Kit Part No: PZQ59-60140 August 2017 Production Onwards ...

FI Doc No: PZQ59-60140FI - Issue: 2 - 10/02/20

PRADO

17Page 01 of

Driving Lamp Harness

Fitting Instructions

DRAFTTO BE FINALISED

Checkers Initials

Date Checked

Fitting Time: 60 minutes

August 2017 Production Onwards

Kit Part No: PZQ59-60140

DRAFTTO BE FINALISED

Checkers Initials

Date Checked

Tail Patch Harness (PZQ59-00170) will need to be purchased separately and installed during this installation.


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17

Parts Supplied

Additional Required Parts

- 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.

Engine Harness x1 Cabin Harness x1 Relay x1Relay Bracket (not used) x1

A B C D

- Check that all work practices comply with safety standards.

- Please wear appropriate clothing and use safety equipment.

60 minutes

1-way Connector x1

E

Switch x1

F

M6 Nut(not used) x1 Cable Ties - 200mm x20

G H I

Fir Tree Clip Cable Tie (not used) x1

J

Edge Clip(not used) x1

K

A5 Flyer x1

L

DL Flyer x1

Tail Patch Harness(PZQ59-00170) x1

A

Cable Ties - 200mm x6

B C

1-Way Male Connector x1

D

Foam Tape (120x30x3mm) x1

E

Scotch Lock Housing x1

General Notes

Safety Notes

Fitting Time

Page 02 of

Live a Genuine Life

www.toyotamanuals.com.au/accessories

T2

01

5-0

00

68

9 P

SA

00

68

0

Congratulations on purchasing your Toyota Genuine Accessory.

Correct installation of your Accessory is critical to ensuring its performance and safe

operation. Before commencing installation, please consider if you have the appropriate

technical skills to successfully install this product.

Fitting instructions are available on the Toyota Service Information & Repair Manuals

website at www.toyotamanuals.com.au/accessories.

To view or download fitting instructions, enter the Accessory part number without the dash.

The part number is found on the barcode label located on the outside of the Accessory

packaging as shown below.

Please follow the fitting instructions closely using the tools specified. If cutting or drilling

templates are required, set the page scale to “none” in the print menu prior to printing.

Always confirm the template size by measuring the scale indicator before cutting or drilling.

To the extent permitted by law, Toyota Australia excludes all liability which may arise because

a user of this publication fails to follow directions in the publication.

If you have any queries regarding the installation of your Toyota Genuine Accessory, please

contact your nearest preferred Toyota Dealer.

ote m“npolnaete” si na rthee r epqriunitr emd,e nseut pthrieo r ptaog per isnctianlge. t

ote m“npolnaete” si na rthee r epqriunitr emd,e nseut pthrieo r ptaog per isnctianlge. tote m“npolnaete” si na rthee r epqriunitr emd,e nseut pthrieo r ptaog per isnctianlge. t



ote m“npolnaete” si na rthee r epqriunitr emd,e nseut pthrieo r ptaog per isnctianlge. tote m“npolnaete” si na rthee r epqriunitr emd,e nseut pthrieo r ptaog per isnctianlge. t

Silastic/Silicone


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17

Tools and Materials Required

Phillips Head Screw Driver Trim Removal Tool Ratchet Socket - 10mm Drill Drill Bit - Ø2mm

Wood Drill Bit - Ø19mm Masking Tape Wire Cutters

Page 03 of


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17

Step 1

Page 04 of

Important

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

• Remove the following six fasteners (1) from underneath the front bumper (four bolts and two hex screws) .

• Remove the four clips (2) at the top of the bumper (3).

• Remove the two hex screws (4) from each side at the edge of the wheel arch.

• If fitted, disconnect fog lamp/park assist connector (5) and headlamp washer system (6).

• Disconnect the 8-way connector and remove the front bumper (3).

• Fully extend the steering wheel in its most upward and pulled out position.

• Note down all clock and radio settings.

• In the engine bay, disconnect the battery negative terminal.

• Remove the grille upper thirteen trim fasteners (1) and remove grille upper trim (2).

Always refer to workshop manual for assistance with part removal.

• Remove the four hex bolts (1) and unclip and remove the grille (2).

Note: If there are connectors (3) available, disconnected before removing grille.

Always refer to workshop manual for assistance with part removal to avoid damaging the grille.

4

2

1

1

1

1

1

1

3

11

11

6

5

Important

Clamp and disconnect headlamp washer hose with flexible hose clamp. Do not use serrated tooth clamp.

2

1 1

3

2 2 22

Step 2

Step 3

4


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17

3

24 41

5 5

Page 05 of

Step 4

Step 5

Step 6

• Remove the glove compartment upper trim (1).

• Remove the LHS instrument panel side trim (2).

1

1

1 1

1 1

11

1

1 1

1 1

1

1 1

1

1 1

11

• On the front passenger side of the vehicle, remove the door sill trim (1) and kick panel (2) by releasing the fastener (3).

• Dislodge the rubber door seal (4) to expose the side trim on the instrument panel.

1

2

3

4

• Release the phillips head screw (1) and remove the glove compartment lower trim (2), unclipping the lamp if present.

• Remove the glove compartment along with the inner trim (3) by removing the hex bolts (4) and two hex screws (5).

• Unclip the inner lining lamp.

2


PRADO

17Page 06 of

Step 7

Step 8

Step 9• On the driver's side of the vehicle, remove the door sill trim (1) and

kick panel (2) by releasing the fastener (3).

3

1

2

• Dislodge and remove the HVAC control panel (1) and then disconnect any control panel connectors.

• Remove the centre console side trims (2).


• Remove the four hex bolts (1).

• Disconnect the audio unit connectors and remove the audio unit and A/C vent assembly (2).


1

22

11

2


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17Page 07 of

Step 10

Step 11

Step 12

• Release the driver's door seal (1) to expose the side trim.

• Remove the driver's dash side trim (2).

• Dislodge the switch panel (3).

• Remove the engine start panel trim (4).

• Open the fastener cover (5), remove the driver's lower dash fasteners (6) and then dislodge the lower dash trim (7).

6 7

34

65

1

2

• Release the three phillips head screws (1) from the lower steering column trim (2) as shown.

• Remove the lower steering column trim (2).

1

2

• In the engine bay, locate the LHS firewall grommet. Cut an access point (1) on the RHS nipple of the firewall grommet.

• Secure the Engine Harness (2) to a guide wire using tape. Feed the guide wire into the previously cut LHS access point of the firewall grommet.

• Ensure the guide wire breaks the internal seal and is fed into the LHS of the cabin until the loop (3) on the Engine Harness meets the grommet. Seal and secure the Engine Harness to the grommet with a Cable Tie.

• Secure the Engine Harness (2) to the vehicle harness using a supplied Cable Tie (4).

• Discard the guide wire after routing.

ImportantIn the engine bay, ensure the loop (3) on the Driving Lamp Harness is downwards. Ensure the grommet access point is sealed.

2

1

1 1

1 1

1

1

1 1

1

1

1 1

1 1

PP

A

A A

A

Nissan pointers

PP

Common Fasteners

Pointers

3

4


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17

Step 13

Step 14

Page 08 of

Step 15

• In the glove compartment cavity, retrieve the Engine Harness (1) from the firewall grommet (2).

• Route the Engine Harness driving lamp terminals (3) towards the front of the glove compartment cavity area following the vehicle harness.

2

•

• House the small terminal (4) on the Engine Harness into the supplied 1-way Female Connector (5).

• Connect the empty 1-way Male Connector supplied with the Tail Patch Harness (PZQ59-00170) to the 1-way Female Connector (5).

• Secure the branch with the 1-way connector onto itself using the supplied Cable Ties.

House the two Engine Harness driving lamp terminals (1) into the Cabin Harness relay connector (2). House the ORANGE wire in position [A] and house the RED wire in position [B]. Then re-engage the secondary lock (3) as shown. A

B

1

2

3

2

•

•

Connect the supplied Relay (1) to the Cabin Harness relay holder (2).

Connect the 1-way Female Connector (3) on the Tail patch Harness to the 1-way Male Connector (4) on the Cabin Harness.

1

2

3

2

1 1

1

1

1 1

1

1

1 1

1 1

PP

A

A A

A

Nissan pointers

PP

Common Fasteners

Pointers

3

4

5

1

View from underneath theglove box compartment

1

Important

Cable Tie Engine Harness to vehicle harness every 200mm

3 4


PRADO

17

Step 16•

•

Route the Tail Patch Harness (1) down to the LHS kick panel area, following the vehicle harness.

Cable tie the harness every 200mm and ensure it is away from sharp edges.

1

Step 17• Dislodge the ‘WHITE’ connector holder (1) to gain access to the

‘BLUE’ 18-way female connector (2) (located on the bottom of the connector housing).

1

2

Page 09 of

1 1

1

1

1 1

1

1

1 1

1 1

PP

A

A A

A

Nissan pointers

PP

Common Fasteners

Pointers

• Scotch Lock the Tail Patch Harness ‘GREEN’ wire (1) on to the ‘LIGHT GREEN’ wire (2) located at PIN location 16 (3).

• Secure the Tail Patch Harness to the vehicle wire harness using the supplied Cable Ties.

Front View18-Way Connector

3

Step 18

1

2

1

1

2

2


PRADO

17

Step 19

Step 20

Step 21

Page 10 of

• In the glove compartment RHS, secure the Relay Base (1) to the vehicle harness with Cable Ties (2).

• Continue to route the Cabin Harness (3) through the audio unit cavity and towards the driver's lower dash area.

21

Important

Ensure to keep all harnesses clear of any moving parts or sharp edges when routing.

Front View64-Way Connector

• Disconnect the stalk connector (1) on the RHS of the steering wheel.

• Patch the Cabin Harness (2) in between stalk connector (1) and the steering wheel.

1 1

1

1

1 1

1

1

1 1

1 1

PP

A

A A

A

Nissan pointers

PP

Common Fasteners

Pointers1

2

• Secure the lower section of the switch terminal branch (1) to the vehicle white clip mechanism (2) with a Cable Tie (3) as shown.

• Cable Tie (3) the Cabin Harness (4) to the vehicle harness just above the existing white cable tie (5) on the vehicle harness.

1

1

4

4

5 3

3

1

2

2

2

3

3


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17

Step 22

Step 23

Step 24

1 1

1

1

1 1

1

1

1 1

1 1

PP

A

A A

A

Nissan pointers

PP

Common Fasteners

Pointers

Page 11 of

• Secure the excess length of the Cabin Harness (1) just below the steering wheel using a Cable Tie (2).

• Route the scotch lock branch on the RHS of the steering wheel and Cable Tie (2) as shown, allowing adequate slack.

• Reconnect negative terminal (1) (if the steering wheel is electric).

• Move the steering wheel in all possible positions and make sure none of the harness branch is too tight in any position.

• Make sure the lower steering wheel cover can be fitted back without pinching on the harness.

• Retry all possible positions of the steering wheel and assess if enough slack is available.

• Disconnect the negative battery terminal (1) (if it has been reconnected).

If vehicle if fitted with Auto High Beam feature, proceed to Step 25. For all other vehicles continue.

• Coil the scotch lock branch onto itself and Cable Tie (1) back to the vehicle harness, (scotch lock will not be used).

Proceed to Step 26.

1

1

2

1

2


PRADO

17

Front View6-way Connector

Step 25

Page 12 of

Step 26

Step 27• Mount the switch (1) to the LHS driver's dash trim (2) and then

connect the terminals (3) to the switch (1).

• Cable Tie the Cabin Harness into the instrument panel.

• Refit the driver's dash trim.

• Using tape, adhere Template (1) to the LHS driver's dash trim (2) and using a Ø2mm drill bit, drill a pilot hole into the drilling point.

• Discard Template after drilling.

• Drill a larger Ø19mm hole.

• Using a file, smooth and deburr any rough edges from the hole.

• Clear the ribs around the drilled hole to make sure they do not interfere with the switch nut.

Important

Use a low speed setting while drilling.

13

The following step is ONLY for vehicles if fitted with Auto High Beam feature. For all other vehicles proceed to Step 26.

• On the RHS of the steering column, open the Scotch Lock Housing on the Cabin Harness (1).

• Locate the BLUE 6-way connector with two ‘WHITE/BLACK’ wires, one ‘PINK’ wire and one ‘GREEN’ wire.

• Splice the Cabin Harness ‘WHITE’ wire on to the connector Pin location 5 ‘PINK’ wire (2) using the supplied scotch lock (3).

• Secure the Scotch Lock connector to the vehicle harness using a supplied Cable Tie.

• Refit the connector back into the Switch.

• Put the Switch back into the vehicle base.

1

2

3

2

2

3

1

2

3

1

1

2


PRADO

17

Step 28

Step 29

• Route the Engine Harness (1) as shown towards the LHS driving light assembly (2).

• Secure the Engine Harness ring terminal (3) to the vehicle earthing point using the existing bolt (4).

• Connect the positive ring terminal (5) of the Engine Harness to the positive battery terminal stud (6).

Page 13 of

• Retrieve the Engine Harness from underneath the LHS headlight assembly area and route the Engine Harness (1) under the grille support as shown.

• Cable Tie (2) the EngineHarness (1) under the grille support as shown.

2

1

Important

Torque positive battery terminal stud to 7.5Nm ± 1.7Nm.

6

5

4

3

2

Important

Torque earth bolt to 8.5Nm ± 1.3 Nm.

1


PRADO

17Page 14 of

• Mount the Driving Lights onto the bullbar by referring to the Driving Lights fitting instructions.

Step 31

Step 30

Step 32

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

• Secure the Driving Lamp Harness to the support arm every 200mm.

Repeat for the RHS.

2

1

• Attach the supplied driving light flyer to the gear knob (1) of the vehicle.

1


PRADO

17

Step 33

Important

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

Important

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

•

•

•

Reconnect the battery negative terminal (1).

Test the Driving Lamp Harness system for correct operation.

Turn the ignition to the "OFF" position.

1

Page 15 of

Please place the in the glov box after installation completed.

Fitting Instructions e is

Important

Post terminal torque to 6.5Nm ± 1.3Nm

1


PRADO

17

Harness Diagram

Page 16 of

110

1120

1120

110

I/P H

AR

NE

SS

, AU

TO H

IGH

BE

AM

SW

ITC

H 6

WAY

CO

NN

EC

TOR

, PIN

#5,

PK

WIR

E

LOC

ATIO

N: D

RIV

ER

'S S

IDE

, RH

S S

TEE

RIN

G W

HE

EL

12

21LH DRIVING LAMP EARTH [BK]

LH DRIVING LAMP +12V [RD]

12

21RH DRIVING LAMP EARTH [BK]

RH DRIVING LAMP +12V [RD]

1 BLACK / EARTH / 6mm RING TERMINAL

LOCATION: VEHICLE EARTH BOLT, ENGINE BAY, LH SIDE PANEL

EA

RTH

[BK

]

LH D

RIV

ING

LA

MP

RH

DR

IVIN

G L

AM

P

30AUF1

ORANGE / POWER / Ø8MM RING TERMINAL

LOCATION: BATTERY, ENGINE BAY LH SIDE PANEL

1

EN

GIN

E B

AY

21

LOW

BE

AM

SW

. [R

D]

LOW

BE

AM

[RD

]

DR

IVIN

G L

AM

P S

WIT

CH

53 1

42

CA

BIN

2A

UF2

UR

1

53 1

42

UR

2

53 1

42

UR

3

[II] S

YS

TEM

SC

HE

MAT

IC

LOW BEAM SWITCH [RD]

HIGH BEAM SWITCH [BL]

HI BEAM [BL] [YL/BK]

[YL]

[YL]

[YL/BK]

[YL]

[WH]

AH

B S

WIT

CH

[WH

]

[OR]

[OR]

FUSED 12V+ [OR]

[RD]

[RD

]

[RD

][R

D]

[OR][OR]

[OR

][O

R]

[OR

]

LOC

ATIO

N: D

RIV

ER

'S S

IDE

, RH

S S

TEE

RIN

G C

OLU

MN

SW

ITC

H A

SY

I/P H

AR

NE

SS

, 20-

WAY

CO

NN

EC

TOR

, T-P

ATC

H

LOC

ATIO

N: R

EA

R G

LOV

E B

OX

AR

EA

2A

18-W

AY B

LUE

CO

NN

EC

TOR

, PIN

#16

, LIG

HT

GR

EE

N

LOC

ATIO

N: L

H S

IDE

KIC

K P

AN

EL

‘NO

CO

NN

EC

T’

[GN

][G

N]

Kit Part No: PZQ59-60140 August 2017 Production Onwards ...

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