The installation of an ARB bull bar is a complex and technical process that requires careful adherence to manufacturer guidelines to ensure both functionality and safety. These instructions are derived from official manufacturer documentation and are intended for trained professionals or experienced DIY enthusiasts. The following article provides a detailed, step-by-step guide to the installation process, safety precautions, and maintenance recommendations for ARB bull bars.
Overview of the Installation Process
The installation of an ARB bull bar involves a series of precise mechanical and electrical steps. The process includes the mounting of the bar to the vehicle, the installation of lighting components, and the securing of additional accessories such as winch covers and washer bottle supports. The instructions emphasize the use of specialized tools, proper torque specifications, and the importance of avoiding modifications that could compromise the structural integrity or functionality of the bull bar.
The following sections outline the key components and procedures involved in the installation process, including mounting, electrical integration, and post-installation checks.
Mounting and Structural Installation
The initial phase of installation focuses on the physical mounting of the bull bar to the vehicle. The process requires the use of power tools, metric socket sets, and a torque wrench to ensure that all bolts are tightened to the correct specifications.
Mounting Preparation: The bar must be positioned so that it is centered on the vehicle's body. The manufacturer specifies that a 10mm to 15mm gap should exist between the bull bar and the grille, as well as a minimum 15mm gap to the headlights and wheel arch flares. This ensures proper clearance and minimizes the risk of interference with other vehicle components.
Mounting Fasteners: The bull bar is fastened to the vehicle using 6x M12x1.75x35mm bolts, 6x M12 spring washers, 6x M12 flat washers, and 6x M12 flange nuts. These bolts must be tightened to a torque of 77Nm. In addition, 4x M10 SEMS bolts and flange nuts are used for pinning, tightened to 44Nm. It is important to apply anti-corrosion touch-up paint to any drilled areas to prevent rusting.
Positioning and Adjustment: The bull bar must be adjusted left and right until it is centered. Once in position, the fasteners are tightened to the specified torque. The manufacturer recommends using mechanical assistance, such as an elevating trolley, due to the weight of the bar and any additional components like a winch.
Impact Absorption System: The bull bar's impact absorption system must remain intact and unmodified. This system is designed to absorb and distribute impact forces during collisions. Any damage to the system must be addressed by contacting an authorized ARB stockist.
Electrical and Lighting Installation
The installation process also includes the integration of lighting components, such as LED combination lamps, fog lamps, and wiring harnesses. These components are essential for maintaining proper visibility and signaling, and their installation must be performed with care.
LED Combination Lamps: The LED combination lamps are installed using the 6821287 – LED Indicator/Clearance Kit. The lamps are mounted to the bull bar using 2x 15mm mounting screws and must be positioned so that the clearance LEDs are on the outboard edge of the bar. The manufacturer emphasizes that the arrows on the lamps should face outward to ensure correct orientation.
Wiring Integration: The wiring for the LED lamps must be connected according to the manufacturer's specifications. The correct wire colors and positions are outlined in the documentation, and it is recommended to use solder for all joints. Each joint should be covered with insulation tape or heat-shrink tubing to prevent short circuits. Cable ties should be used to secure all wiring and keep it away from sharp edges and moving parts.
Fog Lamps: Optional fog lamps can be installed using the fitting instructions provided with fog lamp kit no. 3500590. It is important to note that original equipment manufacturer (OEM) fog lights are 50W, and a relay adapter loom (3500640) is required to supply the higher power of ARB 55W fog lights.
Headlight Connectors: The headlight connectors must be wired according to the specified pin positions. The documentation provides a detailed chart of the wire colors and their corresponding functions (e.g., ground, indicator, clearance, and high beam). This ensures that the headlight and LED systems function correctly after installation.
Wiring Harness and Sensors: If the vehicle is equipped with parking sensors, these must be removed and reconnected after the bull bar is installed. The wiring harness from the original bumper bar must also be disconnected and reconnected to the new bull bar.
Additional Components and Accessories
The installation process may also involve the fitting of additional components such as winch covers, washer bottle supports, and air suspension solenoid packs.
Winch Cover Installation: If a winch is being installed, the winch cover panel must be fitted using 4x M6x20 hex bolts, spring washers, flat washers, and flange nuts. The manufacturer warns that care must be taken to avoid scratching the finish of the winch cover panel.
Washer Bottle Support: The washer bottle must be supported using brackets that are attached to the impact absorber. On the left-hand side, the washer bottle is supported using M8 bolts and a metal spacer. On the right-hand side, the air lines on air suspension models must be routed through the gap in the impact absorber backing plate. The brackets are secured using M8x20mm bolts, M8 flat washers, and spring washers.
Air Suspension Solenoid Pack: On vehicles equipped with air suspension, the solenoid pack must be attached to the bracket. This ensures that the air suspension system continues to function properly after the bull bar is installed.
Safety and Compliance Considerations
The manufacturer emphasizes the importance of safety throughout the installation process. All installation work must be performed in a safe environment, and appropriate personal protective equipment (PPE) must be worn. In particular, safety glasses must be worn during drilling operations due to the risk of flying metal debris.
Professional Installation Recommended: The manufacturer recommends that the bull bar be installed by trained personnel who are familiar with the specifications and torque requirements. This is especially important for complex tasks such as wiring integration and component alignment.
Compliance with Vehicle Manufacturer Guidelines: The bull bar must be installed according to the manufacturer's instructions and must not be used on any vehicle make or model other than those specified by ARB. The manufacturer also notes that any changes made by the vehicle manufacturer after the publication of these instructions may affect the fitment and performance of the bull bar.
Labeling and Modifications: All labels on the bull bar must remain intact and must not be removed. Any modifications to the bull bar or its fixing must be avoided, as these could compromise the structural integrity of the product.
General Care and Maintenance
After installation, it is important to maintain the bull bar to ensure its long-term performance and appearance.
Regular Inspections: The manufacturer recommends conducting a thorough visual inspection of the bull bar on an annual basis or prior to any long trips. This inspection should include checking that all bolts are torqued to the correct specifications and that all wiring sheaths, connectors, and fittings are free from damage.
Cleaning and Polishing: To protect the bull bar from corrosion and maintain its appearance, it should be treated with a Carnauba-based polish on all exposed surfaces. This is recommended to be done every six months or after exposure to salt, mud, sand, or other contaminants.
Professional Servicing: Any necessary repairs or adjustments should be performed by an authorized ARB stockist to ensure that the product remains in compliance with manufacturer standards.
Post-Installation Checks
Once the bull bar is installed, it is important to verify that all components are functioning correctly.
Lighting Operation: All lights wired during the installation process should be checked to ensure that they are working properly. This includes the LED combination lamps, fog lamps, and headlight connectors.
Clearance and Fitment: The bull bar should be visually inspected to ensure that it is properly aligned and that there is sufficient clearance between the bar and other vehicle components. Any misalignment or interference should be corrected before the vehicle is put into use.
Electrical Connections: All electrical connections should be checked for continuity and proper insulation. Any loose or damaged wiring should be repaired or replaced before the vehicle is operated.
Conclusion
The installation of an ARB bull bar is a complex and technical process that requires careful attention to detail. The manufacturer provides detailed instructions for each step of the installation, from mounting the bar to integrating lighting components and additional accessories. These instructions emphasize the importance of using the correct tools, following torque specifications, and avoiding modifications that could compromise the structural integrity or functionality of the bull bar.
Safety is a central concern throughout the installation process, and the manufacturer recommends that the work be performed by trained personnel. Additionally, regular maintenance and inspections are necessary to ensure the long-term performance of the bull bar.
By following the manufacturer's guidelines, users can ensure that their ARB bull bar is installed correctly and functions as intended.