CANOPY INSTALLATION INSTRUCTIONS. Holden Colorado LX and LT-R

Transcription

1 CANOPY INSTALLATION INSTRUCTIONS Holden Colorado LX and LT-R (007 Production Onwards) Installation Time: Hour (Approximately) Without Bed Liner Hour 45 Minutes (Approximately) With Bed Liner Care Instructions: Clean Canopy 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 PLEASE REFER TO PAGE, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES. 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. Recommend installation by people. This Canopy is designed to suit the LX and LT-R Colorado Crew Cab (Double Cab). Sports Bars MUST be removed and returned to Customer with all hardware components. Cabin Guards MUST be removed and returned to Customer (If requested) with all hardware components. For vehicles fitted with a Bed Liner, the Bed Liner will need to be cut to remove the top flange that sits over the bed rails, so the Canopy seals to the tub and prevents any water entering the tub. This Fitting Instruction where a Bed Liner is referred to, is based on - GM Genuine Bed Liner Accessory only. RECOMMENDED TOOL LIST - (Not Supplied in Kit) Loctite 77 thread locking liquid (IMPORTANT) Phillips Head Screwdriver Large Flat Blade Screwdriver Torx Head Screwdriver Side Cutters Sockets 0 & 3mm, Extension Bar and Driver Spanners 0 & 3mm Silicon Dispensing Gun Non Acetic Silicon (Neutral Cure) Spray Bottle (5% isopropyl Alcohol & 75% Water) Spray Bottle Water Torque Wrench - 0-0Nm Hacksaw or Jigsaw Page of 4 Hammer Medium Adjustable Spanner Non Permanent Marker Masking Tape Cleaning Cloths / Rags Steel Rule and Tape Measure Scissors (Sharp) Knife (Sharp) Squeegee Metal Primer File or Deburring Tool Drill and Ø54mm Hole Saw (Optional) Ø5mm Drill Bit (Optional) Rivet Gun for Stainless Steel Rivets

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 HOLDEN COLORADO - CANOPY PARTS CHECK SHEET HOLDEN COLORADO CANOPY PARTS IN MAIN CARTON Canopy Qty - Rail Extrusion Tub Stop (ALUM0038-3) Qty - Front Tub Spacer Extrusion (ALUM0038-4) Qty - Lock Keys (Attached to Canopy Internal Rear Door Handle) Qty - Fitting Kit (KIT03845) Qty - PARTS IN FITTING KIT (KIT03845) Strona Kit - Rail Clamps (CNPY0007) Qty - 6 Clear Abrasion Tape Roll 48mm Wide (TAPE06-) Qty - Tape EPDM mx0mmx6mm (TAPE0386) Qty - Screw M6x30 Hex Head SS304 (SCRW084) Qty - 4 M6 Flat Washer OD. 9mm (WASH069) Qty - 8 M6 Nyloc Nut SS304 (NUTS006) Qty - 4 Cabin Guard Blanking Pate (MISC78) Qty - M8x5 S/S Hex Bolt (SCRW0696-) Qty - 6 M8 S/S Flat Washer (WASH07-) Qty - 6 M8 S/S Spring Washer (WASH05-) Qty - 6 AUTOMOTIVE Tape 406 GHB x700mmx.4 Thick Roll (TAPE065) Qty - Bulb Seal 70mm Cut Length (MISC600-) Qty - Rivet SS304 ST-ST 6-6 (FAST0433) Qty mm Rubber Extrusions (MISC05-4) Qty - 6 Alcohol Wipe (MISC005) Qty - 4 Rust Inhibitor Fitting Instruction Rust Inhibitor Satchel (MISC776) Qty - Primer Stick (MISC365) Qty - 3 Vehicle Wiring Patch Harness Kit (LOOM005) Qty - Fitting Instruction (FIT-) Qty - PARTS IN WIRING PATCH KIT (LOOM005) Vehicle Wiring Patch Harness (LOOM005) Qty - Convoluted Tube Qty - Cable Ties Qty - 7 Adhesive Tie Pad Qty - Page of 4

3 IF A SPORTS BAR IS FITTED TO THE, PLEASE PROCEED TO STEP. IF A CABIN GUARD IS FITTED TO THE, PLEASE PROCEED TO STEP 3. IF THE HAS NO CABIN GUARD OR SPORTSBAR PLEASE PROCEED TO STEP 6. 3mm. Remove the four (4) bolts holding the sports bar feet to the tub as shown. (ref. diagram). REMOVE HARDWARE Diagram: - REMOVE SPORTS BAR HARDWARE REMOVE SPORTS BAR DISCONNECT SPORTS BAR WIRING. If vehicle s sports bar is fitted with an LED stop light, locate the LED stop light wiring harness at the base of the front left hand side leg. Trace back the wiring harness and disconnect from the vehicle. Remove any ties securing it to the vehicle. Carefully remove the sports bar from the vehicle and return to the customer with all hardware components. (ref. diagram). OPTIONAL: If customer requests paint all areas left exposed as primed sheetmetal. Painting is preferred to prevent rust. Diagram: - DISCONNECT WIRING & REMOVE SPORTS BAR 3. Using a torx head screwdriver and flat blade screwdriver, (tap screwdrivers with a hammer to loosen screws first) remove the hardware securing the cabin guard to the side rail as shown. Repeat the process for the other side of the vehicle. (ref. diagram3). REMOVE CABIN GUARD HARDWARE FROM SIDE RAILS Diagram: 3 - REMOVE CABIN GUARD HARDWARE Page 3 of 4

4 3mm REMOVE CABIN GUARD HARDWARE FROM FRONT RAIL 4. Remove the hardware securing the cabin guard to the front rail as shown. (ref. diagram4). Diagram: 4 - REMOVE CABIN GUARD HARDWARE REMOVE CABIN GUARD 5. Carefully remove the cabin guard taking care to avoid scratching the paintwork. (ref. diagram5). OPTIONAL: If customer requests paint all areas left exposed as primed sheetmetal. Painting is preferred to prevent rust. Diagram: 5 - REMOVE CABIN GUARD IF A BED LINER IS FITTED TO THE, PLEASE CONTINUE WITH STEPS 6 TO 3. IF A BED LINER IS NOT FITTED TO THE, PLEASE PROCEED TO STEP 4. DO NOT SLIDE CANOPY ON FIT CANOPY TO RULER FLAT AGAINST FRONT OF TUB 0mm ALIGN FRONT OF CANOPY TO FRONT OF TUB SHEETMETAL Diagram: 6 - CAREFULLY POSITION CANOPY 6. Two people are required for this step. Position the canopy onto the vehicle tub carefully. IMPORTANT: Ensure canopy is placed fully forward on the tub in one action. To avoid damage to the bed liner, DO NOT slide canopy on the vehicle. Align the canopy evenly on the tub. Canopy front face should align with the front of the tub sheetmetal,using a straight edge as shown. This will ensure the rail clamps (CNPY0007) fit neatly into the areas you are about to cut out. (ref. diagram6). Page 4 of 4

5 LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL HOLDEN COLORADO BED LINER TEMPLATE FRONT & MIDDLE CANOPY CLAMP CUT-OUTS CENTRE-PUNCH AND DRILL Ø54mm HOLE SAW LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL THIS FACE OUT LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL HOLDEN COLORADO BED LINER TEMPLATE FRONT & MIDDLE CANOPY CLAMP CUT-OUTS CENTRE-PUNCH AND DRILL Ø54mm HOLE SAW LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL THIS FACE OUT LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL HOLDEN COLORADO BED LINER TEMPLATE REAR CANOPY CLAMP CUT-OUTS MARK AND CUT-OUT RECTANGULAR PROFILE CENTRE-PUNCH AND DRILL (4) Ø0mm HOLES LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL THIS FACE OUT HOLDEN COLORADO - CANOPY SLOT IN CANOPY SIDE RAIL 7. Apply masking tape to the sides of the bed liner, under each slot in the canopy side rails as shown. Apply tape to 50mm below canopy side rail. Repeat process for the other side of the vehicle. (ref. diagram7). APPLY MASKING TAPE TO BED LINER REPEAT FOR ALL SIX (6) SLOTS 50mm BED LINER Diagram: 7 - PROTECT BED LINER LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL HOLDEN COLORADO BED LINER TEMPLATE FRONT & MIDDLE CANOPY CLAMP CUT-OUTS CHECK SCALE OF TEMPLATES ON PAGES 0 & LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL HOLDEN COLORADO BED LINER TEMPLATE REAR CANOPY CLAMP CUT-OUTS MARK AND CUT-OUT RECTANGULAR PROFILE 8. Carefully cut out the two () templates on pages 0 &. Ensure the scale of these templates are correct to the ruler scale printed on each of these pages. (ref. diagram8). NOTE: If you do not have a Ø54mm hole saw you can cut out the inside profiles to trace onto the masking tape and use a saw to cut it out. CENTRE-PUNCH AND DRILL Ø54mm HOLE SAW THIS FACE OUT CUT-OUT TEMPLATES CAREFULLY CENTRE-PUNCH AND DRILL (4) Ø0mm HOLES THIS FACE OUT Diagram: 8 - CUT OUT BED LINER TEMPLATES FRONT OF MARK RHS CENTREPOINTS FOR FRONT & MIDDLE HOLES FIT TO RHS 3 MARK TEMPLATES WITH TEXT FACING OUT, AND ALIGN TAG THROUGH CANOPY SIDE RAIL RECTANGLE ON REAR TEMPLATE TO BE CUT OUT CANOPY SIDE RAIL BED LINER 4 REPEAT FOR OTHER SIDE OF THE Diagram: 9 - FIT TEMPLATES & MARK CUT-OUTS REAR OF RHS 9. Fit templates to the RH side of the vehicle ensuring the text is facing outwards as marked. Align the top tag into the slots of the canopy side rail as shown. Carefully mark the centre points for the front and middle positions, and mark the rectangular profile for the rear template onto the masking tape applied to the bed liner. Alternatively you can trace the profiles onto the tape if you have cut-them out in the previous step. NOTE: If the template is not positioned accurately, the cut-out profile will be incorrect and may cause problems when fitting the clamps. Remove templates and repeat process for the LH side of the vehicle. (ref. diagram9). Page 5 of 4

6 0mm HOLDEN COLORADO - CANOPY REMOVE ALL TEMPLATES DO NOT SLIDE CANOPY ON REMOVE CANOPY FROM 0. Remove all templates. Two people are required to carefully remove the canopy. (ref. diagram0). Diagram: 0 - REMOVE TEMPLATES & THE CANOPY REMOVE TIE DOWNS AND ANY HARDWARE REMOVE BED LINER 5mm 3 MARK A LINE AROUND THE LINER 5mm DOWN FROM THE TOP FACE. Remove and retain any tie down hooks and hardware. Remove and retain the BED LINER from the vehicle. Apply masking tape all around the top of the bed liner to assist with marking the trim line. Mark a line 5mm down from the top surface of the bed liner all the way around as shown. (ref. diagram). 5mm LINE MUST BE ABOVE THE REAR BOLT HOLES AND FOLLOW THE REAR CORNER PROFILE Diagram: - REMOVE BED LINER & MARK TOP TRIM LINE CUT TOP OFF BED LINER 60mm. Using a jigsaw or similar, carefully cut the top of the bed liner off using the line marked 5mm down from the top. On the front face of the bed liner, cut a\ 6mm slot down the corners and back along the wheel arch forms 60mm as shown. Remove all burrs and sharp edges with a file or deburring tool. (ref. diagram). CUT SLOT 6mm WIDE DOWN THE FRONT CORNERS AND BACK ALONG THE TOP OF THE WHEEL ARCH 60mm, BOTH SIDES Diagram: - CUT BED LINER Page 6 of 4

7 Ø54mm CUT OUT and DEBURR THE MARKED AREAS CAREFULLY Diagram: 3 - CUT BED LINER 3. Carefully cut out the sections previously marked with a Ø54mm Holesaw and for the rear template a jigsaw or similar is also required. Alternatively if you have traced the profiles use a saw to cut them out. Remove all burrs and sharp edges with a file or deburring tool. Repeat process for the other side of the vehicle. IMPORTANT: To ensure the clamps fit neatly at a later stage, please take care when cutting the bed liner. When complete remove all masking tape from the bed liner. Do Not re-fit the bed liner at this stage. (ref. diagram3). POSITION CARDBOARD TUB PROTECTION MAT 4. Thoroughly clean and dry installation areas (tub, rear of cabin and glass) as shown. Using cardboard cut from the canopy carton, cut and place a piece inside the tub on the floor as a protection mat while installing the canopy. (ref. diagram4). Diagram: 4 - CLEAN & DRY INSTALLATION AREAS FRONT RAIL OF TUB SIDE RAIL OF TUB 5. Using a sharp knife carefully remove the bead of mastic at each end of the front rail as shown. (ref. diagram5). IMPORTANT: Ensure mastic does not protrude above front tub rail. The objective is to have the front tub rail flat across the top face. REMOVE MASTIC BEAD Diagram: 5 - REMOVE MASTIC BEAD Page 7 of 4

8 NOT SUPPLIED APPLY PRIMER STICK TO SHADED AREA ALONG FRONT RAIL FRONT RAIL 3 POSITION TAPE AGAINST SIDE RAIL 4 APPLY DOUBLE SIDED x700mm ROLL (TAPE065) ACROSS FRONT RAIL Diagram: 6 - FIT 3M TAPE x700mm DO NOT APPLY SILICON OVER THE SIDE RAIL APPLY SILICON FRONT RAIL OF TUB SIDE RAIL OF TUB 6. Using alcohol wipe provided clean the top surface of the front rail and wipe away residue with a dry clean cloth. If heavy cleaning is required use Iso- Propyl alcohol and wipe away residue with a dry clean cloth. Apply (MISC365) primer stick along half the rear edge width of the front tub rail as shown and allow to dry. Starting with a small amount of the tape from the double sided tape roll mm wide (TAPE065), apply it starting from the corner of the front rail to the other side, along the rear edge of the front tub rail pressing down on the liner as you apply the tape across the vehicle as shown. Apply firm pressure to ensure the tape adheres to the vehicle. (ref. diagram6). 7. Apply non-acetic silicon (neutral cure) (not supplied) to the front edge of the front tub rail starting from the edge of the side rail, across the vehicle to the edge of the other side rail as shown. Do Not apply silicon over the side rails. Do Not allow silicon to contact the double sided tape. If silicon does end up on the side rail, clean all excess silicon off using isopropyl alcohol. IMPORTANT: There must be NO silicon residue left on the top of the side bed rail faces, or the bed rail foam tape will not adhere correctly and water leaks will occur. (ref. diagram7). Page 8 of 4 Diagram: 7 - APPLY SILICON TO THE FRONT RAIL FRONT TUB SPACER EXTRUSION APPLY PRIMER 3 REMOVE TAPE LINER 4 FIT FRONT TUB SPACER EXTRUSION 5 APPLY FIRM PRESSURE TO ADHERE SILICON AND TAPE Diagram: 8 - FIT RAIL EXTRUSION SPACER 8. Using alcohol wipes provided clean the long inside face of the front tub spacer extrusion (ALUM0038-4) and wipe away residue with a dry clean cloth as shown. Apply (MISC365) primer stick along the length of the extrusion in front of the slotted holes up to 5mm towards the interior angle of the extrusion and allow it to dry. Remove liner from the double sided tape applied to the front tub rail. Fit rail extrusion spacer to the front rail over the tape and silicon positioning it evenly between the side rails. IMPORTANT: Ensure the long face sits over the front rail, and the short face sits against the front of the tub between the cabin and tub as shown. When fitting, avoid wiping the silicon towards the double sided tape. Apply firm pressure down on the front tub spacer extrusion (ALUM0038-4) and along the length to ensure maximum adhesion of the silicon and foam tape. (ref. diagram8).

9 9. Using alcohol wipes provided clean all top rail areas of the tub and wipe away residue with a dry clean cloth. If heavy cleaning is required use Iso- Propyl alcohol and wipe away residue with a dry clean cloth. Ensure no silicon is squeezed up by the fitting of the front tub spacer extrusion, if it is clean it off with IPA on a rag heavily loaded. (ref. diagram9). Diagram: 9 - SURFACE PREPARATION TAILGATE OF START AT THE EDGE OF THE TAILGATE TRIM EXCESS TO THE EDGE OF THE TAILGATE POSITION EPDM FOAM TAPE OVER THE EDGE OF THE INSIDE RADIUS ALONG THE SIDE RAILS ALONG SIDE RAILS TOP VIEW OF TUB APPLY EPDM FOAM TAPE AROUND BED RAIL POSITION EPDM FOAM TAPE 5mm REARWARD OF THE EDGE OF THE FRONT TUB SPACER EXTRUSION 5mm ALONG FRONT RAIL WITH SPACER CABIN OF 0. Apply EPDM foam tape (TAPE0386) from hardware kit to the bed rails and spacer. IMPORTANT: DO NOT CUT FOAM TAPE! Starting from one side at the rear corner, position the tape end in line with the edge of the tailgate, position the foam tape towards the edge of the inside radius of the top tub rail and continue this position all the way along the side rail in one continuous length, position 5mm rearward along the front tub spacer extrusion as shown and over the edge of the inside radius of the top tub rail down the other side, run tape out onto the tailgate as shown. As the tape bends around the corners ensure the tape sits flat and DOES NOT pucker. Trim off excess to the edge of the tailgate as shown. Ensure all foam tape areas are fully adhered to the tub and spacer by applying moderate pressure down on the tape all the way around the tub. (ref. diagram0). Tape MUST be fully adhered to tub rails and spacer and sit flat in one continuous length to prevent water entering the canopy. FINISH OVER THE EDGE OF THE TAILGATE FOAM TAPE MUST NOT PUCKER AROUND CORNERS ALONG SIDE RAILS Diagram: 0 - INSTALL WATER SEALING TAPE Page 9 of 4

10 NOT SUPPLIED EPDM FOAM TAPE APPLY NON ACETIC SILICON (NEUTRAL CURE) FRONT LEFT HAND INSIDE CORNER OF TUB FRONT TUB SPACER EXTRUSION. With a clean cloth wipe down all areas of the internal front tub corners to be siliconed as shown. Spray areas to be siliconed with water, Do Not dry. Apply non-acetic silicon (neutral cure) (not supplied) inside the tub at the join between the front and side panels of the tub, under the spacer, along the side rail and the gap in the front rail as shown. Re-spray silicon with water and push silicon into gaps and clean up excess silicon. Repeat process for the other side of the vehicle. IMPORTANT: This step must be done properly to ensure the vehicle tub is water sealed. (ref. diagram). Diagram: - APPLY SILICON NOT SUPPLIED FRONT TUB SPACER DOWN AT LEAST THE DEPTH OF THE RETURN OF THE FRONT TUB SPACER EXTRUSION FROM THE TOP OF THE TUB APPLY NON ACETIC SILICON (NEUTRAL CURE) EPDM FOAM TAPE. With a clean cloth wipe down all areas to be siliconed as shown. Spray areas to be siliconed with water, Do Not dry. Apply non-acetic silicon (neutral cure) (not supplied) to the top of the tub and spacer around the foam tape and down the front side of the tub between the tub and the cabin, and down at least the depth of the return of the front tub spacer extrusion, from the top of the tub and push silicon into gaps. Repeat process for the other side of the vehicle. IMPORTANT: This step must be done properly to ensure the vehicle tub is water sealed. (ref. diagram). CABIN NOT SHOWN FOR CLARITY Diagram: - APPLY SILICON REPLACE BED LINER 3. If a bed liner was removed to trim, carefully re-fit the bed liner to the vehicle. If fitted, replace all tie downs and hardware previously removed. (ref. diagram3). REPLACE TIE DOWNS AND HARDWARE Diagram: 3 - REPLACE BED LINER AND HARDWARE Page 0 of 4

11 THIS STEP IS FOR S - NOT FITTED WITH A BED LINER. 3mm 7Nm FIT CABIN GUARD BLANKING PLATE M8 SPRING WASHER M8 FLAT WASHER 4. THIS STEP IS FOR S - NOT FITTED WITH A BED LINER. Fit Cabin Guard blanking plate (MISC78) to side rail and secure with (3) M8x5 bolts M8 flat washers and M8 spring washers as shown. Repeat process for the other side of the vehicle. Tighten to Torque 7Nm. (ref. diagram4). M8x5 BOLT Diagram: 4 - FIT CABIN GUARD BLANKING PLATES THIS STEP IS FOR S - FITTED WITH A BED LINER. 5. THIS STEP IS FOR S - 3mm 7Nm NOT SUPPLIED FIT CABIN GUARD BLANKING PLATE M8 SPRING WASHER M8 FLAT WASHER BED LINER APPLY M8x5 BOLT NON ACETIC SILICON Diagram: 5 - FIT CABIN GUARD BLANKING PLATES FITTED WITH A BED LINER Fit Cabin Guard blanking plate (MISC78) to bed liner and side rail and secure with (3) M8x5 bolts, M8 flat washers and M8 spring washers as shown. Repeat process for the other side of the vehicle. Tighten to Torque 7Nm. Apply non-acetic silicon (neutral cure) (not supplied) to the bed liner in the corner and along the wheel arch form where the bed liner was cut as shown and push silicon into the groove and clean up with rag and water spray. (ref. diagram5). DISCONNECT BRAKE LAMP CLEAN CANOPY FRONT 6. Clean front of canopy including the front window. Disconnect the vehicle mounted brake light on the cabin, by unscrewing the brake lamp screws and removing the light lens, disconnect the loom and tape it to the existing wiring on the back of the light with masking tape so it does not rattle, then refit the light lens and screws. (ref. diagram6). Diagram: 6 - PREPARE CANOPY Page of 4

12 DO NOT SLIDE CANOPY TAPE ON EPDM FOAM TAPE WIRING TO LH SIDE WINDOW FIT CANOPY TO 3 FEED CANOPY BETWEEN TUB AND CABIN DOWN ALONG SIDE 7. Two people are required for this step. First tape harness to the LH side window with masking tape. Position the canopy onto the vehicle tub carefully. IMPORTANT: Ensure canopy is placed fully forward on the tub in one action. DO NOT slide the canopy on the EPDM foam tape, as this can damage the foam tape (break the water seal). Remove masking tape and feed canopy harness down between tub and cabin (left hand side of vehicle) so it is accessible. (ref. diagram7). Diagram: 7 - FIT CANOPY TO TUB VIEW FROM REAR OF CAR CANOPY BASE RAIL EVEN BOTH SIDES AT THE END CAPS RULER FLAT AGAINST FRONT OF TUB 0mm ALIGN FRONT OF CANOPY TO FRONT OF TUB SHEETMETAL 8. Align the canopy evenly on the tub. Canopy front face should align with the front of the tub sheetmetal using a straight edge as shown. Open rear tailgate to check sideways alignment. Using a steel rule position the canopy so both canopy base side rails are even to the width of the vehicle tub. (ref. diagram8). Diagram: 8 - ALIGN CANOPY TO TUB FIT 6 RUBBER EXTRUSIONS TO TUB RAILS DIRECTLY UNDER CLAMP HOLES IN BASE RAILS WHEN A BED LINER IS NOT FITTED 9. Fit six (6) 40mm rubber extrusions to the vehicle tub rails directly under the square holes in the canopy base rails for the clamps as shown. (ref. diagram9). IMPORTANT: If a bed liner is fitted to the vehicle, the rubber extrusions MUST NOT be fitted. Diagram: 9 - FIT RUBBER EXTRUSIONS TO TUB Page of 4

13 DISASSEMBLE CLAMPS 3mm Diagram: 30 - FIT REAR CLAMPS AND CHECK LATCHING 3mm LOCTITE 77 3mm 3mm 9Nm DISASSEMBLE 4 CLAMPS FIT & SLIDE BOTTOM U CLAMP 9Nm 3 4 LOCTITE 77 4 APPLY LOCTITE 77 TO BOLTS, FIT BOLT & WASHERS TORQUE TO 8Nm 4 TIGHTEN - FRONT CLAMPS TORQUE TO 9Nm FIT REMAINING CLAMPS APPLY LOCTITE 77 TO BOLTS FIT TOP L CLAMP 5 CLOSE REAR DOOR CHECK LATCHES ENGAGE 5 TIGHTEN - MIDDLE CLAMPS TORQUE TO 9Nm 6 READJUST LATCH STRIKER POSITION (IF REQUIRED) 3 TIGHTEN - REAR CLAMPS TORQUE TO 9Nm Diagram: 3 - FIT REMAINING CLAMPS AND TIGHTEN ALL 30. Disassemble two () rail clamps. Fit the clamps to the rear holes in the canopy base rails by fitting the top L clamp down through the hole in the rail and sliding the lower U clamp along the side rail over the rubber extrusion. IMPORTANT! Apply Loctite 77 (not supplied) to the bolts liberally. Secure the clamps with the bolts and washers as shown. For vehicles fitted with a bed liner clamps will need to be fitted through the cut-outs. Tighten to Torque 8Nm. Close the rear door firmly, holding the centre handle without slamming it too hard. NOTE: Latch has stages of engagement. Ensure canopy engages with second stage of latch. If required loosen clamps and adjust the canopy position fore and aft, re-tighten to Torque 8Nm and re-check latching. You may also need to adjust the latch striker hoops, loosen bolts with a 0mm socket adjust and tighten to Torque 8Nm. (ref. diagram30). 3. Disassemble remaining four (4) rail clamps. Fit the clamps to the remaining holes in the canopy base rails by fitting the top L clamp down through the hole in the rail and sliding the lower U clamp along the side rail over the rubber extrusion. IMPORTANT! Apply Loctite 77 (not supplied) to the bolts liberally. Secure the clamps with the bolts and washers as shown. For vehicles fitted with a bed liner, clamps will need to be fitted through the cut-outs. Tighten the rear clamps first, then the front clamps and finally the middle clamps, all to Torque 9Nm. (ref. diagram3). 0mm 0mm 6Nm 3 SECURE NYLOC NUT AND WASHER CANOPY BASE RAIL AT FRONT NYLOC NUT BOLT WASHER FRONT TUB SHEETMETAL 3. Fit front rail tub stop extrusion to the under side of the canopy front base rail. Push extrusion up against the front of the tub and secure with four (4) M6 hex head bolts, eight (8) flat washers and four (4) nyloc nuts as shown. Tighten to Torque 6Nm. (ref. diagram3). FIT BOLT AND WASHER FIT FRONT RAIL TUB STOP TIGHTEN TO TORQUE 6Nm Diagram: 3 - FIT FRONT TUB STOP RAIL Page 3 of 4

14 3 4 Ø5mm Rust Inhibitor TOP GROOVE ON FRONT RAIL TUB STOP (x8) MIDDLE GROOVE ON FRONT RAIL TUB STOP 33. (Optional): Recommended for Off Road vehicle use. Mark and drill eight (8) Ø5mm holes into the front rail tub stop and tub rail using dimension s as shown. Rivets must secure to raised form on tub. Apply rust inhibitor to all drilled holes in the tub sheetmetal. Secure with eight (8) stainless steel rivets as shown. (ref. diagram33). RAISED FORM ON TUB Diagram: 33 - (OPTIONAL) SECURE FRONT TUB STOP RAIL REAR WINDOW REAR DOOR SASH APPLY MASKING TAPE TO TAILGATE 34. IF A TAILGATE LINER IS FITTED PLEASE REMOVE TEMPORARILY. With the canopy rear door closed, apply a length of masking tape to the rear tailgate, level with the bottom edge of the canopy rear door sash, when viewed from the rear horizontal position as shown. This will assist in positioning the clear abrasion tape applied to the top of the tailgate in the next step. (ref. diagram34). MASKING TAPE TAILGATE Diagram: 34 - APPLY MASKING TAPE 5% ISOPROPYL ALCOHOL 75% WATER CLEAR ABRASION TAPE ALIGN BOTTOM EDGE OF CLEAR ABRASION TAPE WITH TOP EDGE OF MASKING TAPE 3 TRIM EXCESS CLEAR ABRASION TAPE APPLY CLEAR ABRASION TAPE 5 REMOVE MASKING TAPE 4 SQUEEGEE OUT EXCESS SOLUTION BUBBLES CANOPY NOT SHOWN FOR CLARITY Diagram: 35 - APPLY ABRASION TAPE 35. Using a solution of 5% isopropyl alcohol and 75% water in a spray bottle (not - supplied) Thoroughly spray along the top of the tailgate. Remove liner from clear abrasion tape. Working from one end with a 5mm overhang, place liner on the tailgate. Trim excess tape leaving a 5mm overhang at both ends of the tailgate. When in position use a squeegee to push out any excess water solution and bubbles. Using a sharp knife trim tape to end of tailgate. You may need to squeegee a few times. When finished the tape is virtually invisible. To ensure a good finish please take care an do not rush this step. Remove masking tape. (ref. diagram35). Page 4 of 4

15 MARK THESE TWO ()EDGES & RADIUS LINE UP WITH OUTER TAILGATE LINER EDGE MARK THESE TWO ()EDGES & RADIUS LINE UP WITH OUTER TAILGATE LINER EDGE BULB SEAL FINGER UNDER CLAMP SEAL & AGAINST CANOPY HOLDEN COLORADO - CANOPY OPTION OPTION HOLDEN COLORADO TAILGATE LINER LH TEMPLATE THIS FACE OUT CUT-OUT TEMPLATES CAREFULLY CUT AND REMOVE SHARP EDGES LINE UP WITH SIDE TAILGATE LINER EDGE HOLDEN COLORADO TAILGATE LINER RH TEMPLATE THIS FACE OUT FIT TEMPLATES TO LINER & MARK RH LH LINE UP WITH SIDE TAILGATE LINER EDGE 5mm MARK A LINE 5mm DOWN FROM THE TOP OF THE TAILGATE LINER CUT AND REMOVE SHARP EDGES 36. THIS STEP IS FOR S FITTED WITH A BED LINER. Option. Using templates on page cut out and fit to tailgate liner as shown. Carefully mark the areas to be cutout. Or Option. Mark a line across the tailgate liner 5mm down from the top of the tailgate liner as shown. Option or. Using a jigsaw cut out marked areas and using a file or deburring tool remove all sharp edges. Re-fit tailgate liner to the vehicle. (ref. diagram36). Diagram: 36 - PREPARE TAILGATE LINER ALCOHOL WIPE & PRIME SHADED AREA TAILGATE CANOPY BULB SEAL SIDE TUB RAIL Diagram: 37 - (OPTIONAL) FIT TAILGATE SEALS 3 FIT BULB SEAL CLAMP FRAME SEAL TAILGATE OPEN SPLIT IN TUBE, AND FEED OVER (OPTIONAL): Strongly Recommended for best results for rear door to tailgate water sealing. Using alcohol wipe provided clean directly below the rear door clamp front seal and wipe away residue with a dry clean cloth. Using priming stick (MISC365) prime area directly below the rear door clamp front seal. Apply only a light amount both sides of tailgate in this area, and allow to dry. Apply bulb seal 70mm (MISC600-) to tailgate. Position bulb seal so it's finger seals against the underside of the clamp frame seal and the canopy face as shown and position it out to the side overhanging the tailgate gap to the side tub rails to create a seal in the corners. (ref. diagram37). Fit convoluted tube to canopy harness, by opening up the split in the tube and feeding it over the cable near the connector first. Holding the harness thread the convoluted tube upwards towards the canopy, onto the harness as shown. (ref. diagram38). THREAD TUBE UPWARDS TOWARDS CANOPY Diagram: 38 - FIT CONVOLUTED TUBE TO CANOPY Page 5 of 4

16 S WITH TOW BAR NOT FITTED LHS REAR BUMPER LOCATE TRAILER S WITH TOW BAR FITTED LHS REAR BUMPER TOW BAR LOCATE TRAILER 39. At the rear left hand side of the vehicle locate the trailer harness connectors. For vehicles fitted with a tow bar the tow bar loom will be attached to this connector, for vehicles with no tow bar there will be a blanking cover on the connector. For vehicles fitted with a tow bar disconnect the two () connectors, for vehicles with no tow bar remove the blanking cover and retain as shown. (ref. diagram39). DISCONNECT CONNECTOR & BLANKING COVER TOW BAR DISCONNECT CONNECTORS Diagram: 39 - DISCONNECT TRAILER CONNECTORS S WITH TOW BAR NOT FITTED LHS REAR BUMPER TRAILER S WITH TOW BAR FITTED LHS REAR TRAILER BUMPER 40. For vehicles fitted with a tow bar, connect the tow bar connector to the vehicle harness (LOOM005) (male) connector as shown. For vehicles fitted with no tow bar, connect the blanking cover to the vehicle harness (male) connector as shown. Connect the trailer harness to the vehicle harness (female) connector as shown. (ref. diagram40). BLANKING COVER CONNECT TO TRAILER & BLANKING COVER TOW BAR CONNECT TO TRAILER & TOW BAR Diagram: 40 - CONNECT & TRAILER ES 4. Feed the vehicle harness (LOOM005) from the back to the front of the vehicle running it along side the existing vehicle wiring along the chassis rail ensuring it is fed over the chassis cross rails as shown. (ref. diagram4). CHASSIS CROSS RAIL CHASSIS RAIL EXISTING FEED Diagram: 4 - FIT Page 6 of 4

17 FEED CANOPY BETWEEN TUB & CABIN, THEN OVER CHASSIS RAIL CANOPY WHEEL ARCH CABIN OF EXISTING TUBE 3 FIT CABLE TIE REAR TYRE CHASSIS RAIL CONNECT CANOPY TO CONNECTION BETWEEN CANOPY & WIRING SPARE TYRE 4 FIT CABLE TIES CANOPY EXISTING WIRING CHASSIS RAIL LH REAR GAS STRUT 4. Feed the canopy harness down between the cabin and tub, then inboard over the chassis rail and connect the canopy harness connector to the vehicle harness connector as shown. Attach a cable tie to secure the canopy harness to the tube going through the chassis rail as shown. Attach two () more cable ties either side of the connector, to secure the harness to the existing vehicle wiring as shown. Trim excess ties with side cutters. (ref. diagram4). Diagram: 4 - CONNECT & CANOPY ES EXISTING FIT CABLE TIE CHASSIS RAIL STOP LAMP FIT CABLE TIE REAR BUMPER SPARE TYRE TRAILER 43. Attach a cable tie to the vehicle harness and existing vehicle wiring near the spare tyre as shown. Attach a cable tie to the looped vehicle harness and existing stop lamp harness on the rear left hand side as shown. If a tow bar is fitted secure the tow bar harness to the tow bar mount through the existing hole as shown. Trim excess ties with side cutters. (ref. diagram43). TOW BAR 3 FIT CABLE TIE Diagram: 43 - CABLE TIE ES 44. Two people are required to check the canopy brake light is operational after depressing the brake pedal. Then open the rear window and check that the internal canopy lamp is operating correctly when switched to the ON position only. (ref. diagram44). CHECK BRAKE LIGHTS WORK CHECK CANOPY LAMP WORKS Diagram: 44 - CHECK BRAKE LIGHTS AND CANOPY LIGHT Page 7 of 4

18 CABIN CANOPY TUB 45. Using alcohol wipe provided in the kit, clean the driver s side top corner of the tub as shown, and wipe away residue with a dry clean cloth. Remove tape liner from adhesive tie pad and position on the tub in area previously cleaned as shown. Apply pressure to ensure maximum adhesion. (ref. diagram45). FIT ADHESIVE TIE PAD Diagram: 45 - IT ADHESIVE TIE PAD 46. Fit a cable tie through the adhesive tie pad previously fitted to the front of the tub and secure the canopy wiring harness as shown. Trim excess tie with side cutters. (ref. diagram46). FIT CABLE TIE Diagram: 46 - SECURE CANOPY 47. Water test canopy checking for water leaks. (ref. diagram47). Diagram: 47 - WATER LEAK TESTING Page 8 of 4

19 PLACE FITTING INSTRUCTIONS IN THE CUSTOMERS LOG BOOK 48. Clean canopy including all windows and vehicle thoroughly. Place fitting instructions in the Customers log book, and ensure page 3 of these instructions are discussed with the customer and a copy is given to the customer. (ref. diagram48). Diagram: 48 - FINAL CLEANING Page 9 of 4

20 HOLDEN COLORADO FRONT AND MIDDLE BED LINER TEMPLATE LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL HOLDEN COLORADO BED LINER TEMPLATE FRONT & MIDDLE CANOPY CLAMP CUT-OUTS CENTRE-PUNCH AND DRILL Ø54mm HOLE SAW THIS FACE OUT 00mm when printed Page 0 of 4

21 HOLDEN COLORADO REAR BED LINER TEMPLATE LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL HOLDEN COLORADO BED LINER TEMPLATE REAR CANOPY CLAMP CUT-OUTS MARK AND CUT-OUT RECTANGULAR PROFILE CENTRE-PUNCH AND DRILL (4) Ø0mm HOLES THIS FACE OUT 00mm when printed Page of 4

22 HOLDEN COLORADO REAR TAILGATE LINER TEMPLATE MARK THESE TWO ()EDGES & RADIUS HOLDEN COLORADO TAILGATE LINER LH TEMPLATE THIS FACE OUT LINE UP WITH OUTER TAILGATE LINER EDGE MARK THESE TWO ()EDGES & RADIUS HOLDEN COLORADO TAILGATE LINER RH TEMPLATE LINE UP WITH SIDE TAILGATE LINER EDGE LINE UP WITH SIDE TAILGATE LINER EDGE THIS FACE OUT LINE UP WITH OUTER TAILGATE LINER EDGE 00mm when printed Page of 4

23 OWNERS MANUAL SUPPLEMENT IMPORTANT: PLACE THIS PAGE IN THE CUSTOMER S SERVICE BOOK. WARNING! - SAFETY! Do Not use the canopy as a passenger compartment. Do Not operate/drive vehicle with fold up windows or rear door open. They must be closed when vehicle is in motion. Do Not store or transport volatile materials, such as solvents, chemicals or liquids as fumes may accumulate inside canopy. Do Not allow solvents, chemicals or oils to come in contact with the canopy. If this should occur clean the canopy immediately with a mild detergent and water solution. Do not stand/sit or rest heavy objects on Canopy. Do not fill volatile liquid containers while inside canopy such as fuel cans. S FITTED WITH A BED LINER: Static electricity can cause fire when fuel is pumped into ungrounded fuel containers or equipment (eg: motorcycles, chainsaws etc..). Do Not fill fuel containers or equipment within the vehicle tray as static electricity can cause fuel to ignite, resulting in damage, injury or death. To avoid electricity build-up, place fuel container or equipment on the ground before filling. Maintenance Only use mild detergents or wax polish. Do Not use abrasive compounds on painted or plastic finished canopy surfaces. The gas struts are self lubricating and should only be cleaned with a damp cloth, when regularly cleaning the vehicle. Premature seal failure will result if solvents or lubricants are used to clean struts. Gas struts must be orientated as installed, cylinder (wide end) to canopy and rod (narrow end) to glass. Lightly coat the door and window rubber assemblies with a silicon spray after cleaning periodically. Only locks and lock recesses are to be lubricated with Graphite Powder. Vaseline may be used on the rotary catches on the rear door. DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty. Check canopy attachment clamps every 000 Km. Clamp bolt recommended torque setting is (9 Nm or 6.64 lb/ft). If removed, bolts must have LOCTITE 77 re-applied and be re-tightened on refitting to specified values. CHECK regularly that all screws and fasteners holding windows and doors are tight. The rear tailgate protection tape must be replaced periodically to minimize paint scuffing caused by the canopy rear door opening and closing. HOLDEN COLORADO 006 Onwards KEY IDENTIFICATION CODE CANOPY 34 Please write the key identification code in the boxes above, and retain this copy with the vehicle service history. Replacement keys can be purchased from your local dealer. Warranty Terms EGR warrants that the ABS Canopy 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, alterations, addition of non genuine equipment, abuse, accident, normal wear and tear, lack of maintenance, misuse, and exposure to chemicals that are not safe for plastics or hardware components. Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Canopy is sole responsibility of the vehicle owner and operator. Paint wear to the vehicle bed can happen with any Canopy and is the sole responsibility of the vehicle owner. Paint damage to your vehicle is not covered under this warranty. Disclaimer In the event that your EGR Canopy 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 labour are not associated with this warranty claim. Page 3 of 4

24 INSTALLATION CHECKLIST Dealer Name: Model: Order Date: Required By: Dealer Code: Stock No: Order No: Vin No: Canopy Colour Vehicle Damage Check: Detail: Vehicle Type: LX LT-R Canopy Checklist - Details of rectifications required: KEY No. :. Check paint on canopy. Cleanliness of canopy inside and outside 3. Canopy sealing to tray, tub spacer rail, tub stop rail and foam tape applied correctly 4. Seal around Front of tub, vertical corners & floor with Silicone after foam tape applied 5. Tailgate clear tape fitted 6. Disconnect high mount brake light on rear of vehicle cab 7. Position canopy on tub squarely side to side, rear door closes on second stage latch (not just first latch) both sides and lower door sash seal, seals to tailgate, adjust strikers and /or door latch pull rods via access to centre door handle by removing internal door handle cover 8. Clamps are square and tight (Torque 9Nm) 9. IMPORTANT! Loctite 77 applied to all Clamp Bolt Threads 0. Rear Door, Side Door s and Front window operation. Operation of Brake Light 3. Operation of interior light 3. Water Tested for leaks 4. Clean up of work area 5. Comment Fitted By: Vehicle received and Checked by Dealer Staff: Record Canopy Serial Number: (located on inside LH rear pillar of canopy shell) Checked By: Page 4 of 4