ROOF RACK CP0003a INSTALLATION …

1 Place these instructions in vehicle s glove box after INSTALLATION is complete03/09/10 Page 1 of 14 INSTALLATION Time:2 Hours (Approximately)IMPORTANT! Read instructions carefully before INSTALLATION . It is strongly recommended that INSTALLATION is conducted by an authorised 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 TOOL LIST - (Not Supplied in Kit) Socket Driver and Sockets - 10mm, 13mm & 17mm Spanners - 10mm, 13mm & 17mm Silicon Dispensing Gun Non Acetic Silicon (Neutral Cure) Torque Wrench - 0-10Nm File / De-burring Tool Non Permanent Marker / Metal Scribe Cleaning Cloths / Rags Steel Rule and Tape Measure Drill and 3mm & 9mm Drill Bits 20mm Hole Saw 10mm Socket Drive Drill Attachment (for 14G Tek Screw)FORD RANGER XL and XLT - (2006 Production Onwards)HOLDEN COLORADO - (2006 Production Onwards)MITSUBISHI TRITON MN - (2009 Production Onwards)

2 ROOF RACKINSTALLATION INSTRUCTIONS(FOR FITMENT TO EGR CANOPIES) CP0003aPLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES. Clean Roof Racks with a milddetergent and water not use abrasivecleaners or Instructions:Roof Racks MaximumLoad to be 2 of 1403/09/10 PARTS CHECK SHEETFORD RANGER / HOLDEN COLORADO ROOF RACKSPARTS IN MAIN CARTONPARTS IN HARDWARE KITPARTS IN ROOF RACK KITCP0003aROOF RACKF ront Bracket LHQty - 1 Front Bracket RHQty - 1 Rear Bracket LHQty - 1 Rear Bracket LHQty - 1 Internal Foam PadQty - 4 External FoamPad - AQty - 2 External FoamPad - BQty - 2 PedestalBracket - AQty - 2 PedestalBracket - BQty - 2 Roof Rack Extrusionwith Endcaps & Keys(RACK0005)

3 Qty - 2 Centre TubeQty - 2 FittingInstructionM10x40mmHex Head BoltQty - 4M10 FlatWasherQty - 8M10 SpringWasherQty - 4M10 HexNutQty - 4M8x25mmHex Head BoltQty - 4M8 FlatWasherQty - 12M8 SpringWasherQty - 8M8 HexNutQty - 4M6x20mmHex Head BoltQty - 14M6 LargeFlat WasherQty - 28M6 SpringWasherQty - 14M6 HexNutQty - 14 Fitting Instruction(FIT- CP0003a )Qty - 1M8 ThreadedBlockQty - 4M8x20mmHex Head BoltQty - 414G Tek ScrewQty - 8(8 Spares)Steel BushQty - 4 Front Tube LHQty - 1 Front Tube RHQty - 1 Rear Tube LHQty - 1 Rear Tube RHQty - 1 Roof Rack KitQty - 1 Hardware KitQty - 103/09/10 Page 3 of 14CP0003aROOF RACKD iagram: 3 - FIT FRONT : 2 - REMOVE EXISTING HARDWARE : 1 - CLEAN INSTALLATION AREAS Thoroughly clean and dry installationareas (canopy and inside of the tub)as shown.

4 (ref. diagram1).Open the rear tailgate and canopy rearwindow. Inside the canopy at the front ofthe tub remove the corner L bracketsand hardware as shown for both sidesof the hardware to secure the front brackets in the next the L brackets. (ref. diagram2).Position the front brackets LH and RH tothe location on the canopy rails where the L brackets were previously brackets to rails using hardwarepreviously removed as to Torque 5Nm. (ref. diagram3).10mm10mm10mm5Nm10mmREMOVE & DISCARD L BRACKETSCANOPYFRONT RHCORNERREMOVE & RETAINHARDWARECANOPYFRONT RHCORNERREPLACEHARDWAREFITFRONT BRACKETSTORQUE TO 5Nm03/09/10 Page 4 of 14 Diagram: 6 - FIT REAR : 5 - DRILL REAR BRACKET.

5 4 - MARK REAR BRACKET HOLE POSITIONSCP0003aROOF RACKFor fitment to a Ford Ranger measure andmark a line 5mm rearward of the rear clampslot edge as fitment to a Holden Colorado measureand mark a line 105mm rearward of the rearclamp slot edge as rear brackets LH & RH against theedge of the canopy side rail and align theedge of the bracket with previously markedlines as the (2) hole positions for each side ofthe vehicle. (ref. diagram4).Carefully and accurately mark and indentthe centrepoints for the (4) previouslymarked holes (2 per side), and drill 3mmpilot holes. Re-drill all holes to 9mm. Remove all burrs and sharp edges.(ref.)

6 Diagram5).Fitment to a Ford Ranger and HoldenColorado please proceed with step 4and step to a Mitsubishi Triton pleaseproceed to step the rear brackets LH and RH onthe canopy rails aligning to previouslydrilled holes (Ranger & Colorado), or slotsin rails (Triton) as clamp brackets to rails using (2) M8x25mm bolts, M8 spring washers(4) M8 flat washers and (2) M8 hex nuts(per side) as to Torque 6Nm. (ref. diagram6).0mm1020304050607080906Nm13mm13 mmTORQUE TO 6Nm5mm105mmMEASURE & MARKLINE 5mm FROMCLAMP SLOT EDGEMEASURE & MARKLINE 105mm FROMCLAMP SLOT EDGEFIT REAR BRACKETSMARK HOLE POSITIONSFORD RANGERHOLDEN COLORADO11 FIT REAR BRACKETSMARK HOLE POSITIONS22 3mm 9mm4321 REARBRACKETM8 HEXNUTM8x25 BOLTM8 FLATWASHERM8 SPRINGWASHERCANOPYSIDE RAILFITREAR BRACKETS03/09/10 Page 5 of 14CP0003aROOF RACKD iagram: 9 - ASSEMBLE REAR TUBESFITREAR TUBE LHORIENTCENTRE TUBEFITREAR TUBE : 7 - ASSEMBLE FRONT.

7 8 - FIT FRONT TUBESO rient one centre tube so the foam padon the brackets is facing up and thebrackets are coming out towards the front tube LH assy into the LHside of the centre tube and the front tubeRH into the RH side of the centre tubeas shown. (ref. diagram7).Fit the front tubes into the vehicle andposition the tube brackets to the outsideof the front secure each side with (3) M6x20hex head bolts, M6 Spring washers (6)M6 flat washers and (3) M6 hex nuts the centre tube so the brackets arelocated against the canopy roof as Tighten only, Do Not Torque.(ref. diagram8). the other centre tube so the foampad on the brackets is facing up and thebrackets are pointing away from the rear tube LH into the LH sideof the centre tube and the rear tube RHinto the RH side of the centre tube asshown.

8 (ref. diagram9).FRONT ASSYCANOPY HIDDEN FOR CLARITYFITFRONT TUBE LHFRONT TUBE LHM6x20 HEX HEAD BOLT(3 PER SIDE)M6 HEX NUT(3 PER SIDE)M6 FLAT WASHER(6 PER SIDE)M6 SPRING WASHER(3 PER SIDE)FRONT TUBE RHCENTRETUBEORIENTCENTRE TUBEFITFRONT TUBE RHFRONT BRACKETS31203/09/10 Page 6 of 14CP0003aROOF RACKD iagram: 12 - LOOSEN TUBES & RE-CHECK HOLES0mm102030405060708090 ROTATETUBES2RE-CHECKHOLE ALIGNMENT POSITIONS3 LOOSENM6 : 10 - FIT REAR : 11 - ALIGN TUBE ASEMBLIES & MARK HOLESFit the rear tubes into the vehicle andposition the tube brackets to the outsideof the rear secure each side with (4) M6x20hex head bolts, M6 Spring washers (8)M6 flat washers and (4) M6 hex nuts the centre tube so the brackets arelocated against the canopy roof as Tighten only, Do Not Torque.

9 (ref. diagram10).Check that the centre tube brackets are evenly positioned inside canopy roof,front and the centre tube s so they areparallel across the canopy, by measuringfrom a flat surface at the front of thecanopy, back to each bracket as alignment across the vehicle andmark the centre of the (4) bracket slotsas shown. (ref. diagram11). holes are marked loosen all M6 boltsfinger tightened in steps 9 and 11, androtate centre tube down away from the roofas shown, to gain access to drill holes incanopy drilling re-check position andalignment of all (4) hole positions marked.(ref. diagram12).0mm102030405060708090 REAR ASSYCANOPY HIDDEN FOR CLARITYVIEW FROMINSIDECANOPYFRONT OF VEHICLEALIGNLEFT TO RIGHT1 ALIGNFRONT TO BACK2 BACABCREAR TUBE LHM6x20 HEX HEAD BOLT(4 PER SIDE)M6 HEX NUT(4 PER SIDE)M6 FLAT WASHER(8 PER SIDE)M6 SPRING WASHER(4 PER SIDE)REAR TUBE RHCENTRETUBEREAR BRACKETS03/09/10 Page 7 of : 15 - DRILL HOLES AND DEBURRCP0003aROOF RACKC arefully re-drill the (4) holes with a 20mm hole saw.

10 Remove all burrs and sharp edges.(ref. diagram15). : 14 - RE-CHECK HOLE POSITIONSIMPORTANT: Before proceeding ensureyou spend some time to recheck the(4) hole positions across the vehicleand down the length of the vehicle. This will ensure the pedestal bracketson the top of the canopy will sit in lineand parallel to the canopy and vehicle.(ref. diagram14).0mm102030405060708090 FRONT OF VEHICLEAABCCBVIEW FROMINSIDECANOPY : 13 - PILOT DRILL HOLESFrom inside the canopy carefully drill the(4) holes with 3mm pilot drill.(ref. diagram13).VIEW FROMINSIDECANOPYVIEW FROMINSIDECANOPY 3mm03/09/10 Page 8 of : 17 - RE-ORIENT TUBES & FIT STEEL : 18 - FIT FOAM PADS TO PEDESTAL BRACKETSD iagram: 16 - APPLY FOAM PADS TO CENTRE TUBECP0003aROOF RACKR emove tape liners from all (4) internalfoam pads, and fit to the centre tubebrackets as shown.