vw amarok - egr auto | bar - amarok updated with... · vw amarok (2011 production onwards) bull bar...

Total Pages: 1927/08/13

Approx Bull Bar Weight: 31KGAccessory Part No. EGR-AMRK-BBAR

VW AMAROK(2011 Production Onwards)

BULL BARINSTALLATION INSTRUCTION

!

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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 vehicle’s 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

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• 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.

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VW AMAROK - BULL BARAccessory Part No. EGR-AMRK-BBAR

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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

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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/

4”S

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

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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

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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

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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.

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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.

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Diagram 13: Remove Bumper Supports


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16.

Diagram 16: Cutting The Wheel Well Liner

Mark a horizontal line on the wheel well liner approximately 20mm down from the bottom edge of the Wheel Well Liner Bracket. Cut the wheel well liner off along this line using tin snips or heavy-duty scissors.

WARNING: Always wear personal protective equipment when using cutting tools – safety glasses, earplugs and gloves.

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20 mmgap

18.

Diagram 18: Fasten Bumper To Fender Joints

Install screws from bumper to fender joints using T30 Torx screwdriver. One screw each side.

Diagram 17: Reinstall Cut Bumper

17. Install the top piece of the cut bumper back onto the vehicle. Ensure that the bumper inserts correctly underneath the headlamps and also at the fender flare.

19.

Diagram 19: Fasten Screws

Install screws from wheel well liners using T25 Torx screwdriver. The tag from the fender flare should be on the outside of the wheel well liner. One screw each side.

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21.

Diagram 21: Remove Steel Skid Frame

Remove the steel skid frame from under the vehicle. Remove two bolts on each side at the front and four bolts at the rear. Retain for reinstallation.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Use of a vehicle hoist is recommended but not essential.

WARNING: Heavy weight. A second person may be required to help remove the steel skid frame.

20.

Diagram 20: Install Plastic Scrivets In Grille

Install the four plastic scrivets at the top of the grille. Push in the body of the scrivet and then depress the centre of the scrivet fully.

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22a.

Diagram 22a: Prise Scrivets From Radiator Shroud

Remove the bottom plastic radiator shroud. Prise the centre section out of each white plastic scrivet in the front of the chassis cross beam with a flat blade screwdriver before removing the entire scrivet. These can be discarded.

Diagram 22b: Remove Clips From Radiator Shroud

22b. The rear three underside clips can be carefully prised rearward and down using multi-grips. Be careful not to damage the aluminium of the radiator flange. The large front clip over the chassis crossbeam is released by lifting the centre tongue and pushing the whole shroud rearward.

23. Mark out trim line on the bottom plastic radiator shroud as shown. 100mm x 60mm. Cut and remove these sections using a jigsaw or hacksaw blade. Retain the shroud for reinstallation.

Diagram 23: Mark Out Trim Line and Cut Shroud

100 mmtyp

60 mmtyp

Front clip

Lower clips

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24. Remove the screw from each chassis rail that retains the horn bracket. Prop the horn and bracket in a suitable location or tape to the vehicle so that it does not hang by the electrical cable. The screw can be discarded.

Diagram 24: Remove Screw From Chassis Rail

25.

Diagram 26: Install The Fog Lamps

Remove the Bullbar assembly from the packaging. Do not remove white protective film. Install the fog lamps to the rear of the Fog Lamp Housings using 10g x ¾” Self Tapping Screws from the hardware kit. Do not over tighten screws.

Remove the rear mount brackets from the hardware kit and note which bracket corresponds to each side of the vehicle. Mount the bracket onto the chassis rail on each side. The horn bracket must be located under the rear flange of the mount bracket. Install M8 x 30mm Hex Head Bolt, M8 Spring Washer, and M8 Flat Washer through the mount bracket, horn bracket and into the nut in the chassis. Do not fully tighten.

Horn bracket must be located under the rear flange of the mount bracket

26.

Diagram 25: Install Rear Mount Brackets

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27.

FOR VEHICLES WITHOUT FENDER FLARES.

1. Hold the infill panels into the end caps on the bullbar.2. Drill 7mm diameter holes through end cap and infill panel at rear and front corners as shown.3. Attach the infill panels using the scrivets (Large) provided.

Diagram 27: Installing Infill Panels

11

FOR VEHICLES WITH FENDER FLARES.

If vehicle is fitted with fender flares (higher specification models) Discard Infill Panels and proceed to step 28.

If vehicle does not have add-on fender flares (lower specification models) then continue with the step below.

1

2

3

INFILL PANELS INSTALLATIONINSTRUCTIONS

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28.


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30.

29.

Steps 28 to 31 are for vehicles fitted with front parking sensors only. If your vehicle does not have front parking sensors, please proceed to Step 32.

Remove each sensor from its housing and cut the loom zip tie retainers along the bumper. Retain the parking sensors and loom for further use. Remove the parking sensor housings from the vehicle bumper using a flexible knife blade to cut through the double-sided tape that holds them on. Remove all tape and adhesive residue from the housings.

Mark hole locations on the bullbar as shown for inboard and outboard parking sensor locations. Drill a 5mm pilot hole at each location and then drill out to 20mm at each location. Clean up any burrs around the holes on the outside and inside of the bullbar.

Source glue from a hardware store that is suitable for bonding aluminium and polypropylene (Liquid Nails or similar). Thoroughly clean the bullbar areas where the sensor housings will be attached. Follow the instructions for the glue product and attach the sensor housings to the bullbar, the “open” side of the sensor housings should be oriented with the arrows show. Allow the glue to dry, as per the instructions for the glue product. Do not fit bullbar to the vehicle with insufficiently dry adhesive, as the sensor housings may be bumped or moved.

Diagram 29: Mark and drill sensor holes

Diagram 30: Glue the sensor housings

Diagram 28: Remove sensor loom

30mm

x4

Inboard Outboard

40mm

40mm40mm

Diagram 32: Offer Up The Bull Bar

SK602a

Offer the bull bar up to the vehicle. It is advisable to seek assistance of another person when installing the Bull Bar. Move the bull bar up from slightly underneath the vehicle and ensure that the wheel well liners go inside the bull bar end caps. Push bull bar on and upward and rest the Front Mount Brackets on the chassis cross beam. Ensure the threaded studs on the Rear Mount Brackets go through the slots in the Front Mount Brackets on the Bullbar. While a second person is holding the Bullbar onto the vehicle, install an M10 Flat Washer, M10 Spring Washer, and M10 Hex Nut onto each stud. Do not fully tighten.

WARNING: Heavy weight. A second person may be required to help lift the Bull Bar and position.

Install the sensors and loom to the bullbar, ensuring that the electrical connector is at the left hand (passenger) side. Thread the loom through the mounting brackets. Attach the loom to the bullbar with zip ties at suitable locations.


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Diagram 31: Install Sensor Loom

31.

Loosely install an M10 Hex Head Bolt, M10 Flat Washers, M10 Spring Washer, and M10 Hex Nut into each hole / slot position in the Mount Brackets. This will pull the Rear Mount Bracket and Front Mount Bracket together. Do not fully tighten.

32.

Diagram 33: Install Fasteners

33.

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Gaps to be equal

Centralise the bull bar on the vehicle by checking the distance between the fender flare and End Cap on each side and moving the Bull Bar to make these distances equal. Tighten the M10 Hex Head Bolt and M10 Hex Nut at each position on the Mount Brackets to 50 Nm.

Diagram 35: Centralise Bullbar

35.

Diagram 34: Tighten Rear Mount Brackets

36.

Diagram 36: Check Clearances

CLEARANCE

Check the clearances from the Bull Bar to the bumper along the front and fender flares at the sides to ensure they are approximately equal both sides. Carefully and slowly close the vehicle bonnet and check clearances to the bull bar Side Pipes and Uprights.

!Check these areas for clearance from Bull Bar:

Fender flares

Clearance to Uprights

Bonnet opens and closes freely

a.

b.

c.

c.

b. a.

34. Tighten the M8 x 30mm Hex Head Bolts that retain the Rear Mount Brackets and horn brackets to the side of the chassis to 25 Nm.

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38. Attach the air temperature sensor to the bullbar or grille with a zip tie in a suitable location.

Diagram 38: Zip Tie sensor to bullbar

37.

39.

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Reinstall the bottom plastic radiator shroud. Ensure the large front clip fastens over the chassis cross beam and the lower three clips fasten into the bottom of the radiator.

Lower clips

Diagram 39: Reinstall Radiator Shroud

Adjust the bull bar position (if necessary), loosen the M10 Hex Head Bolts indicated, reposition the Bullbar, and then tighten the M10 Hex Head Bolts to 50 Nm.

Diagram 37: Position Adjustment (If Required)

Front clip

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41.

40.

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Reinstall the steel skid frame by installing the two bolts on each side at the front and four bolts at the rear.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Use of a vehicle hoist is recommended but not essential.

WARNING: Heavy weight. A second person may be required to help install the steel skid frame.

Diagram 40: Reinstall Skid Frame

42.

Reconnect the electrical plugs for the fog lamps.

Reconnect the front parking sensor electrical connector (if fitted).

Diagram 41: Reconnect Foglamps

Diagram 42: Reconnect the sensor

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44. Remove all protective wrap from the Bull Bar. Wipe all fingerprints and marks from the vehicle and Bull Bar.

Diagram 38: Remove Wrap And Clean Bull Bar

PRODUCT CARE INFORMATION

VW AMAROK ALLOYBULL BAR

CUT-OUT AND STAPLE IN A SUITABLE LOCATION IN VEHICLE’S OWNER MANUALIMPORTANT:

This Bull bar is made from aluminium that has been highly polished to a mirror finish. The following regular maintenance actions will be required to remove oxidation and staining from the aluminium surfaces: Wash regularly with car wash detergent, rinse with clean water and chamois. Stubborn grime can be removed with kerosene. The polished aluminium surfaces can be maintained using Autosol or similar products.Plastic mouldings can be maintained using Nulon Ezi-Glide silicon spray or similar products.

APPEARANCE AND PRODUCT CARE:

43. Fit the number plate using the 10G Self Tapping Screws and M6 Flat Washers into the pre-drilled holes in the front of the Bull Bar.

Diagram 37: Fit The Number Plate

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vw amarok - egr auto | bar - amarok updated with... · vw amarok (2011 production onwards) bull bar...

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