ford ranger px mazda bt-50 - egr auto | - px-j26 flee… · · 2014-03-24page 2 of 18 09/08/12...

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CP0073a

RECOMMENDED TOOL LIST - (Not Supplied in Kit)• Loctite 243 thread locking liquid (IMPORTANT)• Phillips Head Screwdriver• Medium Adjustable Spanner• Side Cutters• Sockets 10 & 13mm, Extension Bar and Driver• Spanners 10 & 13mm• Silicon Dispensing Gun• Non Acetic Silicon (Neutral Cure)• Spray Bottle (25% isopropyl Alcohol & 75% Water)• Spray Bottle Water• Torque Wrench - 0-20Nm• T30 Torx Drive Screwdriver• Non Permanent Marker

• Allen Keys• Masking Tape• Cleaning Cloths / Rags• Steel Rule and Tape Measure• Scissors (Sharp)• Knife (Sharp)• Squeegee• File or Deburring Tool• Drill & Ø5mm Drill Bit• Engineers Scribe• Rivet Gun for Stainless Steel Rivets• Electrical tape• Light Gauge Plastic Coated Draw Wire

(October 2011 Production Onwards)MAZDA BT-50

Clean Canopy with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

PLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES. PLEASE NOTE: STEP 19 - MAZDA ONLY. STEP 20 - FORD ONLY.

Sports Bars MUST be removed & returned to Customer with all hardware components if required.Cabin Guards MUST be removed & returned to the Customer if fitted.Product suits fitment with Genuine bedliner (no cutting or modifications required).Additional accessory roof racks are available under Part number: UP11-AC-CANRR

PlPlacece these inststructions inin vevehicle’s gloveve bobox afafter ininstallllation is complplete

Installation Time: Approx. 60 Minutes

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 2 people. (4 people will be required to lift Canopy)

CANOPY INSTALLATION INSTRUCTIONS

(2011 Production Onwards)FORD RANGER PX

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PARTS CHECK SHEET

CanopyQty - 1

PARTS IN MAIN CARTON

Rail ExtrusionTub Stop(ALUM0043-2)Qty - 1

Fitting Kit(KIT032861)Qty - 1

Lock Keys(Attached toCanopy InternalRear Door Handle)Qty - 2

PARTS IN FITTING KIT (KIT032861)

PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0043)

RustInhibitor

Alcohol Wipe(MISC0052)Qty - 4

AUTOMOTIVESURFACE CLEANER

IMPREGNATED WITH 70% ISOPROPYL ALCOHOL

For use in cleaning painted metal,glass and other vehicle surfaces.For external use only.Dispose of properly after use.

Rust InhibitorSatchet(MISC2776)Qty - 1

Primer Stick(MISC1365)Qty - 3

Vehicle WiringPatch Harness Kit(LOOM0043)Qty - 1

FittingInstruction(FIT-CP0073a)Qty - 1

Double Sided Tape1.7m long(TAPE0615)Qty - 1

Rivet (FAST0505)Qty - 4

104x35mm BlackLabel Sticker(LABL1441)Qty - 3

Clear AbrasionTape Roll(TAPE0611-1)Qty - 1

Bedrail Tape 20x6mm 5.25M(TAPE0652)Qty - 1

M6x20 ScrewHex Head (SCRW0028)Qty - 2

M8x25 ScrewHex Head (SCRW0696)Qty - 12

M6 Flat WasherThin(WASH0169)Qty - 2

M8 Flat Washer(WASH0171)Qty - 24

M6 Nyloc Nut(NUTS0016)Qty - 5

M8 Hex Nut(NUTS0217)Qty - 12

FittingInstruction

Vehicle WiringPatch Harness(LOOM0043)Qty - 1

Cable TiesShort 200mmQty - 5

Cable TiesLong 600mmQty - 7

M6x25 ScrewAllen Head(SCRW0845)Qty - 5

M6 Flat WasherThick(WASH0201)Qty - 5

Base Rail MountingBracket(CLIP2960PC)Qty - 6

M6 SpringWasher(WASH0103)Qty - 2

M8 SpringWasher(WASH0152)Qty - 12

Blackout Decalfor Brake Lamp(LABL1486)Qty - 1

CANOPY INSTALLATION INSTRUCTION

Rubber Seal320mm long(EXTR0022)Qty - 1

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Remove four (4) screws in the front rail of the tub, repeat for other side.(ref. diagram1).

1.

2.

Diagram: 2 - APPLYING BLACK DECALS

3.

Diagram: 3 - REMOVE HIGH MOUNT STOP LAMP SURROUND

Diagram: 1 - REMOVING SCREWS FROM TUB

VIEW LOOKING UP INTO LEFT FRONT CORNER

Clean front rail of the tub where screwshave been removed, using alcohol wipe(MISC0052).Using the black decals (LABL1441), coverthe holes as shown on the diagram.One decal must be cut in half andused on the front facing hole. Repeat forboth sides.Note: The front outside hole must stayexposed.(ref. diagram2).

Remove high mount stop lamp surround, bylifting it from the top and pull forward.Clean and dry the surface.(ref. diagram3).

SLIDE LAMP SURROUND OFF BY LIFTING FROM THE TOP

AND PULLING FORWARD1

REMOVE SCREWS

1

VIEW LOOKING UP INTO LEFT FRONT CORNER

APPLY DECALS

IMPORTANT!THIS HOLE BOTHSIDES MUST BE

UNCOVERED

1


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2

Refit the lamp surround. (ref. diagram5).5.

ALIGN THOSERADII TO THELAMP EDGES

3POSITIONDECAL ONTHE LAMP

2

1

Remove backing paper from brake lampblackout decal (LABL1486) at one side foronly the first 50mm. Fold backat 45deg toexpose adhesive.At one side align outside radii on the decal tothe edges of the lens. Adhere first corner. Peel back remaining liner ensuring position ismaintained to the lamp. Fold back tags ondecal to wrap around the lamp. Ensure goodadhesion by rubbing with soft clean soft cloth.(ref. diagram4).

4.

Diagram: 4 - APPLY THE BLACKOUT DECAL

REFIT THE COVER1

Diagram: 5 - REINSTALL THE STOP LAMP SURROUND

PEEL ONE SIDE

CANOPY INSTALLATION INSTRUCTIONCANOPY INSTALLATION INSTRUCTION

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8. Starting with a small amount of the tapefrom the double sided tape roll 12mm wide(TAPE0615) with green liner film, 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. diagram8).

Diagram: 8 - FIT 3M TAPE 12x1700mm

APPLYDOUBLE SIDED 12x1700mm ROLL(TAPE0615) ACROSS FRONT RAIL

STOP

7. Using alcohol wipe (MISC0052) clean thetop surface of the front rail and wipeaway residue with a dry clean cloth.If heavy cleaning is required use Iso-Propyl alcohol and wipe away residuewith a dry clean cloth.Apply (MISC1365) primer stick along the width of the front tub rail as shown all theway across side to side of the front tub railand allow to dry. (ref. diagram7).

Diagram: 7 - APPLY PRIMER TO THE FRONT RAIL

1

2

APPLYPRIMER STICK

TO SHADED AREAALONG FRONT RAIL

SIDE RAILOF TUB

SIDE RAILOF TUB

SIDE TUBRAIL

TOP VIEW OF FRONT OF TUB

TOP VIEW OF TUB

TOP SURFACEOF FRONTTUB RAIL

TOP SURFACEOF FRONTTUB RAIL

TOP SURFACEOF FRONT TUB RAIL

6. Thoroughly clean and dry installationareas (tub, rear of cabin and glass)as shown.Clean front of canopy including the frontwindowUsing cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the canopy. (ref. diagram6 ).

Diagram: 6 - CLEAN & DRY INSTALLATION AREAS

POSITIONCARDBOARD TUBPROTECTION MAT

2

13


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9.

10.

Using alcohol wipes provided, clean the tape contact surfaces of the (ALUM0043-2)rail extrusion tub stop.Apply (MISC1365) primer stick to high-lighted area over full length of the railand allow it to dry. (ref. diagram9).

Remove the green liner film from the double sided tape applied to the front tub rail.Fit rail extrusion tub stop (ALUM0043-1)to the front rail of the tub over the tape aligning the rail evenly to gaps to sides ofthe tub.IMPORTANT: Ensure the short face sitsover the front rail, and the long face withslots overhangs into the tub as shown.Ensure the slots at each end are alignedwith the holes in the tub.Apply firm pressure forward and down onthe rail extrusion tub stop along the lengthto ensure maximum adhesion of the foamtape. (ref. diagram10).

Diagram: 10 - FIT FRONT TUB STOP EXTRUSION

APPLYFIRM PRESSURE TO

ADHERE TAPE

1

TOP VIEW OF THERAIL EXTRUSION TUB STOP

RAIL EXTRUSIONTUB STOP

TAPE

FIT FRONTTUB STOP

HOLES

ALIGN HOLES

CROSS SECTIONTHROUGH FRONT RAIL OF TUB

FRONTRAIL

11.

TOP SURFACE FRONT OF TUB - TOP VIEW

RAIL EXTRUSION TUB STOP

12

Diagram: 9 - CLEAN & PRIME FRONT TUB STOP EXTRUSION

20mm

LOCTITE243

4

(=)(=)

3

2

Diagram: 11 - SECURE TUB STOP WITH BOLTS

IMPORTANT! Apply Loctite 243(not supplied), minimum 20mm alongthe thread on the bolts.Secure the tub stop extrusion to the tub,using two (2) M6x20 hex bolts, M6 spring washers and M6 flat washers through the two (2) front slots as shown. Tighten the bolts to Torque 7Nm.(ref. diagram11).

7Nm

10mm

10mm

TIGHTEN TWO (2) BOLTS TO TORQUE 7Nm4

2

3

1M6x20

HEX BOLT

M6 SPRINGWASHER

M6 FLATWASHER


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Diagram: 12- SECURE FRONT TUB RAIL WITH RIVETS

13.Using alcohol wipes provided clean alltop rail areas of the tub and wipe awayresidue with a dry clean cloth. If heavycleaning is required use Iso-Propylalcohol and wipe away residue with adry clean cloth using priming stick (MISC1365) prime top rails of the tub whereEPDM foam tape will be applied in (step 14).(ref. diagram13).

Diagram: 13 - VEHICLE SURFACE PREPARATION

12. Measure out ,mark and drill four (4) Ø5mm 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 (MISC2776) to all drilled holes in the tub sheet metal.Secure with four (4 ) stainless steel rivets(FAST0505) as shown. (ref. diagram12).

FIT FOUR (4) RIVETS

200

100 400400

Ø5mmRust

Inhibitor

(x4)2 3 4

4

USE “V” NOTCHIN RAIL

VERTICAL SECTION VIEW THROUGHFRONT TUB RAIL AND TUB STOP RAIL FITTED

TAILGATE OFVEHICLE

TOP VIEW OFVEHICLE TUB

CA

BIN

OF

VEH

ICLE

25mm

1 2

20mm25mm


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NOT SUPPLIED

Diagram: 15 - APPLY SILICON

23

4

5

6

Apply EPDM foam tape (TAPE0652) fromhardware kit to the vehicle tub bed rails andrail extrusion tub stop.IMPORTANT: DO NOT CUT FOAM TAPE,IT MUST BE APPLIED IN ONE CONTINOUSLENGTH!Starting from one side at the rear corner.As the tape bends around the corners ensure the tape sits flat and DOES NOTpucker. Trim off excess to the edge of thetub rail as shown.Ensure all foam tape areas are fully adheredto the tub and tub stop by applying moderatepressure down on the tape all the wayaround the tub. (ref. diagram14).

14.

Diagram: 14 - INSTALL WATER SEALING TAPE

APPLYEPDM FOAM TAPEAROUND BED RAIL

TAILGATE OFVEHICLE TOP VIEW OF

VEHICLE TUB

CA

BIN

OF

VEH

ICLE

START AT THEEDGE OF THE

TUB RAIL ON THEREAR EDGE RADIUS

SECTION ATREAR OFVEHICLE

POSITIONEPDM FOAM TAPEON THE EDGE OF

THE INSIDE RADIUSALONG THE SIDE RAILS

POSITIONEPDM FOAM TAPE

20mm REARWARD OFTHE EDGE OF THERAIL EXTRUSION

TUB STOP

ALONGSIDE RAILS

ALONGSIDE RAILS

FOAM TAPE MUST NOTPUCKER AROUND CORNERS

FINISH OVERTHE EDGE OFTHE TAILGATE

TRIM EXCESS TOTHE EDGE OFTHE TUB RAIL

ALONG FRONT RAILWITH TUB STOP

20mm

15. With a clean cloth wipe down all areas ofthe internal front tub corners to besiliconed as shown. Spray areas to besiliconed with water, Do Not dry, to allowthe silicone to flow better.Apply non-acetic silicon (neutral cure)(not supplied) to the top of the tub and tubstop around the foam tape and inside thetub at the join between the front and sidepanels, ensure all gaps on the tub is siliconsealed properly. Re-spray silicon withwater and push silicon into gaps and cleanup excess silicon. Repeat process for theother side of the vehicle.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram15).

1

EPDM FOAMTAPE

TOP VIEW FRONT LEFT HAND CORNER OF TUB

INTERNAL VIEW INSIDE THE TUB

APPLYNON ACETIC SILICON

(NEUTRAL CURE)

FRONTTUB STOP

FRONTTUB STOP

1

1

1

APPLYNON ACETIC SILICON

(NEUTRAL CURE)

2

2

2

50 mm

50 mm


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17. IMPOTRTANT!Apply Loctite 243 (not supplied), minimum 20mm along the thread on the M8x25 hex head bolts for each of the 6 bolts.IMPORTANT: Ensure to have the top of thetub mounting bracket set 2mm above toprail of the vehicle tub. This is to ensure the canopy will seal properly to the tub at the sides. Secure each of the 6 tub mounting brackets with the M8x25 bolts, M8 flat washers, M8 spring washers and M8 nuts. Tighten all 6 bolts to the torque of 12Nm. (ref. diagram 17).

Diagram: 17 - ATTACHING TUB MOUNTING BRACKETS

NOTE: THE TUB MOUNTING PLATE

MUST BE SET AT 2mm ABOVE

THE TOP OF THE TUB RAIL

M8 FLAT WASHER

M8 FLAT WASHER

M8 HEX NUT

M8 SPRING WASHER

FITTUB MOUNTING

BRACKET (CLIP2960PC)

1

5 6

24

3

M8x25 BOLT

20mm

LOCTITE24313mm 12Nm

13mm

DO NOT SLIDE CANOPYON EPDM FOAM TAPE

AND SILICON

2 FITCANOPY TO

VEHICLE

1 TAPEWIRING HARNESS

TO LH SIDE WINDOW

3FEED

CANOPY HARNESSBETWEEN TUB AND

CABIN DOWN TOCHASSIS RAIL

HARNESS

18. Approximate weight of canopy 70Kg.Four people (minimum) are required forthis step.First tape the wiring harness to the lefthand side window with masking tape.Position the canopy onto the vehicletub carefully. IMPORTANT: Ensure canopy is placedfully forward on the tub in one action.DO NOT slide the canopy on the EPDMfoam tape and silicon, as this candamage the foam tape and spread thesilicon (break the water seal).Remove masking tape and feed canopyharness down between tub and cabin (righthand side of vehicle) so it is accessibleunder the vehicle on the outside of thechassis rail. (ref. diagram18).Diagram: 18 - FIT CANOPY TO TUB

+70Kg


16. Apply masking tape to the side of the tub as shown. Measure and mark the holes as indicated in the chart below.

Place canopy on tub with brackets attached to canopy. Position canopy untill the centre of the bracket slot aligns with marked holes centres. Check rear door seal and operation to tailgate before drilling. Drill Ø3.0mm pilot holes and redrill to Ø9mm. Use depth stop set at 10mm.Repeat on the opposite side of the vehicle.(ref. diagram 16).

10mm

Diagram: 16 - MEASURE & MARK SIDE HOLES ON VEHICLE

33mmAPPLYMASKING

TAPE

1

2 MEASURE & MARK

MAZDAFORD 172

164688680

12231215

MODELDIMENSIONS (mm)VEHICLE NOT SHOWN FOR CLARITY

TOP VIEW OF LH CORNER OF TUBSTARTMEASUREFROM REAREDGE OF TUBRAIL SPACER

A

A

B

B

C

C

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CANOPY ALIGHMENT ON THE TUBFOR MAZDA VEHICLES ONLY

CANOPY ALIGHMENT ON THE TUB FOR MAZDA VEHICLES ONLY 19.

Open rear tailgate. Position the canopy sothe center slot in the front lower canopy railis aligned with the slot in the front tub stop.Fit the M6x 25 dome head bolt (SCRW0845) and loosely secure with M6 washer 2.5mm thick (WASH0201) and M6 nyloc nut (NUTS0016).The position of the front base rail should be4mm from the front edge of the tub stop rail.(ref. diagram19).

VEHICLE CABIN AND REAR DOOR NOT SHOWN FOR CLARITY

SECTION VIEW

VIEW INSIDE CANOPY

Diagram: 19 - ALIGN AND SECURE LOOSELY CANOPY TO TUB

10mm

1FIT BOLT

M6 NYLOC NUT AND WASHER

DOMEHEAD BOLT

LOOSELY SECURENYLOC NUT AND WASHER

2


0mm 10 20

CANOPY ALIGHMENT ON THE TUBFOR FORD VEHICLE ONLY

CANOPY ALIGHMENT ON THE TUB FOR FORD VEHICLE ONLY 20.

Open rear tailgate. Position the canopy sothe position of the front base rail should be17mm from the front edge of the tub stop rail.(ref. diagram20).

VEHICLE CABIN AND REAR DOOR NOT SHOWN FOR CLARITY

SECTION VIEW

Diagram: 20 - ALIGN CANOPY TO TUB (FORD ONLY)

0mm 10 20

17mm

4mm

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13mm


21.The slots in the canopy base rails should nowalign to the holes in the top face of each ofthe tub mounting brackets. IMPORTANT: Apply Loctite 243 (not supplied) minimum 20mm along the threadon the M8x25 hex head bolts for each of the 6 bolts. (ref. diagram 21).

Diagram: 21 - ATTACH CANOPY TO THE TUB AT REAR FIRST

M8x25 BOLT

M8 NUT

M8 FLAT WASHER

M8 FLAT WASHER

M8 SPRING WASHER

12Nm

13mm

20mm

LOCTITE243

CLOSE REAR DOOR &RE-CHECK EASE OF TURNING

LOCKS TO LOCK

4

3

2

2

TORQUE BRACKETS BOLTS TO 12Nm

ADJUSTCANOPY FORWARD

IF SEAL IS NOT SEALINGON LOWER DOOR

EDGE TO TUB

ADJUSTIF LOCKS ON REAR

DOOR ARE TOOHARD TO TURN

13mm

If you need to adjust the position of the canopy,to ensure the rear door sash seals to the tailgate,loosen the bolts on the clamps.Adjust the canopy position slightly forward onthe vehicle if the seal is not sealing, or slightlyrearward on the vehicle if the locks are too hardto turn and close.Re-tighten the bolts to Torque 12Nm.Close rear door and re-check locking. (ref. diagram 23).

23.

Diagram: 23 - CHECK AND ADJUST REAR DOOR SEALING & LOCKS

22. Open rear tailgate to check sidewaysalighment of the canopy to the tub, measurewith a ruler from the vehicle’s side tub railedge to the flange on the canopy base rail. Make this even both sides. Check towardsthe front, middle and rear end of the canopy.(ref. diagram 22).

Diagram: 22 - ALIGN CANOPY TO TUB SIDEWAYS

EVEN BOTH SIDES

REAR SECTION VIEW

A=BA B

1 LOOSENBRACKETS BOLTS

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CLEARABRASION

TAPE

TRIMEXCESS CLEARABRASION TAPE

3

REMOVEMASKING TAPE

CANOPY NOT SHOWN FOR CLARITY

5

SQUEEGEE OUTEXCESS SOLUTION

BUBBLES

41

25% ISOPROPYLALCOHOL

75% WATER

APPLYCLEAR

ABRASION TAPE

ALIGNBOTTOM EDGE

OF CLEAR ABRASIONTAPE WITH TOP EDGE

OF MASKING TAPE

2

25.

26.

With the canopy rear door closed, applya length of masking tape to the reartailgate, level with the bottom edge ofthe canopy rear door sash, when viewedfrom the rear horizontal position as shown.This will assist in positioning the clearabrasion tape applied to the top of thetailgate in the next step. (ref. diagram25).

Using a solution of 25% isopropyl alcoholand 75% water in a spray bottle (not -supplied) Thoroughly spray along the topof the tailgate. Remove liner from clearabrasion tape. Working from one end witha 5mm overhang, place liner on the tailgate. Trim excess tape leaving a 5mm overhangat both ends of the tailgate.When in position use a squeegee to pushout any excess water solution and bubbles.Using a sharp knife or scissors, trim tape to end of tailgate.You may need to squeegee a few times.When finished the tape is virtuallyinvisible. To ensure a good finish please take carean do not rush this step. Remove maskingtape. (ref. diagram26).Diagram: 26 - APPLY ABRASION TAPE

Diagram: 25- APPLY MASKING TAPE

24.

Diagram: 24 - SECURE FRONT TUB STOP RAIL

Secure previously installed front rail tubstop extrusion (ALUM0043-2) to thecanopy front base rail spacer using four (4) M6 allen dome head bolts (SCRW0845),2.5mm thick M6 flat washers and M6 nyloc nuts as shown.IMPORTANT! Tighten center bolt first, tigten middle bolts second and tigten outer bolts third to Torque 7Nm. (ref. diagram24).

10mm

TIGHTEN TO TORQUE 7Nm

TIGHTEN TO TORQUE 7Nm

1

CANOPY BASERAIL AT FRONT

2

VEHICLEFRONT TUB

SHEET METAL

THIS BOLT 7Nm ONLY FOR MAZDA

7Nm

10mm

3

SECTION VIEW

M6 NYLOC NUT AND

2.5mm WASHER

ALLEN DOMEHEAD BOLT


TAILGATE

REARDOOR SASH

MASKINGTAPE

REAR WINDOW

APPLYMASKING TAPETO TAILGATE

1

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09/08/12 of 18


Open the rear door and tailgate.Clean and prime the inside side panel belowthe canopy. Cut the seal (EXTR0022) into four even pieces 80mm long. Apply the 80mm long extrusion as indicatedin the diagram on both sides of the tub.Note: The small flap on the seal should facetowards the rear of the vehicle and the sealshould contact the the door seal at the top.(ref. diagram 27).

27.

SEAL

SEAL

Diagram: 27 - SEAL APLICATION

Diagram: 28 - FIT TAILGATE SEALS

28. Using alcohol wipe provided clean the top part of the tailgate about 100mm from eachend. Using priming stick (MISC1365) prime area. Apply only a light amount both sides of tailgate in this area, and allow to dry. Apply bulb seal 80mm to tailgate as shownon both sides of the tailgate. (ref. diagram 28).

BULBSEAL

CLAMPFRAMESEAL

TAILGATE

SIDETUBRAIL

1

2

CANOPY

REAR VIEW

SECTION VIEW REARDOOR

CONTINUE ON THE NEXT PAGE

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5

4

6

7

29.

Diagram: 31 - RUN HARNESS ALONG CHASSIS RAIL

Run the vehicle harness (LOOM043) along the chassis rail with existing wiring, up to the front left hand wheel arch as shown. Fit cable ties in sequence listed.Trim excess cable tie length with side cutters.Ensure harness is run in a direct route fromthe rear of the vehicle to the front.(ref. diagram 31).

3

CHASSIS RAIL

SEE STEP 31,32

SEE STEP 31

SEE STEP 31

SEE STEP 31

SEE STEP 31,33

SEE STEP 31

SEE STEP 31,32

VEHICLEHARNESS

(LOOM0043)

1

30.

31.

Disconnect existing vehicle harness connectors under the rear left hand of the car near the chasis rail and spare tyre.(ref. diagram 29).

Connect the wiring loom (LOOM0043)into the vehicle harness as shown.(ref. diagram 30).

Diagram: 30 - CONNECT LOOM INTO EXISTING VEHICLE CONNECTOR

Diagram: 29 - DISCONECT REAR CONNECTOR UNDER LEFT HAND SIDE

DISCONNECTEXISTING VEHICLE

HARNESS CONNECTORS

CONNECTEXISTING HARNESS CONNECTORS

TO THE VEHICLE HARNESSCONNECTORS

2

1

CANOPYVEHICLE

LOOM(LOOM0043)

1


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5

4

6

7

32.

3

1

At the rear left hand side of the vehicle locate the existing harness connectors and disconnect them.Connect the tail lamp connectors to the vehicle harness (LOOM0043) connectors as shown.

Run the vehicle harness along the left hand chassis rail, then follow the chassis rail to left hand fire wall. Ensure the harness is positioned away from the exhaust system. Ensure the canopy connector is positioned onthe chassis rail between the tub and the cabin as shown. Secure the vehicle harness with cable ties.Position cable ties away from fuel lines, brake cables, moving parts and flexible mounts to body.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. diagram 32).

Diagram: 32 - CONNECT & RUN VEHICLE HARNESS UNDER THE VEHICLE

REAR LEFT HANDSIDE OF VEHICLE

FRONT OF VEHICLE

CABLE TIE (200mm LONG) TIE TO THE MAIN VEHICLE HARNESS

CABLE TIE (200mm LONG) TIE TO THE MAIN VEHICLE HARNESS

CABLE TIE (200mm LONG) TIE TO THE VEHICLE MAIN WIRING HARNESS BETWEEN VEHICLE TUB

AND CABIN, AT THIS POSITION THE CONNECTOR TO THE CANOPY SHOULD BE POSITIONED (SEE STEP 33)

CABLE TIE (200mm LONG) TIE TO THE MAIN WIRINGHARNESS ABOVE AXLE

FROM OUTSIDE PULL LOOM THROUGH UNDER PLASTIC WHEEL LINER AND TUCK THE LOOM

BACK UNDER THE LINERS (SEE STEP 32)

USE A (600mm LONG) CABLE TIE BEFORE ENTRY OFLOOM UP THE FIRE WALL INTO THE ENGINE BAY

AT THE ENTRY OF LOOM INTO ENGINE BAY ENSURELOOM IS RUN ABOVE BRAKE LINES JUST BEFORE

THE FIRE WALL BEGINS UNDER THE CAR

CABLE TIE IN 3 POSITIONS TO TOP OF CHASSIS RAILWITH (600mm LONG) CABLE TIES. BE CAREFUL TO

POSITION AWAY FROM BRAKE LINES ANDEXHAUST SYSTEM

2


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33. Feed the wiring loom along the chassisrail above the rear wheel and tuck the loomback in under the plastic wheel arch liners. Leave the canopy loom conector behindthe plastic wheel arch liner at the front.(ref. diagram 33).

Diagram: 33 - CANOPY CONNECTOR LOCATION

FRONT OF THE CAR

IMPORTANT!CONNECT TO THE

POSITIVE TERMINALON BATTERY

CLIP WIRINGHERE

1

CONNECTR FOR CANOPY LOOM1

35. Feed the wiring loom along thechassis rail up the fire wall into the vehicleengine bay. Clip the corrugated harnessinto the white plastic clip on the fire wall and feed along the side fender and between the fuse box and the battery.Connect the loom into the positive terminal of the battery, as shown. (ref. diagram 35).

Diagram: 35 - CONNECT THE LOOM UNDER THE HOOD

2

Feed the canopy and vehicle wiringharnesses to the gap between the tuband the cabin under the left hand plasticwheel arch liner.Join the connectors from the canopy andvehicle wiring harnesses together.Using a cable tie secure the vehiclewiring harness only to the existing mainwiring harness as shown.(ref. diagram 34).

34.

Diagram: 34 - SECURE CANOPY HARNESS

CONNECTHARNESS

CONNECTORS

1CABLE TIEVEHICLEHARNESS

TO EXISTINGHARNESS

EXISTINGHARNESS

CANOPYHARNESS

TYRE

PLASTIC WHEELARCH LINERS

VEHICLEHARNESS

2

INSIDE PASSENGERSIDE REAR TYRE

CHASSIS RAIL


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KEY IDENTIFICATION CODE

1234

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.

OWNERS MANUAL SUPPLEMENTIMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S

VEHICLE SERVICE BOOK.


CHECKCANOPY LAMP

WORKS

36. Two people are required to check thecanopy brake light is operational afterdepressing the brake pedal.Then open the rear window and checkthat the internal canopy lamp is operatingcorrectly when switched to the ’ON’position only. (ref. diagram34)NOTE: It will not operate in “DOOR”position. A seperate accessory can be purchased to operate the light automatically when the rear door is opened.

Diagram: 36 - CHECK BRAKE LIGHTS AND CANOPY LIGHT

CHECKBRAKE LIGHTS

WORK

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CP0073a

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.

MaintenanceOnly use mild detergents or wax polish. Do Not use abrasive compounds on painted or plastic finishedcanopy surfaces.The gas struts are self lubricating and should only be cleaned with a damp cloth, when regularly cleaningthe 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 brackets every 1000 Km.If removed, bolts must have LOCTITE 243 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 3Mwindow channel dresser lubricant sparingly.

DO NOT use CRC, WD40 or petroleum based lubricants on sliding windows.

Warranty TermsEGR 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 ofpurchase. The gas struts are warranted for one (1) 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.

ExclusionsThis warranty does not cover failure due to neglect, improper installation, including any modifications to installation hardware, alterations, additionof non genuine equipment, abuse, accident, normal wear and tear, lack of maintenance, misuse, and exposure to chemicals that are not safe forplastics 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 ofthe 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.

DisclaimerIn 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 thedefective part. Transportation costs and labour are not associated with this warranty claim.

OWNERS MANUAL SUPPLEMENTIMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S

VEHICLE SERVICE BOOK.

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