26/11/12Page 1 of 20
SB0030 PART A - SPORTS BAR WITH INTEGRATED
STOP LAMP INSTALLATION INSTRUCTIONS
LIST OF PARTS
Vehicle Description:
Part Number: SBAR0073
FORD RANGER 2012
PLEASE KEEP INSTRUCTIONS IN GLOVE BOX FOR FURTHER USE
PART NAME
Sports Bar Main Top Tube
Sports Bar LHS Leg
Sports Bar RHS Leg
Rubber Sleeves - Top Tube
Foot Cups
Foam Gaskets - Foot Cups
M8x30 Hex Head Screws
M8x30 Allen Screws
QTY
11124482
NO.
12345678
M8 Spring Washers
M8 Internal Tooth Washers
M8x40 Countersunk screw
M8 Flat Washers
Nut plates
Front Bracket - RHS
Front Bracket - LHS
Rear Bracket
Front Bracket Foam Pad - RH
91011121314151617
828821121
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20
Front Bracket Foam Pad - LH
Rear Bracket Foam Pad - RH
Rear Bracket Foam Pad - LH
Paint Protection Tape
Rivet
Black Spacer Short
Black Spacer long
Wiring Loom Extension
1819202122232425
11142221
21 22
23 24 25
*
#
#
#
# - Required only when installing sports bar with tonneau cover* - Required when installing sports bar without tonneau cover
EXTRA TOOL LIST - Sports Bar + Tonneau Cover Installation
Ø3mm, Ø6mm & Ø7mm Drill Bits
Torque Wrench
Scissors or Sharp Knife
Socket Set
Spanners
Non-acetic Silicone
Tape Measure
Masking Tape
RECOMMENDED TOOL LIST - Sports Bar Installation
Ø5mm & Ø10mm Drill Bits
Cordless Drill
Cleaning Cloth
Socket Wrench 13mm
5mm Allen Key
Hammer & Centre Punch
Non-permanent Marker
Phillips Head Screwdriver
Rivet Gun
26/11/12Page 2 of 20
SB0030 FORD RANGER 2012 SPORTS BAR
FIG. 1
FIG. 2
2
3
1
Remove cabin guard if fitted.
Thoroughly clean and dry the installation area.
IMPORTANT: To obtain correct installation, we recommend that you follow these step by step instructions carefully.
Please take care when assembling and installing this product to protect the finish and your investment. Regular polishing and waxing is required to protect the finish.
Finish Protection: Our products have a high finish that must be maintained such as any other high finish product on the vehicle. Protect the finish with a non-abrasive automotive wax after polishing. Regular polishing of the sportsbar is required to prevent staining or corrosion of the finish.Use products formulated for stainless steel. Failure to maintain the finish may cause unrepairable damage to the sportsbar.
Disclaimer: The buyer assumes all risk and liability whatsoever from the installation and use of our products. Our products are sold as decorative accessories and should not be relied upon as protection for the vehicle or occupants inthe event of a collision or rollover.The manufacturer assumes no liability for injury, loss, incidental or consequential damages in the event of a collision or rollover.
EGR Customer service hotline, phone; +61 7 3337 0155 (Business hours, Australia)
FIG. 3
1
3
4
4
2
2
41
4
2
2
1
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, and the LED wiring is fed through theoutside hole in the bottom of the sports bar front left hand leg as shown.
26/11/12Page 3 of 20
SB0030
FIG. 4
FORD RANGER 2012 SPORTS BAR
FIG. 5
1
3
44
2
NO POWERTOOLS
Slide rubber sleeves away from join and temporarily secure sports bar top tube to sports bar left and righthand legs using two (2) M8x30 screws and M8 internal tooth washers.
8
10
14
FIG. 6
132
Attach the four moulded foot cups to the sports bar legs. Ensure the LED wiring is fed through the foot cup.
If you are installing a tonneau cover skip to page 7
otherwise continue to Fig 6.
2
5
26/11/12Page 4 of 20
SB0030
17
18
19
20
TORQUE 10Nm
Attach the two front brackets and the two rear brackets to the sports bar legs using two M8x40mm countersunk screws in all four feet positions. Tighten fully.
11
14/15
1116
FIG. 7
FIG. 8
FIG. 10
1
1. Ensure sports bar is sitting correctly on the vehicle. Using the a non permanent marker, mark the centre of theslots as shown. 2. Mark 3 small curves on the top face of the side rail to outline the foot cup locations as shown (keep curves to a minimum). Repeat process for the other 3 foot cup positions.
2MARK 3 SMALL CURVES
AROUND THE FOOT CUPS
FIG. 9
Trial fit the assembled Sports Bar aligning the front mounting brackets with the existing fixing points in the tub. Temporarily secure the front brackets LH and RH side to the vehicle tub using the M8x30mmHex Head Screws, M8 Spring Washers and M8 Flat Washers. Do not tighten fully.
79
12
13 mm
26/11/12Page 5 of 20
SB0030
FIG. 14Using the installed screw as a guide mark a centre point on the top of the tube at each end as shown. Drilltwo Ø5mm holes and remove any burrs or sharp edges. Install the two rivets as shown.
31 2
MARK, CENTREPUNCHAND DRILL Ø5mm TOPOF TUBE.
FIG. 12Using the curves previously marked, position abrasive tapes with equal 3mm overlap to the 3 marked curves. Remove thebacking and adhere the paint protection tape (X4) in the marked positions.
21
TAPE TO BE POSITIONED EQUALLY TO THE
CURVES PREVIOUSLY MARKED
PREVIOUSLY MARKED CURVES
x4
FIG. 13
Re-fit the assembled Sports Bar aligning the front mounting brackets with the existing fixing points in the vehicle tub and the rear mounting brackets with the newly drilled holes. Secure the front brackets LH and RH side to the vehicle tub using the M8x30mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers. Secure the rear mounting brackets using M8x30mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers and the nutplate. Tighten to 10Nm
79
1213 mm
x212 139
7
79
12
Vehicle
14/15
Ø5mm Ø10mm
FIG. 11Remove and retain sports bar and hardware. Centrepunch previously marked centrepoints. Drill a Ø5mm pilothole at positions marked, then re-drill to Ø10mm. Remove any burrs or sharp edges and apply rust inhibitor.
SIDE RAIL1 DRILL Ø5mm PILOT HOLE2 DRILL Ø10mm HOLE
RustInhibitor
26/11/12Page 6 of 20
FIG. 15
TORQUE 7Nm Remove and retain previously installed M8x30 screws and M8 internal tooth washers. Slide rubbersleeves back over tube join aligning the holes. Re-install M8x30 screws and M8 internal toothwashers. Tighten to Torque 7Nm.
NO POWERTOOLS
8
10
FIG. 18
FIG. 17 Remove and retain left hand rear wheel arch inner panel and hardware as shown.
FIG. 16
Feed loom through front left hand side foot
Attach the connector to the wires then route the Stop Lamp Wiring Loom down through the hole in the front left hand corner of the vehicle tub, below where the front LHS foot is located.
SB0030
Locate the tail lamp connectors underneath the LHS rear corner of the vehicle. Unplug the connectors.Plug the two large connectors in the Wiring Loom Extension into these two connectors.
REAR OF VEHICLE / TAIL LAMP
DISCONNECT
REAR OF VEHICLE / TAIL LAMP
Stop LampWiring Plug
Supplied Wiring Loom
CONNECT
CONNECT
Remove screws and scrivets
black wire
red wire
FIG. 19
26/11/12Page 7 of 20
SB0030
Route the Wiring Loom Extension up through the LHS rear wheel well. Inside the vehicle body, connect the Stop Lamp Wiring Loom connector to the Wiring Loom Extension connector. Secure the Wiring Loom Extension to the vehicle using Cable Ties supplied.Test the operation of the stop lamp before re-fitting the screws and scrivets around the LHS wheel well liner.
Connect Stop Lamp Wiring Loom toWiring Loom Extension Connector
26/11/12Page 8 of 20
SB0030
PART B - FORD RANGER 3 PIECE HARD TONNEAU COVERINSTALLATION INSTRUCTIONS
Care Instructions
Clean Tonneau Cover with a milddetergent and water solution.
Do not use abrasivecleaners or solvents.
WARNING!When in the closed position, Tonneau Cover must be latched and tailgate must be closed! Failure to do so could result in unexpectedopening of the Tonneau Cover from sudden wind gusts, driving conditions, which could cause damage to the vehicle and/or yourTonneau Cover!DO NOT close the Tailgate when the Hard Tonneau is in the closed position, as damage may occur to the vehicle and/or yourTonneau Cover!
MAINTENANCE:Only use cleaners, waxes, or products that are labelled safe for use on plastics. Avoid the use of any chemicals to clean your TonneauCover 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 ifsolvents or lubricants are used to clean struts.Gas struts must be connected with the cylinder (wide) end to the Tonneau Cover or Warranty is Void. The locking mechanisms and 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.
TONNEAU COVER - IMPORTANT:• 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.• 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 latch 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.• Recommend installation by 2 people.• Fitting Instructions must be given to the end customer to understand correct removal and replacement process onto the vehicle.
PAINTING INSTRUCTIONS: (IF UNPAINTED)• 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 PC/ABS (Poly-Carbonate-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.
26/11/12Page 9 of 20
SB0030
PARTS CHECK SHEET
25
Tonneau CoverQty - 1
PARTS IN MAIN CARTON
PARTS IN FITTING KIT (KIT032373)
29 30
Hinge Lower(CLIP2720PC)Qty - 2
Hinge PinRetainer(CLIP2717-1)Qty - 2
Upper TailgateBracket(CLIP2834PC)Qty - 2
TailgateTop Hat(CLIP2875PC)Qty - 2
31
Hinge Pin(CLIP2032)Qty - 2
32 33 34 35
Gas StrutStandard(STRT0005-2)Qty - 2
26
LHS CornerPieceQty - 1
27
RHS CornerPieceQty - 1
28
Lock KeysQty - 2
Fitting Kit(KIT032373)Qty - 1
54
HeaderRail Seal(MISC2229-9)Qty - 1
HeaderRail (HBAR0013-1)Qty - 1
52 53
Side DrillTemplate(MISC3452)Qty - 1
PARTS IN KIT (KIT032369)
VOLK
SWAG
EN 2
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.
RustInhibitor
36
JackingBracket(CLIP2646PC)Qty - 2
37 38
Rivet(FAST0505)Qty - 17
Scrivet(FAST0086)Qty - 2
*Parts 37, 45 and 46 are included in this kit, but are not required.
39 40 41 42
M6x20 HexHead Bolt(SCRW0028)Qty - 18
43 44
M6 FlatWasher Small(WASH0153)Qty - 38
45
M6 NylocNut(NUTS0016)Qty - 12
M8 HexNut(NUTS0217)Qty - 2
M8x40 C/SunkHead Screw(SCRW0847)Qty - 8
46
M8x50 HexHead Bolt(SCRW0789)Qty - 2
47
Ball StrutBracket(CLIP2034-1)Qty - 2
AlcoholWipe(MISC0052)Qty - 4
RustInhibitor(MISC2776)Qty - 2
48 49 50 51
A
B
Lock StrikerBracket(CLIP2499-PC)Qty - 2
Striker U-Bolt(LOCK0006)Qty - 2
Anodized Spacer short 10mm thick(MISC3405)Qty - 2
Anodized Spacerlong 8mm thick(MISC3404)Qty - 2
M6 HexNut(NUTS0161)Qty - 8
Qty -(M
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ISCk
pacm t
34-
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Mhic
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Sp0m
SC3Qty
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acm
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MISQ
Ano nodlo
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6
kAnce
464
kw
0848
C/SSc
CRQt
8x4He
45
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unrew
W0y -
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373
26/11/12Page 10 of 20
SB0030
FIG. 8
40 40
39 39
38
HEADER RAIL
SECTION THROUGH THE TUB RAIL
FRONT OF VEHICLE
HEADER RAIL
FRONTPANEL
RHSLHS
SIDEPANEL
SIDEPANEL
Ø5.5mm
1
13
10mm
1
42
RUSTINHIBITOR
CLEAN & DRYINSTALLATION AREAS
ENTIRE LENGTH
FIG. 20 Thoroughly clean and dry the installations areas. See Above Left Place masking tape in sections along the entire length of the side rails as shown. See Above Right.
Attach header rail to the front of the tub using two M6x20 screws and washers.Note the header rail orientation as shown in the section view. Mark and center punch the five hole locations in header rail. Remove the header rail. Drill five (5) holes through the tub using 5.5mm drill.Remove all burrs, sharp edges and swarf from vehicle. Apply rust inhibitor to all drilled holes. Reattach the header rail with screws and washers. NOTE: Top of header rail is to be flush with top of front bed rail. FIG. 21
Rivet the header rail to the tub using five (5) rivets. Once rivets are in, remove M6 screws and retain for step 15 to install sports bar. NOTE: Header rail to be flush with top of front bed rail. .
LHS
SIDEPANEL
1
HEADER RAILRHS
SIDEPANEL
FIG. 22
26/11/12Page 11 of 20
SB0030
FIG. 8
39402930
4041
Measure and cut header rail seal to a length of 1380mm. Locate the centre of the header rail seal and trial fit to the front panel, ensure seal is oriented correctly and centred to the tub. Remove approximately 50mm length from one end of liner. Orient and align centre of seal with centre of front panel and rearward edge of seal against the lower hinge as shown. Starting from one end apply firm pressure and remove liner along the length of the seal, ensuring seal runs parallel with the edge front panel.
Orient the two (2) lower hinges as shown. Align the holes in the hinge lower with the slots in the header rail.Secure with two (2) M6x20 hex head bolts, four (4) M6 flat washers and two (2) M6 nyloc nuts for each hinge as shown. Do not overtighten at this point. Allow side to side movement for adjustment once the tonneau cover is installed.
1380mm MEASURE & CUTHEADER RAIL SEAL
TO LENGTH - 1380mm
FRONTPANEL HEADER RAIL
ALIGN TO REAR EDGE OFTHE FRONTPANEL
FRONT OF VEHICLE
SECTION THROUGH THE TUB RAIL
10mm10mm
10Nm
RHSLHS
TIGHTEN TO TORQUE 10Nm
FIG. 25
FIG. 24
FIG. 23
Position the side drill template against the side of the tub bed rail as shown, ensuring arrows are facing down and to the front of the vehicle. The drill template shape matches the bottom shape of the side of the bed rail. Align the bottom of the template with the bottom of the bed rail as shown. Attach using masking tape. Mark and centrepunch the holes marked with an “F”, the two unmarked holes in the middle and the two rearmost positions. Do not use the holes marked with an “M”. Drill all holes with Ø3 pilot drill and remove the drill template. Drill four (4) holes Ø7mm and two (2) Ø5.5mm as shown. Repeat process by reversing the template to use on the other side of the vehicle. Remove all masking tape from the side rails. Remove all burrs, sharp edges and swarf from vehicle. Apply rust inhibitor to all drilled holes.
15Ø3mm2
FRONTPANEL
ALIGN DRILL TEMPLATEWITH BOTTOM TUB EDGE DO NOT DRILL HOLES
FOR THIS FITMENTHOLES MARKED “M”
DRILL TEMPLATEMUST TOUCH
FRONT OF THE TUB
ALIGN DRILL TEMPLATEWITH BOTTOM TUB EDGE
SIDE PANEL (RHS)
TAILGATE
Ø7mm
3
Ø5.5mm
4
65mm37mm
40mm
70mm
712mm
1256mm813mm
36mm 36mm
M M F F
26/11/12Page 12 of 20
SB0030
FIG. 8
Fit the ball stud bracket to the side rail and secure with two (2) rivets (center pair of holes).Repeat process for the other side of the vehicle.
Pre-assemble M8x50 bolt and M8 nut into each jacking bracket as shown ensuring it is screwed all the way down at this point as shown. Secure a jacking bracket to the vehicle with two (2) M6x20 hex head bolts, four (4) M6 flat washers and two (2) M6 nyloc nuts as shown. Repeat process for the other side of the vehicle. Tighten to Torque 9Nm.
10mm10mm
7Nm
TIGHTEN TO TORQUE 7NmSIDE VIEW
SIDE VIEW
HEADER RAIL
16
TUB
BALL STUDBRACKET
9
FIG. 26
FIG. 27
Attach the striker bracket to the tub using two (2) M6 screws, M6 washers and M6 nylock nuts.Note the orientation of the bracket. Position face “B” of lock striker bracket against the side rail as shown. Tighten to 9Nm.
SIDE VIEW10mm 10mm
9Nm
LETTER “B” SIDESITS AGAINST SIDE RAIL
A
B
1
FIG. 28
38
42
39
3939
40 40
40 40
40
41
41
41
36
33
FIG. 30
Trial fit the assembled Sports Bar aligning the front mounting brackets with the existing fixing points in the tub. Temporarily secure the front brackets LH and RH side to the vehicle tub using the M8x30mmHex Head Screws, M8 Spring Washers and M8 Flat Washers. Do not tighten fully.
26/11/12Page 13 of 20
SB0030
Apply a non-acetic silicone perimeter bead to the foot cups and fit into the sports bar legs, place the spacer plates on top followed by the tonneau corner pieces. Starting with front bracket screw the two M8x40mm bolts into the sports bar. Repeat same procedure for the rear leg and opposite side of the sports bar. Tighten Fully. Note: Remove any excess silicone.
FIG. 82 2
33
4
4 5
6
5
11
SPORTS BAR
X4 X4
FITRUBBERPADS
FEED WIRE THROUGH HOLE IN TONNEAU COVERCORNER PIECE
6FITRUBBERPADS
FIG. 29
26
23 24
15 14
16
27
5/65/6
18/20 17/19
11
TORQUE 10Nm
APPLY NON-ACETIC SILICONETO TOP AND BOTTOM SURFACESAROUND PERIMETERTO PREVENT WATER ENTRY
79
12
Centrepunch previously marked scrivet centrepoints. Drill a Ø6mm hole at the position marked. Remove any burrs and sharp edges and apply rust inhibitor. Repeat on other side.
26/11/12Page 14 of 20
SB0030
FIG. 31
SCRIVET HOLE
REAR BRACKET SLOTS
Apply pressure to push the corner piece and front sports bar feet firmly into the front corner of the tub and down onto the side rail. Mark the scrivet hole and rear bracket slot positions with non permanent marker. Repeat process for the other side of the vehicle.
FIG. 33
Ø6mm SIDE RAIL1 DRILL Ø6mm HOLE
Ø5mm Ø10mm
FIG. 32
Remove and retain sports bar and hardware. Centrepunch previously marked rear bracket centrepoints. Drill a Ø5mm pilot hole at positions marked, then re-drill to Ø10mm. Remove any burrs or sharp edges and apply rust inhibitor. Repeat on other side.
SIDE RAIL1 DRILL Ø5mm PILOT HOLE2 DRILL Ø10mm HOLE
RustInhibitor
RustInhibitor
Re-fit the assembled Sports Bar by aligning the front mounting brackets with the existing fixing points in the vehicle tub and the rear mounting brackets with the newly drilled holes. Secure the front brackets LH and RH side to the vehicle tub using the M8x30mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers. Secure the rear mounting brackets using M8x30mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers and the nutplate. Tighten to 10Nm
13 mm
26/11/12Page 15 of 20
FIG. 35
FIG. 34
Using the installed screw as a guide mark a centre point on the top of the tube at each end as shown. Drilltwo Ø5mm holes and remove any burrs or sharp edges. Install the two rivets as shown.
31 2
MARK, CENTREPUNCHAND DRILL Ø5mm TOPOF TUBE.
FIG. 36
TORQUE 7Nm
Remove and retain previously installed M8x30 screws and M8 internal tooth washers. Slide rubbersleeves back over tube join aligning the holes. Re-install M8x30 screws and M8 internal toothwashers. Tighten to Torque 7Nm.
NO POWERTOOLS
8
10
SB0030
79
12
x212 13 139
7
79
12
Vehicle
14/15
26/11/12Page 16 of 20
SB0030
FIG. 37
FIG. 39
With tailgate open, Close and check Tonneau Cover is central to vehicle and the sides of Tonneau Cover do not contact the vehicle bedrail. Adjust position by loosening the top hinge screws for fore and aft adjustment and hinge mount screws for side to side adjustment to re-position Tonneau Cover to fit centrally on vehicle. Before screwing tight, align each lower hinge section outwards in order to prevent side play. Tighten all hinge brackets to Torque 9Nm.
Adjust jacking bracket bolt to level corner piece to the main surface of the Tonneau Cover.Once in the correct position, lock the bolt into position against the bracket by tightening the M8 nut using a 13mm spanner.Repeat process for the other side of the vehicle.
13mm
13mm
NO POWER TOOLS
Open vehicle’s tailgate and keep it open until locking mechanism has been adjusted correctly. Two people are required to carry out the fitment of the tonneau cover. Carefully fit tonneau cover to vehicle ensuring seal at the front of the tonneau cover sits correctly over the header rail seal as shown, If incorrectly placed this can direct water into the tub. Secure hinges with hinge pins as shown. IMPORTANT: Ensure hinge pins clip into retaining leg on lower hinges, ensuring pin is securely restrained. If misaligned, seal can be pushed forward from inside of the tub.
LOOSEN TOPHINGE SCREWS
TIGHTEN HINGE MOUNT SCREWS TORQUE 9Nm
TONNEAU SEALFITMENT OVER
HEADER RAIL SEAL
ENSURE HINGE PINIS CORRECTLYRESTRAINED
IMPORTANT: Ensure vehicles’s tailgate is opened before installing Tonneau Cover, andremains open until lock striker is fitted and locking mechanism is adjusted correctly.
DO NOT close the Tailgate when the Hard Tonneau is in the closed position, as damagemay occur to the vehicle and/or your Tonneau Cover!
FIG. 38
39
26/11/12Page 17 of 20
SB0030
FIG. 40
FIG. 41 Fit the striker U-bolt to the striker bracket using nuts and washers as shown.
Attach gas struts by clipping into place as shown. Ensure the narrow end mounts to the vehicle and the wide end mounts to the tonneau cover. !! Failure to do so Voids Warranty on gas struts!!
NARROW END MOUNTS TO VEHICLEWIDE END MOUNTS TO TONNEAU COVER
A
B
8
B
39
35
44
40
44
26/11/12Page 18 of 20
SB0030
FIG.42
FIG. 44
FIG. 43
Close Tonneau Cover and inspect locking mechanism. Ensure the latch hits the striker bracket centrally. If it DOES NOT, adjust the latch accordingly by loosening the screws and moving the latch left or right as shown. Tighten to torque 5Nm.Adjust the height of the lock striker bracket by moving it up or down as shown. Tighten nuts to torque 9Nm. Note: Tonneau Cover has 2 stage locks as a safety feature. Ensure Tonneau engages with second stage of the latch.
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 (via internal turn buckle). 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.
IMPORTANT: Ensure that the Tonneau Cover locking mechanism is functioning correctly before closing tailgate.
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
INSPECTION COVERPLASTIC RETAINER
CLIPSPULLRODS
REMOVE INSPECTIONCOVER
RELEASE PLASTICRETAINER CLIPS
UNCLIP PULLRODSFROM PLASTICRETAINER CLIPS
IMPORTANT: Ensure vehicle’s tailgate is opened and remains open.Tonneau could lock during adjustment process.
10mm
10Nm
1
INCORRECT
INSPECT LATCHENGAGEMENT
CORRECT
2 ADJUST U-BOLT
USE A RULER TOENSURE U-BOLT
REMAINS PARALLELTO LOCK STRIKER
3 ADJUST LATCHMECHANISM
4
TORQUE 10Nm
SCREWS
TORQUE 5Nm
ADJUST
0mm
1020
3040
5060
7080
90
Open Tonneau Cover and remove inspection cover by removing scrivets and rotating cover anti-clockwise.Release plastic retainer clips and unclip pullrods as shown.IMPORTANT: TAILGATE MUST BE OPEN, TONNEAU COULD LOCK DURING ADJUSTMENT PROCESS.
26/11/12Page 19 of 20
SB0030
FIG. 45
FIG. 47
FIG. 46
Open tonneau cover. Orient latch mount brackets as shown and attach to the rear of the tonneau inner using two (2) M6 x 20mm hex head bolt and washers. Position latch bracket so screw does up in the middle of the slot as shown. Repeat for the RHS. Do not fully tighten at this stage. Note: Use caution when closing to ensure bracket does not contact vehicle tailgate.
Measure 80mm from LHS edge of the tailgate. Orient top hat latch brackets as shown at 80mm. Mark and center punch four (4) hole locations and drill holes with 5.5mm drill bit. Secure the top hat latch brackets to the tailgate using four (4) blind rivets for each bracket. Repeat for RHS.
Close rear tailgate and then the tonneau cover to check that it closes correctly and the latch bracket does not contact the top hat latch bracket. If required adjust the latch bracket by loosening the screws with and adjusting fore and aft. Re-tighten and recheck. When adjustment is complete tighten M6 screws with captive washers to Torque 9Nm. Note: Use caution when closing to ensure bracket does not contact vehicle tailgate.
10mm
10mm
NARROW END MOUNTS TO VEHICLE
TAILGATE
80mm
1
Ø5.5mm
2
3
2
1
LATCHBRACKET
TAILGATE
TOP HAT LATCHBRACKET
CENTRE LATCH BRACKET AND FINGER TIGHTEN SCREWS
38 38
39
26/11/12Page 20 of 20
FIG. 50
FIG. 49 Remove and retain left hand rear wheel arch inner panel and hardware as shown.
FIG. 48
Feed loom through front left hand side foot
Attach the Connector to to wires then route the Stop Lamp Wiring Loom down through the hole in the front left hand corner of the vehicle tub, below where the front LHS foot is located.
Locate the tail lamp connectors underneath the LHS rear corner of the vehicle. Unplug the connectors.Plug the two large connectors in the Wiring Loom Extension into these two connectors.
REAR OF VEHICLE / TAIL LAMP
DISCONNECT
REAR OF VEHICLE / TAIL LAMP
Stop LampWiring Plug
Supplied Wiring Loom
CONNECT
CONNECT
SB0030
Remove screws and scrivets
black wire
red wire
FIG. 51
Route the Wiring Loom Extension up through the LHS rear wheel well. Inside the vehicle body, connect the Stop Lamp Wiring Loom connector to the Wiring Loom Extension connector. Secure the Wiring Loom Extension to the vehicle using Cable Ties supplied. Test the operation of the stop lamp before re-fitting the screws and scrivets around the LHS wheel well liner.
Connect Stop Lamp Wiring Loom toWiring Loom Extension Connector
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