ARB 3432150 User Manual

LAND ROVER DISCOVERY 3

ARB BULL BAR AND WINCH BAR

• PART No 3432150 DISCOVERY 3 WINCH BAR

• PART No 3232150 DISCOVERY 3 BULL BAR

WARNING

FOR VEHICLES EQUIPPED WITH SRS AIRBAG

WHEN INSTALLED IN ACCORDANCE WITH THESE INSTRUCTIONS, THE FRONT

PROTECTION BAR DOES NOT AFFECT OPERATION OF THE SRS AIRBAG.

TAKE NOTE OF THE FOLLOWING:

• THIS PRODUCT MUST BE INSTALLED EXACTLY AS PER THESE INSTRUCTIONS

USING ONLY THE HARDWARE SUPPLIED.

• IN THE EVENT OF DAMAGE TO ANY BULL BAR COMPONENT, CONTACT YOUR

NEAREST AUTHORISED ARB STOCKIST. REPAIRS OR MODIFICATIONS TO THE
IMPACT ABSORPTION SYSTEM MUST NOT BE ATTEMPTED.

• DO NOT USE THIS PRODUCT FOR ANY VEHICLE MAKE OR MODEL, OTHER THAN

THOSE SPECIFIED BY ARB.

• DO NOT REMOVE LABELS FROM THIS BULL BAR.

• THIS PRODUCT OR ITS FIXING MUST NOT BE MODIFIED IN ANY WAY.

TOOLS REQUIRED :- METRIC 3/8 DRIVE SOCKET SET, METRIC RING AND OPEN ENDED SPANNERS,
TORX BIT SET, PHILLIPS AND FLAT SCREWDRIVERS, KEY HOLE SAW, DRILL AND 8 &10 mm DRILL BIT ,
SHARP KNIFE AND A WHITE PAINT MARKER .

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If you have any queries regarding the installation of this product please contact the distributor from whom it was purchased, or alternatively the ARB office in your state.

WA:[phone] NSW: [phone] ACT: [phone] SA: [phone] QLD: [phone] NT: [phone] TAS: [phone]

Head Office – ARB Corporation Ltd VIC: 42-44 Garden Street, Kilsyth, Victoria, 3137 Tel: [phone] Fax: [phone]

USE PART No QTY DESCRIPTION

IMPACT ABSORBER TO

CHASSIS

BULL BAR TO IMPACT

ABSORBER

BUFFERS TO BULL BAR

BAR

FOG LIGHTS AND

INDICATORS TO BULL BAR

WINCH TO BULL BAR

(SUPPLIED WITH FITTING

KIT 6171975 ONLY)

3756789L 1 CHASSIS MOUNT BRACKET ASSEMBLY

3756789R 1 CHASSIS MOUNT BRACKET ASSEMBLY

6151204 4 BOLT M10 x 35 x 1.5p HEX HEAD
6151321 4 NUT FLANGE M10 x 1.5
4581040 4 WASHER FLAT M10
4581048 4 WASHER SPRING M10
6151022 8 BOLT M8 x 25mm HEX HEAD
4581044 8 WASHER FLAT M8
4581046 8 WASHER SPRING M8

CR08 1 SPIRAL WRAP

6151204 8 BOLT M10 x 35 x 1.5p HEX HEAD
6151321 8 NUT FLANGE M10 x 1.5
4581040 8 WASHER FLAT M10
4581048 8 WASHER SPRING M10

3162470L 1 BUFFER 260 x 230 STANDARD

3162470R 1 BUFFER 260 x 230 STANDARD

6151128 12 NUT FLANGE M6
6821116 2 NYLON PLUG LICENCE PLATE TO BULL

6151143 2 SCREW TEK 8-18 x 20mm
6151300 4 CAGE NUT M6

6821116 4 NYLON PLUG

3756792L 1 FOG LIGHT BRACKET

3756792R 1 FOG LIGHT BRACKET

3756778L 1 COVER MOUNT BRACKET

3756778R 1 COVER MOUNT BRACKET

6821151L 1 INDICATOR COMBINATION LAMP
6821151L 1 INDICATOR COMBINATION LAMP

6821152 2 COMBINATION LAMP WIRING LOOM

180701 6 SCOTCH LOCK
6151309 6 CAPTIVE U-TYPE NUT
3162468 2 FOG LIGHT INSERT
6151317 8 SCREW 8-18 x 5/8 PAN HEAD
6151213 4 BOLT M6 x 20mm BLACK ZINK
4581082 4 WASHER FLAT M6 x 20 BLACK ZINK
4581287 4 WASHER SPRING M6 BLACK ZINK
6151308 4 SCREW 8-AB X 1” PAN HEAD
6821198 1 INDICATOR LOOM KIT

3756499 1 CONTROL BOX MOUNT

EG50 2 RUBBER GROMMET

BLB850 3 WINCH LEAD 850mm BLACK
6151074 2 BOLT 3/8” x 1 ¾” HEX HEAD
6151073 2 BOLT 3/8” x 1 ½” HEX HEAD
4581040 4 WASHER FLAT M10
4581048 4 WASHER SPRING M10
6151021 2 BOLT M8 x 20mm
6151132 2 NUT FLANGE M8
4581044 2 WASHER FLAT M8

180302 6 CABLE TIES

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USE PART No QTY DESCRIPTION

WASHER BOTTLE

SUPPORT TO IMPACT

ABSORBERS

STONE TRAY TO BULL

BAR

WASHER BOTTLE TRAY

TO BULL BAR

RETAINING FENDER
LINERS TO WASHER

BOTTLE TRAYS

AMBIENT TEMP SENDER

TO IMPACT ABSORBER

MISCELLANEOUS

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3756801 2 WASHER BOTTLE SUPPORT BRACKET
6151301 4 CAGE NUT M8
6151021 4 BOLT M8 x 20mm HEX HEAD
4581044 4 WASHER FLAT M8
4581046 4 WASHER SPRING M8
6151300 2 CAGE NUT M6
6151213 2 BOLT M6 x 20mm BLACK ZINK
4581082 2 WASHER FLAT M6 x 20 BLACK ZINK
4581287 2 WASHER SPRING M6 BLACK ZINK

6542064 1 STONE TRAY
6151300 4 CAGE NUT M6
6151213 6 BOLT M6 x 20mm BLACK ZINK
4581082 6 WASHER FLAT M6 x 20 BLACK ZINK
4581287 6 WASHER SPRING M6 BLACK ZINK

6542065L 1 WASHER BOTTLE TRAY

6542065R 1 WASHER BOTTLE TRAY

6151301 2 CAGE NUT M8
6151300 6 CAGE NUT M6
6151262 2 BOLT M8 x 20mm BLACK ZINK
4581045 2 WASHER FLAT M8 BLACK ZINK
4581047 2 WASHER SPRING M8 BLACK ZINK
6151213 6 BOLT M6 x 20mm BLACK ZINK
4581082 6 WASHER FLAT M6 x 20 BLACK ZINK
4581287 6 WASHER SPRING M6 BLACK ZINK

3757570 4 BRACKET CAGE NUT M6
6151300 10 CAGE NUT M6
6151213 10 BOLT M6 x 20mm BLACK ZINK
4581082 10 WASHER FLAT M6 x 20 BLACK ZINK
4581287 10 WASHER SPRING M6 BLACK ZINK

6151021 1 BOLT M8 x 20mm HEX HEAD
6151132 1 NUT FLANGE M8
4581044 1 WASHER FLAT M8

180302 10 CABLE TIES
3162152 2 ARIAL PLUG
6191009 1 PLASTIC SIDE MOULDING
4721542 1 WASHER BOTTLE HOSE 8mm x 400mm

VEHICLE PREPARATION

1. Remove the grill and then the headlights
from the vehicle.

2. Remove the flares from the vehicle.

3. Remove the bumper bar from the vehicle.

4. Remove the two bolts attaching the
bumper cross bar to the washer bottle.

5. Remove the inside plastic brackets and
brake off the inside sections of the outer
plastic brackets.

Remove this
section from both
outside brackets

6. On air suspension models, remove the
solenoid pack attached to the right hand
side of the crossbar.

7. Remove the crossbar from the vehicle.

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VEHICLE PREPARATION

8. Remove the air shield form the vehicle,
and remove the ambient temperature
sender from the air shield.

Short loom .

Longer relay loom .

9. To wire up the indicators from the bull bar
to the vehicle indicators a short loom must
be fitted .

A longer loom with two relays is also to be
fitted in conjunction with the short turn
signal loom .

10. Open the bag containing the long wiring
loom with relays .

Lay the loom across the engine bay from
headlamp to headlamp with the relays on
the Left Hand ( battery ) side of
the vehicle .

Place the relays on the inner guard ( as
shown ) as close as possible to the
battery .

Using a drill and a Phillips head bit attach
the relays to the vehicle with the screws
provided .

Note :­any metal part or sharp edges .

Ensure wiring will not rub on

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RED WIRE TO
BATTERY POSITIVE
TERMINAL

VEHICLE PREPARATION

BLACK WIRE TO
BATTERY NEGATIVE
TERMINAL

11. Find the clearance , indicator and earth
wires for each headlight using a test lamp.

Removal of the headlamp will make this
easier . Wire the park lamp wire ONLY AT

THIS STAGE

from the short indicator looms
into the head light looms using the scotch
locks provided .

WIRING TABLE FOR SHORT LOOM

FUNCTION INDICATOR

HARNESS

INDICATOR GREEN GREEN / WHITE GREEN / RED

EARTH BLACK BLACK BLACK

PARK LAMP RED RED / ORANGE RED / BLACK

VEHICLE COMBINATION LAMP

RIGHT LEFT

12. The remaining wires from the short loom
( tabled above ) will now in conjunction with
the longer loom - will be both wired into the
vehicles headlamp loom . The table below
lists the colour & function of the longer relay
loom .

WIRING TABLE FOR LONG LOOM

FUNCTION RELAY

BATTERY
POSITIVE

BATTERY

EARTH

VEHICLE RH

INDICATOR

BULL BAR

INDICATOR

BULL BAR

INDICATOR

VEHICLE LH

INDICATOR

BULL BAR

INDICATOR

BULL BAR

INDICATOR

HARNESS

RED ------- ------

BLACK ------- ------

GREEN /

BLACK

GREEN GREEN GREEN

BLACK BLACK BLACK

YELLOW /

BLACK

YELLOW GREEN GREEN

BLACK BLACK BLACK

SHORT INDICATOR HARNESS

RIGHT LEFT

------ ------

------ ------

13. The two wires for each common function

from both looms can now be combined and
scotch locked to the appropriate wire in the
vehicles head lamp loom . Replace the
headlamps back into the vehicle if removed .

14. Wire the positive wire to the battery and the

earth wire to the negative as shown .

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VEHICLE PREPARATION

15. With all the wiring connections now
made , feed the harness down so that it
sits neatly and retain in place with the
cable ties provided .

Note :-

Ensure all wiring will not rub or

touch on any metal parts , sharp
edges and hot or moving parts .

16. Replace the headlight and mask the flare
along the line of the headlight.

17. Remove the headlight and remove the
flare.

18. Cut the flare along the line of the
masking tape.

19. Replace the flares making sure to
replace the screw at headlight level.

20. Bend the tag that hangs down below the
line of the guard up and out of the way.

Replace screw

Bend tag

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VEHICLE PREPARATION

21. Once satisfied with the cut of the flare,
replace the headlight and the grill.

22. Clean the flare where it has been cut and
attach the plastic side moulding to the
flare.

23. Cut the plastic side moulding with a
Stanley knife along the back edge of the
flare.

24. It is recommended that the lower portion
of the bodywork below the flare cut off be
painted black. Clean the surface with
prep wash then mask the surrounding
area.

If fog lights not fitted go to step 22

25. Using a TORX bit, remove the fog lights
from the bumper bar and keep the six
retaining screws.

26. Remove the fog light wiring loom from
the bumper bar.

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VEHICLE PREPARATION

27. Unclip the headlight washer hose from the
nozzle and remove both the headlight
washers and the hose.

If air suspension not fitted go to step 23.

28. Cut the supplied spiral wrap in half. Wind
the spiral wrap around the two lower air
hoses that connect to the suspension
actuators.

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BULL BAR SETUP

Nylon plugs

29. Fit both the right and left hand buffers to
the bar using M6 flange nuts. DO NOT
OVER TIGHTEN.

30. Fit 14 M6 cage nuts (10 into the wings
and four into the main pan) and four nylon
plugs to the bar.

M6 cage nuts

31. Install the indicators into the bar using the
self tapping screws (8-AB X 1” pan head)
supplied with the fitting kits. Discard the
screws supplied with the indicators.

NOTE: The indicators should be installed
with the drain holes at the bottom

32. If there are no fog lights fitted to the
vehicle, fit the fog light insert supplied to
the bar. Fit the fog insert bracket to the
fog light insert with the eight pan head
screws as shown opposite.

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BULL BAR SETUP

27. Fit the fog light insert assembly to the bar

using two M6 x 20mm black bolts, M6 flat
black washers and M6 black spring washers.

33. For vehicles with fog lights, fit the U-type
nuts to the fog light brackets as shown
opposite.

U-type nuts

34. Using the original TORX head screws
removed with the fog lights earlier; fit the
fog lights into the fog light brackets.

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BULL BAR SETUP

Clip the fog light assembly into the indicator
bracket and fix in place using two M6 x
20mm black bolts, M6 flat black washers and
M6 black spring washers.

35. If fitted, re-fit the head light washers into
the bar using the original spring clips.

36. Run the fog light wiring loom through the
bullbar. Remove the plastic clips as
necessary.

Remove

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BULL BAR SETUP

37. Replace the small section of hose that
runs between the headlight washers with
the hose supplied in the fitting kit.

38. Run the hose through the bull bar to both
headlight washers.

Replace hose

39. Fit the fog light loom to the fog light and fit
the washer hose to the headlight washer.
Cable tie the head light loom and the
washer hose together making sure they
are away from sharp edges.

This hole can be used
to clip the wiring loom
to the bracket

WINCH FITMENT

IF NOT FITTING A WINCH GO TO STEP 47

40. If fitting a Warn winch, replace the three
cables in the control box marked A, F1
and F2 with the three 850mm cables from
the fitting kit. Mark the new cables as per
the original cables.

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g

WINCH FITMENT

41. Remove the cap head screws retaining
the gearbox to the winch drum. Carefully
lift and rotate the gearbox 144 degrees
counter clockwise (four hole spacings)
and re-fit the cap screws.

42. Lay the winch on a suitable surface and
place the bull bar on top so that the wire
rope will feed from the bottom.

43. Using two 3/8” x 1 1/2” bolts, M10 flat and
spring washers, attach the bull bar to the
winch through the top two holes

44. Using a 12mm drill bit, drill two new holes
in the roller fairlead 25mm below the
original holes.

Drill the new
hole 25mm
below ori

inal

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WINCH FITMENT

45. Remove the cir-clips from the bottom of
the vertical rollers of the fairlead and push
the pin upwards. Push the vertical rollers
inwards und using two 3/8” x 1 ¾” bolts
M10 flat and spring washers, attach the
roller fairlead to the bar.

46. Replace the circlips on the vertical rollers.

47. Insert the two rubber grommets into the
top face of bull bar.

48. Attach the control box to the control box
bracket.

49. Fit the control box to the bar with two M8
x 20mm bolts, M8 flat washers and M8
flange nuts.

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WINCH FITMENT

50. Run the cables through the rubber
grommets and connect to the winch as
per wiring diagram supplied with the
winch.

51. Using cable ties, fix the cables away from
any moving, sharp or hot surfaces.

BULL BAR FITMENT TO VEHICLE

52. Fit the six M8 cage nuts to the impact
absorbers.

53. Mount both the impact absorbers to the
vehicle using four (a side) M8 x 25mm
bolts, M8 flat and spring washers in the
front face, two (a side) M10 x 35mm bolts,
M10 flat washers, M10 spring washers
and M10 flange nuts in the underside.(
DO NOT TIGHTEN)

Left hand side

M10 bolts

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BULL BAR FITMENT TO VEHICLE

815mm

54. Centralise the mounts so that the surface
that mounts to the bull bar is vertical.

55. The mounts must be positioned so that
there is 815mm gap between the outside
surfaces of the bull bar mounting face.

56. Tighten all the bolts.

57. On the left hand side, the washer bottle
sits in front of the mount face. (Make sure
that the metal spacer in the washer bottle
tag remains in place)

58. On the right hand side, the air lines on air
suspension models run through the gap in
the impact absorber backing plate.

Spacer

59. Install two M6 cage nuts into one of the
Washer bottle brackets.

60. Attach the washer bottle bracket wit the
cage nuts installed to the left hand side
impact absorber using two M8 x 20mm
bolts, M8 flat and spring washers.

61. Fix the washer bottle to the bracket using
two M6 x 20mm black bolts, M6 flat black
washers and M6 black spring washers.

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Mount sensor here

BULL BAR FITMENT

62. Attach the washer bottle bracket without
the cage nuts to the right hand side
impact absorber using two M8 x 20mm
bolts, M8 flat and spring washers.

63. On vehicles equipped with air suspension,
attach the solenoid pack to the bracket.

64. Carefully bend the bracket that holds the
temperature sensor to 90 degrees.

65. Re-install the ambient temperature sensor
to the right hand side impact absorber
using a M8 x 20mm bolt, M8 flat washer
and M8 flange nut.

Bend the bracket
along the crease line
to 90 degrees

66. With the help of another person, lift the
bull bar into position and fix in place using
3 (a side) M10 x 35mm bolts, M10 flat
washers, M10 spring washers and M10
flange nuts. Do not tighten.

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BULL BAR FITMENT TO VEHICLE

61. Adjust the bar so there is approximately a

10mm gap between the bull bar wing and the
bottom of the flare. When the bar is in the
correct position tighten the bolts.

10mm gap

67. Using a 10mm drill bit; drill the pinning
bolt hole using the hole in the upright as a
guide.

68. Fix in place using a M10 x 35mm bolt,
M10 flat washer, M10 spring washer and
M10 flange nut. Repeat for the other side.

69. Connect the indicators to the indicator
loom. Re-connect the fog light loom,
headlight washer hose and the ambient
temperature sensor.

70. Fit the stone tray to the bar using six M6 x
20mm black bolts, M6 black flat washers
and M6 black spring washers.

M6 black bolts

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WASHER BOTTLE GUARD FITMENT TO BULL BAR

71. Fit the washer bottle guards to both sides
of the bull bar .

72. Use the three M6 x 20mm black bolts, M6
black flat washers and M6 black spring
washers to attach the guards to the wing
along the front and side edges .

73. Attach the M8 x 20mm black bolt , M8
black flat washer and M8 black spring
washer to attach the guard to the impact
absorber as shown .

74. On the right hand side of the vehicle ,
Push the out side edge of the fender liner
forward and tuck it in behind the outer
edge of the washer bottle guard .

Using a paint marker mark the upper and
lower holes ( through the guard onto the
fender liner ) .
Repeat the marking of the holes on the
Left hand side of the vehicle.

75. Using a 8 mm drill bit - drill the upper and
lower hole in the right hand side fender
liner .

76. With both the upper and lower holes
marked on the Left hand side , pull the

fender liner rearward – clear of the
washer bottle guard and drill the holes.

WARNING :- DO NOT DRILL THE

LEFT HAND FENDER LINER HOLES

IN PLACE AS THE WASHER BOTTLE

WILL BE PUNCTURED .

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WASHER BOTTLE GUARD FITMENT TO BULL BAR

77. Install the cage nut into the cage nut
bracket as shown below .

78. Insert the cage nut bracket up through the
access hole and line up the hole in the
fender liner and bottle guard , use the M6
hardware supplied to bolt the fender liner
to the washer bottle guard .

Repeat for the lower hole and for the Left
hand side . Break off the excess length

of cage nut bracket when finally
secured .

79. Trim the inner guard in line with the lower
edge of the washer bottle cover .

80. Using the washer bottle guard as a
template mark the position of three cage
nuts located on the rear fold with a paint
marker onto the fender liner .

Drill Using a 8 mm drill bit - drill the three
holes .

81. To fit the license plate to the bar, first
push two nylon plugs into the front face of
the top pan. Fit the license plate using two
8-18 x 20mm tek screws .

82. Ensure all lights are functioning correctly
and all bolts are fully tightened .

Also supplied in the kit are two 16mm plugs. The two plastic plugs are for the holes in the top
surface of the wings if no CB aerials are fitted.

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