Ford Ranger XL and XLT CANOPY INSTALLATION

Ford Ranger XL and XLT CANOPY INSTALLATION
CP0002d
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 243 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 - 0-20Nm
• 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
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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
AUTOMOTIV
E
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 - 5
Vehicle Wiring
Patch Harness Kit
(LOOM0013)
Qty - 1
Fitting
Instruction
(FIT-CP0002d)
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
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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
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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
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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
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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
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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
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FORD RANGER - CANOPY
2
1 REMOVE SQUARE PLASTIC NUT
CP0002d
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
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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
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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
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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
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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
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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
CP0002d
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
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1
12V POWER
SOCKET
12 V
TORX HEAD
SCREWS
10 AMPS
MAX
BED
LINER
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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
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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
26/05/11
FORD RANGER - CANOPY
CP0002d
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
26/05/11
FORD RANGER - CANOPY
1
CP0002d
43. Using alcohol wipes provided clean all
2
top rail areas of the tub and wipe away
residue with a dry clean cloth. If heavy
cleaning is required use Iso-Propyl
alcohol and wipe away residue with a
dry clean cloth
Using priming stick (MISC1365) prime top
rails of the tub or bed liner where EPDM
foam tape will be applied in (step 44).
Please do not prime too far over the
sides of the top rails or 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. Follow the
instructions on the priming stick for
optimum results. (ref. diagram43).
Diagram: 43 - VEHICLE SURFACE PREPARATION
START AT THE
EDGE OF THE
TAILGATE
BED LINER
FITTED
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
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).
26/05/11
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
CP0002d
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
26/05/11
FORD RANGER - CANOPY
CP0002d
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
Diagram: 50 - FIT RUBBER EXTRUSIONS TO TUB
13mm
20mm
13mm
LOCTITE
243
8Nm
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
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.
51. Disassemble two (2) rail clamps.
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 243
(not supplied), minimum 20mm along
the thread on 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).
26/05/11
FORD RANGER - CANOPY
52. Disassemble remaining four (4) rail
13mm
13mm
CP0002d
4
TIGHTEN
2 - FRONT CLAMPS
TORQUE TO 9Nm
9Nm
20mm
5
TIGHTEN
2 - MIDDLE CLAMPS
TORQUE TO 9Nm
LOCTITE
243
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.
IIMPORTANT! Apply Loctite 243
(not supplied), minimum 20mm along
the thread on 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
10mm
NYLOC NUT
10mm
WASHER
9Nm
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 9Nm.
(ref. diagram53).
TIGHTEN TO
TORQUE 9Nm
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
26/05/11
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
CP0002d
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
26/05/11
FORD RANGER - CANOPY
DRIVER’S SIDE OF
VEHICLE ONLY
STEERING WHEEL
FUSE BOX
COVER
DRIVER’S
SIDE
KICK PANEL
CP0002d
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
26/05/11
FORD RANGER - CANOPY
CP0002d
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
26/05/11
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
CP0002d
FORD RANGER FRONT BED LINER TEMPLATE
100mm when printed
26/05/11
LINE UP WITH THE CORNER
OF THE BED LINER
FORD RANGER - CANOPY
CP0002d
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
26/05/11
FORD RANGER - CANOPY
CP0002d
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
26/05/11
CP0002d
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
26/05/11
FORD RANGER - CANOPY
CP0002d
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 243 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
26/05/11
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