1PC TONNEAU COVER INSTALLATION INSTRUCTIONS. Ford Ranger (with bedliner)

Transcription

1 PC TONNEAU COVER INSTALLATION INSTRUCTIONS Ford Ranger (with bedliner) Care Instructions: Clean Tonneau Cover with a mild detergent and water solution. Do not use abrasive cleaners or solvents. Place these instructions in vehicle s glove box after installation is complete LIST OF PARTS Item Component Name Item Number Qty Item Component Name Item Number Qty Tonneau Cover M6 Nuts * NUTS07 6 Header Rail HBAR00 Rust Inhibitor MISC09 3 Keys 3 Alcohol Wipe MISC005 4 Self Drilling 0gx30mm Screws SCRW U-Nuts NUTS Striker Bracket 5 Header Rail Bulb Seal MISC08 6 Gas Struts STRT Plastic Plate LHS MISC57 7 Ball Strut Screw SCRW075 7 Plastic Plate RHS MISC573 8 M6x30mm Pan Head Screws SCRW Self Drilling Screws SCRW M6 Flat Washer WASH Rear Drill Template MISC634 0 M6 Sring Washer WASH06 6 * Part is not required for this installation. RECOMMENDED TOOL LIST Phillips Head Screwdriver Non-permanent Marker Hammer & Centre Punch Drill Ø4mm, Ø5mm, Ømm Drill Bit Non-acetic Silicon & Dispenser Cleaning Cloth Deburring Tool Masking Tape Tape Measure Shifting Spanner Jigsaw / Hacksaw 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. page 3/0/09

2 SURFACE CLEANER For use in cleaning painted metal, glass and other vehicle surfaces. For external use only. Dispose of properly after use. IMPREGNATED WITH 70% ISOPROPYL ALCOHOL FORD RANGER PC TONNEAU COVER * AUTOMOTIVE * Part is not required for this installation. page 3/0/09

3 FORD RANGER PC TONNEAU COVER 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 Terms EGR 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 () 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. Exclusions This 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. Disclaimer In 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. Maintenance Your 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 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 (55 F). Allow a minimum of 8 hours after baking before installation on the vehicle. page 3 3/0/09

4 FORD RANGER PC TONNEAU COVER BEDLINDER Diagram #. NOTE: Two people are required to complete installation. Thoroughly clean installation areas. See Dia #. 3 MEASURE FROM THIS LINE 963mm SIDE RAIL MASKING TAPE SIDE RAIL 5mm DRILL Ø5mm PILOT HOLES, THEN DRILL Ømm FRONT BED PANEL Diagram #. Apply masking tape to the bedliner as shown. Mark and centre punch the bedliner rail according to the above dimensions. Repeat process for the other side of the vehicle. See Dia #. MARK OUTLINE SLIDE MARK POSITIONS REAR DRILL TEMPLATE Diagram #3 3. 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 () 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 #3. page 4 3/0/09

5 FORD RANGER PC TONNEAU COVER 3 CENTRE PUNCH & DRILL Ø5mm PILOT HOLES THEN DRILL Ømm Ø5mm Ømm 0mm Diagram #4 4. Centre punch the bedliner at the marked locations and drill Ø5mm pilot holes followed by Ømm holes. Apply rust inhibitor to the drilled holes. Repeat process for the other side of the vehicle. See Dia #4. IMPORTANT: If vehicle s bedliner is fitted with a V power socket, proceed to Diagram #5. Otherwise, proceed to Diagram #7. V 0 AMPS MAX TORX HEAD SCREWS V POWER SOCKET PRESS TO RELEASE Diagram #5 5. If vehicle s bedliner is fitted with a V power socket, remove the four (4) torx head screws. Pull the V power socket away from the bedliner and remove the plastic clip as shown. See Dia #5. PRESS TO RELEASE 3 V POWER SOCKET PUSH CONNECTOR BACK THROUGH HOLE IN Diagram #6 6. Press down on the connector as shown to release and remove V power socket. Push the connector back through the hole in the bedliner. See Dia #6. page 5 3/0/09

6 FORD RANGER PC TONNEAU COVER Diagram #7 7. Remove the bedliner as shown. See Dia #7. SIDE RAIL BEDRAIL VARIATION U-NUT x6 Diagram #8 8. Deburr all drilled holes 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 #8. MASKING TAPE 00mm CUT AWAY AREA 3 mm 4 mm Diagram #9 9. 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 hacksaw or jigsaw. Smooth all the trimmed edges using sandpaper. See Dia #9. NOTE: Take care cutting the long horizontal portion at the front of the bedliner. page 6 3/0/09

7 FORD RANGER PC TONNEAU COVER ENSURE THIS SECTION IS ALSO REMOVED CUT AWAY AREA (WHITE) MARKED OUTLINE Diagram #0 0. 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 #0. Z BRACKET BOLTS (RETAIN) Diagram #. Temporarily remove the Z brackets and retain hardware. See Dia #. Z BRACKET BOLTS HEADER RAIL USE LOWER POSITION Diagram #. Fit the header rail to the front tub panel by reinstalling the Z brackets with retained hardware as shown. See Dia #. page 7 3/0/09

8 FORD RANGER PC TONNEAU COVER BOTTOM HINGES HEADER RAIL TORQUE 5Nm SELF-DRILLING SCREWS Diagram #3 3. Apply rust inhibitor to the threads of the self drilling screws. Install the self drilling screws as shown. Tighten to torque 5Nm. See Dia #3. HALF OF REMAINING LENGTH 700mm HALF OF REMAINING LENGTH HEADER RAIL BULB SEAL BULB SEAL BOTTOM HINGES Diagram #4 4. Clean the top of the header rail with alcohol wipe provided and remove residue with clean cloth. Attach the bulb seal to the top of the header rail as shown. See Dia #4. Diagram #5 5. Replace bedliner. See Dia #5. IMPORTANT: If vehicle s bedliner is fitted with a V power socket, replace it by reversing the procedure outlined in Diagram #5 and Diagram #6. page 8 3/0/09

9 FORD RANGER PC TONNEAU COVER SIDE VIEW U-NUT M6 FLAT WASHER SPRING WASHER BALL STRUT SCREW TORQUE 7Nm Diagram #6 6. 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 torque 7Nm. See Dia #6. SIDE VIEW U-NUTS PLASTIC PLATE STRIKER BRACKET M6 FLAT WASHERS M6 SPRING WASHERS BED- LINER M6 SCREWS Diagram #7 7. 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 # PLASTIC PLATE PLASTIC PLATE Ø4mm 0mm 0mm 0mm MARK & DRILL Ø4mm HOLE SELF DRILLING SCREW Diagram #8 8. Mark and drill Ø4mm hole through the plastic plate and bedliner as per dimensions. Fasten plastic plate to bedliner using self drilling screw as shown. See Dia #8. page 9 3/0/09

10 FORD RANGER PC TONNEAU COVER HEADER RAIL NOT SUPPLIED BULB SEAL BOTTOM HINGE BULB SEAL SILICON Diagram #9 9. 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 between the bulb seal and bottom hinges, and the bulb seal and corner of tub as shown. See Dia #9. NOTE: Silicon is not provided in the kit. Use only non-acetic silicon. IMPORTANT: Ensure vehicles s tailgate is opened before installing Tonneau Cover, as locking mechanism may not function until adjusted correctly. HINGE PIN HINGE PIN RIGHT HAND SIDE SHOWN CLICK RIGHT HAND SIDE SHOWN Diagram #0 0. 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 #0. Diagram #. 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 5Nm torque. See Dia #. page 0 3/0/09

11 FORD RANGER PC TONNEAU COVER TO REMOVE: WIDE END GAS STRUT BOLT GAS STRUT NARROW END Diagram #. Attach gas struts by clipping into place as shown. Ensure the narrow end mounts to the vehicle. See Dia #. REMOVE INSPECTION COVER 3 RELEASE PLACTIC 4 UNCLIP RODS FROM RETAINER CLIPS PLASTIC RETAINER CLIPS INSPECTION COVER PLASTIC RETAINER CLIPS RODS Diagram #3 3. 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 #3. IMPORTANT: Ensure vehicles s tailgate remains open whilst adjusting Tonneau Cover locking mechanism. INSPECT LATCH ENGAGEMENT INCORRECT 3 ADJUST STRIKER BRACKET STRIKER 4 ADJUST LATCH MECHANISM M6 SCREWS BRACKET ADJUST CORRECT SCREWS TORQUE 0Nm TORQUE 4Nm Diagram #4 4. Close Tonneau Cover and inspect locking mechanism. Ensure the latch hits the striker bracket centrally. If it DOES, proceed to Diagram #5 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 #4. Note: Tonneau Cover has stage locks. Ensure Tonneau engages with second stage of the latch. page 3/0/09

12 FORD RANGER PC TONNEAU COVER ENGAGE LOCK 3 ADJUST LENGTH OF 4 PULLRODS BY ROTATION LATCH MECHANISM LOCK PLASTIC RETAINER CLIPS BACK IN POSITION RETAINER CLIPS CLICK 5 6 TEST LOCKING MECHANISM REPLACE INSPECTION COVER PRESS LATCH UPWARDS ROTATE PULLRODS CLOCKWISE = SHORTEN ANTI-CLOCKWISE = LENGTHEN INSPECTION COVER Diagram #5 5. 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 #5. IMPORTANT: Ensure that the Tonneau Cover locking mechanism is functioning correctly before closing tailgate. page 3/0/09

13 FORD RANGER PC TONNEAU COVER REMOVAL OF TONNEAU COVER TWO PEOPLE ARE REQUIRED TO CARRY OUT THE REMOVAL OF THE TONNEAU COVER GAS STRUT BOLT GAS STRUT Diagram #. Detach gas struts by inserting a small screw driver and adjusting the spring clip on the strut. See Dia #. NOTE: Do not remove the spring clip. Only a small amount of levering is required to detach. HINGE PIN HINGE PIN CLICK RIGHT HAND SIDE SHOWN RIGHT HAND SIDE SHOWN Diagram #. Remove hinge pins and then remove the Tonneau Cover. See Dia #. page 3 3/0/09

14 FORD RANGER PC TONNEAU COVER REPLACEMENT OF TONNEAU COVER TWO PEOPLE ARE REQUIRED TO CARRY OUT THE REPLACEMENT OF THE TONNEAU COVER HINGE PIN HINGE PIN RIGHT HAND SIDE SHOWN CLICK RIGHT HAND SIDE SHOWN Diagram #. Fit Tonneau Cover and secure hinges with hinge pins. See Dia #. WIDE END GAS STRUT BOLT GAS STRUT NARROW END Diagram #. Attach gas struts by clipping into place. Ensure the narrow end mounts to the vehicle. See Dia #. page 4 3/0/09

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