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EGR Rolltrac RT040481E Installation Instructions Manual

For vehicle model: toyota tacoma 5ft bed lhd 2022
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INSTALLATION INSTRUCTIONS
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.
RT0097
ELECTRIC
Vehicle Model: Toyota Tacoma 5Ft Bed LHD
Year of manufacture:
Part Number: RT040481E
2022
Page 1 of 27
Issue 1: 22/10/24

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Summary of Contents for EGR Rolltrac RT040481E

  • 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: Installation

    BED PREP ELECTRICAL START SECTION A SECTION B STEP 1-11 STEP 1-10 EGR RollTrac ASSEMBLY EGR RollTrac SECTION C INSTALLATION STEP 1-10 SECTION D STEP 1-5 OPERATIONS CALIBRATION FINAL NOTES SECTION E FINISH RT0097 Page 2 of 27 Issue 1: 22/10/24...
  • Page 3 KIT CONTENTS - COMPONENT NUMBER AND QUANTITY CANISTER ASM. QTY: 1 FRONT COVER QTY: 1 LHS RAIL QTY: 1 RHS RAIL QTY: 1 HEADERBAR QTY: 1 EGR RollTrac FITTING KIT IN BOX MISC4233PC-RH MISC4233PC-LH MISC5421 SCRW0973 MISC5621 CORNER BRACKET SCREW M6x15...
  • Page 4 EGR RollTrac FITTING KIT COMPONENTS IN BAGS MAIN HARNESS BLADE FUSES CABLE TIE (200mm) CABLE TIE (500mm) QTY: 30 QTY: 8 EGR RollTrac FITTING KIT ADDITIONAL ITEMS OWNERS MANUAL & INSTALLATION INSTRUCTIONS RUBBER SETTIG BRACE EXTRUSION QTY: 1 QTY: 2...
  • Page 5 SECTION A BED PREPARATION T40 Torx Key Thoroughly wash the vehicle and bed and ensure that all dirt and grease is removed. Allow to dry. Clean the top surfaces of the bed and tailgate and allow to dry. Carefully remove both Rear Tail Lamps with the appropriate tools and store in safe place.
  • Page 6 Ø29mm (11/8”) HOLE FOR VEHICLE HARNESS LHS ONLY Ø29mm Mark the position for the Vehicle Harness on the LHS of the tub. The distance is 60mm PCD from the drain tube hole. Soapy Water Fit the front drain tubes to the tub. RT0097 Page 6 of 27 Issue 1: 22/10/24...
  • Page 7 Ø29mm (11/8”) 55mm (2.1’’) HOLES FOR REAR DRAIN TUBES RHS & LHS 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 400mm (15.7”) Mark the position of the rear drain tubes holes in the bed rear panel and drill with holesaw.
  • Page 8 T40 Torx Key DO NOT FIT SCREW DO NOT FIT SCREW Place the header bar (5) on top of the tub front panel, press down and secure with 3 screws (12). Torque to 5.5Nm. Allen Key 4mm (5/32’’) T40 Torx Key Assemble the corner bracket to the rail using T-Nut (11), screw (12) and one Torx screw (removed in step 1) as shown on the RHS.

  • Page 9: Vehicle Harness

    ELECTRICAL LOOM INSTALLATION SECTION B IMPORTANT: DISCONNECT CAR BATTERY NEGATIVE TERMINAL. FIT THE FUSE AT THE END OF INSTALLATION. 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.
  • Page 10 USE DRAW WIRE TO BATTERY TERMINAL PULL VEHICLE HARNESS INTO THE ENGINE BAY IMPORTANT: Make sure fuses are not fitted before making connection. Feed the harness into the engine bay on the LHS along the fire wall from underneath the vehicle. Use draw wire first by pushing it down from the engine bay.

  • Page 11: Rubber Grommet

    RUBBER SCUFF PLATE GROMMET Inside the vehicle (LH) side, lift the scuff plate to allow lifting the carpet under the seat in order to expose the rubber grommet in the floor. Remove and discard the grommet. Feed the vehicle harness branch (C) into the cabin.
  • Page 12 CLIP PUSH DOWN CONNECTOR Locate the connector on the outside of the B-pillar and disconnect as shown. NOTE: Pull the tab under the rubber boot to remove the boot. EXPOSED B-PILLAR CONNECTOR VEHICLE HARNESS Locate the B-pillar harness plug and select the X and Y wires from the factory wiring. Strip 0.5 inch to expose copper as shown.
  • Page 13 VEHICLE HARNESS B-PILLAR HARNESS PINK / RED ORANGE PINK / GREEN BROWN WIRE FROM WIRE FROM VEHICLE HARNESS B-PILLAR HARNESS Insert stripped wires from vehicle harness unit 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 14 REAR From underneath the vehicle, route the Vehicle Harness connector D towards the rear of the vehicle, following outside the chassis rail. Use the supplied cable ties and retain the harness every 200mm (8’’) to the chassis rail. GROMMET VEHICLE HARNESS Pull up the connector (C) into the truck bed into the previously drilled hole in the front LHS of the bed, until the rubber grommet sits firmly in the hole.
  • Page 15 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 16 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 (15).
  • Page 17 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 18: Rear View

    5.5Nm (4ft-lb) 4mm(5/32’’) INSERT SCREWS AND TORQUE TO 5.5Nm (ff-lb) REAR VIEW Using 3 screws (6), secure the Front Plate (2) to the Canister Assembly (1) and torque to 5.5Nm (4ft-lb). 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.
  • Page 19 LHS SHOWN - RHS IS A MIRROR IMAGE CLEAN WITH ALCOHOL FIRST TAPE TAPES MUST CONTACT Clean powder coated surface first with alcohol spray. Trim foam tape length to ensure the end will butt against front cover seal - avoiding any gap. Peel the protective liner from the foam tape, adhere to the channel in the side rail, Press down firmly to secure.
  • Page 20 INSTALL RUBBER SEAL IN SIDE RAILS OUTSIDE Install the Rubber Perimeter Seal (16) into each side rail and ensure seal is firmly seated (note the seal orientation). Important: do not stretch the seal while fitting. CONTINUE ON THE NEXT PAGE Page 20 of 27 RT0097 Issue 1: 22/10/24...
  • Page 21 SECTION D EGR RollTrac INSTALLATION SETTING BRACE - USER GUIDE • NOT TO BE USED AS LIFTING DEVICE • DIAGONAL MEASUREMENTS ARE REQUIRED AS PER THE FITTING INSTRUCTIONS • SETTING BRACE SHOULD BE REMOVED ONLY WHEN SET UP IS COMPLETED Setting Brace comes assembled.

  • Page 22: Side Rail

    FOR SETTING BRACE USE, PLEASE REFER TO THE “SETTING BRACE - USER GUIDE” SIDE RAIL TAILGATE CENTRALISE AND ALIGN THE COVER TO THE MARKINGS FRONT SEAL 27mm TAILGATE COVER POSITION REARWARDS 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.
  • Page 23 METRIC Tape Measure PERFORM FITMENT CHECK Perform diagonal fitment check. 5.5Nm VIEW UNDER THE BASE RAIL RHS Bolt Tightening Sequence Fit the side rail brackets to the base rails with two screws (12) as shown in top detail. Torque the screws following the sequence in the detail. Work from the rear to the front as shown. RT0097 Issue 1: 22/10/24 Page 23 of 27...
  • Page 24 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 4mm INSPECTION COVER...

  • Page 25: 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 26 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 27: Key Fob Operation

    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.

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