hilux / fortuner

Fitting Time: 30 minutes

July 2015 Production OnwardsKit Part No: PZQ59-89050

Driving Lamp Harness

Fitting Instructions

Kit Part No: PZQ59-89030

HILUX / FORTUNER

FI Doc No: - Issue: 3 - 08PZQ59-89050FI /10/15 19

A

Engine Harness x1

B

Cabin Harness x1

K

Cable Tie x50

D

Relay x1

E

Relay Bracket x1

F

Switch x1

G

Relay Connector Base x1

H

M6 Nyloc x1

I

M6 Flat Washer x1

Phillips & Flat HeadScrew Drivers Ratchet Sockets

Ø10mm Ø3mm

Clip Remover Tool Wire Cutters 3mm Drill Bit

Drill Ø19mm Stepped Drill bit Trim Removal Tools Hand File Masking Tape

J

M6 Bolt x1

--- Tools Required ----------------------------------------------------------------------------------------------------------------------------------

--- Parts Supplied -----------------------------------------------------------------------------------------------------------------------------------

Page 02 of

- Read through the fitting instructions before installation of accessory.

- Always install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or the accessory.

- Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local recycling regulations.

- It is always recommended that this accessory is fitted by a qualified Toyota Technician.

- Safely store and protect any removed vehicle components.

- Ensure all bare metal surfaces are protected using Automotive Bare Metal Primer and touch-up paint.

- Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.

- Check that all work practices comply with safety standards.

- Please wear appropriate clothing and use safety equipment.

30 minutes

General Notes

Safety Notes

Fitting Time

M

Template x1

Mini Blade Fuse x1

L

Patch Harness x1

C

HILUX / FORTUNER


--- Step 1 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 2 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 3 ---------------------------------------------------------------------------------------------------------------------------------------------------

Page 03 of

Important

Always refer to the vehicle’s Workshop Manual when removing vehicle components.

• Note down all clock and radio settings.

• In the engine bay, disconnect the negative battery terminal (1).

Always refer to the workshop manual for assistance with parts removal.

2

1

• Rotate the steering wheel to the right to gain access to the steering wheel surround RH fastener (1).

Remove RH fastener (1).

Repeat for LH fastener (not shown).

Remove the lower steering surround fastener (2).

•

•

•

• Remove cluster surround (1) by removing two screws (2).

For vehicles fitted with leather trim.

•

•

•

Dislodge the c luster surround (3).

Unclip the dust cover if present.

Remove the c luster surround (3).

Leather trim vehicle

1

3 4120

1

2

3

HILUX / FORTUNER


--- Step 4 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 5 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 6 ---------------------------------------------------------------------------------------------------------------------------------------------------

Page 04 of

HILUX / FORTUNER


For Fortuner models only.

• Remove the vent cover (1).

• Remove the audio side trim on both the LH and RH (2).

• Unclip the upper glove box (3) and remove.

3

1

• Unclip the glove box dampener (1) if present.

Remove LH retaining clip (2) by rotating anti-clockwise.

Remove the glove box (3).

•

•

if present• Remove the passenger lower dash garnish (4) .

4

2

2

1

For Hilux models only.

• Dislodge and remove dash trim (1).

• Unclip the upper glove box (2) and remove.

Proceed to step 7.

1

2

3

--- Step 7 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 8 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 9 ---------------------------------------------------------------------------------------------------------------------------------------------------

Page 05 of

HILUX / FORTUNER


• In the passenger side cabin area, remove the LHS scuff plate (1).

1

1

2

• Remove the fastener (1) from LHS kick panel (2) and remove the panel (2) from the vehicle.

2

1

For Hilux models only.

• Remove heater control knobs (1) & radio surround trim (2).

Proceed to step 12.

of

For SR5 model only.

• Dislodge and remove heater control panel (1).

Unclip and remove any connectors (2) & aircon vents (3) from the back of the heater control panel (1) .

•

1

2

3

For Fortuner models only.

• Remove heater control knobs & dislodge the radio surround trim (1).

Proceed to step 12.

1

• Remove the four screws (1) s ecuring the audio unit (2).

• Dislodge and remove the audio unit, disconnecting all connectors.

21

1

--- Step 10 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 11 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 12 ---------------------------------------------------------------------------------------------------------------------------------------------------

HILUX / FORTUNER


--- Step 13 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 14 ---------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 15 ---------------------------------------------------------------------------------------------------------------------------------------------------

Page 07 of

• Dislodge the cluster (1) by removing the four screws (2).

• Disconnect all cluster connectors and clips and then remove the cluster (1).

• Remove the two fasteners (3) from the cluster (1) if present.

• Secure the Engine Harness (1) to the guide wire (2).

• Cut the LHS access point (3).

Note: If LHS access point is occupied, use the RHS access point.

• Feed the guide wire (2) into the firewall grommet (4).

• Feed through until the harness loop (5) reaches the grammet and is facing down.

• Seal with silicon, then cable tie (6) around the access point.

3

2

4

1

2 2

2 21

3

1

5

1

2 6

• Route Engine Harness (1) towards the battery, following the vehicle harness down the LHS of the engine bay.

Cable tie (2) Engine Harness (1) in the locations shown. •1

2

2

HILUX / FORTUNER


--- Step 16 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 17 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 18 -------------------------------------------------------------------------------------------------------------------------------------------------

Page 08 of

If vehicle is fitted with accessory fuse block continue with step 17 otherwise skip to step 19.

• Remove the accessory fuse block cover (1).

• Disconnect the accessory fuse block (2) from its mounting bracket (3).

• Using side cutters, remove and discard the cable tie (4) from the wire bundle.

• Unclip and dislodge the fuse holder (5) from fuse block (2).

1

2

3

5

3

For vehicles fitted with Accessory fuse block, skip to step 17.

• Remove fuse from engine harness in-line fuse connector (1).

Route the fused orange wire 8mm ring terminal (2) to the positive battery terminal (3).

Secure the vehicle harness positive battery ring terminal (2) to the back section of the battery positive terminal (3) using the existing nut (4).

Secure harness with Cable ties every 200mm.

Skip to Step 19.

•

•

•

2 1

Important

Ensure audible "Click" is heard.

Important

• Feed the Driving lamp harness orange terminal wire (1) through the fuse block funnel.

• Insert the orange wire fuse terminal (2) into the cavity as shown.

• Secure cables with Cable tie (3) where shown.

Replace accessory fuse box onto the mounting bracket (4).

3

12

34

56

78

910

Important

Check Fuse Terminal retention.

Important

2

1

4

4

2

3

HILUX / FORTUNER


--- Step 19 -------------------------------------------------------------------------------------------------------------------------------------------------

Step 20 -------------------------------------------------------------------------------------------------------------------------------------------------

Step 21 -------------------------------------------------------------------------------------------------------------------------------------------------

Page 09 of

• Route the Engine Harness (1) towards the LHS head lamp following the vehicle harness.

• Cable tie (2) the Engine Harness (1) to the vehicle harness every 200mm.

Note: Dislodge and move battery to gain access to M6 earth bolt at junction connectors on fender.

• Using the existing M6 earth bolt (1), fasten ring terminal (2) to the vehicle body.

1

2

1

2

2

2

• Route the Driving Lamp Connectors (1) under the LH head lamp, following the vehicle harness.

• Cable tie every 200mm.

• Route the Driving Lamp Connectors across the bumper support towards the center of the grille support (2).

1

1

2

HILUX / FORTUNER


--- Step 22 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 23 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 24 -------------------------------------------------------------------------------------------------------------------------------------------------

of

• Following the vehicle harness, route the Driving Lamp Connectors (1) across the bumper support and up the centre support bracket (2).

• Cable tie every 200 mm.

• Cut out the switch template provided on page 18.

• Line up the template with edges of the lower steering surround trim (1) and adhere the template to the trim using masking tape.

• Drill a 3 mm pilot hole in the drilling point.

• Discard the template.

• Using a stepped drill bit, drill out the pilot hole to

• Smooth and deburr any sharp edges from the hole using a file.

Ø19 mm.

Important

If vehicle is fitted with Winch Kit, OE Harness and Driving Lamp Harness needs to be moved for clearance.

1

1

2

1

• In the cabin on the driver’s side locate the 20-Way connector (1) on the steering column switch assembly and disconnect.

HILUX / FORTUNER


Ensure the vehicle harness is followed carefully. Adjust the steering column up, down, in and out and check for harness pinch points and snags.

--- Step 25 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 26 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 27 -------------------------------------------------------------------------------------------------------------------------------------------------

2

of

• Connect the Driving Lamp Cabin Harness male and female T-Patch connectors (1) to the steering column switch connectors (2).

• Route the Cabin Harness (1) down the steering column following the vehicle harness.

• Cable tie (2) every 100 mm where shown.

1

2

1

HILUX / FORTUNER


2

2

1

2

2

1234

2

• Insert the Driving Lamp Switch (1) into the previously drilled out hole (2) and tighten the locking nut (3).

• Connect the Cabin Harness terminals (4) to the switch (1).

--- Step 28 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 29 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 30 -------------------------------------------------------------------------------------------------------------------------------------------------

of

• Following the vehicle harness, route the Cabin Harness (1) up the RH driver's side towards the RH side of the cluster cavity.

Route the Cabin Harness (1) across the cluster cavity, following the vehicle harness.

Cable tie (2) every 200mm where shown.

•

•

• Route the Cabin Harness (1) across the audio unit cavity towards the glove box cavity, following the vehicle harness.

• Cable tie (2) the harness to the vehicle harness every 200mm.

1

1

2

2

• Route the Cabin Harness (1) across the glove box cavity unit towards the passenger LHS, following the vehicle harness..


1

22

2

HILUX / FORTUNER


--- Step 31 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 32 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 33 -------------------------------------------------------------------------------------------------------------------------------------------------

• From inside the cabin in the glove box area, retrieve the previously routed Engine Harness (1) from the firewall grommet (2).

of

2

1

• Locate the 40-way combimeter connector (1).

• Apply the Driving Lamp Patch Harness Scotch Lock (2) to the combimeter connector BLUE wire (3), Pin 1.

•

•

Route the Driving Lamp Patch Harness (4) across the cluster cavity, following the vehicle harness.

Cable tie (5) every 200mm where shown.

4

5

22

33

1Pin 1

FRONT FACE OF CONNECTOR

40-way Connector

• Route the Driving Lamp Patch Harness (1) across the audio unit cavity towards the glove box cavity, following the vehicle harness.


1

2

HILUX / FORTUNER


--- Step 34 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 35 -------------------------------------------------------------------------------------------------------------------------------------------------

of

• Route the (1) across the glove box cavity unit towards the passenger LHS, following the vehicle harness.

Driving Lamp Patch Harness

• Cable tie (2) the harness to the vehicle harness every 200mm. 1

2

22

A

B6

1

6

• Disengage the relay holder secondary lock (1).

• On the Engine Harness, locate the large red wire terminal (2) and house that terminal into the supplied relay connector (6) into position [A].

• House the large orange wire (3) terminal in position [B].

• On the Driving Lamp Patch Harness, house the small blue wire (4) terminal in position [C].

• On the Cabin Harness, house the small white wire (5) terminal in position [D].

• Re-engage the secondary lock (1).

2

3

C

5

4

HILUX / FORTUNER


--- Step 36 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 37 -------------------------------------------------------------------------------------------------------------------------------------------------

of

21

2

3

• Connect the relay (1) to the relay holder (2) & connect the relay holder (2) to the relay bracket (3).

1

10mm• On the Engine Harness, locate the small orange wire terminal

(1).

• Using side cutters, remove the small orange wire terminal (1) by cutting the wire

• Fold back the orange wire end (2) and tape wire end to pvc tube (3) using pvc tape (4).

approximately 10mm back from the terminal (1).

2

34

Important

Ensure wire end is completely insulated by PVC tape.

HILUX / FORTUNER


--- Step 38 -------------------------------------------------------------------------------------------------------------------------------------------------

--- Step 39 -------------------------------------------------------------------------------------------------------------------------------------------------

21

of

• Remove the ECU bracket front bolt (1) and loosen the rear bolt (2) from the ECU bracket (3).

• Slide the Relay Bracket assembly (4) between the ECU Bracket (3) and the ECU (5).

• Secure the Relay Bracket (4) by using the previously removed front bolt (1).

• Tighten both bolts (1)(2).

Note: ECU bracket (3) may vary depending on vehicle models.

For Lamps with suitable connector:

• Connect the LHS 2-pin female Driving Lamp Harness connector (1) to the LHS driving lamp connector (2). Ensure an audible “click” is heard.

• Repeat for the RHS.

Go to Step 41.

2

1

If Driving Lamps are not fitted with suitable 2-pin driving lamp connector, continue:

• Fit Driving Lamp Harness (1) to the driving lamp (2) by cutting the driving lamp wiring harness to the suitable length then strip the driving lamp wiring harness to 6 mm [A].

Note: 2-pin driving lamp connectors can be discarded.

• Feed the solder sleeves to each of the Driving Lamp and Harness wires then over lap the strip in the solder sleeve [B] joint and heat the solder sleeves using a heat gun [C].

• Ensure that the solder sleeve has been taken by the two wires in the joint.

--- Step 40 -------------------------------------------------------------------------------------------------------------------------------------------------

12

3

5

4

HILUX / FORTUNER


--- Step 41 -------------------------------------------------------------------------------------------------------------------------------------------------

of

• Mount the Driving Lights on to the bull bar by referring to the driving lights fitting instructions.

--- Step 42 -------------------------------------------------------------------------------------------------------------------------------------------------• For vehicles fitted with accessory fuse block:

- Insert the supplied 20A mini blade fuse (1) into the wired slot.

• For vehicles fitted with ring terminal power wire fastened directly to the positive battery terminal:

- Insert 20A fuse to inline fuse holder.

12

34

56

78

910

1

--- Step 43 -------------------------------------------------------------------------------------------------------------------------------------------------• Ensure all sections of the driving lamp harnesses are secured to

the existing vehicle harness every 200 mm using the supplied cable ties.

• Reconnect the negative battery to Test the operation of the driving lamp.

• The driving lamps should only be functional when high beams engaged and the driving lamp switch is engaged.

Important

Refit all removed parts and secure all fasteners to the Service Manual torque specifications.

Please place the in the glov box after installation completed.

Fitting Instructions e is

Important

Positive Battery Ring Terminal Nut Torque to be tightened to 13 Nm.

Important

Post Terminal Torque to be between 2.9 ~ 7.8 Nm.

Important

Earth Bolt Torque to be between 6.9 ~ 9.8 Nm.

Cable tie the Driving Lamp Harness to the vehicle harness every 200mm. Ensure the harness is not crushed or stretched during Driving Lamp Harness installation.

Reprogram all radio stations and clock settings by referring to the vehicle's owner manual.

HILUX / FORTUNER


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Harness Diagram

CabinEngine Bay

10 20

1

11

Fir

e W

all G

rom

met

+12V

Battery

+12V

Rin

g T

erm

inal

(Alte

rnativ

e: A

ccess

ory

Fuse

Blo

ck)

20A

O

R

RD

BK

21

RD

BK

2

BK

Eart

h R

ing T

erm

inal

Lo

cati

on

: LH

S P

anel (

Engin

e B

ay)

1

Dri

vin

g L

am

p

Sw

itch

Lo

cati

on

: S

teering C

olu

mn

Surr

ound

Dri

vin

g L

am

p

Rela

y L

ocati

on

: R

ear

Glo

ve B

ox

Cavi

ty

BL

RD

WH

OR

Drivi

ng L

am

p C

onnect

ors

(F

ront B

um

per/

Bullb

ar)

l

Lo

cati

on

: S

teering C

olu

mn

Surr

ound

Pin

17 -

HI-

Beam

20-P

in F

em

ale

C

onnect

or

T-P

atc

h.

WH

OR

BL

Pin

1 -

HI-

Beam

Indic

ato

r40-P

in F

em

ale

C

onnect

or

Sco

tch L

ock

Lo

cati

on

: C

om

bim

ete

r

2A

1

20

40

21

1

TERM

.C

OL.

BK

GN

D

1 2

RD

BK

TERM

.C

OL.

LH D

RIV

ING

LA

MP

TERM

.

1 2

CO

L.

RD

BK

RH

DR

IVIN

G L

AM

P

1

TERM

.C

OL.

OR

BAT

T+

1 2

OR

OR

TERM

.C

OL.

FUS

E

TERM

.

1

CO

L.

OR

2

+12VFU

NC

TIO

N

OR

+12V

(RLY

)

3R

DLA

MP

+

RE

LAY

1 2

BL

BL

TERM

.C

OL.

FUS

E

HILUX / FORTUNER


hilux / fortuner

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