canopy installation instructions holden … d-max canopy fitting... · installing the canopy. (ref....

Place these instructions in vehicle’s glove box after installation is complete

Clean Canopy with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

12/08/10 of 24

Installation Time:1 Hour (Approximately) Without Bed Liner

1 Hour 45 Minutes (Approximately) With Bed Liner

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.

RECOMMENDED TOOL LIST - (Not Supplied in Kit)• Loctite 277 thread locking liquid (IMPORTANT)• Phillips Head Screwdriver• Large Flat Blade Screwdriver• Torx Head Screwdriver• Side Cutters• Sockets 10 & 13mm, Extension Bar and Driver• Spanners 10 & 13mm• Silicon Dispensing Gun• Non Acetic Silicon (Neutral Cure)• Spray Bottle (25% isopropyl Alcohol & 75% Water)• Spray Bottle Water• Torque Wrench - 0-10Nm• Hacksaw or Jigsaw

• Hammer• Medium Adjustable Spanner• Non Permanent Marker• Masking Tape• 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

Holden Colorado LX and LT-R(2007 Production Onwards)

CANOPYINSTALLATION INSTRUCTIONS

CP0005

PLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES.

This Canopy is designed to suit the LX and LT-R Colorado Crew Cab (Double Cab).Sports Bars MUST be removed and returned to Customer with all hardware components.Cabin Guards MUST be removed and returned to Customer (If requested) with all hardwarecomponents.For vehicles fitted with a Bed Liner, the Bed Liner will need to be cut to remove the top flangethat sits over the bed rails, so the Canopy seals to the tub and prevents any water enteringthe tub.This Fitting Instruction where a Bed Liner is referred to, is based on -GM Genuine Bed Liner Accessory only.

of 24 12/08/10

PARTS CHECK SHEET HOLDEN COLORADO CANOPY

CanopyQty - 1

PARTS IN MAIN CARTON

Rail ExtrusionTub Stop(ALUM0038-3)Qty - 1

Fitting Kit(KIT031845)Qty - 1

Lock Keys(Attached toCanopy InternalRear Door Handle)Qty - 2

Strona Kit -Rail Clamps(CNPY0007)Qty - 6

Clear AbrasionTape Roll48mm Wide(TAPE0611-1)Qty - 1

Tape EPDM43005.5mx20mmx6mm(TAPE0386)Qty - 1

Screw M6x30Hex Head SS304(SCRW0824)Qty - 4

M6 Flat WasherOD. 19mm(WASH0169)Qty - 8

M6 Nyloc NutSS304(NUTS0016)Qty - 4

Cabin GuardBlanking Pate(MISC2782)Qty - 2

M8x25 S/SHex Bolt(SCRW0696-1)Qty - 6

Vehicle WiringPatch Harness(LOOM0015)Qty - 1

ConvolutedTubeQty - 1

PARTS IN FITTING KIT (KIT031845)

PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0015)

Cable TiesQty - 7

Adhesive TiePadQty - 1

M8 S/S FlatWasher(WASH0171-1)Qty - 6

M8 S/S SpringWasher(WASH0152-1)Qty - 6

Tape 4026 GHB12x1700mmx 1.14Thick Roll(TAPE0615)Qty - 1

Front Tub SpacerExtrusion(ALUM0038-4)Qty - 1

Bulb Seal 70mmCut Length(MISC2600-1)Qty - 2

Rust

Inhibitor

AUTOMOTIVESURFACE CLEANER

IMPREGNATED WITH 70% ISOPROPYL ALCOHOL

For use in cleaning painted metal,glass and other vehicle surfaces.For external use only.Dispose of properly after use.

Rivet SS304ST-ST 6-6(FAST0433)Qty - 8

40mm RubberExtrusions(MISC0521-4)Qty - 6

Alcohol Wipe(MISC0052)Qty - 4

CP0005HOLDEN COLORADO - CANOPY

Rust InhibitorSatchel(MISC2776)Qty - 1

Primer Stick(MISC1365)Qty - 3

FittingInstruction

Vehicle WiringPatch Harness Kit(LOOM0015)Qty - 1

FittingInstruction(FIT-CP0005)Qty - 1

12/08/10 of 24

Remove the four (4) bolts holding thesports bar feet to the tub as shown.(ref. diagram1).

1.

If vehicle’s sports bar is fitted with anLED stop light, locate the LED stop lightwiring harness at the base of the frontleft hand side leg.Trace back the wiring harness anddisconnect from the vehicle.Remove any ties securing it to the vehicle.Carefully remove the sports bar from thevehicle and return to the customer withall hardware components.(ref. diagram2).OPTIONAL: If customer requests paint allareas left exposed as primed sheetmetal.Painting is preferred to prevent rust.

2.

Diagram: 2 - DISCONNECT WIRING & REMOVE SPORTS BAR

Using a torx head screwdriver and flatblade screwdriver, (tap screwdrivers witha hammer to loosen screws first) removethe hardware securing the cabin guard tothe side rail as shown. Repeat the processfor the other side of the vehicle.(ref. diagram3).

3.

Diagram: 3 - REMOVE CABIN GUARD HARDWARE

Diagram: 1 - REMOVE SPORTS BAR HARDWARE


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 6.

REMOVESPORTS BAR2

DISCONNECTSPORTS BAR

WIRING HARNESS

REMOVEHARDWARE

13mm

1

REMOVECABIN GUARD HARDWARE

FROM SIDE RAILS

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Remove the hardware securing the cabinguard to the front rail as shown.(ref. diagram4).

4.

Carefully remove the cabin guard takingcare to avoid scratching the paintwork.(ref. diagram5).OPTIONAL: If customer requests paint allareas left exposed as primed sheetmetal.Painting is preferred to prevent rust.

5.

Diagram: 5 - REMOVE CABIN GUARD

Diagram: 4 - REMOVE CABIN GUARD HARDWARE


IF A BED LINER IS FITTED TO THE VEHICLE, PLEASE CONTINUE WITH STEPS 6 TO 13.IF A BED LINER IS NOT FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 14.

DO NOT SLIDE CANOPYON VEHICLE

1FIT

CANOPY TOVEHICLE

ALIGNFRONT OF CANOPY TO

FRONT OF TUB SHEETMETAL

RULER FLAT AGAINSTFRONT OF TUB

0mm

1020

3040

5060

7080

90

13mm REMOVECABIN GUARD HARDWARE

FROM FRONT RAIL

REMOVECABIN GUARD

Diagram: 6 - CAREFULLY POSITION CANOPY

Two people are required for this step.Position the canopy onto the vehicle tubcarefully. IMPORTANT: Ensure canopy is placedfully forward on the tub in one action.To avoid damage to the bed liner, DO NOT slide canopy on the vehicle.Align the canopy evenly on the tub.Canopy front face should align with thefront of the tub sheetmetal,using a straightedge as shown.This will ensure the rail clamps (CNPY0007)fit neatly into the areas you are about tocut out. (ref. diagram6).

6.

12/08/10 of 24

Apply masking tape to the sides of thebed liner, under each slot in the canopyside rails as shown. Apply tape to 150mmbelow canopy side rail.Repeat process for the other side of thevehicle. (ref. diagram7).

7.

Carefully cut out the two (2) templateson pages 20 & 21. Ensure the scaleof these templates are correct to the rulerscale printed on each of these pages.(ref. diagram8).NOTE: If you do not have a Ø54mm holesaw you can cut out the inside profiles totrace onto the masking tape and use asaw to cut it out.

Fit templates to the RH side of the vehicleensuring the text is facing outwards asmarked. Align the top tag into the slotsof the canopy side rail as shown.Carefully mark the centre points for thefront and middle positions, and mark therectangular profile for the rear templateonto the masking tape applied to the bedliner. Alternatively you can trace the profilesonto the tape if you have cut-them out inthe previous step.NOTE: If the template is not positionedaccurately, the cut-out profile will beincorrect and may cause problems whenfitting the clamps.Remove templates and repeat processfor the LH side of the vehicle.(ref. diagram9).

8.

Diagram: 8 - CUT OUT BED LINER TEMPLATES

9.

Diagram: 9 - FIT TEMPLATES & MARK CUT-OUTS

Diagram: 7 - PROTECT BED LINER


BED LINER

APPLYMASKING TAPETO BED LINER

REPEATFOR ALL

SIX (6) SLOTS

SLOT IN CANOPYSIDE RAIL

150m

m

CHECKSCALE OF TEMPLATES ON PAGES 20 & 21

11

CUT-OUTTEMPLATES CAREFULLY

FIT TO RHSTEMPLATES WITH TEXT FACINGOUT, AND ALIGN TAG THROUGH

CANOPY SIDE RAIL

2

1 MARKRECTANGLE ONREAR TEMPLATETO BE CUT OUT

3

2

THIS FACE OUT

HOLDEN COLORADO BED LINER TEMPLATEREAR CANOPY CLAMP CUT-OUTS

LINE UP WITH THE UNDERSIDEOF THE CANOPY SIDE RAIL

CENTRE-PUNCHAND DRILL (4)Ø10mm HOLES

1

MARK ANDCUT-OUT

RECTANGULARPROFILE

2

THIS FACE OUT

HOLDEN COLORADO BED LINER TEMPLATEFRONT & MIDDLE CANOPY CLAMP CUT-OUTS


CENTRE-PUNCHAND DRILL

Ø54mm HOLE SAW

THIS FACE OUT




Ø54mm HOLE SAW

LOCATE TAGTHROUGH SLOT

IN CANOPYSIDE RAIL


IN CANOPYSIDE RAIL


IN CANOPYSIDE RAIL

BED LINER

REAR OFVEHICLE

RHS

FRONT OFVEHICLE

RHSMARK

CENTREPOINTS FORFRONT & MIDDLE HOLES

2 REPEATFOR OTHER SIDEOF THE VEHICLE

4

THIS FACE OUT




IN CANOPYSIDE RAIL


Ø54mm HOLE SAW

THIS FACE OUT




IN CANOPYSIDE RAIL


1

MARK ANDCUT-OUT

RECTANGULARPROFILE

2

CANOPY SIDE RAIL

12/08/10 of 24

Remove all templates.Two people are required to carefullyremove the canopy. (ref. diagram10).

10.

Remove and retain any tie down hooksand hardware.Remove and retain the BED LINER fromthe vehicle.Apply masking tape all aroundthe top of the bed liner to assist withmarking the trim line.Mark a line 15mm down from the topsurface of the bed liner all the way aroundas shown. (ref. diagram11).

Using a jigsaw or similar, carefully cut thetop of the bed liner off using the linemarked 15mm down from the top.On the front face of the bed liner, cut a\6mm slot down the corners and back alongthe wheel arch forms 60mm as shown.Remove all burrs and sharp edges with afile or deburring tool.(ref. diagram12).

11.

Diagram: 11 - REMOVE BED LINER & MARK TOP TRIM LINE

12.

Diagram: 12 - CUT BED LINER

Diagram: 10 - REMOVE TEMPLATES & THE CANOPY


DO NOT SLIDE CANOPYON VEHICLE

REMOVECANOPY FROM

VEHICLE

REMOVEALL TEMPLATES

2 REMOVEBED LINER

15mm

1 REMOVETIE DOWNS ANDANY HARDWARE

1CUT

TOP OFFBED LINER

MARKA LINE AROUND THE LINER

15mm DOWN FROM THE TOP FACE

1

2

0mm 10 20 30 40 50 60 70 80 90

3

60mm

CUTSLOT 6mm WIDE DOWN

THE FRONT CORNERS ANDBACK ALONG THE TOP OF THE

WHEEL ARCH 60mm, BOTH SIDES

2

15mm LINE MUSTBE ABOVE THE

REAR BOLT HOLESAND FOLLOW THE

REAR CORNER PROFILE

12/08/10 of 24

Carefully cut out the sections previouslymarked with a Ø54mm Holesaw and forthe rear template a jigsaw or similar isalso required.Alternatively if you have traced the profilesuse a saw to cut them out.Remove all burrs and sharp edges with afile or deburring tool.Repeat process for the other side of thevehicle. IMPORTANT: To ensure the clampsfit neatly at a later stage, please takecare when cutting the bed liner.When complete remove all masking tapefrom the bed liner. Do Not re-fit the bed liner at this stage.(ref. diagram13).

13.

Thoroughly clean and dry installationareas (tub, rear of cabin and glass)as shown.Using cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the canopy.(ref. diagram14).

Using a sharp knife carefully removethe bead of mastic at each end of thefront rail as shown. (ref. diagram15).IMPORTANT: Ensure mastic doesnot protrude above front tub rail.The objective is to have the front tub railflat across the top face.

14.

Diagram: 14 - CLEAN & DRY INSTALLATION AREAS

15.

Diagram: 15 - REMOVE MASTIC BEAD

Diagram: 13 - CUT BED LINER


CUT OUT and DEBURRTHE MARKED AREAS

CAREFULLY

Ø54mm

REMOVEMASTIC BEAD

FRONT RAIL OFVEHICLE TUB

SIDE RAIL OFVEHICLE TUB

POSITIONCARDBOARD TUBPROTECTION MAT

1

2

12/08/10 of 24

Using alcohol wipe provided clean thetop surface of the front rail and wipeaway residue with a dry clean cloth.If heavy cleaning is required use Iso-Propyl alcohol and wipe away residuewith a dry clean cloth.Apply (MISC1365) primer stick along halfthe rear edge width of the front tub rail asshown and allow to dry. Starting with a small amount of the tapefrom the double sided tape roll 12mm wide(TAPE0615), apply it starting from thecorner of the front rail to the other side,along the rear edge of the front tub railpressing down on the liner as you applythe tape across the vehicle as shown.Apply firm pressure to ensure the tapeadheres to the vehicle. (ref. diagram16).

16.

Apply non-acetic silicon (neutral cure)(not supplied) to the front edge of the fronttub rail starting from the edge of the siderail, across the vehicle to the edge of theother side rail as shown. Do Not applysilicon over the side rails. Do Not allowsilicon to contact the double sided tape.If silicon does end up on the side rail, cleanall excess silicon off using isopropyl alcohol.IMPORTANT: There must be NO siliconresidue left on the top of the side bed railfaces, or the bed rail foam tape will notadhere correctly and water leaks willoccur. (ref. diagram17).

Using alcohol wipes provided clean thelong inside face of the front tub spacerextrusion (ALUM0038-4) and wipe awayresidue with a dry clean cloth as shown.Apply (MISC1365) primer stick along thelength of the extrusion in front of the slottedholes up to 25mm towards the interior angleof the extrusion and allow it to dry. Remove liner from the double sided tapeapplied to the front tub rail.Fit rail extrusion spacer to the front railover the tape and silicon positioning itevenly between the side rails.IMPORTANT: Ensure the long face sitsover the front rail, and the short face sitsagainst the front of the tub between thecabin and tub as shown.When fitting, avoid wiping the silicontowards the double sided tape.Apply firm pressure down on the front tubspacer extrusion (ALUM0038-4) and alongthe length to ensure maximum adhesion ofthe silicon and foam tape. (ref. diagram18).

17.

Diagram: 17 - APPLY SILICON TO THE FRONT RAIL

18.

Diagram: 18 - FIT RAIL EXTRUSION SPACER

Diagram: 16 - FIT 3M TAPE 12x1700mm


FRONT RAIL APPLYDOUBLE SIDED 12x1700mm ROLL(TAPE0615) ACROSS FRONT RAIL

NOT SUPPLIED

1

4

POSITION TAPEAGAINST SIDE RAIL

APPLYSILICON

DO NOT APPLY SILICONOVER THE SIDE RAIL

2

APPLYPRIMER STICK

TO SHADED AREAALONG FRONT RAIL

2 3

FITFRONT TUB SPACER EXTRUSION

FRONT TUB SPACER EXTRUSION

APPLYFIRM PRESSURE TO

ADHERE SILICON AND TAPE

4

REMOVETAPE LINER

35

12APPLY

PRIMER2

FRONT RAIL OFVEHICLE TUB SIDE RAIL OF

VEHICLE TUB

12/08/10 of 24

Using alcohol wipes provided clean alltop rail areas of the tub and wipe awayresidue with a dry clean cloth. If heavycleaning is required use Iso- Propylalcohol and wipe away residue with adry clean cloth.Ensure no silicon is squeezed up by thefitting of the front tub spacer extrusion,if it is clean it off with IPA on a ragheavily loaded. (ref. diagram19).

19.

Diagram: 19 - VEHICLE SURFACE PREPARATION

Apply EPDM foam tape (TAPE0386) fromhardware kit to the bed rails and spacer.IMPORTANT: DO NOT CUT FOAM TAPE!Starting from one side at the rear corner,position the tape end in line with theedge of the tailgate, position the foamtape towards the edge of the insideradius of the top tub rail and continuethis position all the way along the siderail in one continuous length, position5mm rearward along the front tub spacerextrusion as shown and over the edge ofthe inside radius of the top tub rail downthe other side, run tape out onto the tail-gate as shown. As the tape bends aroundthe corners ensure the tape sits flat andDOES NOT pucker. Trim off excess to theedge of the tailgate as shown.Ensure all foam tape areas are fully adheredto the tub and spacer by applying moderatepressure down on the tape all the wayaround the tub. (ref. diagram20).Tape MUST be fully adhered to tub railsand spacer and sit flat in one continuouslength to prevent water entering thecanopy.

20.


Diagram: 20 - INSTALL WATER SEALING TAPE

APPLYEPDM FOAM TAPEAROUND BED RAIL

TAILGATE OFVEHICLE TOP VIEW OF

VEHICLE TUB

CA

BIN

OF

VEH

ICLE

START AT THEEDGE OF THE

TAILGATE

POSITIONEPDM FOAM TAPE

OVER THE EDGE OFTHE INSIDE RADIUS

ALONG THE SIDE RAILS

POSITIONEPDM FOAM TAPE

5mm REARWARD OFTHE EDGE OF THE

FRONT TUB SPACEREXTRUSION

ALONGSIDE RAILS

ALONGSIDE RAILS

FOAM TAPE MUST NOTPUCKER AROUND CORNERSFINISH OVER

THE EDGE OFTHE TAILGATE

TRIM EXCESS TOTHE EDGE OFTHE TAILGATE

ALONGFRONT RAIL

WITH SPACER

5mm

12/08/10 of 24

If a bed liner was removed to trim,carefully re-fit the bed liner to the vehicle.If fitted, replace all tie downs andhardware previously removed.(ref. diagram23).

23.

Diagram: 23 - REPLACE BED LINER AND HARDWARE

With a clean cloth wipe down all areas ofthe internal front tub corners to besiliconed as shown. Spray areas to besiliconed with water, Do Not dry.Apply non-acetic silicon (neutral cure)(not supplied) inside the tub at the joinbetween the front and side panels of thetub, under the spacer, along the side railand the gap in the front rail as shown.Re-spray silicon with water and pushsilicon into gaps and clean up excesssilicon. Repeat process for the other sideof the vehicle.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram21).

With a clean cloth wipe down all areas tobe siliconed as shown. Spray areas to besiliconed with water, Do Not dry.Apply non-acetic silicon (neutral cure)(not supplied) to the top of the tub andspacer around the foam tape and downthe front side of the tub between the tuband the cabin, and down at least the depthof the return of the front tub spacerextrusion, from the top of the tub and pushsilicon into gaps. Repeat process for theother side of the vehicle.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram22).

21.

Diagram: 21 - APPLY SILICON

22.

Diagram: 22 - APPLY SILICON


1 REPLACEBED LINER

2 REPLACETIE DOWNS AND

HARDWARE

NOT SUPPLIED

NOT SUPPLIED

APPLYNON ACETIC

SILICON(NEUTRAL CURE)

FRONT LEFT HAND INSIDE CORNER OF TUB

APPLYNON ACETIC

SILICON(NEUTRAL CURE)

EPDM FOAMTAPE

DOWN AT LEAST THE DEPTHOF THE RETURN OF THE FRONT

TUB SPACER EXTRUSIONFROM THE TOP OF THE TUB

EPDM FOAMTAPE

FRONT TUBSPACER EXTRUSION

FRONT TUBSPACER

VEHICLE CABIN NOT SHOWN FOR CLARITY

12/08/10 of 24


THIS STEP IS FOR VEHICLES -NOT FITTED WITH A BED LINER.Fit Cabin Guard blanking plate (MISC2782)to side rail and secure with (3) M8x25 boltsM8 flat washers and M8 spring washersas shown. Repeat process for the other sideof the vehicle. Tighten to Torque 7Nm.(ref. diagram24).

THIS STEP IS FOR VEHICLES - NOT FITTED WITH A BED LINER.

THIS STEP IS FOR VEHICLES - FITTED WITH A BED LINER. THIS STEP IS FOR VEHICLES -FITTED WITH A BED LINERFit Cabin Guard blanking plate (MISC2782)to bed liner and side rail and secure with(3) M8x25 bolts, M8 flat washers andM8 spring washers as shown. Repeatprocess for the other side of the vehicle.Tighten to Torque 7Nm.Apply non-acetic silicon (neutral cure)(not supplied) to the bed liner in the cornerand along the wheel arch form where thebed liner was cut as shown and push siliconinto the groove and clean up with rag andwater spray. (ref. diagram25).

24.

Diagram: 24 - FIT CABIN GUARD BLANKING PLATES

25.

Diagram: 25 - FIT CABIN GUARD BLANKING PLATES

Clean front of canopy including the frontwindow.Disconnect the vehicle mounted brakelight on the cabin, by unscrewing thebrake lamp screws and removing thelight lens, disconnect the loom and tapeit to the existing wiring on the back ofthe light with masking tape so it doesnot rattle, then refit the light lens andscrews. (ref. diagram26).

26.

Diagram: 26 - PREPARE CANOPY

CLEANCANOPY FRONT

1

DISCONNECTBRAKE LAMP

2

7Nm

13mm

7Nm

13mm

NOT SUPPLIED

BED LINER

M8x25 BOLT

M8 FLATWASHER

M8 SPRING WASHER

APPLYNON ACETIC SILICON

FITCABIN GUARD

BLANKING PLATE

M8x25 BOLT

M8 FLATWASHER

M8 SPRING WASHERFITCABIN GUARD

BLANKING PLATE

1

2

12/08/10 of 24

Align the canopy evenly on the tub.Canopy front face should align with thefront of the tub sheetmetal using a straightedge as shown.Open rear tailgate to check sidewaysalignment. Using a steel rule position thecanopy so both canopy base side railsare even to the width of the vehicle tub.(ref. diagram28).

27.

28.

Fit six (6) 40mm rubber extrusions to thevehicle tub rails directly under the squareholes in the canopy base rails for theclamps as shown. (ref. diagram29).IMPORTANT: If a bed liner is fitted tothe vehicle, the rubber extrusionsMUST NOT be fitted.

29.

Diagram: 29 - FIT RUBBER EXTRUSIONS TO TUB

Diagram: 27 - FIT CANOPY TO TUB

Diagram: 28 - ALIGN CANOPY TO TUB


Two people are required for this step.First tape harness to the LH side windowwith masking tape.Position the canopy onto the vehicletub carefully. IMPORTANT: Ensure canopy is placedfully forward on the tub in one action.DO NOT slide the canopy on the EPDMfoam tape, as this can damage thefoam tape (break the water seal).Remove masking tape and feed canopyharness down between tub and cabin (lefthand side of vehicle) so it is accessible.(ref. diagram27).

DO NOT SLIDE CANOPYON EPDM FOAM TAPE

2 FITCANOPY TO

VEHICLE

1 TAPEWIRING HARNESS

TO LH SIDE WINDOW

3FEED

CANOPY HARNESSBETWEEN TUB AND

CABIN DOWN ALONG SIDEVEHICLE HARNESS

FIT6 RUBBER

EXTRUSIONSTO TUB RAILS

DIRECTLY UNDERCLAMP HOLES IN

BASE RAILSWHEN A BED LINER

IS NOT FITTED

ALIGNFRONT OF CANOPY TO

FRONT OF TUB SHEETMETAL

RULER FLAT AGAINSTFRONT OF TUB

EVEN BOTH SIDESAT THE END CAPS

CANOPY BASE RAIL

VIEW FROMREAR OF CAR

0mm

1020

3040

5060

7080

90

HARNESS

12/08/10 of 24


Diagram: 30 - FIT REAR CLAMPS AND CHECK LATCHING

Disassemble remaining four (4) railclamps.Fit the clamps to the remaining holes inthe canopy base rails by fitting the top Lclamp down through the hole in the railand sliding the lower U clamp along theside rail over the rubber extrusion.IMPORTANT! Apply Loctite 277(not supplied) to the bolts liberally.Secure the clamps with the bolts andwashers as shown. For vehicles fitted with a bed liner, clampswill need to be fitted through the cut-outs.Tighten the rear clamps first, then the frontclamps and finally the middle clamps, allto Torque 9Nm. (ref. diagram31).

31.

Disassemble two (2) rail clamps.Fit the clamps to the rear holes in thecanopy base rails by fitting the top L clampdown through the hole in the rail andsliding the lower U clamp along the siderail over the rubber extrusion.IMPORTANT! Apply Loctite 277(not supplied) to the bolts liberally.Secure the clamps with the bolts andwashers as shown.For vehicles fitted with a bed liner clampswill need to be fitted through the cut-outs.Tighten to Torque 8Nm. Close the rear door firmly, holding thecentre handle without slamming it too hard. NOTE: Latch has 2 stages of engagement.Ensure canopy engages with second stageof latch. If required loosen clamps andadjust the canopy position fore and aft,re-tighten to Torque 8Nm and re-checklatching. You may also need to adjust thelatch striker hoops, loosen bolts with a10mm socket adjust and tighten toTorque 8Nm. (ref. diagram30).

30.

Diagram: 31 - FIT REMAINING CLAMPS AND TIGHTEN ALL

LOCTITE277

DISASSEMBLE4 CLAMPS

1

FITREMAINING CLAMPS

APPLYLOCTITE 277 TO BOLTS

2

3TIGHTEN

2 - REAR CLAMPSTORQUE TO 9Nm

4TIGHTEN

2 - FRONT CLAMPSTORQUE TO 9Nm

5TIGHTEN

2 - MIDDLE CLAMPSTORQUE TO 9Nm

DISASSEMBLE2 CLAMPS

FITTOP ‘L’ CLAMP

1

2

4FIT & SLIDE

BOTTOM‘U’ CLAMP

APPLYLOCTITE 277 TO BOLTS,

FITBOLT & WASHERSTORQUE TO 8Nm

5CLOSE REAR DOOR

CHECK LATCHES ENGAGE

6READJUST

LATCH STRIKERPOSITION

(IF REQUIRED)

LOCTITE277

3

Fit front rail tub stop extrusion to theunder side of the canopy front base rail.Push extrusion up against the front of thetub and secure with four (4) M6 hex headbolts, eight (8) flat washers and four (4)nyloc nuts as shown.Tighten to Torque 6Nm. (ref. diagram32).

32.

Diagram: 32 - FIT FRONT TUB STOP RAIL

10mm

FITFRONT RAIL TUB STOP

TIGHTEN TOTORQUE 6Nm

1

3

FITBOLT AND WASHER

SECURENYLOC NUT

AND WASHER

WASHER

NYLOC NUT

BOLT

CANOPY BASERAIL AT FRONT

2

VEHICLEFRONT TUB

SHEETMETAL

6Nm

10mm

9Nm

13mm

9Nm

13mm

4

2

13mm

13mm

12/08/10 of 24


(Optional): Recommended for‘Off Road’ vehicle use.Mark and drill eight (8) Ø5mm holes intothe front rail tub stop and tub rail usingdimension’s as shown.Rivets must secure to raised formon tub.Apply rust inhibitor to all drilled holes inthe tub sheetmetal.Secure with eight (8) stainless steel rivetsas shown. (ref. diagram33).

IF A TAILGATE LINER IS FITTEDPLEASE REMOVE TEMPORARILY.With the canopy rear door closed, applya length of masking tape to the reartailgate, level with the bottom edge ofthe canopy rear door sash, when viewedfrom the rear horizontal position as shown.This will assist in positioning the clearabrasion tape applied to the top of thetailgate in the next step.(ref. diagram34).

33.

Diagram: 33 - (OPTIONAL) SECURE FRONT TUB STOP RAIL

34.

Diagram: 34 - APPLY MASKING TAPE

Using a solution of 25% isopropyl alcoholand 75% water in a spray bottle (not -supplied) Thoroughly spray along the topof the tailgate.Remove liner from clear abrasion tape.Working from one end with a 5mm over-hang, place liner on the tailgate. Trim excess tape leaving a 5mm over-hang at both ends of the tailgate.When in position use a squeegee to pushout any excess water solution and bubbles.Using a sharp knife trim tape to end oftailgate.You may need to squeegee a few times.When finished the tape is virtuallyinvisible. To ensure a good finish please take carean do not rush this step.Remove masking tape.(ref. diagram35).

35.

Diagram: 35 - APPLY ABRASION TAPE

RAISED FORMON TUB

150

75150150 150 150150150

TOP GROOVEON FRONT RAIL TUB STOP

MIDDLE GROOVEON FRONT RAIL TUB STOP

Ø5mmRust

Inhibitor

(x8)1 2 3 4

APPLYMASKING TAPETO TAILGATE

CLEARABRASION

TAPE

TRIMEXCESS CLEARABRASION TAPE

3

REMOVEMASKING TAPE

CANOPY NOT SHOWN FOR CLARITY

5

SQUEEGEE OUTEXCESS SOLUTION

BUBBLES

41

25% ISOPROPYLALCOHOL

75% WATERAPPLYCLEAR

ABRASION TAPE

ALIGNBOTTOM EDGE

OF CLEAR ABRASIONTAPE WITH TOP EDGE

OF MASKING TAPE

TAILGATE

REARDOOR SASH

MASKINGTAPE

REAR WINDOW

2

1

12/08/10 of 24

THIS STEP IS FOR VEHICLES FITTEDWITH A BED LINER.Option 1. Using templates on page 22 cutout and fit to tailgate liner as shown.Carefully mark the areas to be cutout.Or Option 2. Mark a line across the tailgateliner 15mm down from the top of the tailgateliner as shown.Option 1 or 2. Using a jigsaw cut outmarked areas and using a file or deburringtool remove all sharp edges.Re-fit tailgate liner to the vehicle.(ref. diagram36).

36.

Diagram: 36 - PREPARE TAILGATE LINER

(OPTIONAL): Strongly Recommendedfor best results for rear door to tailgatewater sealing. Using alcohol wipe provided clean directlybelow the rear door clamp front seal andwipe away residue with a dry clean cloth.Using priming stick (MISC1365) prime areadirectly below the rear door clamp frontseal. Apply only a light amount both sides of tailgate in this area, and allow to dry. Apply bulb seal 70mm (MISC2600-1) totailgate. Position bulb seal so it's fingerseals against the underside of theclamp frame seal and the canopy faceas shown and position it out to the sideoverhanging the tailgate gap to the sidetub rails to create a seal in the corners.(ref. diagram37).

Fit convoluted tube to canopy harness, byopening up the split in the tube and feedingit over the cable near the connector first.Holding the harness thread the convolutedtube upwards towards the canopy, ontothe harness as shown. (ref. diagram38).

37.

Diagram: 37 - (OPTIONAL) FIT TAILGATE SEALS

38.

Diagram: 38 - FIT CONVOLUTED TUBE TO CANOPY HARNESS


BULBSEAL

BU

LB S

EA

L FI

NG

ER

UN

DE

R C

LAM

P S

EA

L&

AG

AIN

ST

CA

NO

PY

CLAMPFRAMESEAL

OPENSPLIT IN TUBE,

AND FEED OVERHARNESS

1

THREADTUBE UPWARDS

TOWARDSCANOPY

2

TAILGATESIDETUBRAIL

CANOPY

OPTION 1 OPTION 2

FIT BULB SEAL

ALCOHOLWIPE &PRIME

SHADEDAREA

1 2

3

TAILGATE

15mm

MARKA LINE 15mm DOWN FROM

THE TOP OF THE TAILGATE LINER

CUT AND REMOVESHARP EDGES

CUT AND REMOVESHARP EDGES

HOLDEN COLORADOTAILGATE LINER

LH TEMPLATE

LINE UP WITH OUTERTAILGATE LINER EDGE

MARK THESETWO (2)EDGES

& RADIUS

LIN

E U

P W

ITH

SID

ETA

ILG

ATE

LIN

ER

ED

GE

THIS FACE OUT

MARK THESETWO (2)EDGES

& RADIUS

HOLDEN COLORADOTAILGATE LINERRH TEMPLATE

THIS FACE OUT

LINE UP WITH OUTERTAILGATE LINER EDGE

LIN

E U

P W

ITH

SID

ETA

ILG

ATE

LIN

ER

ED

GE

CUT-OUTTEMPLATES CAREFULLY

FITTEMPLATES TO LINER & MARK

RH LH

1

2

At the rear left hand side of the vehiclelocate the trailer harness connectors.For vehicles fitted with a tow bar the towbar loom will be attached to this connector,for vehicles with no tow bar there will be ablanking cover on the connector.For vehicles fitted with a tow bar disconnectthe two (2) connectors, for vehicles withno tow bar remove the blanking cover andretain as shown. (ref. diagram39).

39.

Diagram: 39 - DISCONNECT TRAILER CONNECTORS

For vehicles fitted with a tow bar, connectthe tow bar connector to the vehicleharness (LOOM0015) (male) connectoras shown.For vehicles fitted with no tow bar, connectthe blanking cover to the vehicle harness(male) connector as shown.Connect the trailer harness to the vehicleharness (female) connector asshown. (ref. diagram40).

Feed the vehicle harness (LOOM0015) from the back to the front of the vehiclerunning it along side the existing vehiclewiring along the chassis rail ensuring it isfed over the chassis cross rails as shown.(ref. diagram41).

40.

Diagram: 40 - CONNECT VEHICLE & TRAILER HARNESSES

41.

Diagram: 41 - FIT VEHICLE HARNESS

12/08/10 of 24


LHS REARBUMPER

VEHICLES WITH TOW BAR FITTEDVEHICLES WITH TOW BAR NOT FITTED

LOCATETRAILER

HARNESS

DISCONNECTCONNECTOR& BLANKING

COVER

CONNECTVEHICLE

HARNESS TOTRAILER HARNESS& BLANKING COVER

VEHICLEHARNESS

TRAILERHARNESS

BLANKINGCOVER

VEHICLES WITH TOW BAR FITTEDVEHICLES WITH TOW BAR NOT FITTED

LHS REARBUMPER

LHS REARBUMPER

TOW BARHARNESS

TRAILERHARNESS

FEEDVEHICLEHARNESS

EXISTINGHARNESS

CHASSISRAIL

CHASSISCROSS RAIL

1

2

CONNECTVEHICLE

HARNESS TOTRAILER HARNESS

& TOW BAR HARNESS

TOWBAR

TOWBAR

DISCONNECTCONNECTORS

2

LOCATETRAILER

HARNESS

1

LHS REARBUMPER

VEHICLEHARNESS

12/08/10 of 24


Two people are required to check thecanopy brake light is operational afterdepressing the brake pedal.Then open the rear window and checkthat the internal canopy lamp is operatingcorrectly when switched to the ’ON’position only. (ref. diagram44).

44.

Diagram: 44 - CHECK BRAKE LIGHTS AND CANOPY LIGHT

Feed the canopy harness down betweenthe cabin and tub, then inboard over thechassis rail and connect the canopy harnessconnector to the vehicle harness connectoras shown.Attach a cable tie to secure the canopyharness to the tube going through thechassis rail as shown.Attach two (2) more cable ties either sideof the connector, to secure the harness tothe existing vehicle wiring as shown.Trim excess ties with side cutters.(ref. diagram42).

Attach a cable tie to the vehicle harnessand existing vehicle wiring near the sparetyre as shown.Attach a cable tie to the looped vehicleharness and existing stop lamp harnesson the rear left hand side as shown.If a tow bar is fitted secure the tow barharness to the tow bar mount through theexisting hole as shown.Trim excess ties with side cutters.(ref. diagram43).

42.

Diagram: 42 - CONNECT VEHICLE & CANOPY HARNESSES

43.

Diagram: 43 - CABLE TIE HARNESSES

CHECKCANOPY LAMP

WORKS

CHECKBRAKE LIGHTS

WORK

TRAILERHARNESS

VEHICLEHARNESS

FITCABLE TIE

FITCABLE TIE

TOW BARHARNESS

3

1

SPARETYRECHASSIS

RAIL

EXISTINGHARNESS

VEHICLEHARNESS

FEEDCANOPY HARNESS

BETWEEN TUB & CABIN,THEN OVER CHASSIS RAIL

1

CONNECTCANOPY HARNESS

TO VEHICLE HARNESS

FITCABLE TIE

2

VEHICLEHARNESS

STOP LAMPHARNESS

REAR BUMPER

CA

BIN

OF

VEH

ICLE

CHASSISRAIL

LH REARGAS STRUT

CHASSISRAIL

REAR TYRE

FITCABLE TIE

EXISTINGTUBE

SPARE TYREWHEELARCH

CANOPY HARNESS

EXISTINGWIRING

VEHICLEHARNESS

CANOPYHARNESS

CONNECTION BETWEEN CANOPY& VEHICLE WIRING HARNESS

3

FIT CABLE TIES4

2

12/08/10 of 24


Water test canopy checking for waterleaks. (ref. diagram47).

47.

Diagram: 47 - WATER LEAK TESTING

FITCABLE TIE

Using alcohol wipe provided in the kit,clean the driver’s side top corner of thetub as shown, and wipe away residuewith a dry clean cloth.Remove tape liner from adhesive tie padand position on the tub in area previouslycleaned as shown. Apply pressure toensure maximum adhesion.(ref. diagram45).

Fit a cable tie through the adhesive tiepad previously fitted to the front of thetub and secure the canopy wiring harnessas shown. Trim excess tie with sidecutters. (ref. diagram46).

45.

Diagram: 45 - IT ADHESIVE TIE PAD

46.

Diagram: 46 - SECURE CANOPY HARNESS

CANOPY

CABIN

TUB

1FITADHESIVE

TIE PAD

2

Clean canopy including all windowsand vehicle thoroughly .Place fitting instructions in theCustomers log book, and ensurepage 23 of these instructions arediscussed with the customer and acopy is given to the customer.(ref. diagram48).

48.

Diagram: 48 - FINAL CLEANING

12/08/10 of 24


PLACE FITTING INSTRUCTIONSIN THE CUSTOMERS LOG BOOK

12/08/10 of 24


THIS FACE OUT




IN CANOPYSIDE RAIL


Ø54mm HOLE SAW

HOLDEN COLORADO FRONT AND MIDDLEBED LINER TEMPLATE

100mm when printed

12/08/10Page 22 of 24


100mm when printed

HOLDEN COLORADO REARBED LINER TEMPLATE

THIS FACE OUT




IN CANOPYSIDE RAIL


1

MARK ANDCUT-OUT

RECTANGULARPROFILE

2

12/08/10Page 21 of 24


100mm when printed

HOLDEN COLORADO REARTAILGATE LINER TEMPLATE

HO

LDE

N C

OLO

RA

DO

TAIL

GAT

E L

INE

RLH

TE

MP

LATE

LIN

E U

P W

ITH

OU

TER

TAIL

GAT

E L

INE

R E

DG

E

MA

RK

TH

ES

ETW

O (2

)ED

GE

S&

RA

DIU

S

LINE UP WITH SIDETAILGATE LINER EDGE

THIS

FA

CE

OU

T

MA

RK

TH

ES

ETW

O (2

)ED

GE

S&

RA

DIU

S

HO

LDE

N C

OLO

RA

DO

TAIL

GAT

E L

INE

RR

H T

EM

PLA

TE

THIS

FA

CE

OU

T

LIN

E U

P W

ITH

OU

TER

TAIL

GAT

E L

INE

R E

DG

E

LINE UP WITH SIDETAILGATE LINER EDGE

12/08/10 of 24


WARNING! - SAFETY!• Do Not use the canopy as a passenger compartment.• Do Not operate/drive vehicle with fold up windows or rear door open. They must be closed when vehicle is in motion.• Do Not store or transport volatile materials, such as solvents, chemicals or liquids as fumes may accumulate inside canopy. Do Not allow solvents, chemicals or oils to come in contact with the canopy. If this should occur clean the canopy immediately with a mild detergent and water solution.• Do not stand/sit or rest heavy objects on Canopy.• Do not fill volatile liquid containers while inside canopy such as fuel cans.• VEHICLES FITTED WITH A BED LINER: Static electricity can cause fire when fuel is pumped into ungrounded fuel containers or equipment (eg: motorcycles, chainsaws etc..). Do Not fill fuel containers or equipment within the vehicle tray as static electricity can cause fuel to ignite, resulting in damage, injury or death. To avoid electricity build-up, place fuel container or equipment on the ground before filling.

MaintenanceOnly use mild detergents or wax polish. Do Not use abrasive compounds on painted or plastic finishedcanopy surfaces.The gas struts are self lubricating and should only be cleaned with a damp cloth, when regularly cleaningthe vehicle. Premature seal failure will result if solvents or lubricants are used to clean struts.Gas struts must be orientated as installed, cylinder (wide end) to canopy and rod (narrow end) to glass.Lightly coat the door and window rubber assemblies with a silicon spray after cleaning periodically.Only locks and lock recesses are to be lubricated with Graphite Powder.Vaseline may be used on the rotary catches on the rear door.DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.Check canopy attachment clamps every 1000 Km.Clamp bolt recommended torque setting is (9 Nm or 6.64 lb/ft).If removed, bolts must have LOCTITE 277 re-applied and be re-tightened on refitting to specified values.CHECK regularly that all screws and fasteners holding windows and doors are tight.The rear tailgate protection tape must be replaced periodically to minimize paint scuffing caused by the canopy rear door opening and closing.

Warranty TermsEGR warrants that the ABS Canopy will be free from defects in material and workmanship for a period of three (3) years from the retail date ofpurchase. The gas struts are warranted for one (1) year from the retail date of purchase.This warranty only applies to the original purchaser and is nontransferable. Warranty must be claimed with original sales receipt for proof of purchase.

ExclusionsThis warranty does not cover failure due to neglect, improper installation, including any modifications to installation hardware, alterations, additionof non genuine equipment, abuse, accident, normal wear and tear, lack of maintenance, misuse, and exposure to chemicals that are not safe forplastics or hardware components. Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Canopy is sole responsibility ofthe vehicle owner and operator. Paint wear to the vehicle bed can happen with any Canopy and is the sole responsibility of the vehicle owner.Paint damage to your vehicle is not covered under this warranty.

DisclaimerIn the event that your EGR Canopy is found to be defective under the terms of this warranty, it is at the discretion of EGR to repair or replace thedefective part. Transportation costs and labour are not associated with this warranty claim.

KEY IDENTIFICATION CODE

1234

HOLDEN COLORADO 2006 Onwards CANOPY

Please write the key identification code in the boxes above,and retain this copy with the vehicle service history.

Replacement keys can be purchased from your local dealer.

OWNERS MANUAL SUPPLEMENTIMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S

VEHICLE SERVICE BOOK.

Dealer Name:

Model:

Order Date:

Required By:

Canopy Colour

Canopy Checklist - Details of rectifications required: KEY No. :

Vehicle Damage Check: Detail:

Dealer Code:

Stock No:

Order No:

Vin No:

1. Check paint on canopy

2. Cleanliness of canopy inside and outside

3. Canopy sealing to tray, tub spacer rail, tub stop rail and 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. IMPORTANT! Loctite 277 applied to all Clamp Bolt Threads

10. Rear Door, Side Door’s and Front window operation

12. Operation of Brake Light

13. Operation of interior light

13. Water Tested for leaks

14. Clean up of work area

15. Comment

Record Canopy Serial Number: Checked By:

Vehicle Type: LX LT-R

Vehicle received and Checked by Dealer Staff:

Fitted By:

12/08/10 of 24


INSTALLATION CHECKLIST

(located on inside LH rear pillar of canopy shell)

canopy installation instructions holden … d-max canopy fitting... · installing the canopy. (ref....

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