kia sportage - imageapi.partsdb.com.au

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KIA SPORTAGE Kit Part No: D9A30APK00

Cargo Barrier

Fitting Instructions

502750FI C

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General Notes Read through the fitting instructions before installation of the accessory. Install the accessory following the fitting instructions.

Failure to do so may cause damage to the vehicle or the accessory.

Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local recycling regulations.

It is always recommended that this accessory is fitted by a qualified Kia Technician.

Safely store and protect any removed vehicle components.

Ensure all bare metal surfaces are protected using automotive bare metal primer and touch-up paint, or suitable automotive rust

inhibitor.

Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.

Before marking or drilling to install this Cargo Barrier, check vehicle for LPG conversion & non standard fuel tanks. Locate tanks

and all lines attached and take EXTREME CARE not to damage whilst installing this Cargo Barrier.

Safety Notes Check that all work practices comply with safety standards.

Please wear appropriate clothing and use safety equipment.

Parts Supplied

6

Hex Head Screw x4

1 5 4 3 2

Cargo Barrier x1 Floor Bracket x2 Roof Bracket x1 Threaded Insert x2 Mounting Plate x2

12 9

Milbolt (M10x29mm)

8 7 11 10

Mtg. Plate Seal x2 Wave Washer x4 Trim Plug x2

15 14

Warning Label x1 Caution Label x1

(Orange) (Silver)

Automotive Rust Inhibitor x1

(M10 x 20mm)

Hex Head Screw x2

(5/16” x 1”)

13

Milbolt (M10x44mm)

16

Felt Tape x1

Tools Supplied

23 22 21 20

Marking Pin x2 Cotton Bud x1 Cleaning Pad x1 Installation Tool x2

17

Trim Garnish x2

18

Garnish Spacer x2

19

Owners Manual

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Tools Required

13mm Socket Steel Rule Socket Wrench 10mm Socket

Drill Stops Vacuum Cleaner Power Drill Black Maker Pen

5mm Drill Bit

11.5mm Drill Bit

Torque Wrench Masking Tape Trim Removal Tool Tape Measure 12mm Drill Bit Sharp Knife

Threaded Insert Tool with Long Mandrel Ø20mm Vinyl Cutter Deburring Tool

Drop Sheet

Centre Punch Hammer

Clean Cloth

16mm Socket

20Nm

10mm Drill Bit

Ø20mm Hole Saw

Spacer Block Scriber

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Remove the spare wheel, scissor jack and tool pouch.

Always refer to the vehicles Workshop Manual when removing vehicle components.

Important

Step 1

Step 3

Remove the cargo area floor panel and the cargo blind if fitted.

Step 2

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Note: On some variants, the vehicle trim has an additional trim locating foot. If present cut this foot away, back to the edge of the trim using a knife.

On the LHS (Passenger side) of the vehicle, adjacent to the

spare wheel hold, affix masking tape to the floor panel in the approximate location shown.

Mark the LHS floor mounting plate centre hole location as

shown.

36mm from the floor gusset flange rear edge.

8mm from the floor gusset flange inner edge.

On the RHS (Drivers side) of the vehicle adjacent to the spare

wheel hold, affix masking tape to the floor panel in the approximate location shown.

Mark the RHS floor mounting plate centre hole location as

shown.

36mm from the floor gusset flange rear edge.

8mm from the floor gusset flange inner edge.

Tools Used

Masking Tape

Tape Measure or Steel Rule

Marker Pen

Using a mounting plate (2) as a template, locate the centre

hole over the marked location from step 4. With the mounting plate held parallel to the side trim, mark the outer hole positions onto the floor panel.

Repeat on the RHS (Drivers Side).

Tools Used

Mounting Plate (2)

Marker Pen

Use (2) as a template to mark the outer holes

Step 4

Step 6

8mm

36mm

Fro

nt

Fro

nt

36mm

8mm

Tools Used

Masking Tape

Tape Measure or Steel Rule

Marker Pen

Step 5

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Tools Used

Hammer

Centre Punch

Centre punch the 6 marked positions on the floor panel.

Using a Ø5mm drill bit with the drill stop set at 10mm, drill a pilot

hole at each of the centre punched locations (6 places).

Using a Ø10mm drill bit with the drill stop set at 10mm, drill out

the outer pilot holes only as shown (4 places).

Using a Ø12mm drill bit with the drill stop set at 10mm, drill out

the centre holes as shown (2 places).

Tools Used

Power Drill

5mm Drill Bit

10mm Drill Bit

Remove the masking tape.

Vacuum away all drilling swarf.

Tools Used

Vacuum Cleaner

10mm

Step 7

Step 8

Step 9

Ø12mm

Ø10mm

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Apply automotive rust inhibitor (7) to all drilled holes using

cotton bud applicator (22).

Tools Used

Cotton Bud (22)

Place the centre hole of a mounting plate (2) over the

installation tool (21).

Repeat for the other floor mount.

Tools Used

Installation Tool (21)

2

21

Fit the mounting plate seal (8) to the mounting plate (2) as

shown.

Bend the end of installation tool as shown.

Repeat for the other floor mount.

8

Care should be taken when applying Automotive Rust Inhibitor to all holes drilled, to reduce the possibility of skin and eye irritation.

Important

Apply automotive rust inhibitor 7

22

Step 10

Step 11

Step 12

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Line up the floor brackets to be symmetrical and approximately

77mm from the side trims, measured adjacent to the ‘D’ anchor.

Lightly tighten all screws.

Using a suitable torque wrench, torque up the floor bracket

screws.

5/16” BSW (6)—8.5Nm

M10 x 1.5 (12)—17Nm

Repeat for other floor mount.

Tools Used

Socket Wrench

Torque Wrench

13mm A/F Socket

16mm A/F Socket

On the underside of one side of the vehicle, locate the 3 drilled

holes.

Pass the installation tool up through the centre hole then hang

the mounting plate in that position.

Repeat for the other side.

From the top side of the floor panel take hold of the installation

tool and align the outer holes of the mounting plate with the drilled holes in the floor.

Position a floor bracket (3) with holes aligned, over the

mounting plate holes. Attach the floor bracket to the mounting plate using hex head screws (6) in the outer holes.

Once the screws are started remove the installation tool by

pulling upwards.

Insert a hex head screw (12) into the centre hole.

Repeat on other side.

Tools Used

Installation tool (21)

Re-install the spare wheel, jack bracket and jack to the vehicle.

Fit marking pins (20) to each of the floor mount bracket captive

nuts as shown.

Reinstall the floor covering in the vehicle.

At the approximate location of the marking pins, apply light

pressure to the floor cover so as to leave an indent in its underside.

Tools Used

Marking Pins (20)

20

3

6

12

Metal floor panel

2 & 8

6 Front

(77mm)

Step 13

Step 14

Step 15

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Remove the floor covering from the vehicle and locate the

marking pin indents on its underside.

Remove the marking pins from the floor brackets.

At each of the marked locations, drill a 5mm pilot hole.

Using a Ø20mm vinyl cutter, cut through the carpet layer on the

top and bottom surface at the pilot hole locations.

Finish cutting through the floor covering using a Ø20mm hole

saw.

Vacuum away any drilling dust then reinstall the floor covering

into the vehicle with the cut holes located over the floor bracket spacer tubes.

Tools Used

Power Drill

5mm Drill Bit

20mm Vinyl Cutter

20mm Hole Saw

Place a clean drop sheet over the cargo area of the vehicle to

protect the trim.

Using a suitable trim removal tool, unclip the rear pillar trim tops

as far forward as the rear windows.

Ø20mm

Tools Used

Drop Sheet

Trim Removal Tool

Using a suitable trim plug removal tool, remove the 2 trim plugs

securing the back edge of the roof lining in place.

Tools Used

Trim Plug Removal Tool

Step 16

Step 17

Step 18

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Tools Used

Spacer Block

Place a spacer block or similar behind the rear pillar trims as

shown.

At each of the trim plug hole locations in the roof lining and using

a Ø20mm vinyl cutter, cut a 20mm hole through the roof lining.

Tools Used

Power Drill

20mm Vinyl Cutter

At each of the trim plug hole locations, enlarge the hole through

the metal panel using a ø11.5mm drill bit with a drill stop set at 10mm.

Deburr the holes if necessary.

Tools Used

Power Drill

11.5mm Drill Bit

Drill Stop

Deburring Tool

Spacer block

Vinyl cut through roof lining ø20mm

10mm

Ø20mm

Metal panel

Roof lining

Ø11.5 mm

Step 19

Step 20

Step 21

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Vacuum away all drilling swarf.

Tools Used

Vacuum Cleaner

Apply automotive rust inhibitor (7) to all the drilled holes in the

metal panel using a cotton bud applicator (22).

Tools Used

Cotton Bud (22)

Insert the roof bracket (4) in between the roof lining and the

metal panel as shown.

Align the holes in the roof bracket with the enlarged trim plug

holes.

Care should be taken when applying Automotive Rust Inhibitor to all holes drilled, to reduce the possibility of skin and eye irritation.

Important

4 Roof lining

Step 22

Step 23

Step 24

Apply automotive rust inhibitor (7)

22

Holes in metal panel

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Screw a threaded insert (5) onto a suitable threaded insert tool.

Place the threaded insert through a hole in the roof bracket and

metal panel behind.

With the threaded insert pushed hard against the outer panel,

pull up the insert to clamp the assembly firmly in position.

5

Due to limited cavity space behind the metal panel, it is important to ensure the threaded insert is always pushed hard against the roof bracket and metal panel whilst using the installation tool, to ensure correct pull up.

Important

Repeat the above procedure for the other hole.

Tools Used

Threaded Insert Installation Tool

Step 25

Step 26

Cross section of threaded insert shown fully pulled up 5

Metal roof panel

4 (Roof Bracket)

Soft roof lining

Tools Used

Threaded Insert Installation Tool

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Screw a marking pin (20) into each of the roof bracket captive

nuts with just the points protruding.

Tools Used

Marking Pin (20)

Affix masking tape to the roof lining adjacent to the marking

pins.

Tools Used

Masking Tape

Step 27

Step 28

At the approximate locations of the marking pins, apply

pressure to the roof lining until the points of the pins can be seen on the cabin side. Mark the pin centres if necessary.

Remove the marking pins.

Tools Used

Marking Pins

Marker Pen

Step 29

20

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Using a scriber pierce a hole through the roof lining at each of

the marked locations from step 29.

Tools Used

Using a 20mm vinyl cutter, cut a hole through the roof lining at

each of the pierced holes.

Remove the masking tape.

Tools Used

Power Drill

20mm Vinyl Cutter

Step 30

Step 31

Insert a trim plug base (17) into one of the outer 20mm holes in

the roof lining, with the cover positioned towards the front of the vehicle.

Using a small screwdriver or similar push the trim plugs retention

legs outwards to engage them in behind the roof lining.

Tools Used

Small Screwdriver

Step 32

ø20mm

17

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Push a trim plug insert (18) into the centre of the trim plug base

until it clips in place flush.

Repeat steps 32 & 33 on the other side, outer hole.

Insert a plastic trim plug (10) into the two centre threaded

inserts.

Remove the spacer blocks and reinstall all trims.

Reset the rubber door seal over the trims and roof lining.

Step 33

Step 34

On the inside of the drivers door opening clean the area shown

using cleaning pad (23), and allow to dry.

Apply the orange warning label (14) to the drivers door opening

location shown.

18

14

Step 35

Tools Used

Cleaning Pad (23)

10

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The Cargo Barrier may be fitted in either the rear position, See

Step 39, or the front position, See Step 40.

Please place the Owners Manual in the glove box after installation is completed.

Please place the Installation Manual in the

glov box after installation completed.e is

Please place the Fitting Instructions in the glove box after installation is completed.



Please place any unused kit items, (e.g. Front position brackets & Milbolts) in glove box after

installation is completed.



On the forward face of the cargo blind, measure and locate the

centre.

From the centre measure towards one end 490mm and mark

this position.

Ensure the forward face of the cargo blind is clean and free of

grease and wax.

Affix the adhesive backed felt (16) to the forward face of the

cargo blind, starting at the marked position from above.

Tools Used

Tape Measure

Marker Pen

Clean Rag

16

490mm

Step 36

Step 37

15

Step 38

On the plastic trim adjacent to the tailgate catch clean the area

shown using cleaning pad (23).

Allow to dry, then apply silver label (15) to the tailgate catch

location shown.

Tools Used

Cleaning Pad (23)

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REAR POSITION CARGO BARRIER INSTALLATION IN VEHICLE

The Cargo Barrier may be fitted in either the rear position, or the front position, See Step 40.

Place the Cargo Barrier in the vehicle directly behind the 2nd row of seats with the rating label (meshed side of barrier)

facing the rear of the vehicle.

Attach the top straps to the upper mounts using 29mm Milbolts (9) with wave washers (11) under their heads.

Attach the short bottom straps to the floor mounts using 44mm Milbolts (13) with wave washers (11) under their heads.

Tighten all Milbolts.

If the centre seat belt is required, open the lid of the plastic mesh insert in the top RH corner of the cargo barrier. Pass the

seat belt through the insert & attach to the centre sash belt buckle.

Note: The Sportage Cargo Barrier has been designed to integrate with the vehicle design. Due to the tight spacing between the rear seat back and the factory cargo blind, it may be difficult to re-install the cargo blind after the cargo barrier installation. Due to assembly tolerances, in some instances it may not be possible to re-install the cargo blind when the cargo barrier is fitted. In order to ensure the cargo blind does fit where possible, please follow the following installation sequence: 1. Fold the rear seats forward. 2. Loosen off the upper and lower cargo barrier straps, and while supporting the cargo barrier, release the upper barrier straps. 3. Push the cargo barrier forwards to allow the cargo blind to be fully inserted into position. 4. Re-position the cargo barrier to allow the upper straps to be loosely reattached. 5. While maintaining forward pressure on the cargo barrier, tighten all upper and lower barrier straps. Having followed this procedure, if it is not possible to re-install the factory cargo blind when the Sportage cargo barrier is fitted, it will be necessary to store the factory cargo blind safely for use when the barrier is removed.

11

13

11

9

13

11

11

9

Step 39

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FRONT

9

11

13

13

11

11

30

30 33

33

Support Legs 31

Folded seats

35

33

The Cargo Barrier may be fitted in either the front position, or the rear position, See Step 39.

Remove all 3 head restraints from the 2nd row seat by pushing the release button on the left hand side of each of the

restraint pillars, then pulling each restraint upwards.

Fold the 2nd row seat back, downward as shown in the owners handbook.

Lay the cargo barrier on its back in cargo area.

Attach the support legs (31) to the cargo barrier brackets as shown using 29mm Milbolts (32).

Position the cargo barrier in place behind the 1st row seats with the support legs resting on the floor.

Attach the top extension tube straps (30) to the top straps using 14mm Milbolts (33) (2 per strap) as shown.

Attach the other end of the top extension tube straps to the upper mounts using 29mm Milbolts (9) with Wave Washers (11)

under heads.

Untie the long bottom straps from the cargo barrier panel.

Attach the free end of the bottom straps to the floor mounts using 44mm M10 Milbolts (13) with Wave washers (11) under

heads.

Tighten all Milbolts.

Attach the lateral support brackets (35) to the long bottom straps as shown using 14mm Milbolts (33).

FRONT POSITION CARGO BARRIER INSTALLATION IN VEHICLE - Requires Genuine Kia Sportage Cargo Barrier Front Position Kit D9A30APK50 sold separately

Step 40

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