INSTALLATION GUIDE BBCD082 - TO SUIT NISSAN NAVARA D23 2020+ FACELIFT
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INSTALLATION
GUIDE
BBCD082
TO SUIT NISSAN NAVARA D23 2020+ FACELIFT
• Ironman 4x4 BBCD082 Bull Bar to suit Nissan Navara D23 2020+ Facelift.
• It will take approximately 4 hours to install.
BBCD082/110322
Ironman 4x4 does not recommend installation of antennas or aerials to the front of a bull
bar as it may cause the lane departure system to malfunction.
NOTE: This product has been tested for air bag compatibility
and therefore the mounting system MUST NOT be modified
IMPORTANT: Bull bar installations should only be done by a qualified person
and it’s the responsibility of this person to ensure correct fitment.
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BBCD082
Before Installation
PLEASE NOTE:
It is always good practice to disconnect the battery while working on 12-Volt systems.
Please check owner’s manual to see vehicle specific requirements as some models may
need battery backup.
Caution: Auto electrical work should only be carried out by a competent person. Vehicle
wire colours are listed as a guide and may vary on some makes and models. The function
of each wire should be checked before any connections are made.
All wires tapped into the factory harness should be soldered and then insulated with
electrical tape or heat shrink.
Using only a LED test light, test all electrical components of the vehicle before and after
wiring. This is to ensure that everything works correctly.
IMPORTANT:
Bull Bar installations should only be done by a qualified person, and it is the responsibility
of this person to ensure correct fitment.
Read instructions fully before commencing fitment.
Do not remove labels from this bull bar. It is good practice to record the bull bar batch
number on the customer’s job card for future reference.
BULL BAR CARE INSTRUCTIONS:
To maintain finish of the product, wash regularly using a PH neutral Car wash, hose
off and chamois dry. Do not use acidic or alkaline cleaners. Plastic components can be
maintained with a silicon spray or similar (non-acidic or alkaline based).
The fitting instructions are correct at the time of publication date. Ironman 4x4 cannot be
held responsible for any vehicle manufacturer changes. It is the installers responsibility to
ensure correct fitment.
It is important to work safely and use appropriate safety equipment while working.
It is advised to purchase IBBPL082 patch loom because of the complex wiring system.
Note: Pro-4X (with factory flares) requires factory flares to be trimmed to suit bull bar.
Genuine fender flare caps can be purchased from Nissan to finish off cut section. It is
advised to follow the guard to bumper body line to make cut line. Nissan Genuine part
number- F3801-6KG0AAU, this part number was correct at the time of print. Check with
your local Nissan Dealer.
Page 2 of 21
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BBCD082
Bull Bar Parts List
1. Bull Bar 2. Winch Cradle
QTY-1 QTY-1
3. Grill Support Bracket 4. Chassis Bracket 5. Wire Nut 6. Radar Cover Plate 7. License Plate Bracket
Spacer 5mm
QTY-1 QTY-4 QTY-4 QTY-1 QTY-1
8. Radar Mount 9. Mesh 10. Side Protection Plate 11. Side Protection Plate 12. Centre Protection
RHS LHS Plate
QTY-2 QTY-1 QTY-1 QTY-1 QTY-1
13. Connection Bracket 14. Inner Chassis Bracket 15. Inner Chassis Bracket 16. Outer Chassis Bracket 17. Outer Chassis Bracket
RHS LHS RHS LHS
QTY-2 QTY-1 QTY-1 QTY-1 QTY-1
18. Radar cover plate 19. Bolt, Nut, spring/flat 20. Bolt, spring/flat 21. Bolt, spring/flat 22. Bolt, Nut, spring/flat
buckle washers washers washers washers
M12×1.25×40mm M12×1.25×40mm M10×1.25×30mm M10×1.5×100mm
QTY-4 QTY-14 QTY-4 QTY-4 QTY-19
23. Bolt, spring/flat 24. Bolt, Nut, spring/flat 25. Bolt, Nut, flat washers 26. Bolt, Nut, flat washers 27. Bolt, spring/flat
washers washers M6×1×20mm M6×1×20mm washers
M8×1.25×25mm M8×1.25×25mm M6×1×20mm
QTY-19 QTY-11 QTY-11 QTY-2 QTY-2
Tools Required
Metric spanner set Metric socket set Air hacksaw Tape measure Drill and drill bits Screwdriver set
Page 3 of 21
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Installation Guide BBCD082
Bull Bar Parts List
1
18
6
7
9
8
4
3
5
4 16
2
13
17 14
15
10
11 12
17
22
15
20 19
4
4
Bolt Tension Chart
NOMINAL DIAMETER - COARSE THREAD
Property Class TORQUE ma
M6 x 1 M8 x 1.25 M10 x 1.25 M12 x 1.25
Nm 10.5 25 49 88
8.8
ft/lb 7.7 18 36 64
Page 4 of 21
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Installation Guide BBCD082
1. Before installation, check bull bar
application is compatible with your
vehicle.
Remove and retain number plate, if
fitted, to be reinstalled later.
Disconnect negative battery
terminal.
2. Unwrap bull bar. Check overriders
and light assemblies are tight in
the bull bar before installation.
3. Remove and retain top plenum
cover. Ensure to keep all plastic
clips. Once cover is removed,
disconnect front camera wiring.
4. Once plenum cover is removed,
disconnect front camera wiring
and front radar wiring. Unclip the
grille and store in a safe place.
NOTE: It is important not to drop
both the camera and sonar as it
will cause damage.
5. Remove all factory bumper bar
retaining clips and bolts (including
splash tray clips). If vehicle is fitted
with factory fog lights, disconnect
wiring. Unbolt and remove factory
stone tray/bash plate. Now unclip
and remove factory bumper.
Page 5 of 21
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Installation Guide BBCD082
6. Remove and disregard factory lower
headlight bumper retaining clips and
side guard bumper and clips (white).
Remove lower centre air dam, side
dams can be left in place and may
need to be trimmed. The factory bar
reinforcement can now be removed.
7. Carefully remove centre radar,
making sure not to drop sensor.
Remove radar from the factory
bracket to be reinstalled.
8. Remove and disregard both left
and right grille support brackets.
9. Locate the 2 outer chassis holes
on both sides of the outer chassis
rail. Test fit chassis reinforcement
brackets. Once happy with the hole
location remove brackets.
Page 6 of 21
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Installation Guide BBCD082
10. Using a 10mm drill bit, drill through
both sides of the chassis.
NOTE: Its good practice to wear safety
googles, and keep drill square to the
rail to be able to drill straight.
11. It is good practice to use a
telescope magnet and remove
all metal swarf from inside the
chassis rail. Once holes are
cleaned, paint the bare metal
surface.
12. Bolt both sides of the chassis
reinforcement brackets to the
chassis using the hardware
provided. Make note to place the
wing bolting slot to the outside of
the rail.
13. Fit winch cradle to front of vehicle.
Do not tighten the bolts at this
stage as adjustment will be
required once bull bar is installed.
Take note of gap between chassis
face and cradle, it may need shims
fit. Install shims supplied on either
side of the cradle to bracket. If
outer air dams are still installed,
you may need to trim to allow
clearance for cradle.
Page 7 of 21
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Installation Guide BBCD082
14. Find a fixed point on the vehicle, take
measurements, square up the cradle.
Repeat on both sides until cradle is
centred.
15. If winch is being installed, refer to
winch installation instructions on
page.
Wiring for fog lights, blinkers,
parker and DRL can now be wired.
Ironman4x4 recommends using a
bull bar patch loom for plug and
play ease.
If fitting Ironman 4x4 recovery
points, do this now.
16. Install grille support bracket as shown.
17. Using the grille honeycomb openings
as a guide mark a line across from
the outer edge to the centre radar
rectangular cover section.
Page 8 of 21
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Installation Guide BBCD082
18. Trim grille.
NOTE: Its good practice to wear safety
goggles.
19. Install grille loosely and mark the 2
holes for the grille support from in
behind the grille.
20. Drill 2 x 6.5mm holes.
21. Install the radar panel bracket to the
lower inside of the centre grille insert
using M6 hardware. Make note of the
top of the grille insert and top of the
radar.
Page 9 of 21
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Installation Guide BBCD082
22. Install the second radar panel bracket
to the upper inside of the centre grille
insert.
23. Install radar grille insert into the bull
bar making sure the grille and radar
are square. Once happy install plastic
protective cover with clips provided.
24. Reinstall trimmed grille using original
fasters and M6 bolts to new grille
support bracket.
25. Install bull bar to cradle using M12
hardware supplied. Do not tighten.
26. Centralise the bull bar to the vehicle’s
bodywork. Tighten the bolts holding
the chassis brackets and cradle to the
chassis.
Page 10 of 21
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27. Align bull bar with vehicle ensuring
there is a 15-20mm gap between
wing of bull bar, mudguard, and
headlight. Tighten all cradle bolts to
bull bar.
28. Drill and pin bar into position using
M10 bolts, washers and nuts supplied.
29. Connect blinkers, parkers, and fog
lights (if applicable).
Refer to wiring diagram on page 21.
30. Install the protection plate brackets to
bull bar cradle using the inner bolts as
shown. Repeat on the other side.
NOTE: Only use inner bolts at this
stage as shown.
Page 11 of 21
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31. Install centre protection plate with
black M8 bolts provided.
32. Install both wing protection plates with
black M8 bolts provided.
33. Install number flip bracket and number
plate to the vehicle with M6 hardware
supplied.
Page 12 of 21
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34. Trim guard liners, drill 2 holes as
shown and secure in place behind
wing protection plates with cable ties
(not supplied).
NOTE: we recommend removing the
upper sound deadening as this may be
visible and will make it easier to trim.
35. Depending on the model of the vehicle
you may need to notch out the guard
liner from guard join to allow liner to
tuck into bull bar wing end.
36. Reconnect front camera wiring and
radar wiring.
Reinstall top plenum grille and connect
negative battery terminal.
Page 13 of 21
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty LtdInstallation Guide BBCD082
Once Bull Bar is Installed
Ensure all bolts are tensioned correctly, it is good practice to do a vehicle pre trip check before
heading away or every 10k kms. Visually inspect bull bar and hardware, retention bull bar
hardware or when needed.
Check the operation of the blinkers, park lights, fog-lights and winch if installed and ensure that
they are all functioning correctly. Make sure all electrical wiring is clear of sharp edges and is
secured correctly.
If vehicle is fitted with parking sensors, radars and or front cameras check they are operating
correctly. Some makes and models may need to return to the dealership for recalibration.
Stand back and admire your work.
Page 14 of 21
©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty LtdInstallation Guide BBCD082
Plastic Parking Sensor Installation
IMPORTANT: For parking sensors to function correctly these instructions must
be followed closely.
Before removing sensors from original bumper bar, note the location and
orientation of each sensor so when they are fitted the bullbar this can be
duplicated.
1. Remove rubber grommets from
sensor holes in bullbar.
2. Remove blank from sensor holder
and trim any excess plastic from
inside opening if applicable.
Page 15 of 21
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3. Fit sensor with factory silicone
sleeve to the sensor holder and
secure using clamping plate and
screws provided. Do not over
tighten. Clamping plate has a flat
side for thicker sensors and a
raised section on the other side for
thinner sensors. It is important that
clamping plate is the correct way
around as sensor will false alarm
if excess pressure is applied to the
sensor body.
4. Clean inside of bullbar around
sensor holes and mounting surface
of sensor holders using wax and
grease remover.
Page 16 of 21
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5. Apply adhesion promoter to
mounting surfaces around sensor
holes and on sensor holders. This
step is important to ensure sensor
holders adhere properly to the
bullbar.
6. Remove protective film from one
side of double-sided tape and
apply to mounting surface of
sensor holder.
Page 17 of 21
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7. Remove protective film from
double-sided tape and apply
sensor holder/sensor to bullbar
making sure sensors are in the
same positions as they were in the
original bumper and in the same
orientation.
Page 18 of 21
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Winch Installation
1. Bolt winch to cradle. Bolt fairlead
to recess in front of bull bar using
bolts, washers and nuts provided.
2. Fit bull bar to vehicle referring to
steps of bull bar fitting instructions.
3. Mount control box in desired
location.
4. Connect three colour coded cables
to the corresponding poles on
winch motor.
Page 19 of 21
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5. Connect the thin black earth wire
and negative battery cable to the
earth connection on the opposite
side of winch motor.
6. Run the positive and negative
battery cables into the engine bay
taking care to secure cables away
from any sharp or moving objects.
7. Connect positive and negative
battery cables main battery of
vehicle (Not Auxilliary Battery).
8. Attach breather hose to barb fitting
on winch motor. Run hose to the
highest available point in engine
bay and cable tie in position. Cable
tie hose away from any sharp, hot
or moving objects.
Refer back to step 18 of the Bull
Bar fitting instructions on page 7
Page 20 of 21
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Wiring Diagrams
PARK LIGHT & INDICATOR
Red
Daytime Running Light
Brown
Park Light
Yellow
Indicator Light
White
Ground
If vehicle is not fitted with DRL, leave red wire disconnected
FOG LIGHTS
Ground Red
Red Lamp
Fuse
85 30
Connector
87
86 87a Relay
Black
Blue
Battery Lamp
Parklight Switch
SPST
Ground
White
Ground
WITHOUT FACTORY FOG LIGHTS
Ground Red
Red Lamp
Fuse
85 30
Connector
87
86 87a Relay
Black
Blue
Battery Lamp
Positive power supply
at connector to factory fog light
Page 21 of 21
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