Dust Defence Kit (With Tub Liner)

Read the fitting instructions before install. Use a qualified technician. Recycle packaging. Store removed parts safely. Remove swarf/dust from install surfaces. Follow safety standards. Wear appropriate clothing and equipment.

Step 1 of 18

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 2 of 18

IMPORTANT

For vehicles with tub liner complete steps A & B

Step A:

Open the tailgate.
Mark the top of the tub liner as per the dimensions shown using a Marking Pen.
Remove and retain six scrivets (A).

Note: Take the dimensions from the tub rear edge (tailgate not shown for clarity).

Trim the tub liner along the markings.
Deburr edges.

Tools Used

Multi-Tool
Tape Measure
Marking Pen
Deburring Tool
Ruler

Step 3 of 18

Step B:

Close the tailgate.
Mark the sides of the tub liner as per dimensions shown using a Marking Pen.

Note: Horizontal measurements are taken from the tail gate liner.

Note: Vertical measurements are taken from the tub liner floor.

Remove two scrivets (A).
Trim the tub liner along the markings and deburr edges.
Repeat on LHS.

Tools Used

Multi-Tool
Tape Measure
Marking Pen
Deburring Tool
Ruler

Step 4 of 18

IMPORTANT

Install Dust Defence Kit before installing Fleet Canopy, Premium Canopy, Soft Tonneau Cover and Roller Cover.

Always refer to the vehicle’s Workshop Manual when removing vehicle components.

For vehicles with tub liner complete steps A & B

Step 1

Measure and mark a centerline on the Base Extrusion (2). Measure the tub opening and mark a centerline on the base of the tub (A) with a Marking Pen.

Note: Middle hole in the Base Extrusion is not in the centre.

Place the Base Extrusion (2) on the tub and carefully align the centre line marks.
Set the Base Extrusion (2) at 16mm from the rear edge of the tub (section view).

Note: Remove any excess/interfering sealant using a knife.

Using the pre-drilled holes in the Base Extrusion (2) as a guide, mark the five hole locations (B) onto the tub.
Remove the Base Extrusion (2).
Centre Punch the marked locations (B).

Tools Used

Marking Pen
Ruler
Centre Punch
Knife.

Step 5 of 18

Step 2

Drill the five centre punched marks using a Ø5.5mm Drill Bit with a 10mm Drill Stop.
Clean the swarf and apply Rust Inhibitor to each hole onto the exposed metal surfaces.
Secure the Base Extrusion (2) to the tub (A) with the five Rivets (23).

Tools Used

Drill
Ø5.5mm Drill Bit
Drill stop
Rust Inhibitor
Rivet Gun.

Step 6 of 18

Step 3

Drill out the existing holes (A) & (B) to Ø9mm.
Clean the swarf and apply Rust Inhibitor to the exposed metal surfaces.
Install two Rivnuts (26) to the drilled position.
Repeat for LHS.

Tools Used

Drill
Ø9mm Drill Bit
Rust Inhibitor
Rivnut Gun.

Step 7 of 18

Step 4

Pre-assemble the Pinch Weld Seal (10&11) to the Mount Plate (1).
Repeat for LHS.

Note: Seal may need trimming to obtain dimensions shown.

Tools Used

Ruler
Scissors.

Step 8 of 18

Step 5

Assemble Upper Mount Bracket RH (4) and Mount Bracket RH (6) to Mount Plate (1) using three M6x14 Allen Screws (18), six M6 Washers (20) and three M6 Dome Nuts (25).

Note: The screws should be finger tightened only.

Repeat for LHS.

Tools Used

4mm Allen Key
10mm Spanner.

Step 9 of 18

Step 6

Clean the area on the tub where Foam Pad (12) will be applied, with an Alcohol wipe (30).
Once dry apply Primer (29) to the cleaned area. Allow 2 minutes before installing the Foam Pad.
Apply Foam Pad (12) between the Base Extrusion (2) and the Tub side wall.

Note: Tape must be placed as shown in detail view.

Ensure there is no gap between the Foam Tape and tub side wall.

Please ensure that both Primer and Alcohol wipes are used prior to applying the foam pad.

Repeat for LHS.

Step 10 of 18

IMPORTANT

For vehicles with tub liner Complete steps 12 to 15.

Step 12

When installing the Pre-Assembled Mount Plate (1), the Upper Mount Bracket (4) has to sit on top of the tub liner and the Mount Bracket (6) sits under the tub liner.
With the tub liner moved out of the way install two M8x20 Hex Screws (19) and two M8 Washers (22), underneath the tub liner.
Adjust the Mount Plate (1) so you have a 14mm gap from the plate to the tailgate, once in position tighten the M8x20 Hex Screws (19) to 20Nm, then tighten the M6 Dome Nuts (25) to 8Nm. Repeat for LHS

Note: If the Mount Plate (1) is interfering with the trimmed tub liner, trim to make it fit.

Tools Used

6mm Allen Socket
4mm Allen key
10mm Socket
Torque Wrench

NOTE: Step 7 to 11 are not shown on this fitment video due to this vehicle having a tub liner.

Step 11 of 18

Step 13

Align the hole in the Upper Mount Bracket (4) then using M6x20 Allen Screw (17) and M6 Washer (20) fasten and tighten to 8Nm.
In location B fasten the M6x20 Allen Screw (17) and M6 Large Washer (21) into position on top of the tub liner and tighten to 8Nm.
Tighten the M6 Dome Nut (25) to 8NM.
Repeat for LHS.

Tools Used

6mm Allen Socket
4mm Allen key
10mm Socket
Torque Wrench

Step 12 of 18

Step 14

Install the Bulb Seal (9) starting from the top of the RHS Mounting Plate (1). Use a rubber mallet to tap the seal onto the side plates and base extrusion. Trim the excess suitably.

Tools Used

Rubber Mallet
Side Cutters

Step 13 of 18

Step 15

FOR ROLLER COVER:

Assemble the Retention Clips (8) over the Bulb Seal (9) use three M6x14 Allen Screws (18), six M6 washers (20) and three M6 Dome Nuts (25).
Tighten all Screws to 8Nm.
Repeat for LHS.

FOR FLEET CANOPY, PREMIUM CANOPY, ALUMINIUM TONNEAU COVER OR SOFT TONNEAU COVER:

Assemble one Retention Clip (28) at the top over the Bulb Seal (9) use one M6x14 Allen Screw (18), two M6 Washers (20) and one M6 Dome Nut (25).
Assemble two retension clips (8) at the middle and lower positions using two M6x14 Allen Screws (18), Four M6 Washers (20) and two M6 Dome Nuts (25).
Tighten all Screws to 8Nm.
Repeat for LHS.

Note: Discard unused clips.

Tools Used

4mm Allen key
10mm Socket
Torque Wrench.

Step 14 of 18

Step 16

Trim four scrivets removed in step A down to 20mm as shown
Refit the four trimmed scrivets in locations (A)
Refit two untrimmed scrivets in locations (B)

Tools Used

Scissors
Ruler

Step 15 of 18

Step 17

Fit the Base Extrusion Cover (3 or 16) by aligning the pre-existing holes and secure using four Self Tapping Screws (24).

IMPORTANT

For vehicles with tub liner fit Base Extrusion Cover type B (16)

Tools Used

Phillips Head screwdriver

Step 16 of 18

Step 18

Clean the area on the Mount Plate (1) where Foam Pad (13) will be applied, with an Alcohol wipe (30). Once dry apply Primer (29) to the cleaned area. Allow 2 minutes before installing the Foam Pad (13).
Fit Foam Pad (13) in position shown.
Repeat for LHS.

Step 19

IMPORTANT

For vehicles with a Roller Cover fit Foam Block (15) as shown

Clean the area underneath the Roller Cover side rail (A) where Foam Pad (13) will be applied, with an Alcohol wipe (30). Once dry apply Primer (29) to the cleaned area. Allow 2 minutes before installing the Foam Pad.
Fit Foam Pad (13) in position shown.
Repeat for LHS

Note: Foam Pad (15) to be discarded for any other accessories

Step 17 of 18