3PC TONNEAU COVER INSTALLATION INSTRUCTIONS Ford … warranty does not cover failure due to neglect,...

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Place these instructions in vehicle’s glove box after installation is complete

3PC TONNEAU COVERINSTALLATION INSTRUCTIONS

Clean Tonneau Cover with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

Phillips Head Screwdriver

Non-permanent Marker

Hammer & Centre Punch

Drill & Ø2, Ø4, Ø5 & Ø12mm Drill Bits

12mm Socket

Non-acetic Silicon & Dispenser

Cleaning Cloth

Masking Tape

Jigsaw

Tape Measure

Shifting Spanner

Allen Key

Deburring Tool

Safety Glasses

Wire Stripper or Crimper Pliers

RECOMMENDED TOOL LIST

Ford Ranger(with bedliner)

Item

1

2

3

4

5

6

7

8

9

10

11

12

13

14

1

1

2

5

1

1

2

2

2

2

22

24

16

2

Tonneau Cover

Header Rail

Keys

Self Drilling 10gx30mm Screws

LHS Corner Piece

RHS Corner Piece

Striker Bracket

Gas Struts

Ball Strut Screws

Jacking Brackets

M6x30mm Allen Head Screws

M6 Flat Washers

M6 Spring Washers

M8 Hex Head Bolts

HBAR0010-2

SCRW0705

STRT0005

SCRW0725

CLIP2049GZ

SCRW0448

WASH0036

WASH0161

SCRW0696

NUTS0217

MISC2776

MISC0052

NUTS0173

MISC2572

MISC2573

CLIP2307GP

SCRW0348

MISC2633

MISC2634

MISC2608MISC2609

Component Name Item Number Qty Item

15

16

17

18

19

20

21

22

23

24

25

2

2

1

16

1

1

4

2pr

2

1

1

M8 Nuts

Rust Inhibitor

Alcohol Wipes

U-Nuts

Plastic Plate LHS

Plastic Plate RHS

Foot Brackets

Wiring Connectors

Self Drilling Screws

Front Drill Template

Rear Drill Template

Component Name Item Number Qty

LIST OF PARTS

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FORD RANGER 3PC TONNEAU COVER

1

10 11 12 13 14 15

16 17 18 19 20 21

22 23 24 25

2 3

4 5 6 7 8 9

AUTOMOTIVESURFACE CLEANER

IMPREGNATED WITH 70% ISOPROPYL ALCOHOL

For use in cleaning painted metal,glass and other vehicle surfaces.For external use only.Dispose of properly after use.

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WARNING!When in the closed position, Tonneau Cover must be locked and tailgate must be closed! Failure to do so could result in unexpected opening of the Tonneau Cover from sudden wind gusts, which could cause damage to the vehicle and/or your Tonneau Cover!

Warranty TermsEGR warrants that the ABS truck Tonneau Cover EGR will be free from defects in material and workmanship for a period of three (3) years from the retail date of purchase. The gas struts are warranted for one (1) year from the retail date of purchase. This warranty only applies to the original purchaser and is nontransferable. Warranty must be claimed with original sales receipt for proof of purchase.

ExclusionsThis warranty does not cover failure due to neglect, improper installation including any modifications to installation hardware, operating the vehicle with your EGR Tonneau Cover in the open position, alterations, addition of equipment, abuse, accident, corrosion, normal wear and tear, lack of maintenance, and exposure to chemicals that are not safe for plastics.

Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Tonneau Cover is sole responsibility of the truck owner and operator. Paint wear to the truck bed can happen with any truck Tonneau Cover and is the sole responsibility of the truck owner. Paint damage to your truck is not covered under this warranty.

DisclaimerIn the event that your EGR Tonneau Cover is found to be defective under the terms of this warranty, it is at the discretion of EGR to repair or replace the defective part. Transportation costs and labor are not associated with this warranty claim.

MaintenanceYour EGR Tonneau Cover only requires periodic cleaning with mild car wash soap. Only use cleaners, waxes, or products that are labeled safe for use on plastics. Avoid the use of any chemicals to clean your EGR Tonneau Cover unless labelled safe for plastics. Avoid use of abrasive type cleansers as they may dull the finish.

The gas struts are self lubricating and should only be cleaned occasionally with a damp cloth. Premature seal failure will result if solvents or lubricants are used to clean struts.

The locking mechanisms & Latches only require occasional lubrication with Graphite Powder. DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.

All installation hardware and fasteners must be checked every so often for tightness.

IMPORTANT!

• Do not stand/sit or rest heavy objects on Tonneau Cover.

• Humans or animals are not to be under the closed Tonneau Cover at any time.

• Securely lock Tonneau Cover before operating vehicle.

• Do not carry open volatile chemicals with Tonneau Cover installed.

• If contact with volatile chemicals occurs clean Tonneau Cover with mild detergent and water solution.

• Read instructions carefully before installation. It is strongly recommended that installation is conducted by an authorized dealer.

• This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.

• Recommend installation by 2 people.

PAINTING INSTRUCTIONS (IF UNPAINTED)• Sand Tonneau Cover prior to painting recommend 500 grit using an orbital type sander.

• Prior to painting, clean all surfaces to be painted using clean water and a mild detergent, do not use lacquer thinner or any solvent based products. Wipe completely dry.

• Best results will be achieved by wiping the areas to be painted with a tack rag just prior to painting.

• Select a top coat and clear paint that is suitable for ABS (Acrylonitrile-Butadiene-Styrene).

• Automotive paint systems, such as Acrylics or Two Packs, can be applied directly to the components. However, some paints may require a primer. If recommendations on paint specification are not followed, cracking of the part or degradation to the material may result. In all paint systems, aromatic hydrocarbons and alkalies are best avoided to reduce damage to the material properties.

• If using a paint system which requires baking, do not expose the product to temperatures above 70° C (155° F).

• Allow a minimum of 8 hours after baking before installation on the vehicle.


3. NOTE: Two people are required to complete installation. Remove Sports Bar. Refer to Genuine Sports Bar Fitting Instructions for details on removing Sports Bar. Remove all Tie Downs and Retain. Thoroughly clean installation areas. See Dia #3.

Diagram #3

BEDLINDER

NOTE: Install and remove the Ford Sports Bar before installing the Tonneau Cover. Retain all hardware.

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1. If vehicle’s Sports Bar is fitted with an LED stop light, pull LED wiring grommet out of hole in Sports Bar. See Dia #1.

Diagram #1

2. Cut through the LED wiring loom so that the Sports Bar can be removed. See Dia #2.

Diagram #2

IMPORTANT: If vehicle’s Sports Bar is fitted with an LED stop light, proceed toDiagram #1. Otherwise, proceed to Diagram #3.

LED WIRINGLOOM

SPORTSBAR

SPORTSBAR

LED WIRINGLOOM

LED WIRINGLOOM

SPORTSBAR

REMOVE

SPORTSBAR

LED WIRINGLOOM

1 2

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6. Position the rear drill template on the vehicle by sliding it into place on the rear of the bedliner as shown. Ensure the template is correctly orientated. Mark the two (2) hole positions on the bedliner as well as the outline of the template’s internal cutout. Repeat the process for the other side of the vehicle. See Dia #6.

Diagram #6

4. Remove the 4 brackets from the Sports Bar legs as shown. Retain the gaskets. See Dia #4.

Diagram #4

5. Apply masking tape to the sides of the bedliner. Position the front drill template on the vehicle by folding it and aligning it to the bedliner’s edges as shown. Mark the six (6) positions onto the bedliner as shown. Repeat the process for the other side of the vehicle by folding the template in the other direction and placing it on the other side of the vehicle. See Dia #5.

Diagram #5

REAR DRILLTEMPLATE

SLIDE MARKPOSITIONS

MARKOUTLINE

BRACKET (REMOVE & DISCARD)

GASKET (REMOVE & RETAIN)

SPORTS BAR x4

1

IMPORTANT: IT IS CRITICAL TO CHECK AND ENSURE ALL HOLES ARE IN THE CORRECTPOSITION BEFORE DRILLING! PLEASE FOLLOW DIRECTIONS BELOW.

2 3

FRONTDRILL

TEMPLATE

ALIGN

TOP VIEW

FOLDTEMPLATE

MASKINGTAPE

FRONT DRILLTEMPLATE

MARKPOSITIONS

9. Check all holes have been drilled as per step 4 and 5. Remove the bedliner as shown. See Dia #9.

Diagram #9

BEDLINER

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PRESSTO RELEASE

IMPORTANT: If vehicle’s bedliner is fitted with a 12V power socket, proceed toDiagram #8. Otherwise, proceed to Diagram #9.

8. If vehicle’s bedliner is fitted with a 12V power socket, Lift and flex the bedliner to gain access to the rear of the socket. Remove the plastic clip as shown. Press down on the connector as shown to release Connector from 12V power socket. Pull the connector back away from the bedliner and lay in the Tub. See Dia #8.

Diagram #8

Tub Liner

1 2PRESS TORELEASE

10mm

Ø5mm Ø12mm

CENTRE PUNCH &DRILL Ø5mm PILOT HOLES

THEN DRILL Ø12mm

7. Centre punch the bedliner at the marked locations and drill Ø5mm pilot holes followed by Ø12mm holes. IMPORTANT: Ensure holes are drilled 10mm deep Maximum or Damage to Outer Painted Surfaces can occur. Repeat process for the other side of the vehicle. See Dia #7.

Diagram #7

1 2 3

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10. Deburr all drilled holes, apply rust inhibitor and install the U-Nuts onto the side rail as shown. Due to vehicle variation, bedrail lip may need crimping. Repeat for the other side of the vehicle. See Dia #10.

Diagram #10

SIDE RAIL

U-NUT

BEDLINER

MASKING TAPE

12. Apply masking tape to the front of the bedliner as shown. Mark up the bedliner as per dimensions shown in above diagram for the length of the front of the bedliner. Remove cut away section with a jigsaw. Smooth all the trimmed edges using sandpaper.See Dia #12. NOTE: Take care cutting the long horizontal portion at the front of the bedliner.

Diagram #12

1

2

3

4


12

BEDRAIL VARIATION

CUT AWAY AREA

BEDLINER

12mm

12mm

11. Install the U-Nuts onto the side rail as shown. Due to vehicle variation, bedrail lip may need crimping. Repeat for the other side of the vehicle. See Dia #11.

Diagram #11

SIDE RAIL

U-NUTS

BEDRAIL VARIATION

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14. Temporarily remove the Z brackets and retain hardware. See Dia #14.

Diagram #14

Z BRACKET

BOLTS (RETAIN)

Z BRACKET

HEADER RAIL

BOLTS

TORQUE:10 Nm

15. Fit the header rail to the front tub panel by reinstalling the Z brackets with retained hardware as shown. Tighten (torque 10Nm.)See Dia #15.

Diagram #15

USE LOWERPOSITION


BEDLINER

13. Remove cut away section as indicated my the marked outline using a hacksaw or jigsaw. Ensure the small square section is also removed as indicated in the diagram above. Repeat process for the other side of the bedliner. See Dia #13.

Diagram #13

BEDLINER

CUT AWAYAREA (WHITE)

ENSURE THIS SECTIONIS ALSO REMOVED

MARKED OUTLINE

SIDE VIEW

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16. Predrill Ø2mm Pilot holes. Apply rust inhibitor to the threads of the self drilling screws. Install the self drilling screws as shown. Tighten to torque 5Nm. See Dia #16.

Diagram #16

TORQUE 5Nm

HEADER RAILBOTTOM HINGES

SELF-DRILLING SCREWS

17. Replace bedliner and previously removed Tie Downs. See Dia #17.

Diagram #17

21 3

BEDLINER

U-NUT

TORQUE 7Nm

M6 FLATWASHER

BALL STRUTSCREW

SPRINGWASHER

BEDLINER

18. Attach the ball strut screws to the side rail of the vehicle using the M6 spring washers and M6 flat washers as shown. Tighten to 7Nm. See Dia #18.

Diagram #18


IMPORTANT: If vehicle’s bedliner is fitted with a 12V power socket, replace it by reversingthe procedure outlined in Diagram #7 and Diagram #8.

Ø2mm

19. Align and loosely attach the striker brackets and plastic plates to the side rail using the M6 screws, M6 spring washers and M6 flat washers as shown. See Dia #19.

Diagram #19

20. Mark and drill Ø2mm hole through the plastic plate and bedliner as per dimensions. Fasten plastic plate to bedliner using self drilling screw as shown. See Dia #20.

Diagram #20

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21. Attach the jacking brackets to the side rail using the M6 screws, M6 spring washers and M6 flat washers provided. Loosely install M8 hex head bolt and M8 nut into jacking bracket as shown. Thread 2 turns only. See Dia #21.

Diagram #21

10mm

10mm

Ø2mm

2 31

MARK &DRILL Ø2mm

HOLE

4

SELF DRILLINGSCREW

PLASTIC PLATE

BEDLINER

PLASTIC PLATE

BEDLINER

SIDE VIEW

BEDLINER

U-NUTS

BED-LINER

PLASTIC PLATE M6 FLATWASHERS

M6 SPRINGWASHERS

M6 SCREWS

STRIKERBRACKET

10mm

SIDE VIEWJACKING BRACKET

M6 SCREWM6 SPRINGWASHER

M8 NUT

M8 HEX BOLT

U-NUT

M6 FLATWASHER

BEDLINER

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22. Using an allen key, loosen bolt inside the Sports Bar. See Dia #22.

Diagram #22

M6 SCREWS

M6 SPRING WASHERS

M6 FLAT WASHERS

SIDE RAIL

SPORTS BAR

Check Rubber Seals are Orientated correctly

TORQUE 10Nm


23. Loosely attach the foot brackets, corner pieces and gaskets to the Sports Bar using the M6x30 screws and M6 flat washers as shown. See Dia #23.

Diagram #23

24. NOTE: Two people are required to carry out the replacement of the Sports Bar. Position the Sports Bar and corner pieces on vehicle. Attach the legs of the Sports Bar to the side rail using the M6 screws, M6 spring washers and M6 flat washers as shown. Tighten foot brackets to Sports Bar then Legs to Side Rail. Repeat for the other side of the vehicle.See Dia #24.

Diagram #24

UNDERSIDE OFFOOT BRACKET

M6x30 SCREWS

M6 FLAT WASHERS

FOOT BRACKETS

CORNER PIECES

GASKETS

SPORTS BAR

LOOSEN BOLTINSIDE

THIS HOLE

25. If vehicle’s Sports Bar is fitted with an LED stop light, use wire strippers to expose the LED wiring loom wires. Push exposed wires into wiring connectors as shown. Ensure the exposed wires are inserted as far as possible into the wiring connectors. See Dia #25.

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Diagram #25


26. So that the wires remain inserted in the wiring connectors, use the crimper on the correct locations as shown. Connect the wiring connectors together as shown. Ensure that the colours of the wires are matched. See Dia #26.

Diagram #26

27. Ensure that the LED stop light is functioning by applying the brakes. Use electrical tape to cover connections. Feed the LED wiring loom and insert the LED wiring grommet back into the Sports Bar. See Dia #27.

Diagram #27

IMPORTANT: If vehicle’s Sports Bar is fitted with an LED stop light, proceed toDiagram #26. Otherwise, proceed to Diagram #29.

SPORTSBAR

USE STRIPPERSTO EXPOSE

WIRES

WIRES

EXPOSEDWIRES

WIRINGCONNECTORS

1 2

SPORTSBAR

REDWIRES

BLACKWIRES

2CRIMP ONDOTTED

LINES

1

LED WIRINGLOOM

SPORTSBARINSERT

LED WIRINGLOOM

SPORTSBAR

30. Check Tonneau Cover is central to vehicle and the sides of Tonneau Cover do not contact the vehicle bedrail. Adjust position if necessary by loosening the top hinge screws and re-positioning Tonneau Cover to fit centrally on vehicle. Re-tighten hinges to torque 5Nm. See Dia #30.

Diagram #30

“CLICK”

2

RIGHT HAND SIDE SHOWN RIGHT HAND SIDE SHOWN

HINGEPIN

1

HINGEPIN

29. NOTE: Two people are required to carry out fitment of the Tonneau Cover. Open tailgate and fit Tonneau Cover - secure hinges with hinge pins as shown. See Dia #29.

Diagram #29

NOT SUPPLIED

SILICONHEADER RAIL

BOTTOM HINGE

BULB SEAL

CORNERPIECE

IMPORTANT: Ensure vehicles’s tailgate is opened before installing Tonneau Cover,as locking mechanism may not function until adjusted correctly.

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28. To prevent water ingress, apply a bead of non-acetic silicon (not supplied) along the length of the header rail as shown. Also apply a bead of non-acetic silicon to the front of the corner pieces and between the bulb seal and bottom hinges. See Dia #28.NOTE: Silicon is not provided in the kit. Use only non-acetic silicon.

Diagram #28

31. Attach gas struts by clipping into place as shown. Ensure the narrow end mounts to the vehicle. See Dia #31.

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Diagram #31

32. Adjust jacking bolts until corner pieces are level with the main surface of the Tonneau Cover. Once in the correct position, lock the M8 Nut into position against the bracket using a shifting spanner. Repeat for other side of vehicle. See Dia #32.

Diagram #32

33. Open Tonneau Cover and remove inspection cover by removing scrivets and rotating cover anti-clockwise. Release plastic retainer clips and unclip rods as shown. See Dia #33.

Diagram #33

NARROW END

TO REMOVE:

GAS STRUT

BALL STRUTSCREW

WIDE END

JACKINGBRACKET

CORNER PIECE

CORNERPIECE

TONNEAUCOVER

INSPECTION COVERPLASTIC RETAINER

CLIPSRODS

REMOVE INSPECTIONCOVER

2

1

RELEASE PLACTICRETAINER CLIPS

3 UNCLIP RODS FROMPLASTIC RETAINERCLIPS

4

IMPORTANT: Ensure vehicles’s tailgate remains open whilst adjusting Tonneau Cover locking mechanism.


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35. Close Tonneau Cover and inspect locking mechanism. Ensure the latch hits the striker bracket centrally. If it DOES, proceed to Diagram #36 below. If it DOES NOT, adjust the striker bracket accordingly by loosening the M6 screws and moving the bracket up or down as shown. You may also need to adjust the latch mechanism by loosening the screws and moving it left or right as shown.See Dia #35. Note: Tonneau Cover has 2 stage locks. Ensure Tonneau engages with second stage of the latch.

Diagram #35

36. Open the Tonneau Cover and engage the lock by pressing upwards on the latch. Adjust pullrods so that they clip back into the retainer clips correctly. Do this by rotating them clockwise to shorten them or anti-clockwise to lengthen them. Clip pullrods and retainer clips back into position. Test lock by pressing the button on top of Tonneau Cover. If latch mechanism DOES NOT release, return to Step 3 and shorten the pullrods. If it DOES release, replace inspection cover. See Dia #36.

Diagram #36

1

IMPORTANT: Ensure that the Tonneau Cover locking mechanism is functioning correctly before closing tailgate.

37. Retighten Allen key tighten bolt back up on Sports Bar. See Dia #37.

Diagram #37

1

ENGAGE LOCK

LATCH MECHANISM

PRESS LATCHUPWARDS

ROTATE PULLRODS

CLOCKWISE = SHORTENANTI-CLOCKWISE = LENGTHEN

“CLICK”

2 ADJUST LENGTH OFPULLRODS BY ROTATION

3 4

REPLACE INSPECTION COVER6

TEST LOCKING MECHANISM5

RETAINERCLIPS

INSPECTIONCOVER

LOCK PLASTIC RETAINER CLIPSBACK IN POSITION


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INCORRECT

INSPECT LATCHENGAGEMENT

CORRECT

M6 SCREWS

TORQUE 10Nm

2 ADJUST STRIKER BRACKET3 ADJUST LATCHMECHANISM

4STRIKERBRACKET

TIGHTEN BOLTINSIDE

THIS HOLE

SCREWS

TORQUE 4Nm

ADJUST

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REMOVAL OF TONNEAU COVERTWO PEOPLE ARE REQUIRED TO CARRY OUT THE REMOVAL OF THE TONNEAU COVER

1. Detach gas struts by inserting a small screw driver and adjusting the spring clip on the strut. See Dia #1.NOTE: Do not remove the spring clip. Only a small amount of levering is required to detach.

Diagram #1

2. Remove hinge pins and then remove the Tonneau Cover. See Dia #2.

Diagram #2

2

21

HINGEPIN

“CLICK”RIGHT HAND SIDE SHOWN RIGHT HAND SIDE SHOWN

HINGEPIN

1

GAS STRUT

BALL STRUTSCREW

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1. Fit Tonneau Cover and secure hinges with hinge pins. See Dia #1.

Diagram #1

2. Attach gas struts by clipping into place. Ensure the narrow end mounts to the vehicle. See Dia #2.

Diagram #2

REPLACEMENT OF TONNEAU COVERTWO PEOPLE ARE REQUIRED TO CARRY OUT THE REPLACEMENT OF THE TONNEAU COVER

“CLICK”

2

RIGHT HAND SIDE SHOWN RIGHT HAND SIDE SHOWN

HINGEPIN

1

HINGEPIN

NARROW END

WIDE END

GAS STRUT

BALL STRUTSCREW


3PC TONNEAU COVER INSTALLATION INSTRUCTIONS Ford … warranty does not cover failure due to neglect,...

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