FORTUNER

AUG 2015 PRODUCTION ONWARDS

Kit Part No: PZQ61-89160
PZQ61-89170
PZQ61-89180
Fitting Time: 70 minutes

Trailer Wire Harness

Fitting Instructions

FI Doc No: PZQ61-89160FI - Issue: 1.0 - 20/05/15 Page 01 of 16

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General Notes
- Read through the fitting instructions before installation of accessory.
- Always install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or
the accessory.
- Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local
recycling regulations.
- It is always recommended that this accessory is fitted by a qualified Toyota 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.
- Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.

Safety Notes
- Check that all work practices comply with safety standards.
- Please wear appropriate clothing and use safety equipment.

Fitting Time
70 minutes

Parts Supplied
A B C D E F

Trailer Socket - Trailer Socket - Trailer Socket -

7-pin Flat x1 Small Round x1 Large Round x1 7-Pin Flat Bracket x1
Trailer Wire Harness x1 ECU x1 (PZQ61-89160) (PZQ61-89170) (PZQ61-89180) (PZQ61-89160)

G H I J K L

M6x20 Hex Head Bolt x2 M6 Flat Washer x2 M6 Nyloc x2

Small Round Bracket x1 Large Round Bracket x1 (socket bracket to (socket bracket to (socket bracket to
(PZQ61-89170) (PZQ61-89180) 30A Mini Blade Fuse x1 towbar bracket) towbar bracket) towbar bracket)

M N O P Q R

M4x16 Pan Head Bolt x2 M4 Flat Washer x2 M4 Nyloc x2 M5x20 Pan head Bolt x2 M5 Flat Washer x2 M5 Nyloc x2
(PZQ61-89160 for (PZQ61-89160 for (PZQ61-89160 for (PZQ61-89170 for (PZQ61-89170 for (PZQ61-89170 for
7-Pin Flat Socket) 7-Pin Flat Socket) 7-Pin Flat Socket) Small Round Socket) Small Round Socket) Small Round Socket)

S T U V W X

M5x40 Pan head Bolt x3 M5 Flat Washer x3 M5 Nyloc x3

(PZQ61-89180 for Large (PZQ61-89180 for Large (PZQ61-89180 for Large
Round Socket) Round Socket) Round Socket) 200mm cable ties x50 500mm cable ties x2 7 x 12 P-Clips x2

Y Z AA AB AC AD

CLEANING
PAD

2-Way Female Double Sided

1-Way Connector x1 Connector x1 Cable Tie Mounts x3 Foam Tape x1 Cleaning Pad x2 Power Harness x1

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Tools and Materials Required

Phillips & Flat Head Sockets- Ø10mm,

Screwdrivers Ratchet Ø12mm, Ø13mm,Ø14mm Clip Romower Tool Wire Cutters Trim Removal Tools

Jeweller’s Flatblade
Screwdriver 1.0mm or
Picking Tool
(for terminal locking tab)

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Step 1
• Open the vehicle boot (1).
1

Step 2
Important
Always refer to the vehicle’s Workshop Manual when
removing vehicle components.

1
• Note down all clock and radio settings
• In the engine bay disconnect the negative battery terminal (1).

Step 3
• Remove the eight bolts (1) from the rear lower bumper.
1 1

1 1

1 1 1 1

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Step 4
• Remove the three bolts (1) and one clip (2) from the mud guard /
1
wheel arch trim (3).
Repeat for the RHS.

1
2

1
3

Step 5
• Remove all screws and clips from under the vehicle.
Note: Differing vehicle variations may have slightly different fastener
quantities or locations.

Step 6
• Dislodge the bumper and disconnect the harness connector (1)
from the rear bumper (2).
• Remove the rear bumper (2).

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Step 7
• Inside the luggage compartment fold up the back rear seats (1).
• On the LH side, remove the two trims (2) to gain access to the trim
fasteners.

2 2

Step 8
• Remove the three bolts (1) from the seat brackets and then
remove the seat (2).

Important 2
When re-fitting the seat back into place, torque the seat
bolts to 37Nm. 1
1
1

Step 9
• Remove the LHS rear passenger scuff trim (1).

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Step 10
• Remove the access panel (1).
• Remove both seat belt fastener covers (2) and remove bolt (3)
4
from underneath and dislodge the LHS luggage compartment
trim (4).
1
• Disconnect the 12V connector (5).
• Remove the LHS luggage compartment trim (4).
Important 2
When re-fitting the seat belts, torque the seat belt bolts
to 42Nm.

3
5
Step 11
• Disconnect the LHS tail light connectors (1).
• Connect the Trailer Wire Harness patch connectors (2) in
between the vehicle tail light connectors (1).
• Secure the Trailer Wire Harness ground ring terminal (3) to the
vehicle grounding point (4).
Important

Torque earth bolts between 6.9 & 9.8 Nm.

2 2
4 3

1 1

Step 12
• Connect the Trailer Wire Harness ECU connector (1) to the ECU
(2).
• Using a supplied cleaning pad, clean the outer side of the inner
sheet metal (3).
Important
Ensure the surface areas cleaned with the supplied
Cleaning Pad are dry before continuing.

• Peel the backing off the ECU (2) and mount to the cleaned
sheet metal area (3). 2 2 3
• Continue routing the Trailer Wire Harness (4) along the vehicle
harness, towards the rear passenger area.
Important
Ensure the Trailer Wire Harness (4) routing follows the
vehicle harness.
1

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Step 13
• Remove the vehicle grommet (1).
5 5
• Route the Trailer Wire Harness trailer socket wires branch (2)
down into the vehicle grommet hole (3) located next to the 5
wheel arch. Ensure the Trailer Wire Harness grommet is seated
correctly in the vehicle grommet hole (3). 2
• Secure the Trailer Wire Harness branch (2) away from any sheet
metal protrusions using the supplied Cable Tie Mount and
5
Cable Tie (4). 5
• Secure the Trailer Wire Harness to the vehicle harness with
Cable Ties (5). 3 2
1

View from
vehicle LHS rear
quarter exterior.
Step 14
• From the exterior LHS rear of the vehicle, route the Trailer Wire
Harness (1) towards the rear of the vehicle.
• Using a supplied Cleaning Pad, clean the areas (2) where the
Cable Tie Mounts (3) will be placed.
Important 2 3
Ensure the surface areas cleaned with the supplied 1 2 3
Cleaning Pad are dry before continuing.

• Remove the Cable Tie Mount backings and adhere into place
(2) as shown.
• Secure the Trailer Wire Harness (1) to the Cable Tie Mounts using
Cable Ties (3).

Step 15
• In the LHS front cabin, remove the front passenger scuff plate (1).
• Remove the plastic nut (2) securing the driver’s kick panel (3) and
remove the kick panel (3).
• On the ‘B’ pillar trim, remove the seatbelt cap (4) and unfasten 1
the bolt underneath.
• Dislodge the ‘B’ pillar trim lower section (5).
Important
When re-fitting the seat belts, torque the seat belt bolts
to 42Nm.

2 5
3

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Step 16
• Unclip the glove box dampener (1).
• Remove LH and RH retaining clip (2).
• Remove the glove Box (3).
• Remove the driver's lower dash garnish (4).
2 2

3
4

Step 17
• Continue to route the Trailer Wire Harness (1) along the LHS
of the vehicle, past the ‘B’ pillar area and towards the foot-well
area.
• Secure the Trailer Wire Harness (1) to the vehicle harness using
existing clips (2) and cable ties (3) at every 200mm intervals. 3 3
Important 1
Do not secure the Trailer Wire Harness onto the vehicle
washer hose.

Step 18
• Continue routing the Trailer Wire Harness (1) along the vehicle
harness, up to the glove compartment cavity IP/JB area.

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Step 19
• Locate and disconnect the indicated IP/JB 8-way connector (1).
• Undo the connector secondary lock (2) by lifting up the tab.
• Using a jeweller’s flat blade screw driver, terminal locking tab (3)
and release the 8-way connector RED wire terminal (4). 1

4 4 1
2 3 8 5

Cross section of connector

Rear View of
8-way connector

Step 20
• Locate the Trailer Wire Harness GREEN/BLACK wire terminal (1) Rear View of
and insert it into IP/JB 8-way connector’s previously removed RED 8-way connector
wire location (2).
4 1
• Refit the secondary lock and reconnect the IP/JB 8-way 8 5
connector (3).
3
1 2

4 1
8 5
3

Rear View of
8-way connector

Step 21
• Locate the supplied 2-way Female Connector (1) and undo the
locking tab (2).
2 1
• House the disconnected IP/JB RED wire terminal (3) to the
1
supplied 2-way Female Connector (1) PIN 2 location.
3
• Connect the housed 2-way Female Connector (1) to the Trailer 2
Wire Harness 2-way connector (4) and then secure the
connectors to the harness using cable tie.
Important 1
Ensure the wires in the connectors are aligned.
4

• Secure the Trailer Wire Harness (5) to the vehicle harness using
cable ties at 200mm intervals. 5

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Step 22
• In the engine bay, remove the accessory fuse block cover (1).
• Disconnect the Accessory fuse block (2) from its mounting
1
bracket (3).
• Using side cutters, remove and discard the cable tie (4) from
the wire bundle.
• Unclip and dislodge the fuse holder (5).

1
2 5

Step 23
• Feed the Trailer Wire Harness ORANGE terminal wire (1) through
the fuse block funnel.
• Insert the orange fuse terminal (2) into the ‘Fuse Holder 1 LHS’
cavity as shown. 1
Important
Ensure audible "click" is heard. 4

• Insert the supplied 30A Mini Blade Fuse (3) into the wired slot
and re-fit the ‘Fuse Holder 1 LHS’ into the accessory fuse box
(4).
Important

Check fuse terminal retention.

10
9
4
• Secure harness with cable tie (5) where shown. 8
7
6
5 3
4
3
2
1

Fuse 1 2 3 4 5 6 7 8 9 10
Holder 1 30A TWH
LHS
Fuse
Holder 2
RHS

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Step 24
• Route the Power Harness (1) from the accessory fuse box Front of vehicle
towards the firewall grommet, following the vehicle harness 2
along the LHS of the engine bay.
1
• Secure the Power Harness (1) to the vehicle harness using

Step 25
• In the engine bay area, secure the Power Harness male terminal Front of vehicle
(1) to the guide wire (2).
• Cut the LHS access point (3).
Note: If the LHS access point is occupied, use the RHS access point. 4
• Feed the guide wire (2) into the firewall grommet (4). Ensure the
guide wire breaks the internal grommet seal. 1
• Feed through until the Power Harness drip loop (5) reaches the
grommet and is facing down.
• Seal with silicon, then cable tie (6) around the access point.

3 2
2 6

1 1
5

Step 26
• In the glove box cavity area, retrieve the Power Harness (1) from
the firewall grommet hole (2) and discard the guide wire. 2
• House the Power Harness terminal (3) to the supplied 1-way
connector (4). 1
• Connect the housed Power Harness connector (4) to the Trailer 3
Wire Harness 1-way connector (5).

4
5

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Step 27
• Route the Trailer Wire Harness (1) across the rear of the towbar
and secure into the towbar clipping points (2) using the
supplied 7x12mm P-Clips (3).

2 3
1 2 3

Step 28
For 7-Pin Flat Trailer Harness Socket:
• House and secure the Trailer Wire Harness to the supplied 7-Pin
Flat Socket. Refer to the housing table below:
4
Pin No. Function Cable Colour 7
1 Left-hand turn signal Yellow
2
2 Reversing signal Black
3 Earth return White 3
4 Right-hand signal Green 5
5 Service brakes Blue
6
6 Stop lamp signal Red
7 Rear lamps, clearance and Brown 1
side marker lamps

Step 29
Installing 7-Pin Flat Socket
• Secure the 7-pin socket Bracket (1) to the towbar mounting 2 2 4
point using the supplied M6 Hex Head Bolt, Washers and Nylocs
(2). 4
• Attach the 7-Pin flat trailer socket (3) to the tow bar bracket (1)
using the supplied black M5 Bolts, M5 Nylocs and M5 Washers
(4).
Go to Step 34.
1 1

2 2
3 4
4

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Step 30
For 7-Pin Small Round Socket:
• House and secure the Trailer Wire Harness to the supplied 7-Pin
Small Round Socket. Refer to the housing table below:
1
Pin No. Function Cable Colour
1 Left-hand turn signal Yellow 2 6
2 Reverse Black
3 Earth return White 7
Right-hand signal Green
4
5 Service brakes Blue
3 5
6 Stop lamp signal Red 4
7 Rear lamps, clearance and Brown
side marker lamps
7-Pin Socket
(rear view)

Step 31
Installing 7-Pin Small Round Socket 3
3
• Secure the 7-Pin small round Socket Bracket (1) to the towbar
mounting plate (2) using the supplied M6 Hex Bolts, Washers
and Nylocs Nuts (3). 2
5
• Position the Small Round Socket (4) onto the large round Socket
Bracket (1) and secure using the supplied M5 Pan Head Screws,
Washers and Nyloc Nuts (5).

5
Go to Step 34. 1
5
1 4 5

3 3

Step 32
For 7-Pin Large Round Socket:
• House and secure the Trailer Wire Harness to the supplied 7-Pin
Large Round Socket. Refer to the housing table below:
1
Pin No. Function Cable Colour
1 Left-hand turn signal Yellow 2 6
2 Reverse Black
3 Earth return White 7
Right-hand signal Green
4
5 Service brakes Blue
3 5
6 Stop lamp signal Red 4
7 Rear lamps, clearance and Brown
side marker lamps
7-Pin Socket
(rear view)

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Step 33
Installing 7-Pin Large Round Socket
• Secure the 7-Pin large round Socket Bracket (1) to the towbar 3
3
mounting plate (2) using the supplied M6 Hex Bolts, Washers
and Nylocs Nuts (3).
• Position the Large Round Socket (4) onto the large round 2
Socket Bracket (1) and secure using the supplied M5 Pan Head
Screws, Washers and Nyloc Nuts (5).

1
5
3 3

5
5
1
4 5

Step 34
• Re-fit the negative battery post (1) .
Important
Torque vehicle battery post terminal between 2.9Nm
to 7.8Nm.
1
• Test the operation of the Trailer Socket using a trailer wire tester or
a test light to ensure the correct operation.

Step 35
Important
Refit all removed parts and secure all fasteners to the
Service Manual torque specifications.

Important
Torque the seat bolts to 37Nm.

Important
Torque the seat belt bolts to 42Nm.

Important
Reprogram all radio stations and clock settings by
referring to the vehicle’s owner manual.

Please place the Fitting Installation in the glove box

after installation is completed.

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Harness Diagram

PINOUT COLOUR mm 2 FUNC.

1 BN /BK 0.85 TAILS
ENGINE BAY CABIN FRONT CABIN REAR 2 RD/BK 0.85 STOP
3 YL/BK 0.85 LH. IND
4 BK/WH 1.25 REVERSE
5 GY 0.85 -
Wire Harness, Power Wire Harness, Chassis 6 GY/BK 0.85 -

6-Way Connector Patch Cable Location:

1 2
LHS rear tail light connector.
3 6

BN/ RD/ YL/ BK/

BK BK BK WH

2A 2A 2A 2A

Fuse Location: 1P Connector Location:

Aux fuse box. Behind glove box. BN/ RD/ YL/ BK/
BK BK BK WH
ECU Location:
LHS rear tail lamp.
OR 30A OR OR OR
+12V Ground Location:
Above LHS rear tail connector.
ECU
GN/BK
GND
WH WH
2A

GN/BK YL BK GN RD BN
Location:
LHS rear tail lamp
BL
4 1
Service Brake
8 5 Grommet Location:
YL BK GN RD BN WH BL
Rear view of vehicle LHS rear of vehicle.
8-way connector

Location:
Centre rear of vehicle.
Socket

PINOUT COLOUR mm 2 FUNCTION

1 YL 0.85 TRAILER LH IND.
2 BK 0.85 TRAILER REVERSE
3 WH 2.0 EARTH
4 GN 0.85 TRAILER RH IND.
5 BL 2.0 SERVICE BRAKES
6 RD 0.85 TRAILER BRAKE
7 BN 0.85 TRAILER TAIL

Scale Size: 1:1

Page Size: A4

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