Ford - Ranger XL - Workshop Manual - 2006 - 2006

CP0002a CANOPY INSTALLATION INSTRUCTIONS Ford Ranger XL and XLT (2006 Production Onwards) Care Instructions: Clean Canopy with a mild detergent and water solution. Installation Time: 1 Hour (Approximately) Do not use abrasive cleaners or solvents. Place these instructions in vehicle’s glove box after installation is complete PLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES. 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. This Canopy is designed to suit the XL and XLT Ranger Crew Cab (Double Cab). Sports Bars MUST be removed and returned to Customer with all hardware components. Cabin Guards MUST be removed and discarded. For XL vehicles fitted with an after-market Bed Liner that has been cut-out around the Cabin Guard, you will need to remove and discard the Bed Liner, or Fit a new Bed Liner to suit XLT (Non Cabin Guard variant), so the Canopy seals along the front of the tub and prevents any water entering the tub. This Fitting Instruction where a Bed Liner is referred to, is based on Ford Australia Genuine Accessories only. RECOMMENDED TOOL LIST - (Not Supplied in Kit) • Loctite 277 thread locking liquid (IMPORTANT) • Phillips Head Screwdriver • Flat Blade Screwdriver Small • Torx Head Screwdriver • Side Cutters • Sockets 10, 12, 13mm and Driver • Spanners 10, 12 and 13mm • Silicon Dispensing Gun • Non Acetic Silicon (Neutral Cure) • Spray Bottle (25% isopropyl Alcohol & 75% Water) • Spray Bottle Water • Torque Wrench - 0-10Nm • Angle Grinder (Medium Size) • File or De-burring Tool • Medium Adjustable Spanner Page 1 of 28 • Large Pliers • Allen Keys • Non Permanent Marker • Masking Tape • Hacksaw or Jigsaw • Cleaning Cloths / Rags • Steel Rule and Tape Measure • Scissors (Sharp) • Knife (Sharp) • Squeegee • Metal Primer • File or Deburring Tool • Drill and Ø54mm Hole Saw • (Optional) Ø5mm Drill Bit • (Optional) Rivet Gun for Stainless Steel Rivets 15/07/10 CP0002a FORD RANGER - CANOPY PARTS CHECK SHEET FORD RANGER CANOPY PARTS IN MAIN CARTON Rail Extrusion Tub Stop (ALUM0038-2) Qty - 1 Canopy Qty - 1 Lock Keys (Attached to Canopy Internal Rear Door Handle) Qty - 2 Fitting Kit (KIT031807) Qty - 1 PARTS IN FITTING KIT (KIT031807) Strona Kit Rail Clamps (CNPY0007) Qty - 6 Clear Abrasion Tape Roll 48mm Wide (TAPE0611-1) Qty - 1 Tape EPDM4300 5.5mx20mmx6mm (TAPE0386) Qty - 1 Screw M6x20 Hex Head SS304 (SCRW0028) Qty - 4 M6 Flat Washer OD. 19mm (WASH0169) Qty - 8 M6 Nyloc Nut SS304 (NUTS0016) Qty - 4 M8x25mm Hex Head Bolt (SCRW0696) Qty - 2 M8 SS Flat Washer (WASH0171) Qty - 2 M8 Spring Washer Zinc Plate (WASH0144) Qty - 2 Ranger Cabin Guard Bracket - RH (CLIP2708PC) Qty - 1 AUTOMOTIVE SURFAC E CLEANE R For use in cleanin glass and other g painted metal, vehicle surfac es. For external use only. Dispose of proper ly after use. IMPREGNATED Rust Inhibitor WITH 70% ISOPROP YL ALCOHOL Ranger Cabin Guard Bracket - LH (CLIP2707PC) Qty - 1 Rivet SS304 ST-ST 6-6 (FAST0433) Qty - 8 40mm Rubber Extrusions (MISC0521-4) Qty - 6 Alcohol Wipe (MISC0052) Qty - 4 Rust Inhibitor Satchel (MISC2776) Qty - 1 Fitting Instruction Primer Stick (MISC1365) Qty - 3 Vehicle Wiring Patch Harness Kit (LOOM0013) Qty - 1 Fitting Instruction (FIT-CP0002a) Qty - 1 PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0013) Vehicle Wiring Patch Harness (LOOM0013) Qty - 1 Page 2 of 28 Cable Ties Qty - 5 Adhesive Tie Pad Qty - 1 15/07/10 FORD RANGER - CANOPY CP0002a IF A SPORTS BAR IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 1. IF A CABIN GUARD IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 3. IF THE VEHICLE HAS NO CABIN GUARD OR SPORTSBAR PLEASE PROCEED TO STEP 14. 1. If vehicle’s sports bar is fitted with an LED stop light, locate the LED stop light wiring harness at the base of the front drivers side leg. Trace back the wiring harness and disconnect from the vehicle. Remove any ties securing it to the vehicle, and leave harness hanging down beside the vehicle. (ref. diagram1). DISCONNECT SPORTS BAR WIRING HARNESS Diagram: 1 - REMOVE SPORTS BAR WIRING HARNESS 2. Remove the four (4) bolts holding the 2 REMOVE SPORTS BAR sports bar feet to the tub as shown. Carefully remove the sports bar from the vehicle and return to the customer with all hardware components. (ref. diagram2). IMPORTANT: You will need to collect and remove the clamp blocks inside the tub at the end of this Step or after Step #35 (when bed liner is removed). 1 REMOVE (4) ALLEN KEY HEAD BOLTS Diagram: 2 - REMOVE SPORTS BAR 3. Using cardboard cut from the canopy POSITION CARDBOARD TUB AND CABIN PROTECTION MATS CABIN GUARD carton, cut and place a piece inside the tub on the floor as a protection mat while installing the canopy, and a piece between the tub and cabin as a protection sheet while removing the cabin guard. (ref. diagram3). Remove and discard any bed liner in the vehicle that is fitted to a vehicle with a cabin guard. Replace this bed liner (If Required) with a new bed liner that suits the XLT model without a cabin guard. Diagram: 3 - PROTECT VEHICLE SURFACES Page 3 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 4. Apply 200mm lengths of overlapping masking tape to the top and side of the tub rail, up to and around the cabin guard as shown. Recommended: Fit a 2mm thick steel plate as a sacrificial grinding plate (Not supplied in kit), next to the cabin guard as shown, repeat process for the other side of the vehicle. (ref. diagram4). 2 RECOMMENDED FIT SACRIFICIAL GRINDING PLATE 1 FIT TAPE Diagram: 4 - SECURE GRINDING PLATE 5. Secure the sacrificial grinding plate (not supplied in kit) to the tub rail by covering it with masking tape as shown. Repeat process for the other side of the vehicle. (ref. diagram5). SECURE SACRIFICIAL GRINDING PLATE WITH TAPE Diagram: 5 - SECURE GRINDING PLATE 6. Insert a suitable protective timber board INSERT TIMBER BOARD of adequate thickness between the cardboard and cabin guard as shown. IMPORTANT: To avoid accidental damage to the vehicle, the timber board MUST be used when ever cutting of the cabin guard is undertaken. (ref. diagram6). Diagram: 6 - PROTECT VEHICLE SURFACES Page 4 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 7. IMPORTANT: Ensure that the vehicle’s (paint work, glass, etc...) is adequately protected before removing the cabin guard. Using a medium sized angle grinder, partially cut through the rear and side faces of the LH outer cabin guard bar, taking care not to damage vehicle surfaces. Repeat process for the RH side of the vehicle, ensuring the protective timber board is repositioned behind the RH outer cabin guard bar. (ref. diagram7). PARTIALLY CUT THROUGH OUTER CABIN GUARD BARS Diagram: 7 - REMOVAL OF CABIN GUARD 1 INSERT TIMBER BOARD 8. IMPORTANT: Ensure the protective timber board is repositioned behind each of the centre support bars before cutting. Using a medium sized angle grinder, completely cut through the three (3) centre support bars at the base, flush to the front tub rail, taking care not to damage vehicle surfaces. (ref. diagram8). 2 COMPLETELY CUT THROUGH CENTRE SUPPORT BARS Diagram: 8 - REMOVAL OF CABIN GUARD 1 SUPPORT CABIN GUARD 2 COMPLETELY CUT THROUGH OUTER CABIN GUARD BARS 9. IMPORTANT: Ensure the protective timber board is repositioned behind the outer cabin guard bars before cutting. Two people are required to complete this step, one person will need to support the cabin guard and prevent it from damaging the vehicle while the other person finishes cutting through the cabin guard bars completely. Using a medium sized angle grinder, completely cut through the LH and RH outer cabin guard bars, flush to the grinding plates. Carefully remove cabin guard from vehicle and discard. (ref. diagram9). Diagram: 9 - REMOVAL OF CABIN GUARD Page 5 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 10. IMPORTANT: Ensure the protective 1 GRIND AWAY ANY REMAINING METAL NOT FLUSH WITH THE TUB timber board is repositioned to each bar location before cutting. Take care to prevent damage to vehicle. Using a medium sized angle grinder, carefully cut away any remaining metal not flush with the tub rail. Remove sacrificial grinding plates and all masking tape. (ref. diagram10). 2 REMOVE GRINDING PLATES & TAPE Diagram: 10 - PREPARE VEHICLE SURFACES 11. Using a file / de-burring tool, remove all burrs and sharp edges from cabin guard and tub rail surfaces previously cut with the angle grinder. (ref. diagram11). DEBURR ALL SURFACES AROUND CUT CABIN GUARD BARS Diagram: 11 - PREPARE VEHICLE SURFACES 2 1 REMOVE TIMER BOARDS & CARDBOARD PROTECTION MATS 12. Remove all timber boards and cardboard protection mats from the vehicle. Retain cardboard tub floor protection mat for use later during the fitment. Using compressed air, completely blow out all metal filings, swarf etc... in the tub floor. (ref. diagram12). Diagram: 12 - CLEAN VEHICLE SURFACES Page 6 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 13. Using a suitable metal primer, paint over and completely cover all bare metal surfaces previously cut and deburred. (ref. diagram16). Allow some paint drying time by reading through the next steps carefully and installing the vehicle wiring harness through the vehicle cabin. (ref. diagram13). Diagram: 13 - PRIME VEHICLE SURFACES 14. Remove and retain fuse box cover, STEERING WHEEL located under the steering wheel. (ref. diagram14). DRIVER’S SIDE KICK PANEL FUSE BOX COVER Diagram: 14 - REMOVE VEHICLE PARTS DRIVER’S SIDE OF VEHICLE ONLY REMOVE AND RETAIN REAR SCUFF PLATE AND HARDWARE 15. Open front and rear driver’s side doors Remove and retain Front driver’s side scuff plates and hardware (4 screws). Remove and retain Rear driver’s side scuff plates and hardware (1 screw). (ref. diagram15). REMOVE AND RETAIN FRONT SCUFF PLATE AND HARDWARE Diagram: 15 - REMOVE VEHICLE PARTS Page 7 of 28 15/07/10 FORD RANGER - CANOPY 2 1 REMOVE SQUARE PLASTIC NUT CP0002a 16. Remove and retain square plastic nut and driver’s side kick panel as shown. (ref. diagram16). KICK PANEL REMOVE KICK PANEL ACCELERATOR PEDAL Diagram: 16 - REMOVE VEHICLE PARTS 17. Remove and retain nut and washer from GREEN & WHITE WIRES 12mm brake pedal box switch bracket mount stud using a 12mm socket with extension bar as shown. Unplug the brake pedal switch male connector (green and white wires) from the brake pedal switch as shown. (ref. diagram17). 1 REMOVE AND RETAIN NUT AND WASHER 2 REMOVE BRAKE PEDAL SWITCH CONNECTOR STEERING COLUMN Diagram: 17 - REMOVE VEHICLE PARTS 2 RE-ASSEMBLE WASHER, EYELET TERMINAL & NUT 12mm 1 CONNECT BRAKE PEDAL HARNESS CONNECTOR WITH VEHICLE HARNESS FEMALE CONNECTOR 18. Using the vehicle wiring patch harness from the hardware kit connect the female connector to the brake pedal switch male connector as shown. Re-assemble the previously removed washer and nut (from step 5) and vehicle wiring patch harness eyelet terminal onto the brake pedal box switch bracket mount stud in the following order: washer, eyelet terminal and the nut and tighten with the 12mm socket. IMPORTANT: Be careful when tightening to ensure wires are not stripped out of the eyelet terminal. (ref. diagram18). VEHICLE WIRING PATCH HARNESS Diagram: 18 - CONNECT VEHICLE HARNESS Page 8 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 19. Connect the male connector from the VEHICLE HARNESS TO BE BEHIND EXISTING LOOMS vehicle wiring patch harness back into the brake pedal switch as shown. (ref. diagram19). CONNECT VEHICLE HARNESS MALE CONNECTOR BACK INTO BRAKE PEDAL SWITCH Diagram: 19 - CONNECT VEHICLE HARNESS 20. Using the vehicle wiring patch harness from the hardware kit connect the female connector to the brake pedal switch male connector. (ref. diagram20). FEED VEHICLE HARNESS BEHIND EXISTING LOOMS FEED VEHICLE HARNESS BEHIND KICK PANEL STUD BRACKET Diagram: 20 - ROUTING VEHICLE HARNESS 21. Connect the male connector from the vehicle wiring patch harness back into the brake pedal switch as shown. terminal. (ref. diagram21). 1 FEED VEHICLE HARNESS BEHIND MAIN LOOM ‘Y’ JUNCTION 2 FEED VEHICLE HARNESS ALONG EDGE OF CARPET WITH EXISTING LOOM Diagram: 21 - ROUTING VEHICLE HARNESS Page 9 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 22. At the B pillar feed the harness under the carpet and pull out the other side at the rear door scuff plate wiring track. Push down on the carpet around the B pillar to position it back under the B pillar plastic panel. (ref. diagram22). 2 PULL LOOM UNDER B PILLAR 1 FEED LOOM UNDER B PILLAR Diagram: 22 - ROUTING VEHICLE HARNESS 23. Continue feeding the harness along the rear door scuff plate wiring track, under the carpet edge with the existing wiring looms. (ref. diagram23). FEED VEHICLE HARNESS ALONG EDGE OF CARPET WITH EXISTING LOOM Diagram: 23 - ROUTING VEHICLE HARNESS 24. Fold rear seats down by pulling the loop located on the rear of the seat in the middle as shown and folding the seat forward and down. (ref. diagram24). 1 PULL LOOP 2 FOLD SEAT FORWARD Diagram: 24 - FOLD DOWN REAR SEATS Page 10 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 25. Remove three (3) C pillar trim clips with a small flat blade screwdriver, taking care not to damage the plastic panel. Partially remove the rear door seal to release the C pillar plastic panel enough to feed the harness through. (ref. diagram25). 1 REMOVE 3 - ‘C’ PILLAR CLIPS 2 PARTIALLY REMOVE DOOR SEAL TO RELEASE ‘C’ PILLAR PANEL REAR SEAT Diagram: 25 - REMOVE VEHICLE PARTS 26. Feed the harness behind the C pillar panel to the rear of the cabin with existing harness as shown. (ref. diagram26). FEED VEHICLE HARNESS BEHIND ‘C’ PILLAR EXISTING HARNESS REAR SEAT Diagram: 26 - ROUTING VEHICLE HARNESS 27. Expose the existing wiring harness 1 REMOVE GROMMET FROM SHEETMETAL VINYL LINER EXISTING MAIN HARNESS grommet by lifting the vinyl lining on the rear bulkhead as shown. Remove grommet from sheet-metal, pulling inwards into the cabin. With a sharp knife cut a slit on one side of the grommet, taking care not to cut the existing harness. (ref. diagram27). 2 CUT SLIT IN GROMMET Diagram: 27 - CUT GROMMET Page 11 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 28. Feed vehicle wiring patch harness GROMMET through the grommet and out of the cabin, between the cabin and tub. Push the grommet back into the hole in the sheetmetal as shown. DO NOT replace trim panels at this stage. (ref. diagram28). VINYL LINER EXISTING MAIN HARNESS FEED VEHICLE HARNESS THROUGH GROMMET Diagram: 28 - ROUTING VEHICLE HARNESS IF A BED LINER IS FITTED TO THE VEHICLE, PLEASE CONTINUE WITH STEPS 29 TO 37. IF A BED LINER IS NOT FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 38. 29. Two people are required for this step. 90 0mm 10 20 30 40 50 60 70 FIT CANOPY TO VEHICLE RULER FLAT AGAINST FRONT OF TUB 80 DO NOT SLIDE CANOPY ON VEHICLE 1 Position the canopy onto the vehicle tub carefully. IMPORTANT: Ensure canopy is placed fully forward on the tub in one action. DO NOT slide the canopy on the Bed Liner. Align the canopy evenly on the tub. Canopy front face should align with the front of the tub sheetmetal Using a straight edge as shown. This will ensure the clamps fit neatly into the areas you are about to cut out. (ref. diagram29). ALIGN FRONT OF CANOPY TO FRONT OF TUB SHEETMETAL Diagram: 29 - CAREFULLY POSITION CANOPY 30. Apply masking tape to the sides of the bed liner, under each slot in the canopy side rails as shown. Apply tape to 150mm below canopy side rail. Repeat process for the other side of the vehicle. (ref. diagram30). 150mm SLOT IN CANOPY SIDE RAIL APPLY MASKING TAPE TO BED LINER REPEAT FOR ALL SIX (6) SLOTS BED LINER Diagram: 30 - PROTECT BED LINER Page 12 of 28 15/07/10 FORD RANGER - CANOPY 2 1 LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LINE UP WITH THE UNDERSIDE FORD RANGER BED LINER TEMPLATE FRONT CANOPY CLAMP CUT-OUTS CENTRE-PUNCH LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL LINE UP WITH THE CORNER OF THE BED LINER 31. Carefully cut out the three (3) templates 1 CHECK SCALE OF TEMPLATES ON PAGES 24, 25 and 26 LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL OF THE CANOPY SIDE RAIL FORD RANGER BED LINER TEMPLATE MIDDLE CANOPY CLAMP CUT-OUTS CENTRE-PUNCH AND DRILL EXISTING Ø54mm HOLE SAW CUT-OUT FROM SPORTS BAR EXISTING CUT-OUT AND DRILL FROM SPORTS BAR Ø54mm HOLE SAW CP0002a FORD RANGER BED LINER TEMPLATE FOR CANOPY CLAMP CUT-OUTS 2 CENTRE-PUNCH AND DRILL Ø54mm HOLE SAW MARK AND CUT THIS on pages 24, 25 and 26. Ensure the scale of these templates are correct to the ruler scale printed on each of these pages. (ref. diagram31). NOTE: If you do not have a Ø54mm hole saw you can cut out the inside profiles to trace onto the masking tape and use a saw to cut it out. SECTION OUT 1 FRONT RHS THIS FACE OUT FRONT LHS THIS FACE AGAINST BED LINER MIDDLE RHS THIS FACE OUT MIDDLE LHS THIS FACE AGAINST BED LINER REAR RHS THIS FACE OUT REAR LHS THIS FACE AGAINST BED LINER 2 CUT-OUT TEMPLATES CAREFULLY Diagram: 31 - REMOVE VEHICLE PARTS 1 FIT TO RHS TEMPLATES WITH TEXT FACING OUT, AND ALIGN TAG THROUGH CANOPY SIDE RAIL CANOPY SIDE RAIL LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL 3 MARK RECTANGLE ON REAR TEMPLATE TO BE CUT OUT LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LINE UP WITH THE UNDERSIDE LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL OF THE CANOPY SIDE RAIL FORD RANGER BED LINER TEMPLATE LINE UP WITH THE CORNER OF THE BED LINER FORD RANGER BED LINER TEMPLATE MIDDLE CANOPY CLAMP CUT-OUTS LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL CENTRE-PUNCH FORD RANGER BED LINER TEMPLATE FOR CANOPY CLAMP CUT-OUTS EXISTING 2 AND DRILL FRONT CANOPY CLAMP CUT-OUTS Ø54mm HOLE SAW SPORTS BAR CENTRE-PUNCH EXISTING CUT-OUT FROM SPORTS BAR CENTRE-PUNCH AND DRILL Ø54mm HOLE SAW CUT-OUT FROM 1 MARK AND CUT THIS SECTION OUT AND DRILL Ø54mm HOLE SAW FRONT RHS THIS FACE OUT MIDDLE RHS THIS FACE OUT FRONT LHS THIS FACE AGAINST BED LINER MIDDLE LHS THIS FACE AGAINST BED LINER REAR RHS THIS FACE OUT REAR LHS THIS FACE AGAINST BED LINER BED LINER FRONT OF VEHICLE RHS 2 MARK CENTREPOINTS FOR ALL HOLES REAR OF 4 REPEAT VEHICLE FOR OTHER SIDE RHS WITH TEXT FACING TOWARDS THE BED LINER Diagram: 32 - ROUTING VEHICLE HARNESS 32. Fit templates to the RH side of the vehicle ensuring the text is facing outwards as marked. Align the top tag into the slots of the canopy side rail as shown. Carefully mark the centre points and the square profile for the rear template onto the masking tape applied to the bed liner. Alternatively you can trace the profiles onto the tape if you have cut-them out in the previous step. NOTE: If the template is not positioned accurately, the cut-out profile will be incorrect and may cause problems when fitting clamps. Remove templates and fold top tag over to the other side of the template. Repeat process for the LH side of the vehicle, ensuring the text is facing towards the BED LINER. (ref. diagram32). 33. Remove all templates. DO NOT SLIDE CANOPY ON VEHICLE 2 REMOVE CANOPY TO VEHICLE Two people are required to carefully remove the canopy. (ref. diagram33). 1 REMOVE ALL TEMPLATES Diagram: 33 - CUT GROMMET Page 13 of 28 15/07/10 FORD RANGER - CANOPY 1 12V POWER SOCKET 12 V TORX HEAD SCREWS 10 AMPS MAX BED LINER CP0002a 34. If vehicle’s bed liner is fitted with a 12V power socket, remove and retain the four (4) torx head screws. Pull the 12V power socket away from the bed liner and remove and retain the plastic clip as shown. (ref. diagram34). 2 PRESS TO RELEASE Diagram: 34 - DISCONNECT 12V OUTLET IN BED-LINER 35. Press down on the connector as shown 1 2 4 REMOVE BED LINER PRESS TO RELEASE REMOVE 12V POWER SOCKET 3 PUSH CONNECTOR BACK THROUGH HOLE IN THE BED LINER to release, remove and retain the 12V power socket. Push the connector back through the hole in the BED LINER. Remove and retain any tie down hooks and hardware. It is helpful to mark some areas on the tub rails as to the original position of the bed liner before removing it. Remove and retain the BED LINER from the vehicle. If a sports bar was fitted, collect and remove the 4 clamp blocks inside the tub. (ref. diagram35). Diagram: 35 - REMOVE BED-LINER CUT OUT and DEBURR THE MARKED AREAS CAREFULLY Ø54mm 36. Carefully cut out the sections previously marked with a Ø54mm Holesaw and for the rear template an Airsaw or jigsaw is also required. Alternatively if you have traced the profiles use a saw to cut them out. Remove all burrs and sharp edges with a file or deburring tool. Repeat process for the other side of the vehicle. IMPORTANT: To ensure the clamps fit neatly at a later stage, please take care when cutting the bed liner. When complete remove all masking tape from the bed liner. (ref. diagram36). Diagram: 36 - CUT BED LINER Page 14 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 37. Re-fit bed liner to the vehicle tub, if a 12V 1 REPLACE BED LINER 2 REPLACE 12V POWER SOCKET power socket was installed, ensure the harness is fed back through the bed liner. Re-fit tie down hooks (If required). IMPORTANT: If a 12V power socket was installed, replace it by reversing the procedure outlined in Diagram #34 and Diagram #35. (ref. diagram37). 12 V 10 AMPS MAX BED LINER Diagram: 37 - REPLACE BED LINER & 12V POWER SOCKET 38. Thoroughly clean and dry installation areas (tub, rear of cabin and glass) as shown. (ref. diagram38). Diagram: 38 - CLEAN INSTALLATION AREAS REPLACE CARDBOARD TUB PROTECTION MAT 39. Replace cardboard inside the tub on the floor as a protection mat while installing the canopy. (ref. diagram39). Diagram: 39 - PROTECT VEHICLE SURFACES Page 15 of 28 15/07/10 FORD RANGER - CANOPY CP0002a IF A CABIN GUARD WAS FITTED TO THE VEHICLE, PLEASE CONTINUE WITH STEP 40. IF A CABIN GUARD WAS NOT FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 43. 40. Trial fit the cabin guard brackets to the front 1 TRIAL FIT CABIN GUARD BRACKETS TO TUB 2 CHECK THIS EDGE SITS FLAT ON THE TUB 3 BEND IF REQUIRED BEND TAG DOWN AND RECHECK UNTIL IT SITS FLAT of the vehicle tub as shown. Check if the bracket sits flat across the front and side rails as shown. If brackets sit flat proceed to the next step. If brackets do not sit flat you will need to bend the end of the bracket down as shown with a shifter or pliers until it sits flat across the rails. The objective is to provide a flat continuous surface to apply the bed rail sealing EPDM foam tape all round the bed rails. (ref. diagram40). Diagram: 40 - TRIAL FIT CABIN GUARD BRACKETS 41. With a clean cloth wipe down all areas to 1 APPLY SILICON TO TUB NOT SUPPLIED 2 APPLY SILICON TO CABIN GUARD BRACKETS be siliconed as shown. Spray areas to be siliconed with water (to improve ease of application and clean up), Do Not dry. Apply non-acetic silicon (neutral cure) (not supplied) to edges of the remains of the cabin guard frame and fill up the large hole with silicon between the front and side rails of the tub. Apply silicon to the undersides of the cabin guard brackets as shown, use only a small amount so it does not squeeze out the sides when fitted. Repeat process for the other side of the vehicle. (ref. diagram41). Diagram: 41 - APPLY SILICON 42. Fit cabin guard brackets to the tub as 1 FIT CABIN GUARD BRACKETS TO TUB 3 REMOVE ANY EXCESS SILICON OR RESIDUE FROM TUB RAILS 2 SECURE BRACKET TO TUB M8 FLAT WASHER M8 SPRING WASHER M8x25mm HEX HEAD BOLT shown and secure with either existing vehicle tie down hooks, or M8x25mm hex head bolt, M8 spring washer and M8 flat washer (as provided in hardware kit), as shown. Tighten to Torque 7Nm. Spray silicon areas with water and clean up excess silicon. If silicon does squeeze out, clean all excess silicon off using isopropyl alcohol. IMPORTANT: There must be NO silicon residue left on the top of the tub bed rail faces, or the bed rail EPDM foam tape will not adhere correctly and water leaks will occur. (ref. diagram42). Diagram: 42 - FIT & SECURE CABIN GUARD BRACKETS Page 16 of 28 15/07/10 FORD RANGER - CANOPY 1 2 43. Using alcohol wipes provided clean all PRIME VEHICLES WITH A FITTED BED LINER Diagram: 43 - VEHICLE SURFACE PREPARATION START AT THE EDGE OF THE TAILGATE BED LINER FITTED CP0002a FOAM TAPE MUST NOT PUCKER AROUND CORNERS APPLY EPDM FOAM TAPE AROUND BED RAIL NO BED LINER FITTED POSITION EPDM FOAM TAPE OVER THE EDGE OF THE INSIDE RADIUS ALL THE WAY AROUND Diagram: 44 - INSTALL WATER SEALING TAPE top rail areas of the tub or bed liner and wipe away residue with a dry clean cloth. If heavy cleaning is required use IsoPropyl alcohol and wipe away residue with a dry clean cloth. NOTE: If a bed liner is fitted, you will need to prime the top rail surface areas after cleaning with the alcohol wipes. Please do not prime too far over the sides of the bed liner, read step 44 to understand where the foam tape is to be positioned and use this as a guide for priming the area. Use the priming sticks provided to prime the top surfaces where the foam tape will be positioned. Follow the instructions on the priming stick for optimum results. (ref. diagram43). 44. Apply EPDM foam tape from hardware kit to the bed rails as shown. IMPORTANT: DO NOT CUT FOAM TAPE! Starting from one side at the rear corner, position the foam tape over the edge of the inside radius of the top tub rail and continue this position all the way around the tub as shown in one continuous length. As the tape bends around the corners ensure the tape sits flat and DOES NOT pucker. Trim off any excess at each end. Ensure all foam tape areas are fully adhered to the tub or bed liner by applying moderate pressure down on the tape all the way around the tub. (ref. diagram44). Tape MUST be fully adhered to tub rails or bed liner and sit flat in one continuous length to prevent water entering the canopy. 45. THIS STEP IS NOT REQUIRED FOR NOT SUPPLIED EPDM FOAM TAPE APPLY NON ACETIC SILICON (NEUTRAL CURE) ATLEAST 80mm DOWN FROM TOP OF THE TUB Diagram: 45 - APPLY SILICON Page 17 of 28 VEHICLES FITTED WITH A BED LINER. With a clean cloth wipe down all areas to be siliconed as shown. Spray areas to be siliconed with water, Do Not dry. Apply non-acetic silicon (neutral cure) (not supplied) inside the tub at the join between the front and side panels of the tub from the foam tape all the way down to the floor and along the floor to seal all gaps as shown. Re-spray silicon with water and clean up excess silicon. Apply silicon to the join on the top of the rails on the front side of the tub between the tub and the cabin, from the foam tape down at least 80mm from the top of the tub. Repeat process for the other side of the vehicle. (ref. diagram45). 15/07/10 FORD RANGER - CANOPY 1 25% ISOPROPYL ALCOHOL 75% WATER 3 TRIM EXCESS CLEAR ABRASION TAPE 4 SQUEEGEE OUT EXCESS SOLUTION BUBBLES 2 APPLY CLEAR ABRASION TAPE CLEAR ABRASION TAPE Diagram: 46 - APPLY ABRASION TAPE CP0002a 46. THIS STEP IS NOT REQUIRED FOR VEHICLES FITTED WITH A BED LINER. Using a solution of 25% isopropyl alcohol and 75% water in a spray bottle (not supplied) Thoroughly spray along the top of the tailgate. Remove liner from clear abrasion tape. Working from one end with a 5mm overhang, place liner on the tailgate. Trim excess tape leaving a 5mm overhang at both ends of the tailgate. When in position use a squeegee to push out any excess water solution and bubbles. Using a sharp knife trim to end of tailgate. You may need to squeegee a few times. When finished the tape is virtually invisible. To ensure a good finish please take care an do not rush this step. ref. diagram46). 47. Clean front of canopy including the front 1 CLEAN CANOPY FRONT window. Disconnect the vehicle mounted brake light inside the cabin. (ref. diagram47). 2 DISCONNECT INTERNAL BRAKE LAMP Diagram: 47 - PREPARE CANOPY 48. Two people are required for this step. DO NOT SLIDE CANOPY ON EPDM FOAM TAPE 1 FIT CANOPY TO VEHICLE HARNESS Position the canopy onto the vehicle tub carefully. IMPORTANT: Ensure canopy is placed fully forward on the tub in one action. DO NOT slide the canopy on the EPDM foam tape, as this can damage the foam tape (break the water seal). Feed canopy harness down between tub and cabin so it sits next to vehicle harness (from step 28) as shown. (ref. diagram48). 2 FEED CANOPY HARNESS BETWEEN TUB AND CABIN DOWN ALONG SIDE VEHICLE HARNESS Diagram: 48 - FIT CANOPY TO TUB Page 18 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 49. Align the canopy evenly on the tub. RULER FLAT AGAINST FRONT OF TUB 0mm 10 20 30 40 50 60 70 80 90 VIEW FROM REAR OF CAR Canopy front face should align with the front of the tub sheetmetal using a straight edge as shown. Open rear tailgate to check sideways alignment. Using a steel rule position the canopy so both canopy base side rails are 3mm outboard of the tailgate recess as shown, or position this at even amounts both sides due to vehicle variation. (ref. diagram49). CANOPY BASE RAIL ALIGN FRONT OF CANOPY TO FRONT OF TUB SHEETMETAL 3mm Diagram: 49 - ALIGN CANOPY TO TUB 50. Fit six (6) 40mm rubber extrusions to the FIT 6 RUBBER EXTRUSIONS TO TUB RAILS DIRECTLY UNDER CLAMP HOLES IN BASE RAILS WHEN A BED LINER IS NOT FITTED vehicle tub rails directly under the holes in the canopy base rails for the clamps as shown. (ref. diagram50). IMPORTANT: If a bed liner is fitted to the vehicle, the rubber extrusions MUST NOT be fitted. Diagram: 50 - FIT RUBBER EXTRUSIONS TO TUB 51. Disassemble two (2) rail clamps. 13mm LOCTITE 277 13mm 2 FIT TOP ‘L’ CLAMP 6 READJUST LATCH STRIKER POSITION (IF REQUIRED) 3 FIT & SLIDE BOTTOM ‘U’ CLAMP 1 DISASSEMBLE 2 CLAMPS 4 FIT BOLT & WASHERS TORQUE TO 8Nm 5 CLOSE REAR DOOR CHECK LATCHES ENGAGE Diagram: 51 - FIT REAR CLAMPS AND CHECK LATCHING Page 19 of 28 Fit the clamps to the rear holes in the canopy base rails 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 rubber extrusion. IMPORTANT! Apply Loctite 277 (not supplied) to the bolts. Secure the clamps with the bolts and washers as shown. For vehicles fitted with a bed liner clamps will need to be fitted through the cut-outs. Tighten to Torque 8Nm. Close the rear door firmly, holding the centre handle without slamming it too hard. NOTE: Latch has 2 stages of engagement. Ensure canopy engages with second stage of latch. If required loosen clamps and adjust the canopy position fore and aft, re-tighten to Torque 8Nm and re-check latching. You may also need to adjust the latch striker hoops, loosen bolts with a 10mm socket adjust and tighten to Torque 8Nm. (ref. diagram51). 15/07/10 FORD RANGER - CANOPY CP0002a 52. Disassemble remaining four (4) rail 13mm 4 TIGHTEN 2 - FRONT CLAMPS TORQUE TO 9Nm 13mm 5 TIGHTEN 2 - MIDDLE CLAMPS TORQUE TO 9Nm LOCTITE 277 2 FIT REMAINING CLAMPS 1 DISASSEMBLE 4 CLAMPS 3 TIGHTEN 2 - REAR CLAMPS TORQUE TO 9Nm clamps. Fit the clamps to the remaining holes in the canopy base rails 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 rubber extrusion. IMPORTANT! Apply Loctite 277 (not supplied) to the bolts. Secure the clamps with the bolts and washers as shown. For vehicles fitted with a bed liner, clamps will need to be fitted through the cut-outs. Tighten the rear clamps first, then the front clamps and finally the middle clamps, all to Torque 9Nm. (ref. diagram52). Diagram: 52 - FIT REMAINING CLAMPS AND TIGHTEN ALL 53. Fit front rail tub stop extrusion to the NYLOC NUT 10mm WASHER 10mm CANOPY BASE RAIL AT FRONT VEHICLE FRONT TUB SHEETMETAL BOLT 3 SECURE NYLOC NUT AND WASHER 2 FIT BOLT AND WASHER 1 FIT FRONT RAIL TUB STOP under side of the canopy front base rail. Push extrusion up against the front of the tub and secure with four (4) M6 hex head bolts, eight (8) flat washers and four (4) nyloc nuts as shown. Tighten to Torque 6Nm. (ref. diagram53). TIGHTEN TO TORQUE 6Nm Diagram: 53 - FIT FRONT TUB STOP RAIL 1 2 3 4 54. (Optional): Recommended for (x8) t Rus r to Inhibi Ø5mm MIDDLE GROOVE ON FRONT RAIL TUB STOP LOWER GROOVE ON FRONT RAIL TUB STOP 200 RAISED RIBS ON TUB 100 200 50 100 200 100 ‘Off Road’ vehicle use. Mark and drill eight (8) Ø5mm holes into the front rail tub stop and tub rail using dimension’s as shown. Rivets must secure to raised ribs on tub. Apply rust inhibitor to all drilled holes in the tub sheetmetal. Secure with eight (8) stainless steel rivets as shown. (ref. diagram54). 200 CENTRE-LINE OF LOWER RIB ON TUB Diagram: 54 - (OPTIONAL) SECURE FRONT TUB STOP RAIL Page 20 of 28 15/07/10 FORD RANGER - CANOPY 2 CABLE TIE VEHICLE HARNESS TO EXISTING HARNESS 1 CONNECT HARNESS CONNECTORS CANOPY HARNESS EXISTING HARNESS VEHICLE HARNESS CHASSIS RAIL VEHICLE REAR SHOCK ABSORBER INSIDE DRIVERS SIDE REAR TYRE CP0002a 55. Feed the canopy and vehicle wiring harnesses along the top of the driver’s side chassis rail to the rear of the fuel tank. Join the connectors from the canopy and vehicle wiring harnesses together. Using a cable tie secure the vehicle canopy wiring harness (LOOM0013) only to the existing main vehicle wiring harness as shown. IMPORTANT: Apply the cable tie around the black plastic sheath on the vehicle wiring harness side of LOOM0013 ONLY. DO NOT apply the cable tie to the canopy wiring harness. (ref. diagram55). Diagram: 55 - SECURE CANOPY HARNESS 56. Two people are required to check the canopy brake light is operational after depressing the brake pedal. Then open the rear window and check that the internal canopy lamp is operating correctly when switched to the ’ON’ position only. (ref. diagram56). CHECK CANOPY LAMP WORKS CHECK BRAKE LIGHTS WORK Diagram: 56 - CHECK BRAKE LIGHTS AND CANOPY LIGHT 57. Inside the rear of the cabin apply nonGROMMET VINYL LINER NOT SUPPLIED acetic silicon to grommet in location previously cut and around the harnesses to prevent water entering the cabin. (ref. diagram57). EXISTING MAIN HARNESS VEHICLE HARNESS Diagram: 57 - APPLY SILICON Page 21 of 28 15/07/10 FORD RANGER - CANOPY DRIVER’S SIDE OF VEHICLE ONLY STEERING WHEEL FUSE BOX COVER DRIVER’S SIDE KICK PANEL CP0002a 58. With the brake-lights and canopy internal light operating correctly, replace fuse box cover, Front drivers side scuff plates and driver’s side kick panel as shown. (ref. diagram58). RE-FIT FRONT SCUFF PLATE AND HARDWARE Diagram: 58 - RE-ASSEMBLE VEHICLE PARTS DRIVER’S SIDE OF VEHICLE ONLY 59. Replace Rear driver’s side scuff plates, driver’s side C pillar panel as shown. Finally fold seats back to upright position. (ref. diagram59). 2 REPLACE 3 - ‘C’ PILLAR CLIPS REAR SEAT 1 RE-FIT REAR SCUFF PLATE AND HARDWARE 3 REPLACE DOOR SEAL 4 FOLD REAR SEAT UP Diagram: 59 - RE-ASSEMBLE VEHICLE PARTS 60. Using alcohol wipe provided in the kit, CANOPY CABIN clean the driver’s side top corner of the tub as shown, and wipe away residue with a dry clean cloth. Remove tape liner from adhesive tie pad and position on the tub in area previously cleaned as shown. Apply pressure to ensure maximum adhesion. (ref. diagram60). TUB 1 2 FIT ADHESIVE TIE PAD Diagram: 60 - FIT ADHESIVE TIE PAD Page 22 of 28 15/07/10 FORD RANGER - CANOPY CP0002a 61. Fit a cable tie through the adhesive tie pad previously fitted to the front of the tub and secure the canopy wiring harness as shown. Trim excess tie with side cutters. (ref. diagram61). FIT CABLE TIE Diagram: 61 - SECURE CANOPY HARNESS 62. Water test canopy checking for water leaks. (ref. diagram62). Diagram: 62 - WATER LEAK TESTING 63. Clean canopy including all windows PLACE FITTING INSTRUCTIONS IN THE CUSTOMERS LOG BOOK and vehicle thoroughly . Place fitting instructions in the Customers log book, and ensure page 27 of these instructions are discussed with the customer and a copy is given to the customer. (ref. diagram63). Diagram: 63 - FINAL CLEANING Page 23 of 28 15/07/10 Page 24 of 28 FRONT RHS THIS FACE OUT Ø54mm HOLE SAW AND DRILL FRONT LHS THIS FACE AGAINST BED LINER FROM SPORTS BAR EXISTING CUT-OUT CENTRE-PUNCH FORD RANGER BED LINER TEMPLATE FRONT CANOPY CLAMP CUT-OUTS LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL FORD RANGER - CANOPY CP0002a FORD RANGER FRONT BED LINER TEMPLATE 100mm when printed 15/07/10 LINE UP WITH THE CORNER OF THE BED LINER FORD RANGER - CANOPY CP0002a FORD RANGER MIDDLE BED LINER TEMPLATE LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL FORD RANGER BED LINER TEMPLATE MIDDLE CANOPY CLAMP CUT-OUTS CENTRE-PUNCH AND DRILL EXISTING Ø54mm HOLE SAW CUT-OUT FROM SPORTS BAR MIDDLE RHS THIS FACE OUT MIDDLE LHS THIS FACE AGAINST BED LINER 100mm when printed Page 25 of 28 15/07/10 FORD RANGER - CANOPY CP0002a FORD RANGER REAR BED LINER TEMPLATE LOCATE TAG THROUGH SLOT IN CANOPY SIDE RAIL LINE UP WITH THE UNDERSIDE OF THE CANOPY SIDE RAIL FORD RANGER BED LINER TEMPLATE FOR CANOPY CLAMP CUT-OUTS 2 CENTRE-PUNCH AND DRILL Ø54mm HOLE SAW MARK AND CUT THIS SECTION OUT 1 REAR RHS THIS FACE OUT REAR LHS THIS FACE AGAINST BED LINER 100mm when printed Page 26 of 28 15/07/10 CP0002a FORD RANGER - CANOPY OWNERS MANUAL SUPPLEMENT IMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S VEHICLE SERVICE BOOK. 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. Maintenance Only use mild detergents or wax polish. Do Not use abrasive compounds on painted or plastic finished canopy surfaces. The gas struts are self lubricating and should only be cleaned with a damp cloth, when regularly cleaning the 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 (9 Nm or 6.64 lb/ft). If removed, bolts must 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. FORD RANGER 2006 Onwards CANOPY KEY IDENTIFICATION CODE 34 12 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. Warranty Terms EGR 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 of purchase. 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. Exclusions This warranty does not cover failure due to neglect, improper installation, including any modifications to installation hardware, alterations, addition of non genuine equipment, abuse, accident, normal wear and tear, lack of maintenance, misuse, and exposure to chemicals that are not safe for plastics 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 of the 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. Disclaimer In 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 the defective part. Transportation costs and labour are not associated with this warranty claim. Page 27 of 28 15/07/10 FORD RANGER - CANOPY CP0002a INSTALLATION CHECKLIST Dealer Name: Dealer Code: Model: Stock No: Order Date: Order No: Required By: Vin No: Canopy Colour Vehicle Damage Check: Detail: Vehicle Type: XLT XL Bed Liner XLT Genuine Ford Canopy Checklist - Details of rectifications required: KEY No. : 1. Check paint on canopy 2. Cleanliness of canopy inside and outside 3. Canopy sealing to tray, foam tape applied correctly 4. Seal around Front of tub, vertical corners & floor with Silicone after foam tape applied 5. Tailgate clear tape fitted 6. Disconnect high mount brake light on rear of vehicle cab 7. 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 8. Clamps are square and tight (Torque 9Nm) 9. 9. IMPORTANT! Loctite 277 applied to all Clamp Bolt Threads 10. Rear Door, Side Door’s and Front window operation 12. Operations of Brake Light 13. Operation of interior light 13. Water Tested for leaks 14. Clean up of work area 15. Comment Fitted By: Vehicle received and Checked by Dealer Staff: Record Canopy Serial Number: Checked By: (located on inside LH rear pillar of canopy shell) Page 28 of 28 15/07/10