Vanlife Northwest

INSTALLATION - Pluto Bull Bar - KZH V1 - 1996-2004

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INSTALLATION - PLUTO BULL BAR

KZH V1 - 1996-2004

COMPATIBLE MODELS:

  • KZH V1 Bull Bar fits all year Toyota Hiace vans with the following chassis: KZH100, KZH106, KZH110, KZH113, KZH116, KZH120, KZH126, KZH132, KZH138, RZH101

COMPONENTS:

  • Bull bar

  • (6) M14 x 1.5 x 45mm hex bolts

  • (6) M14 x 1.5 hex nuts

  • (6) M14 flat washers

  • (6) M14 split lock washers

  • (6) M14 large gold round washers

  • (2) rubber patch covers

  • (1) license plate adaptor with fasteners


TOOLS:

  • #2 Phillips screw driver

  • Long and wide flat blade screwdriver

  • 12mm socket with ratcheting wrench 

  • Sharpie marker

  • Drill motor

  • 2” sanding drum

  • 1-3/4” hole saw

  • Cutting oil

  • Razor blade

  • Center punch

  • Hammer

  • Angle grinder with cutting wheel

  • Rat tail file

  • Flat file

  • Spray paint

  • Telescoping magnet tool

  • Jack stands (2)

  • Blue lock tite thread locker

  • Long 22mm or 7/8” box end wrench

  • Torque wrench and 22mm or 7/8” socket

  • 1/8” drill bit

  • 1/2” step drill bit

  • 5/8” standard or reaming drill bit

  • Rag

  • Rubbing alcohol

  • Plastic prying tool


DIRECTIONS:

  1. Remove the bumper.

    1. Remove license plate

    2. Remove blinker assemblies

      1. Identify and remove plastic phillips head peg screw in passenger door jam.

        1. NOTE: You may need to pry out the plastic peg screw.

      2. Shut the door and carefully pry off the painted plastic molding using a plastic prying tool. 

      3. Remove the (1) Phillips head screw attaching the blinker assembly

      4. Unsnap the blinker assembly near the screw hole and remove it, pulling it gently at a 45* angle.

      5. Disconnect the electrical connector to the blinker assembly.

      6. Repeat steps to remove drivers side blinker assembly.

    3. Remove grill

      1. Identify and remove (2) phillips head screws along the bottom of the grill

      2. Gently, but firmly, pull grill off towards the front of the van.

    4. Remove the plastic bumper cover

      1. Using your 12mm socket and wrench, remove the (9) bolts fastening the bumper to the van.

      2. Pop off the lower side corners of the bumper by hand.

      3. Slide the bumper cover forward and disconnect the main electrical connector behind the center of the bumper cover.

      4. Remove bumper

  2. Cut reliefs in bumper cover

    1. Identify, remove, and discard passenger and drivers side plastic inner wind diverters.  

    2. Approximate and mark the center point of the bumper, referencing existing holes.

    3. Make (2) additional marks, each 19-3/4” out from your centerline mark. 

    4. Draw a line up from the bottom edge of the bumper, through each of the left and right marks, terminating 1/4” above the horizontal creased line in the bumper. This line will effectively be about 1-5/8” up from the bottom edge of the bumper.

    5. Using your drill motor and 2” sanding drum, follow the centerline of your left and right marks, terminating at the apex of the slot cut at the end of your line marks. NOTE: you may need to remove more material from the sides of the slot once you fit the bumper over the bull bar.

    6. Deburr the plastic with a razor blade 

  3. Prepare frame

    1. Cut lip from lower edge of front cross member.

      1. Make a mark 5-1/2” and 12-1/2” inches from the outer edge of the inner drivers side frame rail.

      2. Repeat marks on the passenger side.

      3. For both drivers and passenger side, cut out area between your marks (7” total for each side). 

        1. NOTE: If your cuts are near AC lines, use a sheet of wood or metal to shield the lines in case your blade catches.

        2. ALSO NOTE: Do not accidentally cut into your frame rails.

      4. Debur with a flat file, and paint edges of cuts.

    2. Cut access holes.

      1. Identify outer most threaded holes on passenger and drivers side of the front cross member.

      2. Using the holes to center your bit, cut a 1-3/4” access hole with your holes saw, on both drivers and passenger sides. NOTE: Have the drill motor oriented squarely towards the rear of the van.

      3. Debur the holes with a rat tail file.

      4. Paint the holes.

    3. Identify, remove, and discard 2 frame member caps.

  4. Install bull bar

      1. Using a friend and (2) jack stands set level with the lower edge of the front crossmember, place the bull bar assembly in place, with the mounting brackets aligned with the outer frame members. 

      2. Insert (1) M14 bolt in the rear most mounting holes of drivers side and passenger side bull bar mounting brackets. These holes corresponds with existing holes in the frame member. 

        1. Bolts should have (1) split lock washer and (1) flat washer.

        2. Bolts should have a small dab of blue lock tite on the threads.

      3. Using your telescoping magnet tool, install (1) large gold round washer on the TOP side of the M14 bolt. NOTE: you’ll need to hold the bolt in place to keep it from falling back through the hole.

      4. Using your telescoping magnet tool, install (1) M14 nut on the TOP side of the M14 bolt, finger tight. NOTE: be sure not to cross thread the nut.

      5. Tighten the (2) mounting bolts to 120 ft/lbs. NOTE: have a friend push the bar towards the rear of the van while tightening the bolts.

        1. Using a 22mm (or 7/8”) box end wrench to secure the upper nut, torque the bolts with a 22mm (or 7/8”) socket and torque wrench to 120 ft/lbs.

      6. Drill (4) remaining mounting holes NOTE: For best results, use cutting oil on your drill bits.

        1. Using the center punch, approximate the center of the (4) holes and make (4) corresponding divots with the punch. These will be used to center your drill bit. 

        2. Drill a pilot hole with the 1/8” drill bit in the center of each of the (4) corresponding mounting holes.

        3. Using the 1/2” step drill bit, drill a 1/2” hole in each of the (4) corresponding holes. 

        4. Using a 5/8” drill bit, widen the (4) 1/2” holes to 5/8”. 

        5. De-bur the holes with the rat tail file.

        6. Using compressed air and your magnet, remove all metal shavings inside the unibody frame members, and between the frame and bull bar mounting brackets.

        7. Clean the oil with rubbing alcohol and a clean rag.

        8. Paint the holes.

      7. Insert the (4) remaining M14 bolts in the recently drilled holes. 

        1. Bolts should have (1) split lock washer and (1) flat washer.

        2. Bolts should have a small dab of blue lock tite on the threads.

      8. Using your telescoping magnet tool, install large gold round washers on the TOP side of the M14 bolt. 

      9. Using your telescoping magnet tool, install M14 nut on the TOP side of the M14 bolt. NOTE: be sure not to cross thread the nut.

      10. Tighten the (4) mounting bolts to 120 ft/lbs. 

        1. Using a 22mm (or 7/8”) box end wrench to secure the upper nut, torque the bolts with a 22mm (or 7/8”) socket and torque wrench to 120 ft/lbs.

  5. Reinstall the bumper.

    1. Install adhesive backed rubber covers over the 1-3/4” access holes.

    2. Install the bumper cover

      1. Slide the bumper cover on, down from the top

      2. Connect the center electrical connector

      3. Snap on the lower side corners of the bumper by hand. 

      4. Using your 12mm socket and wrench, reinstall the (9) bolts fastening the bumper to the van.

    3. Reinstall the plastic grill

      1. Carefully align and snap on the grill.

      2. Reinstall the (2) phillips head screws at the corners of the grill

    4. Install the blinker assemblies and plastic molding, reversing the removal process

  6. Install license plate adaptor

    1. First install the license plate adaptor using the standard hex bolts.

    2. Install your license plate using the flange head hex bolts.

    3. NOTE. Use the provided spacer washers between your license plate and the plate adaptor.