Document: 05.25.00 PIO / DIO 02/01/07 TOYOTA FJ Cruiser 2007- Fog Lights Part Number: 00016-60008Accessory Code:

Kit Contents Item # Quantity Reqd. Description1 2 Fog Lamps2 1 Wiring Harness Assembly3 1 Switch Assembly4 2 Lamp Brace5678

Hardware Bag Contents Item # Quantity Reqd. Description1 1 Sheet Metal Screw2 2 6mm x 20mmbolt3 2 6mm fender washer4 1 Wire loom5 1 Dielectric grease pack6 10 Wire ties78

Additional Items Required For Installation Item # Quantity Reqd. Description

ConflictsNote:

Recommended Tools Safety Tools

Special Tools

Installation ToolsTorque Wrench17mm Wrench10mm WrenchScrew Driver #2PliersDrill

3/4”Drill bit

Special Chemicals

Color Applicability/Trim Level

AccessoryColor

Vehicle/Trim Color

General Applicability

Recommended Sequence of Application Item # Accessory123

*MandatoryLegend

STOP: Damage to the vehicle may occur. Do not proceed until process has been complied with.OPERATOR SAFETY: Use caution to avoid risk of injuryCRITICAL PROCESS: Proceed with caution to ensure a quality installation. These points will be audited on a completed vehicle installationTOOLS & EQUIPMENT: This calls out the specifictools and equipment required for this processREVISION MARK: This mark highlights a change in installation with respect to previous issue.

SPECIAL NOTE:After TMS and Safety mandated preparatory steps have been taken, the installation sequence is the suggested method for completing the accessory installation. In some instances the suggested sequence is written for one associate to install and in others the sequence is given as part of a team accessoryinstallation. Unless otherwise stated in the document, the associates may perform the installation steps in any order to make the installation as efficient as possible while maintaining consistent quality.

Safety Glasses

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1 Tap Connector

Protective Tape

Side Cutters

3mm & 11mm bit

3m Silcone Sealant

LF1

The fog lights mount to the top of the bumper through holes that are drilled.

1.) Location of fog light mounting holes. From underneath the bumper you will see a metal frame just under the top of the bumper skin. This metal frame has four symmetrical placed holes, two on each side. You will use the inboard pair of holes that are also closer to the front. (See figure 1)

2.) Using a drill and a bit, drill up through the center of the holes located in step one. If needed a smaller drill but can be used as a pilot hole from underneath then use the 11mm drill bit from the top for final sizing. (See figures 1 and 2)

3.) Sometimes you will need to trim a rubber strip from the center of the hole because the drill bit does not cut it cleanly.

figure 1

lamp mounting hole

front of vehicle

figure 2

holes drilled for lamps

FOGLIGHT MOUNTING

Remove the negative (-) battery terminalusing a 10mm socket before starting anydisassembly.

Preparation

1.)

Toyota FJ Cruiser Fog Lights

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11mm drill

2.) Protective Tape

figure 3

wedge brace between metal frame and plastic and align bracket hole with drilled hole

figure 4

fasten lamp to bumper using 10mm bolt, nut and lock washer

brace fastens to front of lower core support using 6mm bolt and washer

figure 5

4.) From underneath, wedge the long end of the bracket brace between the bumper skin and the metal frame and align the hole in the brace with the newly drilled hole. The other end of the lamp brace will drop down to the threaded hole in the front of the lower core support. The hole in the short end of the brace should line up with the threaded hole. Use the 6mm bolt and 6mm fender washer to secure the brace to the core support.

5.) Fasten the fog lamp to the top of the bumper using the 10mm bolt through the top and secure it with the 10mm nut and lock washer from the bottom. The 10mm lamp mounting bolt should pass through the lamp bracket, bumper skin, lamp brace and metal frame.

6.) Tighten the 10mm lamp mounting bolt to 38ft/lbs and the 6mm bolt to 14ft/lbs.

7.) Push the white lamp connectors through the gap between the top of the bumper skin and the bottom of the grill, right behind the lamps. It will be easier to push through if you push down on the top of the plastic bumper skin.

8.) Locate the relay mounting position. In the engine compartment on the battery side locate the mounting hole. It is just rearward from the battery grounding point and the relay box mounting point. (See figure 6)

9.) Using the sheet metal screw fasten the relay.

figure 6

relay mounting hole

Wiring Harness Assembly

Lamp Brace

Lamp Connectors

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1.) To mount the switch the left air duct panel must be removed. Panel snaps off. Remove panel.

2.) The switch mounts in the left air duct panel that was just removed. To mount the switch a 3/4” hole will need to be drilled. To locate the drill location measure 1” from the right edge of the panel and 1” up from the inside mold ribbing. This will locate the switch just left of the out side mirror controls.

3.) Mount the switch to the panel using the switch nut.

4.) Route the switch wires from the fire wall grommet to the switch and connect the black 3 wire switch connector to the black 3-wire harness connector.

5.) Snap air duct panel back in place.

6.) Tie the switch wires up under the dash away from moving parts and vehicle control devices.

10.) Route the lamp leads of the harness down to the fog lamps. Follow the inner left fender to the back of the headlamp. Route wires down to lamps through left headlamp location. Notice one of the lamp leads is longer than the other, the longer lead goes to the right lamp and the shorter lead to the left lamp.

Plug lamp leads to lamps and tie the loose wires.

11.) Route the switch wires from the relay up to the left side of the fire wall. Locate the large vehicle harness grommet on the left side. Cut the auxiliary wiring access nipple off the grommet and push the black switch plug through.

12.) From inside the cabin locate the switch wires that where pushed through in step 11 above. It will be the grommet above the clutch pedal or above and to the left of the brake pedal.

Switch

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Apply “Dielectric Grease” to insideof connectors.

Seal with silicone sealant. Fig. 8

13.) Apply tap connector to red/yellow wire connector A-23 pin 1 for day time. For Running light without day time pin 3.

Install power ground rings as shown in fig. 7

LH Headlight

Red/Yellow wire

Fig. 9b.

Figure 7

Figure 8

Figure 9

Figure 10

See diagram below

2.) Turn on headlamp low beams then press fog light rocker switch to the up position. Fog lamps should be working. Fog lamps will only work when the low beam of the headlamps is on.

Traditional fog lights are usually mounted under the front bumper about 10-24 inches from the ground. There are two important issues to address when installing fog lights, the first is to minimize the amount of return glare into the drivers eyes, and the other is to minimize glare into oncoming eyes. Both of those issues must be accomplished while put-ting as much light as possible on the road.

These fog/foul weather light aiming instructions are suggestions taken from common practice and the S.A.E. standard J583. Some modifications to these instructions may be necessary to minimize glare.

Visual aim is made with the top of the beam 4 inches below the lamp center at 25 feet with the lamp facing straight forward. See figure 13.

1.) After aiming the lamps tighten the lamp bolts with a Philips screw driver until the lamps do not move.

2.) Position the lower splash shields back in place and replace the fasteners that were removed.

3.) Perform one final check that all fasteners are tightened and that all vehicle functions work.

figure 13

Final Assembly and Checks

Fog light Aiming

Check System for Operation1.) Re-connect battery negative terminal and torque to 36in lbs.

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TOYOTA FJ CRUISER FOG LIGHTS Checklist - these points MUST be checked to ensure a quality installation.

Check: Look For:

Accessory Function Checks

Fog Lights function

Vehicle Function Checks

Check functions of all switch functions

Turn on low beams

All panels snapped into place Loose panels and switches

Fog lights Visually aim and straight forward

Battery Terminal Re-torqued to 36in lbs.

Torques Verify correct torque 38 & 14 ft. lbs is usedduring installation process.

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