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Total Pages: 1927/08/13
Approx Bull Bar Weight: 31KGAccessory Part No. EGR-AMRK-BBAR
VW AMAROK(2011 Production Onwards)
BULL BARINSTALLATION INSTRUCTION
!
SK602a
IMPORTANT - PLEASE READ INSTRUCTIONS BEFORE COMMENCING INSTALLATION
T25 Torx ScrewdriverT30 Torx ScrewdriverPhillips Head ScrewdriverFlat Blade Screwdriver
Multi-grips
10mm Socket13mm Socket16mm Socket
Torque WrenchRatchet HandleSocket Extension Bar
16mm SpannerMasking Tape
Tape MeasureJigsaw (with coarse wood blade)Hacksaw Blade
Flexible Knife Liquid Nails (or glue suitable for aluminium and polypropylene)
Marking Pen or Pencil
7mm Drill BitElectric Drill
Tin Snips
Personal Protective Equipment - Safety Glasses, Ear Plugs, Gloves
REQUIRED TOOLS | EQUIPMENT
Place these instructions in the vehicles glovebox after installation is complete
To maintain your Bull Bar properly, wash regularly with car wash detergent, hose off & chamois dry. Stubborn grime can be removed with kerosene.
Polished surfaces can be maintained with Autosol metal polish or similar products. Use as recommended.
MAINTENANCE
90 Minutes
27/08/13
Do not attach VFPS to the vehicle using anchorages not intended for this purpose (e.g. engine mountings bolts).
Do not use this product for any vehicle make or model, other than those specified by the VFPS manufacturer.
Do not remove the plaque or label from the VFPS.
Do not modify the structure of the VFPS in any way.
Ensure all torque settings are followed.
It is advisable to seek assistance of another person when installing this product.
SK602a Page 2
VW AMAROK - BULL BARAccessory Part No. EGR-AMRK-BBAR
27/08/13
PARTS LIST
Item Component Description Qty Image
1 Bull Bar Assembly 1
2 Rear Mount Bracket LH 1
3 Rear Mount Bracket RH 1
4 Wheel Arch Liner Bracket LH 1
5 Wheel Arch Liner Bracket RH 1
6 10G x 3/4" Self Tapping Screw 8
7 M6 Scrivet (Small) 4
8 M6 Flat Washer 2
9 M8 x 30mm Hex Head Bolt 2
10 M8 Flat Washer 2
11 M8 Spring Washer 2
12 M10 x 40mm Hex Head Bolt 6
13 M10 Flat Washer 14
14 M10 Spring Washer 8
15 M10 Hex Nut 8
16 Scrivet (Large) 4
17 LH Infill Panel
RH Infill Panel
Ziptie
1
18
19
1
10
SK602a Page 3
VW AMAROK - BULL BARAccessory Part No. EGR-AMRK-BBAR
27/08/13
Layout
Rea
r Mou
nt
Bra
cket
RH
Rea
r Mou
nt
Bra
cket
LH
M8
x 30
mm
B
olt
(typ)
M8
Flat
Was
her
(typ)
10g
x 3/
4S
elf T
appi
ng S
crew
(typ)
Whe
el A
rch
Line
r Bra
cket
LH
M6
Scr
ivet
s(ty
p)
Bul
lbar
A
ssem
bly
RH
Infil
l P
anel
10g
Sel
f Ta
ppin
g S
crew
(typ
)
M6
Flat
W
ashe
r(ty
p)
M8
Spr
ing
Was
her
(typ)
M10
x
70m
m B
olt
(typ)
M10
Fla
tW
ashe
r(ty
p)
M10
Fla
tW
ashe
r(ty
p)
M10
Spr
ing
Was
her
(typ)
M10
Hex
Nut
(typ)
1
68
Scr
ivet
(L
arge
)
2
910
11
1213
13
6
7
3
1514
Bra
cket
Wal
ls
4
Whe
el A
rch
Line
r B
rack
et R
H
518
LH In
fill
Pan
el
17
16
Part
Nu
mb
ers
mar
ked
wit
h
an a
ster
isk
are
req
uir
ed o
nly
fo
r fit
men
t to
a v
ehic
le
wit
ho
ut
fen
der
flar
es
1.
Diagram 1: Removal of Fog Light Trims
Remove LH and RH fog lamp trims by prising with a screwdriver and then pulling forwards out of detent.
3.
Diagram 3: Plastic Scrivets
Open the vehicle bonnet. Remove the four plastic scrivets at the top of the grille. Prise the centre section of each scrivet upwards with a flat blade screwdriver before removing the entire scrivet. Retain for reinstallation.
2. Remove the fog lamp retaining screws with a T25 Torx screwdriver. There are three screws on each side. Pull the fog lamps forward out of bumper and separate the electrical connectors. The screws can be discarded. Retain the fog lamps for reinstallation.
Diagram 2: Removal of Fog Light Assemblies
SK602a Page 4
VW AMAROK - BULL BARAccessory Part No. EGR-AMRK-BBAR
27/08/13
Diagram 5: Fender Joint Screws
5. Remove screws from bumper to fender joints using T30 Torx screwdriver (one screw each side). These are aligned upward and are accessed from below.Retain for re-installation.
6. Remove the number plate (if fitted) and retain for reinstallation. Remove the two bumper screws using a T25 Torx screwdriver.
LHS 4.
Diagram 4: Wheel Well Liner Screws
Remove screws from wheel well liners using T25 Torx screwdriver (two screws each side). Retain for re-installation.
Diagram 6: Bumper Screws
SK602a Page 5
VW AMAROK - BULL BARAccessory Part No. EGR-AMRK-BBAR
27/08/13
With the help of a second person, release the bumper from beneath the headlights and move the bumper forwards and parallel off vehicle. Remove the air temperature sensor (1) from the grille (if fitted). Disconnect the front parking sensor electrical connector (2) (if fitted). Fully remove the bumper from the vehicle and retain for further use.
9.
Diagram 8: Wheel Well Liner Screws
8. Remove screws that retain the front edge of the wheel well liners to the underside of the bumper. Remove inner screws using T25 Torx screwdriver and outer screws using T30 Torx Screwdriver.
RHS
7.
Diagram 7: Bumper Bolts
Remove long bolts from fog lamp recesses in bumper using a 13mm socket (one bolt each side).
Diagram 9: Release Bumper Carefully
13mm
SK602a Page 6
VW AMAROK - BULL BARAccessory Part No. EGR-AMRK-BBAR
27/08/13
1
2
Diagram 10: Cut Out Location For Brackets
10. Apply masking tape to the upper bumper surface to ensure the subsequent trimming operation does not scratch the paint. Find the centre by measuring between the two inner vertical ribs of the grille and mark a centre line down the bumper. Locate the front lip or edge feature in the bumper (front "corner" just above number plate recess). Measure down 30mm on the vertical bumper surface and continue this offset to approx. under the headlamps. Locate points 325mm either side of centre. Locate points 465mm either side of centre. Measure down 15mm between these two points to create a recess in the cut line.
11. Measure "point a" vertically down from the headlamp/fender corner. Points b, c, and d are aligned with the edges and features of the fender flare. The outboard point from Step 10 (465mm from centre and 30mm down from corner) is joined to "Point a" in Step 11.
12.
Diagram 12: Trim The Bumper
Trim the bumper along the marked line using a jigsaw or hacksaw blade. Retain the lower section of bumper if vehicle has front parking sensors. If no front parking sensors are fitted, then discard the lower section of bumper.
WARNING: Always wear personal protective equipment when using cutting tools safety glasses, earplugs and gloves. Clean up swarf immediately to avoid a slipping hazard.
SK602a Page 7
VW AMAROK - BULL BARAccessory Part No. EGR-AMRK-BBAR
27/08/13
325
465
30 30 15
Centre
Front Lip (edge)
c.
d.
b.a.
140
140
Headlight
150160
Diagram 11: Masking / Marking Out Bumper
14.
Diagram 14a,b: Remove Old Brackets, Replace With New
(A) Remove the screw from the top of the existing bracket that retains the wheel well liner to the vehicle. Retain the screws but discard the brackets.
(B) Remove the Wheel Well Liner Brackets from the hardware kit and note which bracket corresponds to each side of the vehicle. Fasten the brackets to the vehicle using the screws previously removed.
13. Remove the lower foam bumper support by rotating up and off the chassis cross member. Remove the upper plastic bumper support by rotating up and off the vehicle.
15.
Diagram 15: Fasten Wheel Well Liner Brackets
Use the two holes in the Wheel Well Liner Brackets as a guide and drill through the wheel well liner with a 6mm drill bit. Fasten the wheel well liner to the Wheel Well Liner Brackets with scrivets (small), attaching from the inside of the wheel well (tyre side). Push the body of the scrivet through the wheel well liner and bracket and then depress the centre of the scrivet fully.
WARNING: Always wear personal protective equipment when using cutting tools safety glasses, earplugs and gloves.
SK602a
Diagram 13: Remove Bumper Supports
Page 8
VW AMAROK - BULL BARAccessory Part No. EGR-AMRK-BBAR
27/08/13
16.
Diagram 16: Cutting The Wheel Well Liner
Mark a horizontal line on the wheel well liner approximately 20mm down from t