Dust Defence Kit (Without 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 14

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 14

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 3 of 14

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 4 of 14

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 5 of 14

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 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 6 of 14

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.

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

Repeat for LHS.

Step 7 of 14

Step 7

IMPORTANT

For vehicles without tub liner Complete steps 7 to 11.
Install the pre-assembled Mount Plate (1) into position shown and secure with two M8x20 Allen Screws (19) and two M8 Washers (22).
Hand tighten M8x20 Allen Screws (19).
Repeat for LHS

Tools Used

6mm Allen key Socket
Ratchet

Step 8 of 14

Step 8

Align the hole in the Upper Mount Bracket (4) with the hole in the tub and secure with M6x20 Allen Screw (17) and M6 Washer (20) and hand tight.
Repeat for LHS.

Tools Used

4mm Allen key Socket
Ratchet.

Step 9 of 14

Step 9

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 10 of 14

Step 10

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 11 of 14

Step 11

Close the tailgate.
Press the side plate assembly down over the Foam Tape (12) and against the tailgate to compress the bulb seal along it’s contact surface to the tailgate.
Also, keep pressing against the tub for Pinch weld seal to compress and seal all along its contact surface.
Torque M6x20 Allen Screw (17) to 8Nm and M8x20 Allen Screws (19) to 20Nm.

Note: When installing Mount Plate (1) press it down and into the side wall of the tub.

Note: Distribute the clearance around bump stop equally.

Tools Used

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

IMPORTANT

For vehicles with tub liner - Complete steps 12 to 16

Step 12 of 14

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 without tub liner fit Base Extrusion Cover type A (3)

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

Tools Used

Phillips Head screwdriver.

Step 13 of 14

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 14 of 14

Step 20

Check and close the gaps by pressing the Pinch Weld Seal (10) against the Tub (A).
Repeat on LHS.

IMPORTANT

Check gap by using torch and adjust the foam tape and seal to eliminate the light gap