canopy cp0016a supplementary instructions toyota … 2005-2014 j... · 2018. 10. 9. · is specific...

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CANOPYSUPPLEMENTARY INSTRUCTIONS

CP0016a

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

Clean Canopy with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

IMPORTANT!• Read instructions carefully before installation. It is strongly recommended that installation is conducted by an authorized dealer.• This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.• Recommend installation by 2 people.

RECOMMENDED TOOL LIST - (Not Supplied in Kit)

• Phillips Head Screwdriver• Sockets 10, 12 & 13mm, Extension Bar and Driver• Spanners 10, 12 & 13mm• Silicon Dispensing Gun• Non Acetic Silicon (Neutral Cure)• Spray Bottle Water• Torque Wrench - 0-10Nm• Hacksaw or Jigsaw• Allen Keys (Ball Ended Type)• Engineers Set Square

• Non Permanent Marker• Masking Tape• Cleaning Cloths / Rags• Steel Rule and Tape Measure• Knife (Sharp)• File or Deburring Tool• Ø3mm, Ø9mm & Ø12mm Drill Bits and Drill• Drill Stop

TOYOTA HILUX DOUBLE CAB ‘J’ DECK KIT - SR ONLYPART NUMBER: KIT-HLX05-JD

(with & without Toyota Genuine Bed Liner)(February 2005 Production Onwards)

PLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES.

This instruction is supplementary to the Hilux Canopy Fitting Instruction (CP0015) andis specific to EGR Hilux Dual Cab Canopies fitted to Toyota Hilux ‘J’ Deck vehicles (SR level).This Fitting Instruction where a Bed Liner is referred to, is based on -Toyota Genuine Over Rail Bed Liner Accessory Part No’s. :- PZ053-0K019 only.

Installation Time:1 Hour (Approximately)Without Bed Liner fitted

1 Hour 45 minutes (Approximately)With Bed Liner fitted

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CP0016aTOYOTA HILUX - CANOPY

PARTS CHECK SHEET TOYOTA HILUX ‘J’ DECK CANOPY KIT

PARTS IN FITTING KIT (KIT031950)

Bracket Canopy‘J’ Deck Mount(CNPY0024PC)Qty - 6

Blackened M8x25Hex Head SS305(SCRW0696-1)Qty - 6

Blackened M8Flat Washer(WASH0171-1)Qty - 12

Blackened M8Spring Washer(WASH0152-1)Qty - 6

Blackened M8Hex Nut(NUTS0217-1)Qty - 6

M8x25 Allen KeyButton Head ScrewSS316(SCRW0623)Qty - 12

M8 Flat WasherOD. 17mm SS(WASH0171)Qty - 24

M8 NylocNut SS(NUTS0242)Qty - 12

Spacer 19mm OD,9m ID, 6mm Thick(MISC3265)Qty - 6

RustInhibitor

FittingInstruction

Rust InhibitorSatchel(MISC2776)Qty - 1

FittingInstruction(FIT-CP0016a)Qty - 1

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Remove cabin guard (if fitted), prime /paint all bare metal surfaces and installvehicle wiring harness, as per the HiluxCanopy fitting instructions (CP0015).(ref. diagram1).

1.

If a bed liner has been fitted to the vehicle, it must be removed and retained with allhardware before proceeding to the nextstep. (ref. diagram2).

Apply masking tape to the inside of theside rails as shown. Using a non permanent marker, measurefrom inside the tub at the front rail andmark the three (3) positions as shown forboth sides of the vehicle. (ref. diagram3).

2.

Diagram: 2 - REMOVE BED LINER (IF FITTED)

3.

Diagram: 3 - APPLY TAPE, MEASURE & MARK HOLE POSITIONS

Diagram: 1 - REMOVE CABIN GUARD & PRIME

REMOVECABIN GUARD

(IF FITTED)

FRONT RAIL

REAR OFVEHICLE

APPLYMASKING TAPE (1400mm) TO SIDE RAILS

MEASURE & MARKTHREE (3) POSITIONS ON SIDE RAILS

VIEW INSIDE VEHICLE TUB

1400mm

1131mm582mm

120mm

1

1 2 3

PLEASE COMPLETE STEPS 1 TO 19 FROM THE HILUX CANOPY FITMENT - FITTING INSTRUCTIONS CP0015, BEFORE CONTINUING WITH THIS INSTRUCTION.

30/11/10 of 13


Rust

Inhibit

or

With two (2) people, trial fit bracket canopyJ deck mounts (CNPY0024PC), orient thebrackets with the horizontal slots againstthe side rail, and align the front edge of thebrackets with previously marked lines.Align the top of the brackets with thetop of the tub rail using a set square andmark the centrepoints of the slots as shown.Remove brackets from the vehicle.(ref. diagram4).

4.

Centrepunch previously marked positions.Using a drill with 10mm drill stop set, drilltwelve (12) Ø3mm pilot holes (6 per side)and re-drill to Ø9mm holes as shown.Remove masking tape from side rails.Remove all burrs and sharp edges.Apply rust inhibitor (MISC2776) to alldrilled holes in the tub sheet metal.(ref. diagram5).

Apply masking tape to the outer sides ofthe bed liner, at the top under the bed raillip as shown.Apply masking tape across the front of theinternal face of the bed liner as shown.Position bed liner in tub, DO NOT fithardware from bed liner kit at this stage.(ref. diagram6).

5.

Diagram: 5 - DRILL HOLES ALONG SIDE RAILS

6.

Diagram: 6 - APPLY MASKING TAPE & FIT BED LINER

Diagram: 4 - TRIAL FIT BRACKETS & MARK SLOT CENTRES

VIEW INSIDE VEHICLE TUB

IF A BED LINER IS FITTED TO THE VEHICLE, PLEASE CONTINUE WITH STEPS 6 TO 11.IF A BED LINER IS NOT FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 12.

FRONT OFVEHICLE

APPLYMASKING TAPE TO

FRONT OF BED LINER

2

APPLYMASKING TAPE TO

OUTER SIDES OF BED LINER

1

RE-FITBED LINER

WITHOUT HARDWARE

3

Ø9mmØ3mm10mm

2 35 6

FRONTRAIL

CENTRE-PUNCHMARKED HOLE POSITIONS

1

REMOVEALL BURRS &

SHARP EDGES

5

APPLYRUST INHIBITOR

TO ALL DRILLED HOLES

6

REMOVE ALL MASKING TAPE

1

DRILLØ3mm PILOT HOLES

2

ALIGNFRONT OF BRACKETWITH MARKED LINE

2ALIGNTOP OF BRACKET

WITH TOP OF BED RAIL

3

MARKCENTRE OF SLOTS REMOVE BRACKETS5

RE-DRILLØ9mm HOLES3

4

4ORIENT BRACKET,HORIZONTAL SLOTSAGAINST SIDE RAIL

3D VIEW OF FRONTBRACKET

1

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Apply firm pressure to top of bed linerabove holes previously drilled into tubsheet metal.Using a non permanent marker, mark thetwelve (12) hole positions on the bed liner.Carefully remove the bed liner.(ref. diagram7).

7.

From the outside of the bed liner drill twelve (12) Ø3mm pilot holes (6 per side).From the inside of the bed liner re-drillthrough Ø3mm pilot holes to Ø12mmholes as shown.Remove all burrs and sharp edges.(ref. diagram8).

Across the front of the bed liner mark a line15mm down from the top face.Measure and mark a line on both sides20mm back from the inside front face.Mark a line from the existing cabin guardcut-out in the bed liner, back to thepreviously marked line as shown.(ref. diagram9).

8.

Diagram: 8 - DRILL HOLES IN BED LINER

9.

Diagram: 9 - MARK BED LINER FRONT TRIM LINE

Diagram: 7 - MARK HOLE POSITIONS & REMOVE BED LINER

0mm 10 20 30 40 50 60 70 80 90

15mm

MEASURE & MARKA LINE ACROSS THE LINER

15mm DOWN FROM THE TOP FACE

DRILLØ3mm PILOT HOLESFROM THE OUTSIDE

REMOVEALL BURRS &

SHARP EDGES

RE-DRILLØ12mm HOLES

FROM THE INSIDE

1

MEASURE & MARKCENTRELINE OF BED LINER

20mm

4

3

5 MARKIN LINE WITHCUT-OUT IN

THE BED LINER

REMOVEBED LINER

3

15mm

Ø12mmØ3mm

10mm

1 2

2

2

21

3

1

3

APPLYFIRM PRESSURE

1

MARKHOLE POSITIONS ON BED LINER

2

BED LINER

BED RAIL

30/11/10 of 13


Using a jigsaw or similar, carefully cut thefront top section of the bed liner off usingthe lines marked 15mm down from the top.Remove all masking tape from bed liner.Remove all burrs and sharp edges.(ref. diagram10).

10.

Re-fit bed liner including all hardware.(ref. diagram11).

Fit bracket canopy J deck mounts(CNPY0024PC), and secure to the vehicleusing two (2) M8x25 allen key button headscrews (SCRW0623), four (4) M8 flatwashers (WASH0171) and two (2) M8 nylocnuts per bracket as shown. (Use only aball ended allen key in bolt heads, foraccess to screw in allen head screws).Tighten all screws to Torque 8Nm.(ref. diagram12).

11.

Diagram: 11 - RE-FIT BED LINER

12.

Diagram: 12 - FIT BRACKET CANOPY ‘J’ DECK MOUNTS

Diagram: 10 - CUT BED LINER

CUT OUT and DEBURRTHE FRONT MARKED

AREA CAREFULLY

REMOVEALL MASKING TAPE

1

2

RE-FITBED LINER1

RE-FITALL BED LINER

HARDWARE

2

8Nm

BallEnded

M8x25mm ALLENKEY SCREWS

TORQUE TO 8Nm

M8x25mmSCREWS

M8 FLATWASHERS

M8 FLATWASHERS

M8 NYLOCNUTS

M8 NYLOCNUTSBRACKET CANOPY

‘J’ DECK MOUNTS

BRACKET BEDRAIL

BED LINER FITTED

BED LINER NOT FITTED

M8x25mmSCREWSM8 FLAT

WASHERS

M8 NYLOCNUTS

BRACKET

BED RAIL

BED LINER

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Using alcohol wipe provided clean thehighlighted face of the front rail and wipeaway residue with a dry clean cloth.If heavy cleaning is required use Iso-Propyl Alcohol and wipe away residuewith a dry clean cloth.Apply (MISC1365) primer stick to high-lighted surface and allow to dry. Starting with a small amount of the tapefrom the double sided tape roll 12mm wide(TAPE0615), apply it starting from theedge of the front rail of the tub to the otherside, along the rear edge of the front tub railpressing down on the liner as you applythe tape across the vehicle as shown.Apply firm pressure to ensure the tapeadheres to the vehicle.IMPORTANT: Ensure the tape sits flatand DOES NOT pucker. (ref. diagram13).

13.

Using a non permanent marker, measureand mark a line at the centre of the tubspacer (ALUM0038-7) and the centre ofthe front rail on the tub as shown.Use alcohol wipes provided clean the tapecontact surfaces of the front tub spacerextrusion and wipe away residue with adry clean cloth. Apply (MISC1365) primerstick to highlighted area on extrusion andallow it to dry. Apply a 12mm bead of non-acetic silicon(neutral cure), (not supplied) to the tubspacer on the short face in the corner asshown. (ref. diagram14).

Remove the liner film from the double sidedtape applied to the front tub rail.Fit rail extrusion spacer to the front rail overthe tape aligning the previously markedcentre lines.Apply firm pressure rearward and down onthe front tub spacer extrusion along thelength to ensure maximum adhesion of thefoam tape.Clean any excess silicon off using isopropylalcohol.IMPORTANT: There must be NO siliconresidue left on the top of the side bed railfaces, or the bed rail foam tape will notadhere correctly and water leaks willoccur. Ensure no silicon is squeezed upby the fitting of the front tub spacerextrusion, if it is clean it off with IPA ona rag heavily loaded.(ref. diagram15).

14.

Diagram: 14 - APPLY SILICON TO THE TUB SPACER

15.

Diagram: 15 - FIT RAIL EXTRUSION SPACER

Diagram: 13 - FIT 3M TAPE 12x1700mm

FRONT RAIL

TAPE COVERSHALF OF THE HOLE APPLY

DOUBLE SIDED 12x1700mm ROLL(TAPE0615) ACROSS FRONT RAIL

1

4

POSITION TAPEAGAINST SIDE RAIL

2

3

FRONT RAIL OFVEHICLE TUB

SIDE RAIL OFVEHICLE TUB

APPLYPRIMER STICK

TO SHADED AREAALONG FRONT RAIL

2

TAPE COVERS1/2 THE HOLE

FRONTRAIL

APPLYFIRM PRESSURE TO

ADHERE TAPEREMOVE

TAPE LINER1

FITFRONT TUB SPACER EXTRUSION

TUBSPACER

TAPE

CROSS SECTIONTHROUGH FRONT RAIL

SILICON

FRONT RAIL

2

3

NOT SUPPLIED

FRONT TUB SPACER EXTRUSIONAPPLY

12mm BEAD OF SILICON

5

5

1 2 MEASURE & MARKCENTRE LINE OF TUB SPACER

MEASURE & MARKCENTRE LINE OF FRONT RAIL

= =3

4

30/11/10 of 13


Using alcohol wipes provided clean alltop rail areas of the tub and wipe awayresidue with a dry clean cloth. If heavycleaning is required use Iso- Propylalcohol and wipe away residue with adry clean cloth.Ensure no silicon is squeezed up by thefitting of the front tub spacer extrusion,if it is clean it off with IPA on a ragheavily loaded.

FOR VEHICLES WITH A BED LINERFITTED. Use a priming stick (MISC1365) to prime the top of bed liner rails whereEPDM foam tape will be applied in step 18.(ref. diagram16).

16.

Diagram: 16 - VEHICLE SURFACE PREPARATION

BED LINER NOT FITTED BED LINER FITTED

FOR VEHICLES WITHOUT A BEDLINER FITTED.Apply EPDM foam tape (TAPE0386) fromhardware kit to the vehicle tub bed rails andspacer fitted in step 15.IMPORTANT: DO NOT CUT FOAM TAPE!Starting from one side at the rear corner,position the tape end in line with theedge of the tailgate, position the foamtape 10mm rearward of the inside edgeof the tub and as it bends around thecorner align it to the edge of the insideradius of the top tub rail and continuethis position all the way along the siderail in one continuous length, position10mm rearward along the front tub spacerextrusion as shown and to the edge ofthe inside radius of the top tub rail downthe other side, run tape out onto the tail-gate as shown. As the tape bends aroundthe corners ensure the tape sits flat andDOES NOT pucker. Trim off excess to theedge of the tailgate as shown.Ensure all foam tape areas are fully adheredto the tub and spacer by applying moderatepressure down on the tape all the wayaround the tub. (ref. diagram17).Tape MUST be fully adhered to tub railsand spacer and sit flat in one continuouslength to prevent water entering thecanopy.

17.

Diagram: 17 - INSTALL WATER SEALING TAPE

1

23

4

5

6

APPLYEPDM FOAM TAPEAROUND BED RAIL

TAILGATE OFVEHICLE TOP VIEW OF

VEHICLE TUB

CA

BIN

OF

VEH

ICLE

START AT THEEDGE OF THE

TAILGATE

POSITIONEPDM FOAM TAPE

OVER THE EDGE OFTHE INSIDE RADIUS

ALONG THE SIDE RAILS


10mm REARWARD OFTHE EDGE OF THE

FRONT TUB SPACEREXTRUSION

ALONGSIDE RAILS

ALONGSIDE RAILS

FOAM TAPE MUST NOTPUCKER AROUND CORNERS

FINISH OVERTHE EDGE OFTHE TAILGATE

TRIM EXCESS TOTHE EDGE OFTHE TAILGATE

ALONGFRONT RAIL

WITH SPACER

10mm

10mm

10mm

1 21

30/11/10 of 13


With a clean cloth wipe down all areas ofthe internal front tub corners to besiliconed as shown. Spray areas to besiliconed with water, Do Not dry.Apply non-acetic silicon (neutral cure)(not supplied) to the top of the tub andspacer around the foam tape and inside thetub at the join between the front and sidepanels, if a cabin guard was fitted, ensureall gaps and the seam on the remainingcabin guard metal work on the tub is siliconsealed properly. Apply silicon between thetub and tub spacer from the corner of thetub up to the first slot in the tub spacer asshown. Re-spray silicon with water andpush silicon into gaps and clean up excesssilicon. Repeat process for the other sideof the vehicle.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram19).

19.

Diagram: 19 - APPLY SILICON

FOR VEHICLES WITH A BED LINERFITTED.Apply EPDM foam tape (TAPE0386) fromhardware kit to the vehicle bed liner railsand spacer fitted in step 15.IMPORTANT: DO NOT CUT FOAM TAPE!Starting from one side at the rear corner,position the tape end in line with theedge of the tailgate, position the foamtape 10mm rearward of the inside edgeof the tub sheet metal and as it bendsaround the corner align it to the edge ofthe inside radius of the top bed liner railand continue this position all the wayalong the bed liner side rail in onecontinuous length, position 10mmrearward along the front tub spacerextrusion as shown and to the edgeof the inside radius of the top bed linerrail down the other side, run tape outonto the tailgate as shown. As the tapebends around the corners ensure thetape sits flat and DOES NOT pucker.Trim off excess to the edge of the tail-gate as shown.Ensure all foam tape areas are fully adheredto the bed liner and spacer by applyingmoderate pressure down on the tape all theway around the tub. (ref. diagram18).Tape MUST be fully adhered to bed linerrails and spacer and sit flat in onecontinuous length to prevent waterentering the canopy.

18.

Diagram: 18 - INSTALL WATER SEALING TAPE

1

2 3

4

5

6

APPLYEPDM FOAM TAPEAROUND BED RAIL

TAILGATE OFVEHICLE TOP VIEW OF

VEHICLE TUB

CA

BIN

OF

VEH

ICLE

START AT THEEDGE OF THE

TAILGATE


OVER THE EDGE OFTHE INSIDE RADIUS

ALONG THE SIDE RAILS


10mm REARWARD OFTHE EDGE OF THE

FRONT TUB SPACEREXTRUSION

ALONGSIDE RAILS

BEDLINER

ALONGSIDE RAILS

FOAM TAPE MUST NOTPUCKER AROUND CORNERS

FINISH OVERTHE EDGE OFTHE TAILGATE

TRIM EXCESS TOTHE EDGE OFTHE TAILGATE

ALONGFRONT RAIL

WITH SPACER

10mm

10mm TOSHEET METAL

BEDLINER

BEDLINER

10mm TOSHEET METAL

NOT SUPPLIED

EPDM FOAMTAPE

FRONT TUBSPACER EXTRUSION

FRONT TUB SPACEREXTRUSION FIRST SLOT

FRONT TUB SPACEREXTRUSION FIRST SLOT

APPLYNON ACETIC SILICON

DETAIL VIEW IFCABIN GUARD

WAS REMOVED


1

2

EPDM FOAMTAPE

INTERNAL VIEW INSIDE THE TUB


1


2

BED LINER FITTEDBED LINER NOT FITTED

FRONT TUBSPACER EXTRUSION

BEDLINER

BEDLINER

30/11/10 of 13


With a clean cloth wipe down all areas tobe siliconed as shown. Spray areas to besiliconed with water, Do Not dry.Apply non-acetic silicon (neutral cure)(not supplied) to the top of the tub andspacer around the foam tape and downthe front side of the tub between the tuband the cabin, and down at least the depthof the return of the front tub spacerextrusion, from the top of the tub and pushsilicon into gaps. Repeat process for theother side of the vehicle.Run a 10mm bead of silicon around the topof the EPDM foam tape, only at the front ofthe vehicle’s tub as shown.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram20).

20.

Diagram: 20 - APPLY SILICON

Clean front of canopy including the frontwindow.We recommend to disconnect the stoplamp located in the tailgate, as an ADRrequirement. (ref. diagram21).

Two people are required for this step.First tape the wiring harness to the RHside window with masking tape.Position the canopy onto the vehicletub carefully. IMPORTANT: Ensure canopy is placedfully forward on the tub in one action.DO NOT slide the canopy on the EPDMfoam tape and silicon, as this candamage the foam tape and spread thesilicon (break the water seal).Remove masking tape and feed canopyharness down between tub and cabin (righthand side of vehicle) so it is accessibleunder the vehicle on the outside of thechassis rail. (ref. diagram22).

21.

Diagram: 21 - PREPARE CANOPY & DISCONNECT TAILGATE STOP LAMP

22.

Diagram: 22 - FIT CANOPY TO TUB

DO NOT SLIDE CANOPYON EPDM FOAM TAPE

AND SILICON

2 FITCANOPY TO

VEHICLE

1 TAPEWIRING HARNESS

TO RH SIDE WINDOW

3FEED

CANOPY HARNESSBETWEEN TUB AND

CABIN DOWN TOCHASSIS RAIL

HARNESS

CLEANCANOPY FRONT

1

RECOMMEND TODISCONNECT

TAILGATESTOP LAMP

2

NOT SUPPLIED

APPLY NON ACETICSILICON (NEUTRAL CURE)

EPDM FOAMTAPEFRONT TUB

SPACER

VEHICLE CABIN NOTSHOWN FOR CLARITY TOP VIEW OF

VEHICLE TUB

CABIN OF VEHICLE

1


(NEUTRAL CURE)TO TOP OF EPDM FOAM TAPE

2 50mmMINIMUM

30/11/10 of 13


8Nm

13mm

8Nm

13mm

Align the canopy evenly on the tub.The canopy lower perimeter extrusion’sfront face, should align with the front of thetub spacer extrusion (ALUM0038-7) usinga straight edge as shown.Open rear tailgate to check sidewaysalignment. Using a steel ruler position thecanopy so both canopy base side railsare even to the width of the vehicle tub.From inside the canopy, also check thefront holes in the front rail of the canopy align to the centre of the holes in the tubspacer extrusion. (ref. diagram23).

23.

Diagram: 23 - ALIGN CANOPY TO TUB

EVEN BOTH SIDESAT THE END CAPS

CANOPY BASE RAIL

VIEW FROMREAR OF CAR

FOR VEHICLES WITHOUT A BEDLINER FITTED.Fit one (1) blackened - M8x25 bolt, M8spring washer, M8 hex nut and two (2) M8flat washers (per side) to the rear hole only inthe canopy rail and bracket mount as shown.Tighten to Torque 8Nm.(ref. diagram24).

24.

Diagram: 24 - SECURE REAR BRACKETS

FOR VEHICLES WITH A BED LINERFITTED.Fit one (1) spacer (MISC3265) through slotin side rail onto the mount bracket and lineup with the holes in the bracket and side rail.Fit one (1) blackened - M8x25 bolt, M8spring washer, M8 hex nut and two (2)M8 flat washers (per side) to the rear holeonly in the canopy rail and bracket mountas shown. Tighten to Torque 8Nm.(ref. diagram25).

25.

Diagram: 25 - SECURE REAR BRACKETS

3

ALIGN FRONT OFCANOPY BASE EDGE

EXTRUSION TOFRONT OF TUB SPACER

RULER FLAT AGAINSTFRONT OF TUB SPACER

0mm

1020

3040

5060

7080

90

1

2

REAR CLAMP BOLT - SECTION

M8x25mmBOLT

BRACKETMOUNT

CANOPYSIDE RAIL

M8 FLATWASHERS

M8 SPRINGWASHER

M8 NUT

TORQUE TO 8Nm

M8x25mmBOLT

BRACKETMOUNT

CANOPYSIDE RAIL

M8 FLATWASHER

M8 FLATWASHER

M8 SPRINGWASHER

M8 NUT

M8x25mmBOLT

BRACKETMOUNT

CANOPYSIDE RAIL

SPACERM8 FLATWASHER

M8 FLATWASHER

M8 SPRINGWASHER

M8 NUT

REAR CLAMP BOLT - SECTION

BRACKETMOUNT

CANOPYSIDE RAIL

M8 SPRINGWASHER

M8 NUT

TORQUE TO 8Nm

M8x25mmBOLT

SPACER

M8 FLATWASHERS

2

2

FITSPACER

1

30/11/10 of 13


ADJUSTLATCH STRIKER

HOOPS TO CENTREOF SLOTS

CLOSE REAR DOOR &CHECK 2 STAGE LATCHING &DOOR SEALS ON TAIL-GATE

LOOSENLATCH STRIKERHOOPS BOLTS

TORQUETO 6Nm

10mm

You will need to adjust the rear door latchstriker hoops, loosen bolts with a 10mmsocket and adjust the bracket so the middleof the slot lines up with the bolt as shown,and tighten to Torque 6Nm. Remove andretain the keys attached to the interior reardoor handle.Close the rear door firmly, fromcentre of lower rear door sash withoutslamming it too hard.NOTE: Latch has 2 stages of engagement.Ensure canopy engages with secondstage of latch and the lower rear doorseal, seals against the tailgate.If it DOES NOT then please proceed todiagram 27 & 28.If it DOES then please proceed to diagram 29.(ref. diagram26).

26.

Diagram: 26 - CHECK AND ADJUST REAR DOOR LATCH STRIKER

4

1

23

IMPORTANT: Steps 27 and 28 are only required if the canopy rear door can not be closed properly, the canopy rear door does not engage with second stage of latch of the locking mechanism,or the lower rear door seal does not seal against the tailgate.If the rear door closes, the latches are engaging with the second stage and the lower rear doorseal, seals against the tailgate, then please proceed to step 43.

REAR DOORNOT SHOWN FOR CLARITY

Diagram: 27 - LOOSEN REAR DOOR LATCH STRIKER BRACKET

10mm

LOOSENM6 BOLTS & NUTS

Rear rail bracket mounts must be installedand tightened to Torque 8Nm.Loosen the two (2) M6 bolts and hex nutssecuring the lower rear corner bracket to thecanopy side rail as shown.Repeat for the other side of the vehicle.IMPORTANT: Do not remove hardware,only loosen enough to slide bracket.(ref. diagram27).

27.

30/11/10 of 13


FOR VEHICLES WITHOUT A BEDLINER FITTED.Fit one (1) blackened - M8x25 bolt, M8spring washer, M8 hex nut and two (2)M8 flat washers (per side) to the front andmiddle slotted holes in the canopy rail andbracket mount as shown.FOR ALL VEHICLES - Tighten the rearbolts first, then the front bolts and finallythe middle bolts, all to Torque 9Nm.(ref. diagram29).

29.

Diagram: 29 - SECURE REMAINING BRACKETS AND TIGHTEN ALL

FOR VEHICLES WITH A BED LINERFITTED.Fit one (1) spacer (MISC3265) through slotin side rail onto the mount bracket and lineup with the holes in the bracket and side rail.Fit one (1) blackened - M8x25 bolt, M8spring washer, M8 hex nut and two (2)M8 flat washers (per side) to the front andmiddle slotted holes in the canopy rail andbracket mount as shown.FOR ALL VEHICLES - Tighten the rearbolts first, then the front bolts and finallythe middle bolts, all to Torque 9Nm.(ref. diagram30).

30.

Diagram: 30 - SECURE REMAINING BRACKETS AND TIGHTEN ALL

WHEN ALL STEPS ARE COMPLETED, RETURN TO THE HILUX CANOPY FITMENTFITTING INSTRUCTIONS CP0015 AND PROCEED TO STEP 44 TO COMPLETE CANOPY FITMENT.

M8x25mmBOLT

BRACKETMOUNT

CANOPYSIDE RAIL

M8 FLATWASHERS

M8 SPRINGWASHER

M8 NUT

8Nm

13mm

8Nm

13mm

FRONT & MIDDLE CLAMP BOLTSECTION

FRONT & MIDDLE CLAMP BOLTSECTION

BRACKETMOUNT

CANOPYSIDE RAIL

M8 SPRINGWASHER

M8 NUT

M8x25mmBOLT

SPACER

M8 FLATWASHERS

M8x25mmBOLT

BRACKETMOUNT

CANOPYSIDE RAILSPACER

M8 FLATWASHER

M8 FLATWASHER

M8 SPRINGWASHER

FRONTSLOT

FRONTSLOT

MIDDLESLOT

MIDDLESLOT

M8 NUT2

2

2

2

M8x25mmBOLT

BRACKETMOUNT

CANOPYSIDE RAIL

M8 FLATWASHER

M8 FLATWASHER

M8 SPRINGWASHER

FRONTSLOT

MIDDLESLOT

M8 NUT2

2

2

2

FITSPACER1

REAR DOORNOT SHOWN FOR CLARITY

GENTLY PULLCANOPY FRAMEREARWARD ONTHE VEHICLE

Diagram: 28 - GENTLY PULL CANOPY & TIGHTEN BOLTS

TORQUE TO 9Nm

10mm

8Nm

1

3

25mm

Two (2) people are required for this step.One person will need to gently pull the canopy frame directly rearward on the vehicle as shown.The other person checks that there is a 5mmgap between the end of the corner bracket andthe slot in the base rail of the canopy, and thentighten the two (2) M6 bolts and hex nuts toTorque 9Nm. Close the rear door firmly, fromcentre of lower rear door sash without slammingit too hard. NOTE: Ensure canopy engageswith second stage of rotary latch. If requiredloosen the rail clamps and adjust the canopyposition fore and aft, re-tighten the rear railclamps to Torque 8Nm and re-check latching.You may also need to adjust the latch strikerhoops on the rear door frame, loosen boltswith a 10mm socket adjust and tighten toTorque 6Nm. Ensure from inside the canopythe seal on the lower door sash still seals tothe tailgate. (ref. diagram28).

28.

canopy cp0016a supplementary instructions toyota … 2005-2014 j... · 2018. 10. 9. · is specific...

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