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EGR ROLLTRAC RT040036E Installation Instructions Manual
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EGR ROLLTRAC RT040036E Installation Instructions Manual

For chevy & gmc 1500 6.5ft lhd my2019 onwards
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INSTALLATION INSTRUCTIONS
Vehicle Model: CHEVY & GMC 1500 6.5ft LHD
Excludes models with accessories that would affect EGR RollTrac fitment
Year of manufacture: MY2019 onwards
Part Number: RT040036E
Installation time: 180 minutes
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.
RT0090
ELECTRIC
Page 1 of 35
*RT0090*
Issue 3: 04/09/24

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Summary of Contents for EGR ROLLTRAC RT040036E

  • Page 1 Installation time: 180 minutes 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.
  • Page 2 BED PREP ELECTRICAL START SECTION A SECTION B STEP 1-15 STEP 1-7 EGR RollTrac ASSEMBLY EGR RollTrac SECTION C INSTALLATION STEP 1-10 SECTION D STEP 1-6 OPERATIONS CALIBRATION FINAL NOTES SECTION E FINISH RT0090 Page 2 of 35 Issue 3: 04/09/24...
  • Page 3 FRONT COVER QTY: 1 LHS RAIL QTY: 1 RHS RAIL QTY: 1 LHS MOUNT EXTRUSION QTY: 1 RHS MOUNT EXTRUSION QTY: 1 RUBBER EXTRUSION QTY: 1 EGR RollTrac FITTING KIT IN BOX RIVET SCRW0973 (BLACK) SETUP JIG MISC5512PC FAST0441 SCREW M6X15MM...
  • Page 4 EGR RollTrac FITTING KIT COMPONENTS IN BAGS DO NOT USE T-PATCH* 4 WAY CONNECTOR BLADE FUSE MINI BLADE FUSE CABLE TIE 12pcs VEHICLE HARNESS PANEL CLIP 5pcs EGR RollTrac FITTING KIT ADDITIONAL ITEMS INSTALLATION OWNERS INSTRUCTIONS MANUAL RUBBER EXTRUSION QTY: 2...
  • Page 5 SECTION A BED PREPARATION NOTE: IF TUBLINER FITTED, REMOVE PLASTIC COVER FIRST TO EXPOSE THE RUBBER PLUG AND REMOVE. Carefully remove any accessories (Sports Bars, Cabin Guards, etc.) attached to the vehicle bed. Do not remove the bed rail caps and tailgate step handle if fitted. Thoroughly wash the vehicle and bed and ensure that all dirt and grease is removed.
  • Page 6 118mm (4.64”) ANTI RUST Ø29mm (11/8”) ATTENTION Ensure that the diameter of the hole does not exceed Ø29mm (11/8”) Larger hole size will lead to water ingress into the bed ATTENTION 483mm (19”) Repeat for RHS Mark the position of the rear drain tubes holes in the bed rear side panel, center punch and drill with Ø29mm (11/8”) hole saw.
  • Page 7 LHS & RHS Secure the drain tube (16) to the sheet metal inside the tail light cavity using one cable tie (15) as shown. Refit the tail lights. Repeat for RHS. ATTENTION USE DRILL JIG Ø6mm (1/4”) 261mm 261mm 508mm 508mm 6mm (1/4”) DRILL BIT WITH 10mm STOPPER SECTION VIEW...
  • Page 8 BED CAP Ø12mm (7/16”) 12mm (7/16”) DRILL BIT WITH 10mm STOPPER PACKER SECTION VIEW Using the pilot holes in bed cap as guides, enlarge the holes with a 12mm (7/16”) drill bit. DO NOT touch the sheet metal while drilling (the use of a drill stop and/or a packer to protect the bed’s sheet metal is recommended). Ensure the holes in plastic clear the holes in bed.
  • Page 9 Fit two setup jigs (8) to the RHS mount extrusion (6) in locations shown. Jigs will be reused for the LHS. Place the mounting extrusion (6) on the inside of the bed until the setup jigs (21) rest on top of the bed cap. Align the 5 holes in the extrusion with the 5 holes in the bed side face (holes previously drilled in the plastic bed cap).
  • Page 10 ATTENTION SECURE LOOSELY 10mm (25/64’’) Secure loosely the mounting extrusion (6) using 5 screws (13) and 5 tapped plates (10). 5.5Nm (4ft-lb) Ruler x2 10mm (25/64’’) RULER SETUP JIG 2.5mm(0.09”) 2.5mm(0.09”) MOUNT EXTRUSION SECTION VIEW - TAILGATE SECTION VIEW - SIDE ATTENTION TORQUE UP FIRST...
  • Page 11 ELECTRICAL LOOM INSTALLATION SECTION B WHILE ROUTING THE VEHICLE HARNESS AVOID ANY VEHICLE COMPONENTS THAT HEAT UP, SUCH AS EXHAUST AND ENGINE COMPONENTS. DO NOT ATTACH HARNESS TO MOVING PARTS, FUEL LINES, BRAKE LINES, MOVING PARTS AND AVOID PINCH POINTS. HARNESS ROUTING OVERVIEW DISCARD 4WAY CONNECTOR...
  • Page 12 BATTERY COVER Remove the battery cover by pressing on the side tabs. PANEL CLIP CONNECT (-) TO BODY CONNECT (+) TERMINAL FRONT Connect the negative terminal (C) to the location on body as shown and positive terminal (D) to the battery terminal. IMPORTANT: Ensure the fuses are not installed to the harness at this stage.
  • Page 13 TRIM NIPPLE FRONT Behind the battery locate the vehicle harness entry point to the cabin. Trim the rubber nipple to open the hole and feed the harness branch (B) into the cabin. WHILE ROUTING THE VEHICLE HARNESS UNDER THE DASH BOARD: DO NOT ATTACH HARNESS TO PEDALS OR OTHER MOVING PARTS.
  • Page 14 SILVERADO & SIERRA MY2019 TO MY2022 models. IMPORTANT: The BCM is located behind the front LHS kick panel. 7” ORANGE BROWN ORANGE BROWN BLACK Remove the connector (G) from the T-Patch and expose the two copper wires (1). The vehicle harness has 4 wires exposed, only the Orange and Brown wires are required (2).
  • Page 15 T-PATCH PINK CONNECTOR PINK CONNECTOR Locate the pink connector and on the BCM (2nd from the bottom) and unplug it. Connect the pink connector to the T-patch (I) as shown and plug the female pink connector from the T-patch (H) into the vehicle. SILVERADO &...
  • Page 16 EXPOSED B-PILLAR CONNECTOR VEHICLE HARNESS Locate the B-pillar harness plug and select the WHITE and BLUE/YELLOW wires from the factory wiring. Strip 0.5 inch to expose copper as shown. Feed the Rolltrac vehicle harness up to the exposed wires on the B-pillar.
  • Page 17 VEHICLE HARNESS B-PILLAR HARNESS ORANGE BLUE/YELLOW WHITE BROWN WIRE FROM WIRE FROM VEHICLE HARNESS B-PILLAR HARNESS Insert stripped wire from the vehicle harness through the hole in the factory wiring and wrap around it tightly. Use needle nose pliers to clamp down on the connection. Wrap the wires with 3M super 33+ or equivelant electrical tape.
  • Page 18 CABLE TIE CABLE TIE CABLE TIE CABLE TIE Run the harness on top of the chassis rail towards rear of the vehicle and secure to the existing vehicle harness using cable ties. RT0090 Page 18 of 35 Issue 3: 04/09/24...
  • Page 19 PANEL CLIP CABLE TIE CABLE TIE CABLE TIE PANEL CLIP Run the harness on top of the chassis rail towards rear of the car and secure to the existing vehicle harness using cable ties. Run the harness across to the LHS following the front edge of the bed and secure with cable ties and panel clips as shown.
  • Page 20 IMPORTANT BULLETIN HAND RAIL ATTACHMENT PARTS: Hand Rail QTY-1 INSTALLATION STEP: Place hand rail onto slat assembly by turning approximately 45 degrees down and inserting it as shown. ° ALIGN ENDS RT0090 Page 20 of 35 Issue 3: 04/09/24...
  • Page 21 EGR RollTrac ASSEMBLY SECTION C DURING ASSEMBLY PROCEDURE SUPPORT AT CENTER 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 RHS 4mm(5/32’’)
  • Page 22 CAUTION 90° FIT FIRST ALIGN HOLES FIT SECOND SLIDE INTO POSITION ALIGN HOLES INSERT SCREWS AND TIGHTEN LOOSELY GENTLY WIGGLING THE PART INTO THE FINAL TUCK LOOM TO THE SIDE POSITION MAY HELP Pull hand rail to expose 3 slats. Slide the RHS Rail over slat ends and onto endcap location pins. Align the holes and secure loosely with two screws (11).
  • Page 23 REMOVE TAPE SECURING THE RUBBER CORNER SEAL CAUTION DO NOT DAMAGE ATTENTION: Remove foam tape end from the side rail before fitting into front cover Slide the Front Plate (2) over the canister and into the side rail channels ensuring that the foam side rail tape is pulled out of side rail and the small rubber corner seal on the RHS and LHS of the front plate are not damaged.
  • Page 24 5.5Nm (4ft-lb) 4mm(5/32’’) REAR VIEW INSERT SCREWS AND TORQUE TO 5.5Nm (fft-lb) Using 5 screws (11), secure the Front Plate (2) to the Canister Assembly (1) and torque to 5.5Nm (4ft-lb). PLEASE CONTINUE ON THE NEXT PAGE RT0090 Page 24 of 35 Issue 3: 04/09/24...
  • Page 25 5.5Nm (4ft-lb) 4mm(5/32’’) SIDE VIEW Carefully flip the assembly over onto a flat protected surface which will not damage the cover or scratch the paint work. Install the 2 screws (11) on each side through the canister and side rail into front cover. Torque all screws in order shown to 5.5Nm (4ft-lb).
  • Page 26 CONNECT PUSH CLICK PULL CONNECT PUSH CLICK PULL SECURE ALL CABLES TO PREVENT PINCHING Connect side rail harness connectors to the connectors on the canister on the LHS and RHS. Connect the lamp connector as shown next to the motor on the RHS. Secure the harness to the canister using cable ties and pads as shown.
  • Page 27 SETTING BRACE - USER GUIDE • NOT TO BE USED AS LIFTING DEVICE • MEASUREMENTS ARE STILL REQUIRED AS PER THE FITTING INSTRUCTIONS • SETTING BRACE SHOULD BE REMOVED ONLY WHEN SET UP IS COMPLETED SETTING BRACE Setting Brace comes pre-assembled. Fit the T-Nuts with washers and wing screws as shown to both ends of the Setting Brace.
  • Page 28 SECTION D EGR RollTrac INSTALLATION FRONT SEAL HEAVY CONNECT PUSH CLICK PULL PULL THE CONNECTORS NOT THE CABLE Spray the top surface of the bed liberally with a soapy water solution to enable the Cover to slide easily. Using two people to lift the cover from both sides and carefully lower it onto the bed.
  • Page 29 CENTRALISE AND ALIGN THE COVER TO THE MARKINGS SIDE RAIL TAILGATE 27mm (1¹/16”) TAILGATE VEHICLE BED COVER POSITION REARWARDS Adjust the front/back position of the cover so that it is 27mm rearward of the tailgate inner edge as shown. Apply masking tape at the centre of the tailgate. Measure the distance between the rear corners of the vehicle bed and draw a centre line on the masking tape.
  • Page 30 PERFORM FITMENT CHECK Perform width check (using canister end as reference) and diagonal fitment check (mounting bolts may need loosening for adjustment). Open and close the cover by hand, checking for smooth operation and consistent 1.5-2.0mm side to side free-play of slat assembly within side rails. If there are any tight spots, then check side rail position and re-adjust side rail width as required.
  • Page 31 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 32 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 33 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 34 RIVETING SIDE BRACKETS ROLLTRAC NOT SHOWN FOR CLARITY (RHS) ANTI RUST Ø5mm Ø3/16”mm After running all fitment checks, confirming all functions and running calibration, drill the 2 hole locations using 5mm (3/16”) drill bit. Secure the brackets with rivets as shown. Repeat for LHS. NOTE: Apply rust inhibitor to drilled holes.
  • Page 35 KEY FOB OPERATION IMPORTANT: We recommend that you program your key fob to lock and unlock all doors using one click only. This function can be set on your infotainment screen using the vehicle system control function/setup: SETTINGS (icon) VEHICLE REMOTE LOCK, UNLOCK.