PART A - SPORTS BAR WITH INTEGRATED STOP LAMP INSTALLATION INSTRUCTIONS

Transcription

1 PART A - SPORTS BAR WITH INTEGRATED STOP LAMP INSTALLATION INSTRUCTIONS SB000 Vehicle Description: FORD RANGER 0 Part Number: SBAR007 LIST OF PARTS PLEASE KEEP INSTRUCTIONS IN GLOVE BOX FOR FURTHER USE NO 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 M8x0 Hex Head Screws M8x0 Allen Screws QTY M8 Spring Washers M8 Internal Tooth Washers M8x0 Countersunk screw M8 Flat Washers Nut plates Front Bracket - RHS Front Bracket - LHS Rear Bracket Front Bracket Foam Pad - RH 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 5 6 # * # # 5 # - Required only when installing sports bar with tonneau cover * - Required when installing sports bar without tonneau cover RECOMMENDED TOOL LIST - Sports Bar Installation Ø5mm & Ø0mm Drill Bits Hammer & Centre Punch Cordless Drill Non-permanent Marker Cleaning Cloth Phillips Head Screwdriver Socket Wrench mm Rivet Gun 5mm Allen Key EXTRA TOOL LIST - Sports Bar + Tonneau Cover Installation Ømm, Ø6mm & Ø7mm Drill Bits Non-acetic Silicone Torque Wrench Tape Measure Scissors or Sharp Knife Masking Tape Socket Set Spanners Page of 0 6//

2 FORD RANGER 0 SPORTS BAR SB000 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 in the 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; (Business hours, Australia) FIG. Remove cabin guard if fitted. FIG. Thoroughly clean and dry the installation area. FIG. Slide the rubber sleeves over the ends of the sports bar left and right hand legs and then slide the sports bar top tube in as shown. Ensure that all holes are aligned with each other, and the LED wiring is fed through the outside hole in the bottom of the sports bar front left hand leg as shown. Page of 0 6//

3 FORD RANGER 0 SPORTS BAR SB000 NO POWER TOOLS 0 8 FIG. Slide rubber sleeves away from join and temporarily secure sports bar top tube to sports bar left and right hand legs using two () M8x0 screws and M8 internal tooth washers. If you are installing a tonneau cover skip to page 7 otherwise continue to Fig 6. FIG. 5 5 FIG. 6 Attach the four moulded foot cups to the sports bar legs. Ensure the LED wiring is fed through the foot cup. Page of 0 6//

4 TORQUE 0Nm /5 6 FIG. 7 Attach the two front brackets and the two rear brackets to the sports bar legs using two M8x0mm countersunk screws in all four feet positions. Tighten fully FIG mm 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 M8x0mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers. Do not tighten fully.. Ensure sports bar is sitting correctly on the vehicle. Using the a non permanent marker, mark the centre of the slots as shown.. Mark small curves on the top face of the side rail to outline the foot cup locations as shown FIG. 0 (keep curves to a minimum). Repeat process for the other foot cup positions. MARK SMALL CURVES AROUND THE FOOT CUPS Page of 0 6//

5 SIDE RAIL DRILL Ø5mm PILOT HOLE DRILL Ø0mm HOLE Ø5mm Ø0mm Rust Inhibitor FIG. Remove and retain sports bar and hardware. Centrepunch previously marked centrepoints. Drill a Ø5mm pilot hole at positions marked, then re-drill to Ø0mm. Remove any burrs or sharp edges and apply rust inhibitor. x TAPE TO BE POSITIONED EQUALLY TO THE CURVES PREVIOUSLY MARKED PREVIOUSLY MARKED CURVES FIG. Using the curves previously marked, position abrasive tapes with equal mm overlap to the marked curves. Remove the backing and adhere the paint protection tape (X) in the marked positions. mm /5 Vehicle 9 7 x 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 M8x0mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers. Secure the rear mounting brackets using M8x0mm Hex Head FIG. Screws, M8 Spring Washers and M8 Flat Washers and the nutplate. Tighten to 0Nm MARK, CENTREPUNCH AND DRILL Ø5mm TOP OF TUBE. FIG. Using the installed screw as a guide mark a centre point on the top of the tube at each end as shown. Drill two Ø5mm holes and remove any burrs or sharp edges. Install the two rivets as shown. Page 5 of 0 6//

6 NO POWER TOOLS 0 8 FIG. 5 TORQUE 7Nm Remove and retain previously installed M8x0 screws and M8 internal tooth washers. Slide rubber sleeves back over tube join aligning the holes. Re-install M8x0 screws and M8 internal tooth washers. Tighten to Torque 7Nm. red wire Feed loom through front left hand side foot black wire FIG. 6 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. Remove screws and scrivets FIG. 7 Remove and retain left hand rear wheel arch inner panel and hardware as shown. Stop Lamp Wiring Plug DISCONNECT CONNECT CONNECT Supplied Wiring Loom REAR OF VEHICLE / TAIL LAMP REAR OF VEHICLE / TAIL LAMP FIG. 8 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. Page 6 of 0 6//

7 Connect Stop Lamp Wiring Loom to Wiring Loom Extension Connector FIG. 9 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. Page 7 of 0 6//

8 PART B - FORD RANGER PIECE HARD TONNEAU COVER INSTALLATION INSTRUCTIONS Care Instructions Do not use abrasive cleaners or solvents. Clean Tonneau Cover with a mild detergent and water solution. WARNING! When in the closed position, Tonneau Cover must be latched and tailgate must be closed! Failure to do so could result in unexpected opening of the Tonneau Cover from sudden wind gusts, driving conditions, which could cause damage to the vehicle and/or your Tonneau Cover! DO NOT close the Tailgate when the Hard Tonneau is in the closed position, as damage may occur to the vehicle and/or your Tonneau 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 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. 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 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 (55 F). Allow a minimum of 8 hours after baking before installation on the vehicle. Page 8 of 0 6//

9 B Dispose of properly after use. IMPREGNATED WITH 70% ISOPROPYL ALCOHOL PARTS CHECK SHEET SB000 PARTS IN MAIN CARTON Tonneau Cover Qty - LHS Corner Piece Qty - RHS Corner Piece Qty - Lock Keys Qty - Fitting Kit (KIT07) Qty - PARTS IN FITTING KIT (KIT07) A Hinge Lower (CLIP70PC) Qty Hinge Pin Retainer (CLIP77-) Qty - Hinge Pin (CLIP0) Qty - Gas Strut Standard (STRT0005-) Qty - Jacking Bracket (CLIP66PC) Qty - Lock Striker Bracket (CLIP99-PC) Qty Striker U-Bolt (LOCK0006) Qty - M8 Hex Nut (NUTS07) Qty - M8x0 C/Sunk Head Screw (SCRW087) Qty Rivet (FAST0505) Qty M6x0 Hex Head Bolt (SCRW008) Qty M6 Flat Washer Small (WASH05) Qty - 8 M6 Nyloc Nut (NUTS006) Qty - M8x50 Hex Head Bolt (SCRW0789) Qty - Ball Strut Bracket (CLIP0-) Qty M6 Hex Nut (NUTS06) Qty - 8 AUTOMOTIVE SURFACE CLEANER For use in cleaning painted metal, glass and other vehicle surfaces. For external use only. Rust Inhibitor Anodized Spacer short 0mm m thick (MISC05) Qty - Anodized d Spacer long 8mm m thick (MISC0) Qty - Scrivet (FAST0086) Qty - Upper Tailgate Bracket (CLIP8PC) Qty - Tailgate Top Hat (CLIP875PC) Qty - Alcohol Wipe (MISC005) Qty - Rust Inhibitor (MISC776) Qty - *Parts 7, 5 and 6 are included in this kit, but are not required. PARTS IN KIT (KIT069) VOLKSWAGEN Header Rail Seal (MISC9-9) Qty - Header Rail (HBAR00-) Qty - Side Drill Template (MISC5) Qty - Page 9 of 0 6//

10 CLEAN & DRY INSTALLATION AREAS ENTIRE LENGTH FIG. 0 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. FRONT PANEL HEADER RAIL 0mm Ø5.5mm RUST INHIBITOR FRONT OF VEHICLE SECTION THROUGH THE TUB RAIL SIDE PANEL SIDE PANEL LHS HEADER RAIL RHS FIG. 8 FIG. Attach header rail to the front of the tub using two M6x0 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. SIDE PANEL SIDE PANEL LHS HEADER RAIL RHS 8 FIG. Rivet the header rail to the tub using five (5) rivets. Once rivets are in, remove M6 screws and retain for step 5 to install sports bar. NOTE: Header rail to be flush with top of front bed rail.. Page 0 of 0 6//

11 0Nm TIGHTEN TO TORQUE 0Nm 0mm 0mm LHS 0 RHS 0 FIG. Orient the two () lower hinges as shown. Align the holes in the hinge lower with the slots in the header rail. Secure with two () M6x0 hex head bolts, four () M6 flat washers and two () 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. 80mm MEASURE & CUT HEADER RAIL SEAL TO LENGTH - 80mm ALIGN TO REAR EDGE OF THE FRONTPANEL FRONT PANEL HEADER RAIL FIG. 8 FRONT OF VEHICLE SECTION THROUGH THE TUB RAIL FIG. Measure and cut header rail seal to a length of 80mm. 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. Ømm 5 56mm Ø5.5mm 70mm 7mm 0mm 8mm 65mm 6mm 7mm 6mm TAILGATE M M F F FRONT PANEL ALIGN DRILL TEMPLATE WITH BOTTOM TUB EDGE DRILL TEMPLATE MUST TOUCH FRONT OF THE TUB DO NOT DRILL HOLES FOR THIS FITMENT HOLES MARKED M SIDE PANEL (RHS) Ø7mm ALIGN DRILL TEMPLATE WITH BOTTOM TUB EDGE FIG. 5 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 Ø pilot drill and remove the drill template. Drill four () holes Ø7mm and two () 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. Page of 0 6//

12 SIDE VIEW HEADER RAIL TUB 8 9 BALL STUD BRACKET 6 FIG. 6 Fit the ball stud bracket to the side rail and secure with two () rivets (center pair of holes). Repeat process for the other side of the vehicle. 7Nm 0mm 0mm SIDE VIEW TIGHTEN TO TORQUE 7Nm FIG. 87 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 () M6x0 hex head bolts, four () M6 flat washers and two () M6 nyloc nuts as shown. Repeat process for the other side of the vehicle. Tighten to Torque 9Nm. 0mm 9Nm 0mm SIDE VIEW LETTER B SIDE SITS AGAINST SIDE RAIL 0 B A FIG. 8 Attach the striker bracket to the tub using two () 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. Page of 0 6//

13 TORQUE 0Nm 8/0 7/9 5 6 FIT RUBBER PADS 5 X X 5 6 FIT RUBBER PADS FEED WIRE THROUGH HOLE IN TONNEAU COVER CORNER PIECE /6 5/6 SPORTS BAR APPLY NON-ACETIC SILICONE TO TOP AND BOTTOM SURFACES AROUND PERIMETER TO PREVENT WATER ENTRY FIG. 8 FIG. 9 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 M8x0mm 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. 9 7 FIG. 0 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 M8x0mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers. Do not tighten fully. Page of 0 6//

14 SCRIVET HOLE REAR BRACKET SLOTS FIG. 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. Ø5mm Ø0mm Rust Inhibitor SIDE RAIL DRILL Ø5mm PILOT HOLE DRILL Ø0mm HOLE FIG. 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 Ø0mm. Remove any burrs or sharp edges and apply rust inhibitor. Repeat on other side. Ø6mm Rust Inhibitor SIDE RAIL DRILL Ø6mm HOLE FIG. 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. Page of 0 6//

15 mm /5 Vehicle 9 7 x FIG. 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 M8x0mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers. Secure the rear mounting brackets using M8x0mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers and the nutplate. Tighten to 0Nm MARK, CENTREPUNCH AND DRILL Ø5mm TOP OF TUBE. FIG. 5 Using the installed screw as a guide mark a centre point on the top of the tube at each end as shown. Drill two Ø5mm holes and remove any burrs or sharp edges. Install the two rivets as shown. NO POWER TOOLS 0 8 TORQUE 7Nm FIG. 6 Remove and retain previously installed M8x0 screws and M8 internal tooth washers. Slide rubber sleeves back over tube join aligning the holes. Re-install M8x0 screws and M8 internal tooth washers. Tighten to Torque 7Nm. Page 5 of 0 6//

16 IMPORTANT: Ensure vehicles s tailgate is opened before installing Tonneau Cover, and remains 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 damage may occur to the vehicle and/or your Tonneau Cover! TONNEAU SEAL FITMENT OVER HEADER RAIL SEAL ENSURE HINGE PIN IS CORRECTLY RESTRAINED FIG. 7 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 TOP HINGE SCREWS TIGHTEN HINGE MOUNT SCREWS TORQUE 9Nm FIG. 8 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. mm mm NO POWER TOOLS FIG. 9 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 mm spanner. Repeat process for the other side of the vehicle. Page 6 of 0 6//

17 NARROW END MOUNTS TO VEHICLE WIDE END MOUNTS TO TONNEAU COVER FIG. 0 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!! 95 0 B B A 8 9 FIG. Fit the striker U-bolt to the striker bracket using nuts and washers as shown. Page 7 of 0 6//

18 IMPORTANT: Ensure vehicle s tailgate is opened and remains open. Tonneau could lock during adjustment process. REMOVE INSPECTION COVER RELEASE PLASTIC RETAINER CLIPS UNCLIP PULLRODS FROM PLASTIC RETAINER CLIPS INSPECTION COVER PLASTIC RETAINER CLIPS PULLRODS FIG. 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. 0Nm 0mm INSPECT LATCH ENGAGEMENT ADJUST U-BOLT ADJUST LATCH MECHANISM USE A RULER TO ENSURE U-BOLT REMAINS PARALLEL ADJUST INCORRECT TO LOCK STRIKER CORRECT TORQUE 0Nm 0mm SCREWS TORQUE 5Nm FIG. 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 stage locks as a safety feature. Ensure Tonneau engages with second stage of the latch. IMPORTANT: Ensure that the Tonneau Cover locking mechanism is functioning correctly before closing tailgate. ENGAGE LOCK ADJUST LENGTH OF PULLRODS BY ROTATION LATCH MECHANISM LOCK PLASTIC RETAINER CLIPS BACK IN POSITION RETAINER CLIPS CLICK PRESS LATCH UPWARDS ROTATE PULLRODS CLOCKWISE = SHORTEN ANTI-CLOCKWISE = LENGTHEN 5 6 TEST LOCKING MECHANISM REPLACE INSPECTION COVER INSPECTION COVER FIG. 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 and shorten the pullrods. If it DOES release, replace inspection cover. Page 8 of 0 6//

19 0mm 9 CENTRE LATCH BRACKET AND FINGER TIGHTEN SCREWS NARROW END MOUNTS TO VEHICLE FIG. 5 Open tonneau cover. Orient latch mount brackets as shown and attach to the rear of the tonneau inner using two () M6 x 0mm 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. 8 8 Ø5.5mm 80mm TAILGATE FIG. 6 Measure 80mm from LHS edge of the tailgate. Orient top hat latch brackets as shown at 80mm. Mark and center punch four () hole locations and drill holes with 5.5mm drill bit. Secure the top hat latch brackets to the tailgate using four () blind rivets for each bracket. Repeat for RHS. 0mm LATCH BRACKET TAILGATE TOP HAT LATCH BRACKET FIG. 7 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. Page 9 of 0 6//

20 Feed loom through front left hand side foot red wire black wire FIG. 8 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. Remove screws and scrivets FIG. 9 Remove and retain left hand rear wheel arch inner panel and hardware as shown. Stop Lamp Wiring Plug DISCONNECT CONNECT CONNECT Supplied Wiring Loom REAR OF VEHICLE / TAIL LAMP REAR OF VEHICLE / TAIL LAMP FIG. 50 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. Connect Stop Lamp Wiring Loom to Wiring Loom Extension Connector FIG. 5 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. Page 0 of 0 6//