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23/11/11Page 1 of 25
CP0057a
CANOPY INSTALLATION INSTRUCTIONS(2011 Production Onwards)FORD RANGER PX
Clean Canopy with a milddetergent and water solution.
Do not use abrasivecleaners or solvents.Care Instructions:
PLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES.
This Canopy is designed to suit the Ford Ranger PX vehicle.Sports Bars MUST be removed & returned to Customer with all hardware components if required.Cabin Guards MUST be removed & returned to Customer if fitted.Product suits fitment with Ford Genuine bedliner (no cutting or mods required).
Place these instructions in vehicle’s glove box after installation is complete
Installation Time: Approx. 90 Minutes
IMPORTANT!• Read instructions carefully before installation.• It is strongly recommended that installation is conducted by an authorized dealer.• This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.• Recommend installation by 2 people. (4 people will be required to lift Canopy)
RECOMMENDED TOOL LIST - (Not Supplied in Kit)• Loctite 243 thread locking liquid (IMPORTANT)• Phillips Head Screwdriver• Medium Adjustable Spanner• Side Cutters• Sockets 10 & 13mm, Extension Bar and Driver• Spanners 10 & 13mm• Silicon Dispensing Gun• Non Acetic Silicon (Neutral Cure)• Spray Bottle (25% isopropyl Alcohol & 75% Water)• Spray Bottle Water• Torque Wrench - 0-20Nm• T30 Torx Drive Screwdriver• Non Permanent Marker
• Masking Tape• Cleaning Cloths / Rags• Steel Rule and Tape Measure• Scissors (Sharp)• Knife (Sharp)• Squeegee• File or Deburring Tool• Drill & Ø5mm Drill Bit• Engineers Scribe• Rivet Gun for Stainless Steel Rivets• Electrical tape• Light Gauge Plastic Coated Draw Wire
Page 2 of 25 23/11/11
CP0057aFORD RANGER T6 - CANOPY
PARTS CHECK SHEET FORD RANGER T6 - CANOPY
CanopyQty - 1
PARTS IN MAIN CARTON
Rail ExtrusionTub Stop(ALUM0043-2)Qty - 1
Fitting Kit(KIT032464)Qty - 1
Lock Keys(Attached toCanopy InternalRear Door Handle)Qty - 2
PARTS IN FITTING KIT (KIT032464)
PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0043)
Vehicle WiringPatch Harness(LOOM0043)Qty - 1
Cable TiesShort 200mmQty - 5
FittingInstruction(FIT-CP0057a)Qty - 1
Cable TiesLong 600mmQty - 7
Clear Tape Pad50x30mm AbrasionResistant(TAPE0011)Qty - 6
RustInhibitor
Alcohol Wipe(MISC0052)Qty - 4
AUTOMOTIVESURFACE CLEANER
IMPREGNATED WITH 70% ISOPROPYL ALCOHOL
For use in cleaning painted metal,glass and other vehicle surfaces.For external use only.Dispose of properly after use.
Rust InhibitorSatchet(MISC2776)Qty - 1
Primer Stick(MISC1365)Qty - 6
Vehicle WiringPatch Harness Kit(LOOM0043)Qty - 1
Double SidedTape 4026GHBWH1.14x12mm 1.7m(TAPE0615)Qty - 1
Bulb Seal 70mmCut Length(MISC2600-1)Qty - 2
Rivet (FAST0505)Qty - 4
104x35mm BlackLabel Sticker(LABL1441)Qty - 3
Kit - RailClamps(CNPY0007)Qty - 6
Clear AbrasionTape Roll(TAPE0611-1)Qty - 1
Bedrail Tape 20x8mm 5.5M(TAPE0625)Qty - 1
M6x20 ScrewHex Head SS304(SCRW0028)Qty - 2
M6x1.2mm ThickFlat Washer19mm OD6.5mm ID(WASH0169)Qty - 2
M6 Nyloc NutSS304(NUTS0016)Qty - 5
FittingInstruction
M6x25 ScrewAlun Head SS304(SCRW0845)Qty - 5
M6x2.5mm ThickFlat Washer25mm OD6.5mm ID(WASH0201)Qty - 5
M6 SpringWasher(WASH0103)Qty - 2
Blackout Decalfor Brake Lamp(LABL1486)Qty - 1
23/11/11Page 3 of 25
CP0057aFORD RANGER T6 - CANOPY
Remove four (4) screws in the front rail of the tub, repeat for other side.(ref. diagram1).
1.
2.
Diagram: 2 - APPLYING BLACK DECALS
3.
Diagram: 3 - REMOVE HIGH MOUNT STOP LAMP SURROUND
Diagram: 1 - REMOVING SCREWS FROM TUB
VIEW LOOKING UP INTO LEFT FRONT CORNER
Clean front rail of the tub where screwshave been removed, using alcohol wipe(MISC0052).Using the black decals (LABL1441), coverthe holes as shown on the diagram.One decal must be cut in half andused on the front facing hole. Repeat forboth sides.Note: The front outside hole must stayexposed.(ref. diagram2).
SLIDE LAMP SURROUND OFF BY LIFTING FROM THE TOP
AND PULLING FORWARD1
REMOVE SCREWS
1
VIEW LOOKING UP INTO LEFT FRONT CORNER
APPLY DECALS
IMPORTANT!THIS HOLE BOTHSIDES MUST BE
UNCOVERED
1
Remove high mount stop lamp surround, bylifting it from the top and pull forward.Clean and dry the surface.(ref. diagram3).
23/11/11Page 4 of 25
CP0057aFORD RANGER T6 - CANOPY
Refit the lamp surround. (ref. diagram5).5.
2
REFIT THE SURROUND1
Diagram: 5 - REINSTALL THE STOP LAMP SURROUND
2ALIGN THOSERADII TO THELAMP EDGES
3
POSITIONDECAL ONTHE LAMP
1
Remove backing paper from brake lampblackout decal (LABL1486) at one side foronly the first 50mm. Fold backat 45deg toexpose adhesive.At one side align outside radii on the decal tothe edges of the lens. Adhere first corner. Peel back remaining liner ensuring position ismaintained to the lamp. Fold back tags ondecal to wrap around the lamp. Ensure goodadhesion by rubbing with soft clean soft cloth.(ref. diagram4).
4.
Diagram: 4 - APPLY THE BLACKOUT DECAL
PEEL ONE SIDE
23/11/11Page 5 of 25
CP0057aFORD RANGER T6 - CANOPY
8. Starting with a small amount of the tapefrom the double sided tape roll 12mm wide(TAPE0615) with green liner film, apply it starting from the corner of the front rail to the other side, along the rear edge of the front tub rail pressing down on the liner as you apply the tape across the vehicle as shown. Apply firm pressure to ensure the tape adheres to the vehicle. (ref. diagram8).
Diagram: 8 - FIT 3M TAPE 12x1700mm
APPLYDOUBLE SIDED 12x1700mm ROLL(TAPE0615) ACROSS FRONT RAIL
STOP
7. Using alcohol wipe (MISC0052) clean thetop surface of the front rail and wipeaway residue with a dry clean cloth.If heavy cleaning is required use Iso-Propyl alcohol and wipe away residuewith a dry clean cloth.Apply (MISC1365) primer stick along the width of the front tub rail as shown all theway across side to side of the front tub railand allow to dry. (ref. diagram7).
Diagram: 7 - APPLY PRIMER TO THE FRONT RAIL
1
2
APPLYPRIMER STICK
TO SHADED AREAALONG FRONT RAIL
SIDE RAILOF TUB
SIDE RAILOF TUB
SIDE TUBRAIL
TOP VIEW OF FRONT OF TUB
TOP VIEW OF TUB
TOP SURFACEOF FRONTTUB RAIL
TOP SURFACEOF FRONTTUB RAIL
TOP SURFACEOF FRONT TUB RAIL
6. Thoroughly clean and dry installationareas (tub, rear of cabin and glass)as shown.Clean front of canopy including the frontwindowUsing cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the canopy. (ref. diagram6).
Diagram: 6 - CLEAN & DRY INSTALLATION AREAS
POSITIONCARDBOARD TUBPROTECTION MAT
2
13
23/11/11Page 6 of 25
CP0057aFORD RANGER T6 - CANOPY
9.
10.
Using alcohol wipes provided, clean the tape contact surfaces of the (ALUM0043-2)rail extrusion tub stop.Apply (MISC1365) primer stick to high-lighted area over full length of the railand allow it to dry. (ref. diagram9).
Remove the green liner film from the double sided tape applied to the front tub rail.Fit rail extrusion tub stop (ALUM0043-1)to the front rail of the tub over the tape aligning the rail evenly to gaps to sides ofthe tub.IMPORTANT: Ensure the short face sitsover the front rail, and the long face withslots overhangs into the tub as shown.Ensure the slots at each end are alignedwith the holes in the tub.Apply firm pressure forward and down onthe rail extrusion tub stop along the lengthto ensure maximum adhesion of the foamtape. (ref. diagram10).
Diagram: 10 - FIT FRONT TUB STOP EXTRUSION
APPLYFIRM PRESSURE TO
ADHERE TAPE
1
TOP VIEW OF THERAIL EXTRUSION TUB STOP
RAIL EXTRUSIONTUB STOP
TAPE
FIT FRONTTUB STOP
HOLES
ALIGN HOLES
CROSS SECTIONTHROUGH FRONT RAIL OF TUB
FRONTRAIL
11.
TOP SURFACE FRONT OF TUB - TOP VIEW
RAIL EXTRUSION TUB STOP
12
Diagram: 9 - CLEAN & PRIME FRONT TUB STOP EXTRUSION
20mm
LOCTITE243
4
(=)(=)
3
2
Diagram: 11 - SECURE TUB STOP WITH BOLTS
IMPORTANT! Apply Loctite 243(not supplied), minimum 20mm alongthe thread on the bolts.Secure the tub stop extrusion to the tub,using two (2) M6x20 hex bolts, M6 spring washers and M6 flat washers through the two (2) front slots as shown. Tighten the bolts to Torque 9Nm.(ref. diagram11).
9Nm
12mm
12mm
TIGHTEN TWO (2) BOLTS TO TORQUE 9Nm4
2
3
1M6x20
HEX BOLT
M6 SPRINGWASHER
M6 FLATWASHER
23/11/11Page 7 of 25
CP0057aFORD RANGER T6 - CANOPY
Diagram: 12- SECURE FRONT TUB RAIL WITH RIVETS
CONTINUE ON THE NEXT PAGE
13.Using alcohol wipes provided clean alltop rail areas of the tub and wipe awayresidue with a dry clean cloth. If heavycleaning is required use Iso-Propylalcohol and wipe away residue with adry clean cloth using priming stick (MISC1365) prime top rails of the tub whereEPDM foam tape will be applied in (step 14).(ref. diagram13).
Diagram: 13 - VEHICLE SURFACE PREPARATION
12. Measure out ,mark and drill four (4) Ø5mm holes into the front rail tub stop and tub rail using dimension’s as shown.Rivets must secure to flat form on tub.Apply rust inhibitor (MISC2776) to all drilled holes in the tub sheet metal.Secure with four (4 ) stainless steel rivetsas shown. (ref. diagram12).
FIT FOUR (4) RIVETS
200
100 400400
Ø5mmRust
Inhibitor
(x4)2 3 4
4
USE “V” NOTCHIN RAIL
VERTICAL SECTION VIEW THROUGHFRONT TUB RAIL AND TUB STOP RAIL FITTED
TAILGATE OFVEHICLE
TOP VIEW OFVEHICLE TUB
CA
BIN
OF
VEH
ICLE
25mm
1 2
10mm25mm
23/11/11Page 8 of 25
CP0057aFORD RANGER T6 - CANOPY
NOT SUPPLIED
Diagram: 15 - APPLY SILICON
23
4
5
6
Apply EPDM foam tape (TAPE0625) fromhardware kit to the vehicle tub bed rails andrail extrusion tub stop.IMPORTANT: DO NOT CUT FOAM TAPE,IT MUST BE APPLIED IN ONE CONTINOUSLENGTH!Starting from one side at the rear corner.As the tape bends around the corners ensure the tape sits flat and DOES NOTpucker. Trim off excess to the edge of thetub rail as shown.Ensure all foam tape areas are fully adheredto the tub and tub stop by applying moderatepressure down on the tape all the wayaround the tub. (ref. diagram14).
14.
Diagram: 14 - INSTALL WATER SEALING TAPE
APPLYEPDM FOAM TAPEAROUND BED RAIL
TAILGATE OFVEHICLE TOP VIEW OF
VEHICLE TUB
CA
BIN
OF
VEH
ICLE
START AT THEEDGE OF THE
TUB RAIL ON THEREAR EDGE RADIUS
SECTION ATREAR OFVEHICLE
POSITIONEPDM FOAM TAPEON THE EDGE OF
THE INSIDE RADIUSALONG THE SIDE RAILS
POSITIONEPDM FOAM TAPE
10mm REARWARD OFTHE EDGE OF THERAIL EXTRUSION
TUB STOP
ALONGSIDE RAILS
ALONGSIDE RAILS
FOAM TAPE MUST NOTPUCKER AROUND CORNERS
FINISH OVERTHE EDGE OFTHE TAILGATE
TRIM EXCESS TOTHE EDGE OFTHE TUB RAIL
ALONG FRONT RAILWITH TUB STOP
10mm
15. With a clean cloth wipe down all areas ofthe internal front tub corners to besiliconed as shown. Spray areas to besiliconed with water, Do Not dry, to allowthe silicone to flow better.Apply non-acetic silicon (neutral cure)(not supplied) to the top of the tub and tubstop around the foam tape and inside thetub at the join between the front and sidepanels, ensure all gaps on the tub is siliconsealed properly. Re-spray silicon withwater and push silicon into gaps and cleanup excess silicon. Repeat process for theother side of the vehicle.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram15).
1
EPDM FOAMTAPE
TOP VIEW FRONT LEFT HAND CORNER OF TUB
INTERNAL VIEW INSIDE THE TUB
APPLYNON ACETIC SILICON
(NEUTRAL CURE)
FRONTTUB STOP
FRONTTUB STOP
1
1
1
APPLYNON ACETIC SILICON
(NEUTRAL CURE)
2
2
2
50 mm
50 mm
23/11/11Page 9 of 25
CP0057aFORD RANGER T6 - CANOPY
DO NOT SLIDE CANOPYON EPDM FOAM TAPE
AND SILICON
2 FITCANOPY TO
VEHICLE
1 TAPEWIRING HARNESS
TO LH SIDE WINDOW
3FEED
CANOPY HARNESSBETWEEN TUB AND
CABIN DOWN TOCHASSIS RAIL
HARNESS
FRONT TUB STOPRAIL (ALUM0043-2)
17. Approximate weight of canopy 70Kg.Four people (minimum) are required forthis step.First tape the wiring harness to the lefthand side window with masking tape.Position the canopy onto the vehicletub carefully. IMPORTANT: Ensure canopy is placedfully forward on the tub in one action.DO NOT slide the canopy on the EPDMfoam tape and silicon, as this candamage the foam tape and spread thesilicon (break the water seal).Remove masking tape and feed canopyharness down between tub and cabin (righthand side of vehicle) so it is accessibleunder the vehicle on the outside of thechassis rail. (ref. diagram17).
Diagram: 17 - FIT CANOPY TO TUB
18. Position canopy on the tub, from in the interior of the canopy, the front face of the aluminium extrusion on the canopy should be aligned to the edge of the tub stop rail(ALUM0043-2).Positioning is critical. Too far forwardthe rear door may not close properly. Too far to the seal at the bottom ofthe rear door may not seal. (ref. diagram18).
Diagram: 18 - ALIGN CANOPY TO TUB
+70Kg
16. With a clean cloth wipe down all areas tobe siliconed as shown. Spray areas to besiliconed with water, Do Not dry. Applynon-acetic silicon (neutral cure) (notsupplied) to the top of the tub to fill the gapto the ends of the tub stop rail. Run a 10mmbead of silicon around the corners for a length of 250mm each way as shown. Repeat process for the other side of the vehicle. IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram16).
Diagram: 16 - APPLY SILICON
NOT SUPPLIED
APPLYNON ACETIC SILICON
(NEUTRAL CURE)
EPDM FOAMTAPE
FRONTTUB STOP
VEHICLE CABIN NOT SHOWN FOR CLARITY
50mm
CANOPY
SECTION VIEW - CHECK ALIGNMENT FROM INSIDE
ALUMINIUMEXTRUSION
50 mm
CANOPY BASERAIL AT FRONTAND TUB STOPRAIL ALIGNED
(USE A STRAIGHTEDGE OR RULER)
VEHICLEFRONT TUB
SHEET METAL
23/11/11Page 10 of 25
CP0057aFORD RANGER T6 - CANOPY
20. Open rear tailgate to check sidewaysalighment. Using a steel ruler positionthe canopy so both canopy base side railsare even to the width of the vehicle tub.(ref. diagram20).
19. Open rear tailgate. Position the canopy sothe center slot in the front lower canopy railis aligned with the slot in the front tub stop.Fit the M6x 25 alun dome head bolt (SCRW0845) and loosely secure with M6washer 2.5mm thick (WASH0201) and M6 nyloc nut (NUTS0016).(ref. diagram19).
VEHICLE CABIN AND REAR DOOR NOT SHOWN FOR CLARITY
SECTION VIEW
Diagram: 20 - ALIGN CANOPY TO TUB
Diagram: 19 - ALIGN AND SECURE LOOSELY CANOPY TO TUB
A=BA B
10mm 11Nm
10mm
1FIT BOLT
M6 NYLOC NUT AND WASHER
ALUN DOMEHEAD BOLT
LOOSELY SECURENYLOC NUT AND WASHER
2
23/11/11Page 11 of 25
CP0057aFORD RANGER T6 - CANOPY
22. Fit two clamps (CNPY0007) to the rear holes in the canopy base rails both sides by fitting the top L clamp down through the hole in the rail and sliding the lower U clamp along the side rail over the clear abrasion tape.IMPORTANT! Apply Loctite 243(not supplied), minimum 20mm alongthe thread on the bolts.(ref. diagram22)
23.
DISASSEMBLE2 CLAMPS
CLICKCLICK
1X CLICK
FITTOP ‘L’ CLAMP
1
1
2
4
FIT & SLIDEBOTTOM
‘U’ CLAMPAPPLY
LOCTITE 243 TO BOLTS,FIT BOLT & WASHERS
TORQUE TO 8Nm
5REMOVE & RETAIN KEYSATTACHED TO INTERIOR
REAR DOOR HANDLE
3
8Nm
13mm
13mm
Diagram: 22 - FIT REAR CLAMPS AND CHECK LATCHING
21. Fit six (6) abrasion resistant clear tape 50x3mm pieces (TAPE0011), to the vehicle tub rails directly under the square holes in the canopy base rails for the clamps as shown. Orient the tape so the long edge runs the length of the vehicle as shown. Position half of the tape on the front face of the rail and fold the remaining half around onto the backof the rail. (ref. diagram21).
Diagram: 21 - FIT CLEAR ABRASION TAPE TO TUB
FITHORIZONTALLY6 CLEAR TAPE
50x3mm ABRASIONRESISTANT TO TUB
RAILS DIRECTLYUNDER CLAMP HOLES
IN BASE RAILS
Diagram: 23 - FIT REAR CLAMPS AND CHECK LATCHING
20mm
LOCTITE243
4
TUBCLEAR TAPE
SECTION VIEW
ADJUSTLATCH STRIKER
POSITION(IF REQUIREDTORQUE 9Nm)
CLOSE REARDOOR & CHECK
LATCHES ENGAGE2X CLICKS OK
2(OPTIONAL)
UNSCREW CLAMPAND MOVE CANOPY
BACK OR FORTH(TORQUE 8Nm WHILE
ADJUSTING)
CLICKCLICK
Secure the clamps with the bolts andwashers as shown. Tighten to Torque 8Nm. Remove and retain the keys attached to theinterior rear door handle. Close the rear doorfirmly, holding the centre handle withoutslamming it too hard. IMPORTANT NOTE!: Latch has 2 stages of engagement. Ensure canopy engages withsecond stage of latch and the lower reardoor seal, seals against the tailgate. If required loosen clamps (CNPY0007) andadjust the canopy position foreward andrearward, re-tighten to Torque 8Nm andre-check latching. You may also need toadjust the latch striker hoops, loosenbolts with a 10mm socket adjust andtighten to Torque 9Nm. (ref. diagram23).
23/11/11Page 12 of 25
CP0057aFORD RANGER T6 - CANOPY
TAILGATE
REARDOOR SASH
MASKINGTAPE
REAR WINDOW
APPLYMASKING TAPETO TAILGATE
1
26. With the canopy rear door closed, applya length of masking tape to the reartailgate, level with the bottom edge ofthe canopy rear door sash, when viewedfrom the rear horizontal position as shown.This will assist in positioning the clearabrasion tape applied to the top of thetailgate in the next step. (ref. diagram26).
Diagram:26- APPLY MASKING TAPE
DISASSEMBLE4 CLAMPS
1FIT
REMAINING CLAMPSAPPLY
LOCTITE 243 TO BOLTS
2
3
TIGHTEN2 - REAR CLAMPSTORQUE TO 11Nm
4TIGHTEN
2 - FRONT CLAMPSTORQUE TO 11Nm
5
TIGHTEN2 - MIDDLE CLAMPSTORQUE TO 11Nm
11Nm
13mm
13mm
24.
Fit the four remaining clamps to the remaining holes in the canopy base rails by fitting the top L-clamp down through thehole in the rail and sliding the lower U clampalong the side rail over the clear abrasion tape.IMPORTANT! Apply Loctite 243(not supplied), minimum 20mm alongthe thread on the bolts.Secure the clamps with the bolts andwashers as shown.IMPORTANT! Re-tighten the front clampsfirst, middle clamps second and the rearclamp towards the door, third to torque11Nm. (ref. diagram25).
Diagram: 25 - FIT REMAINING CLAMPS AND TIGHTEN ALL
20mm
LOCTITE243
2
Diagram: 24 - SECURE FRONT TUB STOP RAIL
25.
Secure previously installed front rail tubstop extrusion (ALUM0043-2) to thecanopy front base rail spacer using four (4) M6 alun dome head bolts (SCRW0845),2.5mm thick M6 flat washers and M6 nyloc nuts as shown.IMPORTANT! Tighten center bolt first, tigten middle bolts second and tigten outer bolts third to Torque 11Nm. (ref. diagram24).
10mm
TIGHTEN TO TORQUE 11Nm
TIGHTEN TO TORQUE 11Nm
1
CANOPY BASERAIL AT FRONT
2
VEHICLEFRONT TUB
SHEET METAL
TIGHTEN TO 11Nm
11Nm
10mm
3
SECTION VIEW
M6 NYLOC NUT AND
2.5mm WASHER
ALUN DOMEHEAD BOLT
23/11/11Page 13 of 25
CP0057aFORD RANGER T6 - CANOPY
CLEARABRASION
TAPE
TRIMEXCESS CLEARABRASION TAPE
3
REMOVEMASKING TAPE
CANOPY NOT SHOWN FOR CLARITY
5
SQUEEGEE OUTEXCESS SOLUTION
BUBBLES
41
25% ISOPROPYLALCOHOL
75% WATER
APPLYCLEAR
ABRASION TAPE
ALIGNBOTTOM EDGE
OF CLEAR ABRASIONTAPE WITH TOP EDGE
OF MASKING TAPE
2
27.
28.
Using a solution of 25% isopropyl alcoholand 75% water in a spray bottle (not -supplied) Thoroughly spray along the topof the tailgate. Remove liner from clearabrasion tape. Working from one end witha 5mm overhang, place liner on the tailgate. Trim excess tape leaving a 5mm overhangat both ends of the tailgate.When in position use a squeegee to pushout any excess water solution and bubbles.Using a sharp knife or scissors, trim tape to end of tailgate.You may need to squeegee a few times.When finished the tape is virtuallyinvisible. To ensure a good finish please take carean do not rush this step. Remove maskingtape. (ref. diagram27).
Diagram: 28 - (OPTIONAL) FIT TAILGATE SEALS
Diagram: 27 - APPLY ABRASION TAPE
30mm
CANOPY
TOP VIEW
SEAL MUST OVERHANG THETAILGATE TO MEET OVER GAP
TO SIDE OF THE TUB
FIT BULB SEAL
ALCOHOLWIPE &PRIME
SHADEDAREA
1 2
3
TAILGATE
1 2
29. Disconnect existing vehicle harness connectors under the rear left hand of the car near the chasis rail and spare tyre.(ref. diagram29).
Diagram: 29 - DISCONECT REAR CONNECTOR UNDER LEFT HAND SIDE
20mm8mm
DISCONNECTEXISTING VEHICLE
HARNESS CONNECTORS
CROSSSECTIONOF SEAL
1
Using alcohol wipe provided clean directlybelow the rear door clamp seal andwipe away residue with a dry clean cloth.Using priming stick (MISC1365) prime areadirectly below the rear door clamp seal. Apply only a light amount both sides of tailgate in this area, and allow to dry. Apply bulb seal 70mm (MISC2600-1) totailgate as shown in the top view pictureopposite. Position bulb seal so it's fingerseals against the underside of theclamp frame seal as shown in the sectionview and position it’s cut end in line with theouter edge of the tailgate as shown.Mark lines with non permanent marker andcurve the seal as it is put on as shown.Repeat on right hand side of tailgate.(ref. diagram28).
LEFT HAND SIDE OF TAILGATE
23/11/11Page 14 of 25
CP0057aFORD RANGER T6 - CANOPY
5
4
6
7
Diagram: 31 - RUN HARNESS ALONG CHASSIS RAIL
31. Run the vehicle harness (LOOM043) along the chassis rail with existing wiring, up to the front left hand wheel arch as shown. Fit cable ties in sequence listed.Trim excess cable tie length with side cutters.Ensure harness is run in a direct route fromthe rear of the vehicle to the front.(ref. diagram31).
CONTINUE ON THE NEXT PAGE
3
CHASSIS RAIL
SEE STEP 32,30
SEE STEP 32
SEE STEP 32
SEE STEP 32
SEE STEP 32
VEHICLEHARNESS
(LOOM0043)
1
30. Connect the wiring loom (LOOM0043)into the vehicle harness as shown.(ref. diagram30).
Diagram: 30 - CONNECT LOOM INTO EXISTING VEHICLE CONNECTOR
CONNECTEXISTING HARNESS CONNECTORS
TO THE VEHICLE HARNESSCONNECTORS
2
1
CANOPYVEHICLE
LOOM(LOOM0043)
SEE STEP 32,34
SEE STEP 32,33
23/11/11Page 15 of 25
CP0057aFORD RANGER T6 - CANOPY
5
4
6
7
32.
3
1
At the rear left hand side of the vehicle locate the existing harness connectors and disconnect them.Connect the tail lamp connectors to the vehicle harness (LOOM0043) connectors as shown.
Run the vehicle harness along the left hand chassis rail, then follow the chassis rail to left hand fire wall. Ensure the harness is positioned away from the exhaust system. Ensure the canopy connector is positioned onthe chassis rail between the tub and the cabin as shown. Secure the vehicle harness with cable ties.Position cable ties away from fuel lines, brake cables, moving parts and flexible mounts to body.Trim excess cable tie length with side cutters.Ensure harness is run in a direct route from the rear of the vehicle to the front. (ref. diagram32).
Diagram: 32 - CONNECT & RUN VEHICLE HARNESS UNDER THE VEHICLE
REAR LEFT HANDSIDE OF VEHICLE
FRONT OF VEHICLE
2
CABLE TIE (200mm LONG) TIE TO THE MAIN VEHICLE HARNESS
CABLE TIE (200mm LONG) TIE TO THE MAIN VEHICLE HARNESS
CABLE TIE (200mm LONG) TIE TO THE VEHICLE MAIN WIRING HARNESS BETWEEN VEHICLE TUB
AND CABIN, AT THIS POSITION THE CONNECTOR TO THE CANOPY SHOULD BE POSITIONED (SEE STEP 34)
CABLE TIE (200mm LONG) TIE TO THE MAIN WIRINGHARNESS ABOVE AXLE
FROM OUTSIDE PULL LOOM THROUGH UNDER PLASTIC WHEEL LINER AND TUCK THE LOOM
BACK UNDER THE LINERS (SEE STEP 33)
USE A (600mm LONG) CABLE TIE BEFORE ENTRY OFLOOM UP THE FIRE WALL INTO THE ENGINE BAY
AT THE ENTRY OF LOOM INTO ENGINE BAY ENSURELOOM IS RUN ABOVE BRAKE LINES JUST BEFORE
THE FIRE WALL BEGINS UNDER THE CAR
CABLE TIE IN 3 POSITIONS TO TOP OF CHASSIS RAILWITH (600mm LONG) CABLE TIES. BE CAREFUL TO
POSITION AWAY FROM BRAKE LINES ANDEXHAUST SYSTEM
23/11/11Page 16 of 25
CP0057aFORD RANGER T6 - CANOPY
33. Feed the wiring loom along the chassisrail above the rear wheel and tuck the loomback in under the plastic wheel arch liners. Leave the canopy loom conector behindthe plastic wheel arch liner at the front.(ref. diagram33).
Diagram: 33 - CANOPY CONNECTOR LOCATION
FRONT OF THE CAR
IMPORTANT!CONNECT TO THE
POSITIVE TERMINALON BATTERY
CLIP WIRINGHERE
1
CONNECTR FOR CANOPY LOOM1
35. Feed the wiring loom along thechassis rail up the fire wall into the vehicleengine bay. Clip the corrugated harnessinto the white plastic clip on the fire wall and feed along the side fender and between the fuse box and the battery.Connect the loom into the positive terminal of the battery, as shown. (ref. diagram35).
Diagram: 35 - CONNECT THE LOOM UNDER THE HOOD
2
Feed the canopy and vehicle wiringharnesses to the gap between the tuband the cabin under the left hand plasticwheel arch liner.Join the connectors from the canopy andvehicle wiring harnesses together.Using a cable tie secure the vehiclewiring harness only to the existing mainwiring harness as shown.(ref. diagram34).
34.
Diagram: 34 - SECURE CANOPY HARNESS
CONNECTHARNESS
CONNECTORS
1CABLE TIEVEHICLEHARNESS
TO EXISTINGHARNESS
EXISTINGHARNESS
CANOPYHARNESS
TYRE
PLASTIC WHEELARCH LINERS
VEHICLEHARNESS
2
INSIDE PASSENGERSIDE REAR TYRE
CHASSIS RAIL
23/11/11Page 17 of 25
CP0057aFORD RANGER T6 - CANOPY
PLACE FITTING INSTRUCTIONSIN THE CUSTOMERS LOG BOOK
Diagram: 38 - FINAL CLEANING
Diagram: 37 - WATER LEAK TESTING
37.
38.
Water test canopy checking for water leaks.Test both canopy keys work to lock andunlock the rear door and side lift up window.Open both side windows.If the rear door handle does not lock,remove the interior lock cover, unclip thepull rods and wind to lengthen them slightly.Re-check rear door lock function.When rear door locks replace interior lockcover, and add the canopy keys to the customers vehicle keys. (ref. diagram37).
Clean canopy including all windowsand vehicle thoroughly .Place fitting instructions in theCustomers log book, and ensurepages 18 and 19 of these instructionsare discussed with the customer anda copy is given to the customer. (ref. diagram38).
DETAILS TO ADJUST PULLRODSADJUST LENGTH
OF PULLRODS BY ROTATION
ANTI-CLOCKWISE = LENGTHEN
3
REMOVE INTERIORLOCK COVER
UNCLIP PULLRODSFROM RETAINER CLIPS
REPLACE INTERIOR LOCK COVER
RE-CHECKLOCK
FUNCTION
4
CLIP PULLRODSINTO RETAINER CLIPS52
16
CHECKCANOPY LAMP
WORKS
36. Two people are required to check thecanopy brake light is operational afterdepressing the brake pedal.Then open the rear window and checkthat the internal canopy lamp is operatingcorrectly when switched to the ’ON’position only. (ref. diagram36)NOTE: It will not operate in “DOOR”position. A seperate accessory can be purchased to operate the light automatically when the rear door is opened.
Diagram: 36 - CHECK BRAKE LIGHTS AND CANOPY LIGHT
CHECKBRAKE LIGHTS
WORK
CP0057aFORD RANGER T6 - CANOPY
23/11/11Page 18 of 25
Place these instructions in vehicle’s glove box after installation is complete
IMPORTANT!• Please carefully check if the canopy has been fitted as per original fitting instruction, if canopy needs repositioning, please follow the steps from canopy fitting instruction ( you may require new hardware kit items such as clamps, foam sealing tape, etc to reposition the canopy ).• Read instructions carefully before installation.• It is strongly recommended that installation is conducted by an authorised dealer.• This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.• Recommend installation by 2 people.
RECOMMENDED TOOL LIST - (Not Supplied in Kit)
CANOPY REAR DOORPULL ROD & LATCH STRIKERADJUSTMENT INSTRUCTIONS
(FOR USE DURING CANOPY FITMENT)
• 10mm Socket, Extension Bar and Driver• 10mm Spanner• Torque Wrench - 0-10Nm• 150mm Steel Rule• Phillips head screwdriver
PLEASE USE THESE INSTRUCTIONS TO ADJUST PULLRODS AND LATCH STRIKERSWHEN THE CANOPY HAS BEEN FITTED TO THE VEHICLE AND YOU ARE FITTING THE
REAR CLAMPS AND CHECKING OPERATION OF THE REAR DOOR.
CP0057aFORD RANGER T6 - CANOPY
23/11/11Page 19 of 25
IMPORTANT!Remove and retain the keys that may be attached to the interior rear door handle. Open the side windows. With the vehicles tailgate closed, close the rear door firmly from the center of the door without slamming it too hard.NOTE: Latch has 2 stages of engagement. Ensure canopy engages with second stage of latch and the lowerrear door seal, seals against the tailgate. Check both the rear door clamp frame seal has sealed and the lower door sash seal is sealed and the latches have engaged to second stage. If you can not close the rear door to second stage, please check the scenarios below. If door closes properly, also check operation of the lock using the keys to lock it. Pull on the handle to open. If the door unlocks follow scenario 4 below. POSSIBLE SCENARIOS:
Rear door latch strikers engaged in 2 stage latching. Door seal not properly contacting the tailgate.Follow stage 1 for adjustment instruction.
Rear door seal contacting tailgate but latch striker not engaging second stage.Follow stage 2 for adjustment instruction.
Rear door does not close, due to latch striker being mis-aligned to latch.Follow stage 2 for adjustment instruction.
Unable to lock-unlock rear door or unable to reopen rear door.Follow stage 3 for adjustment instruction.
ISSUES REQUIRING ADJUSTMENT OFREAR DOOR PULL RODS AND LATCH STRIKERS
STAGE 1- NOT SEALING AT TAILGATE
1.
Diagram: 1 - CHECK AND ADJUST REAR DOOR LATCH STRIKER
Adjust the rear door latch striker hoops, byloosening the bolts with a 10mm socket andadjust the striker bracket and tightento Torque 9Nm. Close the rear door firmly,from centre of lower rear door sash withoutslamming it too hard.NOTE: Latch has 2 stages of engagement.Ensure canopy engages with secondstage of latch and the lower rear doorseal is compressed against the tailgate.(ref. diagram1).If there is not enough travel in the strikerhoops for repositioning them, the canopyposition on the tub must be moved forward. To seal the door to the tailgate.
LOOSENLATCH STRIKERHOOPS BOLTS
10mm
1
PLEASE ENSURE CANOPY IS POSITIONED AS DETAILED IN MASTERCANOPY FITTING INSTRUCTIONS IN THE CORRECT POSITION ON THE TUB.
1.
2.
3.
4.
CP0057aFORD RANGER T6 - CANOPY
23/11/11Page 20 of 25
STAGE 2- DOOR NOT CLOSING PROPERLY
3.
Diagram: 3 - CHECK AND ADJUST REAR DOOR LATCH STRIKER
Diagram: 4 - REFIT REAR DOOR LATCH COVER
Diagram: 2 - CHECK AND ADJUST REAR DOOR LATCH STRIKER
Adjust the rear door latch striker hoops, byloosening the bolts with a 10mm socket andadjust the bracket so the striker lines up withthe opening in the latch, than tighten strikerhoops to 6Nm. Check the door closes tosecond stage with the vehicle’s tailgate closed.Adjust the position of the strikers until you arehappy with the second stage latching, forceand closing effort. Tighten strikers to 9Nm.NOTE: Ensure canopy engages with secondstage of latch and the lower rear doorseal, seals against the tailgate.(ref. diagram3).
4. Refit rear door latch covers and gently replacescrews to avoid striping thread.(ref. diagram4).NOTE:If there is not enough travel in the strikerhoops for repositioning them, the canopyposition on the tub must be moved rearward, or steps 5,6,7 can be attempted.
2. With the side window open remove latch coverby unscrewing phillips head screw holding thecover on.Check and adjust if neccesery the rear doorlatch striker hoop so it avoids hitting the side metal support of the latch mechanism on closing.You will have to climb inside the tub to watch the striker position as you pull therear door towards its closing position.(ref. diagram2).
ADJUSTLATCH STRIKERHOOPS UNTIL
ALIGHNED WITH LATCH
CLOSE REAR DOOR &CHECK 2 STAGE LATCHING &DOOR SEALS ON TAIL-GATE
LOOSENLATCH STRIKER
SCREWS
TORQUETO 9Nm
10mm
6
3
4
REFITREAR DOOR
LATCH COVER
7
SECURELATCH COVERWITH SCREW
8
ADJUSTLATCH STRIKER HOOP
MUST NOT TOUCH SIDEMETAL LATCH AREAS
2
5
10mm
REMOVE SCREW ANDLATCH COVER 1
STRIKERHOOP
ROTARYLATCH
AVOID STRIKER HOOP HITINGSIDE METAL WORK SUPPORTOF THE LATCH MECHANISM
ON CLOSING
CP0057aFORD RANGER T6 - CANOPY
23/11/11Page 21 of 25
STAGE 2 CONTINUED
Diagram: 5 - LOOSEN REAR DOOR LATCH STRIKER BRACKET
5. Loosen the two (2) M6 bolts and hex nutssecuring the lower rear corner bracket to thecanopy side rail as shown.Repeat for the other side of the vehicle.IMPORTANT: Do not remove hardware,only loosen enough to slide bracket.(ref. diagram5).
REAR DOORNOT SHOWN FOR CLARITY
10mm
LOOSENM6 BOLTS & NUTS
6.
Diagram: 6 - GENTLY PULL CANOPY & TIGHTEN BOLTS
7. Measure distance from edge of the baserail to the edge of the lower rear bracketas shown in diagram 7.Record the value and adjust the other side to the same value, after checking if the canopydistance to the tab tailgate is not even both sides, (please check by measuring to the tailgate)Then the canopy position should be moved.Alternatively adjust the opposite side rail lowerrear corner brackets more or less to compensate.Then follow steps 5 and 6 again.(ref. diagram7)
Two (2) people are required for this step.Work right hand side first.One person will need to gradually and firmlypull the canopy frame directly rearward on thevehicle as shown. Second person to tighten thetwo M6 bolts to Torque 9Nm when the lowerrear bracket has been pulled rearward. Closethe rear door firmly, from centre of lower reardoor sash without slamming it too hard.NOTE: Ensure canopy engages with secondstage of rotary latch.Ensure from inside the canopy the seal onthe lower door sash still seals to the tailgate.Ensure when inside the canopy, the sealon the rear door clamp frame still seals tothe glass edges down the sides.(ref. diagram6).When latching and sealing is achieved proceedto next step for the other side.
REAR DOORNOT SHOWN FOR CLARITY
GENTLY PULLCANOPY FRAMEREARWARD ONTHE VEHICLE
TORQUE TO 9Nm
MEASURE DISTANCE
10mm
8Nm
Diagram: 7 - MEASURE DISTANCE
10mm
8Nm
1
3
0mm
10
20
30
40
50
60
70
80
90
0mm
10
20
30
40
50
60
70
80
90
CP0057aFORD RANGER T6 - CANOPY
23/11/11Page 22 of 25
STAGE 3 - LOCK NOT WORKING / ADJUST CORRECTLY
Diagram: 8 - CHECK REAR DOOR & LATCHING OPERATION
8. With both side windows open, test bothrear door keys work to lock and unlock the rear door.If the rear door handle does not lock,remove the interior lock cover (step1),unclip the pull rods (step2) and wind tolengthen (step3) them slightly untill the safetyrelease lever reaches 1mm gap or less!It must not be more than this! (step4).Repeat the pull rod adjustment on theopposite side. Clip pull rods into retainer clips (step5).Check with the latch covers removed and manually closing each of the rotary latches. Adjust pull rods until both latches can be heard to operate simultaneously. Close the door and re-check the door handlelocks with the key. When pulled on thedoor handle should now not unlatch thedoor until the key unlocks it.Then replace interior lock covers x3 and screws x4 (step6).Add the canopy keys to the customersvehicle keys. (ref. diagram8).
OPEN & CLOSEREAR DOOR TO
CHECKLOCK OPERATION
CLOSE REAR DOOR &CHECK 2 STAGE LATCHING &DOOR SEALS ON TAIL-GATE
10mm1
2
DETAILS TO ADJUST PULL RODS
ADJUST LENGTHOF PULL RODS BY ROTATION
ANTI-CLOCKWISE = LENGTHEN
3
REMOVE INTERIORLOCK COVER
UNCLIP PULL RODSFROM RETAINER CLIPS
REPLACE INTERIOR LOCK COVER
LATCH COVERREMOVED FOR
CLARITY
ADJUST PULL RODSUNTILL THE SAFETY LEVER
REACHES 1MM GAP
4
CLIP PULL RODSINTO RETAINER CLIPS5
2
1
6
1.0mm GAP
23/11/11Page 23 of 25
CP0057aFORD RANGER T6 - CANOPY
KEY IDENTIFICATION CODE
1234
MAZDA BT-50 MY10 Onwards CANOPY
Please write the key identification code in the boxes above,and retain this copy with the vehicle service history.
Replacement keys can be purchased from your local dealer.
OWNERS MANUAL SUPPLEMENTIMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S
VEHICLE SERVICE BOOK.
23/11/11Page 24 of 25
CP0057aFORD RANGER T6 - CANOPY
WARNING! - SAFETY!• Do Not use the canopy as a passenger compartment.• Do Not operate/drive vehicle with fold up windows or rear door open. They must be closed when vehicle is in motion.• Do Not store or transport volatile materials, such as solvents, chemicals or liquids as fumes may accumulate inside canopy. Do Not allow solvents, chemicals or oils to come in contact with the canopy. If this should occur clean the canopy immediately with a mild detergent and water solution.• Do not stand/sit or rest heavy objects on Canopy.• Do not fill volatile liquid containers while inside canopy such as fuel cans.• VEHICLES FITTED WITH A BED LINER: Static electricity can cause fire when fuel is pumped into ungrounded fuel containers or equipment (eg: motorcycles, chainsaws etc..). Do Not fill fuel containers or equipment within the vehicle tray as static electricity can cause fuel to ignite, resulting in damage, injury or death. To avoid electricity build-up, place fuel container or equipment on the ground before filling.
MaintenanceOnly use mild detergents or wax polish. Do Not use abrasive compounds on painted or plastic finishedcanopy surfaces.The gas struts are self lubricating and should only be cleaned with a damp cloth, when regularly cleaningthe vehicle. Premature seal failure will result if solvents or lubricants are used to clean struts.Gas struts must be orientated as installed, cylinder (wide end) to canopy and rod (narrow end) to glass.Lightly coat the door and window rubber assemblies with a silicon spray after cleaning periodically.Only locks and lock recesses are to be lubricated with Graphite Powder.Vaseline may be used on the rotary catches on the rear door.DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.Check canopy attachment clamps every 1000 Km.Clamp bolt recommended torque setting is 11Nm.If removed, bolts must have LOCTITE 243 re-applied and be re-tightened on refitting to specified values.CHECK regularly that all screws and fasteners holding windows and doors are tight.The rear tailgate protection tape must be replaced periodically to minimize paint scuffing caused by the canopy rear door opening and closing.For sliding windows use a silicon based Non-Aerosol lubricant or a dry film lubricant or LY70 lubricant or 3Mwindow channel dresser lubricant sparingly. DO NOT use CRC, WD40 or petroleum based lubricants on sliding windows.
Warranty TermsEGR warrants that the ABS Canopy will be free from defects in material and workmanship for a period of three (3) years from the retail date ofpurchase. The gas struts are warranted for one (1) year from the retail date of purchase.This warranty only applies to the original purchaser and is nontransferable. Warranty must be claimed with original sales receipt for proof of purchase.
ExclusionsThis warranty does not cover failure due to neglect, improper installation, including any modifications to installation hardware, alterations, additionof non genuine equipment, abuse, accident, normal wear and tear, lack of maintenance, misuse, and exposure to chemicals that are not safe forplastics or hardware components. Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Canopy is sole responsibility ofthe vehicle owner and operator. Paint wear to the vehicle bed can happen with any Canopy and is the sole responsibility of the vehicle owner.Paint damage to your vehicle is not covered under this warranty.
DisclaimerIn the event that your EGR Canopy is found to be defective under the terms of this warranty, it is at the discretion of EGR to repair or replace thedefective part. Transportation costs and labour are not associated with this warranty claim.
OWNERS MANUAL SUPPLEMENTIMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S
VEHICLE SERVICE BOOK.
23/11/11Page 25 of 25
CP0057aFORD RANGER T6 - CANOPY
Dealer Name:
Model:
Order Date:
Required By:
Canopy Colour
Canopy Checklist - Details of rectifications required: KEY No. :
Vehicle Damage Check: Detail:
Dealer Code:
Part No of Canopy:
Order No:
Vin No:
1. Check paint on canopy
2. Cleanliness of canopy inside and outside
3. Canopy sealing to tray, front tub stop extrusion and foam tape applied correctly
4. Seal around Front of tub, vertical & floor with Silicone after foam tape applied
5. Tailgate clear abrasion wear tape fitted
6. Position canopy on tub squarely side to side, rear door closes on second stage latch (not just first latch) both sides and lower door sash seal, seals to tailgate, adjust strikers and /or door latch pull rods via access to centre door handle by removing internal door handle cover
7. Clamps are square and tight (Torque 11Nm)
8. IMPORTANT! Loctite 243 applied to all Clamp Bolt Threads
9. Rear Door, Side Door’s and Front window operation, side windows lock with keys. Check rear door handle and locks with keys. If not locking remove interior cover on rear door handle and adjust the pull rods by winding them in/out and test the door again, replace cover.
10. Operation of Brake Light
11. Operation of interior light
12. Water Tested for leaks
13. Clean up of work area
14. Comment
Record Canopy Serial Number: Checked By:
Vehicle received and Checked by Dealer Staff:
Fitted By:
INSTALLATION CHECKLIST
(located on inside LH rear pillar of canopy shell)