Isuzu D-Max User manual

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WARNING!
it is necessary to use protective glasses. Check integrity of the design and torque settings of fasteners in each 1000km of the
vehicle usage. Do not use this product if there is any damage to the design or fasteners
In order to reduce the risk of severe injury or property damage: Before installation and use of this product read the whole
procedure, paying special attention to the safety notice and installation notice! Upon installation or maintenance of this product
INSTALLATION MANUAL
PRODUCT: HIDDEN WINCH MOUNTING BRACKET
MODEL: ISUZU D-MAX (2017-)
PART NO: 2L.9101.1

БАМПЕР ПЕРЕДНИЙ TOYOTA HILUX REVO
2L.9101.1
ISUZU
D-Max
2017-
Steel
920x182x221
20,6 kg
RIVAL 2D.9103.1 recovery points
Item:
Make:
Model:
Year of manufacture:
Material:
Dimensions:
Weight:
Compatibility:
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HIDDEN WINCH MOUNTING BRACKET
Date: 30.05.2019 Installation manual 2L.9101.1
< Page 1 of 17 >
* М10 - 44 Nm
* М6 - 9 Nm
* М12 - 80 Nm
TORQUE SETTINGS
INSTALLATION NOTICE
* During installation it is required to use personal protective equipment.
* The hidden winch mount bracket should be mounted in strict compliance with this procedure in
specialized service centers.
* Do not install this hidden winch mount bracket onto the vehicle models other than those
specified herein.
* Scotch tape
* Basic tool kit * Scissors
* Torque wrench * Knife
* Angle grinder * Pliers
* Marker
* Masking tape
SAFETY NOTICE
* The RIVAL hidden winch mount bracket are designed to compliment the use and design of the
specified vehicle under conditions specified by the car manufacturer.
* The operation of a vehicle where the hidden winch mount bracket are not properly attached and
fastened to the vehicle, or where it has been damaged, must be avoided at all cost.
* It is not allowed to load hidden winch mount bracket with force of more than that specified
* It is recommended that you carry out regular inspections of all fittings
* While driving the vehicle at any speed, collision with any other vehicle, animal or object must
always be avoided.
REQUIRED TOOLS

БАМПЕР ПЕРЕДНИЙ TOYOTA HILUX REVOTECHNICAL INFORMATION
Winch measurements:
WINCH INSTALLATION
A winch with a pull capacity of up to 11000lb (4989 kg) can be installed with the RIVAL
concealed winch mounting bracket. It is not advisable to exceed this pulling capacity since
damage, injury or death may occur where the 11000lb recommended capacity is exceeded.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 2 of 16 >
Winch size limits:
L 580 mm х W 170 mm х H 190 mm

КОМПЛЕКТАЦИЯ
PARTS LISTING
3
1
7
2
4
8
56
9
1. License plate.................................
2. Winch bracket...............................
3. External left bracket.......................
4. External right bracket....................
5. Internal left bracket........................
6. ......................Internal right bracket
7. Small end bushing.........................
8. Large end bushing.........................
9. Insert nut М12 ...............................
10. М6х20..............................Screw
11. М8х25.............. ..................Bolt ..
22. М1 ................... ................Nut 0...
19. . ..........Adjusting washer М12 .....
18. ................................Washer М12
20. М6................. ....................Nut ...
16. М6.................................Washer
17. М10 Adjusting washer ................
21. М8.................. ...................Nut ...
23. М12.......................... ........Nut ....
13. ......... ......................Bolt 10х110 ..
14 Bolt 12х40. ........................ ...........
15. ..... ..........................Bolt 12х110 ..
12. ............. ....................Bolt 10х35 ..
3 pc.
2 pc.
2 pc.
1 pc.
2 pc.
1 pc.
1 pc.
1 pc.
2 pc.
1 pc.
4 pc.
8 pc.
10 pc.
6 pc.
1 pc.
2 pc.
3 pc.
2 pc.
6 pc.
12 pc.
2pc.
12 pc.
8 pc.
25. 390х4,8 ......Tie wrap mm.......
24. .. Pressure sensitive liner........
6 pc.
5 pc.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 3 of 16 >

Инструкция по установке
INSTALLATION PROCEDURE
* Set aside for re-use later.
3. Remove 4 screws as shown.
2. Disconnect the negative battery
1. Open the bonnet.
terminal cable.
shown.
Carefully dismantle the radiator grille.
4. Remove radiator grill fittings (6 pc) as
* Set aside for re-use later.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 4 of 16 >

Инструкция по установке
5. Remove plastic plugs out of the
bumper (4 pc) as shown.
* Set aside for re-use later.
6. Unscrew 1 screw in wheel arches on
the vehicle’s left and right side.
* Set aside for re-use later.
the left and right, as shown.
7. Remove 1 plug in wheel arches on
* Set aside for re-use later.
ИНСТРУКЦИЯ ПО УСТАНОВКЕ
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 5 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

bumper, and using torque wrench
unscrew 2 nuts, as shown.
* Set aside for re-use later.
8. Remove 4 plugs in the lower part of
to the center.
9. Carefully dismantle the bumper.
sensors.
Pull the bumper edge by unlatching the
latches, moving from the bumper edge
Disconnect fog lights and parking
10. Dismantle plastic liners, disconnect
plugs (6 pc.), as shown.
* Set aside for re-use later.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 6 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

* Set aside for re-use later.
Remove front bream.
11. Unscrew fitting bolts of the front
beam to the chassis, as shown.
12. Unscrew 2 bolts of the bunoer
brackets, on the left and right side of the
vehicle, as shown.
* Set aside for re-use later.
13. 11. Place bushings (pos. 7,8) into
the chassis, on the left and right side of
the vehicle, as shown.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 7 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

15. Install the bracket (pos.5) on the
left inner side of the frame, as show,
and fix it using adjusting washers M10,
adjusting washer M12, nut M10 and nut
M12.
* Do not tighten yet.
bracket (pos. 6).
Make the same actions, on the right
side of the frame, using right
bracket (pos. 4).
14. Install the bracket (pos.3) on the left
side of the frame, as show, using bolts
M10x100, bolt M12x110, adjusting
washer M10 and washer M12.
Make the same actions, on the right
side of the frame, using right
* Winch fairlead and winch are not
supplied with RIVAL bracket.
16. Install winch bracket (pos. 2), winch
fairlead and winch, using bolts M10x35
and adjusting washers M10.
* Tighten all the joints.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 8 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

19. Adjust and fix winch bracket to the
vehicle’s frame, on the left and right
side, using bolts M10x35 and washers
M10.
* Do not tighten yet.
17. Install winch bracket (pos. 2) and
winch on the brackets, using 2 bolts
M12x40, washers M12 and nuts M12 on
the both sides.
* Do not tighten yet.
Repeat step 17.
If so, then remove the winch bracket of
the vehicle, pull the sensor out of the
bracket, bend the bulge side of the
bracket, using pliers inside (marked
green line) and fix the sensor, using tie
wrap, as shown.
18. Check if winch stuck on the center
part of the bracket..
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 9 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

21. Use templates, attached in the end
* Stick the template over for more
of this manual, to cut the holes on the
front part of the bumper.
hardness, using scotch tape.
Cut template following dashed line
(attachment 1 and 2), remove area #1,
as shown.
22. Protect the bumper, using masking
tape, as showm.
20. Fix left side of th winch bracket,
using bolts M12x40, insert nuts
M12(pos.9), adjusting washers M12, as
shown.
Make the same actions, on the right
side of the winch bracket.
* Tighten all the joints.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 10 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

* Mark cut line, using template.
23. Place template (attachment #1) on
the bumper. Adjust it on the bumper
following cutout (red dash lines) and fix
it using masking tape, as shown.
* Mark cut line, using template.
24. Place template (attachment #2) on
the bumper. Adjust it on the bumper
following cutout (red dash lines) and fix
it using masking tape, as shown.
25. Connect the cut lines on the central
part of the bumper, as shown.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 11 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

Stick masking tape on the grille, and
mark cut line, as shown.
26. Measure width of radiator grille area
to cut out, following winch dimensions,
27. Carefully cut tie wraps, inside the
bumper, that fixed wires with bumper
fittings, as green zone shown.
Cut tie wrap “tails”.
28. Fix wires inside the bumper, as red
zone shown, using pressure sensitive
liner (pos. 24).
Then fix wires at this area, using tie
wraps 390x4,8 mm (pos. 25).
* It is necessary to clean bumper
surface off the fat and dirt, to stick
pressure sensitive liners.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 12 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

29. Make sure, that wires do not
handicap to cut the bumper.
angle grinder.
* Polish burrs and sharp edges.
Carefully cut out marked area, using
30. Try the bumper on the vehicle, and
check that winch doesn’t pull out and
contact the bumper.
Otherwise, it is necessary to cut out the
bumper, following winch, or winch
bracket dimensions.
Polish burrs and sharp edges.
31. In case if bumper doesn’t fit,
depends on winch, cut out inner top part
of bumper, as shown.
Polish burrs and sharp edges.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 13 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

32. Drill 3 holes 7mm diameter, on the
top part of bumper (above the grill), for
license plate, as drawing shown.
33. Install license plate (pos. 1) onto the
bumper using 3 screws M6x20, nuts M6
and washer 6.
Tighten all the joints.
34. Adjust license plate angle.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 15 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

36. Install the bumper and grill in
reverse order.
35. Install the bumper onto the vehicle
and fix it, using bolts M8, adjusting
washers M8 and nuts M8.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 15 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

Before operating a vehicle fitted with a RIVAL hidden winch mounting bracket:
- make sure that all screw joints are tightened;
- check all electrical wiring attached to winch.
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Date: 30.05.2019 Installation manual 2L.9101.1
< Page 16 of 16 >
Инструкция по установке
INSTALLATION PROCEDURE

RIGHT SIDE as viewed in the direction of vehicle motion
1
Masking tape sticking area
Masking tape sticking area
Masking tape sticking area
Template
align area
Template
align area
Attachment #1
TEMPLATE
BUMPER CUT OUT
(RIGHT SIDE)
Cut out line
Connect point №1 and point №2 at the template #2 with cut line
№1

RIGHT SIDE as viewed in the direction of vehicle motion
1
Masking tape sticking area
Masking tape sticking area
Template
align area
Template
align area
Attachment #1
TEMPLATE
BUMPER CUT OUT
(RIGHT SIDE)
COPY
Cut out line
Connect point №1 and point №2 at the template #2 with cut line
№1
Masking tape sticking area

LEFT SIDE as viewed in the direction of vehicle motion
Masking tape sticking area Masking tape sticking area
Masking tape sticking area
Template
align area
Template
align area
1
Attachment 2
TEMPLATE
BUMPER CUT OUT
(LEFT SIDE)
Cut out line
Connect point №1 and point №2
at the template #2 with cut line
№2