TJM T24 User manual

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 1 of 26
11/03/2020
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.
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
Parts List shown on Page 2

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 2 of 26
11/03/2020
ITEM
NO.
Description
Qty
Part
Number
PARTS LIST
1
T24 FPS
1
F-29393
2
Chassis Mount / Winch Frame
1
F-9260
3
Wing Guard LH
1
F-14330L
4
Wing Guard RH
1
F-14330R
5
Center Under Guard
1
F-29553
6
Removeable Top Hoop
1
F-29475
FITTING KIT
7
M12 x 1.75 x 280mm Threaded Rod
2
F-1613
8
Chassis Rail Mounting Block
2
F-9132
9
Chassis End Spacer
2
F-9235
10
Tow Point Washer
2
F-11067
11
Washer Plate
2
F-9792
12
Bending Angle LH
1
F-9790L
13
Bending Angle RH
1
F-9790R
14
Upper Grille Mount
1
F-9315
15
Bending Washer Plate
2
F-9791
16
Center Guard Mount Angle
2
F-9926
17
Spacer Plate
2
F-10308
18
Wing Mount Angle
2
F-10309
19
Bumper Support
1
F-10478
20
Fairlead Cover
1
F-11096
21
Grille
2
F-29417
22
Washer Blank
2
F-10319
23
Parking Sensor Blank
2
F-11073
24
Camera Blanking Plate
1
F-29556
25
Top Hoop Brace
2
F-29493
26
Parking Sensor Housing Sticker
2
F-5569
27
LED Fog-Light Kit & Brackets
1
92675
28
TJM Logo Backing Plate
3
F-13430
29
Top Hoop Gasket
2
F-29778
N/A
Mounting Tape (60mm)
1
K3209
N/A
Cable Tie –300mm
12
K1148
N/A
Rated Recovery Point Label
1
HC0064
N/A
Recovery Point Use Guide
1
F-1768
N/A
Pinchweld (2m Long)
1
93151
FACTORY FITTED
N/A
Rated Recovery Point Label
1
HC0064
N/A
Warning Label - ABC
1
HC0057
N/A
TJM Logo Sticker
1
K3550
ITEM
NO.
Description
Qty
Part
Number
BOLT KIT
N/A
M5 x 0.8 x 20mm Pan Head
2
K0688
N/A
M5 Spring Washer
2
K0914
N/A
M5 x 10 x 1.0 Flat Washer
2
K0417
N/A
M6 x 1.0 x 16mm Socket Head Screw
20
K1630
N/A
M6 x 1.0 x 20mm Hex Bolt
17
K0550
N/A
M6 x 1.0 Flange Nut
3
K3033
N/A
M6 x 1.0 Cage Nut Type B
14
K1550
N/A
M6 x Ø12.5 x 1.2mm Flat Washer
18
K1551
N/A
¼ x ¾ x 1.6mm Flat Washer
37
K2905
N/A
M6 x 2.5 x 1.6 Spring Washer
16
K0915
N/A
M6 x 1.0 Nyloc Nut
18
K1549
N/A
M8 x 1.25 x 16mm Hex Bolt
3
K0767
N/A
M8 x 1.25 x 25mm Hex Bolt
10
K0553
N/A
M8 x 1.25 x 35mm Hex Bolt
2
K0555
N/A
M8 x 1.25 Nyloc Nut
10
K0606
N/A
M8 x 1.25 Flange Nut
3
K3035
N/A
M8 x 1.25 Cage Nut Type B
2
K1560
N/A
5/16" x Ø7/8" Flat Washer
27
K2901
N/A
M8 Spring Washer
2
K0620
N/A
M10 x 1.5 x 25mm Socket Head Screw
2
K2690
N/A
M10 x 1.5 Nyloc Nut
2
K0607
N/A
M10 x 1.25 Nyloc Nut
4
K3099
N/A
M10 x Ø30mm Flat Washer
6
WSST-W13
N/A
M10 x Ø21mm x 2mm Flat Washer
4
K2900
N/A
M12 x 1.25 x 35mm Hex Screw
6
K0570
N/A
M12 x 1.25 x 40mm Hex Screw
8
K0571
N/A
M12 x 1.25 x 45mm Hex Bolt
4
K0772
N/A
M12 x 1.25 Nyloc nut
14
K1200
N/A
M12 x 1.75 Hex Nut
2
K0587
N/A
M12 x 32mm x 2.5mm Flat Washer
32
K0623
N/A
M12 x 24mm x 1.6mm Flat Washer
2
K0425
N/A
M12 Spring Washer
6
K0977

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 3 of 26
11/03/2020
NOTES
•Read instructions fully before commencing fitment.
•Estimated Fitting Time: 4.5hrs (5hrs for winch provisions)
•The fitment of TJM products does not nullify the OE manufacturer's
operating guidelines and/or warnings. Ensure you are familiar with
and adhere to the usage instructions specified by the manufacturer in
the owner's manual or other official documentation.
•Left-hand and Right-hand components are determined as seated in
the vehicle.
•Be aware that several government / fleet departments require that the
tow points be painted red.
•Check for (and remove) any build up in all threads fitted to the
product.
•Ensure that the “Rated Recovery Point Label” is affixed alongside the
compliance label, in the driver’s side doorjamb.
•When fitting accessories to TJM products (ie. driving lights and
aerials), ensure suitable washer plates are used under the mounting
surface that allow the accessory to be secured in a way that prevents
it from damaging the product.
•When removing protective coatings, ensure all new edges are
deburred, clean any swarf from the area and apply rust preventative
to exposed surfaces.
It is recommended that if fitting large spotlights that the top hoop be removed
and to mount the spotlights to the top surface of the bullbar.

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 4 of 26
11/03/2020
1. Remove (& retain) number plate if fitted.
2. Remove (& retain) the front plastic
radiator cover and fasteners (7) located
under hood.
3. Disconnect wiring looms from camera and
radar if fitted.

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 5 of 26
11/03/2020
4. Remove (& retain) chrome headlight trim
covers from front.
5. Remove (& retain) the fasteners (3) along
the top of the grille.
6. Remove (& retain) the grille by releasing
the 8 clips along the bottom of the grille
and the additional clip on each side.
7. If fitted, find the parking sensor / fog-light
wiring loom plug and the headlight washer
hose connection.

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 6 of 26
11/03/2020
8. If fitted, disconnect the parking sensor / fog-
light wiring loom plug.
Note: The OE fog-lights are not
required for the installation of this
FPS.
9. If fitted, unclip the headlight washer hose
from the underneath the bumper support.
Disconnect the headlight washer hose
connection. Fold the hose over and use a zip
tie to crimp the hose. This will prevent the
washer fluid in the reservoir from draining.
10. Remove the clips across the top of the
remaining bumper and discard.
Clip in Bumper Support

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 7 of 26
11/03/2020
11. Remove the fasteners in the wheel arch
securing the front bumper and discard.
12. Remove the fasteners retaining the lower
section of the bumper and discard.
13. Remove the lower outer covers and discard
the fasteners.
14. Remove (& retain) the mud flaps and
fasteners (6) from the lower outer cover.
Discard the covers keeping mud flaps,
fasteners and the backing plates.
STEP 13
STEP 14

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 8 of 26
11/03/2020
15. Remove the tow / tie down points on each
side of the vehicle and discard.
16. Remove the bumper and remove (&
discard) the outer bumper support plastics
from the front guard.
17. Remove (& discard) the impact foam, front
intrusion beam and mounting brackets from
the chassis ends. Retain the 8 flange nuts to
secure the winch frame to the chassis.
18. If necessary, remove the automatic
transmission cooler air guide for trimming.
STEP 17

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 9 of 26
11/03/2020
19. Draw a vertical line from the edge of the
top rib approximately 57mm long. Then
mark a horizontal line across the top of
the rib following the ridge of the plastic.
20. Draw a line on the passenger side, parallel
to the gusset. Draw along the lowest face
of the air guide and up 40mm on the
angle. Then draw a horizontal line as
shown that meets with the vertex shown
in step 22.
21. Draw a vertical line from the top rib down
to the edge.
If fitting a TJM winch additional
material will have to be removed
from the air guide to mount the
control box. If this is the case,
reduce the distance of the vertical
line from 75mm to 10mm.
22. Draw a line with a ruler joining the vertex
to the horizontal line drawn in step 21.
23. Trim the plastic air guide along the lines
drawn.
24. Refit the air guide after trimming if
removed.
75mm
STEP 19
STEP 20
Gusset
Vertex

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 10 of 26
11/03/2020
25. If a camera is fitted to the grill. And if
the top hoop is to be fitted on the
bullbar. Remove and retain the camera.
Discard OE fasteners. Make sure to note
orientation of the camera.
26. Fit the new grille mount bracket (F-9315)
to the 6 center lower tabs of the grille
with bracket folds facing up leaving the
outer tabs free.
If fitting a winch complete steps 27
to 38. Alternatively if the customer
wishes to have a winch fitted in the
future, ensure the bumper support
bracket (F-10478) is retained by the
customer and continue to step 39.
27. Remove the grille support mounting bolt.
Remove Bolt

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 11 of 26
11/03/2020
28. Temporarily refit grille and bracket to the
vehicle. Fasten in place using M8 x 16mm
hex bolts (3) 5/16" x Ø7/8" flat washers
(3) and M8 flange nuts (3).
Note: The grille mount bracket
needs to be fitted to the bumper
support to ensure it is not stressed
out of its designed position after
the grille support is removed in step
29.
29. Remove the grille support mount by
drilling out the spot welds in the locations
shown.
30. Fit new bumper support bracket
(F-10478) to the grille support using an
M6 x 20mm hex bolt (1) ¼ x ¾ x 1.6mm
flat washers (1) and M6 flange nut (1) in
the front location only.
31. Using the new bumper support bracket as
a template, mark the 2 new hole positions
in the radiator support.
Ensure the upper and lower holes
are used.
32. Also, mark the lower section of the
radiator support that requires trimming.
Drill Two
Places
STEP 32
STEP 31

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 12 of 26
11/03/2020
33. Remove (& retain) the grille and the grille
mount bracket in one piece.
34. Remove (& retain) the new bumper
support bracket and fastener. Drill new
hole positions.
35. Trim lower section of the radiator support
marked in step 32.
36. De-burr all new edges, clean any swarf
from the areas and apply rust
preventative to exposed surfaces.
37. Fit new bumper support using M6 x 20
hex bolts (3) ¼ x ¾ x 1.6mm flat
washers (3) and M6 flange nuts (3).
Tension the fasteners to the specified
torque settings listed on page 1.
38. Refer to the winch fitting instructions to
bolt the winch into winch frame.
Note: TJM winch can have control
box mounted in standard position.
Others may have to relocate.

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 13 of 26
11/03/2020
39. Install the grille and bracket to the
vehicle. Fasten in place using M8 x 16mm
hex bolts (3) 5/16" x Ø7/8" flat washers
(3) and M8 flange nuts (3).
40. Position the chassis rail mounting block
(F-9132) in the chassis rail through the
rectangular opening as shown.
Ensure that the threaded hole is
positioned away from the centerline
of the vehicle (closest to outside).
41. Apply Loctite 403 (or an equivalent) to a
40mm length of the M12 x 1.75 x 280mm
threaded rod, 25mm from the end, as
shown.
RHS SHOWN
Front
RHS SHOWN

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 14 of 26
11/03/2020
42. Insert the end that had the Loctite applied to
it through the large hole in the chassis rail
end & secure it into the chassis rail mounting
block that was positioned in step 40.
Ensure that there is 50-55mm of
threaded rod protruding out from the
end of the chassis rail.
43. Repeat steps 40 to 42 for the opposite side
of the vehicle.
44. Fit the chassis end spacers (F-9235) to both
chassis ends as shown.
45. Assemble the bending washer plate (F-9791)
and the bending angle (F-9790R) on to the
winch frame (F-9260) as shown. Align edges
of all plates and fasten in place using
M12 x 35mm hex bolts (3), M12 x Ø32mm
flat washers (6) and M12 x 1.25 nyloc
nuts (3).
RHS SHOWN
Threaded Rod
RHS SHOWN
RHS SHOWN

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 15 of 26
11/03/2020
46. Repeat for the opposite side and tension the
fasteners to the specified torque settings
listed on page 1.
47. Carefully lift the winch frame into position
over the captive studs in the end of the
chassis rail.
Note: If a winch is to be fitted, the
winch must be fitted to the winch
frame before the winch frame is fitted
to the chassis.
48. Secure both sides of the winch frame in place
to the captive studs, using spacer plates
(F-10308) (2) and the OE flange nuts (6)
retained in step 17. Only finger tighten the
fasteners at this point until the winch frame
has been centralized to the vehicle.
49. Secure the inner stud located on both sides
of the chassis mount using M10 x Ø30mm
flat washers (2) and the remaining OE flange
nuts (2) retained in step 17.
RHS SHOWN
STEP 48
STEP 49
RHS SHOWN
RHS SHOWN

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 16 of 26
11/03/2020
50. Position the tow point washer plate
(F-11067) on the underside of the chassis
mount, then secure the chassis mount in
place, using M12 x 45mm hex bolts (2), M12
spring washers (2) and M12 x Ø32mm flat
washers (2). Repeat on opposite side.
51. Secure both sides of the chassis mount in
place to the M12 x 1.75 x 280mm threaded
rod, using M12 x Ø24mm flat washer (2),
M12 spring washer (2) & M12 x 1.75mm hex
nut (2).
52. Centralize the winch frame to the vehicle by
measuring diagonally from mount tip to
headlamp corner as shown, equalize
dimensions as close as practical.
53. Tension all fasteners fitted in steps 48 to 51
to the specified torque settings listed on
page 1.
54. Wire winch at this point if being installed.
55. Refit the grille into the grille mount bracket
and fasten using the original bolts (3) along
the top of the grille removed in step 5.
RHS SHOWN
RHS SHOWN

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 17 of 26
11/03/2020
56. Fit the LED fog-lights as per the instructions
included in the fog-light kit (92675).
57. If headlamp washers are fitted, remove them
from bumper and refit in FPS in the provided
cutouts.
To remove washer assemblies:
I. Extend washer by carefully pulling on
front cover.
II. Holding by the stem carefully remove the
cover from the stem.
III. Remove the metal clip shown from the
rear of the washer, slide the housing
apart and gently remove the washer from
the bumper.
58. If no headlamp washers are fitted, fit the
washer blanks (F-10319).
58.1. Clean the mounting surfaces of
the headlight washer blanks and
around the headlight washer
openings in the FPS.
58.2. Cut the length of mounting tape
into 6 equal sized pieces.
58.3. Fit 2 pieces of the mounting tape
to each of the headlight washer
blanks.
58.4. Fit the headlight washer blanks
to the inside face of the FPS, at
the headlight washer openings.
RHS SHOWN
RHS SHOWN
HEADLIGHT WASHER
OPENING
TAPE
RHS SHOWN

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 18 of 26
11/03/2020
59. If parking sensors are fitted, remove them
from bumper and refit in the same
orientation in FPS.
60. If no parking sensors are fitted, fit parking
sensor blanks (F-11073).
60.1. Clean the mounting surfaces of
the parking sensor blanks and
around the parking sensor
openings in the FPS.
60.2. Fit a mounting sticker (F-5569)
to each of the parking sensor
blanks.
60.3. Fit the parking sensor blanks to
the inside face of the FPS, at the
parking sensor openings.
61. Remove parking sensor / fog-light wiring
loom and headlight washer tubing from
original bumper if fitted and fit to FPS. Feed
ends from center outwards through cutouts
provided, to keep plugs and joiners in center
on LH side as shown.
62. Secure the wiring and tubing to the FPS so
no damage can occur and connect sensors,
fog-lights and washers.
RHS SHOWN
PARKING SENSOR
OPENING
STICKER

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 19 of 26
11/03/2020
63. On both sides of the bullbar, install the pinch
weld to the lip under the top face of the
wing. Trim to suit.
64. Fit the fairlead cover plate (F-11096) to the
FPS if a winch has not been fitted; using
M10 x 1.5 x 25mm button head screws (2),
M10 x Ø21mm flat washers (4) and
M10 x 1.5 nyloc nuts (2).
65. Fit the grilles to the inside of the bar using
M6 x 1.0 x 16mm socket head screws (8), ¼
x ¾ x 1.6mm flat washers (8), M6 x Ø12.5 x
1.2mm flat washers (8) and M6 nyloc nuts
(8). Note: Use Ø12.5mm washer on bolt
head side.
LHS SHOWN
CHAMFER
AT TOP

FITTING INSTRUCTIONS
Product:
T24 Frontal Protection System
Vehicle:
Toyota Landcruiser 200 Series
Part No.
070SB24N82C
For product warranty please refer to our website www.tjm.com.au
File: F-29766
Page 20 of 26
11/03/2020
66. Fit the TJM logo backing plate to the inside
of both wings using M6 x 1.0 x 16mm socket
head screws (4), ¼ x ¾ x 1.6mm flat
washers (4), M6 x Ø12.5 x 1.2mm flat
washers (4) and M6 nyloc nuts (4). Note:
Use Ø12.5mm washer on bolt head side.
STEPS 67 TO 70 APPLIES ONLY IF TOP
HOOP IS TO BE FITTED
67. If step 25 was performed. Reinstall the
camera into the top hoop using M5 x 20mm
pan head screws (2), M5 spring washers (2)
and M5 x 10mm flat washers (2). Make sure
the camera is in the same orientation as it
was when removed.
68. If vehicle is not fitted with a camera. Fit
camera blank.
68.1. Clean the mounting surfaces of
the camera blank and around the
camera opening in the top hoop.
68.2. Use the 2 left over lengths of
tape cut in step 58.2.
68.3. Fit the 2 pieces of the mounting
tape to the camera blank.
68.4. Fit the camera blank to the inside
face of the top hoop, at the
camera opening.
69. If aerial, light bar or spotlights are to be
fitted on top of the hoop, the hoop brace (F-
29493) must be installed using M6 x 1.0 x
16mm socket head screws (2), ¼ x ¾ x
1.6mm flat washers (2), M6 x Ø12.5 x
1.2mm flat washers (4) and M6 nyloc nuts
(2). Note: Use Ø12.5mm washer on bolt
head side. Repeat on opposite side.
STEP 67
STEP 68
TAPE
RHS SHOWN
LHS SHOWN