Transcript
CP0021a
CANOPY INSTALLATION INSTRUCTIONS VW AMAROK Double Cab Installation Time: 1 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 2, 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 2 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 1 and 2 of this Fitting Instruction needs to be completed Before fitting a Bed Liner.
RECOMMENDED TOOL LIST - (Not Supplied in Kit) • Loctite 277 thread locking liquid (IMPORTANT) • Phillips Head Screwdriver • Dehousing Tool (for VW Wiring Genuine) • Medium Adjustable Spanner • Side Cutters • Sockets 10, 12 & 13mm, Extension Bar and Driver • Spanners 10, 12 & 13mm • Silicon Dispensing Gun • Non Acetic Silicon (Neutral Cure) • Spray Bottle (25% isopropyl Alcohol & 75% Water) • Spray Bottle Water • Torque Wrench - 0-10Nm • T30 Torx Drive Screwdriver • Non Permanent Marker Page 1 of 22
• Masking Tape • Cleaning Cloths / Rags • Steel Rule and Tape Measure • Scissors (Sharp) • Knife (Sharp) • Squeegee • Metal Primer • File or Deburring Tool • Drill & Ø5mm Drill Bit • Engineers Scribe • Rivet Gun for Stainless Steel Rivets • Electrical tape • Light Guage Plastic Coated Draw Wire 11/01/11
CP0021a
VW AMAROK - CANOPY PARTS CHECK SHEET
VW AMAROK CANOPY
PARTS IN MAIN CARTON
Rail Extrusion Tub Stop (ALUM0043-1) Qty - 1
Canopy Qty - 1
Lock Keys (Attached to Canopy Internal Rear Door Handle) Qty - 2
Fitting Kit (KIT031998) Qty - 1
PARTS IN FITTING KIT (KIT031998)
Kit - Rail Clamps (CNPY0007) Qty - 6
Clear Abrasion Tape Roll 48mm Wide (TAPE0611-1) Qty - 1
Tape EPDM4300 5.5Mx20mmx6mm (TAPE0386) Qty - 1
Screw M6x30 Hex Head SS304 (SCRW0824) Qty - 4
M6 Flat Washer OD. 19mm (WASH0169) Qty - 8
M6 Nyloc Nut SS304 (NUTS0016) Qty - 4
Tape 4026GHBWH 12mmx1700mmx 1.14mm Thick Roll (TAPE0615) Qty - 1
Bulb Seal 70mm Cut Length (MISC2600-1) Qty - 2
Rivet SS304 ST-ST 6-6 (FAST0433) Qty - 8
104x35mm Label Sticker (LABL1441) Qty - 1
LH-Tub Sealing Block (TAPE0618-LH) Qty - 1
RH-Tub Sealing Block (TAPE0618-RH) Qty - 1
AUTOMOTIVE SURF ACE CLEA NER
For use in cleaning painted metal, glass and other vehicle surfaces . For external use only. Dispose of properly after use.
IMPREGNATED WITH 70%
Rust Inhibitor
Fitting Instruction
ISOPROPYL ALCOHOL
Clear Tape Pad Alcohol Wipe 50x3mm Abrasion (MISC0052) Qty - 8 Resistant (TAPE0011)
Rust Inhibitor Satchet (MISC2776) Qty - 1
Primer Stick (MISC1365) Qty - 4
Vehicle Wiring Patch Harness Kit (LOOM0019) Qty - 1
Fitting Instruction (FIT-CP0021a) Qty - 1
Qty - 6
PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0019) 1 2
Vehicle Wiring Patch Harness (LOOM0019) Qty - 1
Page 2 of 22
Cable Ties Short 200mm Qty - 30
Adhesive Tie Pad Qty - 1
Foam Tape Qty - 1
5 Amp Blade Fuse Qty - 1
2-Way Connector Qty - 1
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STEP 1 & 2 NEEDS TO BE COMPLETED BEFORE FITTING A BED LINER. VIEWS LOOKING UP INTO LEFT HAND SIDE FRONT VEHICLE TUB CORNER
1
CROSS SECTION SIDE PANEL OUTER
2
TUB SEALING BLOCK
3 REMOVE ADHESIVE LINER
TOP OF FRONT RAIL
SIDE PANEL INNER
4 FIT TUB SEALING BLOCK POSITION SLIT OVER SHEET METAL
5 PRESS TUB SEALING BLOCK AROUND TUB SURFACES TO SEAL AND PREVENT WATER ENTRY
Diagram: 1 - FIT TUB SEALING BLOCKS
1. Using alcohol wipe provided clean the front inside corners of the tub and wipe away residue with a dry clean cloth. Apply (MISC1365) 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. diagram1).
2. 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. diagram2).
NOT SUPPLIED
TUB SEALING BLOCK LH
APPLY NON ACETIC SILICON (NEUTRAL CURE)
Diagram: 2 - APPLY SILICON AROUND TUB SEALING BLOCKS
3. Disconnect high mount stop lamp, by
3
1 SLIDE COVER OFF TO THE LEFT
3 SECURE LOOM WITH ELECTRICAL TAPE
2 DISCONNECT CONNECTOR
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. diagram3).
4 SLIDE COVER ON TO THE RIGHT
Diagram: 3 - DISCONNECT HIGH MOUNT STOP LAMP Page 3 of 22
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4. Open the tailgate. Remove and retain the 1 OPEN TAILGATE
LHS ONLY
2 REMOVE 2 SCREWS
two (2) screws from the left hand side as shown securing the left hand side tail lamp, using a T30 torx drive screwdriver. Remove the tail lamp by sliding it to the left to dis-engage it from the ball fixings. (ref. diagram4).
3 SLIDE TAIL LAMP TO THE LEFT TO DIS-ENGAGE
Diagram: 4 - REMOVE REAR LHS TAIL LAMP
5. Disconnect the connector from the tail 2 STORE TAIL LAMP SAFELY
lamp, and store the left hand side tail lamp in a safe place to re-fit at a later stage. (ref. diagram5).
1 DISCONNECT CONNECTOR
Diagram: 5 - DISCONNECT REAR LHS TAIL LAMP
6. Remove the terminal lock from the tail lamp connector as shown. (ref. diagram6).
1 REMOVE TERMINAL LOCK
Diagram: 6 - REMOVE CONNECTOR TERMINAL LOCK Page 4 of 22
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7. Using a VW genuine dehousing tool, remove the brown wire from terminal 2 and the grey/red wire from terminal 3. (ref. diagram7).
1 DE-HOUSE TERMINALS 2 & 3 BROWN WIRE (2)
GREY/RED WIRE (3)
1
2
1
3
4
2
5
3
4
5
Diagram: 7 - DE-HOUSE TERMINALS 2 & 3
8. Fit the previously removed wire terminals
1 FIT GREY/RED WIRE TO TERMINAL (1)
2 FIT BROWN WIRE TO TERMINAL (2)
TERMINALS TO “CLICK” IN 1
2
1
1
1
2
into the 2-way connector supplied in hardware kit. Ensure the grey/red wire goes into terminal 1 & the brown wire goes into terminal 2 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).
2
2
3
2-WAY CONNECTOR
4
3
4
5
5
TAIL LAMP CONNECTOR
Diagram: 8 - FIT WIRES TO 2-WAY CONNECTOR
9. When the wires are correctly fitted close the terminal lock on the 2-way connector over so it snaps firmly into place. (ref. diagram9).
1 CLOSE TERMINAL LOCK SO IT “SNAPS” INTO PLACE
1
1
2
3
2 4
5
3
4
5
Diagram: 9 - LOCK IN TERMINALS Page 5 of 22
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10. Feed a draw wire through the gap
2 ATTACH THIS END OF VEHICLE HARNESS
between the sheet metal surfaces. Under the vehicle attach the draw wire to the end of the vehicle harness with the black 2-pin connector and two (2) 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. diagram10).
3 PULL VEHICLE HARNESS INTO TAIL LAMP AREA
2 ATTACH VEHICLE HARNESS
1
1
2
2
1
1
2
2
3
3
4
4
5
1 FEED DRAW WIRE
5
4 REMOVE DRAW WIRE
Diagram: 10 - USING A DRAW WIRE, FEED VEHICLE HARNESS
11. Connect the vehicle harness connector to the 2-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. diagram11).
1 CONNECT VEHICLE HARNESS CONNECTOR TO 2-WAY CONNECTOR TAIL LAMP CONNECTOR
2-WAY CONNECTOR 1
2
1
2
4
5
1
3
2
1
2
3
4
5
VEHICLE HARNESS CONNECTOR
Diagram: 11 - CONNECT VEHICLE HARNESS TO 2-WAY CONNECTOR
12. Fit the two (2) loose wires from the vehicle harness into the terminals on the tail lamp connector as shown. Ensure the grey/red wire goes into terminal 3 & the brown wire goes into terminal 2 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. diagram12).
1 FIT VEHICLE HARNESS TERMINALS TO TAIL LAMP CONNECTOR TERMINALS 2 & 3 VEHICLE HARNESS
TAIL LAMP HARNESS
1
GREY/RED WIRE (3)
2
1
BROWN WIRE (2)
2
1
2
1
2
3
4
3
4
5
5
Diagram: 12 - FIT WIRES TO TAIL LAMP CONNECTOR Page 6 of 22
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13. Re-fit the terminal lock into the tail lamp connector as shown. Ensure it is pushed all the way back in. (ref. diagram13).
1 RE-FIT TERMINAL LOCK
Diagram: 13 - REPLACE TERMINAL LOCK
14. Remove adhesive liner from the foam tape supplied in the wiring harness hardware kit and wrap it around the 2-way connector and vehicle harness connector as shown. (ref. diagram14). 2 WRAP FOAM TAPE AROUND 2-WAY CONNECTOR
1
1
2
REMOVE LINER FROM FOAM TAPE SUPPLIED IN WIRING HARNESS KIT
3
4
5
Diagram: 14 - FIT FOAM TAPE TO 2-WAY CONNECTORS
15. Re-connect tail lamp connector to tail lamp. 4 CLOSE TAILGATE
2 SLIDE TAIL LAMP TO THE RIGHT TO RE-FIT
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 (2) screws previously removed. Close the tailgate. (ref. diagram15).
3 RE-FIT 2 SCREWS
1
2
3
4
5
1 RE-CONNECT TAIL LAMP CONNECTOR
Diagram: 15 - RE-CONNECT TAIL LAMP & FIT TO VEHICLE Page 7 of 22
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16. 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 300-400mm. 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. diagram16).
VEHICLE HARNESS
CHASSIS RAIL
1 RUN VEHICLE HARNESS ALONG CHASSIS RAIL WITH EXISTING HARNESSS & SECURE WITH CABLE TIES
Diagram: 16 - RUN HARNESS ALONG CHASSIS RAIL
17. Open and secure the bonnet.
1 OPEN BONNET
2 FEED DRAW WIRE 3 ATTACH VEHICLE HARNESS WHEEL ARCH LH FRONT SPLASH GUARD
CHASSIS RAIL 4 ROUTE HARNESS BEHIND SPLASH GUARD
Diagram: 17 - USING A DRAW WIRE PULL HARNESS INTO ENGINE BAY 1 REMOVE BATTERY TERMINAL BLOCK COVER
18. Remove battery terminal block cover using 3 REMOVE BATTERY TERMINAL BLOCK COVER
EXISTING HARNESS
2 ROUTE VEHICLE HARNESS
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 (2) 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. diagram17). 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.
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. diagram18).
4 REMOVE TERMINAL BLOCK COVER
Diagram: 18 - ROUTE VEHICLE HARNESS & REMOVE TERMINAL COVER Page 8 of 22
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19. IMPORTANT: Note the positions of
1 NOTE FUSE POSITIONS
the fuses. Remove fuses and store in a safe place to re-fit at a later stage. (ref. diagram19).
2 REMOVE FUSES
Diagram: 19 - NOTE POSITION OF FUSES & REMOVE
20. Remove the terminal lock from the battery terminal block as shown. (ref. diagram20).
REMOVE TERMINAL LOCK
Diagram: 20 - REMOVE TERMINAL LOCK FROM BATTERY
21. Using the sharp end of an engineers scribe, remove and discard the terminal plug (cover) from the battery terminal block as shown. (ref. diagram21).
REMOVE & DISCARD TERMINAL PLUG (COVER)
Diagram: 21 - REMOVE TERMINAL PLUG (COVER) Page 9 of 22
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22. 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. diagram22).
VEHICLE HARNESS FIT VEHICLE HARNESS TERMINAL INTO BATTERY TERMINAL BLOCK
Diagram: 22 - CONNECT VEHICLE HARNESS TO TERMINAL
23. Re-fit the terminal lock into the battery terminal block as shown. Ensure it is pushed all the way back in. (ref. diagram23).
RE-FIT TERMINAL LOCK
Diagram: 23 - RE-FIT TERMINAL LOCK TO BATTERY
1 RE-FIT FUSES TO NOTED POSITIONS
24. Re-fit the fuses to previously noted positions. Fit the 5 amp fuse from the wiring harness hardware kit, to the vehicle harness terminal position as shown. (ref. diagram24).
2 FIT 5 AMP FUSE FROM KIT
Diagram: 24 - RE-FIT FUSES & FIT 5 AMP FUSE FROM KIT Page 10 of 22
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25. Re-fit the terminal cover.
2 CLOSE BONNET
Close the bonnet (ref. diagram25).
1 RE-FIT TERMINAL BLOCK COVER TERMINAL BLOCK
Diagram: 25 - RE-FIT TERMINAL COVER
26. Thoroughly clean and dry installation
2 3 POSITION CARDBOARD TUB PROTECTION MAT
1
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. diagram26).
Diagram: 26 - CLEAN & DRY INSTALLATION AREAS
1
FRONT RAIL OF VEHICLE TUB SIDE RAIL OF VEHICLE TUB
2 POSITION TAPE ON EDGE OF RADIUS
2 APPLY PRIMER STICK TO SHADED AREA ALONG FRONT RAIL
FRONT RAIL
3 POSITION TAPE AGAINST SIDE RAIL FRONT RAIL
4 APPLY DOUBLE SIDED 12x1700mm ROLL (TAPE0615) ACROSS FRONT RAIL
Diagram: 27 - FIT 3M TAPE 12x1700mm Page 11 of 22
27. 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 IsoPropyl alcohol and wipe away residue with a dry clean cloth. Apply (MISC1365) 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 12mm wide (TAPE0615), 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. diagram27). 11/01/11
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28. Using a non permanent marker, measure 1
MEASURE & MARK CENTRE LINE OF RAIL EXTRUSION TUB STOP
2
3
=
=
4 MEASURE & MARK CENTRE LINE OF FRONT RAIL
RAIL EXTRUSION TUB STOP
and mark a line at the centre of the rail extrusion tub stop (ALUM0043-1) 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 (MISC1365) primer stick to highlighted area over full length of the rail and allow it to dry. (ref. diagram28).
Diagram: 28 - CENTRE & CLEAN FRONT TUB STOP EXTRUSION CROSS SECTION THROUGH FRONT RAIL TAPE FRONT RAIL
RAIL EXTRUSION TUB STOP
2 FIT RAIL EXTRUSION TUB STOP
29. Remove the liner film from the double sided tape applied to the rail extrusion tub stop. Fit rail extrusion tub stop (ALUM0043-1) 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. diagram29).
3 APPLY FIRM PRESSURE TO ADHERE TAPE
1 REMOVE TAPE LINER
Diagram: 29 - FIT FRONT TUB STOP EXTRUSION
2
3
4
30. Mark and drill eight (8) Ø5mm holes into
(x8)
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. diagram30).
t Rus r to Inhibi
Ø5mm
4 FIT EIGHT (8) RIVETS
200
200
200
100
200
200
200
200
Diagram: 30 - SECURE FRONT TUB STOP RAIL Page 12 of 22
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31. 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 IsoPropyl alcohol and wipe away residue with a dry clean cloth.(ref. diagram31).
Diagram: 31 - VEHICLE SURFACE PREPARATION POSITION EPDM FOAM TAPE ON THE EDGE OF THE INSIDE RADIUS ALONG THE SIDE RAILS
2
POSITION EPDM FOAM TAPE 22mm REARWARD OF THE EDGE OF THE RAIL EXTRUSION TUB STOP
3 22mm 1 START AT THE ALONG EDGE OF THE SIDE RAILS TUB RAIL ON THE REAR EDGE RADIUS ALONG FRONT RAIL WITH TUB STOP
TAILGATE OF VEHICLE
TRIM EXCESS TO THE EDGE OF THE TUB RAIL
TOP VIEW OF VEHICLE TUB
APPLY EPDM FOAM TAPE AROUND BED RAIL
CABIN OF VEHICLE
SECTION AT REAR OF VEHICLE
32. Apply EPDM foam tape (TAPE0386) 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 22mm 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. diagram32). Tape MUST be fully adhered to tub rails and tub stop, and sit flat in one continuous length to prevent water entering the canopy.
4 FOAM TAPE MUST NOT PUCKER AROUND CORNERS
FINISH OVER 6 THE EDGE OF THE TAILGATE
5 ALONG SIDE RAILS
Diagram: 32 - INSTALL WATER SEALING TAPE
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33. (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. diagram33).
TOP VIEW LOOKING AT TUB FLOOR FRONT OF TUB
NOT SUPPLIED
FLOOR OF TUB
APPLY NON ACETIC SILICON (NEUTRAL CURE) SIDE WHEEL ARCHES OF TUB
Diagram: 33 - APPLY SILICON AROUND TUB SEALING BLOCKS
34. With a clean cloth wipe down all areas of NOT SUPPLIED
TOP VIEW FRONT LEFT HAND CORNER OF TUB EPDM FOAM TAPE
FRONT TUB STOP
1 APPLY NON ACETIC SILICON (NEUTRAL CURE) FRONT TUB STOP
2 APPLY NON ACETIC SILICON (NEUTRAL CURE)
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. diagram34).
INTERNAL VIEW INSIDE THE TUB
Diagram: 34 - APPLY SILICON 1
2
VEHICLE CABIN NOT SHOWN FOR CLARITY
4
NOT SUPPLIED
1 EPDM FOAM 4 APPLY NON ACETIC SILICON TAPE (NEUTRAL CURE)
2 CUT LABEL STICKER IN HALF
200
3 FIT LABEL STICKER
FRONT TUB STOP
5 APPLY NON ACETIC SILICON (NEUTRAL CURE) TO TOP FRONT CORNERS OF EPDM FOAMTAPE
mm
50mm 50mm
Diagram: 35 - APPLY SILICON Page 14 of 22
35. 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 (LABL1441) 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 200mm as shown. Run a 10mm bead of silicon on top of the EPDM foam tape in the centre, around the corners for a length of 50mm 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. diagram35). 11/01/11
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36. Approximate weight of canopy 70Kg.
+70Kg
1 TAPE WIRING HARNESS TO LH SIDE WINDOW
CP0021a
DO NOT SLIDE CANOPY ON EPDM FOAM TAPE AND SILICON HARNESS
2 FIT CANOPY TO VEHICLE
3 FEED CANOPY HARNESS BETWEEN TUB AND CABIN DOWN TO CHASSIS RAIL
Diagram: 36 - FIT CANOPY TO TUB
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. diagram36).
37. Align the canopy evenly on the tub.
VIEW FROM REAR OF CAR
FRONT EDGE OF TUB STOP RAIL (ALUM0043-1)
0mm
10
20
30
40
50
60
70
80
Canopy front face of extrusion should be 15mm 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. diagram37).
90
15mm CANOPY BASE RAIL
EVEN BOTH SIDES AT THE END CAPS
15mm FROM FRONT OF CANOPY TO EDGE OF TUB STOP RAIL
Diagram: 37 - ALIGN CANOPY TO TUB
38. Fit six (6) clear tape 50x3mm abrasion ORIENT SO THE LONG EDGE RUNS THE LENGTH OF THE VEHICLE
FIT 6 CLEAR TAPE 50x3mm ABRASION RESISTANT TO TUB RAILS DIRECTLY UNDER CLAMP HOLES IN BASE RAILS
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. diagram38).
Diagram: 38 - FIT CLEAR ABRASION TAPE TO TUB
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13mm
4
8Nm
2 FIT TOP ‘L’ CLAMP
LOCTITE 277
6 CLOSE REAR DOOR & CHECK LATCHES ENGAGE 7 ADJUST LATCH STRIKER POSITION (IF REQUIRED)
3 FIT & SLIDE BOTTOM ‘U’ CLAMP
4 APPLY LOCTITE 277 TO BOLTS, FIT BOLT & WASHERS TORQUE TO 8Nm
1 DISASSEMBLE 2 CLAMPS
5 REMOVE & RETAIN KEYS ATTACHED TO INTERIOR REAR DOOR HANDLE
Diagram: 39 - FIT REAR CLAMPS AND CHECK LATCHING
2
4 TIGHTEN 9Nm 2 - FRONT CLAMPS TORQUE TO 9Nm
5 TIGHTEN 2 - MIDDLE CLAMPS TORQUE TO 9Nm
LOCTITE 277
2 FIT REMAINING CLAMPS APPLY LOCTITE 277 TO BOLTS
1 DISASSEMBLE 4 CLAMPS
39. Disassemble two (2) 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 277 (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 2 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 10mm socket adjust and tighten to Torque 6Nm. (ref. diagram39).
40. Disassemble remaining four (4) rail
13mm
13mm
CP0021a
3 TIGHTEN 2 - REAR CLAMPS TORQUE TO 9Nm
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 277 (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. diagram40).
Diagram: 40 - FIT REMAINING CLAMPS AND TIGHTEN ALL 10mm
10mm
6Nm
41. Secure the front of the canopy to the
NYLOC NUT WASHER
CANOPY BASE RAIL AT FRONT
2 SECURE NYLOC NUT AND WASHER
1 FIT BOLT AND WASHER
BOLT
TUB STOP
VEHICLE FRONT TUB SHEET METAL
previously installed front rail tub stop extrusion (ALUM0043-1) with four (4) M6 hex head bolts, eight (8) flat washers and four (4) nyloc nuts as shown. Tighten to Torque 6Nm. (ref. diagram41).
TIGHTEN TO TORQUE 6Nm
Diagram: 41 - SECURE FRONT TUB STOP RAIL Page 16 of 22
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42. 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. diagram42).
1 APPLY MASKING TAPE TO TAILGATE
REAR WINDOW
REAR DOOR SASH
TAILGATE
MASKING TAPE
Diagram: 42- APPLY MASKING TAPE 3 TRIM EXCESS CLEAR ABRASION TAPE
1 25% ISOPROPYL ALCOHOL 75% WATER
4 SQUEEGEE OUT EXCESS SOLUTION BUBBLES
2 APPLY CLEAR ABRASION TAPE
CLEAR ABRASION TAPE
ALIGN BOTTOM EDGE OF CLEAR ABRASION TAPE WITH TOP EDGE OF MASKING TAPE
5 REMOVE MASKING TAPE
CANOPY NOT SHOWN FOR CLARITY Diagram: 43 - APPLY ABRASION TAPE
43. Using a solution of 25% 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. diagram43).
44. (OPTIONAL): Strongly Recommended
1
BULB SEAL FINGER UNDER CLAMP SEAL & AGAINST CANOPY
CANOPY
2
1 2 ALCOHOL WIPE & PRIME SHADED AREA
3 FIT BULB SEAL CLAMP FRAME SEAL
BULB SEAL
TAILGATE
SIDE TUB RAIL
TAILGATE
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 (MISC1365) 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 (MISC2600-1) 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. diagram44).
Diagram: 44 - (OPTIONAL) FIT TAILGATE SEALS
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CP0021a
45. 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. diagram45).
1 CONNECT CANOPY HARNESS TO VEHICLE HARNESS
CHASSIS RAIL
Diagram: 45 - CONNECT VEHICLE & CANOPY CONNECTORS
46. 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. diagram46). CHECK BRAKE LIGHTS WORK
CHECK CANOPY LAMP WORKS
Diagram: 46 - CHECK BRAKE LIGHTS AND CANOPY LIGHT
47. Using alcohol wipe provided in the kit, CABIN
CANOPY
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. diagram47).
TUB
2 FIT ADHESIVE TIE PAD
1
Diagram: 47 - FIT ADHESIVE TIE PAD Page 18 of 22
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CP0021a
48. 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. diagram48).
CABIN
CANOPY
TUB FIT CABLE TIE
Diagram: 48 - SECURE CANOPY HARNESS
ANTI-CLOCKWISE = LENGTHEN
3 ADJUST LENGTH DETAILS TO ADJUST PULLRODS OF PULLRODS BY ROTATION 1 REMOVE INTERIOR 6 REPLACE INTERIOR LOCK COVER LOCK COVER 4 RE-CHECK LOCK FUNCTION
2 UNCLIP PULLRODS FROM RETAINER CLIPS
49. 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. diagram49).
5 CLIP PULLRODS INTO RETAINER CLIPS
Diagram: 49 - WATER LEAK TESTING
50. Clean canopy including all windows PLACE FITTING INSTRUCTIONS IN THE CUSTOMERS LOG BOOK
and vehicle thoroughly . Place fitting instructions in the Customers log book, and ensure pages 20 and 21 of these instructions are discussed with the customer and a copy is given to the customer. (ref. diagram50).
Diagram: 50 - FINAL CLEANING Page 19 of 22
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CP0021a
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 1000 Km. Clamp bolt recommended torque setting is (9 Nm or 6.64 lb/ft). If removed, bolts must have LOCTITE 277 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 3M window channel dresser lubricant sparingly.
DO NOT use CRC, WD40 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 (3) years from the retail date of purchase. 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. 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.
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CP0021a
VW AMAROK - CANOPY OWNERS MANUAL SUPPLEMENT IMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S VEHICLE SERVICE BOOK.
VW Amarok MY10 Onwards
CANOPY
KEY IDENTIFICATION CODE 34
12
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.
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CP0021a
INSTALLATION CHECKLIST Dealer Name:
Dealer Code:
Model:
Stock No:
Order Date:
Order No:
Required By:
Vin No:
Canopy Colour Vehicle Damage Check:
Detail:
Canopy Checklist - Details of rectifications required:
KEY No. :
1. Check paint on canopy 2. Cleanliness of canopy inside and outside 3. Canopy sealing to tray, front tub stop extrusion and foam tape applied correctly 4. Seal around Front of tub, vertical & floor with Silicone after foam tape applied 5. 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 277 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. 10. Operation of Brake Light 11. Operation of interior light 12. Water Tested for leaks 13. Clean up of work area 14. Comment
Fitted By: Vehicle received and Checked by Dealer Staff: Record Canopy Serial Number:
Checked By:
(located on inside LH rear pillar of canopy shell) Page 22 of 22
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