1PC TONNEAU COVER INSTALLATION INSTRUCTIONS · 2016. 6. 6. · fig. 15 fig. 16 isuzu d-max 1pc tonneau cover tc0057c page 6 of 10 15/09/08 “click” left hand side shown 1 3 9 left

TC0057c

1PC TONNEAU COVERINSTALLATION INSTRUCTIONS

TONNEAU COVER LIST OF PARTS

Vehicle Description: ISUZU D-MAX (without bedliner)

PLEASE KEEP INSTRUCTIONS IN GLOVE BOX FOR FURTHER USE

15/09/08page 1 of 10

1 2 3 4 5 6 7 8

9 10 11 12 13 14

17 18 19 20 21 22

15 16

PART NAME

Tonneau Cover

Lock Striker Brackets

Gas Struts

Gas Strut Brackets

U-Bolts

M6 Stainless Flat Washer

M6 Spring Washers

Pop Rivets

12345678

1222284

10

QTYNO. PART NAME

M6 Hex Nuts

M8 Stainless Flat Washers

M8 Stainless Spring Washers

M8x25mm Stainless Hex Bolts

M8 Hex Nuts

Rubber Thread Caps

171819202122

864424

QTYNO.PART NAME

Bottom Hinge Bracket LHS

Bottom Hinge Bracket RHS

Rust Inhibitor

Foam Tape Strip

Keys

Alcohol Wipe

Header Rail Drill Template

Side Rail Drill Template

910111213141516

11112111

QTYNO.

For external use only.

AUTOMOTIVESURFACE CLEANER

IMPREGNATED WITH 70% ISOPROPLY ALCOHOL

For use in cleaning painted metal,glass and other vehicle surfaces.

Dispose of properly after use.

TC0057c

15/09/08page 2 of 10

TOOL NAME

Ø2mm & Ø3mm Drill Bits

Ø5mm & Ø8mm Drill Bits

Drill

Cleaning Cloth

Socket Wrench

12345

NO. TOOL NAME

Tape Measure

Masking Tape

Shifting Spanner

Sharp Knife

11121314

NO.TOOL NAME

5mm Allen Key

Hammer & Centre Punch

Non-permanent Marker

Phillips Head Screwdriver

Rivet Gun

6789

10

NO.

RECOMMENDED TOOLS LIST

1 2 3 4 5 6 7 8

9 10 11 12 13 14

Ø5mm

Ø8mm

Ø2mm

Ø3mm

FIG. 2

FIG. 1

If your vehicle is fitted with a cabin guard continue to next Figure. If not, proceed to Figure 4.

FIG. 5

TC0057cISUZU D-MAX 1PC TONNEAU COVER

15/09/08page 3 of 10

FIG. 3

2

3

1

HEADER RAIL

15

TOPVIEW

TOPVIEWLINE UP WITH

EXISTING HOLESCENTRE OF

FRONT TUB RAILCENTRE OF

FRONT TUB RAILLINE UP WITHEXISTING HOLES

15 15

FIG. 6

HEADER RAIL

ALIGN TOP HOLEWITH POSITION

MARKED IN FIG. 4

10

9

ALIGN TOP HOLEWITH POSITION

MARKED IN FIG. 4

TOP VIEW

HEADERRAIL

FIG. 4

MEASURE AND FIND THE CENTRE OF THE VEHICLE’S FRONT BED RAIL.

FRONT TUB RAIL

MARK CENTRE OF TUB

IMPORTANT! MEASURE VERY CAREFULLY AND DOUBLE CHECK YOUR RESULTS BY MEASURING FROM DIFFERENTPOINTS OF REFERENCE ON THE VEHICLE TUB.


15/09/08page 4 of 10

FIG. 8

FIG. 9

FIG. 7

10mm

8

8

9

10

9

10

8

HEADER RAIL

Ø5mm11

HEADER RAIL

FIG. 10

HEADER RAIL

16

SIDE RAIL

810mm

TOP VIEW ALIGN WITH CORNEROF SIDE RAIL

16HEADER

RAIL

SIDE RAIL

POSITION MARKEDIN FIG. 8

4

TOP VIEW

SIDE VIEW

SIDE RAIL

SID

E R

AIL

ALIGN WITHTOP OF

SIDE RAIL

4

4Ø5mm

11

FIG. 14


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FIG. 13

FIG. 11

FIG. 12

HEADER RAIL

16

SIDE RAIL

8

4

10mm

REAR OF VEHICLE

REMOVE1 2 2

18

1920

TORQUE10Nm

1 22

Ø2mm Ø8mm

21

18

19

2TORQUE

10NmENSURE

BRACKET ISPARALLEL WITH

TOP OF SIDE RAIL

5

17

7

6

17

SIDE VIEW

MEASURE FROM TOP OFSIDE RAIL

5

2

27mm 7mm

0mm10

2030

4050

6070

8090

FIG. 15

FIG. 16


15/09/08page 6 of 10

“CLICK”LEFT HAND SIDE SHOWN

13

9

LEFT HAND SIDE SHOWN

2

9

1

FIG. 17

FIG. 18

HEADER RAIL

ALCOHOL WIPEUNDER SEAL

SIDE RAIL

2 100mm

12For external use only.

AUTOMOTIVESURFACE CLEANER

IMPREGNATED WITH 70% ISOPROPLY ALCOHOL

For use in cleaning painted metal,glass and other vehicle surfaces.

Dispose of properly after use.

14

X (mm) X (mm)

CUT AWAYSHADED

AREA

0mm10

2030

4050

6070

8090

0mm10

2030

4050

6070

8090

1 2 3

5

5

222

22


15/09/08page 7 of 10

2STEP

NEXT FIG.

RE-TORQUE 5Nm

21

ENSURECLEARANCE

TO TUB

LOOSEN HINGE SCREWSTO ADJUST TONNEAU

POSITION IF NECESSARY

FIG. 19

CONTINUED OVER PAGE

FIG. 20

1

TO REMOVE:3

3

34

ATTACH GAS STRUTS

FIG. 21

1

INSPECTION COVERPLASTIC RETAINER CLIPS PULLRODS

REMOVE INSPECTIONCOVER

2 RELEASE PLACTICRETAINER CLIPS

3 UNCLIP PULLRODSFROM PLASTICRETAINER CLIPS

4

OPEN TONNEAU COVER AND REMOVE INSPECTION COVER BY REMOVING SCRIVETS AND ROTATING COVER ANTI-CLOCKWISE. RELEASE PLASTIC RETAINER CLIPS AND UNCLIP PULL-RODS AS SHOWN.

LOCK ADJUSTMENTIF REQUIRED


15/09/08page 8 of 10

FIG. 23

1

OPEN THE TONNEAU COVER AND ENGAGE THE LOCK BY PRESSING UPWARDS ON THE LATCH. ADJUST PULLRODS SO THAT THEY CLIP BACK INTO THE RETAINER CLIPS CORRECTLY. DO THIS BY ROTATING THEM CLOCKWISE TO SHORTEN THEM OR ANTI-CLOCKWISE TO LENGTHEN THEM. CLIP PULLRODS AND RETAINER CLIPS BACK INTO POSITION. TEST LOCK BY PRESSING THE BUTTON ON TOP OF TONNEAU COVER. IF LATCH MECHANISM DOES NOT RELEASE, RETURN TO STEP 3 AND SHORTEN THE PULLRODS. IF IT DOES RELEASE, REPLACE INSPECTION COVER.

ENGAGE LOCK

LATCH MECHANISM

PRESS LATCHUPWARDS

ROTATE PULLRODS

CLOCKWISE = SHORTENANTI-CLOCKWISE = LENGTHEN

“CLICK”

2 ADJUST LENGTH OFPULLRODS BY ROTATION

3 4

REPLACE INSPECTION COVER6

TEST LOCKING MECHANISM5

RETAINERCLIPS

INSPECTIONCOVER

LOCK PLASTIC RETAINER CLIPSBACK IN POSITION


MAINTENANCE:

Only use cleaners, waxes, or products that are labeled safe for use on plastics. Avoid the use of any chemicals to clean your Tonneau Cover unless labelled safe for plastics. Avoid use of abrasive type cleansers as they may dull the finish.

For Tonneau Cover products that have a textured exterior surface, wash the Tonneau Cover and clean dirt out of the texture with a soft brush and apply a commercially available automotive car polish to maintain product shine. If fuel is splashed onto the Tonneau Cover immediately wash it off with car washing detergent and water. If staining is apparent polish the stain out with a commercially available car polish such as "Kitten car polish".

The gas struts are self lubricating and should only be cleaned occasionally with a damp cloth. Premature seal failure will result if solvents or lubricants are used to clean struts.

The locking mechanisms only require occasional lubrication with lithium grease. All installation hardware and fasteners must be checked every so often for tightness.

FIG. 22

CLOSE TONNEAU COVER AND INSPECT LOCKING MECHANISM. ENSURE THE LATCH HITS THE U-BOLT CENTRALLY. IF IT DOES, PROCEED TO FIG 23 BELOW. IF IT DOES NOT, ADJUST THE U-BOLT ACCORDINGLY BY LOOSENING THE M6 NUTS AND MOVING THE U-BOLT UP OR DOWN AS SHOWN. YOU MAY ALSO NEED TO ADJUST THE LATCH MECHANISM BY LOOSENING THE SCREWS AND MOVING IT LEFT OR RIGHT AS SHOWN. NOTE: TONNEAU COVER HAS 2 STAGE LOCKS. ENSURE TONNEAU ENGAGES WITH SECOND STAGE OF THE LATCH.

1


INCORRECT

INSPECT LATCHENGAGEMENT

CORRECT

2 ADJUST U-BOLT

USE A RULER TOENSURE U-BOLT

REMAINS PARALLELTO LOCK STRIKER

3 ADJUST LATCHMECHANISM

4

TORQUE 10Nm

SCREWS

TORQUE 4Nm

ADJUST

5

2

0mm

1020

3040

5060

7080

90

22

FIG. 1


REMOVAL OF TONNEAU COVER

15/09/08page 9 of 10

FIG. 2

FIG. 3

2


1

9


9

1

TO REMOVE:3

3

34


15/09/08page 10 of 10

FIG. 1

REPLACEMENT OF TONNEAU COVER

FIG. 2

FIG. 3

“CLICK”LEFT HAND SIDE SHOWN

2

9


1

9

1 3

3

34

Documents

1PC TONNEAU COVER INSTALLATION INSTRUCTIONS · 2016. 6. 6. · fig. 15 fig. 16 isuzu d-max 1pc tonneau cover tc0057c page 6 of 10 15/09/08 “click” left hand side shown 1 3 9 left