ARB 3915040 User Manual

Part Number:

Product

3915040/050 F/Kit 6172323 ARB SAHARA BAR

Description: Suited to

TOYOTA LANDCRUISER 200 SERIES 2007 ON

vehicle/s:

3915040 NO HLC & 3915050 WITH HLC (SAHARA)

WARNING

REGARDING VEHICLES EQUIPPED WITH SRS AIRBAG;

When installed in accordance with these instructions, the front protection bar does not affect operation of the SRS airbag.

ALSO, NOTE 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.

♦

The installation of this product may require the use of specialized tools and/or techniques

♦

It is recommended that this product is only installed by trained personnel

♦

These instructions are correct as at the publication date. ARB Corporation Ltd. cannot be held responsible for the impact of any changes subsequently made by the vehicle manufacturer

♦

During installation, it is the duty of the installer to check correct operation/clearances of all components

♦ Work safely at all times

♦

Unless otherwise instructed, tighten fasteners to specified torque

ARB 4x4 ACCESSORIES

42-44 Garden St Tel: +61 (3) 9761 6622 Kilsyth, Victoria Fax: +61 (3) 9761 6807 AUSTRALIA 3137

Australian enquiries sales@arb.com.au North & South American enquiries sales@arbusa.com Other international enquiries exports@arb.com.au

Corporate Head Office

www.arb.com.au

Last Rev Date: 28 OCTOBER 2008 Page 1 of 22 Fitting instructions# 3781218

GENERAL CARE AND MAINTENANCE

By choosing an ARB Bar, you have bought a product that is one of the most sought after 4WD products

in the world. Your bar is a properly engineered, reliable, quality accessory that represents excellent value. To keep your bar in original condition it is important to care and maintain it following these recommendations:



Prior to exposure to the weather your bar should be treated to a Canuba based polish on all exposed surfaces. It is recommended that this is performed on a six monthly basis or following exposure to salt, mud, sand or other contaminants.



As part of any Pre Trip Preparation, or on an annual basis, it is recommended that a thorough visual inspection of the bar is carried out, making sure that all bolts and other components are torqued to the correct specification. Also check that all wiring sheaths, connectors, and fittings are free of damage. Replace any components as necessary. This service can be performed by your local authorized ARB Stockist.

FITTING REQUIREMENTS

REQUIRED TOOLS FOR FITMENT OF PRODUCT:

Metric socket and spanner sets 8-25mm range

Screwdrivers, Philips and Flat blade Power Jigsaw with blade for plastic cutting

Short Body Power Drill 13mm (1/2”) capacity Dia 7.0mm (5/16”) and 10.5mm (25/64”) drill bits

Tin snips Marking pen

Half round file Soft Hammer

Metric hex key set Loctite© 262 or equiv.

Wide masking tape Stanley knife

Small Spirit Level Tape Measure & 2 x 300mm rulers

If fitting parking sensors: Dia 22.0 (7/8”) hole saw Paint black fast drying

External Circlip pliers

HAVE AVAILABLE THESE SAFETY ITEMS WHEN FITTING PRODUCT

Protective eyewear

NOTE: ‘WARNING’ notes in the fitting procedure relate to OHS situations, where to avoid a potentially hazardous situation it is suggested that protective safety gear be worn or a safe work procedure be employed. If these notes and warnings are not heeded, injury may result.

Hearing protection

FASTENER TORQUE SETTINGS:

SIZE Torque Nm Torque lbft

M6 9Nm 7lbft

M8 22Nm 16lbft

M10 44Nm 32lbft

M12 77Nm 57lbft

Last Rev Date: 28 OCTOBER 2008 Page 2 of 22 Fitting instructions# 3781218

APPLICATION. PART NO. QTY DESCRIPTION

Mount Brackets To Chassis

Brace Assembly

Bull Bar To Mount Bracket Assy

Stone Tray to Bull Bar

Winch To Bull Bar

Number Plate To Bull Bar

If Not Fitting Winch

Wing Inner Panels

Buffer fasteners

Lights

PARTS LISTING

Bracket Mount RHS

3757602R

3757602L

6151429 6151428 6151396 5846400

4681274 6151357 6151321

6151357 6151321 6151255 6151189 4581049 4581050 6522683 6151300 6151213 4581082 4581287 6151270 4721518 3756499 6151234 4581045 4581047 6151132

180302

EG50 6151074 6821189 6151384 6781408

6522695 6191013 6151256 4581304 6151128

6522685R

6522685L

6151300 6151213 4581082 4581287 6151234 4581045 4581047 6151132 6151128 12 Nut M6 Flanged

3163015

6821151R

6821151L

6821152

180701 180302

1 1 2 2 2 2

1 7 7

2 2 6 6

6 1 4 4 6 6 2 2 1 2 2 2 2 8 2 2 2 2 1

1 1 2 4 2 1

1 10 10 10 10

1PR

Bracket Mount LHS Chassis Stud M12 x 265 x1.75 Flange Nut M12 x 1.75 Nut Clevis Packer M12 x 8mm

Brace SEMS Bolt M10 x 1.5 x 30mm Nut Flanged M10 x 1.5

SEMS Bolt M10 x 1.5 x 30mm Nut Flanged M10 x 1.5 Bolt M12 x 1.75 x 40mm Nut M12 x 1.75 Washer Flat M12 Washer Spring M12 Stone Tray Nut Cage M6 Bolt M6 x 20mm Washer Flat M6 x 16 x 3 Washer Spring M6 Bolt M6 x 40 Spacer Tube 18mm Bracket Control Box Univ. Bolt M8 x 25 Washer Flat M8 BZ Washer Spring M8 BZ Nut M8 Flanged Cable Tie Grommet Dia 50mm Bolt 3/8 x 1 3/4 Grommet round Screw self tapping pan head Tape double sided

Winch Panel Extrusion Screw M6 x 15 st stl Dome Head Washer M6 St Stl Nut Flanged M6 Panel Inner Wing RH Panel Inner Wing LH Nut Caged M6 Bolt M6 x 20 Blk Washer Flat M6 Blk Washer Spring M6 Blk Bolt M8 Washer Flat M8 Washer Spring M8 Nut M8 Flanged

Light Surround Set Indicator Indicator Loom Scotch Locks Cable Ties

Last Rev Date: 28 OCTOBER 2008 Page 3 of 22 Fitting instructions# 3781218

Trim Pinch Weld

6191020 3786342

EG50

Miscellaneous

6151415 4581040 4581048 5868356

Template Bumper Cutting

Grommet Dia 50mm

Cap Screw M10 x 40 ZP

Washer Flat M10

Washer Spring M10

Packer

OPTIONAL LIGHT SETS TO SUIT THIS PRODUCT:

♦ FOG LAMP SET P# 6821201 ADD GXL ONLY P#MD02 LOOM KIT, P#180209 SWITCH AND

P#180215 SWITCH CAP FOR FOGS

♦

UP TO IPF 900 SERIES FOG OR DRIVING LIGHT SETS

♦ IPF 840 FYS FOG LIGHTS CAN BE FITTED TO LOWER PAN AREA

AVAILABLE BUFFER/FRAME SETS:

♦

5100140 BUFFER SET ONLY WITH FRAME HOLE

♦

5100150 BUFFER SET ONLY BLANK

♦

5115010 FRAME ASSEMBLY (NOTE: FASTENERS ARE WITH THIS BAR KIT)

Last Rev Date: 28 OCTOBER 2008 Page 4 of 22 Fitting instructions# 3781218

REMOVAL OF BUMPER

1. Remove number plate

2. Remove number plate mount bracket

3. Remove inner guard bumper retaining

screws three per side using M4 hex key

4. Remove lower trim panel sets each side

which attach to bumper and engine protective plate area then set aside, they will not be reused.

Last Rev Date: 28 OCTOBER 2008 Page 5 of 22 Fitting instructions# 3781218

REMOVAL OF BUMPER

5. When removing lower trim panels, a

plastic nut located on each side will need to be prized open with a small flat blade screwdriver to assist removal.

6. Remove lower bumper retaining screws.

7. Remove plastic engine bay cover above grille area and set aside. Prise open plastic plugs with small flat blade screwdriver or similar as shown.

8. Remove 3 x retaining screws from top of grille

Last Rev Date: 28 OCTOBER 2008 Page 6 of 22 Fitting instructions# 3781218

MASKING BUMPER FOR TRIMMING

9. Apply wide masking tape edge, carefully aligning 10mm above bumper feature line as shown. Keep the same line level through the centre section of the buffer as shown

Hint: Using a marking pen, run a line or dashed lines along the feature line on the bumper to assist in measuring the 10mm offset for the tape application.

10. Mark out centre cut area of bumper as shown, 740mm wide x 30mm back from feature edge.

11. View of masking tape and cut line across bumper for reference.

12. Apply approx.200mm of masking tape with edge exactly 90mm from angled bumper end as shown.

Last Rev Date: 28 OCTOBER 2008 Page 7 of 22 Fitting instructions# 3781218

+ 15 hidden pages

ARB 3915040 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual