Toyota PZQ72-48050 User manual

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 1 OF 15
PLACE THESE INSTRUCTIONS IN VEHICLE GLOVEBOX AFTER INSTALLATION IS COMPLETE
Ensure appropriate PPE is worn
whilst installing this accessory.
!CAUTION
Review the compliance plaque fi tted to the cargo barrier
for correct maintenance of this accessory.
Periodically check the torque of all fasteners to values
listed in instructions.
CARE INSTRUCTIONS
Approximately 90 minutes.
INSTALLATION TIME
KLUGER
FITTING INSTRUCTIONS
PRODUCTION DATE: DECEMBER 2013 ONWARDS
ACCESSORY PART NUMBER: PZQ72-48050 CARGO BARRIER

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 2 OF 15
KIT CONTENTS
TOOLS REQUIRED
1 2 3 4
Fitting Instructions Cargo Barrier LHS & RHS Lower Legs Lower Straps
CHECK THAT THE CONTENTS OF THE CARGO BAR-
RIER KIT ARE COMPLETE & UNDAMAGED PRIOR TO
FITMENT.
!IF ANY CONTENTS OF THE CARGO BARRIER KIT ARE INCOMPLETE OR
DAMAGED THEY MUST BE REPLACED USING SPECIFIED ACESSORY
COMPONENTS.
!
x1 x1 x2 x2
1 2 3 4
Trim Removal Tool Metric Sockets & Spanners Torque wrench Sharp knife
5
9
6 7 8
Hammer
19mm Hole Saw
Drill
19mm Vinyl Cutter
De-Burring Tool
Metric Drill Set
Centre Punch
Allen Key Set
5 6
Upper Straps Bolt Pack
x2 x1
10 11 12

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 3 OF 15
CARGO BARRIER ASSEMBLY
25
18
26
UP
17
2 PLACES
FR
1
2
4
6
3
9
11 10
97
18
7
17
16 12
29
7
21
8
14
13
1011
7
2 PLACES
2 PLACES
2 PLACES
4 PLACES
2 PLACES
2 PLACES
2 PLACES
6 PLACES
1519
12 PLACES
6 PLACES
RH

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 4 OF 15
ITEM NO. PART NO. DESCRIPTION QTY.
1 A41307-A1 WELDED ASSEMBLY 1
2 A41307-A2 LOWER LEG LHS 1
3 A41307-A3 LOWER LEG RHS 1
4 A41307-3 REAR TOP STRAP 2
5 A41307-34 CARGO BARRIER FASTENING TOOL 1
6 PA224 M10 X 3.5 X 2.2 SPRING WSHR 2
7 92358 WASHER M10 WAVE 12
8 PH662 CARGO BOLT M10 x14 X 1.5P 2
9 PG259 SCREW BUTTON HD M10 X 16 X 1.5P G12.9 Z/P 8
10 PG260 SCREW BUTTON HD M6 X 16 X 1P G12.9 Z/P 16
11 PA236 M6 SPRING WASHER 16
12 PA223 WASHER FLAT M10 X 2 3 X 2 Z/ P 2
13 92050 BOLT COACH M10 X 35 X 1.5P G8.8 2
14 40102 HAND KNOB 2
15 40103 CARGO BOLT 35MM 2
16 40105 BUSH RUBBER 25 X 9.5 2
17 PC943 LOWER PLATE 8
18 PE703 COVER PLATE 4
19 40142 18mm PLASTIC BUSH 2
20 PE871 15G ANTI RUST SACHET 1
21 A41307-A5 LOWER STRAP 2
22 PL244 COMPLIANCE PLAQUE STICKER 1
23 40127 C\TIE SMALL 10
24 40128 LARGE CABLE TIES 6
25 PC212 EMERGENCY HAMMER ASSEMBLY 1
26 PC211 EMERGENCY WARNING HAMMER PLAQUE 1
27 PD004 CTN C/B Toyota (1395 x 945 x 125) 1
28 40431 POLY BLOCK FOAM 2
29 PJ780 COMPLIANCE PLAQUE - TOYOTA 1
30 PG215 M10 X 1.5P X 0MM SPIKE 1
31 FIPZQ7248050 FITTING INSTRUCTIONS 1
32 CIPZQ7248050 CUSTOMER INSTRUCTIONS 1
PZQ724800 - CARGO BARRIER

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 5 OF 15
STEP 1
STEP 2
STEP 3
STEP 4
Check contents of kit before commencing fitment.
Open the rear luggage compartment door.
Remove the deck board and left hand side compart-
ment cover.
Remove the left hand side and central storage box from
underneath.
Use a 10mm socket to remove 1 x retaining nut
Using a trim removal tool, remove the rear scuff plate.
Fold the second row seats down and slide the seats
to their most forward position.
Note: Adjust the fi rst row seat forward if necessary.
LHS RETAINING NUT

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 6 OF 15
STEP 5
STEP 6
STEP 7
STEP 8
Ensure the 3rd row seat is upright.
Remove 3rd row seat rail bolt covers from the front of
seat. Use a trim removal tool to pop from front.
Remove the right hand side seatbelt anchor bolt.
Ensure the left hand side seatbelt is fed through the
seat and remove the 3rd row seats.
Remove both the left and right hand side scuff plates
and rear 2nd row seat bolt covers using a trim removel
tool.
Remove the 3rd row seat belt anchorage bolts.
Use trim removal tool to dislodge cup holders from rear
quarter trims.
Remove the fasterners securing the rear quarter trim as
highlighted then remove the trim.
Repeat for opposite side.
Dislodge the C, D panel trims and pop down the trim
panel at the top of the rear quarter window.
Repeat for opposite side.

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 7 OF 15
STEP 9
STEP 10
STEP 11
STEP 12
Using a trim removal tool, remove both second row
grab handles. Take care not to damage whilst removing.
Lower the headliner by unclipping the three trim clips
at the rear of the vehicle and two trim clips above the
second row seats, using a trim removal tool.
Lower the headliner and place the cant rail template
(Pg.13) over the existing holes as shown on template.
Drill all holes as marked on template.
Note: Ensure a 10mm drill stop is used. Take care not
to damage washer fl uid line.
Remove all sharp edges from holes using a de-burring
tool.
Remove swarf and c oat all raw edges with an anti-rust
grease.
Insert an anchor plate through panel cavity and align
with drilled holes.
Place cover plate over holes and align the anchor and
cover plate.
Secure the cover plate to the anchor plate using the
M6x16mm button head bolts and M6 spring
washers.
TORQUE: M6: 13Nm
Insert supplied M10 spike into anchor plate as shown.
Place masking tape on the underside of the headliner
and depress the headliner so the position of the spike
protrudes through. Mark the location of these points
Place a block of wood behind the marked location and
drill using a 19mm vinyl cutter.
Reinstall the vehicle headliner
CLIP LOCATIONS

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 8 OF 15
STEP 13
STEP 14
STEP 15
STEP 16
Reinstall the headliner and rear trim panels.
- C & D pillar trims
- Upper quarter window trims
- Lower quarter trims
- Grab Handles
Temporarily fold back the rear carpet to expose the
fl oor pan.
Measure and mark the rear quarter trims as shown.
Using a sharp knife or other cutting tool, cut the trim as
specifi ed.
Place a lower leg on the fl oor pan and align with the
drilled holes.
Using the hole in the top of the leg as a guide, mark the
centre of the hole on the trim.
Using a 19mm hole saw, drill a hole at the marked
point. Ensure a 10mm drill stop is used.
Repeat for left hand side.
Using the fl oor pan template (Pg.15), align the template
with the contours of the fl oor pan.
Using a drill fi tted with a 10mm drill stop, drill at the
marked points.
Drill the outer holes using a 7mm drill piece and the
centre holes with a 19mm hole saw.
Deburr the edges, remove swarf and coat with anti-rust
grease.
Repeat for left hand side.
280mm
FRONT OF VEHICLE

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 9 OF 15
STEP 17
STEP 18
STEP 19
STEP 20
Secure the anchor plates to the lower leg using the
M6x16mm button head bolts, M6 spring washers,
M10x16mm button head bolt and M10 wave
washer. Install a cover plate between the rear most
point of the lower leg and the fl oor pan.
Repeat for left hand side.
TORQUE: M6: 13Nm
M10: 45Nm
Fasten the lower strap to the lower leg using the M10 x
12mm button head bolt and an M10 spring washer.
TORQUE: M10: 30Nm
NOTE: Ensure the lower strap is fastened to the lower
leg with the weld nut facing the outside of the vehicle.
If you are installing the barrier in the forward position
using adaption kit (Part No: PZQ72-48040) refer to
forward position fitting instructions now, do not
reinstall the rear door scuff gaurd trim panels.
With the anchor plates below the fl oor pan, place
the lower leg on the fl oor pan and feed the cable ties
through the centre holes in the lower leg.
Insert a large cable tie through the centre hole of one of
the anchor plates as shown.
Insert the anchor plate into the 19mm hole and align
with the drilled holes.
Ensure the smooth side of the anchor plate mates
against the fl oor panel.
Repeat for all three mounting locations in the fl oor pan.
COVER PLATE

ISSUE 1: 20/03/2017 PART NUMBER: PZQ72-48050PAGE 10 OF 15
STEP 22
STEP 23
STEP 24
Reinstall the 3rd row seats, rear side scuff panels and
seat bolt covers.
Adjust the height of the lower strap so that the hole in
the strap is positioned 25mm above the folded seats, as
shown.
TORQUE: 37Nm (Seat Anchorage Bolts)
42Nm (Seatbelt Anchorage Bolts)
With the cargo barrier outside the car, insert the M10
X 35mm coach bolts through the upper mounts in the
frame.
Secure the coach bolts in place with the rubber bushes.
Position the barrier so that it rests on the back of the
folded 3rd row seats.
STEP 21
Fasten the rear top straps to the barrier using the M10
fl at washer, M10 wave washer and the hand knobs.
Hand tighten hand knobs to 15 Nm.
25mm
HAND KNOBS