Land Rover Discovery 3 & 4 Roof Rack. Fitting Instructions – 1.6m, or 2.2m
Baskets. Note: Above photos show the 1.6m & 2.2m basket installations with our
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ABN 71 076 674 652 2/248 Welshpool Road WELSHPOOL WA 6106 T : 08 9358 2575 F: 08 9451 2499 E:
[email protected] W: www.dolium.com.au
Land Rover Discovery 3 & 4 Roof Rack Fitting Instructions – 1.6m, or 2.2m Baskets
Note: Above photos show the 1.6m & 2.2m basket installations with our Tracks. There is a small degree of for/aft choice in the placement of the 1.6m basket along the tracks but we recommend locating it as far back as clearance from the opened rear hatch permits. The 2.2m basket location is fixed due to the front leg needing to locate over the captive bolt in the roof channel.
Kit Contents: 1. Alloy Basket ( Choice of 1.6mm & 2.2m lengths ) 2. Pair of Alloy Tracks with Rubber Seals and 6 x Screws (M6x25 C’Sunk) 3. Fitting Kit – 4 x 50mm & 2 x 60mm Feet w Bolts, 12 x Slide Bolts/Nuts, 6 x Spacer Rings If 2.2m Basket – extra 2 x Front Legs w Bolts, 2 extra Spacer Rings 4. Wind Deflector & Bolts (usually packed inside the basket packaging) Alternative Installation if Factory Tracks fitted: It is possible to fit these two roof racks using the genuine Land Rover Tracks if they are already fitted. There is no advantage using the genuine Tracks, however if they are used this rack must be fitted using different Slide Nuts - to order (thinner versions to suit the different profile of the factory Track). In this case ignore the parts of these fitting instructions relating to the Track installation.
Installation: (Assuming new Tracks are to be fitted) 1. Carefully unclip the roof channel cover strip on each side, to reveal the captive nuts/bolts underneath. Note whether the cover strip is pre-drilled over the captive bolts (sometimes they are supplied from the factory pre-drilled and with plastic covers).
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2. There are 3 mounting points on the upper roof section for each track. If the cover strip is not already drilled, carefully mark and drill holes in the cover strip over each mounting hole. 3. Use the 6 aluminium spacer rings over each mounting hole (under the cover strip), replace the cover strip (see Item 4 if using a 2.2m basket) and lift the tracks into position. Using the 6 x bolts supplied with the tracks and a good quality thread sealant, secure the tracks. 4. If 2.2m Basket – A 4th mounting point is used on the lower roof section and a captive nut exists in the roof. If necessary drill this extra hole in the cover plate and use the extra 2 aluminium spacer rings under the cover plate. Using a thread sealant and the bolt provided attach the lower Leg bracket & Rubber Seal to the front mount each side. 5. Unpack the basket taking care not to damage the coating with a knife etc. 6. Place basket upside down on two stands (the raised section of the outer rail will be at the top of the basket when installed). 7. Fit Wind Deflector to front centre of basket. The lip of the deflector is positioned towards the rear of the basket and points downwards.(see notes on Deflector) 8. 1.6m Basket – Attach the Feet Brackets to the 1st, 4th & 7th Slats (from front) 2.2m Basket – Attach Leg to 1st Slat, then Feet Brackets to 4th, 7th & 11th Slats 9. If 2.2m Basket – Attach front Leg to 1st Slat. Refer diagram below. Item # 1 2 3 4 5 6 7 8 9 10 11
Qty 1 1 1 1 1 1 2 2 2 1 2
Gutter Clamp (S/Steel) M 8 Lock Nut Grub Screw M8 x 20 Flat Washer Ø 19 Spring Washer Hex Nut M8 Nyloc Nut M8 Flat Washer Hex Head Bolt M8 x 16 Basket Slat Aluminium Leg
10. Working through the opening in the slat channel, fit the Top Foot Bracket to each side of the slats with the flat section towards the centre. 11. Measure the approx spacings between the Feet brackets (length-wise) and use this dimension to locate the Lower Foot Brackets into the Tracks on the vehicle
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12. Refer to exploded diagram of the Foot assembly below. Take special care to ensure the flat washers are in the correct location to avoid damage to the powder coating. Foot Assembly components 1 2 3 4 5 6 7 8 9 10
2 2 2 2 4 6 12 10 2 4
Rubber Seal Top Foot Bracket Lower Foot Bracket Roof Track Square Nut Nyloc Nut Flat Washer Hex. Bolt M8 x 16 Plastic Cap Spring Washer M8
13. Slide the square channel nuts along the track and using the dimensions noted earlier, position the Lower Foot Bracket. Measure the width across the vehicle between the respective Feet – then use this dimension to locate the Top Foot Bracket in the approx correct location on the underside of the Basket. 14. Loosely tighten one bolt for each Top Foot Bracket 15. With the Top and Lower Feet & the front Leg brackets in approx locations (referring to measurements) lift the Basket into position (requires two people). 16. Fit the bolts joining Top & Lower Foot brackets & front Leg if applicable (ensure the supplied flat washers are used both sides, the bolt can be inserted from either side depending on ease of access). 17. Centralise the basket to the vehicle and using the available adjustment in the Feet ensure the height above the roof line is even and at the desired height. Then firmly tighten all bolts – do NOT use air tools to tighten bolts as the sockets may damage the powder coat and cause peeling later. NOTE: Advise the User to check all bolt tensions after the first usage with a load.
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