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EGR ROLLTRAC Installation Instructions Manual

Ford ranger
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Installation time: 180 minutes (without tubliner)
Caution
• 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.
General Notes
• 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.
Safety Notes
• Check that all work practices comply with safety standards.
• Please wear appropriate clothing and use safety equipment.
ISSUE 4: 26/04/23
--
EGR Document ID#121541 v5
INSTALLATION INSTRUCTIONS
Vehicle Model:
Year of manufacture:
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).
2023-05-09 23:59:32
ELECTRIC
FORD RANGER
MY22 onwards
IMPORTANT:
Page 1 of 33
awilmott --
*RT0063*
RT0063

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Summary of Contents for EGR ROLLTRAC

  • Page 1 Installation time: 180 minutes (without tubliner) Caution • 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.

  • Page 2: Installation Process

    STEP 1-8 EGR ROLLTRAC EGR ROLLTRAC ASSEMBLY INSTALLATION SECTION C SECTION D STEP 1-11 STEP 1-8 OPERATIONS CALIBRATION FINISH FINAL NOTES SECTION E FINISH UNPACKING ISSUE 4: 26/04/23 Page 2 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 3 LHS RAIL QTY: 1 RHS RAIL QTY: 1 MNT BAR MNT BAR TGAT0032-RH TGAT0032-LH QTY: 1 QTY: 1 EGR EGR ROLLTRAC CLAMP KIT IN BAG H-BAR CRN BRK FR MNT BRK FR MNT BRK MNT BRK CLIP4106 CLIP3932PC-LH CLIP3932PC-RH CLIP4108...
  • Page 4 EGR EGR ROLLTRAC MBAR HARDWARE KIT IN BAG M8x25 BUTTON HEAD SCREW END PAD M6x50 HEX HEAD M6x20 HEX HEAD M6x15 HEX DRIVE HEX DRIVE MISC5812 SCRW0997 SCRW0967 SCRW0974 SCRW0973 QTY: 8 QTY: 10 QTY: 8 QTY: 14 QTY: 6...
  • Page 5 Number inside a square indicate part number Number inside circle indicate the sequence within a step Number inside the hexagon indicate torque instruction Silicone ISSUE 4: 26/04/23 Page 5 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...

  • Page 6: Electrical Section

    IMPORTANT: DISCONNECT CAR BATTERY NEGATIVE TERMINAL. FIT THE SUPPLIED FUSES AT THE END OF INSTALLATION. STEP 1 STEP 2 STEP 3 STEP 4 STEP 5,6 STEP 7 ISSUE 4: 26/04/23 Page 6 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 7 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. ISSUE 4: 26/04/23 Page 7 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 8 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. RT0063 ISSUE 4: 26/04/23 Page 8 of 33 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 9 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. ISSUE 4: 26/04/23 RT0063 Page 9 of 33 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 10 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. ISSUE 4: 26/04/23 Page 10 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 11 If CMS rail is present, remove and retain CMS rail, hex head screws (A) and torx screw (B). If CMS rail is not pres- ent, remove torx screw (B) located at the rear of the tub. Retain the CMS bar and hardware for refit. ISSUE 4: 26/04/23 Page 11 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 12 Using hole saw drill 60mm hole in the tubliner only, With a 38mm hole saw, drill hole in the tub following the pilot hole use 10mm stop. Deburr both holes and apply rust inhibitor to the metal. Repeat for LHS. RT0063 ISSUE 4: 26/04/23 Page 12 of 33 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...

  • Page 13: Section View

    EGR ROLLTRAC SPECIFIC DDK’S ARE AVAILABLE FROM YOUR DEALER. IF A DDK IS TO BE INSTALLED, IT SHOULD BE FITTED AFTER INSTALLING EGR ROLLTRAC. NOTE THAT IF DDK IS TO BE INSTALLED, DRILLING AT REAR OF TUB IS NOT REQUIRED.
  • Page 14 Fit the rear drain tubes from the inside of the tail lamp cavity up through the drilled hole. Spray tubes with soapy water to help with fitment. Repeat for LHS. RT0063 ISSUE 4: 26/04/23 Page 14 of 33 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 15 LHS. Apply the front rail seal (17) along the top of the h-bar as shown and ensure ends touch the endcap. Apply Silicone in the gap between the rail seal, bracket and tub rail as shown. NOTE: Seal all holes in the tub as required. RT0063 ISSUE 4: 26/04/23 Page 15 of 33 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 16 Fit the 4 screws (19) into the RHS mounting rail (6) and fit the end pads as shown. Set the screws height as shown in detail. Repeat for the LHS mounting rail. NOTE: Screws will be adjusted in later stage once fitted to the tub. ISSUE 4: 26/04/23 Page 16 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 17 NOTE: Level the bar by pushing it up till it contacts the tub (see section view). Turn the screw (19) up until the cap (18) contacts the inner tub sheet metal (see section view). Do not overtighten. ISSUE 4: 26/04/23 Page 17 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 18 Connect the front drain tubes (8) to the tub. Make sure that both tubes engage over the wall of the tub. Leakage will occur if they are not properly installed. ISSUE 4: 26/04/23 Page 18 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 19 EGR RollTrac ASSEMBLY SECTION C DURING ASSEMBLY PROCEDURE SUPPORT AT CENTRE OF CANISTER ONLY, PLACE ON TOP AND BASE CARTON (OR SIMILAR), COVER WITH FOAM BLANKET. TO AVOID SCRATCHING POWDERCOATED SURFACES. DO NOT LOAD ELECTRICAL CONNECTORS OR MOTOR COVER. FIT FIRST...
  • Page 20 CHECK SEAL IS IN POSITION AND NOT DAMAGED Carefully lay the assembly over onto a protected surface. Remove the tape holding the rubber seal and check the seal position as shown. Page 20 of 33 ISSUE 4: 26/04/23 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...

  • Page 21: Side View

    Spray ENTIRE Side Rail and Seal with soapy water. Slide the side rail seal (16) into the side rail from the front rearwards and trim as illustrated. NOTE: Trim seal backing to aid assembly, see detail. Page 21 of 33 ISSUE 4: 26/04/23 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 22 Using one screw removed in Step 4, secure the Front Cover (2) to the Canister Assembly (1) as shown and torque to 5.5 Nm. ISSUE 4: 26/04/23 Page 22 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 23 Secure the harness to the canister using cable ties at the six locations shown. Secure with zip ties and pads. Ensure all cables are retained to prevent pinching during installation. ISSUE 4: 26/04/23 Page 23 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 24 End cap. NOTE: the brace has 2mm rise at the bottom and it must fit inside the key hole as shown in detail. Tighten the wing bolt (finger tight only). Page 24 of 33 ISSUE 4: 26/04/23 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 25 NOT THE CABLE Spray the side rails seals with a soapy water solution to enable the Rolltrac to slide easily. Using two people on either side and one (or two) in the centre (to support and guide canister weight) place the cover carefully onto the header bar at front, as shown in detail.
  • Page 26 Carefully close the tailgate, lifting the side rails to avoid damage to rubber seals. Place the setup jig on top of the tailgate as shown and move the Rolltrac up or down till the endcap touches the jig, target offset is 34mmTorque the screws in a sequence shown above. Repeat for LHS.

  • Page 27: Side Rail

    Apply masking tape at the centre of the tailgate. Measure the distance between the rear corners of the tub and draw a centre line on the masking tape. Measure the distance from the marked centre line to both rear corners of the EGR Rolltrac and ensure it is equally distanced.
  • Page 28 Fit the RHS water duct over the bottom of the RHS endcap and secure with 3 screws (26) as shown. Important: Hand torque screws (26) until fully seated (contact water duct surface). Repeat for LHS. ISSUE 4: 26/04/23 RT0063 Page 28 of 33 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...

  • Page 29: Cable Tie

    Repeat for LHS. Connect the front drain tubes to the canister. Use soapy water solution to help rubber slide over the fitting. Follow manufacturer’s instructions to refit accessories removed during tub preparation. ISSUE 4: 26/04/23 Page 29 of 33 RT0063 EGR Document ID#121541 v5 2023-05-09 23:59:32 awilmott --...
  • Page 30 SILICONE SPRAY Close the inspection covers and secure with retained screws. Open and close the EGR Rolltrac to distribute lubricant and check operation. Allen Key 2.5mm INSPECTION COVER...

  • Page 31: Calibration Procedure

    WARNING: Keep obstructions clear of cover during calibration mode. 5 SECONDS PULL • Cover will CLOSE and OPEN once automatically. • The EGR RollTrac internal LED light will pulse slowly during calibration and stop pulsing when calibration is complete. 2 SECOND PULSE START OF CALIBRATION...
  • Page 32 NOTE: EGR RollTrac should open and close smoothly. If cover does not lock or open correctly, please refer to the trouble shooting section in the Owners Manual. If the EGR RollTrac closing is slow, clean the siderails and ensure that no dirt or debris is inside the drive rail.

  • Page 33: Key Fob Operation

    If pause is activated by the fob whilst auto closing, the RollTrac can be closed and paused using the RollTrac close button. Reactivate both Rolltrac buttons by unlocking the vehicle. • If the RollTrac is open and the lock button is only pressed once, the vehicle and the RollTrac will lock. RT0063 Page 33 of 33...

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