CANOPY INSTALLATION INSTRUCTIONS. VW AMAROK Double Cab

Transcription

1 CANOPY INSTALLATION INSTRUCTIONS CP00a VW AMAROK Double Cab Installation Time: Hour (Approximately) 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 a Volkswagen 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 Double Cab Amarok. This Fitting Instruction where a Bed Liner is referred to, is based on the Volkswagen Genuine Under Rail Bed Liner Accessory only. Step and of this Fitting Instruction needs to be completed Before fitting a Bed Liner. RECOMMENDED TOOL LIST - (Not Supplied in Kit) Loctite 77 thread locking liquid (IMPORTANT) Phillips Head Screwdriver Dehousing Tool (for VW Wiring Genuine) Medium Adjustable Spanner Side Cutters Sockets 0, & mm, Extension Bar and Driver Spanners 0, & mm Silicon Dispensing Gun Non Acetic Silicon (Neutral Cure) Spray Bottle (% isopropyl Alcohol & 7% Water) Spray Bottle Water Torque Wrench - 0-0Nm T0 Torx Drive Screwdriver 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 & Ømm Drill Bit Engineers Scribe Rivet Gun for Stainless Steel Rivets Electrical tape Light Guage Plastic Coated Draw Wire Page of /0/

2 IMPREGNATED WITH 70% ISOPROPYL ALCOHOL VW AMAROK - CANOPY CP00a PARTS CHECK SHEET VW AMAROK CANOPY PARTS IN MAIN CARTON Canopy Qty - Rail Extrusion Tub Stop (ALUM00-) Qty - Lock Keys (Attached to Canopy Internal Rear Door Handle) Qty - Fitting Kit (KIT0998) Qty - PARTS IN FITTING KIT (KIT0998) Kit - Rail Clamps (CNPY0007) Qty - 6 Clear Abrasion Tape Roll 8mm Wide (TAPE06-) Qty - Tape EPDM00.Mx0mmx6mm (TAPE086) Qty - Screw M6x0 Hex Head SS0 (SCRW08) Qty - M6 Flat Washer OD. 9mm (WASH069) Qty - 8 M6 Nyloc Nut SS0 (NUTS006) Qty - Tape 06GHBWH mmx700mmx.mm Thick Roll (TAPE06) Qty - Bulb Seal 70mm Cut Length (MISC600-) Qty - Rivet SS0 ST-ST 6-6 (FAST0) Qty - 8 0xmm Label Sticker (LABL) Qty - LH-Tub Sealing Block (TAPE068-LH) Qty - RH-Tub Sealing Block (TAPE068-RH) Qty - AUTOMOTIVE SURFACE CLEANER For use in cleaning painted metal, glass and other vehicle surfaces. For external use only. Dispose of properly after use. Rust Inhibitor Fitting Instruction Clear Tape Pad 0xmm Abrasion Resistant (TAPE00) Qty - 6 Alcohol Wipe (MISC00) Qty - 8 Rust Inhibitor Satchet (MISC776) Qty - Primer Stick (MISC6) Qty - Vehicle Wiring Patch Harness Kit (LOOM009) Qty - Fitting Instruction (FIT-CP00a) Qty - PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM009) Vehicle Wiring Patch Harness (LOOM009) Qty - Cable Ties Short 00mm Qty - 0 Adhesive Tie Pad Qty - Foam Tape Qty - Amp Blade Fuse Qty - -Way Connector Qty - Page of /0/

3 CP00a POSITION SLIT OVER SHEET METAL STEP & NEEDS TO BE COMPLETED BEFORE FITTING A BED LINER. VIEWS LOOKING UP INTO LEFT HAND SIDE FRONT VEHICLE TUB CORNER CROSS SECTION TOP OF SIDE PANEL FRONT OUTER RAIL TUB SEALING BLOCK REMOVE ADHESIVE LINER Diagram: - FIT TUB SEALING BLOCKS SIDE PANEL INNER FIT TUB SEALING BLOCK PRESS TUB SEALING BLOCK AROUND TUB SURFACES TO SEAL AND PREVENT WATER ENTRY. Using alcohol wipe provided clean the front inside corners of the tub and wipe away residue with a dry clean cloth. Apply (MISC6) primer stick to shaded areas as shown and allow to dry. Remove adhesive liner from the left hand tub sealing block. Feed tub sealing block through the opening allowing the split to sit over the sheetmetal inner skin panel and firmly press into place as shown. Ensure the perimeter of the tub sealing block makes contact with tub internal surfaces. Repeat process for the other side of the vehicle using the right hand tub sealing block. IMPORTANT: This step must be done properly to ensure the vehicle tub is water sealed. (ref. diagram). NOT SUPPLIED TUB SEALING BLOCK LH. Apply non-acetic silicon (neutral cure) (not supplied) around the tub sealing block and the inside of the tub as shown. 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). APPLY NON ACETIC SILICON (NEUTRAL CURE) Diagram: - APPLY SILICON AROUND TUB SEALING BLOCKS SLIDE COVER OFF TO THE LEFT DISCONNECT CONNECTOR. Disconnect high mount stop lamp, by sliding the stop lamp from right to left to remove it. Tape the loose loom back with electrical tape (not supplied) so the loom does not rattle. Disconnect the connector and re-fit the stop lamp by sliding it on left to right. (ref. diagram). SECURE LOOM WITH ELECTRICAL TAPE SLIDE COVER ON TO THE RIGHT Diagram: - DISCONNECT HIGH MOUNT STOP LAMP Page of /0/

4 CP00a LHS ONLY OPEN TAILGATE. Open the tailgate. Remove and retain the two () screws from the left hand side as shown securing the left hand side tail lamp, using a T0 torx drive screwdriver. Remove the tail lamp by sliding it to the left to dis-engage it from the ball fixings. (ref. diagram). REMOVE SLIDE SCREWS TAIL LAMP TO THE LEFT TO DIS-ENGAGE Diagram: - REMOVE REAR LHS TAIL LAMP STORE TAIL LAMP SAFELY. Disconnect the connector from the tail lamp, and store the left hand side tail lamp in a safe place to re-fit at a later stage. (ref. diagram). DISCONNECT CONNECTOR Diagram: - DISCONNECT REAR LHS TAIL LAMP 6. Remove the terminal lock from the tail lamp connector as shown. (ref. diagram6). REMOVE TERMINAL LOCK Diagram: 6 - REMOVE CONNECTOR TERMINAL LOCK Page of /0/

5 CP00a 7. Using a VW genuine dehousing tool, remove the brown wire from terminal and the grey/red wire from terminal. (ref. diagram7). DE-HOUSE TERMINALS & BROWN WIRE () GREY/RED WIRE () Diagram: 7 - DE-HOUSE TERMINALS & FIT GREY/RED WIRE TO TERMINAL () FIT BROWN WIRE TO TERMINAL () TERMINALS TO CLICK IN 8. Fit the previously removed wire terminals into the -way connector supplied in hardware kit. Ensure the grey/red wire goes into terminal & the brown wire goes into terminal as shown. Terminals will go in one way only. When fitted correctly a CLICK can be felt and heard, and you will not be able to pull the terminals out of the connector. Pull terminals gently to ensure they can not be pulled out. (ref. diagram8). -WAY CONNECTOR TAIL LAMP CONNECTOR Diagram: 8 - FIT WIRES TO -WAY CONNECTOR 9. When the wires are correctly fitted close the terminal lock on the -way connector over so it snaps firmly into place. (ref. diagram9). CLOSE TERMINAL LOCK SO IT SNAPS INTO PLACE Diagram: 9 - LOCK IN TERMINALS Page of /0/

6 VW AMAROK - CANOPY CP00a ATTACH THIS END OF VEHICLE HARNESS ATTACH VEHICLE HARNESS PULL VEHICLE HARNESS INTO TAIL LAMP AREA 0. Feed a draw wire through the gap between the sheet metal surfaces. Under the vehicle attach the draw wire to the end of the vehicle harness with the black -pin connector and two () loose wires as shown. Pull the draw wire so the vehicle harness connector is accessible in the tail lamp opening as shown. Remove the draw wire. (ref. diagram0). FEED DRAW WIRE REMOVE DRAW WIRE Diagram: 0 - USING A DRAW WIRE, FEED VEHICLE HARNESS CONNECT VEHICLE HARNESS CONNECTOR TO -WAY CONNECTOR -WAY CONNECTOR TAIL LAMP CONNECTOR. Connect the vehicle harness connector to the -way connector as shown. Ensure connectors CLICK into place and can not be pulled apart. Pull connectors gently to ensure they can not be pulled out. (ref. diagram). VEHICLE HARNESS CONNECTOR Diagram: - CONNECT VEHICLE HARNESS TO -WAY CONNECTOR BROWN WIRE () FIT VEHICLE HARNESS TERMINALS TO TAIL LAMP CONNECTOR TERMINALS & VEHICLE HARNESS TAIL LAMP HARNESS GREY/RED WIRE (). Fit the two () loose wires from the vehicle harness into the terminals on the tail lamp connector as shown. Ensure the grey/red wire goes into terminal & the brown wire goes into terminal as shown. Terminals will go in one way only. When fitted correctly a CLICK can be felt and heard, and you will not be able to pull the terminals out of the connector. Pull terminals gently to ensure they can not be pulled out. (ref. diagram). Diagram: - FIT WIRES TO TAIL LAMP CONNECTOR Page 6 of /0/

7 VW AMAROK - CANOPY CP00a. Re-fit the terminal lock into the tail lamp connector as shown. Ensure it is pushed all the way back in. (ref. diagram). RE-FIT TERMINAL LOCK Diagram: - REPLACE TERMINAL LOCK. Remove adhesive liner from the foam tape supplied in the wiring harness hardware kit and wrap it around the -way connector and vehicle harness connector as shown. (ref. diagram). WRAP FOAM TAPE AROUND -WAY CONNECTOR REMOVE LINER FROM FOAM TAPE SUPPLIED IN WIRING HARNESS KIT Diagram: - FIT FOAM TAPE TO -WAY CONNECTORS SLIDE TAIL LAMP TO THE RIGHT TO RE-FIT CLOSE TAILGATE RE-FIT SCREWS. Re-connect tail lamp connector to tail lamp. Neatly position harnesses inside the recess for the tail lamp and re-fit tail lamp to the vehicle by locating it on the ball fixings and sliding the tail lamp to the right. Secure to the vehicle with the two () screws previously removed. Close the tailgate. (ref. diagram). RE-CONNECT TAIL LAMP CONNECTOR Diagram: - RE-CONNECT TAIL LAMP & FIT TO VEHICLE Page 7 of /0/

8 CP00a 6. Run the vehicle harness along the chassis rail with existing wiring, up to the front left hand wheel arch as shown. Fit cable ties to secure the vehicle harness to the existing harness every 00-00mm. Trim excess cable tie length with side cutters. Ensure harness is run in a direct route from the rear of the vehicle to the front. (ref. diagram6). VEHICLE HARNESS RUN VEHICLE HARNESS ALONG CHASSIS RAIL WITH EXISTING HARNESSS & SECURE WITH CABLE TIES CHASSIS RAIL Diagram: 6 - RUN HARNESS ALONG CHASSIS RAIL FEED DRAW WIRE OPEN BONNET ATTACH VEHICLE HARNESS WHEEL ARCH LH FRONT SPLASH GUARD CHASSIS RAIL ROUTE HARNESS BEHIND SPLASH GUARD Diagram: 7 - USING A DRAW WIRE PULL HARNESS INTO ENGINE BAY 7. Open and secure the bonnet. Feed a draw wire down through the engine bay in the rear left hand corner where the inner left hand front quarter panel meets the firewall as shown. From inside the left hand front wheel arch, attach the end of the vehicle harness to the draw wire. Using two () people, one person feeding the vehicle harness and the second person to pull the draw wire until the harness is at the top of the engine bay. Ensure harness is positioned behind the splash guard inside the wheel arch as shown. Remove the draw wire. (ref. diagram7). IMPORTANT: The wiring must be positioned against the firewall and avoid contact against any pipes or other wiring under tension of canopy vehicle wiring harness. REMOVE BATTERY TERMINAL BLOCK COVER EXISTING HARNESS REMOVE BATTERY TERMINAL BLOCK COVER 8. Remove battery terminal block cover using a flat blade screwdriver. Route the vehicle harness along side the existing harness under the battery terminal block cover to the terminal block as shown. Replace the battery terminal block cover. Remove terminal block cover carefully so you do not break the clipping tags. (ref. diagram8). ROUTE VEHICLE HARNESS REMOVE TERMINAL BLOCK COVER Diagram: 8 - ROUTE VEHICLE HARNESS & REMOVE TERMINAL COVER Page 8 of /0/

9 CP00a NOTE FUSE POSITIONS 9. IMPORTANT: Note the positions of the fuses. Remove fuses and store in a safe place to re-fit at a later stage. (ref. diagram9). REMOVE FUSES Diagram: 9 - NOTE POSITION OF FUSES & REMOVE 0. Remove the terminal lock from the battery terminal block as shown. (ref. diagram0). REMOVE TERMINAL LOCK Diagram: 0 - REMOVE TERMINAL LOCK FROM BATTERY. Using the sharp end of an engineers scribe, remove and discard the terminal plug (cover) from the battery terminal block as shown. (ref. diagram). REMOVE & DISCARD TERMINAL PLUG (COVER) Diagram: - REMOVE TERMINAL PLUG (COVER) Page 9 of /0/

10 CP00a. Fit the vehicle harness terminal into the battery terminal block as shown. Terminal will go in one way only. When fitted correctly a CLICK can be felt and heard, and you will not be able to pull the terminal out of the block. Pull terminal gently to ensure it can not be pulled out. (ref. diagram). VEHICLE HARNESS FIT VEHICLE HARNESS TERMINAL INTO BATTERY TERMINAL BLOCK Diagram: - CONNECT VEHICLE HARNESS TO TERMINAL. Re-fit the terminal lock into the battery terminal block as shown. Ensure it is pushed all the way back in. (ref. diagram). RE-FIT TERMINAL LOCK Diagram: - RE-FIT TERMINAL LOCK TO BATTERY RE-FIT FUSES TO NOTED POSITIONS. Re-fit the fuses to previously noted positions. Fit the amp fuse from the wiring harness hardware kit, to the vehicle harness terminal position as shown. (ref. diagram). FIT AMP FUSE FROM KIT Diagram: - RE-FIT FUSES & FIT AMP FUSE FROM KIT Page 0 of /0/

11 CP00a CLOSE BONNET. Re-fit the terminal cover. Close the bonnet (ref. diagram). RE-FIT TERMINAL BLOCK COVER TERMINAL BLOCK Diagram: - RE-FIT TERMINAL COVER POSITION CARDBOARD TUB PROTECTION MAT 6. Thoroughly clean and dry installation areas (tub, rear of cabin and glass) as shown. Clean front of canopy including the front window 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. diagram6). Diagram: 6 - CLEAN & DRY INSTALLATION AREAS APPLY PRIMER STICK TO SHADED AREA ALONG FRONT RAIL POSITION TAPE ON EDGE OF RADIUS FRONT RAIL POSITION TAPE AGAINST SIDE RAIL FRONT RAIL APPLY DOUBLE SIDED x700mm ROLL (TAPE06) ACROSS FRONT RAIL Diagram: 7 - FIT M TAPE x700mm FRONT RAIL OF VEHICLE TUB SIDE RAIL OF VEHICLE TUB 7. 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 (MISC6) 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 (TAPE06), 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. diagram7). Page of /0/

12 CP00a MEASURE & MARK CENTRE LINE OF RAIL EXTRUSION TUB STOP = = MEASURE & MARK CENTRE LINE OF FRONT RAIL RAIL EXTRUSION TUB STOP 8. Using a non permanent marker, measure and mark a line at the centre of the rail extrusion tub stop (ALUM00-) and the centre of the front rail on the tub as shown. Use alcohol wipes provided clean the tape contact surfaces of the rail extrusion tub stop and wipe away residue with a dry clean cloth. Apply (MISC6) primer stick to highlighted area over full length of the rail and allow it to dry. (ref. diagram8). Diagram: 8 - CENTRE & CLEAN FRONT TUB STOP EXTRUSION REMOVE TAPE LINER CROSS SECTION THROUGH FRONT RAIL RAIL EXTRUSION TUB STOP FIT RAIL EXTRUSION TUB STOP APPLY FIRM PRESSURE TO ADHERE TAPE TAPE FRONT RAIL 9. Remove the liner film from the double sided tape applied to the rail extrusion tub stop. Fit rail extrusion tub stop (ALUM00-) to the front rail over the tape aligning the previously marked centre lines. IMPORTANT: Ensure the short face sits over the front rail, and the long face with slots overhangs into the tub as shown. Apply firm pressure forward and down on the rail extrusion tub stop along the length to ensure maximum adhesion of the foam tape. (ref. diagram9). Diagram: 9 - FIT FRONT TUB STOP EXTRUSION Ømm Rust Inhibitor (x8) FIT EIGHT (8) RIVETS 0. Mark and drill eight (8) Ømm holes into the front rail tub stop and tub rail using dimension s as shown. Rivets must secure to flat form on tub. Apply rust inhibitor to all drilled holes in the tub sheet metal. Secure with eight (8) stainless steel rivets as shown. (ref. diagram0) Diagram: 0 - SECURE FRONT TUB STOP RAIL Page of /0/

13 CP00a. Using alcohol wipes provided clean all top rail areas of the bed liner 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.(ref. diagram). Diagram: - VEHICLE SURFACE PREPARATION SECTION AT REAR OF VEHICLE START AT THE ALONG EDGE OF THE SIDE RAILS TUB RAIL ON THE REAR EDGE RADIUS TAILGATE OF VEHICLE TRIM EXCESS TO THE EDGE OF THE TUB RAIL POSITION EPDM FOAM TAPE ON THE EDGE OF THE INSIDE RADIUS ALONG THE SIDE RAILS TOP VIEW OF VEHICLE TUB APPLY EPDM FOAM TAPE AROUND BED RAIL POSITION EPDM FOAM TAPE mm REARWARD OF THE EDGE OF THE RAIL EXTRUSION TUB STOP mm ALONG FRONT RAIL WITH TUB STOP CABIN OF VEHICLE. Apply EPDM foam tape (TAPE086) from hardware kit to the vehicle tub bed rails and rail extrusion tub stop. 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 tub rail, position the foam tape on the edge of the rear radius of the tub and as it bends around the corner align it to 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 mm rearward along the rail extrusion tub stop as shown and to 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 tub rail as shown. Ensure all foam tape areas are fully adhered to the tub and tub stop by applying moderate pressure down on the tape all the way around the tub. (ref. diagram). Tape MUST be fully adhered to tub rails and tub stop, and sit flat in one continuous length to prevent water entering the canopy. 6 FINISH OVER THE EDGE OF THE TAILGATE ALONG SIDE RAILS FOAM TAPE MUST NOT PUCKER AROUND CORNERS Diagram: - INSTALL WATER SEALING TAPE Page of /0/

14 CP00a NOT SUPPLIED TOP VIEW LOOKING AT TUB FLOOR FRONT OF TUB FLOOR OF TUB. (Recommended) Apply silicon to all openings in the tub floor as shown. IMPORTANT: This step must be done properly to ensure the vehicle tub is water sealed. (ref. diagram). APPLY NON ACETIC SILICON (NEUTRAL CURE) SIDE WHEEL ARCHES OF TUB Diagram: - APPLY SILICON AROUND TUB SEALING BLOCKS NOT SUPPLIED EPDM FOAM TAPE FRONT TUB STOP TOP VIEW FRONT LEFT HAND CORNER OF TUB APPLY NON ACETIC SILICON (NEUTRAL CURE) FRONT TUB STOP APPLY NON ACETIC SILICON (NEUTRAL CURE) INTERNAL VIEW INSIDE THE TUB. 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) to the top of the tub and tub stop around the foam tape and inside the tub at the join between the front and side panels, ensure all gaps on the tub is silicon sealed properly. 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 CUT LABEL STICKER IN HALF Page of NOT SUPPLIED FIT FRONT LABEL STICKER TUB STOP APPLY NON ACETIC SILICON (NEUTRAL CURE) TO TOP FRONT CORNERS OF EPDM FOAMTAPE VEHICLE CABIN NOT SHOWN FOR CLARITY Diagram: - APPLY SILICON APPLY EPDM FOAM NON ACETIC SILICON TAPE (NEUTRAL CURE) 00mm 0mm 0mm. Using alcohol wipe provided, clean the front rail of the tub around the hole and wipe away residue with a dry clean cloth. Cut black label sticker (LABL) in half as shown. Remove adhesive liner from label sticker and adhere to the front tub rail to cover the hole in the front of the tub as shown. 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 tub stop around the foam tape, between the top of the tub and the tub stop for a length of 00mm as shown. Run a 0mm bead of silicon on top of the EPDM foam tape in the centre, around the corners for a length of 0mm each way as shown. 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). /0/

15 0mm VW AMAROK - CANOPY CP00a TAPE WIRING HARNESS TO LH SIDE WINDOW +70Kg DO NOT SLIDE CANOPY ON EPDM FOAM TAPE AND SILICON FIT CANOPY TO VEHICLE Diagram: 6 - FIT CANOPY TO TUB HARNESS FEED CANOPY HARNESS BETWEEN TUB AND CABIN DOWN TO CHASSIS RAIL 6. Approximate weight of canopy 70Kg. Two people (minimum) are required for this step. First tape the wiring harness to the left hand 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 and silicon, as this can damage the foam tape and spread the silicon (break the water seal). Remove masking tape and feed canopy harness down between tub and cabin (right hand side of vehicle) so it is accessible under the vehicle on the outside of the chassis rail. (ref. diagram6). VIEW FROM REAR OF CAR FRONT EDGE OF TUB STOP RAIL (ALUM00-) 7. Align the canopy evenly on the tub. Canopy front face of extrusion should be mm from the edge of the tub stop rail 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. diagram7). CANOPY BASE RAIL mm EVEN BOTH SIDES AT THE END CAPS mm FROM FRONT OF CANOPY TO EDGE OF TUB STOP RAIL Diagram: 7 - ALIGN CANOPY TO TUB ORIENT SO THE LONG EDGE RUNS THE LENGTH OF THE VEHICLE FIT 6 CLEAR TAPE 0xmm ABRASION RESISTANT TO TUB RAILS DIRECTLY UNDER CLAMP HOLES IN BASE RAILS 8. Fit six (6) clear tape 0xmm abrasion resistant, to the vehicle tub rails directly under the square holes in the canopy base rails for the clamps as shown. Orient the tape so the long edge runs the length of the vehicle as shown. Position half of the tape on the front face of the rail and fold the remaining half around onto the back of the rail. (ref. diagram8). Diagram: 8 - FIT CLEAR ABRASION TAPE TO TUB Page of /0/

16 CP00a mm mm LOCTITE 77 mm DISASSEMBLE CLAMPS mm DISASSEMBLE CLAMPS 8Nm 9Nm FIT & SLIDE BOTTOM U CLAMP LOCTITE 77 TIGHTEN - FRONT CLAMPS TORQUE TO 9Nm FIT TOP L CLAMP APPLY LOCTITE 77 TO BOLTS, FIT BOLT & WASHERS TORQUE TO 8Nm FIT REMAINING CLAMPS APPLY LOCTITE 77 TO BOLTS 6 CLOSE REAR DOOR & CHECK LATCHES ENGAGE 7 ADJUST LATCH STRIKER POSITION (IF REQUIRED) REMOVE & RETAIN KEYS ATTACHED TO INTERIOR REAR DOOR HANDLE Diagram: 9 - FIT REAR CLAMPS AND CHECK LATCHING TIGHTEN - MIDDLE CLAMPS TORQUE TO 9Nm TIGHTEN - REAR CLAMPS TORQUE TO 9Nm 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 clear abrasion tape. IMPORTANT! Apply Loctite 77 (not supplied) to the bolts liberally. Secure the clamps with the bolts and washers as shown. Tighten to Torque 8Nm. Remove and retain the keys attached to the interior rear door handle. 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 and the lower rear door seal, seals against the tailgate. 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 6Nm. (ref. diagram9). Disassemble remaining four () 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 clear abrasion tape. IMPORTANT! Apply Loctite 77 (not supplied) to the bolts liberally. Secure the clamps with the bolts and washers as shown. Tighten the rear clamps first, then the front clamps and finally the middle clamps, all to Torque 9Nm. (ref. diagram0). Diagram: 0 - FIT REMAINING CLAMPS AND TIGHTEN ALL 0mm 0mm 6Nm SECURE NYLOC NUT AND WASHER CANOPY BASE RAIL AT FRONT NYLOC NUT BOLT TUB STOP WASHER VEHICLE FRONT TUB SHEET METAL. Secure the front of the canopy to the previously installed front rail tub stop extrusion (ALUM00-) with four () M6 hex head bolts, eight (8) flat washers and four () nyloc nuts as shown. Tighten to Torque 6Nm. (ref. diagram). FIT BOLT AND WASHER TIGHTEN TO TORQUE 6Nm Diagram: - SECURE FRONT TUB STOP RAIL Page 6 of /0/

17 BULB SEAL FINGER UNDER CLAMP SEAL & AGAINST CANOPY VW AMAROK - CANOPY CP00a REAR WINDOW APPLY MASKING TAPE TO TAILGATE. 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. diagram). REAR DOOR SASH MASKING TAPE TAILGATE Diagram: - APPLY MASKING TAPE % ISOPROPYL ALCOHOL 7% WATER CLEAR ABRASION TAPE ALIGN BOTTOM EDGE OF CLEAR ABRASION TAPE WITH TOP EDGE OF MASKING TAPE TRIM EXCESS CLEAR ABRASION TAPE APPLY CLEAR ABRASION TAPE REMOVE SQUEEGEE OUT EXCESS SOLUTION BUBBLES MASKING TAPE CANOPY NOT SHOWN FOR CLARITY Diagram: - APPLY ABRASION TAPE. Using a solution of % isopropyl alcohol and 7% 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 mm overhang, place liner on the tailgate. Trim excess tape leaving a mm 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. diagram). ALCOHOL WIPE & PRIME SHADED AREA TAILGATE CANOPY BULB SEAL SIDE TUB RAIL FIT BULB SEAL CLAMP FRAME SEAL TAILGATE. (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 (MISC6) 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 in line with the outer edge of the tailgate as shown. (ref. diagram). Diagram: - (OPTIONAL) FIT TAILGATE SEALS Page 7 of /0/

18 CP00a. Feed the canopy harness along the chassis rail to the vehicle harness connector, and connect them together. IMPORTANT: Wiring harnesses should be positioned away from the exhaust system side. (ref. diagram). CONNECT CANOPY HARNESS TO VEHICLE HARNESS CHASSIS RAIL Diagram: - CONNECT VEHICLE & CANOPY CONNECTORS 6. 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. NOTE: An additional accessory can be ordered from EGR to turn the light on in DOOR position of the switch when the door is opened automatically. (ref. diagram6). CHECK BRAKE LIGHTS WORK CHECK CANOPY LAMP WORKS Diagram: 6 - CHECK BRAKE LIGHTS AND CANOPY LIGHT FIT ADHESIVE TIE PAD CABIN CANOPY TUB 7. Using alcohol wipe provided in the kit, clean the left hand side top corner of the front tub rail 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. diagram7). Diagram: 7 - FIT ADHESIVE TIE PAD Page 8 of /0/

19 CP00a CABIN 8. 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. diagram8). CANOPY TUB FIT CABLE TIE Diagram: 8 - SECURE CANOPY HARNESS ANTI-CLOCKWISE = LENGTHEN ADJUST LENGTH DETAILS TO ADJUST PULLRODS OF PULLRODS BY ROTATION REMOVE INTERIOR LOCK COVER 6 REPLACE INTERIOR LOCK COVER RE-CHECK LOCK FUNCTION 9. Water test canopy checking for water leaks. Test both canopy keys work to lock and unlock the rear door and side lift up window. Open both side windows. If the rear door handle does not lock, remove the interior lock cover, unclip the pull rods and wind to lengthen them slightly. Re-check rear door lock function. When rear door locks replace interior lock cover, and add the canopy keys to the customers vehicle keys. (ref. diagram9). UNCLIP PULLRODS FROM RETAINER CLIPS CLIP PULLRODS INTO RETAINER CLIPS Diagram: 9 - WATER LEAK TESTING PLACE FITTING INSTRUCTIONS IN THE CUSTOMERS LOG BOOK 0. Clean canopy including all windows and vehicle thoroughly. Place fitting instructions in the Customers log book, and ensure pages 0 and of these instructions are discussed with the customer and a copy is given to the customer. (ref. diagram0). Diagram: 0 - FINAL CLEANING Page 9 of /0/

20 CP00a OWNERS MANUAL SUPPLEMENT IMPORTANT: PLACE THIS PAGE IN THE CUSTOMER S VEHICLE 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. VEHICLES 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 6.6 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. For sliding windows use a silicon based Non-Aerosol lubricant or a dry film lubricant or LY70 lubricant or M window channel dresser lubricant sparingly. DO NOT use CRC, WD0 or petroleum based lubricants on sliding windows. Warranty Terms EGR warrants that the ABS Canopy will be free from defects in material and workmanship for a period of three () 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 0 of /0/

21 CP00a OWNERS MANUAL SUPPLEMENT IMPORTANT: PLACE THIS PAGE IN THE CUSTOMER S VEHICLE SERVICE BOOK. VW Amarok MY0 Onwards KEY IDENTIFICATION CODE CANOPY 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. Page of /0/

22 CP00a INSTALLATION CHECKLIST Dealer Name: Model: Order Date: Required By: Dealer Code: Stock No: Order No: Vin No: Canopy Colour Vehicle Damage Check: Detail: Canopy Checklist - Details of rectifications required: KEY No. :. Check paint on canopy. Cleanliness of canopy inside and outside. Canopy sealing to tray, front tub stop extrusion and foam tape applied correctly. Seal around Front of tub, vertical & floor with Silicone after foam tape applied. Tailgate clear abrasion wear tape fitted 6. 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 7. Clamps are square and tight (Torque 9Nm) 8. IMPORTANT! Loctite 77 applied to all Clamp Bolt Threads 9. Rear Door, Side Door s and Front window operation, side windows lock with keys. Check rear door handle and locks with keys. If not locking remove interior cover on rear door handle and adjust the pull rods by winding them in/out and test the door again, replace cover. 0. Operation of Brake Light. Operation of interior light. Water Tested for leaks. Clean up of work area. Comment Fitted By: Vehicle received and Checked by Dealer Staff: Record Canopy Serial Number: (located on inside LH rear pillar of canopy shell) Page of Checked By: /0/