PARTS, SERVICE & ACCESSORIES Toyota HiLux J-Deck 2015 Hard

Page 1 of 31

Place these instructions in vehicle’s glove box after installation is complete

Installation Time: Approx. 3h 30min

Clean Tonneau Coverwith a mild detergent and water solution.

Do not use abrasive cleaners or solvents.Care Instructions:

IMPORTANT!

Please check content of kit using this list and subsequent sketches. Advise discrepancies to TMCA at once.

Do not stand/sit or rest heavy objects on Tonneau Cover.

Do not carry open volatile chemicals with Tonneau Cover installed.

Humans or animals are not to be under the closed Tonneau Cover at any time.Securely lock Tonneau Cover before operating vehicle.Tonneau Cover is not dust or water tight.

If contact with volatile chemicals occurs clean Tonneau Cover with mild detergent and water solution.

PARTS, SERVICE & ACCESSORIES

MAINTENANCE If lubrication of the locks or hinges is required use only Graphite Powder. DO NOT use any other lubricants or oils.

Toyota HiLux J-Deck 2015Hard Tonneau Cover

With UtelinerInstallation Instructions

ISSUE 1: 16/01/18

- Check that all work practices comply with safety standards.- Please wear appropriate clothing and use safety equipment.

Safety Notes

--

-

----

Read through the fitting instructions before installation of accessory.Always 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 Toyota 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.Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.

General Notes

TC0402

Accessory Part No. PZQ70-89855 / PZQ70-89860 / PZQ70-89865


Page 2 of 31

PARTS CHECK SHEET

PARTS IN MAIN CARTON

PARTS IN FITTING KIT

ISSUE 1: 16/01/18

Hard Tonneau Cover, J-DeckAccessory Part No. PZQ70-89855 / PZQ70-89860 / PZQ70-89865

TC0402


1

Tonneau CoverQty - 1

4 5

Ball StrutScrew(SCRW0724)Qty - 2

6

Gas Strut(STRT0006-2)Qty - 2

7 8 9 10

Hinge Pin(CLIP3243)Qty - 2

12 13 14 15 16 17

18 19 20 21 22 23 24

25 2726

FittingInstructions

FittingInstruction(FIT-TC0402)Qty - 1

2 3

11

Header BarAluminium(HBAR0018)Qty - 1

Lock Keys(Attached toTonneau)Qty - 2

Fitting KitQty - 1

RustInhibitor

StrikerBracket(CLIP3150PC)Qty - 2

Striker U-Bolt(LOCK0006)Qty - 2

Rust Inhibitor(MISC2776)Qty - 1

Pop Rivet(FAST0505)Qty - 11

Alcohol Wipe(MISC0052)Qty - 2

AUTOMOTIVESURFACE CLEANER

IMPREGNATED WITH 70% ISOPROPYL ALCOHOL

For use in cleaning painted metal,glass and other vehicle surfaces.For external use only.Dispose of properly after use.

M6 Small S/SFlat Washer(WASH0153)Qty - 10

M6 Large S/SFlat Washer(WASH0169)Qty - 2

M6 S/SSpring Washer(WASH0103)Qty - 4

M6 S/SHex Nut(NUTS0161)Qty - 8

M6 S/SNylock(NUTS0016)Qty - 2

RubberThread Cap(MISC2532)Qty - 4

HeaderRail Seal(MISC2229)Qty - 1

Primer Stick(MISC1365)Qty - 2

Corner PieceMoulding(INJM0012-1)Qty - 1 Pair

M5 Nylock Nut(NUTS0171)Qty - 2

Wiring Loom(LOOM0082 RCL) or(LOOM0099 non RCL)Qty - 1

M5x16 Hex Head Bolt (SCRW0450)Qty - 2

M5 Flat Washer (WASH0190)Qty - 4

Pin Switch Plate (CLIP3141PC)Qty - 1

Harness Bracket (CLIP3304PC)Qty - 1

Anti-abrasive Tape (TAPE0698)25mm x 1.55mQty - 1

PARTS IN LOOM KIT

Tools Required:• Pen / Marker• Centre Punch• Drill & drill bits; Ø3mm, Ø5.5mm, Ø6mm, Ø7mm & Ø9mm• Phillips Screwdriver• Torque Wrench• Trim removal Tools• Step Drill Ø25mm, Ø35mm

• Caulking Gun• Silicon - Non Acetic• Die Grinder & multi tool• Masking Tape• Scissors & Knife• Ruler• Wire Cutters• Drill Stop

• 10mm,12mm,13mm & 14mm Spanner & Socket• Rivet Gun• Tape Measure• Soapy Water Solution• Allen Key Set (Metric)• 35mm Hole Saw• Ratchet• Jeweller’s Flat Head Screwdriver

Page 3 of 31 ISSUE 1: 16/01/18

Relay Harness x1(locking variant only)

A B D

Extension Patch x1

C

Power Harness x1

1-Way Female Connector x2

(locking variant only)

E

6-Way Female Connector x1

6-Way Male Connector x1(locking variant only)

F

Scotch Lock Housing x1

G H

J

Mini Blade Fuse - x17.5A

I

Cleaning Pad x2Adhesive Cable Tie

Mounts x4

K

Cable Tie - Lamp only variant x25

Locking variant x35

200mm

Cable Tie - 600mm x3

L

Ø8mm P-Clip x2

M N

M6 Flange Nut x1(locking variant only)

O

Ø6mm P-Clip x1

P

7x12 Cable Tie Clips x2

CLEANINGPAD


TC0402


Page 4 of 31ISSUE 1: 16/01/18

Toyota Hilux HTCInstallation Steps Flow Chart

START

FINISH

STEP 6 - STEP 18

STEP 1 - STEP 5

STEP 19 - STEP 24

STEP 25 - STEP 56

PAGE 26

PAGE 25

TUB PREP FOR HTC INSTALL

HTC INSTALL AND ADJUSTMENT

HTC ADJUSTMENT

LOCK ADJUSTMENT

WIRING HARNESS INSTALLATION

UTELINER MODIFICATIONS TO FIT HTC (IF APPLICABLE)

DUST DEFENCE KIT INSTALLATION


TC0402


TC0402

Page 5 of 31Accessory Part No. PZQ70-89855 / PZQ70-89860 / PZQ70-89865ISSUE 1: 16/01/18

1. Remove the vehicle’s ute liner as shown. Retain all the hardware. NOTE: Two people are required to complete installation. See Dia #1.

Diagram #1

2. Thoroughly clean installation areas. See Dia #2.

Diagram #2

3. Drill 25mm hole and cut out 100x35mm hole in the LHS of the ute liner as shown, repeat on the RHS side. See Dia #3.

Diagram #3

UTE LINER

Ø25mm

100

692560

22mm8mm

35mm

Ø25mm

Page 6 of 31ISSUE 1: 16/01/18

HOLE FOR ELECTRICAL HARNESS IN TUB

6. Cut out and adhere the supplied Template (1) from page 33, to the LHS front inner tub panel area (2) using tape. Mark Ø3mm on the drill (3) using a drill stop (4) to a depth of 10mm. Drill a pilot hole through the template crosshair centre (5). Remove and discard the template (1). Using a stepped drill bit, drill out the previously drilled pilot hole toØ30mm. See Dia #6.

Diagram #6

10mm

4

3

1 2

5

4. Apply masking tape to the front of the ute liner as shown. Mark up the ute liner as per dimensions shown in above diagram on either side (continue cutting line along the length of the front of the ute liner). Remove cut away section with a jigsaw. Smooth all the trimmed edges using sandpaper. See Dia #4.

Diagram #4

Diagram #5

UTE LINER

MASKING TAPE

1

2

3 4

CUT AWAY AREA(SHADED)

FRONTOF TUB


TC0402


45mm

5. Cut out the paper template from the last page of this fitting instruction. Place the template in the front left corner of the ute liner as shown. Mark and drill 35mm hole in the ute liner for the lamp harness. See Dia #5.

DRILL Ø35mm HOLE

PAPER TEMPLATE

Ø35mm

Page 7 of 31ISSUE 1: 16/01/18

7. Using a file (1) de-bur the hole (2) and remove any rough or sharp edges. Apply rust inhibitive compound around the edges of the hole. See Dia #7.

Diagram #7

21

2


TC0402


9. Carefully place the Header Bar (2) on the tub and apply pressure on top of the double sided tape to activate the adhesive. Mark and drill the 7 holes with 5.5mm drill bit. Apply the Rust Inhibitor to all drilled holes. Secure the Header Bar to the tub with 7 pop rivets. See Dia #9.

Diagram #9

Ø5.5mm

AUTOMOTIVESURFACE CLEANER

IMPREGNATED WITH 70% ISOPROPYL ALCOHOL

For use in cleaning painted metal,glass and other vehicle surfaces.For external use only.Dispose of properly after use.

8. Clean and prime (IPA wipes and primer sticks) front of the tub where the double sided tape will contact.Remove the red liner from the double sided tape and apply a bead of non-acetic silicon to the underside of the Header Bar (2) along the full length of the rail as shown in the section view of the header rail. See Dia #8.

Diagram #8

2

2

12

12

SILICONE

PRIME TOP RAIL

HEADER RAIL SECTION VIEW

DOUBLE SIDEDTAPE

FOAM TAPE

RustInhibitor


TC0402


12. Apply masking tape to the inside edge of the tub rail as shown. Measuring from the rear edge of the front headerbar, mark and centre punch the indicated positions on the inside of the tubrail as shown. See Dia #12.

Diagram #12

SIDE VIEW

2 3 4

FRONTMASKING TAPEHEADERBAR

701mm575mm66mm

17.5mm16.3mmBA A

Diagram #10

11. To prevent water ingress, apply a bead of silicon (non-acetic) to the gap between the front bar and the side rail as shown. Repeat for the other side of the vehicle. Add a bead of silicone along the front of the tub between the header barand the front tub rail. Ensure that silicone is applied around the legs of the cabin guard. See Dia #11.

10. To prevent water ingress, apply a bead of silicon (non-acetic) along the edge of the LHS & RHS inspection panels inside the tub, as shown. See Dia #10.

Diagram #11

1



TC0402

FRONT

14. Use the primer (19) to prime the top of the header rail and tub rail in areas shown. Place the header bar seal (3), 13mm from the inside edge of the LHS side rail. Note the seal orientation as shown in the section view. Remove tape liner from the header rail seal and apply the seal (3) along the top of the header bar (2). Trim the seal 13mm from the RHS inside edge of the tub. Align the seal corner piece (17) on inside edge of the tub rail. Remove tape liner from corner piece moulding and fit into header rail seal as shown. Apply firm vertical pressure to the bulb seal to ensure proper adhesion.Note: If uteliner is fitted, the corner piece will sit on top of the uteliner. See Dia #14.

Diagram #14

10mm 10mm

13. Drill Ø5.5mm holes in positions “A” and Ø6.5mm in position “B”. Repeat for the other side of the vehicle tub. Apply rust inhibitor to the drilled holes. See Dia #13.

Diagram #13

SIDE VIEW

BA A

Ø5.5mm

1

Ø6.5mm

2

3

3 17

3

ALIGN EDGESSECTION

VIEW

PRIME THIS AREA

13MM

UTE LINER

15. Replace the vehicle’s ute liner as shown. NOTE: Ute liner may require further trimming to fit correctly into tub.See Dia #15.

Diagram #15



TC0402

2122

2323

24

24

2220

Diagram #16

17. Attach the ball strut screw to the side rail (position B) using the flat washers, and M6 nyloc nut as shown (Torque 8Nm). See Dia #17.

Diagram #17

13mm

SIDE RAIL

TORQUE 8Nm

1018

19

6

B

FRONT

SECTIONVIEW

16. Attach the Pin Switch Contact Plate (23) to the top of the Header Bar and the Harness Bracket to the bottom using two M5 bolts (21), washers (22) and Nylock nuts (20). Torque to 5Nm. See Dia #16.

18. Align lock striker bracket with previously drilled holes in position “A”, ensuring bracket side marked with the letter “B”is hard against side rail and parallel with top of side rail. Secure to each side of the vehicle using two pop rivets. See Dia #18.

Diagram #18

Diagram #19

Diagram #20


TC0402


SIDE RAIL

A

B

4

1212

1313

1

2

GAP

A

FLAP SEAL

HEADER-RAIL SEAL

J-DECK SECTION VIEW

19. NOTE: Two people are required to carry out fitment of the Tonneau Cover. Carefully lift and fit the tonneau cover (1) to the vehicle. Ensure the hinges sit correctly in the header rail and that the tonneau flap/header rail seals are sittingcorrectly (check that they are not pushed out of alignment or being pinched by the lid. Secure the tonneau hinges with hinge pins (13) hooked into header bar (2). See Dia #19.

20. Check clearance of tonneau cover to vehicle rear corners. Ensure the tailgate is open and close tonneau cover. Check clearances at both rear corners between tonneau cover and sheet metal. Gaps should be consistent. If tonneau cover is touching sheet metal or gaps are not even, adjustment of the tonneau position may be required. Refer to the Tonneau Cover Position Adjustment and Latch Position Adjustment section of this fitting instruction for more information. Note: If there is no ajustment required, torque all hinges and latches to 5Nm.

FRONT

10mm


TC0402


Diagram #21

Diagram #23

Diagram #22

4

56

6

7

8

8

21. Attach gas struts by clipping them into place. Ensure narrow end mounts to the vehicle. See Dia #21.

10

1

11

11

9

9

23. Measure the length of exposed thread (Xmm) from bottom of the nut to the end of the thread. Measure length (Xmm) on the rubber thread cap (9) and cut to length. Repeat for four thread caps and fit to threads. See Dia #23.

(Xmm)

(Xmm)

A A

22. Assemble striker U-bolt (5), M6 small flat washers (6), M6 stainless spring washers (7) and M6 stainless hex nuts (8) onto lock striker bracket (4). Adjust so the top of the striker U-bolt (5) is high enough for the latchesto reach second stage locking. Ensure that the tonneau lid seals contact the vehicle tub.Tighten ensuring the distance to the top of the side rail is maintained, (Torque 8Nm). Note: Refer to Striker Height Adjustment section of this fitting instruction for more information if necessary.Note: Set striker height at 10mm for starting point. See Dia #22.

TORQUE 8Nm

Page 13 of 31ISSUE 1: 16/01/18

FOR FUTHER INFORMATION ON ADJUSTING THE TONNEAU COVER REFER TO PAGES 25-27

FOR THE ELECTRICAL INSTRUCTION TURN TO THE NEXT PAGE



TC0402

44

Diagram #24

TRIMEXCESS CLEARABRASION TAPE

3TONNEAU NOT SHOWN FOR CLARITY

SQUEEGEE OUTEXCESS SOLUTION

BUBBLES

4

1

25% ISOPROPYLALCOHOL

75% WATER

APPLYCLEAR

ABRASION TAPE

ALIGNCLEAR ABRASION

TAPE WITH TOP EDGEOF THE TAILGATE

2

24. Using a solution of 25% isopropyl alcohol and 75% water in a spray bottle (not -supplied) Thoroughly spray along the top of the tailgate. Remove liner from clear abrasion tape. Working from one end with a 5mm overhang to the side of the tailgate, place the clear abrasion tape (26) on the tailgate. Trim excess tape leaving a 5mm overhang at both ends of the tailgate. When in position use a squeegee to push out any excess water solutionand bubbles. Using a knife trim the tape to end of the tailgate. You may need to squeegee a few times.When finished the tape is virtually invisible. To ensure a good finish please take care and do not rush this step. See Dia #24.

Page 14 of 31ISSUE 1: 16/01/18

25. Important: Always refer to the vehicle’s Workshop Manual when removing vehicle components. Note down all clock and radio settings. Disconnect the negative terminal of the battery (1) in the engine bay. See Dia #25.

Diagram #25

26. At the front passenger side foot well area: remove front passenger scuff plate, remove the kick panel trim nut (2) and remove the kick panel (3). See Dia #26.

Diagram #26

27. Unclip the glove box dampener (1). Remove LH retaining clip (2) by rotating anti-clockwise. Remove the glove box (3). Remove the driver's lower dash garnish (4). See Dia #27.

Diagram #27

1

123

4

2

3

1



TC0402

Page 15 of 31ISSUE 1: 16/01/18

28. Dislodge upper glove box trim (1). Unclip the upper glove box (2) and remove. See Dia #28.

Diagram #28

29. Locate and disconnect the 20-way hybrid junction connector (1) in the passenger side kick panel area. Identify the two Lock/Unlock terminal wires as shown: See Dia #29.

Diagram #29

30. Using a precision screw driver, unclip the connector secondary lock (1). Carefully remove the two Lock/Unlock wires from the rear of the connector using a precision screw driver. House the BLUE and GREEN lamp Relay Harness terminals (2) into the rear of the connector cavities in the positions shown:BLUE WIRE UPPER CAVITY (3). GREEN WIRE LOWER CAVITY (4). Push the 20-way connector secondary lock (1) into place to retain terminals. See Dia #30.

Diagram #30

2

1

2

3

4

Blue

Green

1

Front view of 20-way connector

Pin 10

Pin 20

Connector Pin 10: Lock / Black WireConnector Pin 20: Unlock / White Wire


1

1

Important: Ensure an audible ‘click’ is heard.



TC0402

Page 16 of 31ISSUE 1: 16/01/18

31. House the previously removed vehicle lock terminals into the supplied 1-way connectors (1) Push the secondary lock into place to retain terminals. Important: Ensure an audible ‘click’ is heard. Connect the Relay Harness BLUE wire 1-way connector (2) to the vehicle BLACK 1-way connector (3) Connect the Relay Harness GREEN wire 1-way connector to the vehicle WHITE 1-way connector. Reconnect the 20-way hybrid junction connector to the vehicle.See Dia #31.

Diagram #31

32. Disconnect the 20-way junction connector (1). Scotch lock the Relay Harness terminal (2) to the 20-way junction connector Pin 20 (3) RED wire/terminal. House the scotch lock terminal (2) with the supplied scotch lock housing (4). Reconnect the 20-way junction connector (1). Disconnect the 20-way junction connector (1). See Dia #32.

Diagram #32

33. Route the two Relay Harness bases (1) up the vehicle harness (2) towards the LH glove box cavity area.Secure the Relay Harness (1) to the vehicle harness (2) at every 150mm intervals with supplied Cable Ties. See Dia #33.

Diagram #33

1

1

14

4 2

2

3

3


3

1

2

1

23

1



TC0402

Page 17 of 31ISSUE 1: 16/01/18

34. In the upper glove box cavity area, if vehicle is equipped with an ECU (1) in the location shown, remove vehicle nut (2). Route Relay Harness ground ring terminal (3) to the vehicle grounding point (4) located in the upper LH glove box cavity area on the I/P reinforcement bar. Fasten the ring terminal (3) using the existing nut (2) to the vehicle grounding point (4). Note: If no ECU is present, use the supplied M6 Flange Nut to the grounding point (4). See Dia #34.

Diagram #34

35. In the engine bay area, secure the Power Harness male terminals (1) to the guide wire (2). Cut the LHS access point (3). Note: If the LHS access point is occupied, use the RHS access point. Feed the guide wire (2) into the firewall grommet (4). Ensure the guide wire breaks the internal grommet seal. Feed through until the Power Harness loop (5) reaches the grommet and is facing down. Seal with silicon, then cable tie (6) around the access point. See Dia #35.

Diagram #35

36. In the glove box cavity area, retrieve the Power Harness (1) from the firewall grommet hole (2). House the five terminals (3) on the end of the Power Harness to the supplied connector (4), in the positions shown in Table 1 and then secure the secondary locks. Connect the housed Power Harness connector (4) to the Relay Harness 6-way connector (5). See Dia #36.

Diagram #36

Important

Important

1

2

4

4

5

3

2

43

1

ImportantEnsure the wire colours correspond between the Sensor Harness and Relay Harness when connected.


13

2456

Wiring Information1

Table 1

BLACK

BLUEGREEN

GREY

23456

REDRED/BLACK

Important: Torque earth bolts between 6.9 & 9.8 Nm.

Important: Ensure the earth wire and Relay Harness are free from sharp edges and pinch points.



TC0402

1

6

1

23

5

Front of vehicle

6

1

2

1

Page 18 of 31ISSUE 1: 16/01/18

37. Route the previously retrieved Power Harness (1) from the firewall grommet hole towards the battery (or accessory fuse box if fitted), following the vehicle harness down the LHS of the engine bay. Secure the Power Harness (1) to the vehicle harness using Cable Ties (2) in the locations shown. See Dia #37.

Diagram #37

38. If vehicle is NOT fitted with accessory fuse block go to Step 41, otherwise, continue with Step 38: Remove the accessory fuse block cover (1). Disconnect the accessory fuse block (2) from its mounting bracket (3). Using side cutters, remove and discard the cable tie (4) from the wire bundle. Unclip and dislodge the fuse holder (5). See Dia #38.

Diagram #38

39. Connect the Power Harness 1-way male connector (1) to the RED Extension Harness 1-way female connector (2).Secure Power Harness to the vehicle harness in between the battery and the fuse box. See Dia #39.

Diagram #39

2

4

5

3

1

2

2

2

1

2

1



TC0402

Page 19 of 31ISSUE 1: 16/01/18

40. Feed the Extension Harness RED terminal wire (1) through the fuse block funnel. Insert the ORANGE fuse terminal (2) into the cavity as shown. Insert the supplied Mini Blade Fuse (3) into the wired slot and refit back into the accessory fuse box (4). Secure harnesses with a Cable Tie (5) where shown. Go to Step 42. See Dia #40.

Diagram #40

41. If vehicle is NOT fitted with accessory fuse block continue with Step 41. Note: Ring terminal power harness supplied with non accessory fuse block variants only. Connect the Power Harness 1-way male connector (1) to the fused Extension Harness 1-way female connector (2). Route the fused RED wire 8mm ring terminal (1) to the positive battery terminal (3).Secure the fused RED wire 8mm ring terminal (1) to the back section of the battery positive terminal (3) using the existing nut (4). Secure Power Harness with supplied Cable Ties at every 200mm intervals. See Dia #41.

Diagram #41

42. Route the Power Harness (1) down into the engine bay towards the LHS chassis rail and secure to the chassis rail using Cable Ties (2) at the locations shown. See Dia #42.

Diagram #42

Ensure an audible ‘click’ is heard.ImportantImportant

Check fuse terminal retention.

1

41

3

3

2 1

1

5

4

12345678910 3

2

1

2

2

Front of vehicleImportant

Avoid sharp edges, brake lines and sources of heat.

12

Front of vehicle

2

Important Positive battery ring terminal nut to be tightened to 13Nm. Battery post terminal torque to be between 2.9 and 7.8Nm.


TC0402


Page 20 of 31ISSUE 1: 16/01/18

43. Continue routing along the chassis rail towards front tub panel.Secure the Power Harness (1) to the chassis using Cable Ties (2) in the locations shown. See Dia #43.

Diagram #43

44. From underneath the vehicle, route the Power Harness power wire (1) towards the front tub panel, following the inside of the LHS chassis rail. Secure the Power Harness (1) to the chassis using Cable Ties (2) in the locations shown. See Dia #44.

Diagram #44

45. Following the LHS chassis frame, route the remaining Power Harness branches (1) towards the LHS front of the tub.Secure the Power Harness to the chassis using supplied Cable Ties (2) to the locations shown. See Dia #45.

Diagram #45

Front of vehicle

2

12

22 2 2

2

Front of vehicle

1

Important


Important


Important

Avoid sharp edges, brake lines and sources of heat.1 2

2

2

Front of vehicle



TC0402

Page 21 of 31ISSUE 1: 16/01/18

46. Continue routing along the chassis rail towards the LHS front tub panel.Secure the Power Harness (1) to the chassis using a supplied Cable Tie (2) to the location shown. See Dia #46.

Diagram #46

47. Continue routing along the chassis rail towards the LH front tub panel.Secure the Power Harness (1) to the chassis using supplied Cable Ties (2) to the locations shown. See Dia #47.

Diagram #47

48. Continue routing along the chassis rail towards the LH front tub panel.Secure the Power Harness (1) to the chassis using supplied Cable Ties (2) to the locations shown. See Dia #48.

Diagram #48

Important


221

Front of vehicle

1

2

Front of vehicle

12

2

Front of vehicle



TC0402

Page 22 of 31ISSUE 1: 16/01/18

49. Feed a guide wire (1) through the Ø30mm hole (2) From underneath the LHS front of the tub, retrieve the guide wire and secure it to the Power Harness connectors. Pull the Power Harness (1) through the hole (2) and into the tub. Ensure a good seal has been achieved between the Ø30mm grommet (3) and Ø30mm tub panel hole. Note: Ensure the larger grommet (Ø30mm) is used. See Dia #49.

Diagram #49

50. From underneath the LHS front tub area, clean the front tub panel (1) with the supplied Cleaning Pad. Secure the Power Harness to the front tub panel using the supplied Cable Tie Mount and Cable Tie (2). See Dia #50.

Diagram #50

51. Underneath the vehicle, locate the Power Harness (1). See Dia #51.

Diagram #51

23

12

ImportantAllow the areas cleaned with the supplied Cleaning Pad to dry before continuing.

21

Front of tub outer panel LHS

ImportantEnsure the Power Harness (1) is kept clear of all sharp edges or moving parts.

1

Front of vehicle


TC0402


Page 23 of 31ISSUE 1: 16/01/18

52. Secure excess Power Harness (1) away from the rear RH wheel arch area using the supplied Cable Ties (2). See Dia #52.

Diagram #52

53. Using a supplied Cleaning Pad, clean the outside of the front tub panel in the area shown (1).Secure the Power Harness to the front section of the tub using supplied Cable Tie Mount and Cable Tie (2). See Dia #53.

Diagram #53

54. Connect the 6-way male connector (1) to the front LH tonneau rail bracket (2). See Dia #54.

Diagram #54

ImportantEnsure the Power Harness is kept clear of all sharp edges or moving parts.

122

1

Front of vehicle

ImportantAllow the areas cleaned with the supplied Cleaning Pad to dry before continuing.

2 1

2

1



TC0402

Page 24 of 31ISSUE 1: 16/01/18

55. Connect the 6-way male connector (1) to mating female connector (2) located in the front/LH Tonneau area.Using a 7x12 cable tie clip (3), fasten the female harness to the bracket (4). See Dia #55.

Diagram #55

56.

34

2

1ImportantOpen and close the Tonneau lid to confirm theharness does not snag in the hinge operation of theTonneau lid.

Important

• Reconnect the negative battery terminal.

Battery Post terminal to be torqued in between 2.9and 7.8Nm.

• Check the operation of the Tonneau cover ajar feedback system: o Ensure the car is unlocked. o Open the Tonneau cover window. o Check that the door ajar indicator on the instrument cluster is “on”. o Close the Tonneau cover. o Check the door ajar indicator on the instrument cluster is “off”.

For Locking Tonneau Cover Variants:• Check the operation of the Locking system: o Lock the car and check that the Tonneau Cover is locked. o Unlock the car and check that Tonneau Cover is unlocked.



TC0402


TC0402


TORQUE 5Nm

TONNEAU COVER POSITION ADJUSTMENT

A A

B B

1. Open the tonneau cover and lower the tailgate.2. Loosen the screws on the hinges and latches at the positions shown.

3. Ensure that the gas struts are NOT attached. Adjust the position of the tonneau lid to the desired position or until the side and rear gaps are even, ie. A=A and B=B. Tighten the hinge screws to 5Nm.4. Perform a latch position adjustment if necessary.

5. Tighten remaining screws to 5Nm.6. Repeat steps 2-4 if further adjustment is required.

LOOSENSCREWS

LOOSENSCREWS

LOOSENSCREWS

LOOSENSCREWS



TC0402

STRIKER HEIGHT ADJUSTMENT LATCH POSITION ADJUSTMENT

1. 1.

2. 2.

3.

3.

4.

5.

FIGURE 2

FIGURE 2

FIGURE 1

0mm

1020

3040

5060

7080

90

FIGURE 1

Open the tonneau cover and lower the tailgate. Open the tonneau cover and lower the tailgate.

Using a 10mm spanner, loosen the nuts holding the lock striker in place. Wind the nuts to move them up or down depending upon the direction the striker hoop is to be moved.

Once the striker is set at the desired height tighten the nuts and torque to 8Nm. With the tailgate still open, carefully close the tonneau lid to check that the latches engage/release correctly with the strikerhoops and that the height is correct.

Test cycle the locks with the handle. Open the tonneau lid and close the tailgate. Close thetonneau lid and close the tonneau lid to check that the latches still engage/release correctly with the striker hoops and that the height is correct.

If the striker height requires further adjustmentrepeat steps 2- 4 until the latches engage/release correctly striker height is correct.

Using a Phillips head screwdriver (No. 2) loosenthe four screws holding the latch in place on the tonneau lid so that the latch can freely slide. Repeat this for the other latch if both need adjustment.

FIGURE 3

Carefully close the tonneau lid. Check the positioningof the striker hoops inside the locking pawl in the latches. The striker hoops should be centred in the latch pawl when the latch is locked. If required slide the latches until they are correctly positioned.

4. Once the latches are set at the desired positiontighten the screws and torque to 5Nm.

5 Nm

Harness Circuit Diagram

Fron

t vie

w o

f 20

-way

con

nect

or

Fro

nt v

iew

of 6

-way

con

nect

or

1 32

45

6

Col

our

1

BLA

CK

BLU

EG

RE

EN

GR

EY

2 3 4 5 6R

ED

RE

D/B

LAC

K

Func

tion

GR

OU

ND

LOC

KU

NLO

CK

DR

SIG

NA

L12

V+

LAM

P V

+

Col

our

1

BLA

CK

BLU

EG

RE

EN

GR

EY

/BLA

CK

2 3 4 5 6R

ED

RE

D/B

LAC

K

Func

tion

GR

OU

ND

LOC

KU

NLO

CK

DR

SIG

NA

L12

V+

LAM

P V

+

7.5A

7.5A



TC0402

Page 28 of 31ISSUE 1: 16/01/18


TC0402


2

REPLACEMENT OF TONNEAU COVER

2. Attach gas struts (2) by clipping into place. Ensurenarrow end (1) mounts to the vehicle. Reconnect the 6-way connector located in the front/LH tonneau area. Refit the tie clip to the bracket. Refer to figure 6.

1.

Fit tonneau cover (2) and secure hinges with hinge pins (1). Refer to figure 5.

NOTE: 2 people are required to lift and fit the tonneau cover onto the vehicle.

FIGURE 4

FIGURE 5

FIGURE 6

REMOVAL OF TONNEAU COVER

1. Open tonneau cover. Disconnect the 6-way connectorlocated in the front/LH tonneau area. Remove the tie clip.from the bracket. Detach gas strut (1) by inserting a small screwdriver and adjusting the spring clip (2) on the gas strut (1). Refer to figure 2.NOTE: Do not remove the spring clip. only a smallamount of levering is required to detach.

2.

Remove hinge pins (1) and remove tonneau cover (2). Refer to figure 3.

NOTE: 2 people are required to lift and remove the tonneau cover from the vehicle.

FIGURE 3

FIGURE 2

FIGURE 1

2

2

1

11

1

1

2

1

1

Documents

PARTS, SERVICE & ACCESSORIES Toyota HiLux J-Deck 2015 Hard