FITTING INSTRUCTIONS FOR: ACCESSORY PART NUMBER: …

ISSUE 3: 27/02/2019 PART NUMBER: PZQ6442100 PAGE 1 OF 12

PLACE THESE INSTRUCTIONS IN VEHICLE GLOVEBOX AFTER INSTALLATION IS COMPLETE

This kit weighs in excess of 40kg.Seek help to lift if required.

! CAUTION

Wash with regular car wash products.Regularly check bolt torque settings.

CARE INSTRUCTIONSApproximately 90 minutes.

INSTALLATION TIME

RAV4PRODUCTION DATE: JANUARY 2019

FITTING INSTRUCTIONS FOR:ACCESSORY PART NUMBER: PZQ6442100

CLASS 4 TOW BAR

This product is not compatible with Weight Distribution Systems

! CAUTIONWhen not towing, the tongue must be removed and stored safely. Toyota recommends that the tongue not be

stored in the vehicle.

! CAUTION


KIT CONTENTS

1 2 4Fitting Instructions Tow Bar Tongue

CHECK THAT THE CONTENTS OF THE TOW BAR KIT ARE COMPLETE & UNDAMAGED PRIOR TO FITMENT.! IF ANY CONTENTS OF THE TOW BAR KIT ARE INCOMPLETE OR DAMAGED

THEY MUST BE REPLACED USING SPECIFIED ACCESSORY COMPONENTS.!

x1 x1 x1

5 Flat side arm RHS & LHS

x2

SAMPL

E ONLY

3 Shims

x2

6

x1

7Bent side arm RHS

x1

9 Pull Pin & R clip

x1

10 Fasteners

8Bent side arm LHS

x1

Anti Rattle Set

10 Hitch Box Collar

see Bill Of Material x1

11 Bumper Trim Pinch Weld

x1

12 Shims

x3

13 Torque Wrench Adapter

x1


TOOLS REQUIRED

1 2 3 4Protective tape Metric sockets & spanners Torque wrench Sharp knife

5 6 7Jigsaw Drill Phillips head screwdriver

8,10,12,13,14,17&18mm

8 Body Clip Tool

9 Side Cutters


ITEM NO. DESCRIPTION QTY.

1 TOWBAR WELDED ASSEMBLY 1

2 TONGUE 1

3 SHIM 2

4 FLAT SIDE ARM RHS & LHS 2

5 BENT SIDE ARM RHS 1

6 BENT SIDE ARM LHS 1

7 PULL-PIN 1

8 R-CLIP 1

9 SET SCREW M12 x 50 x 1.25 4

10 SET SCREW M12 x 30 x 1.25 8

11 NUT SCREW M12 x 1.25 4

12 Anti Rattle Nut M10 x 1.5 1

13 Anti Rattle Screw M10 1

14 Hitch Box Collar 1

15 Bumper Trim Pinch Weld - 850mm 1

TOW BAR ASSEMBLY

PARTS LIST Check contents of kit before commencing & report any discrepancies.

This tow bar is to be used for trailer towing only.

CAUTION!

4

1

2

9

- M12 Fastener Torque: 150 Nm

- M10 Fastener Torque: 40 Nm

M12

M12

M12

4

7

8 10

3

5

6

10

10

12

11

11

10

3

9

1314

15

M10

M10

1617

ShimsTorque Wrench Adapter 1/2 to 17 AF

31

16

17

Refer to Appendix A for altered torquewhen using Torque Wrench Adapter

! CAUTION


STEP 1

STEP 2

STEP 3

STEP 4

Remove the 2 x clips and 1 x screw from the inside of the wheel arch. Repeat for other side.

For the RHS remove two outer clips holding the mudflap and rotate out of the way.

On LHS remove one clip to rotate mudflap out of the way.

Dislodge the rear wheel arch moulding.

1. For standard grade:By releasing 4 x moulding clips from forward side with trim tool

2. For high grade:Garnish unclips by pulling outwards.

Remove the screws holding the mud guard to the fender liner. Repeat for other side.

Disconnect the -ve battery terminal. For HV this is in the boot on the RHS.

Screw

Remove clip holding bumper to body panel

10

10

HV

LHS

RHS

10


STEP 5

STEP 6

STEP 7

STEP 8

Remove the 2 long clips from the lower bumper cover to the sheet metal under the car.

Unclip the cover plate next to the tail lamp to access the bumper attachment screw. Repeat for other side.

Unclip by hand.

Disconnect the WH from the LHS of the bumper allowing the bumper cover to be removed from the vehicle.

Remove the 4 screws holding the bumper cover to the vehicle.

Unclip the bumper cover starting at the wheel arch.

10

1 each side


STEP 9

STEP 10

STEP 11

STEP 12

Remove the 8 x plug hole stickers from the chassis rails inside and outside left and right to expose the M12 mounting weld nuts.

Loosely secure the Inboard and Outboard sidearms on the RHS with 4 x M12x30 bolts (Item 10).

Repeat for LHS.

Remove the 6 x M10 bolts holding the bumper beam. Discard bumper beam and bolts.

Remove the 2 x M12 bolts attaching the OE tow hook

Discard tow hook and replace the bolts in the holes. Torque to 66Nm.

14

17

17 17

BOTH LHS & RHS


STEP 13

STEP 14

STEP 15

STEP 16

Hand tighten all bolts.

Loosely attach the Towbar Welded Assy (Item 1) to the side arms (Item 4,5&6) using 4 x M12x50mm bolts & M12 nuts (Item 9&11).

Hand tighten RHS sidearm x Towbar bolts.

Torque all bolts as per the torques shown on page 4. Start with 8 x chassis attachment bolts and then 4 x side arm at-tachment bolts.

For most bolts into the chassis the Torque Wrench Adapter (Item 17) will be required due to limited clearance.NOTE: Refer to Appendix A for altered torque value!

Shim selection: On LHS take 2x1mm, put them between the side arms and the centre section’s end plate.

17 17

17 17

17 17

17


STEP 17

STEP 18

STEP 19

STEP 20

Re-install the bumper into the vehicle using the original fas-teners. Ensure electrical connectors and harnesses are recon-

Check that no removed fasteners are remaining.

Fit the hitch box collar (Item 14) on the hitch box.

Place top edge of collar on hitch box and tap lower edge intoplace with a rubber mallet.

Cut bumper as per templates attached. Ensure the template is centred to the bumper and joined as indicated.

Note: Check dimensions on template are correct with ruler to scale.

Note: Do NOT cut the plastic reinforcement on front loweredge.

Attach pinch weld as shown.

Trim the inside at the join line between the upper and lower.

Trim inside

NOTE: Fit trailer wiring harness before refitting bumper.

Insert the tongue (Item 2) into the hitch box with the pull pin (Item 7) and R- clip (Item 8).


STEP 21

STEP 22

STEP 24

Insert the anti ratle nut (Item 12) & bolt (Item 13) under the hitch box.

Torque the bolt and nut as per the torque shown on page 4.

driver’s side door.

16

STEP 23

STEP 24

Assess tongue (Item 2) clearance condition in the hitch box. If loose, trial fit shims (Item 17) on vertical and horizontal faces and select appropriate number of shims to minimise tongue movement. NOTE: Ensure that tongue can be easily inserted and removed.

Drill holes in tongue as per template attached and paint or apply anti-corrosion material to drilled surfaces.

Install required shims into drilled holes and bend tabs overinside of tongue tube to hold shims in place.


STEP 25Re-connect the battery negative terminal.

Ensure battery negative terminal is tightened to: Torque: 5.0Nm

10


APPENDIX A

IMPORTANT! The value on your Torque wrench will need to be adjusted when using the TorqueWrench Adapter (Item 17). Refer to the calculation or table below to determine the new torque value depending on the lengh of tools used.

M1 = M2 x L1 / L2

Where:M1 = torque setting for wrenchM2 = torque required at nut (M12 = 150Nm, refer page 4)L1 = normal length of torque wrenchL2 = extended length of wrench (with Torque Wrench Adapter)

M1 torque setting at wrench for 150Nm torque at nut:L2 EXTENDED LENGTH

(mm)M1 TORQUE SETTING AT WRENCH

(Nm)730 123720 123710 123700 122690 122680 121670 121660 120650 120640 120630 119620 119610 118600 118590 117580 116570 116560 115550 115540 114530 113520 113510 112500 111490 110480 109470 109460 108450 107440 106430 105

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FITTING INSTRUCTIONS FOR: ACCESSORY PART NUMBER: …