Dobinsons BU59-5557 Toyota 4Runner 2010 Plus Bullbar Installation Guide

BU59-5557 Toyota 4Runner 2010 Plus Bullbar

Product Information: Dobinsons Bull Bar for Toyota 4Runner (2010+)

The Dobinsons Bull Bar is designed to fit Toyota 4Runner models from 2010 and onwards. It is a heavy-duty, durable, and reliable bull bar that is easy to install. The bull bar comes with a winch cradle installation kit and is made from high-quality materials that provide excellent protection for your vehicle.

Product Usage Instructions

Tools Required

• Spanners and Socket Set
• Allen/Torx Key Set
• Screw Drivers
• Drill with Assorted Drill Bits
• Clip Removal Tool
• Torque Wrench
• Rubber Mallet/Deadblow Mallet
• Jig Saw or other plastic cutting tool
• Masking Tape
• Black Paint

Bull Bar Installation Guide

Step 1: Remove OEM Bumper

1. Remove Screws holding front license plate. Set aside for reassembly (if applicable).
2. Remove plastic radiator cover by removing the plastic pop rivets (push in center then pry to remove). Set aside for reinstallation later.
3. Remove plastic pop rivets from the top of the grill and front bumper (pry the center piece to remove).
4. Remove the three front screws from the inner fender well on both sides of the vehicle. Take note of different-sized screws and set aside for reinstallation.
5. Remove the seven screws on the bottom of the bumper. Take note of different-sized screws and set aside for reinstallation.
6. Peel back the inner fender well and disconnect the fog lights from the wiring harness.
7. Remove the top center screw from the top of the grill and carefully pull the OEM bumper off (pops will be heard from the side clips coming loose, pull gently to prevent breaking of any clips).

Step 2: Preparing for Bull Bar Install

8. Place masking tape on the OEM Bumper around the cut area to protect the paint.
9. Place the provided cutting template on the OEM bumper and cut. We recommend the initial cut to be done with a 10mm buffer to prevent excessive cutting of the OEM bumper. All gaps from Dobinsons Bull Bar to OEM bumper must be at least 8-10mm after edge trim is placed. This is to prevent the Bull Bar from coming into contact with the vehicle’s body. Do not use image as a cut guide, go by measurements only.
10. Remove the lower grill section from the OEM bumper (pushing top tabs upwards and bottom tabs downward, pull the grill out).
11. Cut the lower grill as shown. We recommend the initial cut to be done with a 10mm buffer to prevent excessive cutting. Then continue to cut down to measured lines.
12. Remove the fog light trim pieces from the OEM Bumper and trim along the dashed line shown in the image.
13. Remove the side bumper retainers and cut on the dashed lines shown in the image.
14. Reinstall all bumper trim to OEM bumper for reinstallation.
15. Remove M10 bolt holding the power steering clamps on either side of the vehicle, set aside as these will be re-used later.

Step 3: Winch Cradle Installation

16. Starting at the passenger’s side of the vehicle, loosely install the L-shaped bracket (pictured) with the provided U-bolts around the frame. Insert the M12 cap venuts through the opening on the front of the frame. Use M12x30mbolt with washer to loosely fasten.
17. Repeat step 1 on the driver’s side. Vehicles equipped with KDSS will have a reinforcement plate positioned where the bolt hole should be. Drill through the frame using a 13mm drill bit to fasten this bolt. (Drilling through the frame is optional as some states may consider this frame damage). The driver’s side of the vehicle does not use the cap venut, instead use the provided M12x100mm bolt going through the frame. Fasten with a provided M12 nut and washers loosely.
18. Install the winch base onto the vehicle using the provided fine-thread M10x30mm bolts with washers. Fasten to the OEM weld nuts on the frame loosely. Holes are slotted to easily center the base to the vehicle.

This Bull Bar will take approximately 6-8 hours to install
Dobinsons BULLBARS should be installed by a qualified installer and it is the installers responsibility to ensure correct fitment.
Dobinsons is not responsible for any damage incurred to the vehicle during installation.

Tools Required

• Spanners and Socket Set
• Allen I Torx Key Set
• Screw Drivers
• Drill with Assorted Drill Bits
• Clip Removal Tool
• Torque Wrench
•  Rubber Mallet I Deadblow Mallet
• JigSaw or other plastic cutting tool
• Masking Tape
• Black Paint

Remove OEM Bumper

1. Remove Screws holding front license plate. Set aside for reassembly. (If applicable)

2. Remove plastic radiator cover by removing the plastic pop rivets (push in center then pry to remove). Set aside for re-installation later.
   (Pl.1)

3. Remove plastic pop rivets from the top of the grill and front bumper. (Pry the center piece to remove). (Pl.2)

4. Remove the three front screws from the inner fender well on both sides of the vehicle. Take note of different sized screws and set aside for re-installation. (Pl.3)

5. Remove the seven screws on the bottom of the bumper. Take note of different sized screws and set aside for re-installation

6. Peel Back the inner fender well and disconnect the fog lights from the wiring harness. (Pl.4)

7. Remove the top center screw from the top of the grill and carefully pull the OEM bumper off. (Pops will be heard from the side clips coming loose, pull gently to prevent breaking of mentioned clips). (Pl.5)
   Preparing for Bull Bar Install

8. Place masking tape on the OEM Bumper around the cut area to protect the paint.

9. Place the provided cutting template on the OEM bumper and cut, we recommend the initial cut to be done with a 10mm buffer to prevent excessive cutting of the OEM bumper. (P2.1)
   NOTE: All gaps from Dobinsons Bull Bar to OEM bumper must be at least 8-l0mm after edge trim is placed. This it to prevent the Bull Bar from coming into contact with the vehicles body Do NOT use image as cut guide, go by measurements ONLY

10. Remove the lower grill section from the OEM bumper. (Pushing top tabs upwards and bottom tabs downward, pull the grill out.) 

11. Cut the lower grill as shown. we recommend the initial cut to be done with a 10mm buffer to prevent excessive cutting. Then continue to cut down to measured lines. (P2.2)

12. Remove the fog light trim pieces from the OEM Bumper and trim along the dashed line shown in the image. (P2.3)

13. Remove the side bumper retainers and cut on the dashed line shown in the image.(P2.4)

14. Reinstall all bumper trim to OEM bumper for reinstallation.

15. Remove MlO bolt holding the power steering clamps on either side of the vehicle, set aside as these will be re-used later.   Winch Cradle Installation

16. Starting at the passenger’s side of the vehicle loosely install the L shaped bracket (pictured) with the provided U-Bolts around the frame. insert the M12 captive nuts through the opening on the front of the frame, Use M12x30m bolt with washer to loosely fasten (P3.1)

17. Repeat step 1 on the Drivers side, Vehicles equipped with KDSS will have a reinforcement plate positioned where the bolt hole should be. Drill through the frame using a 13mm drill bit to fasten this bolt. (Drilling through the frame is optional as some states may consider this frame damage).
    The driver’s side of the vehicle does not use the captive nut, instead use the provided M12x100mm bolt going through the frame. fasten with a provided M12 nut and washers loosely. (P3.1)

18. Install the winch base onto the vehicle using the provided fine thread M10x30mm bolts with washers, fasten to the OEM weld nuts on the frame loosely. Holes are slotted to easily center the base to the vehicle.

19. Use the provided M12 bolts, washers and flange nuts to fasten the top and bottom holes of the winch base to the frame bracket. (P3.2)

20. Center the winch base and torque all hardware.
    M12 – 77Nm / 56.Sft/lb Ml0 – 44Nm / 32.Sft/lb

21. Relocate the power steering line bracket to the hole on the vertical flange of the winch base using an M6 bolt, nut and washers.
    If installing a winch now is the time. Once the bumper shell is installed, it will need to be removed to gain access to the winch cradle.
    The winch may contact the OEM bumper grill, trim accordingly. leave a gap of at least 10mm to avoid contact.
    If installing LED auxiliary lights on top of the bumper (NOT FOG LIGHTS), It is highly recommended that you do this now. It can be done after the Bull Bar is installed, but will be more difficult.
    Bull Bar Installation

22. With the help of a mate, carefully lift the Bull Bar Shell and mount to the winch cradle. Loosely fasten the Bull Bar Using 6 x M12 Bolts, oversized flat washers, spring washers and flange nuts. (P4.1)

23. Level the Bull Bar Shell to the vehicle body, ensure to leave an 8-l0mm gap between the Bull Bar and the body. Tighten till snug.

24. Ensure the Bull Bar is centered to the vehicle, if not, remove the bull bar and center the winch cradle. then repeat steps 1 and 2.

25. Once happy with Bull Bar placement, torque all M12 bolts.
    M12 – 77Nm / 56.8ft/1b

26. Install fog light surround and optional fog lights (wiring guidelines on the following page).

27. Test to make sure all lights are functioning correctly before moving on to the next step.
    Bash Guard Installation

28. 28. Insert 3 cage nuts to the lower-middle part of (P4.2) the Bull Bar. (P4.2)

29. Fasten the front of the central bash guard to the Bull Bar.

30. Fasten the rear part of the central bash plate to the sides of the winch cradle with a bolt, nut and washers. (This is height adjustable to suit your specific skid plate). (P4.2)

31. Insert 5 cage nuts to the lower part on each side of the bumper. (P4.3)

32. Fasten the side bash plates to the bull bar.

33. Fasten the rear part of the side bash plates to the sides of the winch cradle with a bolt, nut and washers. (P4.3)

34. Torque all bash plate bolts.
    Torque bash plate bolts to 22Nm / 16.25ft/1b

Wiring Guidelines – Zenith Bullbars

Dobinsons Zenith Bull bars are supplied with LED indicator/Parker lights. Available extra are DRL’s and Fog Lights.

Indicator/Parker Lights
Use a multimeter to locate the existing positive and negative lights for the existing vehicle headlights park light circuit and indicator circuit and using the scotch-locks or soldering, connecting directly to the existing vehicle wiring circuit using the diagram on the following page.
NOTE: For some later model Toyota 150 prado vehicles the Parker lights must be wired using a relayed wiring loom (a modified spotlight/fog light loom or similar) as the vehicle headlight wiring will not work -see the specific instructions with the bu I bar for more information on these.

Fog lights (optional extra}
Install the fog lights into the bu I bar before installing the bu I bar. Use a sharp knife and from the back side of the bar carefully cut the retaining tabs on the plastic cover insert and remove.
Install the fog light with the breather at the top . Use the 6mm bolt and washer, then place the tooth washer between the light insert mount and light, then the flat washer and nyloc nut as seen on the diagram below.

Wire the fog lights as per the diagram on the following page. There are 2 switches provided -a prewired universal single large din switch and a small universal switch. Dobinsons have some other plug and play switches available that are vehicle specific. Ashdown Ingram and similar electric wholesalers also have these switches-Check the wiring diagrams on the packet of the switch first to ensure they will plug in and work correctly or need wiring altered.
A round universal switch is also supplied- install the switch by drilling a xxmm hole and altering the wiring as shown.

DRL Lights (optional extra}
Install the DRL lights into the bu I bar before installing the bulbar. Use a sharp knife and from the back side of the bar carefully cut the retaining tabs on the plastic cover insert and remove. Attach with 2 x screws supplied (there are left and right sides). Wire the lights as per the diagram on the following Page-the switching wires can be wired to ignition for lights to operate when vehicle is running, or to parker / low beam for operation when the lights are turned on only. Use screws or good quality double sided tape (such as 3m brand) to fix the control box to the vehicle body.

FOG LIGHT
WIRING DIAGRAM – SERIES 2 

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