Pirate FJ0011SC User manual

NOTE: DISCONNECT NEGATIVE BATTERY CABLE
BEFORE BEGINNING INSTALLATION!
INSTALLATION:
1. Using a small flat blade screw driver, remove the
bolt head covers on the driver side front and top grab
handles. Using a 10mm socket, remove the driver
side front and top grab handles.
2. Using a Phillips head screw driver, remove driver
side visor. On some models, it may be necessary to
twist the visor mount 90 degrees counter clockwise to
pull the visor mount out.
#FJ0011SC & #FJ0011SB
LIGHT BAR
TOYOTA FJ CRUISER
Please read and understand these instructions completely before installation to avoid any
possible injury to yourself or the vehicle and/or accessory.
1/22/09
FIG. 1
FIG. 2
PARTS LIST:
ITEM: PART NAME: DESCRIPTION: QTY.
#1 ALLEN HEAD BOLT SUPPLIED 2
#2 NUTSERT SUPPLIED 2
#3 ALLEN HEAD SET SCREW SUPPLIED 2
#4 SELF-TAPPING SCREW SUPPLIED 1
#5 MAIN WIRE HARNESS SUPPLIED 1
#6 FUSEABLE LINK SUPPLIED 1
#7 SHRINK TUBING SUPPLIED 2
#8 LIGHT BAR CENTER SECTION SUPPLIED 1
#9 LIGHT BAR END MOUNT SUPPLIED 2
#10 SWITCH SUPPLIED 1
TOOLS REQUIRED:
3/16 ALLEN WRENCH. 5/16” DRILL BIT, OR 3/16”-7/8” UNIBIT. 13/16” DRILL BIT. DRILL
MOTOR. T20 TORX BIT OR DRIVER. T40 TORX BIT OR DRIVER. 10MM SOCKET. TUBE
OF CLEAR SILICONE. ELECTRICAL CONNECTOR CRIMPING TOOL. FLAT HEAD &
PHILLIPS HEAD SCREW DRIVER. NON-FLAME HEAT GUN.
PAGE 1

3. Pull down the door weatherstrip as shown.
4. Carefully pull back side pillar trip as shown.
Use a flat blade screw driver to pop out the two plastic
retaining clips inside the pillar trim. See FIG 4 & 4A.
5. Remove the top plugs on both the right and left
side of the factory roof rack as shown. Once you pry
them up, use needle nose pliers to pull them out com-
pletely. See FIG 5.
6. Line one of the Light Bar End Caps with the top
hole that you just removed the plug from. Next, scribe
or mark the location of the wiring hole in the side of
the roof rack as shown. The wiring from the Light Bar
will pass through this hole. Drill hole using a 5/16” drill
bit. Using a small round file, debur the hole to remove
any burs or sharp edges See FIG 6 & 7.
FIG. 3
FIG. 4
FIG. 5
FIG. 4A
2 Retaining
Clips
FIG. 6
FIG. 7
PAGE 2

FIG. 8
FIG. 10
Remove gasket
to expose screw
FIG. 11
FIG. 13
FIG. 12
FIG. 9
STEP 7. Using a T40 TORX bit, remove the two mount-
ing screws on the front base plate mount. Repeat for
the middle base plate mount. Raise front section of roof
rack and remove rubber sealing gasket to expose a T20
TORX mounting screw. Remove screw using a T20
TORX bit or driver. See FIG 8, 9, 10.
STEP 8. After removing the TORX mounting screw,
slide the front base mount off as shown. See FIG 11.
STEP 9. Let the roof rack rest on the center mount and
mark the location of the wiring hole in the roof. Drill a
5/16” and file or debur any sharp edges
See FIG 12 & 13.
Drill 5/16” hole
for wiring.
Debur hole.
PAGE 3

STEP 10. Using a 5/16” drill bit, drill one hole in the
base plate mount and rubber gasket as shown. The
screwdrivers and arrows point to the hole locations.
See FIG 14, 15, 16.
STEP 11. Feed the wires through the light bar end
mount, the base plate mount and the rubber gasket as
shown.
See FIG 17 & 18.
STEP 12. Run wires through hole in roof and down side pil-
lar. WARNING: INSURE THAT WIRES DO NOT INTER-
FERE WITH SIDE CURTAIN AIR BAG. WIRES MUST NOT
BE ROUTED NEAR SIDE CURTAIN AIR BAG.
See FIG 19.
FIG. 15
FIG. 16
FIG. 18
FIG. 17
FIG. 14
FIG. 19
PAGE 4

FIG. 20
FIG. 22
STEP 13. Install one Nutsert on each side of roof rack
as shown. The Nutserts install in place of the rubber
plugs that were removed. See FIG 20.
STEP 14. CRIMP BOTH NUTSERTS: Hold the Nutsert
Installation Tool with an open end wrench. Next, tighten
the Nutsert Installation Bolt so that it draws up the bot-
tom of the Nutsert inside the roof rack and crimps the
Nutsert into place. See FIG 21.
STEP 15. Place the remaining Light Bar End Mount on
the end of the right (passenger) side of the Light Bar
and place the Light Bar on the passenger side of the
roof rack. See FIG 22.
STEP 16. Plug the Light Bar into the wire harness and
push excess wire back into Light Bar. See FIG 23 & 24.
STEP 17. Slide the left side Light Bar End Mount on to
the end of the Light Bar. LOOSELY Install a Allen Bolt
into each Nutsert in the Roof Rack just to hold the Light
Bar in place for now. See FIG 25.
FIG. 23
FIG. 24
FIG. 25
Push excess wires back into end of light bar.
Nutsert tool
Nutsert
Wrench
PAGE 5

STEP 18. Re-install the base plate with the T20 TORX
screw. See FIG 26.
STEP 19. Seal the wiring holes in the roof, base plate,
and rubber gasket with clear silicone sealer. See FIG
27 & 28.
STEP 20. Push the roof rack in towards center of roof
to align the base plate with the mounting holes and re-
install the two T40 mounting bolts in both the front and
center mounting plates. See FIG 29 & 30.
STEP 21. Tighten both Allen Head Screw in the Light
Bar End Mounts. Insert one allen set screw on each
Light Bar Mount, adjust Light Bar to desired angle, and
tighten allen set screws. See FIG 33.
FIG. 26
FIG. 28
FIG. 30
FIG. 33
FIG. 29
FIG. 27
Push to align base plate.
Allen Set Screw
Allen Head Screw
PAGE 6

STEP 22. Remove rubber plug in firewall at location
indicated by arrow. See FIG 34.
STEP 23. Make a hole in the insulation behind the fire-
wall with a pick and widen the hole with a Phillips
screwdriver See FIG 35.
STEP 24. Install the Relay as shown using the self tap-
ing screw.. Connect Black ground wire to a 10mm bolt
under the dash. There are 2 to the left of the steering
column. Either can be used. See FIG 36.
STEP 25. Slide a piece of Shrink Tubing on the black
and white wires that lead from the light bar. Using a
wire crimping too, crimp the wires from the relay har-
ness plug to the black and white wires from the light bar
(Crimp white to white, and black to black). Then shrink
the tubing using a heat gun or small flame. Be careful
not to melt the insulation on the wires. Next, route
these wires down the pillar and under the dash.
See FIG 37 & 38.
STEP 26. From the inside, run the RED wire from the
wiring harness through the hole in the firewall. Make a
small hole in the rubber grommet, slide the RED wire
through it, and re-install the grommet in the firewall as
shown. See FIG 39.
FIG. 34
FIG. 36
FIG. 37
FIG. 39
FIG. 38
FIG. 35
PAGE 7

FIG. 40
FIG. 41
FIG. 42
STEP 27. Slide a piece of Shrink Tubing on the Red
wire and crimp Red Wire to Fuseable Link. Then shrink
the tubing using a heat gun or small flame. Be careful
not to melt the insulation on the wires. See FIG 40.
STEP 28. Using a 10mm socket, connect loop on the
Fuseable Link to the main power lug in the fusebox as
shown. See FIG 41.
STEP 28. Determine desired location of power switch.
We prefer the location shown in FIG 42. Access is easy
though the removable fuse panel door.
Drill a 13/16” hole and pull the Red, Blue, and Black
wire leads through the hole and connect to switch as
shown in FIG 43. Insert switch into 13/16” hole.
Reconnect negative battery cable.
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PAGE 8
FIG. 43
Red wire
Blue wire
Black wire