Place these instructions in the vehicles glovebox after installation is complete

Tools Required:

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Installation Time: 50minApprox Nudge Bar Weight: 5KG

Important: Please read each step of these instructions carefully prior to commencing installation! !

Accessory Part No. NBAR0030

VW AMAROK(2011 Production Onwards)

NUDGE BARINSTALLATION INSTRUCTION

- T30 Torx Screwdriver- T25 Torx Screwdriver

- Phillips Head Screwdriver- Flat Blade Screwdriver

- Socket Extension Bar

- 16mm Spanner

- 13mm Socket

- Masking Tape- Drill

- 20mm Drill Bit (Hole Saw)- Safety Glasses

- 16mm Socket - Pencil- Hacksaw Blade (Fine Tooth) - 13mm Spanner

- Tape Measure

- 3mm Drill Bit

SK587

Important:Do not use this product in any other motor vehicle for which it is not designed.Do not use any other mounting location / method other than described in this instruction.It is advisable to seek assistance of another person when installing this product.

Do not remove the label from the Nudge Bar.

!

Do not repair or modify the Nudge Bar and / or its mounting bracket in any way - repair or modification may effect proper operation of the airbag resulting in serious injury.

Layout:

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VW AMAROK - NUDGE BARAccessory Part No. NBAR0030

ICONQTYCOMPONENT

1NUDGE BAR

ITEM

1

1BRACKET - RHS FRONT2

1BRACKET - LHS FRONT3

2BRACKET - REAR4

2BRACKET - JOINER5

2M6x12mm Pan Head Screw6

2M6 Serrated Flange Nut7

2M6 Flat Washer8

12M10x30mm Hex Head Bolt9

12M10 Spring Washer10

24M10 Flat Washer11

12M10 Hex Nut12

Parts List

• To maintain your Nudge Bar properly, wash regularly with car wash detergent, hose off& chamois dry. Stubborn grime can be removed with kerosene.

• Polished surfaces can be maintained with Autosol® metal polish or similar products. Use as recommended.

LHS

SK587 Page 3 of 8

1.

Diagram 1: Removal of fog light trims

VW AMAROK - NUDGE BARAccessory Part No. NBAR0030

2.

Diagram 2: Location of plastic scrivets

USE SHIFTING SPANNER OR STEEL BARTO BREAK OFF WELDS.

BREAK WELDS

RETAIN THETOW HOOK

DISCARD THE TIE DOWN LOOP

3.

Diagram 3: Wheel well liner screws

Remove screws from wheel well liners using T25 Torx screwdriver (two screws each side). Retain for re-installation.

Remove LH and RH fog lamp trims by prising with a screwdriver and then pulling forwards out of detent. Retain for re-installation.

Prise out four plastic scrivets at top of grille using a screwdriver. Retain for re-installation.

Remove LHTow Hook

Remove RHTie Down Loop

Remove RegistrationPlate (if applicable)

LHS

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VW AMAROK - NUDGE BARAccessory Part No. NBAR0030

Diagram 4: Fender Joint screws

4. Remove screws from bumper to fender joints using T30 Torx screwdriver (one screw each side). These are aligned upward and are accessed from below. Retain for re-installation.

Diagram 5: Number plate screws

Remove number plate (if fitted). Remove two screws from bumper using T25 Torx screwdriver. Retain for re-installation.

6.

Diagram 6: Fog lamp mounting bolts

Remove long bolts from fog lamp recesses in bumper using a 13mm socket (one bolt each side). Retain for re-installation.

5.

13mm

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VW AMAROK - NUDGE BARAccessory Part No. NBAR0030

Diagram 7: Wheel well liner screws

7. Remove screws that retain the front edge of the wheel well liners to the underside of the bumper. Remove inner screws using T25 Torx screwdriver and outer screws using T30 Torx Screwdriver. Retain for re-installation.

Diagram 9: Fog lamp connector

Separate connectors to fog lamps and any other electrical components (if fitted). Lay the bumper assembly in a safe place where paint and surface damage cannot occur.

10.

Diagram 10: Foam bumper support

Remove foam piece from the vehicle by rotating up and off the chassis cross member.

9.

With the help of a second person, release the bumper from beneath the headlights and remove the bumper forwards and parallel off vehicle.

8.

LHS

RHS

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VW AMAROK - NUDGE BARAccessory Part No. NBAR0030

Diagram 11: Foam bumper support cut & removal

11. Mark a line from the outer edge of the large rectangular slots in the foam to the rear of the part. Cut along this line with a hacksaw. Wear protective equipment such as safety glasses and gloves. Discard cut ends.

Diagram 12: Installing RHS Mounting Bracket

Attach the RH front bracket and a rear bracket to the chassis cross member.

The tab on the front bracket should be inboard. The actual bracket assembly should be on the outboard side of the vehicle’s main chassis rails. Each joint is fastened with an M10 x 30mm Hex Head Bolt, one M10 Spring Washer and two M10 Flat Washers. Repeat for LH side.

Torque to 30 Nm.

13.

Diagram 13: Attaching Joiner Brackets

Attach the joiner brackets to the LH and RH front mount brackets. The long end of the bracket goes forward and the joggle goes outboard. Each joint is fastened with an M10 x 30mm Hex Head Bolt, one M10 Spring Washer and two M10 Flat Washers.

Torque to 30 Nm.

12.

RHS

RHS

RHS

RHS16mm

16mm

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VW AMAROK - NUDGE BARAccessory Part No. NBAR0030

Diagram 14: Cut out location for brackets

14. Find the centre of the bumper by measuring between the vertical elements of the lower grille. Place a piece of masking tape vertically on the bumper at this point. Extend the centre mark down onto the bumper’s vertical face and mark a vertical line on the masking tape. Measure out 500 to either side of the centre mark and add vertical strips of masking tape to the bumper at these locations. Draw vertical lines at these 500mm from centre points. Find the centre of the vertical face of the bumper and then measure up and down 30mm.

Diagram 15: Cut out for brackets

Drill small pilot holes at these intersection points and then enlarge by drilling 20mm holes. Mark the vertical edges of the holes and then trim with a hacksaw blade or similar to produce a 20 x 80mm rounded end slot. Clean up roughness on all cut edges. Remove all masking tape from bumper.

16.

Diagram 16: Installing rubber extrusion

Start at the bottom of the slot and attach the rubber extrusion to the cut edge of the bumper. Add some drops of glue to hold extrusion in place.

15.

Ø20mm

LHS

LHS

500mm500mm

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VW AMAROK - NUDGE BARAccessory Part No. NBAR0030

Diagram 17: Re-attaching foam bumper support

17. Replace the cut-down foam piece back onto the chassis cross member by pushing on hard. Ensure the foam piece is central on the chassis cross member.

Diagram 19: Installing Nudge Bar

Attach Nudge Bar to the forward facing brackets protruding through the bumper. The Nudge Bar mount plates should be on the outside of the mount brackets. Each joint is fastened with an M10 x 30mm Hex Head Bolt, one M10 Spring Washer and two M10 Flat Washers. Finger tighten nuts first and ensure the Nudge Bar is level and vertical.

Then torque fasteners to 30 Nm.

20.

Diagram 20: Installing number plate

Fasten number plate to Nudge Bar using M6 x 12mm Pan Head Screws, M6 Flat Washers, and M6 Hex Serrated Flange Nuts.

19.

Replace the bumper by working backwards through Step 9 through to Step 1. The forward facing brackets should protrude through the slots in the bumper.

18.

RHS

LHS

RHS

16mm

16mm