canopy installation instructions nissan navara d40 … canopy.pdf · page 3 of 21 18/02/11 cp0019a...
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18/02/11Page 1 of 21
CP0019a
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:
Installation Time:1 Hour (Approximately)
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)• Loctite 277 thread locking liquid (IMPORTANT)• Phillips Head Screwdriver• Large Flat Blade Screwdriver• Medium Adjustable Spanner• Side Cutters• Sockets 10, 12 & 13mm, Extension Bar and Driver• Spanners 10, 12 & 13mm• Silicon Dispensing Gun• Non Acetic Silicon (Neutral Cure)• Spray Bottle (25% isopropyl Alcohol & 75% Water)• Spray Bottle Water• Torque Wrench - 0-10Nm
• Non Permanent Marker• Masking Tape• Cleaning Cloths / Rags• Steel Rule and Tape Measure• Scissors (Sharp)• Knife (Sharp)• Squeegee• Metal Primer• Light Gauge Plastic Coated Draw Wire• Small Round File or Deburring Tool• Ø5mm Drill Bit• Rivet Gun for Stainless Steel Rivets
NISSAN NAVARA D40 Double Cab - RX / ST / ST-X(with & without Nissan Genuine Bed Liner)
(For Australia: 2005 Production Onwards for ST & ST-X)(January 2009 Production Onwards for RX)
CANOPYINSTALLATION INSTRUCTIONS
PLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES.
IF FITTING THE CANOPY TO A 2006 Production Onwards ‘ST-X’ MODEL ,THEN ADDITIONAL SUPPLEMENTARY KIT PART No:- D40STX-CNPY-HARN
WITH FITTING INSTRUCTIONS (CP0020) WILL BE REQUIRED.
This Canopy is designed to suit the Double Cab (4x2 & 4x4) RX, ST & ST-X Navara D40.Sports Bars MUST be removed & returned to Customer with all hardware components if required.Cabin Guards MUST be removed & discarded. This canopy is only designed to work withunboltable Cabin Guards on on RX models from January 2009 Release.This Fitting Instruction where a Bed Liner is referred to, is based on -Nissan Genuine Under Rail Bed Liner Accessory only.
Page 2 of 21 18/02/11
CP0019aNISSAN NAVARA D40 - CANOPY
PARTS CHECK SHEET NISSAN NAVARA D40 CANOPY
CanopyQty - 1
PARTS IN MAIN CARTON
Front Tub StopExtrusion(ALUM0038-10)Qty - 1
Fitting Kit(KIT032043)Qty - 1
Lock Keys(Attached toCanopy InternalRear Door Handle)Qty - 2
Kit - RailClamps(CNPY0007)Qty - 6
Clear AbrasionTape Roll48mm Wide(TAPE0611-1)Qty - 1
Tape EPDM43005.5mx20mmx6mm(TAPE0386)Qty - 1
Screw M6x30Hex Head SS304(SCRW0824)Qty - 4
M6 Flat WasherOD. 19mm(WASH0169)Qty - 8
M6 Nyloc NutSS304(NUTS0016)Qty - 4
Tape 4026 GHBWH12x1700mmx 1.14Thick Roll(TAPE0615)Qty - 1
Bulb Seal 70mmCut Length(MISC2600-1)Qty - 2
Vehicle WiringPatch Harness(LOOM0027)Qty - 1
PARTS IN FITTING KIT (KIT032043)
PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0027)
Cable Ties(3) Long(27) ShortQty - 30
Adhesive TiePadQty - 1
10 Amp BladeFuseQty - 1
Rivet SS304ST-ST 6-6(FAST0505)Qty - 8
Clear Tape Pad50x3mm AbrasionResistant(TAPE0011)Qty - 6
Front Tub SpacerExtrusion(ALUM0038-9)Qty - 1
LH TubRe-InforcementBracket(CNPY0027PC-LH)Qty - 6
RH TubRe-InforcementBracket(CNPY0027PC-RH)Qty - 4
M8x25 HexHead Bolt(SCRW0696)Qty - 10
M8 FlatWasher(WASH0171)Qty - 12
M8 SpringWasher(WASH0152)Qty - 10
M8 Hex NutSS304(NUTS0217)Qty - 2
RustInhibitor
Alcohol Wipe(MISC0052)Qty - 4
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.
Rust InhibitorSatchel(MISC2776)Qty - 1
Primer Stick(MISC1365)Qty - 5
Vehicle WiringPatch Harness Kit(LOOM0027)Qty - 1
FittingInstruction(FIT-CP0019a)Qty - 1
FittingInstruction
104x35mmLabel Sticker(LABL1441)Qty - 1
18/02/11Page 3 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
IF A SPORTS BAR IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 1.IF A CABIN GUARD IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 2.
IF THE VEHICLE HAS NO CABIN GUARD OR SPORTS BAR PLEASE PROCEED TO STEP 4.
Remove the four (4) bolts holding thesports bar feet to the tub as shown.Carefully remove the sports bar from thevehicle and return to the customer withall hardware components.(ref. diagram1).
1.
Remove and retain the twelve (12)hardware items securing the cabin guardto the front rail as shown. (ref. diagram2).
2.
Diagram: 2 - REMOVE HARDWARE SECURING CABIN GUARD
Carefully remove the cabin guard takingcare to avoid scratching the paintwork.(ref. diagram5).OPTIONAL: If customer requests paint allareas left exposed as primed sheetmetal.Painting is preferred to prevent rust.(ref. diagram3).
3.
Diagram: 3 - REMOVE CABIN GUARD
Diagram: 1 - REMOVE SPORTS BAR & HARDWARE
REMOVEHARDWARE
REMOVE &RETAIN
HARDWARE
1
2
5mm
REMOVECABIN GUARD
12mm
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CP0019aNISSAN NAVARA D40 - CANOPY
At the rear left hand side of the vehicle locate the existing harness connectors and disconnect them.For RX, ST & pre 2006 ST-X vehicle’s connect the tail lamp connectors to the vehicle harness (LOOM0027)connectors as shown. For 2006 Production Onwards ST-X vehicle’s, you will need to fit D40STX-CNPY-HARNusing Fitting Instructions CP0020 as detailed. Run the vehicle harness across the back of the vehicle to the righthand chassis rail, then follow the chassis rail to the front right hand wheel arch. Ensure the harness is positioned awayfrom the exhaust system. Ensure the canopy connector is positioned on the chassis rail between the tub and the cabinas shown. Secure the vehicle harness with cable ties spaced 300mm - 400mm apart. Position cable ties away fromfuel lines, brake cables,moving parts and flexible mounts to body. Trim excess cable tie length with side cutters.Ensure harness is run in a direct route from the rear of the vehicle to the front. (ref. diagram4).
4.
Diagram: 4 - CONNECT & RUN VEHICLE HARNESS UNDER THE VEHICLE
RUNVEHICLE HARNESS
ALONG CHASSIS RAIL
APPLYCABLE TIES EVERY
300-400MM
FUSE TERMINALCONNECTION
RIGHT HAND SIDE OF VEHICLE
REAR LEFT HANDSIDE OF VEHICLE
FRONT OF VEHICLE
RUNVEHICLE HARNESS ACROSSTHE REAR OF THE VEHICLE
POSITION CANOPYCONNECTOR UNDERTHE GAP BETWEENTHE CABIN & TUB
DISCONNECTEXISTING VEHICLE
HARNESS CONNECTORS
1
CONNECTEXISTING HARNESS CONNECTORS
TO THE VEHICLE HARNESSCONNECTORS
CANOPY VEHICLEHARNESS (LOOM0027)
EX
ISTI
NG
VE
HIC
LE H
AR
NE
SS
CO
NN
EC
TOR
S
2
3
4
5
6
FOR 2006 PRODUCTION ONWARDSST-X VEHICLE’S REFER TO
FITTING INSTRUCTION CP0020KIT NUMBER - D40STX-CNPY-HARN
FOR RX, ST & PRE 2006 ST-XVEHICLE’S SEE BELOW
18/02/11Page 5 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
Open and secure the bonnet.Feed a draw wire down through the enginebay in the rear right hand corner where theinner right hand front quarter panel meetsthe firewall as shown.From under the left hand front wheel arch,attach the end of the vehicle harness to thedraw wire. Using two (2) people, one personfeeding the vehicle harness and the secondperson to pull the draw wire until theharness is at the top of the engine bay.Remove the draw wire.(ref. diagram5).
5.
Remove the cover on fuse box carefullyso you do not break the clipping tags.Remove the cable clamp securing theharnesses in the fuse box carefully soyou do not break the clipping tags.(ref. diagram6).
Remove the horn fuse as shown (for RXand ST vehicles only).The horn fuse is in a different location onST-X vehicles and does not need to beremoved. (ref. diagram7).
6.
Diagram: 6 - REMOVE FUSE BOX COVER & CABLE CLAMP
7.
Diagram: 7 - REMOVE HORN FUSE FOR RX & ST VEHICLES ONLY
Diagram: 5 - USING A DRAW WIRE PULL HARNESS INTO ENGINE BAY
1 OPEN BONNET
FEED DRAW WIRE2
ATTACHVEHICLE HARNESS
CHASSISRAIL
WHEEL ARCHRH FRONT
REMOVEFUSE BOX
COVER
1 REMOVECABLE CLAMP2
3
FRONT OF VEHICLE
FRONT OF VEHICLE
FRONT OF VEHICLE
REMOVEHORN FUSERX & ST
VEHICLE’S ONLY
18/02/11Page 6 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
Release the 3 clips holding the fuseholder as shown.Remove the fuse holder from the fuse box.(ref. diagram8).
8.
Diagram: 8 - RELEASE & REMOVE THE FUSE HOLDER
CONTINUED OVER THE PAGE
2 REMOVE FUSE HOLDER1 RELEASE ALL 3 CLIPSHOLDING THE FUSE HOLDER
18/02/11Page 7 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
Route canopy harness with existing harnesses as shown. Connect the canopy harness terminal to a spare fuse holeas shown. Fit the 10 amp fuse from the wiring harness hardware kit, to the spare fuse hole that lines up with canopyharness terminal as shown. (ref. diagram9).
9.
Diagram: 9 - FIT CANOPY HARNESS & FUSE TO FUSE HOLDER
RX VEHICLE ONLY
ST VEHICLE ONLY
ST-X VEHICLE ONLY
FIT10 AMPFUSE
3
ROUTECANOPY
HARNESS
CONNECTTERMINAL TOSPARE FUSE
HOLE
1
2
ROUTECANOPY
HARNESS
CONNECTTERMINAL TOSPARE FUSE
HOLE
1
2
ROUTECANOPY
HARNESS
CONNECTTERMINAL TOSPARE FUSE
HOLE
1
2
FIT10 AMPFUSE
3
FIT10 AMPFUSE
3
CANOPYHARNESS
CANOPYHARNESS
CANOPYHARNESS
18/02/11Page 8 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
Replace the fuse holder ensuring the (3)clips, clip back into position.Gently pull fuse holder to ensure it isclipped in correctly and can not beremoved.For RX and ST vehicles replace previouslyremoved horn fuse. (ref. diagram11).
10.
Diagram: 10 - REPLACE THE FUSE HOLDER & HORN FUSE
Diagram: 12 - NEATLY SECURE HARNESS & CLOSE BONNET
Diagram: 11 - REPLACE FUSE BOX COVER & CABLE CLAMP
11.
12.
Replace the cable clamp to secure theharnesses in the fuse box and ensurethe clipping tags are engaged.Replace the cover on fuse box and ensurethe clipping tags are engaged.(ref. diagram11).
Use cable ties to neatly position andsecure vehicle harness.Close the bonnet.(ref. diagram12).2 CLOSE
BONNET
NEATLY POSITION HARNESS& SECURE WITH CABLE TIES
1
2
REPLACEFUSE BOX
COVER
2REPLACECABLE CLAMP1
REPLACE HORN FUSERX & ST VEHICLE’S ONLY
1 REPLACE FUSE HOLDER,ENGAGE ALL 3 CLIPS
CANOPYHARNESS
CANOPYHARNESS
CANOPYHARNESS
CANOPY HARNESS
18/02/11Page 9 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
POSITIONCARDBOARD TUBPROTECTION MAT
1
2
Diagram: 15 - FIT 3M TAPE 12x1700mm
Diagram: 14 - MARK & CUT-OUT BED LINER
Diagram: 13 - CLEAN & DRY INSTALLATION AREAS
13.
14.
15.
Thoroughly clean and dry installationareas (tub, rear of cabin and glass)as shown.Using cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the canopy. (ref. diagram13).
For “RX” vehicle’s only, with a genuineunder rail bed liner fitted.Carefully remove the bed liner.Mark out the bed liner using the existingedge and bottom of radius as shown.Cut out the marked area on the bed liner.Remove all sharp edges and burrs.Repeat process for the other side.Do Not re-install the bed liner at this stage.(ref. diagram14).
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 thecorner of the front rail of the tub to the otherside, along the centre 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. diagram15).
FRONT RAIL
APPLYDOUBLE 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
FRONTRAIL
TAPE
RIGHT HAND SIDEOF BED LINER
FRONT OF
BED LINER
MARKA LINE USING THEEXISTING EDGE
MARKA LINE USING THE
BOTTOM EDGE OF THERADIUS & EXTEND TOEDGE OF BED LINER
CUT-OUTMARKED AREAOF BED LINER
1 REMOVE & RETAINBED LINER &
ALL HARDWARE
2
2 4 5
34
3
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CP0019aNISSAN NAVARA D40 - CANOPY
Diagram: 16 - “RX” - FIT TUB STOP & RE-INFORCEMENT BRACKETS
16. For “RX” vehicle’s only.If the bare metal areas left from removingthe cabin guard have not been painted,complete this step to fit the label sticker.Using alcohol wipe provided, clean thebare metal area around the lower hole onthe side panel where the cabin guardhardware was removed and wipe awayresidue with a dry clean cloth.Cut black label sticker (LABL1441) in halfas shown.Remove adhesive liner from label stickerand adhere over the hole and bare metalsurface on the side panel as shown.Repeat process for the other side of thevehicle. (ref. diagram16).
Diagram: 17 - “RX” - FIT TUB STOP & RE-INFORCEMENT BRACKETS
17. For “RX” vehicle’s only.Position the front tub stop extrusion(ALUM0038-10) on the front tub rail andsecure loosely using previously retainedcabin guard bolts through the four (4)middle slots as shown.Fit LH/RH re-inforcement brackets(CNPY0027) to the front tub stop extrusionand secure loosely using one (1) retainedcabin guard bolt, M8 spring washer andM8 flat washer through the inboard slot,one (1) M8x25 hex bolt, M8 spring washer,two (2) M8 flat washers and one (1) M8hex nut through the outboard slot, andone (1) M8x25 hex bolt, M8 spring washerand M8 flat washer through the slot in theside of the bracket into the side panel asshown (for both sides). Centre front tub stop extrusion to tub, andalign the top face of the front tub stopextrusion to the top of the front tub rail andtighten all ten (10) bolts to Torque 9Nm. Re-install bed liner if removed previously.(ref. diagram17).
9Nm
15mm
15mm
VEHICLE CABIN NOTSHOWN FOR CLARITY
2
2 CUT LABELSTICKER IN HALF
1
FITLABEL STICKER
POSITIONTUB STOP EXTRUSION
(ALUM0038-10)
FRONT RAIL
3
1
LOOSELY FIT(4) RETAINED CABIN GUARD BOLTS
RETAINED CABINGUARD BOLT
FITLH/RH RE-INFORCEMENT BRACKETS(CNPY0027PC-LH & CNPY0027PC-RH)
M8x25HEX BOLT
M8x25HEX BOLT
M8 SPRINGWASHER
M8 SPRINGWASHER
M8 FLATWASHER
M8 FLATWASHER
M8 FLATWASHER
M8 HEX NUT
TIGHTEN ALL TEN (10) BOLTS TO TORQUE 9Nm
3
4
5
6
7
LOWER HOLEIN SIDE PANEL
UPPER HOLEIN SIDE PANEL
1
CROSS SECTION THROUGH FRONTRAIL & RE-INFORCEMENT BRKT
FRONTRAIL
TUB STOPEXTRUSION
RE-INFORCEMENTBRACKET
TAPE
5
2
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CP0019aNISSAN NAVARA D40 - CANOPY
Diagram: 20 - FIT RAIL EXTRUSION SPACER
20. Remove the liner film from the double sidedtape applied to the front tub rail.Fit rail extrusion spacer(ALUM0038-9) to thefront rail over the tape aligning thepreviously marked centre lines. Apply firmpressure rearward and down on the fronttub spacer extrusion along the length toensure maximum adhesion of the foamtape. Clean any excess silicon off usingisopropyl alcohol.IMPORTANT: There must be NO siliconresidue left on the top of the side bedrail faces, or the bed rail foam tape willnot adhere correctly and water leakswill occur. Ensure no silicon is squeezedup by the fitting of the front tub spacerextrusion, if it is clean it off with IPA ona rag heavily loaded. (ref. diagram20).
CROSS SECTION THROUGH FRONT RAIL
TUBSPACER
SILICON
FRONT RAIL
TUB STOPTAPE
APPLYFIRM PRESSURE TO
ADHERE TAPE
REMOVETAPE LINER
1
FITFRONT TUB SPACER EXTRUSION
2
3
NOT SUPPLIED
FRONT TUB SPACER EXTRUSION
Diagram: 19 - APPLY SILICON TO THE TUB SPACER
19. Use alcohol wipes provided clean the tapecontact surfaces of the front tub spacerextrusion (ALUM0038-9) and wipe awayresidue with a dry clean cloth.Apply (MISC1365) primer stick to high-lighted area on extrusion and allow it to dry.Using a non permanent marker, measureand mark a line at the centre of the tubspacer (ALUM0038-9) and the centre ofthe front tub stop extrusion (ALUM0038-10)as shown. Apply a 10mm bead of non-acetic silicon(neutral cure), (not supplied) to the tubspacer on the short face between thetwo (2) grooves as shown.(ref. diagram19).APPLY
10mm BEAD OF SILICON
5
5
3 4 MEASURE & MARKCENTRE LINE OF TUB SPACER
MEASURE & MARKCENTRE LINE OF FRONT TUB STOP
= =1
2
Diagram: 18 - “ST” - FIT TUB STOP
18. For “ST” vehicle’s onlyAlong the inside front face of the front railremove and discard the eight (8) plastic caps.Position the front tub stop extrusion(ALUM0038-10) on the front tub rail andsecure loosely using six (6) M8x25 hex bolts,M8 spring washers and M8 flat washersthrough the six (6) middle slots.Fit two (2) M8x25 hex bolts, M8 springwashers four (4) M8 flat washers and two (2)M8 hex nuts through the outboard slots asshown. Centre front tub stop extrusion to tub, andalign the top face of the front tub stopextrusion to the top of the front tub rail andtighten all eight (8) bolts to Torque 9Nm.(ref. diagram18).
CROSS SECTION THROUGH FRONT RAIL
FRONT RAIL
TUB STOPTAPE
9Nm
15mm
15mm
TIGHTEN ALL EIGHT (8) BOLTS TO TORQUE 9Nm5
POSITIONTUB STOP EXTRUSION
(ALUM0038-10)
2
3 3 3 3 34
4
4
4
M8x25HEX BOLT
M8 SPRINGWASHER
M8 FLATWASHER
M8 FLATWASHER
M8 HEX NUT
REMOVE & DISCARD(8) PLASTIC CAPS
1
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CP0019aNISSAN NAVARA D40 - CANOPY
Diagram: 22 - INSTALL WATER SEALING TAPE
22. Apply EPDM foam tape (TAPE0386) fromhardware kit to the bed rails and spacer.Trim end of tape at 45° (20mm x 20mm) toalign with marks on the tub rail as shown.IMPORTANT: DO NOT CUT FOAM TAPE!Trim one end of the foam tape square.Starting from one side at the rear corner,position the tape end 30mm rearward ofthe tailgate stop and 5mm outboard ofthe inside edge and continue thisposition all the way along the side rail inone continuous length. Position tape25mm from the front edge of the fronttub spacer and apply tape down the otherside rail 5mm outboard of the inside edgeto the end of the side rail.IMPORTANT: As the tape bends aroundthe corners ensure the tape sits flat andDOES NOT pucker.Trim off excess square, 30mm rearwardof the tailgate stop 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. diagram22).Tape MUST be fully adhered to tub railsand spacer and sit flat in one continuouslength to prevent water entering thecanopy.
1
Diagram: 21 - VEHICLE SURFACE PREPARATION
21. 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 clothUsing priming stick (MISC1365) prime toprails of the tub where EPDM foam tapewill be applied in (step 22). Please do notprime too far over the sides of the toprails, read (step 22) to understand wherethe foam tape is to be positioned anduse this as a guide for priming the area.Follow the instructions on the primingstick for optimum results.(ref. diagram21).
NOT SUPPLIED
APPLYEPDM FOAM TAPEAROUND BED RAIL
TOP VIEW OFVEHICLE TUB
CA
BIN
OF
VEH
ICLE
TRIM SQUARE
POSITIONEPDM FOAM TAPE
5mm OUTBOARD OF THEINSIDE EDGE ALONG
THE SIDE RAILS
POSITIONEPDM FOAM TAPE
25mm FROM THE FRONTEDGE OF THE FRONT
TUB SPACER EXTRUSION
ALONGSIDE RAILS
ALONGSIDE RAILS
FOAM TAPE MUST NOTPUCKER AROUND CORNERS
TRIM EXCESS SQUARE 30mm REARWARDOF TAILGATE STOP
ALONGFRONT RAIL
WITH SPACER
5mm 25mm
5mm
TAILGATE OFVEHICLE
30mm
30mm
2
18/02/11Page 13 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
Diagram: 23 - APPLY SILICON
23. 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, ensure all gaps are silicon sealedproperly. 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. diagram23).
Diagram: 25 - PREPARE CANOPY
Diagram: 24 - APPLY SILICON
24.
25.
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. Run a 10mm bead ofsilicon on top of the EPDM foam tape inthe centre, around the corners for a lengthof 70mm each way as shown. Repeatprocess for the other side of the vehicle.Also check from inside and outside of thefront corners near the top of the tub andsilicon seal gaps in the tub sheetmetal.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram24).Clean front of canopy including the frontwindow.Apply a length of masking tape to thefront tub spacer (ALUM0038-9) for alength of 20mm and leave a length that isaccessible over the edge of the vehicle toassist in removing when the canopy hasbeen aligned.Using a non-permanent marker, measureand mark lines rearward from the frontedge of the front tub spacer as shown.“RX” vehicle’s - 14mm“ST” vehicle’s - 10mm“ST-X” vehicle’s - 17mmRepeat process for the other side of thevehicle. (ref. diagram25).
NOT SUPPLIED
CLEANCANOPY FRONT
1
20mm
SHEETMETALSIDE RAIL
FRO
NT
TUB
SPA
CE
R
TOP VIEW OF TUB FRONT CORNERAPPLY
MASKINGTAPE
2
MARK LINES3
“ST”
10m
m“S
T-X
”17
mm
“RX
”14
mm
APPLYNON ACETIC
SILICON(NEUTRAL CURE)
EPDM FOAMTAPE
DOWN AT LEAST THE DEPTHOF THE RETURN OF THE FRONT
TUB SPACER EXTRUSIONFROM THE TOP OF THE TUB
SILICON SEAL GAPS IN THE CORNER OF TUB AT TOP
FRONT TUBSPACER
VEHICLE CABIN NOTSHOWN FOR CLARITY
NOT SUPPLIED
EPDM FOAMTAPE
TOP VIEW FRONT LEFT TUB CORNER INTERNAL VIEW INSIDE THE TUBFRONT
TUB STOPEPDM
FOAM TAPE
FRONTTUB STOP
FRONTTUB SPACER
APPLYNON ACETIC SILICON
(NEUTRAL CURE)
1
APPLYNON ACETIC SILICON
(NEUTRAL CURE)
2
70mm
70mm
18/02/11Page 14 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
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
FIT6 CLEAR TAPE
50x3mm ABRASIONRESISTANT TO TUB
RAILS DIRECTLYUNDER CLAMP HOLES
IN BASE RAILS
ORIENTSO THE LONG EDGERUNS THE LENGTHOF THE VEHICLE
Diagram: 28 - FIT CLEAR ABRASION TAPE TO TUB
Diagram: 27 - ALIGN CANOPY TO TUB
27.
28.
Align the canopy evenly on the tub.The canopy lower perimeter extrusion’sfront face, should align with lines markedpreviously on the masking tape applied tothe front tub spacer using a straight edge.“RX” vehicle’s - 14mm“ST” vehicle’s - 10mm“ST-X” vehicle’s - 17mmOpen rear door 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.Remove masking tape from front tubspacer. (ref. diagram27).
Fit six (6) clear tape 50x3mm abrasion resistant (TAPE0011), to the vehicle tubrails directly under the square holes in thecanopy base rails for the clamps as shown.Orient the tape so the long edge runs thelength of the vehicle as shown.Position half of the tape on the front faceof the rail and fold the remaining halfaround onto the back of the rail.(ref. diagram28).
Diagram: 26 - FIT CANOPY TO TUB
26. Two people (minimum) are required forthis 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. diagram26).
EVEN BOTH SIDESAT THE END CAPS
CANOPY BASE RAIL
VIEW FROMREAR OF CAR
RX=14mm, ST=10mm, ST-X=17mmFROM FRONT TUB SPACER
TO VERTICAL RULER
RULER VERTICAL AT LINEMARKED IN STEP 24.
0mm
1020
3040
5060
7080
90
18/02/11Page 15 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
DISASSEMBLE2 CLAMPS
FITTOP ‘L’ CLAMP
1
2
4FIT & SLIDE
BOTTOM‘U’ CLAMP APPLY
LOCTITE 277 TO BOLTS,FIT BOLT & WASHERS
TORQUE TO 8Nm
6CLOSE REAR
DOOR & CHECKLATCHES ENGAGE
5REMOVE & RETAIN KEYSATTACHED TO INTERIOR
REAR DOOR HANDLE
7READJUST
LATCH STRIKERPOSITION
(IF REQUIRED)
LOCTITE277
3
9Nm
13mm
413mm
Diagram: 29 - FIT REAR CLAMPS AND CHECK LATCHING
29. Disassemble two (2) rail clamps.Fit the clamps to the rear holes in the canopybase rails by fitting the top L clamp downthrough the hole in the rail and sliding thelower U clamp along the side rail over theclear abrasion tape.IMPORTANT! Apply Loctite 277(not supplied) to the bolts liberally.Secure the clamps with the bolts andwashers as shown. Tighten to Torque 8Nm. Remove and retain the keys attached to theinterior rear door handle. Close the rear doorfirmly, holding the centre handle withoutslamming it too hard. NOTE: Latch has 2 stages of engagement.Ensure canopy engages with second stageof latch and the lower rear door seal, sealsagainst the tailgate on the car.(ref. diagram29).
LOCTITE277
DISASSEMBLE4 CLAMPS
1
FITREMAINING CLAMPS
APPLYLOCTITE 277 TO BOLTS
23
TIGHTEN2 - REAR CLAMPSTORQUE TO 9Nm
4TIGHTEN
2 - FRONT CLAMPSTORQUE TO 9Nm
5TIGHTEN
2 - MIDDLE CLAMPSTORQUE TO 9Nm
10mm
FIT / SECUREFRONT RAIL TUB STOP
TIGHTEN TOTORQUE 6Nm
1
3
FITBOLT AND WASHER
SECURENYLOC NUT
AND WASHER
WASHER
NYLOC NUT
BOLT
CANOPY BASERAIL AT FRONT
2
VEHICLEFRONT TUB
SHEET METAL
6Nm
10mm
9Nm
13mm
2
13mm
Diagram: 31 - FIT / SECURE - FRONT TUB STOP RAIL
Diagram: 30 - FIT REMAINING CLAMPS AND TIGHTEN ALL
30.
31.
Disassemble remaining four (4) railclamps.Fit the clamps to the remaining holes inthe canopy base rails by fitting the top Lclamp down through the hole in the railand sliding the lower U clamp along theside rail over the clear abrasion tape.IMPORTANT! Apply Loctite 277(not supplied) to the bolts liberally.Secure the clamps with the bolts andwashers as shown. Tighten the rear clamps first, then the frontclamps and finally the middle clamps, allto Torque 9Nm. (ref. diagram30).
For “ST-X” vehicle’s only.Fit front rail tub stop extrusion(ALUM0038-10) to the under side of thecanopy front base rail and front tub spacer.Push extrusion up against the front of thetub and secure with four (4) M6 hex headbolts, eight (8) flat washers and four (4)nyloc nuts as shown.Tighten to Torque 6Nm. For “RX & ST” vehicle’s only.Secure previously installed front rail tubstop extrusion (ALUM0038-10) to thecanopy front base rail and front tub spacerusing four (4) M6 hex head bolts, eight (8)flat washers and four (4) nyloc nuts asshown.Tighten to Torque 6Nm. (ref. diagram31).
18/02/11Page 16 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
CLEARABRASION
TAPE
TRIMEXCESS CLEARABRASION TAPE
4
REMOVEMASKING TAPE
CANOPY NOT SHOWN FOR CLARITY
6
SQUEEGEE OUTEXCESS SOLUTION
BUBBLES
5
2
25% ISOPROPYLALCOHOL
75% WATER
APPLYCLEAR
ABRASION TAPE
ALIGNBOTTOM EDGE
OF CLEAR ABRASIONTAPE WITH TOP EDGE
OF MASKING TAPE
3
CUTCLEAR ABRASION TAPE
INTO TWO EQUAL HALVES
1
200 200 200
194
2009797 200 200
BOTTOM GROOVEON FRONT RAIL TUB STOP
TOP GROOVEON FRONT RAIL TUB STOP
Ø5mmRust
Inhibitor
(x8)1 2 3 4
Diagram: 32 - SECURE FRONT TUB STOP RAIL
32.
Diagram: 34 - APPLY ABRASION TAPE
34. Unroll and cut abrasion tape (TAPE0611-1) into two equal halves. Using a solution of25% isopropyl alcohol and 75% water in aspray bottle (not supplied) thoroughly sprayalong the top of the tailgate.Remove liner from clear abrasion tape.Working from one end with a 5mm over-hang, place liner on the tailgate. Trimexcess tape leaving a 5mm overhang atplastic infill panel. When in position use asqueegee to push out any excess watersolution and bubbles. Using a sharp knifeor scissors trim tape to end of tailgate &infill panel.You may need to squeegee a few times.When finished the tape is virtuallyinvisible. Repeat for the other side.To ensure a good finish please take carean do not rush this step. Remove maskingtape. (ref. diagram34).
For “ST-X” vehicle’s onlyMark and drill eight (8) Ø5mm holes intothe front rail tub stop and tub rail usingdimension’s as shown.Rivets must secure to flat form on tub.Apply rust inhibitor (MISC2776) to alldrilled holes in the tub sheet metal.Secure with eight (8) stainless steel rivetsas shown. (ref. diagram32).
TAILGATE
REARDOOR SASH
MASKINGTAPE
REAR WINDOW
APPLYMASKING TAPETO TAILGATE
1
Diagram: 33 - APPLY MASKING TAPE
33. With the canopy rear door closed, applya length of masking tape either side of theplastic infill panel to the rear tailgate, levelwith the bottom edge of the canopy reardoor sash, when viewed from the rearhorizontal position as shown.This will assist in positioning the clearabrasion tape applied to the top of thetailgate in the next step.(ref. diagram33).
1
18/02/11Page 17 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
CHECKCANOPY LAMP
WORKS
Diagram: 37 - CHECK BRAKE LIGHTS AND CANOPY LIGHT
Diagram: 36 - CONNECT VEHICLE & CANOPY CONNECTORS
36.
37.
Feed the canopy harness down to thevehicle harness on the chassis rail.Connect the canopy harness connector tothe vehicle harness connector as shown.IMPORTANT: Wiring harnesses shouldbe positioned away from the exhaustsystem side. (ref. diagram36).
Two people are required to check thecanopy brake light is operational afterdepressing the brake pedal.Then open the rear window and checkthat the internal canopy lamp is operatingcorrectly when switched to the ’ON’position only.NOTE: An additional accessory can beordered from EGR to turn the light onin ‘DOOR’ position of the switch when thedoor is opened automatically.(ref. diagram37).
CHECKBRAKE LIGHTS
WORK
CONNECTCANOPY HARNESS TO VEHICLE HARNESS
1
CHASSIS RAIL
Diagram: 35 - (OPTIONAL) FIT TAILGATE SEALS
35. (OPTIONAL): Strongly Recommendedfor best results for rear door to tailgatewater sealing. Using alcohol wipe provided clean directlybelow the rear door clamp front seal andwipe away residue with a dry clean cloth.Using priming stick (MISC1365) prime areadirectly below the rear door clamp frontseal. Apply only a light amount both sides of tailgate in this area, and allow to dry. Apply bulb seal 70mm (MISC2600-1) totailgate. Position bulb seal so it's fingerseals against the underside of theclamp frame seal after the bulb on the clampframe seal as shown and position it in linewith the outer edge of the tailgate as shown.(ref. diagram35).
BULBSEAL
CLAMPFRAMESEAL
TAILGATE
SIDETUBRAIL
ALCOHOLWIPE &PRIME
SHADEDAREA
1 2
TAILGATE
1
2
BU
LB S
EA
L FI
NG
ER
UN
DE
R C
LAM
P S
EA
L&
AG
AIN
ST
FIN
GE
R
CANOPYCROSS SECTIONOF SEAL
FIT BULB SEAL3
18/02/11Page 18 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
FITCABLE TIE
Diagram: 40 - WATER LEAK TESTING
Diagram: 39 - SECURE CANOPY HARNESS
39.
40.
Fit one (1) short cable tie through theadhesive tie pad previously fitted to thefront of the tub and secure the canopywiring harness as shown. Trim excess tiewith side cutters. (ref. diagram39).
Water test canopy checking for water leaks.Test both canopy keys work to lock andunlock the rear door and side lift up window.Open both side windows.If the rear door handle does not lock,remove the interior lock cover, unclip thepull rods and wind to lengthen them slightly.Re-check rear door lock function.When rear door locks replace interior lockcover, and add the canopy keys to the customers vehicle keys.(ref. diagram40).
CANOPY
CABIN
TUB
Diagram: 38 - FIT ADHESIVE TIE PAD
38. Using alcohol wipe provided in the kit,clean the driver’s side, front face of thefront tub panel as shown, and wipeaway residue with a dry clean cloth.Remove tape liner from adhesive tie padand position on the front tub panel in areapreviously cleaned as shown.Apply pressure to ensure maximumadhesion. (ref. diagram38).
CANOPY
CABIN
TUBSPACER
TUB
1 FITADHESIVETIE PAD TOFRONT TUB
PANEL
2
TUBSPACER
DETAILS TO ADJUST PULLRODSADJUST LENGTH
OF PULLRODS BY ROTATION
ANTI-CLOCKWISE = LENGTHEN
3
REMOVE INTERIORLOCK COVER
UNCLIP PULLRODSFROM RETAINER CLIPS
REPLACE INTERIOR LOCK COVER
RE-CHECKLOCK
FUNCTION
4
CLIP PULLRODSINTO RETAINER CLIPS52
16
18/02/11Page 19 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
PLACE FITTING INSTRUCTIONSIN THE CUSTOMERS LOG BOOK
Diagram: 41 - FINAL CLEANING
41. Clean canopy including all windowsand vehicle thoroughly .Place fitting instructions in theCustomers log book, and ensurepage 20 of these instructions arediscussed with the customer and acopy is given to the customer. (ref. diagram41).
18/02/11Page 20 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
Warranty Terms - EGR warrants that the ABS Canopy 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.
Exclusions - This warranty does not cover failure due to neglect, improper installation, including any modifications to installation hardware, alterations, addition of non genuine equipment, abuse, accident, normal wear and tear, lack of maintenance, misuse, and exposure to chemicals that are not safe for plastics or hardware components. Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Canopy is sole responsibility of the vehicle owner and operator. Paint wear to the vehicle bed can happen with any Canopy and is the sole responsibility of the vehicle owner. Paint damage to your vehicle is not covered under this warranty.
Disclaimer - In the event that your EGR Canopy 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 labour are not associated with this warranty claim.
KEY IDENTIFICATION CODE
1234
Nissan Navara D40 CANOPY
Please write the key identification code in the boxes above,and retain this copy with the vehicle service history.
Replacement keys can be purchased from your local dealer.
OWNERS MANUAL SUPPLEMENTIMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S
VEHICLE SERVICE BOOK.
WARNING! - SAFETY!• Do Not use the canopy as a passenger compartment.• Do Not operate/drive vehicle with fold up windows or rear door open. They must be closed when vehicle is in motion.• Do Not store or transport volatile materials, such as solvents, chemicals or liquids as fumes may accumulate inside canopy. Do Not allow solvents, chemicals or oils to come in contact with the canopy. If this should occur clean the canopy immediately with a mild detergent and water solution.• Do not stand/sit or rest heavy objects on Canopy.• Do not fill volatile liquid containers while inside canopy such as fuel cans.• VEHICLES FITTED WITH A BED LINER: Static electricity can cause fire when fuel is pumped into ungrounded fuel containers or equipment (eg: motorcycles, chainsaws etc..). Do Not fill fuel containers or equipment within the vehicle tray as static electricity can cause fuel to ignite, resulting in damage, injury or death. To avoid electricity build-up, place fuel container or equipment on the ground before filling.
MaintenanceOnly use mild detergents or wax polish. Do Not use abrasive compounds on painted or plastic finishedcanopy surfaces.The gas struts are self lubricating and should only be cleaned with a damp cloth, when regularly cleaningthe vehicle. Premature seal failure will result if solvents or lubricants are used to clean struts.Gas struts must be orientated as installed, cylinder (wide end) to canopy and rod (narrow end) to glass.Lightly coat the door and window rubber assemblies with a silicon spray after cleaning periodically.Only locks and lock recesses are to be lubricated with Graphite Powder.Vaseline may be used on the rotary catches on the rear door.DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.Check canopy attachment clamps every 1000 Km.Clamp bolt recommended torque setting is (9 Nm or 6.64 lb/ft).If removed, bolts must have LOCTITE 277 re-applied and be re-tightened on refitting to specified values.CHECK regularly that all screws and fasteners holding windows and doors are tight.The rear tailgate protection tape must be replaced periodically to minimize paint scuffing caused by the canopy rear door opening and closing.For sliding windows use a silicon based Non-Aerosol lubricant or a dry film lubricant or LY70 lubricant or 3Mwindow channel dresser lubricant sparingly. DO NOT use CRC, WD40 or petroleum based lubricants on sliding windows.
18/02/11Page 21 of 21
CP0019aNISSAN NAVARA D40 - CANOPY
Dealer Name:
Model:
Order Date:
Required By:
Canopy Colour
Canopy Checklist - Details of rectifications required: KEY No. :
Vehicle Damage Check: Detail:
Dealer Code:
Stock No:
Order No:
Vin No:
1. Check paint on canopy
2. Cleanliness of canopy inside and outside
3. Canopy sealing to tray, tub spacer rail, tub stop rail and foam tape applied correctly
4. Seal around Front of tub, vertical corners & floor with Silicone after foam tape applied
5. Tailgate clear tape fitted
6. Position canopy on tub squarely side to side, rear door closes on second stage latch (not just first latch) both sides and lower door sash seal, seals to tailgate, adjust strikers and /or door latch pull rods via access to centre door handle by removing internal door handle cover
7. Clamps are square and tight (Torque 9Nm)
8. IMPORTANT! Loctite 277 applied to all Clamp Bolt Threads
9. Rear Door, Side Door’s and Front window operation, side windows lock with keys. Check rear door handle and locks with keys. If not locking remove interior cover on rear door handle and adjust the pull rods by winding them in/out and test the door again, replace cover.
10. Operation of Brake Light
11. Operation of interior light
12. Water Tested for leaks
13. Clean up of work area
14. Comment
Record Canopy Serial Number: Checked By:
Vehicle Type: RX 4x2 RX 4x4 ST 4x4 ST-X 4x4
Vehicle received and Checked by Dealer Staff:
Fitted By:
INSTALLATION CHECKLIST
(located on inside LH rear pillar of canopy shell)