TOYOTA FJ CRUISER 2007 AUXILIARY LIGHTS

Preparation
Part Number: PT297-35061 NOTE: Part number of this accessory may not be
the same as the part number shown.
Kit Contents
Item # Quantity Reqd. Description General Applicability
1 2 Driving Lamp Assembly All Models
2 1 Switch Harness
3 1 Lamp Harness
4 2 Stone Shield Recommended Sequence of Application
Hardware Bag Contents Item # Accessory
Item # Quantity Reqd. Description 1 Off Road Lights
1 1 Relay 2 Auxiliary Lights
2 1 15A Fuse 3 TVIP
3 1 Switch
4 16 7” Tie Wrap *Mandatory
5 1 24” Tie Wrap Vehicle Service Parts (may be required for reassembly)
6 2 T-Tap Connectors
Item # Quantity Reqd. Description
7 1 Foam Tape
1
8 1 Car Care Guide
2
Additional Items Required For Installation 3
Item # Quantity Reqd. Description
1 1 FJ Auxiliary Lamp Bumper
Brackets (PT297-35062) if
vehicle does not have brush Legend
guard
2 STOP: Damage to the vehicle may occur. Do not
proceed until process has been complied with.
Conflicts OPERATOR SAFETY: Use caution to avoid risk of
None injury.
Recommended Tools CAUTION: A process that must be carefully observed
in order to reduce the risk of damage to the
Personal & Vehicle Notes accessory/vehicle and to ensure a quality installation.
Protection TOOLS & EQUIPMENT: Used in Figures calls out the
Safety Goggles specific tools and equipment recommended for this
Watch and Belt Buckle process.
Protectors, Blankets
Protective Tape
Special Tools Notes
Torque wrench 10-50 lbs-ft.
Shop Vacuum
Drill Template IADS: FJC07-044-01
Installation Tools Notes
12mm Socket/box wrench
17mm Socket/box wrench
10mm Socket
Panel Removal Tool
Drill
7/8” Hole Saw
Side Cutters
Long Nose Pliers
Exacto Knife
Special Chemicals Notes

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Procedure
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. Vehicle Dissemble
(a) Set parking brake.
10 mm Socket
(b) Remove the negative battery cable (Fig. 1-1).
(1) Protect the fender before starting.
(2) Do not touch the positive terminal with
any tool when removing cable.
(c) Wait 90 seconds before proceeding to
Fig. 1-1 disassemble vehicle.
NOTE: Place all removed parts on a protected
surface.
NOTE: When disconnecting wiring connectors
do not pull on the wiring, pull on the connector
only.
(d) Add protective tape to front bumper and grill
(Fig. 1-2)

Fig. 1-2

Panel Removal Tool

and 10 mm Socket
(e) Remove Front Grill
(1) Remove two clips and two screws.
(Fig. 1-3)
(2) Disengage the five clips and remove the
Pull
radiator grill by pulling straight forward.

Fig. 1-3

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Procedure

Panel Removal Tool

(3) Remove the three clips. (Fig. 1-4)

Fig. 1-4

Panel Removal Tool (f) Remove Lower Instrument Panel Finish

(1) Disengage the four clips and two claws
and remove the IP register by pulling
straight rearward. (Fig 1-5)

Fig. 1-5

(2) Disengage the three claws and separate

the hood release lever. (Fig. 1-6)

Fig. 1-6

(3) Open driver side rear (2nd ) door.

Nylon Panel Removal Tool (4) Remove the driver side step cover.
(Fig. 1-7)
(i) Cover the floor and seats before
starting.

Step Cover

Fig. 1-7

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Procedure

Nylon Panel Removal Tool

(5) Remove the footrest. (Fig. 1-8)
Footrest
(6) Remove the one nut securing cowl cover
Cowl Cover and remove cowl cover. (Fig. 1-8)

Fig. 1-8

(7) Remove the two screws. (Fig. 1-9)

(8) Disengage the five clips and claw and
remove the lower IP trim.

Fig. 1-9 10 mm Socket

(9) Remove the four screws and remove the

lower metal instrument panel. (Fig. 1-10)

Fig. 1-10 10 mm Socket

(10) Remove the parking brake cover plate.

Panel (Fig. 1-11).
Removal Tool

Fig. 1-11

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Procedure

(11) Shift the lever into the N position.

(Fig. 1-12)
(i) Remove the shift lever knob(s).

Fig. 1-12

(12) Remove the box bottom mat.

(Fig. 1-13)

Fig. 1-13

(13) Disengage and remove the top panel

Panel Removal Tool of center console. (Fig. 1-14)
(14) Reattach shift lever knob(s).

Fig. 1-14

(15) Remove the four screws. (Fig. 1-15)

10 mm socket

(16) Carefully disengage the console

assembly and position rearward.
(17) Cover front portion of console with
cloth.

Fig. 1-15

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Procedure

(18) Remove the lower instrument console

assembly. (Fig. 1-16)
Panel Removal (i) Remove the two clips and two
Tool and 10 mm
Socket screws.
(ii) Disengage the three clips and two
claws and tilt the instrument console
rearward to allow access to remove
Fig. 1-16 knockouts.

2. Interior Installation of Switch/Wire Harness

Auxiliary
Switch
Location (a) Locate the bottom left unused knockout.
(Fig. 2-1)
RR
DIFF
LOCK

400W
AC
P
115V
100W

Fig. 2-1

(b) Install the switch in the orientation shown.

(Fig. 2-2)
(c) Plug the Auxiliary wire harness 6 pin
connector into the Auxiliary switch.

Fig. 2-2

(d) Locate the grey connector at the rear of the

“RR DIFF LOCK” switch. (Fig. 2-3)
RR
DIFF
LOCK

400W
AC
P
115V
100W

Fig. 2-3

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Procedure

(e) Locate the Green and White-Green wires at

G & W-G
the rear of the knockout/switch in location 2.
(Fig. 2-4)
(1) Apply T-taps to the Green wire and
White-Green wires.
(2) Connect the T-taps from the switch wire
harness to the T-taps on the Green and
Long Nose Pliers
Fig. 2-4 White-Green wires.

W/H clamp
(f) Route the wire harness from instrument
console area and along the vehicle wire
harness. (Fig. 2-5)
(1) Be sure to route wire harness through the
w/h clamp.

Fig. 2-5

(g) Continue routing the wire harness down and

along vehicle wire harness.
(Fig. 2-6)

Fig. 2-6

Connector
(h) Connect the 13 pin connector of the wire
harness to the vehicle connector located in
the left side cowl area.
(Fig. 2-7)

Fig. 2-7

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Procedure

(i) Remove the ground screw and attach the

Ground screw ground wire with terminal to the ground
point. (Fig. 2-8)

Fig. 2-8 10 mm socket

4 Wire ties Foam tape (j) Adjust wire harness so that the slack is
located behind the lower instrument panel.
(1) Secure the wire harness with four wire
ties to the vehicle wire harness.
(Fig. 2-9)
(2) Secure the wire harness to the air duct
Fig. 2-9 with foam tape.

(k) Secure wire harness with wire tie to main

vehicle wire harness. (Fig 2-10)
(l) Cut all excess wire ties.
(m) Reposition the lower instrument panel.
2 Wire Ties

3. Exterior Installation of the Lamp wire

Fig. 2-10 harness and Auxiliary lights.

Wire Tie Two pin connector (a) Locate the two pin connector on the vehicle
wire harness. (Fig. 3-1)
(1) Remove the break-away tape and
connector plug.
(2) Plug the accessory wire harness into the
two pin connector.
Fig. 3-1 (3) Secure the connector to the vehicle
harness with wire tie.

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Procedure

(b) Route the wire harness along side of the fuse

24” Wire Tie
box and battery. (Fig. 3-2)

(1) Secure wire harness with the 24”

wire tie to the vehicle wire harness at
the location between the fuse box
and battery. (Fig. 3-2)
Fig. 3-2

(c) Secure the wire harness to the vehicle

3 Wire Ties
harness behind the headlamp with 3 wire ties
and continue the routing of the harness along
the vehicle harness. (Fig. 3-3)

Fig. 3-3

(d) Continue routing the harness along the

vehicle harness in front of the radiator.
Secure the wire harness to the vehicle wire
harness under the top front radiator support
with 4 wire ties. (Fig 3-4)

4 Wire ties
Fig. 3-4

4. Installation of Lights on Brush Guard (see

Nut step 5 for bumper installation)

(a) Attached the lamps to the Brush Guard.

(Fig. 4-1)
Center
of
(1) Confirm that the 14 mm nut is installed
vehicle
towards center of vehicle.
Fig. 4-1 (i) If necessary remove nut and bolt and
reinstall so nut is towards center of
vehicle.
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Procedure

(2) Align the lamps so that the brackets are

parallel to each other as shown.
(3) Tighten each 14 mm nut to 40 lbs-ft.
(b) Reattach the front grill with screws and clips.
(c) Install the Brush Guard as indicated in the
Brush Guard installation instructions.
(d) Route the pig tail wire harness from each
Fig. 4-2 lamp directly rearward and through the grill.
(Fig. 4-2)

2 Wire ties (e) Connect the pig tail connectors to the mating
connectors on the wire harness.
(f) Secure the pigtails connections with 2 wire
ties. (Fig. 4-3)

Fig. 4-3

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Procedure

Align template along

bumper ridge 5. Installation of Lights on Bumper

(a) Cut out template provided in kit.

(b) Lay left side template on top of bumper and

align along ridge with tab against side ridge.
Align tab along (Fig. 5-1)
Fig. 5-1 side ridge
(c) Center punch the cross hairs.
(d) Place cardboard between bumper fascia and
Cardboard Support bracket
support bracket to protect metal. (Fig. 5-2)

(e) Adjust pilot drill so tip does not exceed

height of hole saw teeth.
(f) At center punch marks, drill 7/8” holes with
Fig. 5-2 hole saw. (Fig. 5-2)
7/8” hole saw, drill
(1) Be sure not to cut through cardboard
and scratch the bumper bracket.
Support Tube
(g) Repeat steps a though f for right side of
bumper.
(h) Remove excess rubber material with Exacto
knife to expose the four factory provided
holes in the bumper support bracket.
(i) Vacuum up any remaining rubber material.
Fig. 5-3

(j) Insert bumper support tube into opening

Torque wrench
12 mm socket
beneath the bumper. (Fig. 5-3)

(k) Install bumper support tube in the bumper

support channel and loosely secure with the 2
M8 bolts and 2 M8 nuts to the center radiator
support. (Fig. 5-4)

Fig. 5-4

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Procedure

(l) Hand tighten 2 bolts and washers to the

outside holes on the top of the bumper.
(Fig. 5-5)
(m) Tighten the 2 M8 bolts and 2 M8 nuts that
attach the support bracket to the center
radiator support to 15 lbs-ft. (Fig 5-4)
(n) Reattach the front grill with screws and clips.
Fig. 5-5

12 mm wrench (o) Remove the 2 bolts and washers holding the

support bracket to the bumper.
(p) Install left hand lamp bracket with 2 M8
bolts and 2 washers. Tighten the bolts to 15
lbs-ft. (Fig. 5-6)
(q) Repeat for right hand lamp bracket.
Fig. 5-6

Torque wrench (r) Remove M10 nut from lamp assembly and
15 mm socket attach the lamps to the left and right hand
lamp brackets. Tighten each 15 mm nut to
40 lbs-ft. (Fig. 5-7)

Fig. 5-7
(s) Route the pig tail wire harness from each
lamp directly rearward and through the grill.
(Fig. 5-8)

(t) Connect the pig tail connector to the mating

connectors on the wire harness and secure the
with 2 wire ties as per step 4f.
(u) Adjust the horizontal and vertical aiming of
Fig. 5-8 the lamps as per step 4g and 4h.

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Procedure

6. In Process Function Check

Aux Fuse
(a) Install the provided 15 amp fuse. (Fig. 6-1)
(1) Install the provided relay.
(b) Reconnect the negative battery terminal.
(c) Turn the ignition key to IG position.
(d) Turn on the running head lamps in high beam
mode.
(e) Press the Auxiliary switch in and out and
confirm that the Auxiliary lights turn on and
off.
(f) Confirm that the green indicator lamp is on
when the Aux lights are on.
(g) Confirm that the switch illumination back
Fig. 6-1 light is on.

Aux Relay

(h) Adjust the horizontal and vertical aiming of

the lamps as shown. Place horizontal and
vertical cross hairs on a wall 10 to 15 feet in
front of the vehicle as shown. The center of
the bright spot of the beam pattern should be
centered on the cross hairs. (Fig. 6-2)
(i) Tighten the 12mm nut to 15 lbs-ft.

(j) Disconnect the negative terminal of the

Fig. 6-2 battery.

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Procedure

7. Reassembly of Vehicle

(a) Reassemble the lower instrument console.

(b) Reassemble the center console.
(c) Reattach gear shift knobs.
(d) Reassemble the lower metal instrument panel
and trim cover.
(e) Reassemble the cowl and foot rest.
(f) Reassemble the door scuff plate.
(g) Reassemble the IP register.
(h) Verify the panels fit together properly with
no uneven gaps between them.
(i) Place the care card in the glove box.
(j) Place the stone shield covers in the front
passenger floor.

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Checklist - these points MUST be checked to ensure a quality installation.
Check: Look For:
Accessory Function Checks

Auxiliary Lights function Only turns on with high beams

Auxiliary switch indicator Indicator lamp is on when Aux lights are

on.

Auxiliary switch back light Switch back light turns on

Vehicle Function Checks

Check functions of all switch functions on

center IP console

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