FI11979 - TPWKIT-007 - Toyota Kluger and Prado - Electric ... · Tow-Pro Wiring Kit Suitable for:...

FI11979 Issue: 4 Date: 14/08/2018© 2018

Kit Part No: TPWKIT-007

Suitable for: Kluger / Prado

Page 01 of

Tow-Pro Wiring Kit

Suitable for: Toyota Prado / Kluger

Fitting Instructions


Accessory KitEstimated Fitting Time: 120 Minutes (Prado)Estimated Fitting Time: 140 Minutes (Kluger)

21

Parts Supplied

Safety Notes

General Notes

Tools Required

FI11979 Issue: 4 Date: 14/08/2018© 2018



•

•

•

•

•

•

Read through the fitting instructions before installation of the accessory. Install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or the accessory.

Ensure all recyclables, discarded vehicle accessory components and packaging are recycled following local recycling regulations.

It is always recommended that this accessory is fitted by a qualified automotive 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, or suitable automotive rust inhibitor.

Remove all metals swarf and dust from all vehicle surfaces if surfaces is used for accessory installation.

•

•

Check that all work practices comply with safety standards.

Please wear appropriate clothing and use safety equipment.

Ratchet Socket Set Guide wirePhillips Head Screw Driver Trim Removal Tools PVC Tape

D

J

M4 Pan Head Screws x4

H

M4 Flat Washer x4

B

Electric Brake Harness x1

G

Switch Insert x1

N

Cable Ties x40

200mm x20900mm x20

K

M6 Flat Washer x1

L

M6x16 Bolt x1

Fitting Instruction x1

F

Ø6mm Heatshrink x1

Silicone Spray Silicone Sealant

Page 02 of

A

2.5m Cat 5 Cable x1

C

4-way Connector x1

E

Butt Splice x1

I

M4 Nyloc Nut x4

M

Brake Controller Bracket x1

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FI11979 Issue: 4 Date: 14/08/2018© 2018



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Wiring Diagram

Page 03 of

Kluger(Page 4)

Prado(Page 13)

ECU Switch SwitchECU

Step 1

Step 3

FI11979 Issue: 4 Date: 14/08/2018© 2018



KLUGER (For Prado refer to Page 13)

Step 2

• Note down radio settings, as per Toyota Workshop manual.

• In the engine bay, disconnect the negative battery terminal (1).

Important

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

1

Page 04 of

32

• Inside the vehicle, remove the passenger side scuff plate trim (1).

• Remove the kick panel trim nut (2).

• Remove the kick panel (3).

Repeat for RHS.

• Remove the LHS dash side garnish (1).

Repeat for RHS.1

21

Step 4

Step 6

FI11979 Issue: 4 Date: 14/08/2018© 2018



Step 5

Page 05 of

• Push down on the clips (1) and remove the lower glovebox cover (2).

2

11

1

1

• Dislodge the glovebox damper (1).

• Push the side walls inwards and then remove the glovebox (2).

1

2

• Remove the three upper glovebox surround fasteners (1).

• Remove the two lower glovebox surround fasteners (2).

• Dislodge the glovebox surround (3).

• Disconnect the light connector (4) from behind the glovebox surround (3).

• Remove the glovebox surround (3).

4

KLUGER

21

Step 7

Step 9

FI11979 Issue: 4 Date: 14/08/2018© 2018



Step 8

Page 06 of

• Remove the two fasteners (1) from the driver’s garnish underside trim (2).

• Press down on the clip (3) and remove driver’s garnish underside trim (2).

• Remove the one lower trim fastener (4).

• Dislodge the driver’s garnish lower trim (5).

• Disconnect all switch connectors from behind the switch panel and one connector (6) next to the boot latch .

• Disconnect the boot latch (7).

• Remove the driver’s garnish lower trim (5).

1

1

2

4

5

7SRS AIRBAG

3

6

• In the front passenger side foot well, locate the upper grommet nipple (1) on the firewall grommet.

• Carefully cut off the grommet nipple (1) using a sharp knife.

1

• ecure the section of the Electric Brake Harness (1) with the four terminals to a guide wire (2) using tape. Keep the thickness of the taped section small.

• On the LHS firewall grommet (3), lubricate the upper grommet access point (4) with a suitable lubrication if required. Feed the guide wire (2) into the upper grommet access point (4).

• Ensure the guide wire (2) breaks the internal seal and continue feeding the harness into the cabin until the corrugated section of the harness contacts the grommet (3).

In the engine bay, s

2

1

2

3

4

4

KLUGER

21

FI11979 Issue: 4 Date: 14/08/2018© 2018



Step 10

Step 11

Step 12

Page 07 of

• Clean off any lubricant used in previous step.

• Seal the grommet (1) around the Electric Brake Harness (2) using silicone sealant, on the engine bay and cabin sides of the grommet (1).

• Secure the Electric Brake Harness (2) to the vehicles main harness using a supplied Cable Tie (3).

both

• Inside the vehicle, route the Electric Brake Harness (1) from the grommet towards front passenger RHS footwell area.

• Secure the Electric Brake Harness (1) to the existing vehicle harness using the supplied 200mm Cable Ties (2) as shown.

ImportantEnsure the Electric Brake Harness is kept away from any sharp or moving parts and clear of being pinched by trim re-fitment.

3

2

1

1

2 2

• Using the table below, house the terminals (1) from the Electric Brake Harness into the supplied 4-Way Connector (2) ensuring the terminals lock into the housing.

• Snap off the secondary lock (3) from behind the 4-Way Connector (2).

• Fit the secondary lock (3) to the underside of the 4-Way Connector (2).

Wire ColourTerminal

1234

RedBlue

WhiteBlack

Rear View of Connector(Wire Entry Side)

4 3 2 1

2

3

3

2

KLUGER

1

21

FI11979 Issue: 4 Date: 14/08/2018© 2018



Step 14

Step 13

Step 15

Page 08 of

Cat 5 Cable

4-way ECUconnector

• Secure the Brake Controller ECU (1) to the ECU Bracket (2) using the supplied M4 Pan Head Screws (3), M4 Flat Washers (4) and M4 Nyloc Nuts (5).

• On the support bar located in the RHS area of the glove box, release the two vehicle M8 nuts (1) from the threaded studs.

• Using the vehicle M8 nuts (1), secure the ECU Bracket assembly (2) onto the two threaded studs as shown.

Important

Ensure to use the mounting holes (6) on the ECU Bracket (2) that are designed for the Toyota Kluger.

6

6

6

6

2

1

• Connect the 4-way connector (1) from the Electric Brake Harness to the Brake Controller ECU (2).

• Connect the Cat 5 Cable (3), supplied in the wiring kit, to the Brake Controller ECU (2).

2

31

KLUGER

3

5

4

11

2

21

FI11979 Issue: 4 Date: 14/08/2018© 2018



Step 17

Step 16

Page 09 of

• Remove the switch blank (1) from the drivers under dash trim (2).

• Route the Cat 5 Cable (3) along the dash towards the under dash trim (2) area. Secure using the supplied Cable Ties.

2

1

(Kluger)

• Insert the supplied Switch Insert (1) into the vacant cavity on the drivers under dash trim (2).

• Insert the Electric Brake Switch (3) into the Switch Insert (1) from behind.

• Fasten the supplied Nut (4) locking the Electric Brake Switch (3) to the Switch Insert (1). Torque the Nut (4) to 0.8Nm.

• Rotate the shaft (5) fully anti-clockwise and fit the knob (6) to the shaft with “0" pointing upwards as shown.

• Connect the Cat 5 Cable (7) to the Electric Brake Switch (3) from behind.

• Secure the excess Cat 5 Cable (7) with the supplied Cable Ties.

• Reinstall the drivers under dash trim (2).

1

7

3

6

45 6

2

1

Important

Ensure the Cat 5 Cable (3) does not interfere with the steering column, any of the vehicle pedals or the airbag system.

3

• In the engine bay, locate the three loose wires on the Electric Brake Harness (1) and route down the firewall and towards the LHS chassis rail.

• Secure to the existing vehicle harness using the supplied Cable Ties.

ImportantEnsure the Electric Brake Harness (1) does not make contact with any sharp edges or moving parts. Avoid areas of extreme temperatures.

Step 18

1

KLUGER

21

FI11979 Issue: 4 Date: 14/08/2018© 2018



Step 19

Step 20

Step 21

Page 10 of

• Under the LHS of the vehicle, remove the fasteners and dislodge the underbody cover (1).

• Route the Electric Brake Harness (2) along the LHS chassis or along the air conditioning pipes towards the vehicles rear cross member.

• Secure using the supplied 900mm Cable Ties at 300mm intervals.

• Reinstall the underbody cover (1).

• At the rear cross member, route the Electric Brake Harness (1) towards the rear of the vehicle, following the existing vehicle harness.

• From the LHS of the rear cross member, route the Electric Brake Harness (1) behind the trim towards the trailer socket.


• At the rear of the vehicle, remove the vehicles trailer socket fasteners to release the trailer socket (1).

• Remove the cover (2) from the trailer socket (1).

2

KLUGER

2

1

1

1

21

FI11979 Issue: 4 Date: 14/08/2018© 2018



Step 22

Step 23

Step 24

Page 11 of

• Remove the ‘BLUE’ wire (1) from the trailer wiring harness socket head (2).

• Tape back and isolate.

• Insert new ‘BLUE’ wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket.

Pin No. Function Cable Colour123456

7

Left-hand turn signalReversing signalEarth returnRight-hand signalService brakesStop lamp signalRear lamps, clearance andside marker lamps

YellowBlackWhiteGreen

BlueRed

Brown

4

7

2

3

5

6

1

2

1

• Locate ‘RED’ wire (1) on the trailer wiring harness socket head.

• Cut the wire 150mm from the base of the socket.

• Remove the cut ‘RED’ wire (1) from the trailer socket.

4

7

2

3

5

6

1


7



BlueRed

Brown

1

150mm

X

• Butt-splice and heat shrink the previously cut ‘RED’ wire on the vehicle end, to the ‘RED/WHITE’ wire on the Electric Brake Harness.

• Slide the supplied Heatshrink over the wires before c

•

•

rimping both wires to the supplied Butt Splice using indent type crimpers.

Solder the wires to the Butt Splice. Ensure that a good connection is made.

Wait for the Butt Splice to cool, slip heatshrink over the joint and heat.

Keep heatshrink away from joint until after soldering is complete and cooled.

• Insert new ‘RED’ wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket.

1 2

3 4

11

2

Red

Red/White

Red/White

KLUGER

21

FI11979 Issue: 4 Date: 14/08/2018© 2018



Step 25

Step 26

Page 12 of

• In the engine bay, route the Electric Brake Harness (1) along the existing vehicle harness towards the battery.

• Fasten the positive terminal of the Electric Brake Harness (1) to the positive battery terminal.

• Fasten the negative terminal of the Electric Brake Harness (1) to the negative battery terminal.

• Secure the harness with Cable Ties at 200mm intervals. Secure the harness fuse to the vehicle harness with a Cable Tie.

• Reconnect the engine bay negative battery terminal.

• Test the operation of the Electric Brake Harness using a test lamp or a multimeter to ensure correct operation.

• Dispose of any parts not used from the fitment.

Please place the Owners Manual in the glov box after installation completed.

e the is

ImportantSecure all harnesses to the vehicle using the supplied cable ties. Refit all removed parts and secure all fasteners to Service Manual torque specifications.

Important

Reprogram all radio stations and clock settings by referring to the vehicle's Workshop Manual.

1

1

KLUGER

21

FI11979 Issue: 4 Date: 14/08/2018© 2018



21

Step 1

Step 3

Step 2

PRADO (For Kluger refer to Page 4)

• Note down radio settings, as per Toyota Workshop manual.

• In the engine bay, disconnect the negative battery terminal (1).

Important

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

1

• Inside the vehicle, remove the passenger side scuff plate trim (1).

• Remove the kick panel (2).

• Open the glovebox (3) and dislodge the dampener.

• Remove the glovebox (3).

• Remove the upper glovebox garnish (4).

• Remove the LHS dash side garnish (5).

• Remove the glovebox undertray (1) by first removing the screw (2).

• Remove the four bolts (3) from the glovebox surround (4).

• Remove the glovebox surround (4).

2

1

5 4

3

2

1

3 3

4

3

3

Page 13 of

FI11979 Issue: 4 Date: 14/08/2018© 2018



21

Step 4

Step 6

Step 5

•

• Dislodge the driver’s garnish lower trim (2).

• Remove the vehicle switch blank (3) by pushing from behind.

Remove the RHS dash side garnish (1).

1

2

3

• On the LHS side of the engine bay, locate the grommet nipple (1) on the firewall grommet (2).

• Carefully cut off the grommet nipple (1) using a sharp knife.

2

1

• ecure the section of the Electric Brake Harness (1) with the four terminals to a guide wire (2) using tape. Keep the thickness of the taped section small.

• On the LHS firewall grommet (3), lubricate the upper grommet access point (4) with a suitable lubrication if required. Feed the guide wire (2) into the upper grommet access point (4).

• Ensure the guide wire (2) breaks the internal seal and continue feeding the harness into the cabin until the corrugated section of the harness contacts the grommet (3).

S

Page 14 of

PRADO

2

1

24

4

3

FI11979 Issue: 4 Date: 14/08/2018© 2018



21

• Using the table below, house the terminals (1) from the Electric Brake Harness into the supplied 4-Way Connector (2) ensuring the terminals lock into the housing.

• Snap off the secondary lock (3) from behind the 4-Way Connector (2).

• Fit the secondary lock (3) to the underside of the 4-Way Connector (2).

Step 7

Step 9

Step 8

• Clean off any lubricant used in previous step.

• Seal the grommet (1) around the Electric Brake Harness (2) using silicone sealant, on the engine bay and cabin sides of the grommet (1).

• Secure the Electric Brake Harness (2) to the vehicles main harness using a supplied Cable Tie (3).

both 1

Wire ColourTerminal

1234

RedBlue

WhiteBlack

Rear View of Connector(Wire Entry Side)

4 3 2 1

2

3

3

2

Page 15 of

PRADO

• Secure the Brake Controller ECU (1) to the ECU Bracket (2) using the supplied M4 Pan Head Screws (3), M4 Flat Washers (4) and M4 Nyloc Nuts (5).

Important

Ensure to use the mounting holes (6) on the ECU Bracket (2) that are designed for the Toyota Prado.

6

6

6

6

2

1

5

4

3

1

3

2

FI11979 Issue: 4 Date: 14/08/2018© 2018



21

Step 10

Step 11

Step 12

• Using the supplied M6 Bolt (1) and M6 Flat Washer (2), secure the ECU Bracket assembly (3) to the inside panel on the LHS of the glovebox area.

Important

Ensure the vehicle metal tab (4) is located in the slot of the ECU Bracket.

21

3

• Connect the 4-way connector (1) from the Electric Brake Harness to the Brake Controller ECU (2).

• Connect the Cat 5 Cable (3), supplied in the wiring kit, to the Brake Controller ECU (2).

1

2

3

Page 16 of

PRADO

• Inside the vehicle, route the Electric Brake Harness (1) towards the front passenger kick panel area.

• Secure the Electric Brake Harness (1) to the existing vehicle harness using the supplied 200mm Cable Ties (2) as shown.

ImportantEnsure the Electric Brake Harness is kept away from any sharp or moving parts and clear of being pinched by trim re-fitment.

1

2

Note: In some vehicles a spare connector or clip may be located here. If so, unclip and secure back to existing wiring out of the way before proceeding.

Important

If the area is being used by another ECU, remove the main unit from its bracket and secure it with Cable Ties in this area.

4

FI11979 Issue: 4 Date: 14/08/2018© 2018



21

• Route the Cat 5 Cable (1) towards the drivers under dash trim area.

• Secure the Cat 5 Cable (1) to the existing vehicle harness using the supplied 200mm Cable Ties.

Step 13

Step 14

Step 15

• Insert the supplied Switch Insert (1) into the vacant cavity on the drivers under dash trim (2).

• Insert the Electric Brake Switch (3) into the Switch Insert (1) from behind.

• Fasten the supplied Nut (4) locking the Electric Brake Switch (3) to the Switch Insert (1). Torque the Nut (4) to 0.8Nm.

• Rotate the shaft (5) fully anti-clockwise and fit the knob (6) to the shaft with “0" pointing upwards as shown.

• Connect the Cat 5 Cable (7) to the Electric Brake Switch (3) from behind.

• Secure the excess Cat 5 Cable (7) with the supplied Cable Ties.

• Reinstall the drivers under dash trim (2).

5 6

• In the engine bay, locate the three loose wires on the Electric Brake Harness (1) and route down the firewall and towards the LHS chassis rail.

• Secure to the existing vehicle harness using the supplied Cable Ties.


Page 17 of

1

7

3

6

4

2

PRADO

1

1

FI11979 Issue: 4 Date: 14/08/2018© 2018



21

Step 16

Step 17

Step 18

• Under the LHS of the vehicle, continue routing the Electric Brake Harness (1) along the LHS chassis

• Secure using the supplied 900mm Cable Ties.

• At the rear cross member, route the Electric Brake Harness (1) towards the rear of the vehicle, following the existing vehicle harness.

• From the LHS of the rear cross member, route the Electric Brake Harness (1) behind the trim towards the trailer socket.


Page 18 of

1

PRADO

1

• At the rear of the vehicle, remove the vehicles trailer socket fasteners to release the trailer socket (1).

• Remove the cover (2) from the trailer socket (1).

2

1

FI11979 Issue: 4 Date: 14/08/2018© 2018



21

Step 19

Step 20

Step 21

• Remove the ‘BLUE’ wire (1) from the trailer wiring harness socket head (2).

• Tape back and isolate.

• Insert new ‘BLUE’ wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket.


7



BlueRed

Brown

4

7

2

3

5

6

1

2

1

• Locate ‘RED’ wire (1) on the trailer wiring harness socket head.

• Cut the wire 150mm from the base of the socket.

• Remove the cut ‘RED’ wire (1) from the trailer socket.

4

7

2

3

5

6

1


7



BlueRed

Brown

1

150mm

X

• Butt-splice and heat shrink the previously cut ‘RED’ wire on the vehicle end, to the ‘RED/WHITE’ wire on the Electric Brake Harness.

• Slide the supplied Heatshrink over the wires before c

•

•

rimping both wires to the supplied Butt Splice using indent type crimpers.

Solder the wires to the Butt Splice. Ensure that a good connection is made.

Wait for the Butt Splice to cool, slip heatshrink over the joint and heat.

Keep heatshrink away from joint until after soldering is complete and cooled.

• Insert new ‘RED’ wire with brass ferrule from the Electric Brake Harness into the same position in the trailer socket.

1 2

3 4

11

2

Red

Red/White

Red/White

Page 19 of

PRADO

FI11979 Issue: 4 Date: 14/08/2018© 2018



21

Step 22

Step 23

• In the engine bay, route the Electric Brake Harness (1) along the existing vehicle harness towards the battery.

• Fasten the positive terminal of the Electric Brake Harness (1) to the positive battery terminal.

• Fasten the negative terminal of the Electric Brake Harness (1) to the negative battery terminal.

• Secure the harness with Cable Ties at 200mm intervals. Secure the harness fuse to the vehicle harness with a Cable Tie.

• Reconnect the engine bay negative battery terminal.

• Test the operation of the Electric Brake Harness using a test lamp or a multimeter to ensure correct operation.

• Dispose of any parts not used from the fitment.

Please place the Owners Manual in the glov box after installation completed.

e the is

ImportantSecure all harnesses to the vehicle using the supplied cable ties. Refit all removed parts and secure all fasteners to Service Manual torque specifications.

Important

Reprogram all radio stations and clock settings by referring to the vehicle's Workshop Manual.

1

E. & O.E. This document is copyright and must not be used except as permitted below or under the Copyright Act 1968. You may reproduce and publish this document in whole or in part for your or your organisation's own personal or internal compliance, educational or non-commercial purposes. You must not alter or amend this document in any way. You must not reproduce or publish this document for commercial gain without the prior written consent of the copyright owner.

Page 20 of

PRADO

1

FI11979 Issue: 4 Date: 14/08/2018© 2018



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FI11979 - TPWKIT-007 - Toyota Kluger and Prado - Electric ... · Tow-Pro Wiring Kit Suitable for:...

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