download 1. Vehicle Preparation. (a) Using tape measure, measure rearward
from front window lace 425mm ± 25mm (16¾” ± 1”) and mark the factory
ditch mold for cutting. (Fig. 1-1a) (b) Carefully lift ditch molding,
starting at the rear to just beyond the cut line. Do not remove molding
totally from front ditch & clip. Place a protective cloth. (Fig.
1-1b) (c) Using shears, cut ditch mold. (Fig. 1-1c) (d) Carefully
remove any remaining tape residue from rear of ditch. (e) Using trim
removal tool and rubber mallet, break off vertical walls of rear ditch
clips (RH & LH). Wedge trim removal tool in from outside then give
it a sharp blow with the rubber mallet. This should cause wall to break.
Repeat for both sides.
(Fig. 1-2) (f) Clean work area before installing rails (1) Saturate
a clean lint-free cloth with approved cleaner and clean the work
surface of the vehicle. Follow the solvent manufacturer’s directions
carefully. Do not allow cleaner to air dry. (2) Wipe the clean surface
with a clean, dry, lint-free cloth. 2. Prepare Roof for Rack
Installation (Fig. 2-1) (a) Puncture tape that covers the 10 weldnuts
(5 RH & 5 LH) with a ball point pen. (b) Using an X-Acto knife or
de-burring tool, carefully remove all seal material so that the weld nut
is visible and no seal material is down near the threads. 3. Install
Mastic Washers (Fig. 3-1) (a) Remove tape backing from the adhesive
backed washers and install to bottom of side rail base (5 places each
side). 4. Secure Rails to Roof (Fig. 4-1) (a) Fit rail into ditch
above hole positions and hand start 5 T-30 mounting screws per rail.
(b) Remove tape backing from rear ditch molding. (c) Using the hand
roller, roll around the rear ditch molding with at least 15lbs (7kg) of
pressure to ensure complete adhesion of tape to vehicle. (d) Using the
T-30 torque wrench, torque bolts to 13.0 – 13.6 Nm (115 – 120 Lbf.-in.)
5. Install Covers (Fig. 5-1) (a) Align cover over clips on side rails.
Starting from the center moving outward, press down onto rail until all
clips are fully engaged (9 places per side). NOTE: Verify clip
orientation to rail cover before installation. RH & LH sides are
different. 6. If Crossbars are being installed at this time, proceed to
STEP 7, if NOT then: (a) Use 3/32” or 2mm T-Handle tool or equivalent
to insert plugs (4 each side). (Fig. 6-1) (b) Place the crossbar kit
box inside the cargo area. (c) Place installation instructions in the
glove box.