Toyota HiLux Aug 2006 Onwards - egrdealernet.com.au · Toyota HiLux Aug 2006 Onwards ... The locking mechanisms & Latches only require occasional lubrication with Graphite Powder

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

Clean Tonneau Cover with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

Tools Required:

Toyota HiLux Aug 2006 OnwardsHard Tonneau Cover, J-Deck & A-Deck

Without Uteliner

• Non-permanent Marker• Long Series Phillips Screwdriver Bit• Drill with Ø4mm, Ø5mm and Ø7mm Drill Bits

• Hammer & Centre Punch• Phillips Screwdriver• Torque Wrench

• Caulking Gun• Silicon - Non-acetic• Tape Measure

1 2 3 4

5 876 9

Item

1

2

3

4

5

6

7

8

1

1

2

2

2

2

5

4

Tonneau Cover

Front Bar (Includes Hinge Pins)

Ball Strut Screw

Lock Striker Bracket

Lock Striker U-Bolt

Gas Struts

Self Drilling 14Gx22mm Screw

Rivet

Component Name Qty

PARTS LIST

Item

9

10

11

12

13

14

10

12

6

1

1

1

M6 Nut

Flat Washers

M6 Spring Washers

Rust Inhibitor

Keys

Fitting Instructions

Component Name Qty

10

11 141312

A

B

TC0164

01/05/09 Page 1 of 10

TONNEAU COVERINSTALLATION INSTRUCTION

01/05/09 Page 2 of 10

TC0164TOYOTA HILUX Hard Tonneau Cover, J-Deck & A-Deck

IMPORTANT!Read instructions carefully before installation. It is strongly recommended that installation is conducted by a Toyota Dealer, using a vehicle hoist. This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention

WARNING!When in the closed position, Tonneau Cover must be locked and tailgate must be closed! Failure to do so could result in unexpected opening of the Tonneau Cover from sudden wind gusts, which could cause damage to the vehicle and/or your Tonneau Cover!

Warranty TermsEGR warrants that the ABS Tonneau Cover EGR will be free from defects in material and workmanship for a period of three (3) years from the retail date of purchase. The gas struts are warranted for one (1) year from the retail date of purchase. This warranty only applies to the original purchaser and is nontransferable. Warranty must be claimed with original sales receipt for proof of purchase.

ExclusionsThis warranty does not cover failure due to neglect, improper installation including any modifications to installation hardware, operating the vehicle with your EGR Tonneau Cover in the open position, alterations, addition of equipment, abuse, accident, corrosion, normal wear and tear, lack of maintenance, and exposure to chemicals that are not safe for plastics.

Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Tonneau Cover is sole responsibility of the vehicle owner and operator. Paint wear to the vehicle bed can happen with any Tonneau Cover and is the sole responsibility of the vehicle owner. Paint damage to your vehicle is not covered under this warranty.

DisclaimerIn the event that your EGR Tonneau Cover is found to be defective under the terms of this warranty, it is at the discretion of EGR to repair or replace the defective part. Transportation costs and labor are not associated with this warranty claim.

MaintenanceYour EGR Tonneau Cover only requires periodic cleaning with mild car wash soap. Only use cleaners, waxes, or products that are labeled safe for use on plastics. Avoid the use of any chemicals to clean your EGR 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 & Latches only require occasional lubrication with Graphite Powder. DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.

All installation hardware and fasteners must be checked every so often for tightness.

IMPORTANT: • Do not stand/sit or rest heavy objects on Tonneau Cover.• Humans or animals are not to be under the closed Tonneau Cover at any time.• Securely lock Tonneau Cover before operating vehicle.• Do not carry open volatile chemicals with Tonneau Cover installed.• If contact with volatile chemicals occurs clean Tonneau Cover with mild detergent and water solution.• Recommend installation by 2 people.

PAINTING INSTRUCTIONS (IF UNPAINTED)

• If product surface is textured painting is not required.• Sand Tonneau Cover prior to painting recommend 500 grit using an orbital type sander.• Prior to painting, clean all surfaces to be painted using clean water and a mild detergent, do not use lacquer thinner or any solvent based products. Wipe completely dry. • Best results will be achieved by wiping the areas to be painted with a tack rag just prior to painting.• Select a top coat and clear paint that is suitable for ABS (Acrylonitrile-Butadiene-Styrene).• Automotive paint systems, such as Acrylics or Two Packs, can be applied directly to the components. However, some paints may require a primer. If recommendations on paint specification are not followed, cracking of the part or degradation to the material may result. In all paint systems, aromatic hydrocarbons and alkalies are best avoided to reduce damage to the material properties.• If using a paint system which requires baking, do not expose the product to temperatures above 70° C (155° F).• Allow a minimum of 8 hours after baking before installation on the vehicle.

1. NOTE: Two people are required to complete installation. Thoroughly clean installation areas. See Dia #1.

Diagram #1

3. Drive 14Gx22mm self drilling screws halfway into position, then remove and apply rust inhibitor to the thread.Re-insert the 14Gx22mm self drilling screws into previous positions (5 places). (Torque 5-7Nm). See Dia #3.

Diagram #3

2. For ‘A’ Deck Installation only - Trim foam tape as required to remove plastic endcaps from both ends of front bar as shown.For ‘A’ & ‘J’ Decks Place the front bar up against the front tub panel, aligning the top of the front bar with the top of the side rail.See Dia #2.

Diagram #2

14Gx22mm SELFDRILLING SCREW

TORQUE 5-7Nm

01/05/09 Page 3 of 10


‘A’DECK INSTALLATION

SIDE VIEW

TOP OFSIDE RAIL

TOP OFFRONT BAR

12

TRIM FOAMTAPE

REMOVEEND CAP

FRONTBAR

5. Measuring from the rear edge of the front bar, mark and centre punch the indicated position on the inside of the side rail as shown.Drill a Ø4mm pilot hole followed by a Ø7mm hole in the side rail at the marked position and apply rust inhibitor. Repeat for the other side of the vehicle. See Dia #5.

Diagram #5

6. Attach the ball strut screw to the side rail using the flat washers, spring washer and M6 nut as shown (Torque 5-7Nm). See Dia #6.

Diagram #6

FRONTTUBPANEL

FRONT BAR FRONT

TOP EDGEOF SIDE RAIL

665mm

20mm

SIDE VIEW

1 2 3

4. To prevent water ingress, apply a bead of silicon (non-acetic) to the gaps between the front bar and side rails and around the hinges. Repeat for the other side of the vehicle. Apply a bead of silicon (non-acetic) to the entire length between the front bar andfront rail as shown. See Dia #4.

Diagram #4

NOT SUPPLIED

Ø4mm

4

Ø7mm

5

13mm

FLATWASHERS

M6 NUTBALL STRUTSCREW

SIDE RAIL

MARKED POSITION

TORQUE 5-7Nm


01/05/09 Page 4 of 10

6

SPRINGWASHER

FOAMTAPE

HINGEFRONTRAIL

FRONTBARSIDE

RAIL

APPLY SILICONAROUND HINGE

APPLY SILICON BETWEENFRONT BAR & FRONT RAIL

APPLY SILICON BETWEENFRONT BAR & SIDE RAIL

8. ‘J’ Deck Installation. Align lock striker brackets with previously drilled holes, ensuring brackets are parallel with top of side rail and secure with four (4) pop rivets (2 per side). See Dia #8. IMPORTANT: Ensure side “B” as marked on the Lock Striker Bracket is positioned against the sheetmetal as shown. Orientation is different between ‘A’ & ‘J’ Deck vehicles.

9. ‘A’ Deck Installation. Align lock striker brackets with previously drilled holes, ensuring brackets are parallel with top of side rail and secure with four (4) pop rivets (2 per side). See Dia #9. IMPORTANT: Ensure side “A” as marked on the Lock Striker Bracket ispositioned against the sheetmetal as shown. Orientation is different between ‘A’ & ‘J’ Deck vehicles.

Diagram #8

7. Using a non-permanent marker, measure and mark a line on the side rail 1345mm and 1395mm from the rear edge of the front baras shown. Measure and mark a line on the side rail 13mm down from the top edge of the side rail. Centrepunch the position of thetwo holes as shown. Drill two (2) Ø5mm holes. Remove any swarf and apply rust inhibitor to all the drilled holes. Repeat for other side of the vehicle. See Dia #7.

Diagram #7

ENSUREBRACKET IS

PARALLEL WITHTOP OF

SIDE RAIL

NOTE:LOCK STRIKER

BRACKETORIENTATION

SIDE “B” AGAINSTSHEETMETAL

01/05/09 Page 5 of 10


FRONTTUBPANEL

FRONT BAR FRONT

TOP EDGEOF SIDE RAIL

1395mm

1345mm

13mm

SIDE VIEW

1 2 3

Ø5mm

4 5

B

A

RIVETS

LOCK STRIKERBRACKET

Diagram #8

‘J’ DECK INSTALLATION

ENSUREBRACKET IS

PARALLEL WITHTOP OF

SIDE RAIL

A

B

RIVETS

LOCK STRIKERBRACKET

‘A’ DECK INSTALLATIONNOTE:

LOCK STRIKERBRACKET

ORIENTATIONSIDE “A” AGAINST

SHEETMETAL

TOP HINGE SCREWS TORQUE 5Nm

10. Remove and retain the hinge pins from the front bar as shown. See Dia #10.

Diagram #10

12. Check Tonneau Cover is central to vehicle and the sides of Tonneau Cover do not contact the vehicle bedrail. Adjust position if necessary by loosening the top hinge screws and re-positioning Tonneau Cover to fit centrally on vehicle. Re-tighten hinges to torque 5Nm. See Dia #12.

Diagram #12

3

LEFT HAND SIDE SHOWN LEFT HAND SIDE SHOWN

21

“CLICK”

HINGEPIN

HINGEPIN

11. NOTE: Two people are required to carry out fitment of the Tonneau Cover. Fit Tonneau Cover - secure hinges with hinge pins as shown. See Dia #11.

Diagram #11

2

LEFT HAND SIDE SHOWN

HINGEPIN


1HINGE

PIN

01/05/09 Page 6 of 10


14. IMPORTANT: Open Tailgate during Lock Adjustment. Open Tonneau Cover. Assemble striker U-bolt, washers and nuts ontolock striker bracket as shown. Adjust so the top of the striker U-bolt is 10mm down from the top of the side rail. Tighten ensuring the10mm to the top of the side rail is maintained. See Dia #14.

Diagram #14

13. Open Tonneau Cover and attach gas struts by clipping into place as shown. Ensure the narrow end mounts to the vehicle.See Dia #13.

Diagram #13

15. 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. See Dia #15.

Diagram #15

1

TO REMOVE:GAS STRUT

GAS STRUT

GAS STRUT BALL STRUT SCREW

WIDEEND

(TOP)

NARROWEND

(BOTTOM)

OPEN TAILGATE

INSPECTION COVERPLASTIC RETAINER CLIPS PULLRODS

REMOVE INSPECTIONCOVER

2 RELEASE PLASTICRETAINER CLIPS

3 UNCLIP PULLRODSFROM PLASTICRETAINER CLIPS

4

01/05/09 Page 7 of 10


1

2

1

SIDE VIEW

MEASURE FROM TOP OFSIDE RAIL

0mm10

2030

4050

6070

8090

10mm 10mm

A

A

B

FLATWASHERS

LOCK STRIKERU-BOLT

SPRINGWASHERS

M6 NUTS

3 4

16. Close tonneau cover and inspect locking mechanism. Ensure the latch hits the U-bolt centrally. If it Does, proceed to figure 17.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 alsoneed to adjust the latch mechanism by loosening the screws and moving it left or right as shown. See Dia #16. Note: Tonneau cover has 2 stage locks. Ensure tonneau engages with the second stage of the latch.

Diagram #16

17. Open the tonneau cover and engage the lock by pressing upwards on the latch. Adjust pullrods so they clip back into the retainerclips correctly. Do this by rotating them clockwise to shorten them or anti-clockwise to lengthen them. Clip pullrods and retainer clipsback into position. Test lock by pressing the button on top of the tonneau cover. If latch mechanism Does Not release, return to step 3 and shorten the pullrods. If it Does release, replace inspection cover. See Dia #17.

Diagram #17

1

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

1

INCORRECT

INSPECT LATCHENGAGEMENT

CORRECT

2 ADJUST U-BOLTUSE A RULER TO ENSURE

U-BOLT REMAINS PARALLELTO LOCK STRIKER

3 ADJUST LATCHMECHANISM

4

TORQUE 10Nm

SCREWSTORQUE 4Nm

ADJUST

0mm

1020

3040

5060

7080

90

01/05/09 Page 8 of 10


2. Remove hinge pins and then remove the Tonneau Cover as shown. See Dia #2.

Diagram #2

1. Open Tonneau Cover and detach gas struts by inserting a small screw driver and adjusting the spring clip on the strut as shown. See Dia #1. NOTE: Do not remove the spring clip. Only a small amount of levering is required to detach.

Diagram #1

1

GAS STRUT

BALL STRUT SCREW

GAS STRUT

REMOVAL OF TONNEAU COVER

2 3

2

3


1


HINGEPIN

HINGEPIN

01/05/09 Page 9 of 10


1. Fit Tonneau Cover and secure hinges with hinge pins. See Dia #1.

Diagram #1

2. Attach gas struts by clipping into place. Ensure the narrow end mounts to the vehicle. See Dia #2.

Diagram #2

GAS STRUT

REPLACEMENT OF TONNEAU COVER

3


2

1


BALL STRUT SCREW

GAS STRUT

“CLICK”

HINGEPIN

HINGEPIN

01/05/09 Page 10 of 10


Documents

Toyota HiLux Aug 2006 Onwards - egrdealernet.com.au · Toyota HiLux Aug 2006 Onwards ... The locking mechanisms & Latches only require occasional lubrication with Graphite Powder