FORD ESCAPE/KUGA SUV CARGO BARRIER INSTALLATION INSTRUCTION

Transcription

1 This cargo barrier is capable of being located in two positions, behind the 2nd row of seats with the seats in an upright position, and behind the 1st row of seats with the 2nd row of seats in their folded position. The installation kit contains sufficient components for fitment to both locations. A high degree of technical competence is necessary to correctly install this product. We recommend this cargo barrier be installed by an authorised outlet to ensure the barrier installation complies with AS/NZS 4034 Standard. The cargo barrier is designed, manufactured and fitted to decrease the impact hazard in an accident to occupants from cargo carried within the interior cargo space of the vehicle. In the event of an accident, a cargo barrier can reduce injuries caused by cargo intruding into occupant s space. Installation time approximately 1.5 Hours WARNINGS The estimated fitting time is based on an experienced fitter conversant with the fitment procedure Strict compliance with fitting instructions is essential for this safety product to meet its rated capacity. Refer user instructions regarding correct usage of the cargo barrier. Do not modify cargo barrier in any way. Do not use this cargo barrier in any other vehicle for which it is not designed. Modifications to the cargo barrier or its fixings or use in any other vehicle for which it is not designed may void the load rating and warranty. Do not attach the cargo barrier to the vehicle using seat, seat belt or child restraint anchorage s. Where high tensile threaded fasteners are used, the cargo barrier must be installed using the size and grade fasteners specified by Milford Industries. Do not drill, rivet, adhere or attach objects to the front or rear of the cargo barrier. Do not place smaller items, that may bypass the cargo barrier in the event of heavy braking or collision, near the edges of the barrier. Position the load against the cargo barrier. When load is positioned against cargo barrier, secure the load with a restraint system. During a collision moving cargo may damage seat belts or tether straps of a child restraint device, or its anchorage. Load should be carefully positioned so as not to come in contact with these items. Do not obstruct seat belts or child restraints, or their operation. Long thin items of cargo should be positioned in the vehicle with the long axis across the vehicle to minimise the penetration risk. If involved in an accident or accidentally damaged, the cargo barrier should be replaced and the anchorage s repaired to as new condition. Clean with soap and water only. Do not use solvents or chemicals. Discard cargo barrier if it becomes rusted. Do not expose to direct sunlight for long periods. It is extremely dangerous to ride in the cargo area of the vehicle behind the cargo barrier. It is recommended that the cargo barrier be removed. In a collision people or children riding unrestrained in these areas are more likely to be seriously injured or killed. Never leave a child in the vehicle unattended, particularly in the rear cargo area. The cargo area should never be used as a play area for children. The cargo barrier may deform and significantly intrude into occupant s space in an accident. Remember that the tailgate cannot be opened from inside the cargo area. The fixed labeling should not be removed from the cargo barrier. Failure to comply with warning notes may prevent the barrier protecting the occupants. Parents should explain to children how and when to use EMERGENCY ESCAPE HAMMER attached to cargo barrier. Do not remove the rating plaque from the cargo barrier. NOTICE TO INSTALLERS & DISTRIBUTORS Please ensure User Instructions are left with vehicle owner after installation. Page No. 1 of 16

2 IMPORTANT: The installation kit contains sufficient components to fit the cargo barrier. A high degree of technical competence is necessary to correctly install this product. We recommend this cargo barrier be installed by an authorised outlet to ensure the barrier installation is correct. These instructions must be read and clearly understood before commencing installation. Check contents of kit before commencing fitment and report any discrepancies or damage. Parts List Item Component Name Part No. Qty 1 Cargo Barrier ASM (not shown) Bottom Bracket ASM Mounting Plate ZP Screw - Button Head, M10 x 1.5 x 16mm ZP Cover Plate Screw - CSK, 5/16 BSW x 1/2 ZP Trim plug - Base Trim plug - Insert Marking Pin - M10 x 25mm Installation Tool - Long Rust Preventative Sealer (Sachet) Warning Label (Orange) Milbolt - M10 x 29mm Milbolt - M10 x 19mm Wave Washer - 10mm Marking Template - (roof mounts) Tube Extension Strap Flat Extension Strap LHS Flat Extension Strap RHS Support Leg ASM E and OE Errors and Omissions Excepted Page No. 2 of 16

3 ADVICE TO FITTER Note: To fit the cargo barrier the following is essential: (where applicable) Always drill perpendicular to surface (Unless stated otherwise). A positive drill stop should always be used to prevent accidental damage to external panels, fuel lines etc. Ensure Safety Eye Protection and Gloves are worn as required when using cutting tools. When cutting metal panels be very careful of sharp edges, for risk of skin cuts etc. Care should be taken when applying Rust Preventative sealer to all holes drilled, to negate the possibility of skin and eye irritation. Check screws in relevant components by hand before installation. Should there be resistance re-tap threads and re-check. 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. Before drilling to install this cargo barrier, check for concealed wiring looms. E.g. tow bar, reversing camera, reversing sensor wiring etc.. Relocate before drilling to avoid damage. CARE SHOULD BE TAKEN NOT TO CROSS THREAD THE FASTENERS DURING INSTALLATION OF COMPONENTS TO THE VEHICLE. TOOLS REQUIRED Steel Rule Socket wrench Metric hex sockets Trim removal tools Hammer Screwdriver (#4 Phillips) Screwdriver (small flat blade) Power Drill Masking Tape Marker Pen Centre Punch 5mm, 9mm, 11mm, 12mm Drill Bits Long Nose Pliers Drill stop s 22mm Hole Saw 25mm Vinyl Cutter Hole De-Burring Tool Hex bits & driver Magnetic Pickup Tool Rust Preventative Applicator Vacuum Cleaner Cover sheet / Drop sheet Torque Wrench (8Nm/44Nm) Clean Rag Turpentine (for tailgate door seal, sealant removal) Duct Tape Page No. 3 of 16

4 FORD ESCAPE/KUGA SUV PREPARATION FOR FLOOR MOUNTS 1. Remove the cargo area cargo blind if installed Lay 2nd row of seats flat. Remove cargo area floor panel. 4. Remove the spare wheel. 5. Remove the jack holder styrene foam insert. Page No. 4 of 16

5 FORD ESCAPE/KUGA SUV PREPARATION FOR FLOOR MOUNTS - Cont d 6. Remove the styrene foam inserts from the cargo floor area. 7. Remove the 2 screws and 2 clips securing the hard plastic bottom tailgate opening trim, in place. 8. Remove the bottom tailgate opening trim by pulling upwards. 9. Fold the cargo area floor sound deadening forward to expose the metal floor underneath. Page No. 5 of 16

6 MARKING PROCEDURE FOR FLOOR MOUNTS 10. Familiarise yourself with the round holes in the floor panel (circled), which will be used to position bottom brackets for floor marking. LHS Shown 11. Mark a line from the inside edge of the oval hole through the centre of the round hole as shown. 12. Repeat on the other side. (Centre mounting hole) Masking tape LHS Shown 13. Using a bottom bracket ASM (2) as a guide affix masking tape to the side trims as shown. 14. Position the centre mounting hole of the bottom bracket over the existing hole in the floor panel as indicated above. 15. With the mounting holes centred on the marked line from step 11, mark through the rear most bracket hole only, onto the floor panel. (Note: Forward most bracket hole will not be used) 16. With the bottom bracket still in position mark through the captive nut at the top of the bracket onto the masking tape. 17. Repeat steps 13 to 16 on the other side. Page No. 6 of 16

7 DRILLING PROCEDURE FOR FLOOR MOUNTS 18. Centre punch the marked locations from steps 15/17. Also centre punch this location 19. Just behind the centre punched locations from above, also centre punch the peak at the centre of the floor brace panel as shown. (See step 23 for more detail) Pilot drill Pilot drill side trim 20. Using a Ø5mm drill bit with drill stop set at 5mm, pilot drill the centre punched locations through the floor brace panels only. (4 places) 21. Using a Ø5mm drill bit with drill stop set at 5mm, pilot drill the marked locations on the side trims. 5mm Page No. 7 of 16

8 DRILLING PROCEDURE FOR FLOOR MOUNTS - Cont d 22. Using a Ø11mm drill bit with drill stop set at 5mm, enlarge only the holes indicated through the floor brace panels. (2 places) Drill Ø11mm 5mm 23. Using a Ø22mm hole saw enlarge the rear most holes only, through the floor brace panels. (2 places) Cut Ø22mm 5mm Ø25mm 24. Using a Ø25mm vinyl cutter enlarge the pilot holes in the side trims also cutting away the sound deadening behind. 25. Remove masking tape. 26. Vacuum away all drilling swarf. 27. Apply rust preventative sealer (11) to all raw edges of holes drilled in metal panels. 11 Page No. 8 of 16

9 INSTALLATION PROCEDURE FOR FLOOR MOUNTS Place a mounting plate (3) over installation tool (10) as shown. Rear mounting plate hole not used 29. Using the 22mm hole in the floor brace panel as an entry point, feed the installation tool in between the panels exiting through the oval hole at the front of the brace panel as shown. (use long nose pliers to assist with this step) 30. Pull the mounting plate into position in between the floor panels. Note: Only the centre and forward mounting plate holes are used to secure floor brackets. 4 Front bracket hole not used Place the rear mounting hole of a bottom bracket ASM (2) over the 11mm hole in the floor panel as shown. 32. Secure the bracket to the mounting plate using M10 button head screw (4). 33. Remove the installation tool by pulling firmly forwards. 34. Align the bracket centre hole with the mounting plate forward hole using a centre punch or Phillips screwdriver as shown. Duct tape Secure the assembly in place using 5/16 BSW CSK head screw (6). 36. With both screws in place tighten and torque up. M10-44Nm, 5/16 BSW - 8Nm. 37. Repeat steps 28 to 36 on the other side with the ends of the installation tool reset. 38. Affix a piece of duct tape over the entry hole in the floor panel as shown. 39. Replace all items except the cargo blind which were removed from the vehicle earlier. Page No. 9 of 16

10 PREPARATION FOR UPPER MOUNTS 40. Place a drop sheet over the cargo area floor and side trims to protect from drilling swarf. 41. Carefully unfasten the tailgate door seal at the sides adjacent to the hard plastic side trims. (take care not to spread sealant used on the gripper part of the door seal) 42. Using a suitable trim removal tool, carefully unclip the back edge of the hard plastic lower trim. 43. Carefully unclip the back edge of the upper hard plastic trim. 44. Starting at the back carefully unclip the top trim panel from the bottom trim panel. (4 clips) Page No. 10 of 16

11 PREPARATION FOR UPPER MOUNTS - Cont d 45. With the trims separated unclip the top trim from the vehicle then carefully remove taking care not to scratch the trim on the lower clips. 46. Repeat steps 42 to 45 on the other side. MARKING PROCEDURE FOR UPPER MOUNTS LHS Shown 16 FRONT OF VEHICLE Join in panel 47. On the LHS (passenger side) position the upper mount marking template (16) as shown and as instructed on the template. 48. With the template in the correct position, mark through the template onto the metal panel at the mounting hole locations. 49. Repeat on the RHS (drivers side) with the template reversed. 50. Centre punch the marked locations from above. (6 places) Page No. 11 of 16

12 DRILLING PROCEDURE FOR UPPER MOUNTS Pilot drill Ø5mm 51. Using a Ø5mm drill bit with drill stop set at 5mm, pilot drill the centre punched locations from step 50. (6 places) 5mm Drill Ø9mm 52. Using a Ø9mm drill bit with drill stop set at 5mm enlarge the outer holes only. (4 places) 5mm Drill Ø12mm 53. Using a Ø12mm drill bit with drill stop set at 10mm enlarge the centre holes only. (2 places) 54. Deburr the drilled holes if necessary. 10mm 55. Vacuum away all drilling swarf. 56. Apply rust preventative sealer (11) to all raw edges of holes drilled in metal panels. 11 Page No. 12 of 16

13 INSTALLATION PROCEDURE FOR UPPER MOUNTS Place a mounting plate (3) over installation tool (10) as shown Use the large hole in the 1/4 pillar just forward of the mounting location as an access point for the mounting plate. 59. Feed the installation tool through the hole and back out through the 12mm centre hole. 60. Pull the mounting plate into position behind the panel with the outer holes aligned. 6 5 Metal panel Whilst keeping hold of the installation tool feed a cover plate (5) centre hole over the installation tool. 62. With all holes aligned secure the assembly in place using CSK screws (6) through the outer holes. 63. Remove the installation tool then tighten the screws. 64. Repeat on the other side with the ends of the installation tool reset Screw a marking pin (9) into a mounting plate with the point + 1 thread protruding. (about 10mm) Page No. 13 of 16

14 INSTALLATION PROCEDURE FOR UPPER MOUNTS Cont d Marking pin witness mark 66. On the side with the marking pin carefully resecure the upper 1/4 trim in place. 67. With the trim back in its correct position apply pressure to the trim face at the approximate location of the marking pin until a positive witness mark can be seen on the cabin side. Mark position if necessary. Pilot drill then cut Ø22mm 68. Carefully unclip just the back edge of the upper trim. 69. Using a Ø5mm drill bit with drill stop set at 10mm, pilot drill the marked location from above. 70. Using a Ø22mm hole saw with drill stop set at 5mm enlarge the hole in the trim. 71. Clip the 1/4 trim back in place and remove the marking pin. 72. Repeat steps 65 to 71 on the other side. 7 Cross section of trim plug ASM 5mm 73. Carefully deburr the cut holes in the 1/4 trims if necessary. 74. Vacuum away all drilling swarf. 75. Push a trim plug base (7) into one of the cut holes with the lid facing forwards. 76. Push the retention legs outwards gripping the backside of the trim. 8 Note: It is important to ensure the base legs are fully back before inserting centre plug 77. With the trim plug base legs pushed fully outwards, push a trim plug insert (8) into the base until it clips in place flush. 78. Repeat steps 75 to 77 on the other side. 79. Reset the tailgate door seal back over the hard plastic trims. Page No. 14 of 16

15 AFFIXING OF WARNING LABEL 80. Clean the area inside the drivers door opening as shown. 81. Affix orange warning label (12) at that location as shown. 12 Please ensure User Instructions are left with vehicle owner after installation. INSTALLATION OF CARGO BARRIER Behind 2nd row of seats 1. Ensure the cargo barrier straps are pivoted towards the meshed side of the cargo barrier. 2. Ensure the cargo area floor panel is in its lower position. (Refer owners handbook for details) 3. With the 2nd row of seats folded down manoeuvre the cargo barrier through the tailgate opening with the top of the cargo barrier leaning forward and the meshed side of the barrier towards the back of the vehicle. 4. With the cargo barrier bottom sitting in the behind 2nd row seats position, lean the cargo barrier backwards. 5. Attach the top straps to the upper mounts using 29mm Milbolts (13) with wave washers (15) under heads. 6. Attach the bottom straps to the bottom side mounts using 19mm Milbolts (14) with wave washers (15) under heads. 7. Tighten all Milbolts including the ones securing the bottom straps to the cargo barrier brackets. 8. Reposition the 2nd row seat backs. 9. Reinstall the cargo blind if required. 13 & 15 19mm Milbolt with Wave washer 14 & 15 Page No. 15 of 16

16 INSTALLATION OF CARGO BARRIER Behind 1st row of seats 1. Remove the cargo blind if fitted. 2. Remove the head restraints from the 2nd row of seats and store in a safe place. 3. Fold the 2nd row of seats down flat and move the front row of seats forward on their sliders to allow manoeuvring space. 4. If moving from the rear position undo the Milbolts securing the bottom straps to the cargo barrier brackets. (Leave the short bottom straps attached to the bottom side mounts) 5. If moving from the rear position undo the Milbolts securing the top straps to the upper mounts. 6. Lean the cargo barrier forward then remove the cargo barrier from the vehicle through the tailgate opening. 7. Manoeuvre the cargo barrier back into the vehicle but with the top of the barrier leaning backward. 8. Lay the cargo barrier on it meshed side on the back of the folded seats. 9. Attach the tube support legs (20) to the leg brackets on the cargo barrier as shown. 10. Move the cargo barrier into position behind the 1st row of seats with the support legs sitting on the floor. 11. Attach the tube extension straps (17) to the top straps using 19mm Milbolts (14) (2 per strap). 12. Attach the other end of the tube extension straps to the upper mounts using 29mm Milbolts (13) with wave washers (15) under heads. 13. Attach the flat extension straps (18/19) to the bottom straps as shown using 19mm Milbolts (14) (2 per strap). 14. Attach the other end of the flat extension straps to the cargo barrier brackets using 19mm Milbolts with wave washers under heads. 15. Tighten all Milbolts 16. Reposition 1st row seats & 15 19mm Milbolt with Wave washer 29mm Milbolt & 15 IMPORTANT NOTE: Check that all bolts and screws are tight and re check periodically. Page No. 16 of 16