volt systems.
Please check the owner’s manual to see vehicle-specific requirements as some models may
need battery backup.
Caution: Auto electrical work should only be carried out by a competent person. Vehicle wire
colours are listed as a guide and may vary on some makes and models. The function of each
wire should be checked before any connections are made.
All wires tapped into the factory harness should be soldered and then insulated with electrical
tape or heat shrink.
Using only a LED test light, test all electrical components of the vehicle before and after wiring.
This is to ensure that everything works correctly.
IMPORTANT:
Bull Bar installations should only be done by a qualified person, and it is the responsibility of
this person to ensure correct fitment.
Read instructions fully before commencing fitment.
Do not remove labels from this bull bar. It is good practice to record the bull bar batch number
on the customer’s job card for future reference.
BULL BAR CARE INSTRUCTIONS:
To maintain finish of the product, wash regularly using a PH neutral Car wash, hose off and
chamois dry. Do not use acidic or alkaline cleaners. Plastic components can be maintained
with a silicon spray or similar (non-acidic or alkaline based) The fitting instructions are correct
at the time of publication date. Ironman 4x4 cannot be held responsible for any vehicle
manufacturer changes. It is the responsibility of the installer to ensure correct fitment. It is
important to work safely and use appropriate safety equipment while working.
Page 2 of 21
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Before Installation
Installation Guide

Page 3 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Bullbar Accessories
• Synthetic rope winch WWB9500SR/ WWB12000SR
• Winch extension cable WWB031 / WWB032
• Bull bar multi-Function light patch loom IBBPL084
WARNING
• Ironman 4x4 includes specific mounting hardware to ensure correct fitment to your 4WD. The correct fitment
of these components is critical for your safety.
• Ensure that bolts are tightened to specified torque.
• It is advised to use an equalizing or bridle strap, failure to do so correctly can result in recovery point fatigue
and bending and voiding your warranty.
• It will take approximately 4 hours to install
• NOTE: This product has been tested for airbag compatibility and therefore the mounting system MUST NOT
be modified.
• Ironman 4x4 does not recommend the installation of large or light-colored antennas or aerials to the front of
a bull bar as it may cause the lane departure system to malfunction.
• Warning : For vehicles equipped with forward face radar. Any accessories mounted in radar exclusion
zone will impede sensor operation causing malfunction & misoperation.

Page 4 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Bolt Tension Chart
Property Class TORQUE ma
NOMINAL DIAMETER - COARSE THREAD
M6 x 1 M8 x 1.25 M10 x 1.25 M12 x 1.25
8.8
Nm 10.5 25 49 88
ft/lb 7.7 18 36 64
Parts List
Tools Required
Page 4 of 12
RTB085AUInstallation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Parts List
Bolt Tension Chart
Property Class TORQUE ma
NOMINAL DIAMETER - COARSE THREAD
M6 x 1 M8 x 1.25 M10 x 1.25 M12 x 1.25
8.8
Nm 10.5 25 49 88
ft/lb 7.7 18 36 64
1. Rear Bumper Assembly
QTY-1
2. Work Light Protection Shell
QTY-2
3. Nut Plate
QTY-2
4. Number Plate Light
QTY-2
5. Zip Tape
QTY-10
6. 8mm Spacer
QTY-2
7. Adhesion Promoter
QTY-1
8. Parking Sensor Kit
QTY-6
9. Bolt, spring/flat washers,
Cage nut M6×1×30mm
QTY-2
10. Bolt, spring/flat washers
M12×1.75×45mm
QTY-4
11. Bolt, spring flat washers,
nut M4×0.7×10mm
QTY-2
12. Allen Key S=2.5
QTY-1
Parts List
Tools Required
Page 4 of 14
BBP082Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Parts List
1. Bull Bar
QTY-1
2. Winch Cradle
QTY-1
3. Grill Support Bracket
QTY-1
4. Chassis Bracket Spacer
5mm
QTY-4
5. License Plate Bracket
QTY-1
6. LED Lightbar Infill Panel
QTY-1
7. Mesh
QTY-1
8. Winch Control Box
Bracket
QTY-1
9. Side Protection Plate
LHS
QTY-1
10. Side Protection Plate
RHS
QTY-1
11. Centre Protection Plate
QTY-1
12. LHS - Chassis Brackets
QTY-2
13. RHS - Chassis
Brackets
QTY-2
14. Centre Protection
Plate Bracket
QTY-2
15. Bolt, Nut, spring/flat
washers M12×1.25×40mm
QTY-14
16. Bolt, spring/flat washers
M12×1.25×40mm
QTY-4
17. Bolt, spring/flat
washers M10×1.25×30mm
QTY-4
18. Bolt, Nut,
spring/flat washers
M10×1.5×100mm
QTY-
19. Bolt, Nut, spring/flat
washers M8×1.25×25mm
QTY-
20. Bolt, spring/flat washers
M8×1.25×25mm
QTY-
21. Bolt, Nut, flat washers
M6×1×20mm
QTY-
22. Bolt, Nut, flat washers
M6×1×20mm
QTY-
23. Bolt, spring/flat
washers M6×1×20mm
QTY-
Parts List
Tools Required
Metric spanner set Metric socket set Air hacksaw Tape measure Drill and drill bits Screwdriver set

Page 5 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Parts List

Page 6 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
1. Before Installation, check bull bar
application is compatible with your
vehicle.
Remove and retain the number
plate, if fitted, to be reinstalled
later, also remove factory number
plate holder.
Disconnect negative battery
terminal if applicable.
2. Unwrap the bull bar and ensure
all hardware is provided, including
mounting brackets.
3. Remove and retain the top two
plenum covers. Ensure to keep all
plastic clips.
4. Unplug the front camera if
applicable, located in the center of
the grille.

Page 7 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
6. Remove the 6 x clips along the top of
the bar reinforcement.
Remove the bolt from rear corner of
bumper under guard liner
7. Remove bolts from the corners of the
guard liners and the 4 x centre bolts
holding the factory plate.
5. It is advised to apply masking tape all the way
across the front of the bumper and under the
headlights.
8. Under the right hand side of the bumper, unclip the main bumper bar harness

Page 8 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
9. On the right hand side next to the bar
harness, disconnect the washer nozzle
with care (hose connector).
Depress and pull.
10. Unclip grille- it is advised to start on the
outside headlight mould section.
Once headlight sections are unclipped,
depress the inner lower grille clips and
remove grille.
11. Unbolt the 4 x bolts on both sides of
the bar reinforcement, then discard the
reinforcement.
Note: Retain hardware.

Page 9 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
12. If the vehicle has a front radar,
carefully unplug, and remove the
radar and radar bracket.
Note: Ensure you do not drop the
radar.
13. Remove the 4 x 13mm support
bracket bolts & the upper support
bolts from bracket to radiator
support.

Page 10 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
14. Unclip the side air duct and trim
down.
The air duct must be trimmed to
allow room to fit the cradle.
15. Drill a 10mm hole into the lower
chassis rail.
Debur and paint.

Page 11 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
16. Fit the right-hand side chassis bracket
with M12 through bolts and the 2 x
single nut plates on the inside of the
rail, Now secure the 2 x M10 bolts
with double nutplate
Repeat on the opposite side. Don’t
tighten yet.
17. Now mount the winch cradle using
the 4 x factory bar nuts and supplied
washes and the 3 x M12 bolt, nut, and
washes.
Repeat on opposite side.
18. Find a fixed point on the vehicle, take
measurements, and square up the
cradle.
Repeat on both sides until the cradle
is centered.

Page 12 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
19. Once happy with position torque all
bolts to torque settings on page 4.
20. Winch option
Install the winch into the cradle.
Using the supplied winch control
box bracket, mount winch control
box to the middle reinforcement
ensuring there is enough room at
the front as the grille will need to be
reattached.
Connect the optional winch control box
extension wiring loom.
WWB031/WWB032

Page 13 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
21. It is advised to paint under the guard liner
where seen in a satin black paint.
22. Position cutting template in place under
headlight and align with guard edge and grill
line. Use bodyline on bumper as reference to
mark cut line on assembly as shown.
Note it is advise to use marking tape of surface
of bar to protect paint work.
23. Cut along lines marked in previous step and
along the lower vent edge, then straight across
under grille opening. Remove lower section of
bumper from vehicle.

Page 14 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
24. De-bur cut sections on the bumper
and apply pinch mould.
25. Refit the grille and plug the front
camera back in if applicable to this
vehicle.
Note: a minimum of 20-25mm gap
between bumper and bar wing needs
to be achieved.
27. Remove the parking sensor wiring
and parking sensors from the factory
bumper taking note of the direction
and position of each sensor.
28. Fit sensor with factory silicone sleeve
to the sensor holder. Use flat side of
clamping plate to secure the sensor.
The sensor will false alarm if excess
pressure is applied to the sensor body.
26. IMPORTANT: For parking sensors to function correctly these instructions must be followed
closely. Before removing sensors from original bumper bar, note the location and orientation
of each sensor so when they are fitted back into the Raid bar this can be replicated.

Page 15 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
29. Clean inside the Bull bar, around
sensor holes and mounting surface of
parking sensor holders using grease
and wax remover.
30. Apply adhesion promoter to mounting
surfaces around sensor holes and on
sensor holders. This step is important to
ensure sensor holders adhere properly
to the bull bar.
31. Remove protective film from one side
of double-sided tape and apply to
mounting surface of sensor holder.

Page 16 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
32. Clip in parking sensors into parking
sensor housings.
33. If the vehicle has factory radar, follow the steps below. If the vehicle doesn’t have radar
move on to step.
34. Fit radar cover to bull bar, if the vehicle
does not have a radar, still fit the
supplier radar cover to the bar.
35. Secure factory radar into position and
tighten all hardware.
Note: Ensure you do not drop the radar
whilst installing back into the bull bar.

Page 17 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
36. Using supplied radar bracket (number
16 of the parts list) fit behind the radar
and secure.
39. Drill and pin bar into position using
M10 bolts supplied.
37. Connect blinkers, parkers & fog lights if applicable.
There is an optional plug-n-play wiring harness available for purchase.
IBBPL084 Please refer to IBBPL084 fitting instructions.
38. Install the Bull bar into position, aligned
to the chassis mounting holes. We
recommend 2 people when lifting the
bumper into position to avoid injury or
damage to the vehicle and components.
Centralize the bull bar to the vehicle’s
bodywork. Tighten the bolts holding
the chassis brackets and cradle to the
chassis. Refer to page 2 for tension
specs.
Note: a minimum of 25mm gap between
bumper and bar wing needs to be
achieved.

Page 18 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
40. Reconnect wiring harness, washer nozzle, radar and parking sensor harness.
41. Fit center plate using 4 x Black M8
bolts at the front and 4 x M12 bolts at
the back with the cradle.
42. Hold the side plate in position and
mark a cut line, repeat on the opposite
side.

Page 19 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
43. Remove the side plate and trim the
side guard liner.
Repeat on the opposite side.
44. Fit side plates using 5 x Black M8
bolts on the outside and 1 x Black M8
bolt to cradle.
45. Install number plate and number
plate to the vehicle with M6 hardware
supplied.

Page 20 of 21
BBP084Installation Guide
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Wiring Diagrams
Blue
Relay
Connector
Ground
Fuse
Red
3085
86
87
87a
Red Lamp
Black
Lamp
Positive power supply
at connector to factory fog light
WITHOUT FACTORY FOG LIGHTS
FOG LIGHTS
DRL/PARKING/INDICATOR LIGHTS
If vehicle is not fitted with DRL, leave red wire disconnected
Daytime Running Light
Park Light
Indicator Light
Battery
Blue
White
White
Brown
Red
Yellow
Ground
Parklight
Relay
Connector
Ground
Fuse
Red
3085
86
87
87a
Red Lamp
Black
LampBattery
Ground
Ground
Switch
SPST