Installation Instructions for Toyota C-HR (2018-Current) and Corolla Hatchback (2019-Current)

Part Numbers:

• 24991
• 77991
• CQT24991

Tools Required:

• Ratchet
• Torque Wrench
• Safety Glasses
• Sockets: 10mm, 12mm, 13mm
• Flat Head Screwdriver
• Plastic Trim Tools
• Hammer
• Silicone Sealant
• 6" Socket Extension

Step-by-Step Instructions:

1. Remove Underbody Panels:

   • Using a flat head screwdriver, remove:
     • (5) plastic push pin rivets and loosen (2) threaded fasteners from the driver-side panel.
     • (4) push pin rivets and loosen (1) threaded fastener from the passenger-side panel.

2. Remove Lower Fascia:

   • (a) Remove (6) retaining clips (3 per side) that connect the lower fascia to the upper fascia. Two clips are behind the aluminum bumper beam.
   • (b) Use a 10mm socket to remove (1) screw from the wheel well trim on each side.
   • (c) Use a flat head screwdriver to remove (1) push pin rivet from behind the wheel well trim on both sides.
   • (d) Carefully pry (3) clips holding the wheel well trim using plastic trim tools.
   • (e) Remove the lower fascia by starting at the outer edges near the wheel wells and pulling rearward to release the clips.

3. Remove Bumper Beam:

   • Using a 12mm socket, remove (8) M8 bolts (4 per side) securing the bumper beam to the end panel.
   • Return the factory bolts to the vehicle owner.

4. Modify Bumper Beam:

   • Using a hammer, bend the metal tabs on the back of the bumper beam so they are flush with the mounting surface.

5. Install Hitch:

   • Apply silicone sealant to the hitch bracket mounting surfaces to prevent water and exhaust fumes from entering.
   • Raise the hitch and bumper beam into position, aligning the holes with the weldnuts in the end panel. The hitch should be sandwiched between the bumper beam and the end panel.

6. Install Fasteners:

   • Using a 13mm socket, install (8) M8 hex bolts, lock washers, and flat washers provided with the hitch into the weldnuts in the end panel (4 per side).
   • Torque all M8 CL8.8 fasteners to 20 ft-lb (27 N*m).

7. Reinstall Lower Fascia:

   • Align the lower fascia tabs with the upper fascia and reinstall the (6) retaining clips into the fascia tabs.

8. Reinstall Wheel Well Trim and Underbody Panels:

   • Reinstall the wheel well trim and underbody panels using the original fasteners removed earlier.

Hardware List:

• (8) Hex Bolt, M8 x 1.25 x 30 CL8.8
• (8) Lock Washer, M8
• (8) Flat Washer, 5/16"

Safety Notes:

• Always wear safety glasses during installation.
• Frequently check the hitch to ensure all fasteners and the ball are securely tightened.
• Plug any removed holes in the trunk pan or body panels to prevent water or exhaust fumes from entering.
• Replace any damaged hitch or ball immediately.
• Do not cut access or attachment holes with a torch.

Specifications:

• Installation Time: 60 minutes
• Max Gross Trailer Weight: 2,000 lb (908 kg)
• Max Tongue Weight: 200 lb (90.8 kg)
• Complies with SAE J684 and VESC Regulation V-5 standards.

Installation Instructions for T-One® T-Connector for Toyota C-HR

Part Numbers:

• 118756

Tools Required:

• Trim Panel Remover
• 10mm Socket & Ratchet or Wrench
• Drill (3/32” Drill Bit)
• 1/4” Socket
• Wire Crimpers
• Wire Cutters
• Phillips Head Screwdriver
• Test Probe
• Torx T10 Driver

Step-by-Step Instructions:

1. Remove the Taillight Assemblies:

   • Open the rear tailgate to access the bolts holding the taillights in place.
   • Remove the two 10mm screws on both the driver and passenger sides.
   • Carefully pull the taillights away from the vehicle, ensuring not to damage the alignment pins. Set the housings aside.

2. Locate the Taillight Wiring Harness:

   • On both sides of the vehicle, locate the taillight wiring harness.
   • Disconnect the connectors carefully, ensuring not to break the locking tabs. Ensure all connector surfaces are clean and free of dirt.

3. Mount the T-One® Black Box:

   • Determine a suitable mounting point behind the rear bumper fascia on the driver’s side.
   • Mount the T-One® Connector black box using the provided double-sided tape.
   • Ensure the module's epoxy side faces downward to prevent water accumulation.

4. Route the Driver-Side T-Connector:

   • Fish the T-One® Connector end with the yellow wires up between the bumper and vehicle body into the driver’s side taillight pocket.
   • Insert the T-One® Connector end with the yellow wire between the taillight socket and vehicle wiring harness.

5. Route the Passenger-Side T-Connector:

   • Route the T-One® Connector end with the green wire underneath the bumper to the passenger side.
   • Route the green wire up through the opening on the passenger side and into the taillight pocket, avoiding hot pipes, heat shields, or the fuel tank.
   • Connect the green wire end between the taillight socket and vehicle wiring harness.

6. Ground the White Wire:

   • Locate a suitable grounding point near the connector, such as the vehicle frame or crossmember.
   • Clean the grounding area to remove dirt and rustproofing.
   • Drill a 3/32” hole and secure the white wire using the provided eyelet and screw.

   Caution: Verify what is behind the surface before drilling to avoid damage or injury.

7. Route the Power Wire:

   • Locate the black 12-gauge power wire from the T-One® Connector box.
   • Attach the provided black wire and route it along the frame rail to the vehicle’s battery.
   • Avoid hot pipes, heat shields, or other areas that may pinch or break the wire.

8. Connect to the Vehicle Battery:

   • Disconnect the Negative (-) battery cable.
   • Remove the fuse from the yellow fuse holder and attach the ring terminal to the Positive (+) battery cable.
   • Connect the other end of the fuse holder to the black 12-gauge wire using the provided yellow butt connector.

   Warning: Follow all warnings printed on the tow vehicle’s battery.

9. Reconnect the Battery and Test:

   • Reconnect the Negative (-) battery cable.
   • Insert the 15-amp fuse into the fuse holder.
   • Test the installation using a test light or trailer.

10. Secure the Wiring Harness:

    • Use the provided cable ties to secure the wiring harness, avoiding areas that may pinch, cut, or melt the wire.

11. Reassemble the Vehicle:

    • Reinstall all panels, trim, and components removed during installation, ensuring no wires are pinched or damaged.

12. Store the 4-Flat Connector:

    • When not in use, store the 4-flat connector in the rear cargo area. When in use, pull it through the hatch and close the door.

    Caution: Avoid pinching the harness in the door latch.

Safety Notes:

• Overloading circuits can cause fires. Do not exceed stated product ratings or vehicle manufacturer specifications.
• Always wear safety glasses and follow all safety precautions during installation.

Manufacturer Notes:

• Refer to the vehicle owner’s manual and the instruction sheet for additional details.
• Store these instructions for future reference.