Contents (Click to view).
Contents (Click to view)
Components List
Components List
Components List
Components List
Tools List
Torque Values
Remove the negative terminal before starting.
Remove the tie-downs points at the front of the wellside.
Remove the tie downs at the rear of the wellside.
Ensure these spacers are kept when taking the tie-down points off as these will need to be used when fitting the brackets.
Using the original tie-down points, fit the rear brackets (CP106364/66) using:
M8x35 Bolts
M8 Washers
Loctite.
Tighten to wellside.
Fit the front brackets (CP106363/65) to the wellside using:
M8x35 Bolts
M8 Washer
Loctite
Fit loosely.
Tape prep the front of the wellside for foam tape using tape primer.
Fit 19x9mm foam tape (RS102633) to the front of the wellside.
Urethane both corners as shown.
Use D-type rubber (RS101034) on the side rails (CP106361/62) as shown. Ensure to tape prep with tape primer.
Fit the side rails to the wellside. The rear holes will need to be countersunk to fit CSK bolts.
Tighten the side rails to the rear brackets.
Counter sink the front rail (CP106531) outer holes.
Fit to the front of the wellside.
Fit using CSK Bolts:
M8x25 Bolts
M8 Washers
M8 Nylocs
Tighten to the front brackets.
Tighten the side rails to the front bracket using:
M8x25 Bolts
M8 Washers
M8 Nylocs
Urethane the front of the fitting kits corners neatly.
Remove the bolts from the factory tailgate bracket.
Using an M8 Heavy washer and an M8 flat washer in each groove where the bolts were prior.
Use double-sided tape on the tailgate bracket
Fit the new tailgate bracket over the existing bracket and secure it with the double-sided tape.
Tighten using the factory bolts.
Position 40 mm × 4.8 mm foam tape (RS109360) along the bottom of the canopy. Use additional foam tape in the corners for enhanced sealing, and place protective padding underneath the canopy to avoid scratches while fitting.
Bolt positions for mounting the canopy to the fitting kit.
Bolt to fitting kit
Mount to fititng kit.
Route the wiring up behind the liner and then down the wellside pulling it out the bottom.
Pull the loom down along the top of the chassis to prevent it from being ruined if it scraped on the ground.
Locate this grommet underneath the passenger side cab and punch a hole through it so the loom can pass through.
Route the loom into the cab, putting the grommet into the original spot.
Pull the loom out from underneath the matting in the rear of the cab.
Feed it through the pillar from the back to the front of the cab.
Pull all the way through and clip down as shown.
Connect the loom to the Deutsch plug, and connect the correct colours as shown on this diagram.
Connected to the Deutch plug and ensure to use the green clip to prevent the wires from coming loose.
Connect the relay to the relay holder. Ensure that none of the wires slip out.
Remove the plug from the spot shown. This is located behind the passenger kick panel.
Locate the solid black and white wires and strip 5 mm of instulation of them.
From the incab loom, brown connects to white and green connects to black. Ensure to fully solder and then wrap with electrical tape.
Underneath the door sill on the passenger side, cut open the large loom and locate the thin blue wire; ensure it's not the larger blue wire. and connect to the white wire from the incab loom
Ensure to solder and tape.
Locate the fuse box underneath. Use the next step to find which fuse spot to use.
Where to insert the fuse blade holder.
Remove the factory bolt from the passenger side above the wiring block.
Once the factory bolt has been removed sand the rear to remove paint.
Using an M6 x 20, fit it where the original factory bolt was and place the earth on as shown.
Fit an M6 Nyloc nut to the M6 x 20 bolt and tighten.
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