Download - Hilux (Double Cab)
Hilux (Double Cab) Hard tonneau cover with High over bar Installation Instructions
Model year: As from 2015/04
Vehicle code: GUN1***-D***HW GUN1***-D**SXW GUN1***-D**LXW
Part number: PW3B0-0K001 High over bar (Stainless steel) PW3B0-0K016 High over bar PW3B0-0K018 High over bar (painted Mat black) PW3B1-0K008 Hardtonneaucover(grainedfinish) PW3B1-0K028 -** Hard tonneau cover (painted) PW3B1-0K101 Hardtonneaucover-sidecovers(grainedfinish) PW3B1-0K093-** Hard tonneau cover-side covers (painted) PW178-0K000 Tailgate Protection Film PW178-0K003 Double Cab - Rail Protection Film
Manual reference number: AIM 003 426-10
1x
4x8x
1x1x
PW3B0-0K001 / PW3B0-0K016 / PW3B0-0K018 High over bar
A
G H6x4xD F
M8M10 M6
PW178-0K000
TailgateProtectionFilm
RailProtectionFilm (DC)
PW178-0K003
1xE 1x I
1xB 1x C
Manual reference number: AIM 003 426-10 2 of 33
Revision recordRev. No. Date Page Step Remarks
02.05.2019 27-29, 33 33,34, OM, CS Clarify HTC fixations adjustment
16.05.2019 29, 33 OM, CS Clarify HTC fixations adjustment
20.12.2019 1, 29, 31 Model year & veh. code updated
20.12.2019 28 33.2 Updated.
8
9
10
10
1x 1x
2x
2x
1x
4x6x
PW3B1-0K008 Hard tonneau cover (grained finish)PW3B1-0K028-** Hard tonneau cover (painted)
PW3B1-0K101 Hard tonneau cover-side covers (grained finish)PW3B1-0K093-** Hard tonneau cover-side covers (painted)
J AF
Q
M
1xL
X Y 4x Z 30x
26x
4x
22x
4x
AA 26x AB 20x AC 4x6x AD4x 4xX
4xK
4xAE
8x N
2x R 4x S 2x T 2x U 4x V 4x W
2x O 2x P 1x AF 1x AG
M6 M6 M6 M6
LHSM6 RHS
2x
M8X20 M8 M8 M8 M8 M8M8X35
LHS
RHS
Manual reference number: AIM 003 426-10 3 of 33
Ø 30mm
or
4 mm
Ø 8mmØ 10mmØ 12mmØ 13mmØ 17mm
COBALTDRILL BITS
CAVITY WAX
or
SikaflexRef.: 555
Butyl
or
Loctite 222
Loctite 243
Ø 12mmØ 13mmØ 17mm
Ø 3mmØ 5mmØ 9mm
A: Standox® Etching AdhesionPrimer 020 16167
B: Standox® Etching AdhesionActivator 020 16168
A: Sikkens® primer surfacer EP II
B:Sikkens® primer surfacerEP II Hardener
A: PRIMERB: ACTIVATOR
DEGREASER
CLEANER
AIM 003 516-*
Manual reference number: AIM 003 426-10 4 of 33
x2
M6
40°C
18°C
MSDS TDS
Material Safety Data Sheet Technical Data Sheet
AIM 003 421-*RAIL PROTECTION FILM
For full installation instruction:http://www.toyota-tech.eu
AIM 003 422-*TAILGATE PROTECTION FILM (DC)
AIM 004 420-*LOCK REPLACEMENT
INFO
Manual reference number: AIM 003 426-10 5 of 33
1
N
AF
2
3
3
Y
1 CLEANER / DEGREASER
Y
0 mm
5
4
6 2x
8mm8 Nm
Manual reference number: AIM 003 426-10 6 of 33
2
N
T
L
AF
U
V
L
1
2xØ 3 mmØ 5 mm
3 10 mm 2
6x
5 10 mm 4COBALT
DRILL BITSØ 3 mmØ 5 mm
COBALTDRILL BITS
2x
1 2
6x
Manual reference number: AIM 003 426-10 7 of 33
4
3
L
1 4
6 7
3mm
30 min.
21°C
8
21°C
3
10 min.
MAX 15 min.1 6
2
3x 3x
2x
5
3mmCLEANER / DEGREASER
Manual reference number: AIM 003 426-10 8 of 33
5
2
1
2x
8mm8 Nm
Manual reference number: AIM 003 426-10 9 of 33
6
N
T
U L
V
S
3
x81
2
1
2
Manual reference number: AIM 003 426-10 10 of 33
7
M M
M M
M
2x 2x
2x
8x
1
2
PROTECTIVECLOTH
BOX
BOX
BOX
BOX
6x
4 mm
Manual reference number: AIM 003 426-10 11 of 33
9
8
K
AG
AA
Z
AB
PAF
A
F
LHS=RHS
2x4 mm
5 Nm
4x4 mm
10 Nm
4x
4
5
6D
F
F
A
B
C
K
E
I
K
2x 2
F
1
1
3 3K K
Manual reference number: AIM 003 426-10 12 of 33
10
S
0 mm
B
0 mm
B
A
A
C
C
D
D
SEC. D-D SEC. C-C
0 mm
X
0 mm
X X=X
SEC. B-B SEC. A-A
2
2
3
4
1
1
Manual reference number: AIM 003 426-10 13 of 33
12
11
K
K
K
K
V
V
U
U
W
W
1
x14
2
1(5) mm
Manual reference number: AIM 003 426-10 14 of 33
14
3
3
1
2
14x
Ø 3 mmØ 5 mm
Ø 10 mm
2 10 mm 1
3 67
8 930 min.
21°C
10
21°C
5
10 min.
MAX 15 min.2 8
4 3mm
3mm
CLEANER / DEGREASER
COBALTDRILL BITS
Manual reference number: AIM 003 426-10 15 of 33
15
14
4
4
5
6
10 mm
3
Ø6mm
CLEANER / DEGREASER
or
SikaflexRef.: 555
Butyl
2
1 1
or
SikaflexRef.: 555
Butyl
30mm
(2x)Ø6mm
Manual reference number: AIM 003 426-10 16 of 33
16
LHS=RHS
6x
12 mm
1
2
8x
13 mm
Manual reference number: AIM 003 426-10 17 of 33
18
17
X Z AA
AC
G
H
C
Bedliner Bedliner
Ø 30mm
ALUMINIUM BEDLINERPW3B1-0K002
PW3B1-0K002 PW3B1-0K010
PLASTIC BEDLINERPW3B1-0K010
Ø 30mm
45°
> 0mm
45°
13mm 17mm
1 23
1 2
For full Installation instructions
http://www.toyota-tech.eu
Manual reference number: AIM 003 426-10 18 of 33
19
S
32
1
Ø6mm
or
SikaflexRef.: 555
Butyl
Manual reference number: AIM 003 426-10 19 of 33
20
O
SikaflexRef.: 555
Ø6mm
Manual reference number: AIM 003 426-10 20 of 33
22
21
J
4x
4x
18 Nm13mm
SEC.
1
2
13mm
Manual reference number: AIM 003 426-10 21 of 33
24
23
J
L
X Z
AB
S
A
X≠X
SEC. B-B
A BB
SEC. A-A
X X
X=X
SEC. B-BSEC. A-A
X X
X
X=X
Manual reference number: AIM 003 426-10 22 of 33
25
K
J
LHS=RHS
D D
E
E
F
F
CC SEC. D-D SEC. C-C
X=X
(X) mm(X) mm
SEC. E-E SEC. F-F
X=X
(X) mm(X) mm
X=XX=X
ClickClick
Click Click
Manual reference number: AIM 003 426-10 23 of 33
27
26
K
X=X
X
X=X
X=X
(X) mm
Manual reference number: AIM 003 426-10 24 of 33
28
LHS=RHS
4x
12 mm
SEC.
6x
18 Nm12mm
4x
22 Nm17mm
8x
18 Nm12mm
2x
8 Nm10mm
1
2 5
6
12mm
12mm
4x
18 Nm13mm
3
4x
18 Nm13mm
4
Manual reference number: AIM 003 426-10 25 of 33
30
29
Q
AD Z Y
R
S
4x
4 mm
1
2
4
3
1mm
4x
4 mm
5
Manual reference number: AIM 003 426-10 26 of 33
31
1
2
4x
12 Nm12mm
2
ClickCL
1
ClickCL
1
ClickCL
Manual reference number: AIM 003 426-10 27 of 33
32
33.1
33.2
8S
4x
4 mm6 Nm
2
1
3
CL CL
2
ClickCL
1
ClickCL
1
ClickCL
2
ClickCL
1
ClickCL
2
2 mmMAX.
11
2 mmMAX.
SEC.
Manual reference number: AIM 003 426-10 28 of 33
33.2
33.1
33.2
8
10
S
OWNER’S MANUALHilux (Double Cab)Model year: As from 2015/04Vehicle code: GUN1***-D***HW GUN1***-D**SXW GUN1***-D**LXW
Part number: PW3B0-0K001 High over barPW3B0-0K016 High over bar PW3B1-0K008 Hard tonneau cover (grained PW3B1-0K028- ** Hard tonneau cover (painted)PW3B1-0K101 Hard tonneau cover-side covers (grained finish) PW3B1-0K093- ** Hard tonneau cover-side covers (painted)
KG
KG
KG
CAUTION
CLOSING SEQUENCE
1
1 3
23
Click
2x
Click
1x
Click
2x
Click
1x
9
Manual reference number: AIM 003 426-10 29 of 33
Manual reference number: AIM 003 426-10 30 of 33
CHECK SHEET
VIN n°
Model / Year Hilux (Double Cab)As from 2015/04
Hard tonneau coverwith High over bar
SEC.
LHS = RHS
13
2
Serial NumberCLICK
Click
1
118Nm
4x6Nm
4x12Nm
4x
2
3
2 3 ...
S
BLHS RHS
A BA
P/N = OK
Owner’s
manual
=A =B
DURING INSTALLATION
Page 1 of 3
3
21
Manual reference number: AIM 003 426-10 31 of 33
1
3
2
4
6
5
5
7
7
Serial NumberCLICK
10
88
9
Click
1
18Nm
2x22Nm
2x22Nm
2x
2
3
2 3 ... BLHS RHS
A BA
4 18Nm4x
18Nm6x
18Nm4x
5
6
18Nm8x7
10Nm
8Nm2x
4x8
9
5Nm2x10
DURING INSTALLATION Page 2 of 3
4
LHS = RHS
S
Manual reference number: AIM 003 426-10 32 of 33
Installation Date: Stamp:Technician Name & Signature:
. . / . . / . . . .
3x
= OK
= OK = OK
1
1 3
23
AFTER INSTALLATION Page 3 of 3
1
2
Click
2x
Click
1x
Click
2x
Click
1x
9
Manual reference number: AIM 003 426-10 33 of 33