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
Remove the 4 scrivets holding the bed cap using Phillips Screwdriver and Trim Removal Tool.
Remove the bed cap using Trim Removal Tool.
Retain all hardware for reinstall.
Repeat for LHS.
Tools Used
Phillips Head Screwdriver
Trim Removal Tool.
Step 2
Mark the bed cap (RHS shown) with a pen as shown.
Trim the bed cap along the marked line on the inside face.
Deburr and clean the edges.
Repeat for LHS.
Tools Used
Tape Measure
Marking Pen
Multi-Tool
Deburring Tool.
IMPORTANT
All dimensions are in millimeters (mm).
Step 2 (cont.)
Step 3
Remove the four scrivets (A) holding the tub liner as shown. Discard all hardware.
Tools Used
Phillips Head Screwdriver.
IMPORTANT
Perform this step only if the tub liner is fitted.
Step 4
Remove the three torx screws (A) and hooks from tub (if present) and discard.
Place the Paper Template (26) on the tub front RH corner as shown and align with the two holes (B) in the tub \and top edge of the tub liner as shown on the template.
Using a Marking Pan, trace the template on the tub liner as shown. Repeat for LHS.
Tools Used
Marking Pen
T40 Torx Tool
Wrench.
IMPORTANT
Perform this step only if the tub liner is fitted.
Step 5
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 and along the markings for the Reinforcement Brackets (8 & 9).
Deburr and clean the edges.
Note: Lift the tub liner away from the tub during the trimming.
Remove the required fasteners to keep the OE assembled tub liner away from the tub when trimming.
Tools Used
Multi-Tool
Deburring Tool.
IMPORTANT
Perform this step only if the tub liner is fitted.
Step 5
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 and along the markings for the Reinforcement Brackets (8 & 9).
Deburr and clean the edges.
Note: Lift the tub liner away from the tub during the trimming.
Remove the required fasteners to keep the OE assembled tub liner away from the tub when trimming.
Tools Used
Multi-Tool
Deburring Tool.
IMPORTANT
Perform this step only if the tub liner is fitted.
Step 6
In the top rear corner of the tub mark the centre hole position using the tub liner.
If no tub liner is present measure and mark the hole position as shown.
Drill a pilot hole with Ø5mm drill bit.
Pull the tub liner away from the tub and drill Ø38mm hole in the tub liner only.
Drill a Ø30mm hole in the tub for the drain tube.
Repeat for LHS.
Apply Rust Inhibitor.
Tools Used
Hole Saw 30mm & 38mm
Drill
5mm Drill Bit
Deburring Tool
Step 7
In the top front corner of the tub, measure and mark the hole position for the front drain tube (RHS is shown).
Drill through the tub liner (if fitted) and tub a pilot hole with Ø5mm drill bit at the marked position.
Repeat for LHS.
Tools Used
Drill
5mm Drill Bit
Marker
Tape
Step 8
Note: For this step pull the tub liner away from the tub so that the holes are drilled through the tub liner only.
Drill a 2nd pilot hole with Ø5mm drill bit through the tub liner only at 30mm above the previous hole.
Drill a clearance hole in the tub liner only with Ø48mm hole saw at the two pilot holes just drilled.
Note: Remove the tub liner material between the holes to create a slotted hole.
Repeat for LHS
Tools Used
Hole Saw 48mm
Drill
5mm Drill Bit
Deburring Tool
Multi-Tool.
IMPORTANT
Perform this step only if a tub liner is fitted. Pull the tub liner away from the tub when trimming.
Step 9
Enlarge the pilot hole through the tub (at distance 230mm) with a Ø38mm Hole Saw, set a 10mm drill stop.
Repeat for LHS.
Apply Rust Inhibitor.
Tools Used
Hole Saw 38mm.
Step 10
Place the Reinforcement Bracket RH (9) on tub and align with existing holes for reference.
Remove any sealant obstructing the Reinforcement Bracket RH (9) from seating correctly.
Enlarge the hole location (A) to 11mm, set a 10mm drill stop.
Apply rust inhibitor to the hole (A) and where the sealant was removed.
Use a Rivnut Tool to fit the M8 Rivnut (11) in location (A).
Repeat for the LHS.
Tools Used
Drill
11mm Drill Bit
Rivnut Tool
Deburring Tool.
Step 11
Place and secure the Reinforcement Bracket RH (9) to the tub with five M8x30 Torx Screws (13).
Torque to 20Nm.
Repeat for the LHS.
Tools Used
T40 Torx Tool
Torque Wrench.
Step 12
Measure and mark 60mm from the existing hole (A) in the tub rear RHS part of the side rail as shown.
Drill Ø5mm pilot hole followed by Ø10mm drill, set a 10mm drill stop.
Apply Rust Inhibitor.
Repeat for the LHS.
Tools Used
Drill, Ø5mm & Ø10mm Drill Bits and Centre Punch.
BED CAP SEALING
Step 13
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.
IMPORTANT
Always refer to the vehicle’s Workshop Manual when removing vehicle components.
Step 14
Refit the trimmed bed cap using the previously retained hardware.
Enlarge the x2 existing holes in location (A) as shown to 10mm, set a 10mm drill stop.
Apply Rust Inhibitor.
Repeat for LHS.
Tools Used
Drill
10mm Drill Bit
Rust Inhibitor
Phillips Head Screwdriver.
Step 15
Apply Silicone between the Header Bar and bed cap to close the gap.
Spread the Silicone evenly and level with the tub.
Tools Used
Silicone Gun
Step 16
Place the Header Bar (7) on the tub and mark the 3 holes (A) on the front face of the tub using a pen.
Remove the Header Bar (7).
Drill the marked existing holes with a Ø11mm drill, set a 10mm drill stop.
Apply Rust Inhibitor.
Using a Rivnut Tool fit the three M8 Rivnuts (11
Repeat for LHS.
Tools Used
Marking Pen
Drill
11mm Drill Bit
Rivnut Tool
Step 17
Place the Header Bar (7) centrally on the tub along with the Cover Plate (20) and secure with three M8x30 Torx Screws (13).
Torque to 20Nm. Cover Plate (20) should hold the tub liner (A) as show in the detail.
Note: Only install the Cover Plate (20) if a tub liner is fitted.
Tools Used
T40 Torx Tool
Torque Wrench.
Step 18
Install the Mount Extrusion RH (5) as shown and loosely secure with six M8x30 Torx Screws (13) and three Backing Plates (12) as shown in the section view in the next step.
Torque to 20Nm. Cover Plate (20) should hold the tub liner (A) as show in the detail.
Repeat for LHS
Tools Used
12mm socket and Rachet
Step 19
Using a straight edge or metal ruler (C) set the Mount Extrusion RH (5) level with the bed cap (A).
Align with the base of the bed caps, not the raised ridges.
Torque all six M8x30 Torx Screws (13) to 20Nm.
Repeat for LHS.
Tools Used
Metal Ruler
T40 Torx Tool
Torque Wrench.
Step 20
Fit the Rear Drainage Tube (18) through the drilled hole (A).
Note: Spray Rear Drainage Tube (18) with soapy water to help with fitment.
Note: Trim 150mm from the end of each drain tube.
Repeat for LHS.
Tools Used
Soapy Water
Scissors.
Step 21
Fit the Front Drainage Tube (17) through the drilled hole (A).
Note: Spray Front Drainage Tube (17) with soapy water to help with fitment.
Repeat for LHS.
Tools Used:
Soapy Water
Step 22
Remove the bottom part of the rear LHS wheel arch to allow feeding the Vehicle Harness (21) from inside the tub down to the floor.
Install the supplied fuse in the fuse holder on the Vehicle Harness (21).
Note: Feed the black connector on the Vehicle Harness (21) into the tub.
Feed the Vehicle Harness (21) into the tub through the gap in the tub wall as shown.
Connect the Patch Harness (22) to the vehicle harness as shown inside the tub.
Tools Used
Draw Wire
Masking Tape
Step 23
On the LHS under the tub locate the factory harness placed along the chassis rail and remove the blanking plug from the connector (A).
Note: The factory harness may be taped to the vehicle under body. If required for access remove this tape.
Step 22
Secure the Vehicle Harness (21) to the inside panel with adhesive pad in location (A).
Fit the edge clip to the tub in location (B).
Continue routing the Vehicle Harness (21) towards the connector on the inside chassis rail.
Step 23
Connect the Vehicle Harness (21) to the connector (A).
Secure the Vehicle Harness (21) to the tub using the adhesive pad located on the harness in location (B).
ROLLER COVER ASSEMBLY
Step 1
Place the Canister Asm (1) on the protected box as shown.
Pull out hand rail and 3 slats. Ensure hand rail and slat ends are aligned.
Flip over the canister and place on box.
IMPORTANT
During assembly procedure support at centre of the Canister Asm (1) only by placing it on top of carton (base or similar), covered with foam blanket to avoid scratching the powder coated surfaces.
Step 2
Ensure to fit Side Rail RH (3) first. Use the Side Rail Guide (22) to protect the Side Rail RH (3) seal during fitment, it will also help during the Side Rail RH (3) fitment to the Canister Asm (1).
IMPORTANT
Seal must face in the direction as shown. Warranty void if assembled incorrectly.
Step 3
Slide the Side Rail RH (3) over the slat ends and onto the endplate location pins to align the holes.
Remove the Side Rail Guide (25) and reuse on the LHS.
Secure loosely with two M6x15 Screws (15), do not tighten.
Repeat for Side Rail LH (4).
Tools Used
4mm Hex Tool
IMPORTANT
Carefully align and slide the side rail over the handrail and Canister Arm (1) endplate taking particular care to ensure that the side rail is slid straight and no undue force is applied to the side rail.
Details in following steps.
Step 4
Carefully lay the assembly over onto a protected surface.
Check the seal position as shown. Repeat for Side Rail LH (4).
Step 5
Evenly slide the Front Cover (2) over the Canister Asm (1) and into both Side Rails (3 & 4) channels ensuring that the foam tape (B) from under the Side Rails is pulled out (see detail) and the small rubber corner seal (A) on the RHS and LHS of the Front Cover (2) are not damaged.
Tools Used
Soapy Water
IMPORTANT
Spray the Front Cover (2) edge with soapy water to allow it to slide easily into the Side Rails (2 & 4).
Step 6
While sliding the Front Cover (2) ensure the cast connectors are aligned.
Step 7
Using three M6x15 Screws (15), secure the Front Cover (2) to the Canister Asm (1) and torque to 5.5Nm.
Tools Used
Torque Wrench
4mm Hex Tool.
Step 8
Carefully flip the assembly over onto a flat protected surface which will not damage the cover or scratch the paint work.
Install the two M6x15 Screws (15) on each side through the Canister Asm (1) and Side Rails (3 & 4) into the Front Cover (2).
Torque all screws in order shown to 5.5Nm.
Tools Used
Torque Wrench
4mm Hex Tool.
Step 9
Clean powder coated surface first with Alcohol Spray.
Trim foam tape (A) length to ensure the end will butt against Front Cover (1) seal - avoiding any gap.
Peel the protective liner from the foam tape, adhere to the channel in the Side Rail LH (4) and press down firmly to secure.
Repeat for Side Rail RH (3)
Tools Used
Alcohol Spray
Scissors.
Step 10
Connect the Side Rail RH (3) harness connectors to the connectors on the Canister Asm (1) as shown.
Secure the harness to the Canister Asm (1) using a cable tie (A) shown.
Ensure all cables are retained to prevent pinching during installation.
Step 11
Connect the Side Rail LH (4) harness connectors to the connectors on the Canister Asm (1) as shown.
Secure the harness to the Canister Asm (1) using a cable tie (A) as shown.
Ensure all cables are retained to prevent pinching during installation.
Step 12
Install the Rubber Extrusion (19) into each Side Rail (3 & 4) and ensure the Rubber Extrusion (19) seated (note the extrusion orientation).
IMPORTANT
Do not stretch the extrusion while fitting.
Step 13
IMPORTANT
Setting Brace (10) should not be used as lifting device. Measurements are still required as per the Fitting Instructions.
Setting Brace (10) should be removed only when the set up is completed.
Fit the T-Nuts with washers and wing screws as shown to both ends of the Setting Brace (10).
Place the Setting Brace (10) over the rear of the roller cover and slide the T-Nuts into the slots as shown. Once in position, slide the brace backwards until the plastic part of the brace comes into contact with the edge of the rear End Cap.
Note: Setting Brace is equipped with locators at the bottom and those must be fitted into the side rails. Tighten the wing bolt (finger tight only).
Step 14
Spray the top surface of the tub liberally with a soapy water solution to enable the Roller Cover to slide easily.
Using two people lift the Roller Cover from both sides and carefully lower it onto the tub.
Connect the Patch Harness (22) to the ECU as shown.
Note: Ensure rear seals (A) are sitting vertically as shown.
Tools Used
Soapy Water.
Step 15
Apply masking tape at the centre of the tailgate.
Measure the distance between the rear corners of the tub (A) and draw a centre line on the masking tape.
Measure the distance from the marked centre line to both rear corners of the Roller Cover (B) and ensure it is equally distanced.
Tools Used
Tape Measure
Marking Pen
Masking Tape
Step 16
Place masking tape on the tailgate (both sides) and mark 26mm from the inside face of the tailgate (A) as shown.
Adjust the Roller Cover so that the Roller Cover endcap (B) is aligned with the 26mm marking on both ends as shown.
IMPORTANT
Ensure seals are not deformed when lifting the Roller Cover and dropping vertically on tub.
Tools Used
Tape Measure
Marking Pen
Masking Tape
Step 17
Secure the Roller Cover to the Mount Extrusion LH (6) with six M6x20 Screws (14) as shown.
Repeat for RHS.
Torque to 9Nm.
IMPORTANT
Check the clearance between the rear corner casting (A) and the top of tailgate (B), target is 11mm. Open and close the tailgate (B). Adjust the height if required refer to earlier steps.
Tools Used
10mm Socket
Torque Wrench
Step 18
Connect the LED Light (24) to the Side Rail RH (3) harness located underneath.
Fit the LED Light (24) to the Side Rail RH (3) using two Screws M5x15 (15).
Torque to 5.5Nm.
Tools Used
4mm Hex tool
Torque Wrench
Step 19
Perform width and diagonal fitment check (bolts may need loosening for adjustment).
Open and close the Roller cover by hand (push in the clutch), checking for smooth operation and consistent 1.5-2.0mm side to side free-play of slat assembly within Side Rails.
If there are any tight spots, then re-adjust the Side Rail width as described in the previous steps.
Remove the Setting Brace (10).
Tools Used
Tape Measure
Step 20
Connect the Front Drain Tubes (17) to the Canister Arm (1)
IMPORTANT
Make sure that both Front Drain Tubes (17) engage over the wall of the Canister Asm (1). Leakage will occur if they are not properly installed.
Step 21
Connect Rear Drain Tubes (18) to the Side Rails (3 & 4) and secure with Cable Ties (16).
IMPORTANT
Important Make sure that both Rear Drain Tubes (18) engage
over the tub. Leakage will occur if they are not properly installed.
FINISHED PRODUCT