TJM T15 User manual

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 1 of 18
15/03/2021
Australian Standards Relating to Installing Vehicle Frontal Protection Systems (VFPS): AS 4876.1-2002
a) Do not attach V.F.P.S. to vehicle using anchorages not intended for this purpose (e.g. engine mounting bolts), other than those
specified by the V.F.P.S. manufacturer in this instruction.
b) Do not use this product for any vehicle make or model other than those specified by the V.F.P.S. manufacturer (as above).
c) Do not remove any plaques or labels from the V.F.P.S.
d) Do not modify the structure of the V.F.P.S. in any way.
•Read instructions fully before commencing fitment.
•Left hand & Right hand components are determined as seated in the vehicle.
•Check for (and remove) any build up in all captive nuts fitted to the FPS.
•Be aware that a number of government / fleet departments require that the
tow points be painted red.
•Ensure that the “Rated Recovery Point Label” is affixed alongside the
compliance label, in the driver’s side doorjamb.
Bolt tensions
Dia. (mm)
Nm
ft.lbs
Dia. (inch)
Nm
ft.lbs
All bolt tensions are
as follows unless
otherwise
specified.
5
5
4
1/4”
9
7
6
9
7
5/16”
22
15
8
22
16
3/8”
33
27
10
44
32
7/16”
55
43
12
77
57
1/2”
86
66

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 2 of 18
15/03/2021

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 3 of 18
15/03/2021
ITEM
NO.
Description
Qty
Part
Number
PARTS LIST
1
FPS
1
F-17359
2
Bar Mount / Winch Frame
1
F-7855
3
Chassis Mount LH
1
F-8430L
4
Chassis Mount RH
1
F-8430R
5
Center Guard
1
F-8690
6
Wing Guard RH
1
F-25212R
7
Wing Guard LH
1
F-25212L
8
Hinged No Plate
1
F-25211
9
Grill Centre
1
F-7892
10
Grill RH
1
F-9971R
11
Grill LH
1
F-9971L
FITTING KIT
12
Wing Guard Mount
2
F-10994
13
Bend Angle LH
1
F-17394L
14
Bend Angle RH
1
F-17394R
15
Bending Washer Plate
2
F-7870
16
Outer Washer Plate
2
F-17393
17
Spacer
4
F-9007
18
Rear Inner Chassis Support
2
F-9008
19
Spacer
2
F-9009
20
Mount Spacer
2
86528
21
Grille Latch
3
F-9969
22
Spring Latch Spacer
1
F-18168
23
Hinge Bush
6
K1292
24
LED Parker/Indicator
2
92600
25
Fog Light Blanking
2
92091
26
Bumperette LH
1
F-17368L
27
Bumperette RH
1
F-17368R
28
Fog Light Washer Plate
4
88057
29
Parking Sensor Blanking Plug
2
K0663
N/A
Pinch-Weld (285mm Long)
2
93154
N/A
Nylon Plug
4
K0665
N/A
Rated Recovery Point Label
1
HC0064
N/A
Recovery Point Use Guide
1
F-1768
N/A
Parking Sensor Housing Sicker
2
F-50070
N/A
2020 Model Trim Template
F-31638
FACTORY FITTED
N/A
Rated Recovery Point Label
1
HC0064
N/A
TJM Logo Sticker
1
K3550
N/A
Warning Label - ABC
1
HC0057
ITEM
NO.
Description
Qty
Part
Number
BOLT KIT
N/A
R-Clip
2
91130
N/A
M5 x 0.8 x 20mm Pan Head Screw
6
K0688
N/A
M5 x Ø10mm Flat Washer
8
K0417
N/A
M5 x 0.8 Nyloc Nut
6
K0604
N/A
M6 x 1.0 x 20mm Hex Head Bolt
11
K0550
N/A
M6 x 1.0 x 16mm SS Button Head Bolt
3
K1630
N/A
M6 x 1.0 x 20mm SS Button Head Bolt
14
K3218
N/A
M6 x 1.0 SS Nyloc Nut
9
K1549
N/A
M6 x 1.0 Flange Nut
16
K3033
N/A
M6 Spring Washer
3
K0915
N/A
M6 SS Spring Washer
8
K1552
N/A
M6 x Ø12.5mm SS Flat Washer
18
K1551
N/A
M6 x Ø12.5mm Flat Washer
8
K0897
N/A
M6 x Ø18mm x 1.6mm Flat Washer
3
K2905
N/A
M6 x Ø18mm SS Flat Washer
8
K1554
N/A
M6 Cage Nut Type B
8
K1550
N/A
M8 x 1.25 x 25mm Hex Head Screw
4
K0553
N/A
M8 x 1.25 x 35mm Hex Head Screw
2
K0555
N/A
M8 x 1.25 x 40mm Hex Head Screw
2
K0556
N/A
M8 Spring Washer
6
K0620
N/A
M8 x Ø19mm Flat Washer
10
K0628
N/A
M8 x 1.25 Cage Nut Type B
4
K1560
N/A
M8 x 1.25 Nyloc Nut
2
K0606
N/A
M10 x 1.25 x 30mm Hex Head Screw
10
K0564
N/A
M10 x 1.25 Nyloc Nut
6
K3099
N/A
M10 x Ø30mm Flat Washer
16
WSST-W13
N/A
M10 Spring Washer
4
K0621
N/A
M12 x 1.25 x 35mm Hex Head Screw
10
K0570
N/A
M12 x 1.25 x 40mm Hex Head Screw
10
K0571
N/A
M12 x 1.25 x 100mm Hex Head Bolt
4
K1240
N/A
M12 x 1.25 Nyloc Nut
22
K1200
N/A
M12 Spring Washer
2
K0977
N/A
M12 x 32mm x 2.5mm Flat Washer
46
K0623

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 4 of 18
15/03/2021
MARK BUMPER WHILE STILL ON VEHICLE.
NOTE: BUMPER TRIM GARNISH SHOULD
REMAIN ON BUMPER TO BE MARKED/CUT
1. Affix the supplied bumper trim template
(F-31638) to the vehicle.
2. Mark a point on the indicated bumper
contour 125mm verticaly down from the
headlight bumper contour.
3. Extend a line across the bumper from the
bumper trim template to the point marked in
step 2.
4. Extend a line from the point marked in step
2 to the bottom spar in the lower grille
opening.
REPEAT ABOVE STEPS FOR THE
OPPOSITE SIDE OF THE VEHICLE
5. Remove & retain the number-plate,
discarding the fasteners.
6. Remove & retain the plastic clips /
fasteners (8) that secure the top of the
grille/radiator shroud.
7. Remove shroud.
RHS SHOWN
RHS SHOWN
STEP 2
125mm
GARNISH TO
REMAIN ON BUMPER
STEP 4

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 5 of 18
15/03/2021
8. Locate and remove grill retaining screws (4)
upper and (4) lower.
9. Disconnect radar plug from back of grill then
remove and retain grill
10. Release the plastic inner guard from the
bumper, discarding all of the fasteners.
11. Remove bumper to fender screw both sides
and retain.
Repeat on LHS.
12. Remove and discard lower bumper clips
13. If there are fog lights and parking sensors
fitted to the vehicle, disconnect the plugs
from the back of the sensors and fog lights.
14. Remove the bumper from the vehicle and
retain.
RHS SHOWN
STEP 10
STEP 11
RETAIN

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 6 of 18
15/03/2021
15. Remove & discard the front intrusion beam
using the following steps:
15.1. Remove & discard all plastics in front
and below beam.
15.2. Remove and discard front intrusion
beam and fasteners (4).
These steps only apply for vehicles fitted
with parking sensors
16. Looking at the lower bumper section from
the rear, record each parking sensor’s
position and orientation.
17. Remove the parking sensors.
18. Carefully remove the blue parking sensor
housing from the bumper and remove
excess double sided tape from the housing.
Reinsert the sensor into the housing and set
aside to be reinstalled to the FPS.
DISCARD LOWER
PLASTIC PANEL
LHS SHOWN

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 7 of 18
15/03/2021
Fit the Indicator / Parker flying lead or plug and play harness to the vehicle loom as per
instructions.
Temporarily plug in supplied indicator/park.
Check the operation then disconnect the light assemblies.
19. Cut the bumper and grille along the
previously marked trim lines.
20. Refit the grille and bumper to the vehicle,
using the OE fasteners retained previously
21. Reconnect the radar.
22. Assemble outer chassis mount with spacer
(item-19) using M12 x 1.25 x 100mm hex
bolt (2), & M12 x 32mm x 2.5mm flat
washer (2) in position shown holding spacer
in place. Fit spacer (item-17) (2) onto bolts.
LHS SHOWN

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 8 of 18
15/03/2021
23. Position the assembled outer chassis mount
on the outer face of the chassis rail aligning
the respective holes to the chassis.
24. Slide rear inner chassis support onto bolts
and fasten loosely using M12 nyloc nuts (2)
& M12 x 32mm x 2.5mm flat washer (2).
Important:
Spacers must pass through chassis
holes and fit against the inner and
outer chassis mounts.
Repeat chassis mount steps on both
RHS.
25. Fit the wing guard mount and loosely secure
it in place, using M12 x 1.25 x 40mm hex
screws (1), M12 spring washers (1) &
M12 x 32mm x 2.5mm flat washer (1) into
captive nut in the chassis rail.
26. Insert 2-off M8 X 1.25 cage nuts as shown.
Repeat on RHS.
LHS SHOWN
LHS SHOWN

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 9 of 18
15/03/2021
27. Loosely secure in place at the positions
shown using M10 x 1.25 x 30mm hex
screws (4), M10 spring washer (4) and
M10 x Ø30mm flat washer (4).
28. Secure bracket loosely using the following
fasteners:
28.1. M10 x 1.25 x 30mm hex screws (3),
M10 x Ø30mm flat washers (6) &
M10 nyloc nuts (3).
28.2. M12 x 1.25 x 35mm hex screws (2),
M12 x Ø32mm x 2.5mm flat
Washers (4) & M12 nyloc nuts (2).
Repeat on LHS.
29. Centralize the bar mount / winch frame to
the vehicle by measuring diagonally from
mount tip to headlamp corner as shown,
equalize as close as practical.
Tighten all winch frame and chassis mount
bolts from previous steps to relevant torque
settings listed on page 1.
RHS SHOWN
28.2
28.1

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 10 of 18
15/03/2021
30. Fit clamp Angle bracket to inboard face of
winch frame and washer plate to front using
M12 x 1.25 x 35mm bolts (3),
M12 x 32mm x 2.5mm flat washer (6) & M12
nyloc nuts (3).
Important –fit M12 bolt assembly with bolt
head on front face.
31. Align plate with existing holes and edges,
tighten to specified torque. Check holes and
slots align after tightening to allow easy bolt
fitment/clearance.
Repeat on LHS.
NUTS
TO INSIDE!
RHS SHOWN
Clamping
angle
Holes must
align

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 11 of 18
15/03/2021
Next step only applies if a winch is to be fitted.
Otherwise please proceed
32. Refer to the winch fitting instructions to fit
the winch to the bar mount / winch frame.
At this stage, DO NOT FASTEN THE WINCH
TO THE WINCH FRAME, ONLY PLACE
WINCH IN POSITION.
33. Fit pinch weld to bumper trim at wheel arch
as shown, to both sides.

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 12 of 18
15/03/2021
34. Fit the centre grille using M6 x 1.0 x 20mm
S/S button head bolt (4), M6 x Ø12.5mm S/S
flat washers (8) & M6 S/S nyloc nut (4).
35. Fit the LH & RH grilles using hinge bush (4),
M5 x 0.8 x 20mm pan head screw (4),
M5 x Ø10mm flat washers (4) & M5 nyloc
nut (4).
No M5 x Ø10mm flat washers in the
fairlead recess.
36. Fit the spring latch to the FPS as shown,
using a M6 x 1.0 x 16mm SS button head
bolt, M6 x Ø 12.5mm SS flat washers (2) &
M6 SS nyloc nut.
37. Adjust as required to reduce play in the grill
and allow easy unlatching.
Repeat on opposite side.

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 13 of 18
15/03/2021
38. Secure the hinged number plate to top holes
using hinge bush (2), M5 x 0.8 x 20mm pan
head screw (2), M5 x Ø10mm flat washers
(4) & M5 nyloc nut (2).
39. Using a M6 x 1.0 x 16mm SS button head
bolt, M6 x Ø 12.5mm SS flat washers (2) &
M6 SS nyloc nut, secure the spring latch and
spacer to the FPS, as shown.
ALTERNATIVELY, USE R-CLIP (2) IN
LOWER HOLE FOR ABSOLUTE POSITION
LOCK OF THE HINGED NUMBER PLATE.
40. Insert the nylon plugs supplied, into the
square cut-outs for the indicator/park lights.
41. Separate the indicator / park light body from
the backing plate.
42. Secure the backing plate to the FPS, using
the screws provided with the light
assemblies.
43. Supporting the backing plate, re-fit (clip)
each indicator / park light body (ensuring
that an adequate seal is achieved).
Ensure that the park light is towards
the outside of the vehicle.
Repeat the previous four steps for the opposite
side of the vehicle.
HINGE BUSH

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 14 of 18
15/03/2021
44. Refer to the fitting instructions provided in
the indicator/parker wiring loom kit to
connect it to the vehicle. Test operation of
the lights before proceeding.
45. Apply the supplied parking sensor housing
sticker to the OE housing and affix to the
FPS, as shown. Ensure sensor orientation is
as per notes made from OE bumper.
Reconnect to OE loom.
46. For vehicles without parking sensors use the
supplied parking sensor blanking plugs, use
a small amount of adheisive to aid retention
if necessary.
If a Foglight Kit has been purchased, install
it now referring to the instructions provided
in the kit. Otherwise, follow the below steps
to install the provided Foglight Blanking
Cover.
47. Sandwich the foglight mounting bracket
between Foglight Washer Plates (2).
48. Position the Foglight Blanking Cover as
shown opposite.
49. Using M6 x 1.0 x 20 Hex Head Screws (4),
M6 x Ø12.5mm Flat Washers (4) and M6 x
1.0 Flange Nuts (4), secure the Foglight
Blanking Cover to the FPS.
Repeat for opposite side of FPS

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 15 of 18
15/03/2021
50. Install bumperettes to the FPS using
M6 x 1.0 flange nuts (16). Tighten only
enough to hold firmly against bar.
Adjust bumperettes whilst tightening for best
fit.
51. With the assistance of another person,
carefully lift the FPS into position on the
chassis mount, then loosely secure it in
place, using the sliding washer plate and
M12 x 1.25 x 40mm hex bolts (4),
M12 x 32mm x 2.5mm flat washer (8) & M12
nyloc nuts (4) at the indicated locations.
Repeat both sides
IMPORTANT: SLIDING WASHER PLATE
MUST BE ORIENTATED CORRECTLY AS
SHOWN!
52. Align the FPS to the vehicle so that the
guard to FPS wing clearance is 20 to 25mm,
and wing end is aligned with wheel arch.
53. Tighten all of the fasteners to the relevant
torque settings listed on Page 1.
54. Re-connect the indicator / park lights & fog-
lights to the corresponding wiring harness.
55. Check the operation of the indicators, park
lights, fog-lights, winches, etc. to ensure
that they are functioning correctly.
RHS SHOWN
CHAMFER
TO TOP
20-25mm

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 16 of 18
15/03/2021
56. Use the indicated hole in the sliding washer
plate as a guide and drill an Ø8mm hole
through the mounts in both sides of the
vehicle. Keep the drill square to align with
holes in winch frame.
57. De-burr all new edges, clean any swarf
from the areas and apply rust preventative
to exposed surfaces.
58. Secure through the holes drilled in Previous
step using M8 x 1.25 x 35mm hex screws
(2), M8 x Ø19mm flat washers (4) & M8 x
1.25 nyloc nuts (2).
Tension the fasteners to the specified torque
settings listed on page 1.
59. Insert M6 cage nuts (4) into each wing
guard, as shown opposite.
60. Position the wing guard as shown, and
secure it in place.
60.1. M6 x 1.0 x 20mm SS button head
bolts (4), M6 SS spring washers (4) &
M6 x Ø18mm SS flat washers (4).
60.2. M8 x 1.25 x 25mm hex screw (2),
M8 spring washers (2), & M8 x 19mm
flat washer (2).
61. Repeat on LHS.
RHS SHOWN
RHS SHOWN
1
2

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 17 of 18
15/03/2021
62. Mark and trim inner guard aligning to
features shown.
.
63. Trim inner guard in line with under wing
guard edge as shown. Remove any burrs
from cutting
RHS SHOWN
ALIGN TO
FEATURE
EDGE
ALIGN TO BUMPER
TRIMMED EDGE
60mm
AS TRIMMED
RHS SHOWN

FITTING INSTRUCTIONS
Product:
T15 Signature Frontal Protection System
Vehicle:
Toyota HiLux (MY2020)
Part No.
070AP15N87J
For product warranty please refer to our website www.tjm.com.au
F-31649
Page 18 of 18
15/03/2021
64. Remove the front bolts from OE underbody
guard and discard.
65. Position the centre guard & loosely secure
the front edge using M6 x 1.0 x 20mm hex
bolts (3), M6 spring washers (3) &
M6 x Ø18mm flat washers (3).
66. Fasten the rear with spacer (item 20)
positioned between centre guard and OE
under body guard using M8 x 1.25 x 40mm
hex bolt (2), M8 spring washer (2) &
M8 x Ø19mm flat washer (2).
67. Tighten all guard fasteners to the relevant
torque settings listed on Page 1. If a winch
was installed, torque its fasteners now.
68. Using M6 x 1.0 x 20mm SS button head
bolts (2), M6 x Ø12.5mm SS flat washers (4)
& M6 SS nyloc nuts (2), secure the number-
plate in place, to the front of the FPS.
69. Ensure that all of the fasteners are fully
tightened to the specified torque settings &
that, as a results of fitting the product, no
vehicle components are crushed or will
chafe.