IMPORTANT!• Read instructions carefully before installation.• It is strongly recommended that installation is conducted by an authorised 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)

• Non Permanent Marker• Spanners 10 and 13mm

• Adjustable Spanner• Sockets & Driver 10 and 13mm

• Pliers or Similar• Torque Wrench 7-20Nm• Sikaflex 252• Dispensing Gun for Sikaflex

PARTS CHECK SHEET CANOPY REAR DOOR WINDOW REPLACEMENTS

PARTS IN MAIN CARTON

Rear Door Windowwith HingesQty - 1

PARTS IN REAR DOOR LOCK (PROVIDED FOR CLARITY ONLY, TO BE PURCHASED SEPARATELY IF REQUIRED)

Lock AssemblyQty - 1

Lock AssemblyQty - 4

Lock KeysQty - 2

PLEASE NOTE: CANOPY REAR DOOR WINDOW IS SUPPLIED WITH-OUT A LOCK.- YOU CAN RE-FIT PREVIOUS (NON-DAMAGED) LOCK TO THE NEW WINDOW. - YOU CAN ORDER A NEW SET OF LOCKS FOR THE REAR WINDOW & THE SIDE

WINDOW, SO THEY ARE KEYED ALIKE • REAR DOOR LOCK (REFER FITTING INSTRUCTIONS CP0055 FOR INSTALLATION).

• GAS STRUTS CAN BE ORDERED SEPARATELY AND ARE NOT INCLUDED

Clean Canopy with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

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Page 1 of 625/07/11

Installation Time: Approx. 30 Minutes

CanopyRear Door Replacement Instructions

( WIND 0004)

Fitting Instruction(FIT-CP0053)Qty - 1

FittingInstruction

1.

2.

3.

Diagram: 3 - DISCONNECT GAS STRUTS

Diagram: 2 - MARK HINGE LOCATIONS ON CANOPY

Diagram: 1 - CLEAN & CLEAR WORK AREA

Ensure that any broken glass is removedfrom the window frame & canopy interior.Ensure work area has been made safe.(ref. diagram1).CAUTION: Use caution when workingnear broken edges.Use a vacuum cleaner to removebroken glass.

Carefully open the rear door.Using a non permanent marker, markthe position of the two (2) hinges on thecanopy as shown to assist with positioningthe replacement door. (ref. diagram2).

Detach gas struts from the canopy reardoor by inserting a small flat bladescrewdriver and adjusting the spring clipon the strut as shown. (ref. diagram3).

DO NOT CLEANGLASS WINDOW PANELS

OPENREAR DOOR1

1DETACHGAS STRUT FROM

CANOPY REAR DOOR

MARKHINGE POSITION

2

TO REMOVE:

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REMOVE BOLT

NOTE ORIENTATIONOF THE SPRING

1

NOTE ORIENTATIONOF THE SPRING

3

REMOVE LEVERASSEMBLY

REMOVESPRING

REMOVE LOCK NUT

REMOVE SPRING RETAINER

REMOVE NUTS& WASHERS

4.

5.

6.

Diagram: 6 - DISASSEMBLE (IF NEW LOCK WAS ORDERED)

Diagram: 5 - (OPTIONAL) REMOVAL OF (NON-DAMAGED) LOCKS

Diagram: 4 - UNDO HINGE NUTS AND REMOVE REAR DOOR

Two (2) people are required for this step.One person will need to support the weightof the door and carefully remove it whenthe hardware has been removed.The other person will need to be inside thecanopy to remove the four (4) nuts andwashers securing the hinges to the canopyas shown. Remove old Sikaflex sealant on the outsideof the canopy beneath the hinges. Clean with wax and grease remover and dry.IMPORTANT: Take care when removingthe nuts and washers, by supporting andremoving the metal plate, as the nuts arethe only items holding the plate in place.If metal plate is not supported it couldfall and cause damage to the vehicle oryourself. (ref. diagram4).

Remove plastic cover by removing two (2)phillips head screws.Disconnect the pullrods as shown.Note the orientation of the spring.Using a 10mm socket or spanner remove the interior handle and the bolt securing the lever assembly to the lock.Remove the lever assembly and spring.Remove the lock nut and spring retainer.Remove the nut securing the handle to thedoor. Remove the handle assembly fromthe door as shown.(ref. diagram5).

If new lock was ordered, note the orientation of the spring.Using a 10mm ring spanner or socket remove the interior handle and the bolt securing the lever assembly to the lock.Remove the lever assembly and spring.Remove the lock nut and spring retainer.Remove the nut and washers from thethread on the handle as shown.Remove and retain the plastic cover andhardware from the new door.(ref. diagram6).

VIEW FROM INSIDE THE CANOPY LOOKING REARWARD

REMOVEHINGE NUTS,

WASHERS ANDMETAL PLATE

2

SUPPORTMETAL PLATE

REMOVEREAR DOOR3

REMOVE INTERIORLOCK COVER

UNCLIP PULLRODSFROM RETAINER CLIPS2

1

13mm

10mm

1

7 2

REMOVE BOLT4

3

REMOVE LEVER ASSEMBLY5

4

REMOVE SPRING6

56

REMOVE LOCK NUTREMOVE SPRING RETAINERREMOVE NUTS & WASHERS9

REMOVEHANDLE ASSEMBLY

10

78

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7.

8.

9.

Diagram: 9 - APPLY SIKAFLEX TO HINGE STUDS

Diagram: 8 - FIT SPRING & LEVER ASSEMBLY

Diagram: 7 - ORIENT AND FIT LOCK TO WINDOW

Fit the handle to the new door and securewith removed nut and washers.Fit spring retainer and secure with lock nut.Re-fit the spring in the orientationpreviously noted. (ref. diagram7).

Fit the lever assembly and secure withbolt and washer as shown.Using a 10mm ring spanner tighten the boltto secure the lever assembly to the lock.Using pliers or similar you will need to bringthe long leg of the spring around to the frontof the cam as shown.Connect the pullrods, Do Not replace thecover at this stage. (ref. diagram8).

Apply Sikaflex bead in 5mm diameter aroundeach of the four (4) studs on the top of hingegasket, onto the gasket surface that willcontact the canopy. (ref. diagram9).

CLIP PULLRODSINTO RETAINER CLIPS4

FIT HANDLE1

FIT LEVER ASSEMBLY

CAM

SPRING IN ITSRELAXED STATE

APPLY SIKAFLEXAROUND STUDS

RUBBER GASKET

1

TIGHTENBOLT TO 7Nm

FIT SPRING TOFRONT OF CAM

FIT NUTS & WASHERSDO UP TO 5Nm

2

FIT SPRING RETAINER3

FIT LOCK NUT DO UP TO 7Nm

POSITION SPRING RETAINER

4

5

2

3

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Page 4 of 625/07/11

1

NOT SUPPLIED

11.

Diagram: 11 - CONNECT GAS STRUTS

Attach gas struts. Narrow end should beattached to the rear door strut bracket.Attach wide end to the strut bracket on thecanopy clamp frame as shown.Repeat for the other side of the rear door.(ref. diagram11).It is important gas struts are orientatedcorrectly.

ATTACHGAS STRUTTO CANOPY

CLAMP FRAME

2 MOUNT WIDE END OF GAS STRUTTO CANOPY CLAMP FRAME

1 ENSURE NARROW ENDOF GAS STRUT ISMOUNTED TO THE

REAR DOOR

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CONTINUE TO NEXT PAGE

10.

Diagram: 10 - FIT REAR DOOR AND SECURE HINGES

Two (2) people are required for this step.One person will need to support the weightof the door and carefully align the hingeswith lines previously marked on the canopy.The other person will need to be inside thecanopy to re-fit the metal plate and securethe four (4) nuts and washers to the threadson the hinges as shown and tighten to 17Nm.(ref. diagram10).

VIEW FROM INSIDE THE CANOPY LOOKING REARWARD

RE-INSTALLHINGE NUTS,WASHERS &

METAL PLATEDO UP TO 17Nm

3

FITREAR DOOR

1

ALIGN HINGES TO MARKED LINES2

13mm

12.

Diagram: 12 - CHECK REAR DOOR & LATCHING OPERATION

IMPORTANT: Open both side windows.Close the rear door firmly, from centre of lowerrear door sash without slamming it too hard.NOTE: Latch has 2 stages of engagement.Ensure canopy engages with secondstage of latch and the lower rear doorseal, seals against the tailgate.You may also need to adjust the latch strikerhoops on the rear door frame, loosen boltswith a 10mm socket adjust and tighten toTorque 9Nm. Ensure from inside the canopythe seal on the lower door sash still seals tothe tailgate.Test both rear door keys work to lock andunlock the rear door.If the rear door handle does not lock,unclip the pull rods and wind to lengthenthem slightly.Re-check rear door lock function.When the rear door locks, re-fit the plasticcover and hardware. (ref. diagram12).

OPEN & CLOSEREAR DOOR TO

CHECKLOCK OPERATION

DETAILS TO ADJUST PULLRODS

ADJUST LENGTHOF PULLRODS BY ROTATION

ANTI-CLOCKWISE = LENGTHEN

4

UNCLIP PULLRODSFROM RETAINER CLIPS

REPLACE INTERIOR LOCK COVER

RE-CHECK LOCK FUNCTION5

CLIP PULLRODSINTO RETAINER CLIPS6

3

7

CLOSE REAR DOOR &CHECK 2 STAGE LATCHING &DOOR SEALS ON TAIL-GATE10mm

1

2

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