hyundai fitting instructions template v12

of 8.

Nudge Bar. Fitting instructions. Estimated fitting time 70 minutes.

Issue 5. Date 03/05/2018

HYUNDAI Kona. Kit part no. J9A14APH00. Kit part no. J9A14APH10. Kit part no. J9A14APH20.

Issue 5. Date 03/05/2018. of 8.

HYUNDAI Kona. Kit part no. J9A14APH00 / Kit part no. J9A14APH10 / Kit part no. J9A14APH20.

General Notes. • Read through the fitting instructions before installation of the accessory. 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 Hyundai 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, or suitable automotive rust inhibitor.

• 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.

Fitting Time.

Est. 70 minutes.

Parts Supplied. 1 2 3 4 5 6

Lower Side Brackets

Alloy Nudge Bar x 1 Spacers x 3 Saddle Brkt x 1 Top Mount x 1 LH x 1 RH x 1 Angle Bracket x 2

7 8 9 10 11 12

M10 x 50 Hex M10 x 30 Hex M10 Spring M5 x 12 Pan Head

Bolts x 3 Bolts x 6 M10 Flat Washers x 12 Washers x 9 M10 Hex Nuts x 6 Screw x 2

13 14 15 16

J9A14APH00 ONLY Light Bar

M5 Flange Nuts x 2 Light Bar Fitting Instructions Fitting Instructions x 1

J9A14APH00 ONLY


Issue 5. Date 03/05/2018. of 8.

Tools Required.

Philips Head Screwdriver

Ratchet & Extension

Metric Socket Set

Torque Wrench

Open-end / Ring

Spanner Set

Hack Saw Blade

ø30mm and ø40 Hole

Saw

Drill

Eye, Hand & Arm

Protection

Marking Pen

Straight Edge

e.g. Steel Ruler

Tape Measure

Tin Snips or similar

Nudge Bar Assembly.

⑧

⑤

⑥

⑥

②

②

④ ③

⑨⑩⑪

⑦

⑦⑩

⑦

⑤

⑨

⑩

⑨⑩⑪

⑧⑨

⑨⑩⑪ ⑧⑨

②

⑧

⑨

⑩ ①

⑭ (J9A14APH00 ONLY)


Issue 5. Date 03/05/2018. of 8.

Step 1.

• Remove Bumper / Grille assembly –

• Top edge - 4 Hex Bolts A

• Wheel Arches - 1 hex head bolt each side, B & 3 scrivets C

• Lower edge – 6 scrivets on each side D

• If Fog Lamps or FPA (front parking assist) are fitted, unplug the harness at the rear of the lamp as the bumper is being removed.

Note : To reduce likelihood of damage to bumper paintwork, use an assistant to remove bumper & place on a soft surface.

Tools Used

• Metric Socket Set

• Ratchet

• Phillips Head Screwdriver

Step 2.

• On the air deflector mark a zone 50mm wide, 70mm deep and about 105mm on the passenger side of the centre line.

• Trim the marked section from the air deflector to prevent fouling on the top mounting bracket, using tin snips or similar.

Tools Used

• Tape measure

• Tin Snips or similar

Step 3.

• Place saddle bracket ③ behind crossbeam on LHS of radar unit and loosely attach top mounting bracket ④ with Qty2- M10 x 30 hex bolts ⑧ from behind and flat washers ⑨, spring washers ⑩ and nuts ⑪ from in front.

Note: No flat washer under bolt head. Do not tighten yet.

Important

A

B&C D

Crossbeam ③ ④

⑨⑩⑪

⑧

Radar Unit Air-deflector

Crossbeam Air-deflector

Mark & Trim -50mm wide -70mm deep -105mm offset from ℄


Issue 5. Date 03/05/2018. of 8.

Step 4.

• Mark a centre line on the vehicle cross beam.

• Measure from the centre line to the centre of the mount point as 46mm.

Note: Temporarily placing a bolt in the mount can make measuring more accurate.

• Measure from the top face of the radar to the centre of the mount as 83mm.

• Fully tighten M10 x 30 hex bolts ⑧.

M10 Torque 44 Nm

Tools Used

• Marking Pen


• Torque Wrench

• Steel Ruler

Step 5.

• Remove the two outer most bolts that attach the crossbeam to the chassis. Install the lower side bracket ⑤, repeat for LH & RH sides.

• Ensure brackets are vertical and in the right orientation.

• Fully tighten vehicle bolts E

M10 Torque 44 Nm

Tools Used


• Torque Wrench

Step 6.

• Loosely fit the angle brackets ⑥ with M10 x 30 hex bolts ⑧, flat washers ⑨, spring washers ⑩ and nuts ⑪ to LH & RH sides.

• Position the angle brackets ⑥ so the bottom edge of the bracket is 190mm below the crossbeam with a separation of 1160 LH to RH. Measure off other features to ensure the parts are symmetrically positioned on the vehicle.

Do not tighten yet.

Tools Used

• Tape Measure

46mm

83

mm

⑧

Radar Unit

Vehicle centre line

E ⑤

19

0m

m

⑥

⑨⑩⑪

⑧⑨


Issue 5. Date 03/05/2018. of 8.

Step 7.

Note: Skip this step for non-light bar variants.

• Fit the light bar ⑭ and associated wiring according to the fitting

instructions included in light bar kit ⑯.

Step 8.

• Temporarily offer alloy nudge bar ① to the mounts using three spacers ② and M10 x 50 hex bolts ⑦ to check mounting alignment and that the nudge is central and horizontal. Adjust M10 x 30 hex bolts ⑧ from previous steps if necessary.

Note: The spacer goes between the Nudge and the mounts.

• Fully tighten M10 x 30 hex bolts ⑧ (from previous steps) in six places.

M10 Torque 44 Nm

Note: Do not tighten M10 x 50 Hex Bolts ⑦ as they are to be removed.

• Remove alloy nudge bar ①.

Tools Used


• Ring Spanner Set

• Tape Measure

• Torque Wrench

Step 9.

• Using the grille features as a guide drill a 25mm to 30mm hole through the bumper facia.

• Deburr as necessary

Tools Used

• 25 – 30mm hole saw

• Drill

Front view of Bumper Facia

LHS RHS

Important

②

⑦

② ⑦

②

⑦

⑧

⑧

⑧ ①


Issue 5. Date 03/05/2018. of 8.

Step 10.

• Mark two points on the bottom face of the bumper with a separation of 1160mm, and 34mm forward of the protruding lip. Check the marks are symmetrical with the bumper features (LH & RH)

• Drill the two 40mm holes as marked through the bumper facia.

Tools Used

• 40mm hole saw

• Drill

• Marking Pen

• Tape Measure

Step 11.

• Identify the foam bumper insert in the rear of the bumper facia.

• Mark the centre line on the foam bumper insert from bumper features. Mark the section of the foam insert which will foul on the top mounting bracket ④ from 25-95mm on the LHS of the centre line.

• Remove the foam bumper Insert from bumper facia.

• Using a hack saw or similar remove a depth of 10 to 15mm of the foam bumper insert to prevent fouling top mounting bracket ④.

Tools Used

• Hack Saw Blade

• Marking Pen

• Tape Measure

Step 12.

• Reinstall the foam bumper insert from bumper facia.

• Reinstall the bumper facia and vehicle components removed in Step 1.

• Check the function of the reconnected vehicle lighting.

Tools Used

• Hack Saw Blade


• Ratchet

• Phillips Head Screwdriver

Centre Line Foam Bumper Insert

25mm

95mm

Bottom view of Bumper Facia 1160mm

Protruding Lip

Typical Bumper Features


Issue 5. Date 03/05/2018. of 8.

Step 13.

• Attach alloy nudge bar ① through the trimmed bumper facia to the angle bracket ⑥, using spacers ②, flat washers ⑨, spring washers ⑩ and M10 x 50 Hex Bolts ⑦.

• Attach alloy nudge bar ① through the trimmed bumper facia to the top mounting bracket ④, using a spacer ②, spring washer ⑩ and M10 x 50 hex bolt ⑦.

• Fully tighten M10 x 50 Hex Bolts ⑦ in three places.

M10 Torque 44 Nm

Tools Used


• Ring Spanner Set

• Tape Measure

• Torque Wrench

• To maintain your Alloy Nudge Bar, wash regularly with car wash detergent,

hose off & chamois dry. Stubborn grime can be removed with kerosene.

• Polished surfaces can be maintained with Autosol® metal polish or similar

products. Use as recommended.

Important

②

②

⑥

⑨⑩⑦ ①

⑩⑦

⑨⑩⑦

④

Care Instructions

Do not attach the Alloy Nudge Bar to any vehicle

using anchorages not intended for this purpose.

Important

Always refer to the vehicle’s Workshop Manual when removing vehicle components.

Do not use this Alloy Nudge Bar for any vehicle or

model, other than those specified in these

instructions.

Important


Do not remove the plaque or label from the Alloy

Nudge Bar.

Important


Do not modify the Alloy Nudge Bar in any way. Important


hyundai fitting instructions template v12

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