Page 1 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Cargo Barrier
Fitting Instructions
502750FI C
Page 2 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
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 Kia 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.
Before marking or drilling to install this Cargo Barrier, check vehicle for LPG conversion & non standard fuel tanks. Locate tanks
and all lines attached and take EXTREME CARE not to damage whilst installing this Cargo Barrier.
Safety Notes Check that all work practices comply with safety standards.
Please wear appropriate clothing and use safety equipment.
Parts Supplied
6
Hex Head Screw x4
1 5 4 3 2
Cargo Barrier x1 Floor Bracket x2 Roof Bracket x1 Threaded Insert x2 Mounting Plate x2
12 9
Milbolt (M10x29mm)
8 7 11 10
Mtg. Plate Seal x2 Wave Washer x4 Trim Plug x2
15 14
Warning Label x1 Caution Label x1
(Orange) (Silver)
Automotive Rust Inhibitor x1
(M10 x 20mm)
Hex Head Screw x2
(5/16” x 1”)
13
Milbolt (M10x44mm)
16
Felt Tape x1
Tools Supplied
23 22 21 20
Marking Pin x2 Cotton Bud x1 Cleaning Pad x1 Installation Tool x2
17
Trim Garnish x2
18
Garnish Spacer x2
19
Owners Manual
Page 3 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Tools Required
13mm Socket Steel Rule Socket Wrench 10mm Socket
Drill Stops Vacuum Cleaner Power Drill Black Maker Pen
5mm Drill Bit
11.5mm Drill Bit
Torque Wrench Masking Tape Trim Removal Tool Tape Measure 12mm Drill Bit Sharp Knife
Threaded Insert Tool with Long Mandrel Ø20mm Vinyl Cutter Deburring Tool
Drop Sheet
Centre Punch Hammer
Clean Cloth
16mm Socket
20Nm
10mm Drill Bit
Ø20mm Hole Saw
Spacer Block Scriber
Page 4 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Remove the spare wheel, scissor jack and tool pouch.
Always refer to the vehicles Workshop Manual when removing vehicle components.
Important
Step 1
Step 3
Remove the cargo area floor panel and the cargo blind if fitted.
Step 2
Page 5 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Note: On some variants, the vehicle trim has an additional trim locating foot. If present cut this foot away, back to the edge of the trim using a knife.
On the LHS (Passenger side) of the vehicle, adjacent to the
spare wheel hold, affix masking tape to the floor panel in the approximate location shown.
Mark the LHS floor mounting plate centre hole location as
shown.
36mm from the floor gusset flange rear edge.
8mm from the floor gusset flange inner edge.
On the RHS (Drivers side) of the vehicle adjacent to the spare
wheel hold, affix masking tape to the floor panel in the approximate location shown.
Mark the RHS floor mounting plate centre hole location as
shown.
36mm from the floor gusset flange rear edge.
8mm from the floor gusset flange inner edge.
Tools Used
Masking Tape
Tape Measure or Steel Rule
Marker Pen
Using a mounting plate (2) as a template, locate the centre
hole over the marked location from step 4. With the mounting plate held parallel to the side trim, mark the outer hole positions onto the floor panel.
Repeat on the RHS (Drivers Side).
Tools Used
Mounting Plate (2)
Marker Pen
Use (2) as a template to mark the outer holes
Step 4
Step 6
8mm
36mm
Fro
nt
Fro
nt
36mm
8mm
Tools Used
Masking Tape
Tape Measure or Steel Rule
Marker Pen
Step 5
Page 6 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Tools Used
Hammer
Centre Punch
Centre punch the 6 marked positions on the floor panel.
Using a Ø5mm drill bit with the drill stop set at 10mm, drill a pilot
hole at each of the centre punched locations (6 places).
Using a Ø10mm drill bit with the drill stop set at 10mm, drill out
the outer pilot holes only as shown (4 places).
Using a Ø12mm drill bit with the drill stop set at 10mm, drill out
the centre holes as shown (2 places).
Tools Used
Power Drill
5mm Drill Bit
10mm Drill Bit
Remove the masking tape.
Vacuum away all drilling swarf.
Tools Used
Vacuum Cleaner
10mm
Step 7
Step 8
Step 9
Ø12mm
Ø10mm
Page 7 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Apply automotive rust inhibitor (7) to all drilled holes using
cotton bud applicator (22).
Tools Used
Cotton Bud (22)
Place the centre hole of a mounting plate (2) over the
installation tool (21).
Repeat for the other floor mount.
Tools Used
Installation Tool (21)
2
21
Fit the mounting plate seal (8) to the mounting plate (2) as
shown.
Bend the end of installation tool as shown.
Repeat for the other floor mount.
8
Care should be taken when applying Automotive Rust Inhibitor to all holes drilled, to reduce the possibility of skin and eye irritation.
Important
Apply automotive rust inhibitor 7
22
Step 10
Step 11
Step 12
Page 8 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Line up the floor brackets to be symmetrical and approximately
77mm from the side trims, measured adjacent to the ‘D’ anchor.
Lightly tighten all screws.
Using a suitable torque wrench, torque up the floor bracket
screws.
5/16” BSW (6)—8.5Nm
M10 x 1.5 (12)—17Nm
Repeat for other floor mount.
Tools Used
Socket Wrench
Torque Wrench
13mm A/F Socket
16mm A/F Socket
On the underside of one side of the vehicle, locate the 3 drilled
holes.
Pass the installation tool up through the centre hole then hang
the mounting plate in that position.
Repeat for the other side.
From the top side of the floor panel take hold of the installation
tool and align the outer holes of the mounting plate with the drilled holes in the floor.
Position a floor bracket (3) with holes aligned, over the
mounting plate holes. Attach the floor bracket to the mounting plate using hex head screws (6) in the outer holes.
Once the screws are started remove the installation tool by
pulling upwards.
Insert a hex head screw (12) into the centre hole.
Repeat on other side.
Tools Used
Installation tool (21)
Re-install the spare wheel, jack bracket and jack to the vehicle.
Fit marking pins (20) to each of the floor mount bracket captive
nuts as shown.
Reinstall the floor covering in the vehicle.
At the approximate location of the marking pins, apply light
pressure to the floor cover so as to leave an indent in its underside.
Tools Used
Marking Pins (20)
20
3
6
12
Metal floor panel
2 & 8
6 Front
(77mm)
Step 13
Step 14
Step 15
Page 9 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Remove the floor covering from the vehicle and locate the
marking pin indents on its underside.
Remove the marking pins from the floor brackets.
At each of the marked locations, drill a 5mm pilot hole.
Using a Ø20mm vinyl cutter, cut through the carpet layer on the
top and bottom surface at the pilot hole locations.
Finish cutting through the floor covering using a Ø20mm hole
saw.
Vacuum away any drilling dust then reinstall the floor covering
into the vehicle with the cut holes located over the floor bracket spacer tubes.
Tools Used
Power Drill
5mm Drill Bit
20mm Vinyl Cutter
20mm Hole Saw
Place a clean drop sheet over the cargo area of the vehicle to
protect the trim.
Using a suitable trim removal tool, unclip the rear pillar trim tops
as far forward as the rear windows.
Ø20mm
Tools Used
Drop Sheet
Trim Removal Tool
Using a suitable trim plug removal tool, remove the 2 trim plugs
securing the back edge of the roof lining in place.
Tools Used
Trim Plug Removal Tool
Step 16
Step 17
Step 18
Page 10 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Tools Used
Spacer Block
Place a spacer block or similar behind the rear pillar trims as
shown.
At each of the trim plug hole locations in the roof lining and using
a Ø20mm vinyl cutter, cut a 20mm hole through the roof lining.
Tools Used
Power Drill
20mm Vinyl Cutter
At each of the trim plug hole locations, enlarge the hole through
the metal panel using a ø11.5mm drill bit with a drill stop set at 10mm.
Deburr the holes if necessary.
Tools Used
Power Drill
11.5mm Drill Bit
Drill Stop
Deburring Tool
Spacer block
Vinyl cut through roof lining ø20mm
10mm
Ø20mm
Metal panel
Roof lining
Ø11.5 mm
Step 19
Step 20
Step 21
Page 11 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Vacuum away all drilling swarf.
Tools Used
Vacuum Cleaner
Apply automotive rust inhibitor (7) to all the drilled holes in the
metal panel using a cotton bud applicator (22).
Tools Used
Cotton Bud (22)
Insert the roof bracket (4) in between the roof lining and the
metal panel as shown.
Align the holes in the roof bracket with the enlarged trim plug
holes.
Care should be taken when applying Automotive Rust Inhibitor to all holes drilled, to reduce the possibility of skin and eye irritation.
Important
4 Roof lining
Step 22
Step 23
Step 24
Apply automotive rust inhibitor (7)
22
Holes in metal panel
Page 12 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Screw a threaded insert (5) onto a suitable threaded insert tool.
Place the threaded insert through a hole in the roof bracket and
metal panel behind.
With the threaded insert pushed hard against the outer panel,
pull up the insert to clamp the assembly firmly in position.
5
Due to limited cavity space behind the metal panel, it is important to ensure the threaded insert is always pushed hard against the roof bracket and metal panel whilst using the installation tool, to ensure correct pull up.
Important
Repeat the above procedure for the other hole.
Tools Used
Threaded Insert Installation Tool
Step 25
Step 26
Cross section of threaded insert shown fully pulled up 5
Metal roof panel
4 (Roof Bracket)
Soft roof lining
Tools Used
Threaded Insert Installation Tool
Page 13 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Screw a marking pin (20) into each of the roof bracket captive
nuts with just the points protruding.
Tools Used
Marking Pin (20)
Affix masking tape to the roof lining adjacent to the marking
pins.
Tools Used
Masking Tape
Step 27
Step 28
At the approximate locations of the marking pins, apply
pressure to the roof lining until the points of the pins can be seen on the cabin side. Mark the pin centres if necessary.
Remove the marking pins.
Tools Used
Marking Pins
Marker Pen
Step 29
20
Page 14 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Using a scriber pierce a hole through the roof lining at each of
the marked locations from step 29.
Tools Used
Using a 20mm vinyl cutter, cut a hole through the roof lining at
each of the pierced holes.
Remove the masking tape.
Tools Used
Power Drill
20mm Vinyl Cutter
Step 30
Step 31
Insert a trim plug base (17) into one of the outer 20mm holes in
the roof lining, with the cover positioned towards the front of the vehicle.
Using a small screwdriver or similar push the trim plugs retention
legs outwards to engage them in behind the roof lining.
Tools Used
Small Screwdriver
Step 32
ø20mm
17
Page 15 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
Push a trim plug insert (18) into the centre of the trim plug base
until it clips in place flush.
Repeat steps 32 & 33 on the other side, outer hole.
Insert a plastic trim plug (10) into the two centre threaded
inserts.
Remove the spacer blocks and reinstall all trims.
Reset the rubber door seal over the trims and roof lining.
Step 33
Step 34
On the inside of the drivers door opening clean the area shown
using cleaning pad (23), and allow to dry.
Apply the orange warning label (14) to the drivers door opening
location shown.
18
14
Step 35
Tools Used
Cleaning Pad (23)
10
Page 16 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
The Cargo Barrier may be fitted in either the rear position, See
Step 39, or the front position, See Step 40.
Please place the Owners Manual in the glove box after installation is completed.
Please place the Installation Manual in the
glov box after installation completed.e is
Please place the Fitting Instructions in the glove box after installation is completed.
Please place the Installation Manual in the
glov box after installation completed.e is
Please place any unused kit items, (e.g. Front position brackets & Milbolts) in glove box after
installation is completed.
Please place the Installation Manual in the
glov box after installation completed.e is
On the forward face of the cargo blind, measure and locate the
centre.
From the centre measure towards one end 490mm and mark
this position.
Ensure the forward face of the cargo blind is clean and free of
grease and wax.
Affix the adhesive backed felt (16) to the forward face of the
cargo blind, starting at the marked position from above.
Tools Used
Tape Measure
Marker Pen
Clean Rag
16
490mm
Step 36
Step 37
15
Step 38
On the plastic trim adjacent to the tailgate catch clean the area
shown using cleaning pad (23).
Allow to dry, then apply silver label (15) to the tailgate catch
location shown.
Tools Used
Cleaning Pad (23)
Page 17 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
REAR POSITION CARGO BARRIER INSTALLATION IN VEHICLE
The Cargo Barrier may be fitted in either the rear position, or the front position, See Step 40.
Place the Cargo Barrier in the vehicle directly behind the 2nd row of seats with the rating label (meshed side of barrier)
facing the rear of the vehicle.
Attach the top straps to the upper mounts using 29mm Milbolts (9) with wave washers (11) under their heads.
Attach the short bottom straps to the floor mounts using 44mm Milbolts (13) with wave washers (11) under their heads.
Tighten all Milbolts.
If the centre seat belt is required, open the lid of the plastic mesh insert in the top RH corner of the cargo barrier. Pass the
seat belt through the insert & attach to the centre sash belt buckle.
Note: The Sportage Cargo Barrier has been designed to integrate with the vehicle design. Due to the tight spacing between the rear seat back and the factory cargo blind, it may be difficult to re-install the cargo blind after the cargo barrier installation. Due to assembly tolerances, in some instances it may not be possible to re-install the cargo blind when the cargo barrier is fitted. In order to ensure the cargo blind does fit where possible, please follow the following installation sequence: 1. Fold the rear seats forward. 2. Loosen off the upper and lower cargo barrier straps, and while supporting the cargo barrier, release the upper barrier straps. 3. Push the cargo barrier forwards to allow the cargo blind to be fully inserted into position. 4. Re-position the cargo barrier to allow the upper straps to be loosely reattached. 5. While maintaining forward pressure on the cargo barrier, tighten all upper and lower barrier straps. Having followed this procedure, if it is not possible to re-install the factory cargo blind when the Sportage cargo barrier is fitted, it will be necessary to store the factory cargo blind safely for use when the barrier is removed.
11
13
11
9
13
11
11
9
Step 39
Page 18 of 18 Issue: 3 Date: 17/03/2016
KIA SPORTAGE Kit Part No: D9A30APK00
FRONT
9
11
13
13
11
11
30
30 33
33
Support Legs 31
Folded seats
35
33
The Cargo Barrier may be fitted in either the front position, or the rear position, See Step 39.
Remove all 3 head restraints from the 2nd row seat by pushing the release button on the left hand side of each of the
restraint pillars, then pulling each restraint upwards.
Fold the 2nd row seat back, downward as shown in the owners handbook.
Lay the cargo barrier on its back in cargo area.
Attach the support legs (31) to the cargo barrier brackets as shown using 29mm Milbolts (32).
Position the cargo barrier in place behind the 1st row seats with the support legs resting on the floor.
Attach the top extension tube straps (30) to the top straps using 14mm Milbolts (33) (2 per strap) as shown.
Attach the other end of the top extension tube straps to the upper mounts using 29mm Milbolts (9) with Wave Washers (11)
under heads.
Untie the long bottom straps from the cargo barrier panel.
Attach the free end of the bottom straps to the floor mounts using 44mm M10 Milbolts (13) with Wave washers (11) under
heads.
Tighten all Milbolts.
Attach the lateral support brackets (35) to the long bottom straps as shown using 14mm Milbolts (33).
FRONT POSITION CARGO BARRIER INSTALLATION IN VEHICLE - Requires Genuine Kia Sportage Cargo Barrier Front Position Kit D9A30APK50 sold separately
Step 40