General Notes
Read through the fitting instructions before installation of the accessory. Install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or the accessory.
Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local recycling regulations.
It is always recommended that this accessory is fitted by a qualified Kia Technician.
Safely store and protect any removed vehicle components.
Ensure all bare metal surfaces are protected using automotive bare metal primer and touch-up paint, or suitable automotive rust inhibitor.
Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.
Safety Notes
Check that all work practices comply with safety standards.
Please wear appropriate clothing and use safety equipment.
Step 1
IMPORTANT
Always refer to the vehicle’s Workshop Manual when removing vehicle components.
Remove the four scrivets holding the bed cap and lift the bed cap from the tub. Retain all hardware for reinstall.
Repeat for LHS.
TIP: Recommended to use an 8mm Socket to remove the bed cap without breakage.
Step 2
IMPORTANT
All dimensions are in millimeters (mm).
Mark the bed cap (RHS front shown) with a pen as shown.
Drill location A & B with 25mm hole saw, set a 10mm drill stop.
Deburr and clean the edges.
Repeat for LHS.
Tools Used
Tape Measure
Marking Pen
Drill
Hole Saw 25mm
Deburring Tool.
Step 3
IMPORTANT
All dimensions are in millimeters (mm).
Mark the bed cap (RHS rear shown) with a pen as shown.
Drill location C & D with 25mm hole saw, set a 10mm drill stop..
Deburr and clean the edges.
Repeat for LHS.
Tools Used
Tape Measure
Marking Pen
Drill
Hole Saw 25mm
Deburring Tool.
Step 4
IMPORTANT
Perform this step only if the tub liner is fitted.
Mark the line on the tub liner using a pen, 45mm from top of the tub liner.
Trim the tub liner along the marked line on the front face of the tub.
Deburr and clean the edges.
Note: Lift the tub liner away from the tub during the trimming. Remove the
required fasteners to keep the minimum disturbance to the OE assembled
tub liner away from the tub when trimming.
Please note that the corner markings are not applicable for this fitment.
Tools Used
Trimming Tool
Deburring Tool.
Step 5
Mark the centre line on the front header of the tub using a pen, mark 645mm from the centre and 15mm from the front inner wall towards the cab.
Centre punch the top locations (A) and drill pilot hole with 5mm drill, then drill 11mm.
Deburr and clean the edges.
Apply Rust Inhibitor (18).
Tools Used
Measuring Tape
Marking Pen
Drill
5mm Drill Bit
11mm Drill Bit
Deburring Tool
Step 6
Locate the two holes on front face in locations as shown, drill out the two existing holes (A) with an 11mm drill bit, set a 10mm drill stop.
Deburr and clean the edges.
Apply Rust Inhibitor (18).
Use a Rivnut Tool to fit the five M8 Rivnuts (9) as shown.
Tools Used
Measuring Tape
Rivnut Tool, Drill
11mm Drill Bit
Deburring Tool.
Step 7
Place the Header Rail (2) into position.
Secure with M8 x 25 Torx Screws (12) and M8 Small Washers (14).
Torque the screws to 20Nm.
Tools Used
T40 Torx Tool
Torque Wrench.
Step 8
IMPORTANT
Only install cover plate if tub liner is fitted.
Install the Cover Plate (3) on the top of the Header Rail (2) if a tub liner is installed.
Secure the Header Rail (2) with M8x25 Torx Srews (12) and M8 Small Washers (14).
Torque the screws to 20Nm.
Tools Used
T40 Torx Tool
Torque Wrench.
BED CAP SEALING
IMPORTANT
Always refer to the vehicle’s Workshop Manual when removing vehicle components.
Note: This product requires the addition of sealing to the bed cap along
the edge where it will contact the tub.
The 3M double sided tape must be applied underneath the bed cap along the outside edge as shown on the RHS.
Repeat for the LHS.
Step 9
Refit the bed cap (A) using previously retained hardware.
Apply Silicone between the Header Rail (2) and bed cap to close the gap.
Spread the Silicone evenly to be level with the tub.
Repeat for LHS.
Tools Used
Phillips Head Screwdriver
Silicone Gun.
Step 10
Apply Foam Pad (17) next to the bed cap (A), leaving a space to Header Rail (B).
Repeat for LHS.
Step 11
Install Front Side Rail RH (5) and Rear Side Rail RH (7) using four M8x45 Torx Screws (11) and four M8 Small Washers (14) onto the bed caps.
Install M8 Large Washer (13), M8 Nut (16) underneath the tub rail at the front and rear.
Finger tighten only. Do not torque.
Repeat for LHS.
Note: The Sports Bar Bracket is showing in this film due to prior fitment.
Tools Used
T40 Torx Tool
Wrench.
Step 12
Refit the Sports bar.
Apply Loctite 243 to all Sports Bar bolts during reinstallation.
Secure the brackets with two M8x25 Screws (B) retained earlier.
Torque the screws to 20Nm.
Fit the retined Tube Cover RHS (A) by locking the hooks to the tube.
Secure the rear leg with two M8 Nuts (C) and Washer Plate (D) retained earlier.
Torque to 20Nm.
Repeat for LHS.
NOTE: Please follow Sportsbar Fitting Instructions to reinstall the Sportsbar
Step 13
Place the Tonneau Cover (1) onto the Header Rail (2) at the front of the tub.
Note: Ensure the two straps are inside the tub on installation.
Step 14
Secure the Tonneau Cover (1) to the Header Rail (2) using five M6x20 Torx Screws (10) and five M6 Washers (15).
Torque to 8Nm.
Tools Used
T30 Torx Tool
Torque Wrench.
Step 15
Unravel the Tonneau Cover (1) which will expose the latches on the cover, leave the plastic covers on the catches.
Step 16
Set the latches to ensure that the Tonneau Cover (1) fits at the rear within the RH and LH rails, with minimal lateral movement.
Remove the plastic covers (A) to expose the latches.
Step 17
Roll back the Tonneau Cover (1).
Torque the four M8 Screws fixing the side rails to the tub to 20Nm.
Repeat for LHS
Tool Used
T40 Torx Tool
Torque Wrench.
Step 18
Fit the Rubber Caps (19) along the side rails by rolling back the Tonneau Cover (1).
Repeat for LHS
Step 19
Apply Foam (20) & (21) to the Sports Bar legs above the foot cap as shown.
Fit foam blocks in the following order, starting from the Rear RH Leg fit the Side Rail Foam Rear RH (27).
Next fit Side Rail Foam front (25) and Front Rail Foam RH (23) to the
Front RH Leg as shown.
Repeat for LHS
Step 20
Install the two Crossbars (8). Install at one side and then rotate into the opposite side, do this to both the front and rear bars.
Note: There are stickers located on the side rails which show where to
position the Crossbars (8).
Step 21
To close the Tonneau Cover (1) correctly fold over the edges on the side to stretch the cover.
Press down at the rear until the latches click.
Step 22
Open the tailgate (A). Locate latch release tab (B) under the centre rear of the cover and pull in a downward direction to disengage the latches.
Twist the rear rail upward to completely release the latches.
FINISHED PRODUCT