LANDCRUISER 100 SERIES CARGO BARRIER - REAR POSITION ONLY Installation Instructions GXL V8, GXL TD, SAHARA August 05 onward- Accessory Part No. 608825 Installation Time: Approx 1 hr Place these Instructions in the glove box after installation is complete IMPORTANT: The installation kit contains sufficient components to fit the cargo barrier. A high degree of technical competence is necessary to correctly install this product. We recommend this Cargo Barrier be installed by a Milford Dealer. These instructions must be read and clearly understood before commencing installation. Strict compliance with installation instructions is essential for this safety product to meet its rated capacity. Parts List Check contents of kit before commencing fitment and report any discrepancies. Item Component Name Part No. Qty. 1 Cargo Barrier Assy. (not shown) 608825 1 2 Mounting Plate 754000 4 3 Metal Cover Plate Assy. 754655 2 4 Metal Cover Plate (Countersunk) 754235 2 5 Mounting Plate Seal (Rubber) 904020 2 6 Cover Plate Seal (Rubber) 754647 2 7 Rubber Washer 904315 2 8 5/16 BSW x 1 CSK Screw 912000 8 9 3/8 Crinkle Washer 932125 4 10 Button Hd Cap Screw - M10 x 1.5 x 25 912510 2 2 3 4 5 6 7 8 9 10 TOOLS REQUIRED 11 Milbolt - M10 x 1.5 x 29 912830 2 12 Tekote Sealer / Rust Preventative (Not Shown) 906300 1 13 Warning Label (Not Shown) 905016 2 14 Cleaning Pad - Sachet (Not Shown) 906302 1 15 Installation Tool 754200 2 16 Allen Key 6mm 753019 1 Hammer Screwdriver Drill Masking Tape Marker (Pen) Centre Punch 5mm, 9mm, Drill Bits 19mm,22mm hole saws Ø16mm Wad Punch or Vinyl cutter Tape Measure Steel rule Drill stops Allen Key - 6mm AF FITTERS ADVICE 11 15 Note: To fit the Cargo Barrier the following is essential: Always drill perpendicular to surface (Unless stated otherwise). A positive drill stop should always be used to prevent accidental damage to external panels, fuel lines etc. A vinyl cutter assembly should be used for all soft material (i.e. Hood lining, floor covering etc). This can be made by grinding the teeth from a hole-saw at an angle of about 45 degrees. Care should be taken when applying Tekote Sealer/Rust Preventative to all holes drilled to negate the possibility of skin and eye irritation. Check screws in relevant components by hand before installation. Should there be resistance re-tap threads and re-check. Before marking or drilling for this Cargo Barrier, check vehicle for LPG Conversion. If LPG is fitted, locate gas unit and all lines attached and take EXTREME CARE whilst installing this Cargo Barrier. CARE SHOULD BE TAKEN NOT TO CROSS THREAD THE FASTENERS DURING INSTALLATION OF COMPONENTS TO THE VEHICLE. 608825 Issue A Oct 05 Milford Industries Page 1 of 8 16
1. This diagram shows the right hand side TOP MOUNT LOCATION SEQUENCE The left-hand side is the opposite 3rd Row of seats must be removed prior to installation of this cargo barrier & must not be used whilst barrier is in use. Remove rear grab handles & replace after fitment. B. NOTE : When M10 location has been established, drill a 5mm pilot hole through plastic side window trim & steel panel behind. Remove plastic trim and replace after fitment. (For ease of trim removal remove the centre plastic trim above tailgate). A. Along centre line between grab handle screw holes, measure from the rear grab handle screw hole 90mm. 90 Rear passenger window Measure 6mm towards window from centre line between grab handle screw holes. Repeat on other side. R/H side shown Cargo area window Diagram 1: Top mount locations 2. This diagram shows the right hand side BOTTOM MOUNT LOCATION SEQUENCE The left hand is the opposite. Follow Steps A to C on Diagram Rear Seat C A A. Remove child restraint anchorage (if fitted) from this location. Replace after installation & tighten to 27Nm. B 25 155 Wheel Arch B. Remove floor covering. (Diagram shown with covering already removed). Replace covering after installation. C. Measure dimensions from centre of child restraint anchorage captive nut. Mark center hole location. Front of Vehicle Diagram 2: Bottom mount locations Hint: You may need to remove a small amount of plastic sound installation so top cover plate can fit flat on steel. Ensure paint is not damaged. 608825 Issue A Oct 05 Milford Industries Page 2 of 8
Front of vehicle 3. MARK MOUNTING PLATE OUTER HOLES FOR TOP MOUNTS Place centre hole of Mounting Plate (Item 2) over drilled location s from step 1. Mark outer holes of Mounting Plate with felt pen. Note: Mounting plate should be Diagram 3: Marking outer holes with Mounting Plate. Do not drill holes until marked locations are confirmed. 4. MARK MOUNTING PLATE OUTER HOLES FOR BOTTOM MOUNTS Place centre hole of Mounting Plate (Item 2) over marked location s from step 2. Mark outer holes of Mounting Plate with felt pen. Note: Mounting plate should be parallel to wheel arch. Front of vehicle Diagram 4: Marking outer holes with Mounting Plate. Do not drill holes until marked locations are confirmed by offering barrier to marked vehicle & check that straps will fit marked locations. 5. CENTRE PUNCH Centre punch all marked locations Centre Punch metal panels. Diagram 5: Centre Punch all marked locations 608825 Issue A Oct 05 Milford Industries Page 3 of 8
6. SETTING DRILL STOP LENGTH. Set all drill stop lengths as shown in picture. 20mm Diagram 6: Drill Stop Settings. Set Drill stop so outer panels do not get damaged 7. DRILLING PILOT HOLES. Drill 5mm pilot holes at all marked points. Diagram 7: Drilling 5mm pilot holes in top panel as shown Drill perpendicular to all surfaces. Metal Panel 9mm 8. DRILLING TOP MOUNTS. Plastic trim 19mm 22mm Drill holes according to picture. Plastic trim to be drilled out to 19mm using a hole saw or wood drill. Diagram 8: Drilling top mounts Caution should be taken not to drill through outer panels. IMPORTANT Apply Tekote sealer (item 12) to all drilled metal panels to prevent corrosion. All drilling swarf should be vacuumed away before refitting trim. 608825 Issue A Oct 05 Milford Industries Page 4 of 8
Carpet 9. DRILLING BOTTOM MOUNTS. Drill holes according to picture. 22mm Metal panel 9mm Diagram 9: Drilling bottom mounts. IMPORTANT Apply Tekote sealer (Item 12) to all drilled metal panels to prevent corrosion. All drilling swarf should be vacuumed away before refitting trim. 10. ASSEMBLY OF INSTALLATION TOOL AND MOUNTING PLATE FOR TOP MOUNTS. Push eye of Installation Tool (Item 15) through centre hole of Mounting Plate (Item 2) as shown in picture. Diagram 10: Assembly of Installation Tool and Mounting Plate. 11. INSERTING MOUNTING PLATE FOR TOP MOUNTS. Insert Mounting Plate through centre 22mm holes drilled in step 8 as shown in picture. Diagram 11: Inserting mounting plate. 608825 Issue A Oct 05 Milford Industries Page 5 of 8
These diagrams show the Right-Hand side Top Mounts installation procedure. (The left-hand side is the same). Item 8 Item 2 Metal Panel Item 3 Plastic trim 12.Top Mount 1. Slide Mounting Plate Assy (Item 3) over installation tool (Item 15). Ensure spacer tube is facing down. 2. With outer holes aligned fasten with 5/16 x 1 BSW screws (Item 8) 3. Ensure M10 thread is aligned before tightening outer 5/16 x 1 BSW screws to 8Nm. See diagram 12 4. Replace plastic trim and repeat on opposite side. 5. Refit seat belt bolts & tighten to 42Nm. 6. Refit rear grab handles. Diagram 12: Top mount assembly. These diagrams show the Right-Hand side Floor Mount installation procedure. (The left hand side is the same). Fig B Item 15 Floor covering Item 5 Fig C 16mm vinyl cut or Wad punch Item 8 13. Floor Mounts 1. Insert installation tool (Item 15) through mounting plate M10 centre hole (Item 2). 2. Insert mounting plate & installation tool into mounting plate seal (Item 5) see Fig B. 3. Insert mounting plate assy. through 22mm hole in panel. (see Fig C) 4. Assemble as per diagram. Ensure centre M10 thread is aligned before tightening outer 5/16 X 1 BSW screws to 8Nm.(Item 8) 5. Floor covering Refit after mount installation. Drill 16mm hole at centre M10 Hole location with Vinyl cutter or alternatively use a Ø16 Wad punch. Metal panel Item 4 Item 5 Item 6 Item 2 When cutting Ø16mm hole in carpet use backing protector such as a block of wood between carpet & floor. Caution should be taken not to drill through outer panels. Diagram 13: Floor mount assembly. 608825 Issue A Oct 05 Milford Industries Page 6 of 8
Installation of Cargo Barrier Fit rubber washer (Item 7) between strap and trim. Fit Button Cap Screw (Item 10) with crinkle washer (Item 9) & tighten with Allen Key (Item 16). Fit Milbolt (Item 11) with crinkle washer (Item 9). REAR POSITION With the second row of seats in an upright position, stand the cargo barrier directly behind. The cargo barrier compliance plate must be in the top left hand corner, and facing towards the rear of the vehicle. Attach the top & bottom straps to mounts with Milbolts & Button Cap Screw as shown. 608825 Issue A Oct 05 Milford Industries Page 7 of 8
Installation of Warning Labels 1. Clean dash board and tail gate label locations with cleaning pad (Item 14 ) 2. Affix warning labels ( Item 13 ) in locations shown. Item 13 DASHBOARD LOCATION Item 13 TAILGATE LOCATION 608825 Issue A Oct 05 Milford Industries Page 8 of 8