TOYOTA HIGHLANDER TOWING HITCH Preparation

Transcription

1 TOYOTA HIGHLANDER TOWING HITCH Preparation Part Number: PT Kit Contents Item # Quantity Reqd. Description 1 1 Trailer Hitch 2 1 LH Mounting Bracket 3 1 RH Mounting Bracket 4 1 Molded Lower Fascia Cover 5 1 Trailer Hitch Plug Hardware Bag Contents Item # Quantity Reqd. Description 1 14 M10 x 1.25 x 35mm bolt 2 3 Plastic Push-pin NOTE: Part number of this accessory may not be the same as the part number shown. General Applicability All vehicles Recommended Sequence of Application Item # Accessory 1 Towing Hitch 2 Towing Hitch Wiring Harness 3 Exhaust Tip 4 Mudguard *Mandatory Vehicle Service Parts (may be required for reassembly) Item # Quantity Reqd. Description Legend Additional Items Required For Installation Item # Quantity Reqd. Description 1 2 Conflicts Recommended Tools Personal & Vehicle Protection Safety Glasses Cloth (shop towel) Special Tools Notes Notes STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with. OPERATOR SAFETY: Use caution to avoid risk of injury. CAUTION: A process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation. TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process. REVISION MARK: This mark highlights a change in installation with respect to previous issue. SAFETY TORQUE: This mark indicates that torque is related to safety. Installation Tools Notes Torque Wrench lbf-ft ½ x 6 socket extension ½ socket 14mm ⅜ socket wrench ⅜ x 6 socket extension ⅜ sockets 10mm, 14mm Small flat-head screwdriver Phillips head screwdriver Rotary Cutting Tool Drill Motor Drill Bit Special Chemicals None 15mm Notes Page 1 of 10 pages

2 Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the "Accessory Installation Practices" document. This document covers such items as:- Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.). Safety (eye protection, rechecking torque procedure, etc.). Vehicle Disassembly/Reassembly (panel removal, part storage, etc.). Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.). Please see your Toyota dealer for a copy of this document. 1. Prepare Vehicle for Hitch Installation Fig. 1-1 ⅜ socket wrench 10mm socket Flat-head screwdriver Phillips screwdriver tie down bolts (a) Verify kit contents (b) Wear safety glasses (c) Cover exhaust pipe with clean shop towel. (d) Caution: muffler may be hot and/or sharp (e) Remove the lower undercover by removing 5 fasteners. Set aside the cover and fastening hardware for later use. (Fig. 1-1) (f) Remove the tie down hook by removing 2 bolts. Discard the tie down hook and bolts. (Fig. 1-1) ⅜ socket wrench 10mm socket Flat-head screwdriver Phillips screwdriver (g) Remove the lower undercover by removing 4 fasteners. Set aside the cover and fastening hardware for later use. (Fig. 1-2) Fig. 1-2 tie down bolts (h) Remove the tie down hook by removing 2 bolts. Discard the tie down hook and bolts. (Fig. 1-2) Page 2 of 10 pages

3 Flat-head screwdriver 2. Remove the factory lower fascia cover (a) Remove and discard the push-pins (1 per side). (Fig. 2-1) Fig. 2-1 Remove clip (LH shown) (b) Locate the lower cover tab that sticks through the bumper fascia and is held in place with a plastic clip. (1 per side) Depress the latch and remove the 2 clips and save for later use. (Fig. 2-2) Fig. 2-2 (c) Remove the lower fascia cover from the bumper by pulling the cover away from the vehicle and disengaging the latches. The cover can be discarded. (Fig. 2-3) Fig Prepare Frame Rails shown (a) Remove the rubber drain plugs from the bottom and outside of both the LH and RH frame rails. (Fig. 3-1) Fig. 3-1 Page 3 of 10 pages

4 4. Install Hitch (a) Lift towing hitch into position under the vehicle frame. Line the slots in the brackets up with the holes in the frame. (Fig. 4-1) NOTE: This step requires two people. Fig. 4-1 shown (b) Install (3) M10 bolts into the bottom of the frame on both the LH and s. (Fig. 4-2) Hand-tighten the bolts but allow for cross-car adjustment in later steps. Fig. 4-2 Fig. 5-1 Shop towel Install bolts Remove sealant 5. Install LH Mounting Bracket (a) If needed, remove excess sealant on frame at bracket location. (Fig. 5-1) (b) Align the top two bracket holes with the holes in the frame rail. (c) Install (2) M10 bolts into the holes. (Fig. 5-1) (d) Push the hitch up so it is flush to the frame rail and align the bottom two mounting bracket holes with the hitch bracket holes. (Fig. 5-2) (e) Install (2) M10 bolts in the holes. (Fig. 5-2) Fig. 5-2 Page 4 of 10 pages

5 Fig. 6-1 Shop towel Remove sealant Install bolts 6. Install RH Mounting Bracket (a) If needed, remove excess sealant on frame at bracket location. (Fig. 6-1) (b) Align the top two bracket holes with the holes in the frame rail. (c) Install (2) M10 bolts into the holes. (Fig. 6-1) (d) Push the hitch up so it is flush to the frame rail and align the bottom two mounting bracket holes with the hitch bracket holes. (Fig. 6-2) (e) Install (2) M10 bolts in the holes. (Fig. 6-2) Fig Tighten Bolts (a) Tighten (4) M10 bolts (2 per side) labeled 1. (Fig. 7-1) Fig (b) Center the hitch in the cross-car direction between the LH and RH mounting brackets by creating an equal gap on each side. (c) Tighten (6) M10 bolts (3 per side) to pull the hitch up flush to the frame. (Fig. 7-2) (d) Tighten (4) M10 bolts (2 per side) labeled 2 to pull the mounting brackets flush to the hitch brackets. (Fig. 7-1) Fig. 7-2 Page 5 of 10 pages

6 ½ drive torque wrench Torque bolts (a) Tighten (4) M10 bolts (2 per side) labeled 1 to 54 lbf-ft (74 Nm). (Fig. 8-1) 2 2 Fig. 8-1 ½ drive torque wrench (b) Tighten (6) M10 bolts (3 per side) to to 54 lbf-ft (74 Nm). (Fig. 8-2) (c) Tighten (4) M10 bolts (2 per side) labeled 2 to 54 lbf-ft (74 Nm). (Fig. 8-1) Fig Install Cover (a) Install the lower fascia cover over the hitch by aligning the tabs along the top edge with the slots in the bumper fascia. Fig. 9-1 Before snapping in the cover, be sure the outboard tabs are installed through the slots in the factory cover (Fig. 9-2). install clips from center outward ( shown) Snap in the center tabs first, and continue working outward until all of the clips are snapped in. (Fig. 9-1) (b) Install the (2) clips (1 per side) from the factory cover that were removed in step 2-b. Install the clips from the center of the vehicle outward. (Fig. 9-2) Fig. 9-2 Page 6 of 10 pages

7 bend tab up installed position (c) Bend the LH and RH cover mounting tabs up towards the hitch brackets. Using 2 of the push pins provided in the hardware kit, attach the cover to the hitch attachment brackets. (Fig. 9-3) Fig. 9-3 shown after installation (d) Above the tailpipe, bend the exhaust deflector tab on the hitch cover up towards the hitch bracket. Use the remaining pushpin to attach to the hitch attachment bracket. (Fig. 9-4) bend tab up Fig. 9-4 ½ drive torque wrench 10. Retorque bolts (a) Retighten all (14) M10 bolts (7 per side) to 54 lbf-ft (74 Nm). (Figs and 10-2) Fig ½ drive torque wrench Fig Page 7 of 10 pages

8 11. Install Wire Harness (a) Connect, route, and secure the wiring harness per the applicable installation instructions. 12. Modify and Reinstall LH undercover (a) Take the LH undercover removed in step 1-e and locate the scribe lines molded into the part as shown in Figure Fig rotary cutting tool (b) Cut the cover along the scribed lines and remove the cut-out sections. When finished, the modified cover should look like the one shown in Figure Fig / 8 socket wrench 10mm socket Phillips head screwdriver (c) Reinstall the modified cover onto the vehicle. Reattach using the hardware removed in Step 1-e. (Fig. 12-3) Be careful not to damage the bumper fascia during installation. Fig Page 8 of 10 pages

9 13. Modify and Reinstall RH undercover (a) Take the RH undercover removed in step 1-g and locate the scribe lines molded into the part as shown in Figure Fig Fig rotary cutting tool drill drill bit 15mm drill (b) Cut the cover along the scribed lines and remove the cut-out sections. When finished, the modified cover should look like the one shown in Figure (c) Using a 15mm drill bit, drill a hole in the location indicated by the scribed circle. (Fig. 13-2) Fig (d) Reinstall the modified cover onto the vehicle. Use the access hole cut into the bottom of the cover to install the 10mm frame mounting bolt removed in Step 1-g. Install the bolt through the hole drilled into the cover and into the weld nut on the hitch bracket. (Fig. 13-3) 3 / 8 socket wrench 10mm socket (e) Reattach using the hardware removed in Step 1-g. Secure the cover by fully tightening the 10mm bolt installed in Step 13-d. (Fig. 13-4) Fig Be careful not to damage the bumper fascia during installation. Page 9 of 10 pages

10 TOYOTA HIGHLANDER TOW HITCH Checklist - these points MUST be checked to ensure a quality installation. Check: Look For: Accessory Function Checks Perform visual check of trailer hitch. Inspect torque (M10 bolts) Hitch Plug No visible gaps between mating parts or loose parts lbf-ft ( Nm) Place in glove box. Vehicle Function Checks N/A Page 10 of 10 pages