SUBARU FORESTER - SIDE STEP DIESEL VERSION … Slide Tabs as shown & slide four (4) slide tab assemblies into the back of each aluminium step as shown. See Dia #14. Important : Ensure

VEHICLE DESCRIPTION:PART NUMBER:

SUBARU FORESTERSACC2040

TOOLS & EQUIPMENT REQUIRED

13mm and 17mm Socket

½” Drive Ratchet

13mm and 17mm Spanner

Right Angle Drill

Ø3.5mm, Ø6mm, Ø10mm, Ø15mm & Ø30mm Drill Bit

10mm Socket

10mm Spanner

Cleaning Materials

Pliers

150mm Adjustable Spanner

Scissors

Tape

Non Permanent Marker

R

L

SS0012

page 1 of 11

PLACE THESE INSTRUCTIONS IN VEHICLE’S GLOVE BOX AFTER INSTALLATION IS COMPLETE.

SUBARU FORESTER - SIDE STEP DIESEL VERSIONINSTALLATION INSTRUCTIONS

20/04/10

IMPORTANT

Read instructions carefully before installation. It is strongly recommended that installation is conducted by a Subaru Dealer, using a vehicle hoist. This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.

1819 1

20

1 21

Clean Side Steps with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions: Side Step Max. Load.

150KgMAX.

COMPONENTS LIST

NO.

123456789

101112131415161718192021222324252627282930313233343536

Aluminium Step - LHAluminium Step - RHBar - LHBar - RHBracket MountingSpacer - Ø19x15mmSpacer - Ø19x25mmCup Head Bolt M8x65mm LongM10 Flat WasherM10 Spring WasherM10 Hex NutScrew M10x30mmScrew M8x50mmScrew M8x80mmM8 Flat WasherM8 Spring WasherCup Head Bolt M8x30mmM8 Hex NutBolt TabConnector (LHFC) *Connector (LHRC) *Connector (RHRC) *Connector (RHFC) *M8 In-Pull NutSmall Christmas Tree ClipLarge Christmas Tree ClipAlcohol WipesRubber TreadM6 Hex NutsM6 WashersM6 Spring WashersM6 In-Pull NutSpacer - Ø19x20mmSpacer - Ø19x50mmSlide TabRust Inhibitor

11114224866222

14148

10211112

1241188442281

5. 6. 7. 8. 9.

10. 11. 12.

1. 2.

3. 4.

13. 14.

15. 16. 17. 18. 19.

20.* 21.* 22.* 23.* 24.

25.

35.

26. 27. 28. 29.

30. 31.

36.

32. 33. 34.

* Use (4-letter code) found on part to identify.

COMPONENT QTY

SS0012

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SUBARU FORESTER - SIDE STEPS DIESEL VERSION

20/04/10

1. Remove one (1) fastener from front wheel arch as shown. Thoroughly clean & dry the installation area. Repeat process on the other side of the vehicle. See Dia #1.

Diagram #1

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.

REMOVE FASTENER (x1)

- Use (4-letter code) found on part to identify.*RUST

INHIBITOR

page 3 of 11 20/04/10

3. Fit bar to rear of the vehicle with the cup head bolt M8, M8 flat washers & M8 spring washers, M8 hex nut as shown above. Finger tighten only at this stage. See Dia #2.IMPORTANT: Ensure RH Angle Ext is fitted to RHS of vehicle & LH Angle Ext to the LHS of vehicle.

Diagram #3

4. Remove front rubber plug & fit one (1) bolt tab as shown. Fit angle ext to front of the vehicle with one (1) M8 hex nut, M8 flat washer & M8 spring washer as shown above. Tighten front M8 hex nut & rear screw M10x30mm to Torque 20Nm. See Dia #4.

Diagram #4

REMOVE UNDERTRAY

CUP HEAD BOLT M8

RH & LHBAR

SS0012SUBARU FORESTER - SIDE STEPS DIESEL VERSION

2. Remove the undertray and cut it as shown. Install the Cup Head Bolt M8 into the LH & RH BAR, as shown. See Dia #2.

Diagram #2

FRONT OFVEHICLE

REMOVE RUBBER PLUG

FIT BOLT TAB

1

2

BOLT TAB

M8 FLATWASHER

M8 SPRINGWASHER

M8 HEX NUT

BAR

VEHICLE MOUNTM8 FLAT WASHER

M8 HEX NUT

CUP HEAD BOLT M8 BAR

BAR LH & RHDETAILED VIEW FROM

REAR OF VEHICLE

RHSLHS

M8 SPRING WASHER

RHS SHOWN

VEHICLE MOUNT

BAR

42 95

40100

70

Ø30 155

70120

65

110

222

35

Ø30 30

Ø30mm

Diagram #7

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20/04/10

5. Using a non permanent marker, mark the two (2) hole positions as shown for both sides of the vehicle. See Dia #5.

Diagram #5

MARK THETWO (2) HOLE

POSITIONS

6. Remove bars from both sides of the vehicle. See Dia #6.

7. Centrepunch the four (4) previously marked hole positions.Drill four (4) pilot holes (Ø3.5mm), then re-drill to Ø10mm.Apply rust inhibitor to all drilled holes. See Dia #7.

Diagram #6

REMOVE BAR

5mm

Ø3.5mmØ10mm

RUSTIN

HIBITO

R

1

2

3

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20/04/10

8. Install four (4) M6 in-pull nuts to the previously drilled holes as shown. See Dia #8.

Diagram #8

9. Re-fit the bars back on both sides of the vehicle as per steps 3 and 4. See Dia #9.

Diagram #9

10. At the rear of the vehicle remove the outboard hex head bolts & discard, for both sides of the vehicle as shown. See Dia #10.

Diagram #10

REMOVE & DISCARD HEX HEAD BOLT

FRONT OFVEHICLE

ANGLE EXT

RHS SHOWN

FITM6 IN-PULL NUT

M6 IN-PULL NUT

RE-FIT BAR

13. Fit one (1) cup head bolt M8x65mm through the rear hole in the angle ext, position one (1) bracket mount to the rear of the vehicle & secure loosely with one (1) M8 flat washer, M8 spring washer & M8 hex nut. Install one (1) spacer - Ø19x50mm & secure loosely with one (1) screw M8x80mm, M8 flat washer & M8 spring washer. Finger tighten screw M8x80mm & M8 hex nut. Repeat step 13for the other side of the vehicle. See Dia #13.

Diagram #13

12. Install one (1) M8 in-pull nut at the front of the vehicle as shown. Fit one (1) cup head bolt M8x65mm through the front hole in the angle extrusion, position one (1) bracket mount to the front of the vehicle & secure loosely with one (1) M8 flat washer, M10 spring washer & M8 hex nut. Install one (1) spacer - Ø19x20mm & secure loosely with one (1) screw M8x50mm, M8 flat washer & M8 spring washer. Finger tighten screw M8x50mm & M8 hex nut. Repeat step 12 for the other side of the vehicle. See Dia #12.

Diagram #12

1 CHASSIS RAIL

ANGLEEXT

FRO

NT

WH

EEL

FITM8 IN-PULL NUT

M8x65MM CUP HEAD BOLTM8 IN-PULL NUT

M8 FLATWASHER

BRACKETMOUNT

M8 FLATWASHER

M8 SPRINGWASHER

SCREWM8x50mm

M8 SPRING WASHER

M8 HEX NUT

BARSPACERØ19x20mm

SPACERØ19x15mm

SPACERØ19x25mm

M8x65MM CUPHEAD BOLT

BAR

M8 FLATWASHER

BRACKETMOUNT

M8 FLATWASHER

M8 SPRINGWASHER

SCREW M8x80mm

M8 SPRINGWASHER

M8 HEX NUT

SPACERØ19x50mm

11. Re-install the undertray. See Dia #11.

Diagram #11

SS0012

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20/04/10

RE-INSTALL UNDERTRAY

14. Insert the eight (8) M8 cuphead screws into the eight (8) slide tabs as shown. Fit Rubber Tread to Side Step Groove and trim,repeat process for all Grooves on both steps. Orient Slide Tabs as shown & slide four (4) slide tab assemblies into the back of eachaluminium step as shown. See Dia #14. Important : Ensure both Side steps are pre-assembled before proceeding to next step.

Diagram #14

SS0012

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20/04/10

SLIDE TABSLIDE TABASSEMBLY

ALUMINIUM STEP

1 4

x4 (Per Step)x8 (4 Per Step)

M8 CUPHEADSCREW

IMPORTANT: Repeat steps 15 & 16 for LHS of the vehicle.

REAR CONNECTORRHS (RHRC)

REMOVETAPE LINER

SCPU0004 RHRC

15. Remove tape liner. Fit front connector to side step and align the 3 pre-drilled holes. Fit three (3) small christmas tree clips into theholes. See Dia #15.

Diagram #15

16. Remove tape liner. Fit rear connector to side step and align the 3 pre-drilled holes. Fit three (3) small christmas tree clips into theholes. See Dia #16.

Diagram #16

3FIT FRONT CONNECTORTO SIDE STEP

2

1 3FIT REAR CONNECTORTO SIDE STEP

2

1

FRONT CONNECTOR RHS (RHFC)

REMOVETAPE LINER

SCPU0004 RHFC

ATTACHSMALL

CHRISTMASTREE CLIPS

ATTACHSMALL

CHRISTMASTREE CLIPS

2

2

3

SLIDE TABS SLIDE TABS

RUBBERTREAD

ALUMINIUM STEP

Fit Rubber Tread toStep & Trim leaving

15mm of Tread outsideof step both ends.

Orient Slide Tabs BeforeFitting to Side Step.

18. Clean the area on the vehicle that the tape will come into contact with using an alcohol wipe as shown and wipe away residuewith a dry, clean cloth. Prime areas the tape will contact the vehicle using a small amount of the primer stick from the Flare Kit.Position the aluminium step and connectors onto the vehicle, inserting the slide tab assemblies into the mounting brackets and alignthe connectors to the vehicle as shown. See Dia #17. IMPORTANT : Ensure RH Step is fitted to RHS of vehicle & LH Step to the LHS of vehicle.

Diagram #17

SS0012

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20/04/10

18. Loosely fasten the aluminium step assy to the front & rear mounting brackets using four (4) M8 flat washers, M8 spring washers and M8 nuts as shown. Do not tighten at this stage. See Dia #18.

Diagram #18

ATTACHALUMINIUM STEP

RHS SHOWN

REAR


FRONT

SIDESTEP

M8 SPRINGWASHER

(x2)

M8 FLATWASHER

(x2)

M8 NUT(x2)

SIDESTEP

M8 SPRINGWASHER (x2)

M8 FLATWASHER

(x2)M8 NUT

(x2)

3

1 2

NO.

1

2

3 &4

5, 6, 7 & 8

Screw M8x80mm

Screw M8x50mm

M8 Hex Nut

M8x30mm Cup Head Bolt

20Nm

15Nm

20Nm

20Nm

COMPONENT TORQUE

SS0012

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20/04/10

20. Fit one (1) large christmas tree clip to secure front connector to the vehicle as shown. Apply firm pressure to tape area to ensure maximum adhesion. See Dia #20.

Diagram #20

ENSURE GAPIS EVEN FORLENGTH OF STEP

19. (1) person is required to support & adjust the step, & (1) person will be required to tighten all the hardware as specified below. First - Adjust the step In & Out from the vehicle ensuring connectors fit up to the vehicle. Tighten the inboard bolt on the rear bracketto 20Nm, then the inboard bolt on the front bracket to 15Nm. Check step is still aligned to vehicle. Tighten nut on rear bracket then the nut on the front bracket to 32Nm as shown.Second - Adjust the step Up & Down on the vehicle so an even gap exist between the vehicle & the step for the entire length of the vehicle and the connectors fit up to the vehicle. Tighten the nut at the rear of the vehicle closest to the rear wheel to 20Nm, followed by the Nut at the front of the vehicle closest to the front wheel to 20Nm as shown. Check step is still aligned to vehicle. Tighten the final nut on the rear bracket to 20Nm, followed by the remaining nut on the front bracket to 20 Nm as shown above. See Dia #19.

Diagram #19

IMPORTANT: Repeat step 19 for LHS of the vehicle.

13mm 13mm

REAR - RHSFRONT - RHS

IMPORTANTPlease read the full instruction before starting to tighten & lock the Step Assembly into position.

Follow the Numbers as Illustrated to prevent any twist or movement while tightening all Bolts & Nuts.Apply a Torque to all Bolts and Nuts detailed in this step.

FRO

NT

WH

EE

L

2 4571 3 6 8

ATTACH LARGECHRISTMASTREE CLIP

1

APPLY FIRMPRESSURE

2

SS0012

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20/04/10


Do Not drive the vehicle for 24 Hours (Minimum) after installation,to allow Tape to Cure, to ensure Maximum Adhesion

Do Not use an Automatic Car Wash for 24 Hours (Minimum) afterinstallation, to allow Tape to Cure, to ensure Maximum Adhesion

21. Apply firm pressure to tape area on rear connector to ensure maximum adhesion. Drill a Ø6mm hole in the plastic wheel arch through the existing hole in the rear connector. Fit one (1) large christmas tree clip to secure rear connector to the vehicle as shown. See Dia #21.

Diagram #21

1APPLY FIRMPRESSURE

DRILL Ø6MMHOLE

FIT LARGECHRISTMASTREE CLIP

2

Ø6mm

3

SS0012

page 11 of 11

SUBARU FORESTER - SIDE STEPSDIESEL VERSION

CARE AND USE INSTRUCTIONS

20/04/10

Dear Customer,

Congratulations on the purchase of your EGR Accessory Product.

Below are some important requirements on maintaining the condition of Aluminum side steps and connector trim mouldings installed to your vehicle. Please read themcarefully to ensure they remain in excellent condition.

Clean all connector trim mouldings with a sponge and warm soapy water only.Use only cleaners that are labeled safe for use on plastics.Do not apply any polish or waxes to the side steps and connector trim mouldings,as this may affect the condition.Use standard car shampoo to clean the vehicle with a clean soft sponge/cloth.

Take care when using a high powered pressure washer, as this may also affect theaccessory fixing and condition. Do not spray directly at the connector trim mouldings.

Maximum load of 150kg for each side.All installation hardware and fasteners must be checked regularly for tightness.The side steps are designed to aid access into your vehicle and should not be usedfor any other purpose.

The side steps and connector trim mouldings have been designed and engineeredto the highest automotive specifications however on-going maintenance and care ofthese accessories is the responsibility of the vehicle owner.

Further maintenance information on the exterior of your vehicle can be found in yourowners handbook.

RETAIN IN GLOVE BOX FOR FUTURE REFERENCE

Documents

SUBARU FORESTER - SIDE STEP DIESEL VERSION … Slide Tabs as shown & slide four (4) slide tab assemblies into the back of each aluminium step as shown. See Dia #14. Important : Ensure