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.
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 (TUB PREPARATION)
Process
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.
Tools Used:
Phillips Head Screwdriver
Step 2
Process
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
Process
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
Note: Perform this step only if the tub liner is fitted.
Process
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.
Tools Used:
Trimming Tool
Deburring Tool.
Step 5
Process
Mark the Centre line on the front header of 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 out to 11mm.
Deburr and clean the edges.
Apply Rust Inhibitor (16).
Tools Used:
Measuring Tape
Marking Pen
Drill
5mm and 11mm Drill Bit
Deburring Tool.
Step 6
Process
Locate the two holes (A) on front face in locations as shown and drill out the two existing holes (A) with 11mm drill bit.
Deburr and clean edges.
Apply Rust Inhibitor (16).
Use a Rivnut Tool to fit the five M8 Rivnuts (7).
Tools Used:
Measuring Tape
Rivnut Tool
Drill
11mm Drill Bit
Deburring Tool.
Step 7
Process
Place the Header Rail (2) into position.
Secure with three M8x25 Torx Screws (10) and M8 Small Washers (12).
Torque screws to 20Nm.
Tools Used:
T40 Torx
Torque Wrench
Step 8 (Bed Cap Sealing)
Important: Only install Cover Plate (3) if tub liner is fitted.
Process
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 Screws (10) and M8 Small Washers (12).
Torque the screws to 20Nm.
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.
Tools Used:
T40 Torx
Torque Wrench.
Step 9
Process
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 and level with the tub.
Repeat for LHS.
Tools Used:
Phillips Head Screwdriver
Silicone Gun.
Step 10
Process:
Install Side Rail RH (5) and secure with four M8x45 Torx Screws (9) and four M8 Small Washers (12).
Install M8 Large Washer (11) and M8 Nut (14) underneath the tub rail at the front and rear.
Finger tighten only. Do not torque.
Repeat for LHS.
Tools Used:
T40 Torx Tool
Wrench.
Step 11
Process
Locate the screws (A) on each side and loosen by a few turns this will enable you to slide the Tonneau Cover (1) into the Side Rails (4).
Place the Tonneau Cover (1) on the Header Rail (2).
Note: Ensure the two straps are inside the tub on installation.
Tools Used:
Phillips Head Screwdriver.
Step 12
Process:
Fully tighten the screw (A).
Repeat for LHS.
Note: Ensure the two straps are inside the tub on installation.
Tools Used:
Phillips Head Screwdriver.
Step 13
Process
Secure the Tonneau Cover (1) to the Header Rail (2) with five M6x20
Torx Screws (8) and M6 Washers (13).
Torque to 8Nm.
Tools Used:
T30 Torx Tool
Torque Wrench.
Step 14
Process:
Unravel the Tonneau Cover (1) which will expose the latches on the cover, leave the plastic covers on the catches.
Step 15
Process:
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 16
Process:
Roll back the Tonneau Cover (1).
Torque the four M8 Screws fixing the side rails to the tub to 20Nm.
Repeat for LHS
Tools Used:
T40 Torx Tool
Torque Wrench.
Step 17
Process:
Fit the Rubber Caps (15) along the side rails by rolling back the Tonneau Cover (1).
Repeat for LHS
Step 18
Process:
Install the two Crossbars (6) 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 best to position the Crossbars (6).
Step 19
Process:
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 20
Process:
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 upwards to completely release the latches.
Final Product