Toyota - FJ Cruiser - Parts Catalogue - 2011 - 2011

RLCP25 Rhino Heavy Duty Two Crossbar System Toyota FJ Cruiser Important: Please read these instructions carefully prior to installation. Please refer to your fitting instruction to ensure that the roof racks are installed in the correct locations. Check the contents of kit before commencing fitment and report any discrepancies. Place these instructions in the vehicle’s glove box after installation is complete. Layout Important Information Maximum carrying capacity: 68kg (150lbs) Please refer to your vehicle manufacturers handbook for maximum carrying capacity of your roof racks. Always use the lower of the two figures. Load must be evenly distributed over the crossbars. Warning: Do not attempt to fit the roof racks to your vehicle unless you fully understand this fitting instructions. Please direct any questions regarding fitting to the dealer from where the roof racks was purchased. Use only non-stretch fastening ropes or straps. Recommendations: It is essential that all bolt connections be checked after driving a short distance when you first install your roof racks. Bolt connections should be checked again at regular intervals (once a week is enough, depending on road conditions, usage, loads and distances travelled). You should also check the roof racks each time they are re-fitted. Always make sure to fasten your load securely. Please also ensure that all loads are evenly distributed and that the centre of gravity is kept as low as possible. Long loads (e.g. canoes and kayaks) must be secured front and rear with non-stretch fastening ropes or straps. Roof racks must be removed when putting vehicle through an automatic car wash. Caution: The handling characteristics of the vehicle changes when you transport a load on the roof. For safety reasons we recommend you exercise extreme care when transporting wind-resistant loads. Special consideration must be taken into account when cornering and braking. Note for Dealers and Fitters: It is your responsibility to ensure these fitting instructions are given to the end user or client. Rhino-Rack 3 Pike Street, Rydalmere, NSW 2116, Australia. (Ph) (02) 9638 4744 (Fax) (02) 9638 4822 Document No: R129 Prepared By: Andy Wana Authorised By: Chris Murty Issue No: 02 Issue Date: 09/12/2011 These instructions remain the property of Rhino-Rack Australia Pty Ltd and may not be used or changed for any other purpose than intended. Page 1 of 6 RLCP25 Rhino Heavy Duty Two Crossbar System - Toyota FJ Cruiser ! Parts List 1 3 2 4 5 6 7 Item Component Name Qty 1 1375mm HD Bar (sold separately) 2 2 HD Bar Rubber (sold separately) 2 3 End Cap 4 4 M10 Channel Nut 4 5 Heavy Duty Leg 4 6 M10 Flat Washer 4 7 M10 Shakeproof Washer 4 8 M10 x 20mm Bolt 4 9 M6 x 27mm Screw 4 10 M6 Spring Washer 4 11 M6 Flat Washer 4 10 11 12 13 12 Mounting Pad Cover 4 14 13 5mm Allen Key 1 14 M8 x 40mm Bolt 4 15 M8 x 50mm Bolt 4 16 M8 Spring Washer 8 15 16 17 18 17 M8 Flat Washer 8 19 18 7mm x 4mm O-ring 8 19 Mounting Pad Washer 8 20 Front RIGHT Mount Pad 1 20, 21, 22, 23 21 Front LEFT Mount Pad 1 22 Middle RIGHT Mount Pad 1 24, 25 23 Middle LEFT Mount Pad 1 24 LEFT Pad Mount Skirt 2 25 RIGHT Pad Mount Skirt 2 26 Fitting Instruction 1 Page 2 of 6 8 9 Tools needed: Flat blade screwdriver, Phillips head screwdriver, Rubber mallet, Socket wrench & 13mm socket. RLCP25 Rhino Heavy Duty Two Crossbar System - Toyota FJ Cruiser 1 Carefully remove the roof trim covers using a flat blade screwdriver. Remove all brackets, bolts and washers using a 13mm socket. Store the covers and attachment hardware for future use if needed. NOTE: The existing bolts and washers are not used to fit the roof rack mounting pads. 2 Place the foam covered copper washers over the plastic tubes in the roof channel. Make sure they are fitted neatly around the plastic tubes. NOTE: Failure to fit the foam covered copper washers will result in water leaks. 3 Fit RIGHT rubber skirt to pads marked FR, MR. Fit LEFT rubber skirt to pads marked FL, ML. FR = Front Right. MR = Middle Right. (Top View) FRONT of Vehicle. FL = Front Left. ML = Middle Left. NOTE: Arrows on top of parts must point towards front of vehicle when correctly installed. Left skirt FL FR ML MR Right skirt REAR of Vehicle. Page 3 of 6 RLCP25 Rhino Heavy Duty Two Crossbar System - Toyota FJ Cruiser 4 Place each pad into its position as stated in the previous step. Check to make sure the rubber skirt does NOT fold or twist when placed on the roof. It must flare out over surface of the roof. Middle Right. Front Right. 5 Assemble M8 bolts, washers and O-ring in the order shown. Push the O-ring up against the washers before locating into mounting pad. Finger tighten each pad first to ensure all parts are seated correctly. M8 x 50mm bolt (Front) M8 x 50mm bolt (Front) M8 x 40mm bolt (Middle) M8 spring washer. M8 flat washer. 7mm x 4mm O-ring. 6 Tighten all M8 bolts using the 6mm allen key supplied. Recommended tightening torque 9-11 Nm. DO NOT OVER TIGHTEN. Page 4 of 6 M8 x 40mm bolt (Middle) RLCP25 Rhino Heavy Duty Two Crossbar System - Toyota FJ Cruiser 7 8 Insert the rubber buffer strip into the top of the cross bar. Assemble the M6 screw and washers in the order shown. Place the M6 screw/washer assembly through the heavy duty leg and fasten to the mounting pad using the supplied 5mm security allen key. Do not fully tighten at this stage. 9 M5 security allen key. M6 x 27mm security screw. M6 spring washer. M6 flat washer. Attach the cross bar to the heavy duty legs. Make sure the channel nut is fully located across inside of the cross bar. Lightly finger tighten the M10 bolt only. Channel nut must locate fully across the cross bar. Page 5 of 6 RLCP25 Rhino Heavy Duty Two Crossbar System - Toyota FJ Cruiser 10 Tighten the M6 leg attachment screws to secure the legs to the mounting pads. Recommended tightening torque 3-4 Nm. 11 Adjust all cross bars to achieve equal over hang. Tighten the M10 cross bar attachment bolts. Recommended tightening torque 17-19 Nm. = Equal over hang. Re-check that channel is still fully located across the cross bar when tight. 12 Fit the end caps into the end of the cross bar. A rubber mallet may be used to knock the end caps in place. Page 6 of 6 =