26/11/12Page 1 of 20

SB0030 PART A - SPORTS BAR WITH INTEGRATED

STOP LAMP INSTALLATION INSTRUCTIONS

LIST OF PARTS

Vehicle Description:

Part Number: SBAR0073

FORD RANGER 2012

PLEASE KEEP INSTRUCTIONS IN GLOVE BOX FOR FURTHER USE

PART NAME

Sports Bar Main Top Tube

Sports Bar LHS Leg

Sports Bar RHS Leg

Rubber Sleeves - Top Tube

Foot Cups

Foam Gaskets - Foot Cups

M8x30 Hex Head Screws

M8x30 Allen Screws

QTY

11124482

NO.

12345678

M8 Spring Washers

M8 Internal Tooth Washers

M8x40 Countersunk screw

M8 Flat Washers

Nut plates

Front Bracket - RHS

Front Bracket - LHS

Rear Bracket

Front Bracket Foam Pad - RH

91011121314151617

828821121

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 20

Front Bracket Foam Pad - LH

Rear Bracket Foam Pad - RH

Rear Bracket Foam Pad - LH

Paint Protection Tape

Rivet

Black Spacer Short

Black Spacer long

Wiring Loom Extension

1819202122232425

11142221

21 22

23 24 25

*

#

#

#

# - Required only when installing sports bar with tonneau cover* - Required when installing sports bar without tonneau cover

EXTRA TOOL LIST - Sports Bar + Tonneau Cover Installation

Ø3mm, Ø6mm & Ø7mm Drill Bits

Torque Wrench

Scissors or Sharp Knife

Socket Set

Spanners

Non-acetic Silicone

Tape Measure

Masking Tape

RECOMMENDED TOOL LIST - Sports Bar Installation

Ø5mm & Ø10mm Drill Bits

Cordless Drill

Cleaning Cloth

Socket Wrench 13mm

5mm Allen Key

Hammer & Centre Punch

Non-permanent Marker

Phillips Head Screwdriver

Rivet Gun

26/11/12Page 2 of 20

SB0030 FORD RANGER 2012 SPORTS BAR

FIG. 1

FIG. 2

2

3

1

Remove cabin guard if fitted.

Thoroughly clean and dry the installation area.

IMPORTANT: To obtain correct installation, we recommend that you follow these step by step instructions carefully.

Please take care when assembling and installing this product to protect the finish and your investment. Regular polishing and waxing is required to protect the finish.

Finish Protection: Our products have a high finish that must be maintained such as any other high finish product on the vehicle. Protect the finish with a non-abrasive automotive wax after polishing. Regular polishing of the sportsbar is required to prevent staining or corrosion of the finish.Use products formulated for stainless steel. Failure to maintain the finish may cause unrepairable damage to the sportsbar.

Disclaimer: The buyer assumes all risk and liability whatsoever from the installation and use of our products. Our products are sold as decorative accessories and should not be relied upon as protection for the vehicle or occupants inthe event of a collision or rollover.The manufacturer assumes no liability for injury, loss, incidental or consequential damages in the event of a collision or rollover.

EGR Customer service hotline, phone; +61 7 3337 0155 (Business hours, Australia)

FIG. 3

1

3

4

4

2

2

41

4

2

2

1

Slide the rubber sleeves over the ends of the sports bar left and right hand legs and then slide the sports bartop tube in as shown. Ensure that all holes are aligned with each other, and the LED wiring is fed through theoutside hole in the bottom of the sports bar front left hand leg as shown.

26/11/12Page 3 of 20

SB0030

FIG. 4

FORD RANGER 2012 SPORTS BAR

FIG. 5

1

3

44

2

NO POWERTOOLS

Slide rubber sleeves away from join and temporarily secure sports bar top tube to sports bar left and righthand legs using two (2) M8x30 screws and M8 internal tooth washers.

8

10

14

FIG. 6

132

Attach the four moulded foot cups to the sports bar legs. Ensure the LED wiring is fed through the foot cup.

If you are installing a tonneau cover skip to page 7

otherwise continue to Fig 6.

2

5

26/11/12Page 4 of 20

SB0030

17

18

19

20

TORQUE 10Nm

Attach the two front brackets and the two rear brackets to the sports bar legs using two M8x40mm countersunk screws in all four feet positions. Tighten fully.

11

14/15

1116

FIG. 7

FIG. 8

FIG. 10

1

1. Ensure sports bar is sitting correctly on the vehicle. Using the a non permanent marker, mark the centre of theslots as shown. 2. Mark 3 small curves on the top face of the side rail to outline the foot cup locations as shown (keep curves to a minimum). Repeat process for the other 3 foot cup positions.

2MARK 3 SMALL CURVES

AROUND THE FOOT CUPS

FIG. 9

Trial fit the assembled Sports Bar aligning the front mounting brackets with the existing fixing points in the tub. Temporarily secure the front brackets LH and RH side to the vehicle tub using the M8x30mmHex Head Screws, M8 Spring Washers and M8 Flat Washers. Do not tighten fully.

79

12

13 mm

26/11/12Page 5 of 20

SB0030

FIG. 14Using the installed screw as a guide mark a centre point on the top of the tube at each end as shown. Drilltwo Ø5mm holes and remove any burrs or sharp edges. Install the two rivets as shown.

31 2

MARK, CENTREPUNCHAND DRILL Ø5mm TOPOF TUBE.

FIG. 12Using the curves previously marked, position abrasive tapes with equal 3mm overlap to the 3 marked curves. Remove thebacking and adhere the paint protection tape (X4) in the marked positions.

21

TAPE TO BE POSITIONED EQUALLY TO THE

CURVES PREVIOUSLY MARKED

PREVIOUSLY MARKED CURVES

x4

FIG. 13

Re-fit the assembled Sports Bar aligning the front mounting brackets with the existing fixing points in the vehicle tub and the rear mounting brackets with the newly drilled holes. Secure the front brackets LH and RH side to the vehicle tub using the M8x30mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers. Secure the rear mounting brackets using M8x30mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers and the nutplate. Tighten to 10Nm

79

1213 mm

x212 139

7

79

12

Vehicle

14/15

Ø5mm Ø10mm

FIG. 11Remove and retain sports bar and hardware. Centrepunch previously marked centrepoints. Drill a Ø5mm pilothole at positions marked, then re-drill to Ø10mm. Remove any burrs or sharp edges and apply rust inhibitor.

SIDE RAIL1 DRILL Ø5mm PILOT HOLE2 DRILL Ø10mm HOLE

RustInhibitor

26/11/12Page 6 of 20

FIG. 15

TORQUE 7Nm Remove and retain previously installed M8x30 screws and M8 internal tooth washers. Slide rubbersleeves back over tube join aligning the holes. Re-install M8x30 screws and M8 internal toothwashers. Tighten to Torque 7Nm.

NO POWERTOOLS

8

10

FIG. 18

FIG. 17 Remove and retain left hand rear wheel arch inner panel and hardware as shown.

FIG. 16

Feed loom through front left hand side foot

Attach the connector to the wires then route the Stop Lamp Wiring Loom down through the hole in the front left hand corner of the vehicle tub, below where the front LHS foot is located.

SB0030

Locate the tail lamp connectors underneath the LHS rear corner of the vehicle. Unplug the connectors.Plug the two large connectors in the Wiring Loom Extension into these two connectors.

REAR OF VEHICLE / TAIL LAMP

DISCONNECT

REAR OF VEHICLE / TAIL LAMP

Stop LampWiring Plug

Supplied Wiring Loom

CONNECT

CONNECT

Remove screws and scrivets

black wire

red wire

FIG. 19

26/11/12Page 7 of 20

SB0030

Route the Wiring Loom Extension up through the LHS rear wheel well. Inside the vehicle body, connect the Stop Lamp Wiring Loom connector to the Wiring Loom Extension connector. Secure the Wiring Loom Extension to the vehicle using Cable Ties supplied.Test the operation of the stop lamp before re-fitting the screws and scrivets around the LHS wheel well liner.

Connect Stop Lamp Wiring Loom toWiring Loom Extension Connector

26/11/12Page 8 of 20

SB0030

PART B - FORD RANGER 3 PIECE HARD TONNEAU COVERINSTALLATION INSTRUCTIONS

Care Instructions

Clean Tonneau Cover with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.

WARNING!When in the closed position, Tonneau Cover must be latched and tailgate must be closed! Failure to do so could result in unexpectedopening of the Tonneau Cover from sudden wind gusts, driving conditions, which could cause damage to the vehicle and/or yourTonneau Cover!DO NOT close the Tailgate when the Hard Tonneau is in the closed position, as damage may occur to the vehicle and/or yourTonneau Cover!

MAINTENANCE:Only use cleaners, waxes, or products that are labelled safe for use on plastics. Avoid the use of any chemicals to clean your TonneauCover unless labelled safe for plastics. Avoid use of abrasive type cleansers as they may dull the finish.The gas struts are self lubricating and should only be cleaned occasionally with a damp cloth. Premature seal failure will result ifsolvents or lubricants are used to clean struts.Gas struts must be connected with the cylinder (wide) end to the Tonneau Cover or Warranty is Void. The locking mechanisms and latches only require occasional lubrication with Graphite Powder.DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.All installation hardware and fasteners must be checked every so often for tightness.

TONNEAU COVER - IMPORTANT:• Read instructions carefully before installation. It is strongly recommended that installation is conducted by an authorized dealer.• This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.• Do not stand/sit or rest heavy objects on Tonneau Cover.• Humans or animals are not to be under the closed Tonneau Cover at any time.• Securely latch Tonneau Cover before operating vehicle.• Do not carry open volatile chemicals with Tonneau Cover installed.• If contact with volatile chemicals occurs clean Tonneau Cover with mild detergent and water solution.• Recommend installation by 2 people.• Fitting Instructions must be given to the end customer to understand correct removal and replacement process onto the vehicle.

PAINTING INSTRUCTIONS: (IF UNPAINTED)• Prior to painting, clean all surfaces to be painted using clean water and a mild detergent, do not use lacquer thinner or any solvent based products. Wipe completely dry. • Best results will be achieved by wiping the areas to be painted with a tack rag just prior to painting.• Select a top coat and clear paint that is suitable for PC/ABS (Poly-Carbonate-Acrylonitrile-Butadiene-Styrene).• Automotive paint systems, such as Acrylics or Two Packs, can be applied directly to the components. However, some paints may require a primer. If recommendations on paint specification are not followed, cracking of the part or degradation to the material may result. In all paint systems, aromatic hydrocarbons and alkalies are best avoided to reduce damage to the material properties.• If using a paint system which requires baking, do not expose the product to temperatures above 70° C (155° F). • Allow a minimum of 8 hours after baking before installation on the vehicle.

26/11/12Page 9 of 20

SB0030

PARTS CHECK SHEET

25

Tonneau CoverQty - 1

PARTS IN MAIN CARTON

PARTS IN FITTING KIT (KIT032373)

29 30

Hinge Lower(CLIP2720PC)Qty - 2

Hinge PinRetainer(CLIP2717-1)Qty - 2

Upper TailgateBracket(CLIP2834PC)Qty - 2

TailgateTop Hat(CLIP2875PC)Qty - 2

31

Hinge Pin(CLIP2032)Qty - 2

32 33 34 35

Gas StrutStandard(STRT0005-2)Qty - 2

26

LHS CornerPieceQty - 1

27

RHS CornerPieceQty - 1

28

Lock KeysQty - 2

Fitting Kit(KIT032373)Qty - 1

54

HeaderRail Seal(MISC2229-9)Qty - 1

HeaderRail (HBAR0013-1)Qty - 1

52 53

Side DrillTemplate(MISC3452)Qty - 1

PARTS IN KIT (KIT032369)

VOLK

SWAG

EN 2

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.

RustInhibitor

36

JackingBracket(CLIP2646PC)Qty - 2

37 38

Rivet(FAST0505)Qty - 17

Scrivet(FAST0086)Qty - 2

*Parts 37, 45 and 46 are included in this kit, but are not required.

39 40 41 42

M6x20 HexHead Bolt(SCRW0028)Qty - 18

43 44

M6 FlatWasher Small(WASH0153)Qty - 38

45

M6 NylocNut(NUTS0016)Qty - 12

M8 HexNut(NUTS0217)Qty - 2

M8x40 C/SunkHead Screw(SCRW0847)Qty - 8

46

M8x50 HexHead Bolt(SCRW0789)Qty - 2

47

Ball StrutBracket(CLIP2034-1)Qty - 2

AlcoholWipe(MISC0052)Qty - 4

RustInhibitor(MISC2776)Qty - 2

48 49 50 51

A

B

Lock StrikerBracket(CLIP2499-PC)Qty - 2

Striker U-Bolt(LOCK0006)Qty - 2

Anodized Spacer short 10mm thick(MISC3405)Qty - 2

Anodized Spacerlong 8mm thick(MISC3404)Qty - 2

M6 HexNut(NUTS0161)Qty - 8

Qty -(M

cerhic

04)2

d S8m

ISCk

pacm t

34-

izeng

Mhic

5)

Sp0m

SC3Qty

odizho

(k

acm

405- 2

zedrt 1

MISQ

Ano nodlo

r

6

kAnce

464

kw

0848

C/SSc

CRQt

8x4He

45

7)

unrew

W0y -

0 Cad

(S

M

373

26/11/12Page 10 of 20

SB0030

FIG. 8

40 40

39 39

38

HEADER RAIL

SECTION THROUGH THE TUB RAIL

FRONT OF VEHICLE

HEADER RAIL

FRONTPANEL

RHSLHS

SIDEPANEL

SIDEPANEL

Ø5.5mm

1

13

10mm

1

42

RUSTINHIBITOR

CLEAN & DRYINSTALLATION AREAS

ENTIRE LENGTH

FIG. 20 Thoroughly clean and dry the installations areas. See Above Left Place masking tape in sections along the entire length of the side rails as shown. See Above Right.

Attach header rail to the front of the tub using two M6x20 screws and washers.Note the header rail orientation as shown in the section view. Mark and center punch the five hole locations in header rail. Remove the header rail. Drill five (5) holes through the tub using 5.5mm drill.Remove all burrs, sharp edges and swarf from vehicle. Apply rust inhibitor to all drilled holes. Reattach the header rail with screws and washers. NOTE: Top of header rail is to be flush with top of front bed rail. FIG. 21

Rivet the header rail to the tub using five (5) rivets. Once rivets are in, remove M6 screws and retain for step 15 to install sports bar. NOTE: Header rail to be flush with top of front bed rail. .

LHS

SIDEPANEL

1

HEADER RAILRHS

SIDEPANEL

FIG. 22

26/11/12Page 11 of 20

SB0030

FIG. 8

39402930

4041

Measure and cut header rail seal to a length of 1380mm. Locate the centre of the header rail seal and trial fit to the front panel, ensure seal is oriented correctly and centred to the tub. Remove approximately 50mm length from one end of liner. Orient and align centre of seal with centre of front panel and rearward edge of seal against the lower hinge as shown. Starting from one end apply firm pressure and remove liner along the length of the seal, ensuring seal runs parallel with the edge front panel.

Orient the two (2) lower hinges as shown. Align the holes in the hinge lower with the slots in the header rail.Secure with two (2) M6x20 hex head bolts, four (4) M6 flat washers and two (2) M6 nyloc nuts for each hinge as shown. Do not overtighten at this point. Allow side to side movement for adjustment once the tonneau cover is installed.

1380mm MEASURE & CUTHEADER RAIL SEAL

TO LENGTH - 1380mm

FRONTPANEL HEADER RAIL

ALIGN TO REAR EDGE OFTHE FRONTPANEL

FRONT OF VEHICLE

SECTION THROUGH THE TUB RAIL

10mm10mm

10Nm

RHSLHS

TIGHTEN TO TORQUE 10Nm

FIG. 25

FIG. 24

FIG. 23

Position the side drill template against the side of the tub bed rail as shown, ensuring arrows are facing down and to the front of the vehicle. The drill template shape matches the bottom shape of the side of the bed rail. Align the bottom of the template with the bottom of the bed rail as shown. Attach using masking tape. Mark and centrepunch the holes marked with an “F”, the two unmarked holes in the middle and the two rearmost positions. Do not use the holes marked with an “M”. Drill all holes with Ø3 pilot drill and remove the drill template. Drill four (4) holes Ø7mm and two (2) Ø5.5mm as shown. Repeat process by reversing the template to use on the other side of the vehicle. Remove all masking tape from the side rails. Remove all burrs, sharp edges and swarf from vehicle. Apply rust inhibitor to all drilled holes.

15Ø3mm2

FRONTPANEL

ALIGN DRILL TEMPLATEWITH BOTTOM TUB EDGE DO NOT DRILL HOLES

FOR THIS FITMENTHOLES MARKED “M”

DRILL TEMPLATEMUST TOUCH

FRONT OF THE TUB

ALIGN DRILL TEMPLATEWITH BOTTOM TUB EDGE

SIDE PANEL (RHS)

TAILGATE

Ø7mm

3

Ø5.5mm

4

65mm37mm

40mm

70mm

712mm

1256mm813mm

36mm 36mm

M M F F

26/11/12Page 12 of 20

SB0030

FIG. 8

Fit the ball stud bracket to the side rail and secure with two (2) rivets (center pair of holes).Repeat process for the other side of the vehicle.

Pre-assemble M8x50 bolt and M8 nut into each jacking bracket as shown ensuring it is screwed all the way down at this point as shown. Secure a jacking bracket to the vehicle with two (2) M6x20 hex head bolts, four (4) M6 flat washers and two (2) M6 nyloc nuts as shown. Repeat process for the other side of the vehicle. Tighten to Torque 9Nm.

10mm10mm

7Nm

TIGHTEN TO TORQUE 7NmSIDE VIEW

SIDE VIEW

HEADER RAIL

16

TUB

BALL STUDBRACKET

9

FIG. 26

FIG. 27

Attach the striker bracket to the tub using two (2) M6 screws, M6 washers and M6 nylock nuts.Note the orientation of the bracket. Position face “B” of lock striker bracket against the side rail as shown. Tighten to 9Nm.

SIDE VIEW10mm 10mm

9Nm

LETTER “B” SIDESITS AGAINST SIDE RAIL

A

B

1

FIG. 28

38

42

39

3939

40 40

40 40

40

41

41

41

36

33

FIG. 30

Trial fit the assembled Sports Bar aligning the front mounting brackets with the existing fixing points in the tub. Temporarily secure the front brackets LH and RH side to the vehicle tub using the M8x30mmHex Head Screws, M8 Spring Washers and M8 Flat Washers. Do not tighten fully.

26/11/12Page 13 of 20

SB0030

Apply a non-acetic silicone perimeter bead to the foot cups and fit into the sports bar legs, place the spacer plates on top followed by the tonneau corner pieces. Starting with front bracket screw the two M8x40mm bolts into the sports bar. Repeat same procedure for the rear leg and opposite side of the sports bar. Tighten Fully. Note: Remove any excess silicone.

FIG. 82 2

33

4

4 5

6

5

11

SPORTS BAR

X4 X4

FITRUBBERPADS

FEED WIRE THROUGH HOLE IN TONNEAU COVERCORNER PIECE

6FITRUBBERPADS

FIG. 29

26

23 24

15 14

16

27

5/65/6

18/20 17/19

11

TORQUE 10Nm

APPLY NON-ACETIC SILICONETO TOP AND BOTTOM SURFACESAROUND PERIMETERTO PREVENT WATER ENTRY

79

12

Centrepunch previously marked scrivet centrepoints. Drill a Ø6mm hole at the position marked. Remove any burrs and sharp edges and apply rust inhibitor. Repeat on other side.

26/11/12Page 14 of 20

SB0030

FIG. 31

SCRIVET HOLE

REAR BRACKET SLOTS

Apply pressure to push the corner piece and front sports bar feet firmly into the front corner of the tub and down onto the side rail. Mark the scrivet hole and rear bracket slot positions with non permanent marker. Repeat process for the other side of the vehicle.

FIG. 33

Ø6mm SIDE RAIL1 DRILL Ø6mm HOLE

Ø5mm Ø10mm

FIG. 32

Remove and retain sports bar and hardware. Centrepunch previously marked rear bracket centrepoints. Drill a Ø5mm pilot hole at positions marked, then re-drill to Ø10mm. Remove any burrs or sharp edges and apply rust inhibitor. Repeat on other side.

SIDE RAIL1 DRILL Ø5mm PILOT HOLE2 DRILL Ø10mm HOLE

RustInhibitor

RustInhibitor

Re-fit the assembled Sports Bar by aligning the front mounting brackets with the existing fixing points in the vehicle tub and the rear mounting brackets with the newly drilled holes. Secure the front brackets LH and RH side to the vehicle tub using the M8x30mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers. Secure the rear mounting brackets using M8x30mm Hex Head Screws, M8 Spring Washers and M8 Flat Washers and the nutplate. Tighten to 10Nm

13 mm

26/11/12Page 15 of 20

FIG. 35

FIG. 34

Using the installed screw as a guide mark a centre point on the top of the tube at each end as shown. Drilltwo Ø5mm holes and remove any burrs or sharp edges. Install the two rivets as shown.

31 2

MARK, CENTREPUNCHAND DRILL Ø5mm TOPOF TUBE.

FIG. 36

TORQUE 7Nm

Remove and retain previously installed M8x30 screws and M8 internal tooth washers. Slide rubbersleeves back over tube join aligning the holes. Re-install M8x30 screws and M8 internal toothwashers. Tighten to Torque 7Nm.

NO POWERTOOLS

8

10

SB0030

79

12

x212 13 139

7

79

12

Vehicle

14/15

26/11/12Page 16 of 20

SB0030

FIG. 37

FIG. 39

With tailgate open, Close and check Tonneau Cover is central to vehicle and the sides of Tonneau Cover do not contact the vehicle bedrail. Adjust position by loosening the top hinge screws for fore and aft adjustment and hinge mount screws for side to side adjustment to re-position Tonneau Cover to fit centrally on vehicle. Before screwing tight, align each lower hinge section outwards in order to prevent side play. Tighten all hinge brackets to Torque 9Nm.

Adjust jacking bracket bolt to level corner piece to the main surface of the Tonneau Cover.Once in the correct position, lock the bolt into position against the bracket by tightening the M8 nut using a 13mm spanner.Repeat process for the other side of the vehicle.

13mm

13mm

NO POWER TOOLS

Open vehicle’s tailgate and keep it open until locking mechanism has been adjusted correctly. Two people are required to carry out the fitment of the tonneau cover. Carefully fit tonneau cover to vehicle ensuring seal at the front of the tonneau cover sits correctly over the header rail seal as shown, If incorrectly placed this can direct water into the tub. Secure hinges with hinge pins as shown. IMPORTANT: Ensure hinge pins clip into retaining leg on lower hinges, ensuring pin is securely restrained. If misaligned, seal can be pushed forward from inside of the tub.

LOOSEN TOPHINGE SCREWS

TIGHTEN HINGE MOUNT SCREWS TORQUE 9Nm

TONNEAU SEALFITMENT OVER

HEADER RAIL SEAL

ENSURE HINGE PINIS CORRECTLYRESTRAINED

IMPORTANT: Ensure vehicles’s tailgate is opened before installing Tonneau Cover, andremains open until lock striker is fitted and locking mechanism is adjusted correctly.

DO NOT close the Tailgate when the Hard Tonneau is in the closed position, as damagemay occur to the vehicle and/or your Tonneau Cover!

FIG. 38

39

26/11/12Page 17 of 20

SB0030

FIG. 40

FIG. 41 Fit the striker U-bolt to the striker bracket using nuts and washers as shown.

Attach gas struts by clipping into place as shown. Ensure the narrow end mounts to the vehicle and the wide end mounts to the tonneau cover. !! Failure to do so Voids Warranty on gas struts!!

NARROW END MOUNTS TO VEHICLEWIDE END MOUNTS TO TONNEAU COVER

A

B

8

B

39

35

44

40

44

26/11/12Page 18 of 20

SB0030

FIG.42

FIG. 44

FIG. 43

Close Tonneau Cover and inspect locking mechanism. Ensure the latch hits the striker bracket centrally. If it DOES NOT, adjust the latch accordingly by loosening the screws and moving the latch left or right as shown. Tighten to torque 5Nm.Adjust the height of the lock striker bracket by moving it up or down as shown. Tighten nuts to torque 9Nm. Note: Tonneau Cover has 2 stage locks as a safety feature. Ensure Tonneau engages with second stage of the latch.

Open the Tonneau Cover and engage the lock by pressing upwards on the latch. Adjust pullrods so that they clip back into the retainer clips correctly. Do this by rotating them clockwise to shorten them or anti-clockwise to lengthen them (via internal turn buckle). Clip pullrods and retainer clips back into position. Test lock by pressing the button on top of Tonneau Cover. If latch mechanism DOES NOT release, return to Step 3 and shorten the pullrods. If it DOES release, replace inspection cover.

IMPORTANT: Ensure that the Tonneau Cover locking mechanism is functioning correctly before closing tailgate.

1 ENGAGE LOCK

LATCH MECHANISM

PRESS LATCHUPWARDS

ROTATE PULLRODS

CLOCKWISE = SHORTENANTI-CLOCKWISE = LENGTHEN

“CLICK”

2 ADJUST LENGTH OFPULLRODS BY ROTATION

3 4

REPLACE INSPECTION COVER6

TEST LOCKING MECHANISM5

RETAINERCLIPS

INSPECTIONCOVER

LOCK PLASTIC RETAINER CLIPSBACK IN POSITION

INSPECTION COVERPLASTIC RETAINER

CLIPSPULLRODS

REMOVE INSPECTIONCOVER

RELEASE PLASTICRETAINER CLIPS

UNCLIP PULLRODSFROM PLASTICRETAINER CLIPS

IMPORTANT: Ensure vehicle’s tailgate is opened and remains open.Tonneau could lock during adjustment process.

10mm

10Nm

1

INCORRECT

INSPECT LATCHENGAGEMENT

CORRECT

2 ADJUST U-BOLT

USE A RULER TOENSURE U-BOLT

REMAINS PARALLELTO LOCK STRIKER

3 ADJUST LATCHMECHANISM

4

TORQUE 10Nm

SCREWS

TORQUE 5Nm

ADJUST

0mm

1020

3040

5060

7080

90

Open Tonneau Cover and remove inspection cover by removing scrivets and rotating cover anti-clockwise.Release plastic retainer clips and unclip pullrods as shown.IMPORTANT: TAILGATE MUST BE OPEN, TONNEAU COULD LOCK DURING ADJUSTMENT PROCESS.

26/11/12Page 19 of 20

SB0030

FIG. 45

FIG. 47

FIG. 46

Open tonneau cover. Orient latch mount brackets as shown and attach to the rear of the tonneau inner using two (2) M6 x 20mm hex head bolt and washers. Position latch bracket so screw does up in the middle of the slot as shown. Repeat for the RHS. Do not fully tighten at this stage. Note: Use caution when closing to ensure bracket does not contact vehicle tailgate.

Measure 80mm from LHS edge of the tailgate. Orient top hat latch brackets as shown at 80mm. Mark and center punch four (4) hole locations and drill holes with 5.5mm drill bit. Secure the top hat latch brackets to the tailgate using four (4) blind rivets for each bracket. Repeat for RHS.

Close rear tailgate and then the tonneau cover to check that it closes correctly and the latch bracket does not contact the top hat latch bracket. If required adjust the latch bracket by loosening the screws with and adjusting fore and aft. Re-tighten and recheck. When adjustment is complete tighten M6 screws with captive washers to Torque 9Nm. Note: Use caution when closing to ensure bracket does not contact vehicle tailgate.

10mm

10mm

NARROW END MOUNTS TO VEHICLE

TAILGATE

80mm

1

Ø5.5mm

2

3

2

1

LATCHBRACKET

TAILGATE

TOP HAT LATCHBRACKET

CENTRE LATCH BRACKET AND FINGER TIGHTEN SCREWS

38 38

39

26/11/12Page 20 of 20

FIG. 50

FIG. 49 Remove and retain left hand rear wheel arch inner panel and hardware as shown.

FIG. 48

Feed loom through front left hand side foot

Attach the Connector to to wires then route the Stop Lamp Wiring Loom down through the hole in the front left hand corner of the vehicle tub, below where the front LHS foot is located.

Locate the tail lamp connectors underneath the LHS rear corner of the vehicle. Unplug the connectors.Plug the two large connectors in the Wiring Loom Extension into these two connectors.

REAR OF VEHICLE / TAIL LAMP

DISCONNECT

REAR OF VEHICLE / TAIL LAMP

Stop LampWiring Plug

Supplied Wiring Loom

CONNECT

CONNECT

SB0030

Remove screws and scrivets

black wire

red wire

FIG. 51

Route the Wiring Loom Extension up through the LHS rear wheel well. Inside the vehicle body, connect the Stop Lamp Wiring Loom connector to the Wiring Loom Extension connector. Secure the Wiring Loom Extension to the vehicle using Cable Ties supplied. Test the operation of the stop lamp before re-fitting the screws and scrivets around the LHS wheel well liner.

Connect Stop Lamp Wiring Loom toWiring Loom Extension Connector