10/11 ONWARDS EGR REF: SK597TBAKIT NUMBER:

DATE: REVISION: A

Please read each step of these instructions carefully prior to commencing installation!

Place these instructions in the vehicle’s glovebox after installation is complete

IMPORTANT:!

IMPORTANT:!

• Do not use this product in any other motor vehicle for which it is not designed.• Do not use any other mounting location / method other than described in this instruction.• It is advisable to seek assistance of another person when installing this product.• Do not remove the label from the Sports Bar. • Ensure all torque settings are followed.

Note: This is an Aluminium product. Beware of belts, buckles zippers, etc. when lifting Sportsbar as these will easily damage the finish. To avoid corrosion stains, clean up after completion of installation - remove all drill swarf & wipe all fingerprints from car & product.

VW AMAROK SPORTS BARINSTALLATION INSTRUCTIONS

60 Minutes

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VW AMAROK SPORTS BARAccessory Part No.

SK597

Parts List

Component NameNUDGE BAR

A.S. LABEL

LH MOUNT BRACKET

RH CLAMP BRACKET

LHS MOUNT BRACKET

RHS MOUNT BRACKET

M12 FLAT WASHER

M10 NYLOCK NUT

Item1

2

3

4

5

67

8

INSTALLATION PRECAUTIONS

Follow all standard workshop and occupational health and Safety practices during the installation and re-work process.

Safety glasses and hearing protection must be used. Avoid contact with the hot steel when the vehicle tray is being drilled or cut. Clean up the swarf from the bumper fascia re-work immediately to avoid a slipping hazard.

STOCKTAKE OF PARTS

Check supplied Sports Bar parts and fasteners against BOM, before commencing assembly or modifications to the vehicle.

INSTALLATION PRECAUTIONS

STOCKTAKE OF PARTS ( PARTS LIST IN ILLUSTRATION IS AN EXAMPLE ONLY )

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VW AMAROK SPORTS BARAccessory Part No.

SK597

5mm pilot

marker centre punch philips head wire or string tape measure

5mm Allen Key

10mm drill bit

electric drilltorque wrenchM10 – 30Nm

3/8

16 Rubber Sleeves 2

Fig.1

1

2

VW AMAROK SPORTS BARAccessory Part No.

SK597

4/8

1. NOTE: Two people are required to complete installantion. Thoroughly clean and dry the installation areas. See Dia#1

Fig.22. Slide the rubber sleeves over the ends of the sports bar left and right hand legs and then slide the sports bartop tube in as shown. Ensure that all holes are aligned with each other. See Dia#2

3. Slide rubber sleeves away from join and temporarily secure sports bar top tube to sports bar left and righthand legs using two (2) M8x30 black screws and M8 black internal tooth washers. Tighten to Torque 7Nm.See Dia#3

3

1

16

1

16

16

2

3

16

1

3

FIG. 3

3

1

1616

2

NO POWERTOOLS

TORQUE 7Nm

12

11

316

5

5 4

10mm

Ø5mm

Ø12mm15mm

USE RUST INHIBITOR4

2 DRILL Ø5mm PILOT HOLEMARK & CENTRE PUNCH

3

1

DRILL Ø12mm HOLE

3 41 2

SIDE RAIL

FRONT OF THE VEHICLE

TUB FRONT PANEL

VW AMAROK SPORTS BARAccessory Part No.

SK597

5/8

Fig.4

Fig.5

4. Remove protective tape lining from the foam gaskets and attach to the moulded leg bracket cups, aligningthe holes and slots as shown. See Dia#4

5. Attach the moulded leg bracket cups and foam gaskets to the sports bar legs as shown. See Dia#5

6. On the top surface of the side rail, mark and do a centre punch 35mm from the inside of the left hand side rail and 65mm from the front of the side rail and 15mm down from the top edge, as shown. Drill a Ø5mm pilot hole at position marked, then re-drill to Ø12mm. Remove any burrs or sharp edges and apply rust inhibitor to drilled hole. See Dia#6

FIG. 6

1/2

4

1/2

4

55

12

3

35mm 30mm

MARK HOLES

10

7 89

1/2

4

1

10mm

Ø5mm

Ø10mm

SIDE RAIL

USE RUST INHIBITOR3

1 DRILL Ø5mm PILOT HOLE

2 DRILL Ø10mm HOLE3 42

VW AMAROK SPORTS BARAccessory Part No.

SK597

6/21

Fig.7

Fig.8

7. Trial fit the sports bar to the vehicle. See Dia#7

8. Ensure sports bar is sitting corectly on the vehicle. Using the slots in the rear sports bar leg feet measure andmark the centre of the slots as shown. See Dia#8

9. Remove and retain Sports Bar and hardware. Centre punch previously marked centrepoints. Drill a Ø5mm pilothole at positions marked, then re-drill to Ø10mm. Remove any burrs or sharp edges and apply rust inhibitorto drilled holes as shown. See Dia#9

FIG. 9

TORQUE SETTING: 10Nm

10

879

31 2

1/2

4

SIDE RAIL

VW AMAROK SPORTS BARAccessory Part No.

SK597

7/8

Fig.10

Fig.11

10. Fit the sports bar to the vehicle. See Dia#10

11. Re-fit and secure the Sports Bar to the vehicle. See Dia#11

12. Using the installed screw as a guide mark a centre point on the top and bottom of the tube at each end asshown. Drill two (4) Ø5mm holes and remove any burrs or sharp edges. Install two (2) rivets as shown.See Dia#12

FIG. 12

13MARK, CENTREPUNCHAND DRILL Ø5mm TOPAND BOTTOM OF TUBE.

TORQUE 7Nm

NO POWERTOOLS

12

11

VW AMAROK SPORTS BARAccessory Part No.

SK597

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Fig.1313. Remove and retain previously installed M8x30 black screws and M8 black internal tooth washers. Slide rubbersleeves back over tube join aligning the holes. Re-install M8x30 black screws and M8 black internal toothwashers. Tighten to Torque 7Nm. See Dia#13

VW AMAROK SPORTS BAR

CUT-OUT AND STAPLE IN A SUITABLE LOCATION IN VEHICLE’S OWNER MANUALIMPORTANT:

Your Sports Bar is rated to 50 kg.LOAD RATING:

This Sports Bar is made from aluminium that has been highly polished to a mirror finish. The following regular maintenance actions will be required to remove oxidation and staining from the aluminium surfaces: Wash regularly with car wash detergent, rinse with clean water and chamois. Stubborn grime can be removed with kerosene. The polished aluminium surfaces can be maintained using Autosol or similar products.Plastic mouldings can be maintained using Nulon Ezi-Glide silicon spray or similar products.

APPEARANCE AND PRODUCT CARE:FOR POLISHED FINISH:

16