EGR RollTrac Manuale utente
RT0063
Page 1 of 33
ISSUE 4: 26/04/23
Installation time: 180 minutes (without tubliner)
INSTALLATION INSTRUCTIONS
ELECTRIC
• Check that all work practices comply with safety standards.
• Please wear appropriate clothing and use safety equipment.
Caution
Safety Notes
• Do not attach EGR RollTrac in a location or by a method not specified.
• Do not use this product for any vehicle make or model, other than those specified in this document.
• Do not remove the plaque or label from this product.
• Do not modify the structure of the EGR RollTrac in any way.
• Read through the fitting instructions before installation of EGR RollTrac.
• Always install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or the accessory.
• Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local recycling regulations.
• It is always recommended that this accessory is fitted by a qualified Technician.
• Safely store and protect any removed vehicle components.
• Ensure all bare metal surfaces are protected using Automotive Bare Metal Primer and touch-up paint.
• Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.
General Notes
Vehicle Model: FORD RANGER
Year of manufacture: MY22 onwards
*RT0063*
IMPORTANT:
IF THE EGR ROLLTRAC IS FITTED TO THE VEHICLE WITH ANY ACCESSORY
LOADED WITH MORE THAN 45KG, A TUB REINFORCEMENT KIT MUST BE
FITTED. THE TUB REINFORCEMENT KIT CAN BE PURCHASED FROM YOUR
LOCAL FORD DEALER OR DIRECTLY FROM EGR (PART No. KIT040256).
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
RT0063
TUB PREP
SECTION B
STEP 1-14
ELECTRICAL
SECTION A
STEP 1-8
EGR ROLLTRAC
ASSEMBLY
SECTION C
STEP 1-11
CALIBRATION
SECTION E
OPERATIONS
FINAL NOTES
FINISH
EGR ROLLTRAC
INSTALLATION
SECTION D
STEP 1-8
Page 2 of 33ISSUE 4: 26/04/23
FINISH
START
INSTALLATION PROCESS
UNPACKING
FITTING KIT
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
KIT CONTENTS - COMPONENT NUMBER AND QUANTITY
LHS RAIL QTY: 1
FR MNT BRK
CLIP3932PC-LH
QTY: 1
MNT BAR
TGAT0032-LH
QTY: 1
MNT BAR
TGAT0032-RH
QTY: 1
FR MNT BRK
CLIP3932PC-RH
QTY: 1
H-BAR CRN BRK
CLIP4106
QTY: 2
MNT BRK
CLIP4108
QTY: 4
REAR SUPP BRK
CLIP4110-LH
QTY: 1
REAR SUPP BRK
CLIP4110-RH
QTY: 1
REAR MNT BRK
CLIP4109-LH
QTY: 1
REAR MNT BRK
CLIP4109-RH
QTY: 1
M6 NUT PLATE
MISC5793
QTY: 2
RHS RAIL QTY: 1
FRONT COVER QTY: 1
CANISTER ASM. QTY: 1
12
34
56
789
11 12 13 14 15
16
10
EGR EGR ROLLTRAC CLAMP KIT IN BAG
EGR EGR ROLLTRAC BULB KIT IN BAG
RT0063
Page 3 of 33ISSUE 4: 26/04/23
17
SIDE RAIL SEAL
EXTR0112-32
QTY: 2
FRONT RAIL SEAL
TAPE0752
QTY: 1
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
SCREW END PAD
MISC5812
QTY: 8
M6x50 HEX HEAD
SCRW0967
QTY: 8
M6x20 HEX HEAD
SCRW0997
QTY: 10
M6x15 HEX DRIVE
SCRW0973
QTY: 14
M6x15 HEX DRIVE
SCRW0973
QTY: 6
M8x25 BUTTON HEAD
HEX DRIVE
SCRW0974
QTY: 6
EGR EGR ROLLTRAC MBAR HARDWARE KIT IN BAG
EGR EGR ROLLTRAC FITTING KIT IN BOX
INSTALLATION
INSTRUCTIONS
&
OWNERS MANUAL
RT0063
Page 4 of 33
ISSUE 4: 26/04/23
18 19 20 21
M6x15 HEX HEAD
SCRW01001
QTY: 16
SPACER
MISC5457
QTY: 6
WATER DUCT
INJM0274-RH
QTY: 1
REAR DRAIN TUBE
(VEHICLES WITHOUT DDK ONLY)
QTY: 2
M6 HEX NUT
NUTS0285
QTY: 8
M6 HEX NUT
NUTS0284
QTY: 2
FIT JIG
MISC5822
QTY: 1
22
23 24 25
26 27
FR DRAIN TUBE
MISC5222
QTY: 2
28 30
31
REAR DRAIN TUBE
(DDK ONLY)
MISC5223-32
QTY: 2
32
CABLE TIE BASE
MISC5128
QTY: 2
33
WATER DUCT
INJM0274-LH
QTY: 1
29
CONS70097
CABLE TIE
QTY: 8
34
35
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
PARTS IN VEHICLE HARNESS
TOOLS REQUIRED - NOT SUPPLIED IN KIT
Page 5 of 33ISSUE 4: 26/04/23 RT0063
ANTI RUST
Torque Wrench
50/50
Isopropyl Alcohol/Water Soapy Water
Silicone Spray
Silicone
Silicone
(non-acidic)
Rust Inhibitor
Flat Screwdriver
Spanners 8,10,13mm
Allen Key 2.5 & 4mm
Ratchet & Sockets
7,10,13mm
Phillips Screwdriver
Drill Tape Measure
Scissors
Masking Tape
Fiberglass Tape
Black Cloth Tape
Anti-abresion tape to seal
holes & slots Non-permanent pen
Drill Bits
Bobbin Sander Ø60mm
Ø60mm
Ø38mm
Ø29mm
Drill Stop
Centre Punch & Hummer
Holesaw
Side Cutters
Cutting device
needed to trim
bed cap
6mm File
1
1
1
GLOSSARY:
Number inside a square indicate part number
Number inside circle indicate the sequence within a step
Number inside the hexagon indicate torque instruction
SPP UNIT
VEHICLE HARNESS
CABLE TIE
QTY: 12
MINI FUSE
25A FUSE
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
RT0063
SECTION - A ELECTRICAL SECTION
Page 6 of 33ISSUE 4: 26/04/23
A
C
DEF
G
H
I
B
AB
CD
FG
E
STEP 1
STEP 2
STEP 5,6
STEP 7
STEP 4
STEP 3
IMPORTANT: DISCONNECT CAR BATTERY NEGATIVE TERMINAL.
FIT THE SUPPLIED FUSES AT THE END OF INSTALLATION.
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
RT0063
Page 7 of 33ISSUE 4: 26/04/23
IMPORTANT: Make sure the fuses are not fitted before making connection.
Connect the vehicle harness branch (B) to vehicle body negative ground as shown and secure with M6 hex nut (35).
Connect the vehicle harness branch (A) to the positive terminal of the battery and secure with M6 hex nut (35).
Once it is positioned, secure in place using two cable ties as shown.
Pull the vehicle harness from engine bay down to the floor behind the front left wheel. Direct it towards the rear of
the vehicle. Secure the vehicle harness to the vehicle loom in the two areas shown using cable ties.
A
A
B
B
BATTERY
POSITIVE TERMINAL
NEGATIVE TERMINAL
A
B
REAR
1
2
35
35
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
RT0063
Page 8 of 33ISSUE 4: 26/04/23
Continue running the vehicle harness along the chassis rail inner side. Feed the harness to the outside of the
chassis rail (over the top of the rail) at the rear wheel arch as shown. Secure with two cable ties as shown.
Continue to the rear along the chassis rail inner side (above the crossmembers). Secure the vehicle harness to
the existing vehicle harness as shown using cable ties.
REAR
REAR
4
3
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
RT0063
Page 9 of 33
ISSUE 4: 26/04/23
CD
E
CD
E
H
I
Push a draw wire down through the opening in the front LHS of the tub. Under the tub, wrap the vehicle harness
connectors: C, D & E to the draw wire as shown. Pull them up into the tub until approximately 300mm protrudes.
Remove tape and draw wire from the harness.
DRAW
WIRE
TAPE
VEHICLE
HARNESS
DRAW WIRE
VIEW INSIDE TUB
VIEW INSIDE TUB
REAR
C
D
E
5
6
Connect the SPP unit to the vehicle harness as shown. Secure SPP unit and connectors to underside of tub
flange using cable ties and cable tie base x2.
SPP UNIT
TUB
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
RT0063
Page 10 of 33ISSUE 4: 26/04/23
F G
Run the vehicle harness along the inner chassis rail aide and along the tail end of the vehicle till reaching the
loom connectors on as shown. Using cable ties, secure the vehicle harness to the vehicle tub in 4 locations as
shown . Disconnect the 16 pin vehicle loom connectors and patch it using the vehicle harness connectors F& G.
VEHICLE HARNESS
VEHICLE LOOM VEHICLE LOOM
RHS
REAR
REAR
Push the remaining harness over to the chassis rail inner and continue running it towards the rear of the vehicle.
Secure with 3 Cable Ties as shown.
REAR
7
8
-- EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --
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